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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit under 35 USC 119(e) of U.S. provisional application No. 62/144,440, filed Apr. 8, 2015, the contents of which are herein incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to synchronous serial interfaces, for example, and more particularly to a method of improving the performance of such interfaces.
BACKGROUND OF THE INVENTION
[0003] Low speed synchronous serial interfaces, such as the System Peripheral Interface (SPI) and its numerous variants, are widely used for interfacing microprocessors with peripheral devices, including flash memories, sensors, data conversion devices, timing and synchronization devices, communication devices, audio codecs, and liquid crystal displays.
[0004] For some of these applications, it is desired to maximize the bandwidth of data transfers by increasing the clock rate. In a 4-wire SPI interface, this is relatively easy to achieve for master-to-slave transfers, which transmit clock and data in a source synchronous manner. Slave-to-master transfers however transmit clock and data in opposite directions, and thus suffer from the effects of round trip time delay, severely limiting performance.
[0005] A known technique to increase clock rate on SPI and similar interfaces involves modification to the master side of the interface, supporting an adjustable data sampling point. While this technique may be effective, it has some disadvantages: It has a high degree of design complexity. System integrators simply adding a new slave device to an existing SPI bus may be resistant to any master side modifications that may risk affecting communications with other devices. The required modifications may not be possible, e.g. when the master is integrated into an existing microprocessor design that does not support these features. Delaying the sampling point at the master requires the host processor to accept the data at a later point in time, which may require further, potentially infeasible system level changes or may impact system performance.
SUMMARY OF THE INVENTION
[0006] Embodiments of the invention make a modification to the hardware design of the slave side of the SPI interface and higher-level protocol between the master and slave to advance the launch point for data after receipt of a command from the master. As a result, the interface clock speed can be increased, improving bandwidth beyond what was initially limited by round trip time
[0007] According to the present invention there is provided a slave device for exchanging data with a master device over a synchronous serial interface, wherein the slave device sends data to the master device upon receipt of a command from the master device, the slave device comprising: a receive shift register for storing incoming commands; a transmit shift register for storing outgoing data; and a controller responsive to a command in the receive register to transmit data in the transmit register under the control of a clock signal, said controller being configured to commence transmission of said data in response to said command prior to complete reception of said command.
[0008] Typically, the shift registers will be have a length capable of storing a complete byte, i.e. 8 bits, but one skilled in the art will appreciate that other bit-lengths could be employed, for example, 12 bits or 16 bits.
[0009] Embodiments of the invention may offer the several advantages over previously known methods. The hardware changes are confined to the slave side only. The hardware implementation uses efficient standard digital logic and does not require modification to input and output buffers. The device may be implemented in both direct-clocked and sample-clocked designs and maintain backward compatibility with existing SPI masters, at supported clock rates. The device can also co-exist with peer slave devices not supporting the enhancement.
[0010] In another aspect the invention provides a master device for receiving data from a slave device over a synchronous serial interface, wherein the slave device sends data to the master device upon receipt of a command from the master device, the master device being configured to send out a command to the slave device wherein a last transmitted bit of the command is a dummy bit containing no useful data.
[0011] In yet another aspect the invention provides a method for sending data to a master device from a slave device over a synchronous serial interface, the method comprising: the slave device receiving a command from the master device; and the slave device in response to partial reception of said command transmitting data to the master device prior to complete reception of the command.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] This invention will now be described in more detail, by way of example only, with reference to the accompanying drawings, in which:
[0013] FIG. 1 illustrates a prior art serial Peripheral Interface (SPI);
[0014] FIGS. 2 a and 2 b are timing diagrams showing standard launch and early launch respectively in accordance with an embodiment of the invention; and
[0015] FIG. 3 is a schematic diagram of a modified SPI slave interface with support for standard and early launch in accordance with an embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0016] FIG. 1 shows a high level view of a prior art 4-wire Serial Peripheral Interface (SPI). A master device 101 communicates with a slave device 102 using four signals: a clock signal SCLK 103 ; master output to slave input data signal MOSI 104 ; master input to slave output data signal MISO ( 105 ); and a slave chip select signal /SS 106 . In the case of multiple slave devices, a separate /SS line is typically used for each slave, although target addressing schemes also exist. Many variants of SPI and other similar synchronous serial interfaces exist.
[0017] FIGS. 2 a and 2 b show a timing diagram of the interface, with standard launch and with early launch in accordance with an embodiment of the invention. In this example, a one byte command C 7 -C 0 is transferred from master device 101 to the slave device 102 on the MOSI line requesting data from the slave. After receiving the hill command, the slave immediately responds with one byte of data D 7 -D 0 . The higher layer protocol could extend this to an arbitrary number of bytes. We assume an operating mode with an initially low clock (clock polarity CPOL=0) and capture on the leading clock edge (clock phase CPHA=0). However, all other CPOL, CPHA combinations are equally valid for the invention.
[0018] The round trip delay, which includes the propagation of SCLK from master device 101 to slave device 102 plus the propagation of MISO from slave back to the master reduces the setup time for sampling the MISO signal at the master device. The setup time is the time a signal is stable before it is sampled. Flip flop D pins at the circuit level and clocked input data pins at the device level specify a minimum required setup time in their datasheets. With increasing clock rate, the setup time is eventually reduced to the point where timing failure occurs. With the early launch scheme in accordance with embodiments of the invention, the data is driven from the slave device 102 earlier, one half clock cycle earlier in this example, providing additional setup margin, allowing for higher clock rates, and thus increased interface bandwidth.
[0019] With the early launch feature in accordance with the invention, there is insufficient time for the slave to decode the last transmitted bit of the command byte. To overcome this problem, the higher layer protocol is modified to change the last hit into a dummy zero bit, which is ignored by the slave device, The host system software need only shift the command left by one bit, with no changes required to the typical master hardware design. If the remaining 6 bits of command is insufficient, multiple command bytes could be used for some or all commands.
[0020] FIG. 3 shows a schematic diagram for the modified SPI slave device 200 supporting both standard launch and early launch in accordance with the invention. The slave device 200 comprises shift registers receive register 201 , transmit register 202 , flip-flop 204 , multiplexer 205 , MISO input 205 a, MISO output driver 205 b, //SS input 207 , and SCLK input 208 .
[0021] Receive data and commands are clocked on the rising edge from MOSI into the receive shift register 201 . The transmit data and commands are clocked on the falling edge from the transmit shift register 202 out to MISO output 205 b. A controller 203 processes commands and coordinates shift register operation.
[0022] Rising edge flip-flop 204 and multiplexer 205 allow selection of the launch edge, with the launch cycle being determined by logic in the controller 203 .
[0023] In the illustrated example the contents of the shift registers 201 , 202 correspond to point indicated by * in FIG. 2 b , just before the rising edge of the clock in the last bit of the command byte. At this point, command bits C 6 - 0 have been shifted in and decoded. The receive shift register has deepest bit location 208 containing an unknown value X left over from a previous transaction and thus ignored. Data bit D 7 is about to be loaded into flip-flop 204 at the same time as the output driver 205 b is enabled.
[0024] The launch point can be made configurable. Also, the embodiment wherein the slave device clocks directly from SCLK as in FIG. 3 could launch data on any preceding clock edge, while slave devices using a high speed internal sampling clock could have finer grain control over the launch point. When selecting a launch point, care must be taken not to violate hold time. For a half cycle early launch, hold time is easily guaranteed by the minimum round trip delay.
[0025] It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative circuitry embodying the principles of the invention. For example, a processor may be provided through the use of dedicated hardware as well as hardware capable of executing software in association with appropriate software. When provided by a processor, the functions may be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which may be shared. Moreover, explicit use of the term “processor” should not be construed to refer exclusively to hardware capable of executing software, and may implicitly include, without limitation, digital signal processor (DSP) hardware, network processor, application specific integrated circuit (ASIC), field programmable gate array (FPGA), read only memory (ROM) for storing software, random access memory (RAM), and non-volatile storage. Other hardware, conventional and/or custom, may also be included. The functional blocks or modules illustrated herein may in practice be implemented in hardware or software running on a suitable processor.
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A slave device for exchanging data with a master device over a serial interface sends data to the master device upon receipt of a command from the master device. A controller responsive to a command byte in a receive register commences transmission of data in the transmit register under the control of a clock signal prior to reception of a complete command.
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RELATED APPLICATIONS/PRIORITY
[0001] This application is a divisional of U.S. patent application Ser. No. 11/257,831 filed Oct. 25, 2005, which is a continuation of U.S. patent application Ser. No. 10/210,643, filed Jul. 31, 2002, now U.S. Pat. No. 7,010,221, which is a continuation of U.S. patent application Ser. No. 09/415,405, filed on Oct. 8, 1999, now U.S. Pat. No. 6,464,666.
BACKGROUND
[0002] This invention is generally related to parenteral fluid warming systems and, more particularly, to the structure of a warming cassette that includes a stiffening frame with an attached fluid container and that is used in a parenteral fluid warming apparatus.
[0003] Fluid warming apparatuses, designed to warm and administer parentarel fluids and blood products (hereinafter “fluids”), are in common use. Generally, these fluids are administered using a disposable fluid container which includes a fluid pathway and one or more heat exchange surfaces. The fluid container may be made of plastic film material or thin metal. A warming cassette incorporates such a fluid container, imparting structural support to the container for handling and for being received and supported in the warming unit.
[0004] Specifics of a multi-layered fluid container compatible with a supporting cassette frame structure are discussed in applicants U.S. patent application Ser. No. 09/415,558, entitled “PRESSURE TOLERANT PARENTERAL FLUID AND BLOOD CONTAINER FOR A WARMING CASSETTE”, invented by Augustine et al., filed on Oct. 8, 1999, now abandoned.
[0005] A warming cassette is placed into a warming unit to heat fluids as they flow through the fluid pathway. Heat is transferred to the fluid through the fluid container by contact with a heat source such as heated metal plates, heated liquid, or heated gas. Metal plate, “dry heat” exchanger warming units are widely known. However, in the last 10 to 15 years, water bath heat exchangers have become the norm in the United States.
[0006] While convenient to use, water bath heat exchangers can pose health risks. The warm water in these systems is often circulated for long periods of time without being changed or sterilized. The warm water provides an excellent growth medium for microbes. After several weeks of use, bacteria and fungi can be cultured from these water baths. For these reasons, a “dry heat” system is probably safest for warming medical fluids. However, there are significant fluid thermodynamic problems, as well as convenience, reliability, and cost issues that must be solved for a “dry heat” system to replace the water bath systems.
[0007] The American Association of Blood Banks (AABB) mandates that blood products and IV fluids must not be heated above a temperature of 42° C., so as to prevent blood cell damage and thermal injury to a patient. A temperature of 42° C. is easy to maintain under steady-state flow conditions, a low flow rates. However, as the flow rate of the fluid increases, the rate of heat transfer to the fluid must keep pace in order to achieve a target fluid temperature. The boost in the rate of heat transfer is most obviously achieved by using larger heater and by increasing the temperature difference (−T) between the heater and the fluid. Both solutions effectively drive more heat into the fluid. Unfortunately, these solutions are not necessarily effective when the fluid flow rates are highly dynamic. Large heaters and high temperature differentials are not responsive enough to sudden changes in fluid flow rates. For example, in the case of a sudden change from a high fluid flow rate to a low one, the high temperature limit can be exceeded, potentially causing thermal damage to the fluid or patient.
[0008] The problems of thermal efficiency and temperature responsiveness over a wide range of flow rates can be met by improving the thermal conductivity of the fluid cassette materials, and minimizing the thickness of the fluid at the point of heat transfer. This implies a thin, flat fluid container, constructed from properly selected materials.
[0009] Plastic film materials are commonly used in the manufacture of disposable fluid warming cassettes. However, plastic is a poor heat transfer material. Metal foils, or metal conduits have been used with plastic materials in warming cassettes to enhance thermal conductivity; however, it is difficult to bond metal to plastic materials, and leakage can occur along bonding seams between these materials. Further, metal foils generally increase the cost of cassette manufacturing.
[0010] Fluid temperature response may also be improved by reducing the thickness of the fluid channel in the fluid container. In this regard, the space between the heater plates is then reduced to be compatible with thin cassettes. Assume, for example, that an optimal balance between fluid flow resistance and heat transfer for a particular warming unit design yields a distance of 0.048 inches between the heater plates of the unit. It is very difficult to insert an appropriately dimensioned cassette into such a warming unit simply by sliding it between the warming plates. The plastic materials of which such cassettes are made impart little rigidity. Consequently, such a cassette may kink or tear when being slid into or out of such a small space. As a result, “clamshell” solutions have been proposed that spread the warming plates apart when a cassette is inserted or removed from a warming unit.
[0011] The limitations of the clamshell design are manifest. Moving parts add to the warming unit's cost, and reduce reliability. It is very difficult to maintain an accurate 0.048 in. spacing across the entire plate surface, when hinges, clasps, and other moving parts are required. Finally, insertions of the cassette into such a warming system becomes a multi-step process, which is both time consuming and inconvenient.
[0012] Other problems occur with the use of plastic fluid containers in fixed plate warming units. For example, the fluid channel formed between the plastic films of a fluid container must be contained entirely within the space between the heater plates. However, some portion of the cassette must extend outside of the heater plates in order to provide structure that can be grasped to extract the cassette. If the portion of the cassette that extends outside of that space includes an unsupported portion of the fluid container, the container can rupture when the fluid pressure is increased to increase the flow rate.
[0013] It would be advantageous if an efficient and low cost fluid cassette could be developed for a “dry heat” parenteral fluid warming system. Advantage would be gained if the fluid cassette permitted the rapid heating of parenteral fluid under high pressures. Further, it would also be advantageous if the cassette could be made rigid, yet thermally conductive, without the use of metal.
[0014] It would be advantageous if a cassette fluid container could be made with plastic walls stiff enough for insertion in between close-set parallel warming plates of a warming unit, yet thin enough to efficiently transfer heat from the plates to the fluid.
[0015] It would be advantageous if the above-mentioned cassette could be easily inserted into and removed from the warming unit without being kinked or torn. It would further be advantageous if the cassette had a handle for insertion of the cassette between the warming plates of a fluid warming unit. It would be advantageous if the above-mentioned cassette handle extended outside the unit for convenient handling.
SUMMARY
[0016] Accordingly, a warming cassette for parenteral fluids, used in a parenteral fluid warming system, is provided. The cassette comprises a flexible fluid container made from thermally conductive material and attached to a planar frame structure, which imparts structural rigidity to stiffen and support the fluid container. The fluid container and the frame structure are all of a piece, permanently bonded, joined or connected together in a unitary, integrated structure. The frame structure is in the shape of a planar figure bounded by sides. Preferably the figure is a quadrilateral, with sides, a distal end, and a proximal end. A handle is provided on the proximal end. A fluid container is disposed inside the shape of the frame structure, attached along its periphery to the sides and ends. Optionally, the container could be attached to just the sides or just the ends. The handle provides an element that may be grasped to manipulate the cassette for insertion into and extraction from a warming unit.
[0017] Optionally, the warming cassette is provided with a keying mechanism that prevents it from being inserted either upside down, or backwards in a warming unit. The keying mechanism also prevents the cassette from being inserted too far into the warming unit. The keying mechanism comprises lands on the sides of the frame structure. To key the cassette, the lands mate with corresponding grooves in the warming unit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1A is a perspective view of a warming cassette according to this invention for use in an intravenous fluid warming system.
[0019] FIG. 1B is side sectional view of the cassette taken along A 1 -A 1 of FIG. 1B .
[0020] FIG. 2A is a more detailed depiction of the warming cassette of FIG. 1A .
[0021] FIG. 2B is an exploded view of the warming cassette of FIG. 1A .
[0022] FIGS. 3A and 3B illustrate the warming cassette 10 of FIG. 1A , detailing an optional bubble trap feature.
[0023] FIGS. 4A through 4C illustrate details of the present invention keying system used to selectively orient the cassette in the warming apparatus
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] This invention is a system for warming fluids during intravenous infusion. The system includes a cassette designed for use with a “dry heat” warming unit in which heater plates are disposed in a parallel, spread-apart orientation, separated by a thin laminar space. The cassette is received in the space between the heater plates, in close contact with the heater plates.
[0025] The warming cassette has a unitary integral structure that includes two portions: a frame structure, and a fluid container attached, or joined, to the frame structure. The fluid container portion of the cassette is made of two sheets of thermally conductive plastic film material. Preferably, the two sheets of plastic film material are bonded together in a pattern which creates a fluid channel between the sheets. A fluid channel with a serpentine pattern is illustrated, although other patterns are contemplated. Preferably the plastic film is 0.004 in. (4 mil) thick, or less.
[0026] FIG. 1A is a perspective illustration of a warming cassette 10 according to the invention for use with an intravenous fluid warming unit 12 . The warming unit 12 is a “dry heat” unit with warming plates 14 and 16 . The plates 14 and 16 are maintained spread apart at a fixed distance, and the cassette 10 is inserted between the plates 14 and 16 so that the fluid in the cassette 10 is heated before infusion into a body.
[0027] FIG. 2A is a more detailed depiction of the warming cassette 10 of FIG. 1A ; FIG. 2B is an exploded view of the cassette 10 showing two of its elements. The cassette 10 comprises a flexible fluid container 20 and a frame structure 22 to which the fluid container 20 is attached, joined, or bonded. The frame structure 22 stiffens the cassette within a first plane represented by orthogonal X and Y axes. The X and Y axes are referred to herein as first and second directions, respectively. Likewise, the fluid container 20 is substantially planar and disposed in the first plane. The frame structure 22 is considered to be rigid with respect to the flexible fluid container 20 . However, the frame structure 22 also has some degree of flexibility. Preferably, the frame structure 22 is semi-rigid.
[0028] The frame structure 22 is in the shape of a planar figure bounded by sides; preferably the figure is a closed figure. For example, FIGS. 2A and 2B , the figure is a quadrilateral having sides 24 and 26 , a distal end 30 , and a proximal end 28 . The figure of the quadrilateral defines an opening 31 within which the fluid container 20 is received. The fluid container 20 has a periphery including opposing, parallel sides 21 a and 21 b , and opposing, parallel ends 21 c and 21 d . The cassette 10 is assembled by receiving the fluid container 20 within the opening 31 and joining the fluid container 20 to the frame structure 22 by bonding, or otherwise permanently joining or connecting, the periphery 21 a , 21 b , 21 c , and 21 d of the fluid container 20 to the sides and ends 24 , 26 , 28 , and 30 of the frame structure 22 . Alternatively, the peripheral bonds could include just the sides 24 and 26 , or just the ends 28 and 30 . As a consequence of such bonding, joining, or connecting, the fluid container cannot be separated from the frame structure. The result, best seen in FIG. 2A is a unitary integrated warming cassette structure that may be handled, manipulated, or otherwise used or processed as a single piece. The inventors contemplate that the quadrilateral shape of the frame structure 22 may be practiced in an alternate embodiment in which distal end 30 is omitted, or is not continuous with the sides 24 and 26 . As best seen in FIG. 2A , the sides 24 and 26 are oriented, and provide stiffness in the first direction (X-axis) while the ends 28 and 30 are oriented, and provide stiffening in the second direction (Y-axis). Taken together, the sides 24 and 26 and the ends 28 and (optionally end 30 ) provide stiffness generally in the X Y plane.
[0029] In some aspects of the invention the proximal end 28 includes a handle portion 29 , formed to be manipulable by hand. That is, the proximal end 28 is given sufficient surface area, extending away from the fluid container 20 to accommodate finger purchase. When the cassette 10 is engaged with warming device 12 (see FIG. 1 ), the handle portion 29 is not received (at least, not entirely received) between the plates 14 and 16 . The handle portion 29 remains accessible while the rest of the cassette is being heated between plates 14 and 16 .
[0030] The handle portion 29 serves several purposes:
[0031] first, the handle portion 29 maintains the sides 24 and 26 in proper alignment and position for easy, one handed indexing with the warming unit;
[0032] second, the handle portion 29 may include a hole 29 a for accommodating and holding a bubble trap which is part of the tubing connected to the fluid outlet (see FIG. 3A );
[0033] third, the handle portion 29 includes a stopping mechanism 65 which mechanically prevents handle portion 29 from entering fluid warming unit 12 and assures proper insertion depth (see FIGS. 1B , 2 A, 2 B, 3 A and 3 B);
[0034] fourth, the handle portion 29 preferably includes a mechanism 38 for supporting fluid inlet and fluid outlet tubing (see FIG. 2A ), and providing strain relief preventing undue tension being applied to the tubing. Without this kind of strain relief, there is the risk of tension on the tubing, resulting in tearing the plastic film material. Attaching the tubes helps to prevent kinking of the tubing as it leaves the warming unit; and
[0035] fifth, the handle portion 29 includes a substantially flat area 56 which may be used for labeling (see FIG. 3A ). Since the majority of the cassette 10 is inside the warming unit during use, it is convenient to have labeling visible to the user even during use. Handle portion 29 is always external to the warming unit and, therefore, is an ideal platform for such labeling.
[0036] The frame structure 22 can be formed from a material selected from the group consisting of polyester, polyamide (Nylon®, DuPont), polyethylene glycol terephthalate (Mylar®, DuPont), and ionomer resins (Surlyn®, DuPont). The frame structure 22 can be manufactured by die cutting, injection molding, and thermal processes.
[0037] The fluid container 20 can be made from one or more materials selected from the group consisting of polyvinyl chloride (PVC), polyurethane, polypropylene, polyethylene, polyester, and other polymeric materials.
[0038] The fluid container 20 includes a fluid channel 32 and at least a first port 34 for fluid communication with the fluid channel 32 , which is highlighted with cross-hatched lines in FIGS. 2A and 2B . A first tube 36 is joined to the first port 34 . Optionally, the first tube is attached to the frame structure 22 at its proximal end 28 . Alternately, the first tube 36 is, at least partially, formed to be an integral part of the handle portion 29 . In FIG. 2A , the area of attachment is represented with double cross-hatched lines and labeled with reference numeral 38 . The fluid container 20 also includes a second port 40 in fluid communication with the fluid channel 32 . A second tube 42 is joined to the second port 40 .
[0039] FIGS. 3A and 3B illustrate the warming cassette 10 of FIG. 1 , detailing an optional bubble trap feature. FIG. 3B is an enlargement of Section A of FIG. 3A . The warming cassette 10 optionally includes a bubble trap 50 attached to the handle portion 29 for support. The bubble trap 50 traps any air bubbles that may have inadvertently been introduced into the inlet tubing from the IV bag or may have been created by “out-gassing” during the warming of the fluids. The bubble trap 50 has an input 52 connected to the second port 40 . The bubble trap 50 has an output 54 to supply fluid, and a gas exhaust port (not shown) to vent gases escaping from the communicated fluid. The output 54 is operatively connected to the patient's IV catheter (not shown).
[0040] The bubble trap 50 can be mechanically attached or bonded through thermal, adhesive, or chemical means to the handle portion 29 . Attaching the bubble trap 50 to the handle portion 29 makes it less likely that the trap 50 , or its associated tubing will be inadvertently disconnected from the cassette 10 .
[0041] The handle portion 29 optionally includes a label surface 56 , highlighted with cross-hatched lines in FIGS. 3A and 3B . The cassette 10 then may receive a label (not shown) overlying the second stiffening member label surface 56 . The label can be visible to the eye, or configured for electronic identification, such as a bar code.
[0042] FIGS. 4A through 4C illustrate details of keying elements used to orient the cassette 10 in the warming unit 12 . The intravenous warming unit 12 includes the first and second opposing warming plates 14 and 16 , adapted to accept the warming cassette 10 in a first orientation. FIG. 4A is a simplified end view of the warming unit 12 . The warming plates 14 and 16 have been separated for the purpose of clarifying the invention. Two grooves 60 are formed in the upper plate 14 to cooperate with a key mechanism on the warming cassette 10 . FIG. 4B illustrates the warming unit 12 with the warming plates 14 and 16 assembled for normal operation.
[0043] Refer now to FIGS. 1A-3B and 4 C. FIG. 4C is a sectional view taken along A 4 -A 4 of FIG. 1A . In these figures, there are illustrated two lands 64 that act as a key mechanism with the grooves 60 to mate the cassette 10 with the warming plates in a predetermined orientation. Preferably, the lands 64 are formed integrally with the sides 24 and 26 , and extend longitudinally thereon. When the warming cassette 10 is received between the plates 14 and 16 , the lands 64 key the warming cassette 10 by permitting the cassette to be inserted or slid into the space between the plates only if the lands 64 are received in the grooves 60 . Otherwise, the lands 64 will prevent the cassette from being inserted into the warming unit 12 between the plates 14 and 16 .
[0044] Referring to FIGS. 1B-3B , a stop mechanism is illustrated in the form of a ridge 65 that extends parallel to the distal end 28 on an upper surface of the handle portion 29 . The ridge 65 is high enough to contact the upper plate 14 when the fluid pathway 32 is fully received between the plates 14 and 16 ; this contact stops the cassette from being inserted any further between the plates 14 and 16 . Manifestly another ridge, or an alternate ridge, can be provided on the lower surface of the handle portion 29 .
[0045] The unitary, integrated warming cassette 10 of FIGS. 1A and 2A can be inserted into the warming unit 12 by a user, employing one hand to grasp the integral handle portion 29 , orienting the warming cassette 10 so that the lands 64 are aligned with the grooves 60 , inserting the distal end 30 between the plates 14 and 16 and sliding the warming cassette 10 inwardly between the plates 14 and 16 until the stopping mechanism 65 halts further insertion.
[0046] Other variations and embodiments of the prevent invention will occur to those skilled in the art with reflection upon the disclosed examples of the fluid warming system.
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A fluid warming cassette system in which the cassette has a stiffening frame structure and an integral handle is provided to support a parenteral fluid container. The fluid container is desirably thin to minimize heat exchange inefficiencies. The frame structure permits the thin fluid container to be inserted into the narrow space between fixed position warming plates of a warming unit. The frame structure has a quadrilateral shape with sides and ends. The fluid container is attached, at its periphery to the sides and ends of the frame structure, within the quadrilateral shape. Part of the frame structure is formed into a handle to assist in both the insertion and removal of the cassette from a warming unit.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a divisional application of Ser. No. 710,960 filed Aug. 2, 1976, now U.S. Pat. No. 4,125,593.
BACKGROUND OF THE INVENTION
It is ecologically unacceptable to release halogenated hydrocarbons into the atmosphere or into public waters. Among the methods used in attempts to abate such pollution has been combustion (thermal oxidation) of the halogenated hydrocarbons in bricklined furnaces or other refractory furnaces. There have been some attempts to extract some of the heat values and chemical values by heat exchange and aqueous scrubbing of the combustion gases which are emitted from the refractory furnace.
It is the field of thermal oxidation of halogenated hydrocarbons to which the present invention most closely pertains. More precisely, the invention pertains to thermally oxidizing halogenated hydrocarbons in such a manner that the heat of combustion and the halogen values in the combustion product are recovered, thus salvaging valuable energy and chemical values.
It is an object of the present invention to provide for improved disposal of halogenated hydrocarbons by employing thermal oxidation.
It is a further object to provide for combusting of halogenated hydrocarbons in such a manner that pollution of public waters and the atmosphere is abated.
It is also an object to provide for combusting of halogenated hydrocarbons in such a manner that valuable energy and chemical values are recovered.
Another object is to provide a horizontal fire-tube boiler which has been modified so as to withstand the highly corrosive gases from the thermal oxidation of halogenated hydrocarbons for extended periods of time.
These, and other objects, are attained by performing the combustion (thermal oxidation) of halogenated hydrocarbons in accordance with the present invention.
SUMMARY OF THE INVENTION
It has now been found, surprisingly and unexpectedly, that halogenated hydrocarbons can be burned, generally along with a supplemental fuel, directly in the water-cooled combustion chamber of a horizontal fire-tube boiler and that the intense corrosion of the water-cooled metal surfaces in contact with the hot combustion gases which one would expect to get are substantially avoided by carefully controlling the pressure of the saturated steam which is produced in the boiler. Corrosion of other boiler surfaces which are contacted by the hot corrosive gases, and which are not water-cooled, are either constructed of corrosion-resistant material, e.g. nickel or nickel alloy, or else are protected by insulation which keeps the metal surfaces in the desired temperature range at which corrosion is substantially minimized.
In its broadest sense the present invention comprises the combustion (thermal oxidation) of halogenated hydrocarbon fuels directly in a modified horizontal fire-tube boiler wherein the heat of combustion is transferred through the metal walls directly into water to make saturated steam and to substantially cool the combustion gases. Preferably, the combustion gases are then passed into contact with liquid-absorbents, e.g., water-scrubbers, to recover halogen values.
As used herein, the terms "halogenated hydrocarbon" and "halogenated hydrocarbons" refers to single chemical entities or to mixtures of various halogenated hydrocarbons. The halogenated hydrocarbons may be either liquid or gaseous or both.
DETAILED DESCRIPTION OF THE INVENTION
Halogenated hydrocarbons are thermally oxidized to gaseous products CO 2 , H 2 O, HX (X=halogen), and some free halogen by being burned in an excess of air in a horizontal fire-tube boiler in which water is directly heated to form useable saturated steam and, preferably, the halogen values are collected from the exit gases by an aqueous scrubber. The fire-tube boiler is substantially of a conventional design, but since such conventional fire-tube boilers are not normally intended for use with highly corrosive fuels, it has been found to be advantageous to employ corrosion resistant surfaces at certain places in the boiler. The fire-tube boiler comprises, basically, a boiler section, a front-end section, and a rear section. The boiler section is essentially a horizontally-positioned shell and tube heat-exchanger. This heat-exchanger comprises a shell having its ends closed with tube-sheets. Extending between and communicating through the tube-sheets are a plurality of tubes. One of the tubes is a relatively large-diameter tube, herein called combustion chamber or furnace, and a plurality of smaller tubes, herein called return-tubes.
The front-end section, sometimes referred to in the industry as a front-end door or front door, can, conveniently, be swung open or removed, even partly, to expose the front tube-sheet of the boiler section and allow inspection or maintenance to be performed. The front-end section contains the feed means for transmitting air, supplemental fuel, and halogenated hydrocarbon fuel into the burner which is positioned at about the front-end of the combustion tube. The front-end section may contain baffles, as needed, to cause flow of hot gases entering it to flow back through the fire-tube boiler through a different set of return-tubes.
The rear section which, conveniently, can be swung open, may also contain baffles, as needed, to cause the flow of hot gases to flow back through the fire-tube boiler through a different set of return-tubes. The rear section may, conveniently, contain one or more ports or sight glasses for inspection or observation purposes. The inner surfaces of the rear section may be lined with a refractory material or other such insulation which will help prevent heat losses and help protect the metal from the hot, corrosive gases. Optionally, the rear section may be water-cooled by having water circulate between an inner wall and the outer wall or by having water flow through tubes which are juxta-positioned with the inside of the rear section wall.
Operation of the process is performed by mixing air, supplemental fuel (as needed), and halogenated hydrocarbon to provide a combustible mixture to the combustion chamber. The mixture is then burned in the combustion chamber. The ratio of supplemental fuel/halogenated hydrocarbon is adjusted to maintain flame stability and high halogen conversion to HX. The amount of supplemental fuel can vary from 0 to about 95% of the total heat input, depending on the heating value and the uniformity of the halogenated hydrocarbon which is being burned. The higher the heating value of the halogenated hydrocarbon, the less supplemental fuel is needed.
The water flow through the fire-tube boiler is adjusted to maintain a water level covering all the tubes; it is critical to keep all the tubes submerged to prevent their overheating. It has been found that corrosion is held to a surprisingly low minimum by operating in a manner to produce saturated steam at a pressure in the range of about 150 to about 275 psig., even when the fire-tube boiler is constructed of relatively inexpensive metals, such as carbon steel which is commonly and conventionally used to construct ordinary boilers. In this steam pressure range, the water in the boiler is maintained at a temperature in the range of about 186° to about 210° C. and this, along with maintaining scale-free metal surfaces on the water side of the boiler, keeps the walls of the furnace, return-tubes and tube-sheets which are exposed to the hot corrosive gases, at about 200° C. to about 250° C. If the steam pressure is allowed to drop below about 150 psig the walls of the furnace, return-tubes, and tube sheets can cool down to the point (downwards from 200° C.) at which accelerated corrosion is encountered. On the other hand, if the pressure is allowed to climb upwards much above 275 psig, the walls of the furnace, return-tubes, and tube-sheets can approach 300° C. or more (especially if any scale has formed) and severe corrosion may be encountered.
It is essential that care be taken to assure that the water in the boiler be non-scale-forming so as to substantially avoid formation of scale on the water side of the return-tubes, tube-sheets and combustion chamber. If significant amounts of scale accumulate on these surfaces, heat transfer through these metal walls is adversely affected and the resulting higher wall temperature on the combustion gas side of the walls will cause severe corrosion rates. Persons skilled in the art of boiler water control are aware of the various water treatments which are customarily used for prevention of scale. The exact nature of any scale-inhibitors or other means used for avoiding scale formation is not especially critical. Obviously, ingredients in the water which are corrosive or will cause substantial oxidation of the metal surfaces should be avoided or inhibited.
The expression "fire-tube boiler" as used herein refers to commonly used and well-known boilers which have water-cooled combustion chambers and which are called "stationary, horizontal, internally-fired, fire-tube boilers." These boilers are available commercially and can be built, or modified, to be multi-pass, e.g., two-pass, three-pass, four-pass, or more passes. The expression "pass" refers to the travel of the combustion gases through one or more tubes in one direction; a second "pass" occurs when the hot gases travel in the reverse direction through one or more other tubes. In multiple-pass boilers, the flow of gases in each "pass" is through one or more tubes not used in another "pass".
FIG. 1 depicts a cross-section view, not to scale, showing the principal features of a horizontal fire-tube boiler.
FIG. 2 depicts an end-view, not to scale, of a fire-tube boiler tube-sheet with end views of the combustion chamber and return tubes depicted.
FIG. 3 is a flow-sheet diagram, not to scale, showing a generalized view of a fire-tube boiler and two scrubbing units, with appropriate piping, for halogen recovery.
A common embodiment of a fire-tube boiler, modified according to the present invention, is defined, generally, by reference to FIG. 1 which is a cross-sectional view depicting the essential main parts of the boiler, as a boiler having a boiler section (1), a front-end section (2), and a rear section (3). The boiler section comprises a horizontal combustion chamber (4) in parallel alignment with a plurality of return-tubes (5), said combustion chamber and return-tubes being positioned within said boiler section, terminating at the tube-sheets (6) and (8) at the ends of the boiler section and communicating with the space contained within (3), said space within (3) being designated as (7). The other ends of the return-tubes and combustion chamber terminate at tube-sheet (8) and communicate with the space contained within (2) said space within (2) being designated, generally, as (9). A supplemental fuel, air, and halogenated hydrocarbon feeder device (denoted generally as 10) communicates from the supplemental fuel, air, halogenated hydrocarbon supply lines through front end section (2) and through space (9) into combustion chamber (or furnace) (4). Conveniently, there is a sight glass (11) through rear section (3) which allows one to observe the burning in the combustion chamber. Also, conveniently, there is a thermocouple (12) protruding through rear section (3). The interior wall surface (14) of rear section (3) is conveniently lined with refractory material or high-temperature insulation (13). The external wall surface (14a) may be water-cooled by, e.g., water conduits (not shown) or may be protected against the vagaries of weather and against loss of heat by refractory or insulation material (13a). The wall defining section (3) should be protected against contact with corrosive agents, e.g., HCl. Preferably the amount of insulation used at (13) and (13a) is selected on the basis of keeping the wall in the range of about 200° C. to about 250° C. during the combustion of halogenated hydrocarbon. The space within rear section (3), which is designated as (7) may be divided into two or more separate spaces, if desired, by using one or more corrosion-resistant baffles (15) which direct flow of hot gases back through return-tubes not yet traveled. In space (7), at the area at which hot combustion gases from the combustion chamber impinge on the inner surface of the insulation or refractory (13), there is preferably installed a corrosion-resistant material (15a) which is selected for its ability to withstand hot, corrosive material over a substantial length of time and also to help in avoiding heat losses. Many refractories are known which will withstand the hot, corrosive gases encountered in the present invention.
Within section (2) there may be, if desired, one or more baffles (32) to direct the flow of hot gases through the appropriate return-tubes. The space within section (2) may be divided into two major spaces (9) and (9a) by the use of a barrier wall (17) having a corrosion-resistant or insulated surface (31) and an insulated surface (16) which serve to keep the wall (17) in the desired temperature range during operation. The inner major space (9), which may contain one or more baffles (32) carries the hot gases which flow from space (7) until the gases eventually flow from the exit (18) provided and on to further processing. Depending on the number of passes, exit (18) may communicate with space (7) instead of space (9). The feeder device (10) communicates through spaces (9a) and (9) into the combustion chamber (4). The space within the feeder device does not communicate directly with space (9). Passages (not shown) in the walls of the feeder device receive air from space (9a). Air may be supplied to space (9a) by means of forced air (19) or by being drawn in with induced draft attained by drawing exit gases out through exit (18). Damper means (not shown) may be employed on the feeder device (10) to regulate the amount of air reaching the burner.
In one embodiment of an actual operation atomizing air (21) and halogenated hydrocarbon (22) are mixed in a feed line approximately centrally located within feeder device (10) and are thereby supplied to the atomizing nozzle (23) of the feeder device. Supplemental fuel gas (26) is fed to the pilot (25) and/or through the vapor inlet pipe (24) and through openings (30) where it mixes with air (19) in the region of the nozzle (23). Chlorinated hydrocarbon vapors may also be conveniently fed to the burner through pipe (26). The mixture of air, fuel and halogenated hydrocarbon is mixed and burned in combustion chamber (4), the hot gases passing into one portion of space (7), then through a plurality of return-tubes (5) to one portion of space (9), then through a plurality of return-tubes (5) into another portion of space (7), then back to another portion of space (9) where it then exits (18) the boiler into other processing equipment (not shown in FIG. 1). During operation non-scaling water is supplied to the boiler so as to completely surround the return-tubes and the combustion chamber. The combustion is regulated by adjusting the flow of fuel and/or air so as to maintain excess oxygen in the exit gases and to keep the temperature of the gases leaving the combustion chamber space near thermocouple (12) at not more than about 1100° C. and to maintain a saturated steam pressure in the range of about 150 to about 275 psig which gives a boiler water temperature in the range of about 186° to about 210° C. The desired water level is maintained by regulating the flow of make-up water. The desired pressure is maintained by regulating the flow of saturated steam from the boiler at steam vent (27) and/or by regulating the fuel mixture being fed to the combustion chamber.
FIG. 2 depicts an end-view of a fire-tube boiler section (1) and shows a plurality of return-tubes (5) communicating through tube-sheet (6) or (8). Combustion chamber (4) is considerably larger in diameter than the return-tubes.
Even though combustion chamber (4) is depicted as a straight-wall tube, practitioners of the art of fire-tube boilers will realize that the combustion chamber walls may be convoluted.
It will also be readily apparent that the positioning of baffles (15) and (32) should be done commensurately with the contracting volume of the gases as they cool during flow through the return-tubes. That is, the total cross-sectional area of the first "set" of return-tubes should be less than the cross-sectional area of the combustion chamber; the second "set" of return-tubes should have a total cross-sectional area less than the first "set" and so on. Thus, the gas velocity from one "pass" to another is kept high so as to keep heat transfer rates efficient.
In a typical operation in the depicted apparatus, the temperature profile in a boiler such as depicted in FIG. 1 will be: about 2100°-1600° C. (average) in the combustion chamber (4); about 500°-1100° C. in the area of thermocouple (12); about 280°-400° C. in first space (9), measured by thermocouple (12a); about 250°-320° in space (7), measured by thermocouple (12b); and about 215°-260° C. in second space (9), mesured by thermocouple (12c) as the gases leave through exit (18).
FIG. 3 is a flow-sheet diagram depicting an embodiment of the overall process wherein supplemental fuel (24), air (21) and halogenated hydrocarbon (22) are burned in a fire-tube boiler (1), combustion gases which exit are carried by conduit (18) to a liquid-contactor, e.g., an aqueous scrubber (30), through a separator (31) from which aqueous solution is drawn (43), then through conduit (18a) to a second aqueous scrubber (30a), on through a second separator (31a) from which aqueous solution is drawn (32a), then through a conduit (18b) to a vent or other suitable processing. Water (40) and/or other appropriate aqueous scrubbing liquid, e.g., dilute caustic (40a) is supplied to scrubbers (30) and (30a) and aqueous solution is drawn from the separators at a rate commensurate with the flow of aqueous solution from the scrubbers. A blower or other appropriate gas-moving device (50) may be conveniently employed to enhance the flow of the combustion gases through the system and to safeguard against leaks of corrosive materials from the system in the event a leak occurs. By pulling the combustion gases through the system, a positive pressure is avoided, and in fact, a slightly reduced pressure within the system may be attained. Steam exits the boiler through vent (27) and is used elsewhere.
The supplemental fuel used in the burning process may be any of the lower hydrocarbons ordinarily employed as fuels, such as, methane, ethane, propane, butane, isopropane, isobutane, pentane, hexane, heptane, octane, isoctane or mixtures of these or may be L.P.G. (liquified petroleum gas). Any aliphatic hydrocarbon having 1-12 carbons, especially 1-4 carbons, are suitable. The most ordinary fuel and most preferred as supplemental fuel, is natural gas. Virtually any vaporizable or atomizable hydrocarbon may be employed, such as gasoline, kerosene, petroleum ether, fuel oil, No. 2 fuel oil, No. 4 fuel oil, Bunker C oil, etc. Clean-burning fuels or clean-burning mixtures of fuels are preferred.
The "halogenated hydrocarbon" as used herein includes hydrocarbons which have chlorine, bromine, or iodine values. Usually the halogenated hydrocarbon desired to be burned according to the present invention is a waste stream of chlorinated hydrocarbon or mixture of chlorinated hydrocarbons. It is within the purview of the present invention to combine various streams containing chlorinated, brominated, or iodinated organics for burning. Fluorinated organics may also be mixed in for burning, but since fluorine values are normally so highly corrosive as to substantially limit the life of the equipment, it is best to hold the maximum amount of organic fluorides to a small percent. The present invention also contemplates that the air supplied to the burner may contain vapors of halogenated hydrocarbons, such as vinyl chloride and others, which may be swept from an area for protection of personnel in the area.
The following examples are meant to illustrate operation of some embodiments of the present invention. The scope of the invention is restricted only by the attached claims.
EXAMPLES
Various halogentaed hydrocarbons were burned in a 4-pass fire-tube boiler substantially in accordance with the above teachings. The data are shown in Table I. The supplemental fuel was natural gas. The calculated average temperature in the furnace was the arithmetic average of measured outlet temp. and theoretical flame temperature, based on the measured temperature at the thermocouple (12) positioned at the end of the first pass. The steam pressure was maintained in the range of about 150 to about 275 psig and the water in the boiler was in the range of about 186° C. to about 210° C. The water level was maintained so as to completely cover the uppermost return-tubes. During operation a blower at the vent stack operated to pull excess air through the burner, through two aqueous caustic scrubbers in series and out through the vent stack.
The RCl's (halogenated hydrocarbons) in the vent gas were determined by entrapment in heptane followed by electron capture gas chromatography analysis except for Run Nos. 9, 11, and 12. Run Nos. 9 and 11 were determined by total organic chloride analysis of RCl's trapped in heptane and Run No. 12 was determined by trapping RCl's on activated charcoal, extracting with carbon disulfide and analyzing by hydrogen flame gas chromatography.
The RCl feed streams in Table I are identified as follows (percents are by weight):
A. Commercial grade propylene dichloride.
B. Waste mixture of about thirty different RCl's with elemental analysis of 32.8% C, 63.2% Cl, 4.0% H.
C. Waste mixture of 6 RCl's containing mostly dichloroisopropyl ether with elemental analysis 40.2% C, 43.6% Cl, 6.7% H, 9.5% O.
D. Waste mixture of about 23 RCl's containing mainly trichloroethane, trichlorobromopropane, and pentachloroethane; also contained hexachloroethane, hexachlorobutane, hexachlorobutadiene and had elemental analysis 17.2% C, 77.1% Cl, 4.6% H, 1.1% Br.
E. Waste mixture of about 13 RCl's containing mainly hexachlorobutadiene and symmetrical tetrachloroethane; also contained hexachloroethane and hexachlorobenzene and had elemental analysis of 17.5% C, 81.6% Cl, 0.9% H.
F. Waste mixture of about 14 RCl's containing mainly propylene dichloride, hexachloroethane, sym-tetrachloroethane; also contained hexachlorobenzene and had elemental analysis 24.5% C, 72.3% Cl, 3.2% H.
G. Waste mixture of about 5 RCl's containing mainly sym-tetrachloroethane, hexachloroethane, hexachlorobutadiene; 1.9 wt. % iron as Fe, 2.7 wt. % ash at 950° C.; elemental analysis 15.61% C, 82.96% Cl, 1.46% H.
It will be readily apparent to persons skilled in the art that other embodiments and modifications in the process and in the apparatus may be made without departing from the present invention.
TABLE I__________________________________________________________________________Furnace Parameters Feed to Boiler Calc. T.C.* Residence RCL in RCL ChlorineRun RCL Feed Lb./Hr. Ave. Temp. Temp. Time Outlet Gas Conversion ConversionNo. Stream RCL CH.sub.4 (° C.) (° C.) (Sec.) (wt. ppm) (%) To HCl (%)__________________________________________________________________________1 A 66.5 9.6 1361 870 0.36 0.083 99.99++ 97.92 B 74.0 17.0 1327 888 0.27 0.076 99.99++ 98.93 B 64.8 17.3 1312 870 0.28 0.128 99.99++ 98.94 C 88.0 8.5 1423 1050 0.24 0.234 99.99++ 98.45 C 101.5 6.0 1374 990 0.22 0.203 99.99++ 98.36 D 159.4 14.7 1291 790 0.33 8.06 99.99++ 93.47 D 100.0 31.7 1339 875 0.24 1.57 99.99++ 97.78 E 67.3 34.0 1293 837 0.25 1.13 99.99++ NA**9 E 67.3 34.0 1293 837 0.25 0.53 99.99++ NA10 F 96.6 19.1 1333 923 0.26 8.8 99.99++ NA11 F 96.6 19.1 1333 923 0.26 1.98 99.99++ NA12 G 75.1 26.4 1362 945 0.29 14.7 99.98++ 99.3__________________________________________________________________________ *T.C. Temp. is measured by the thermocouple at end of first pass. **NA: Not Analyzed
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Halogenated hydrocarbon materials are burned in an internally-fired horizontal fire-tube boiler and the heat of combustion directly produces saturated steam. Halogen values may be recovered from the combustion gases, e.g., by being absorbed in water. Thus halogenated hydrocarbon material which may need to be disposed of, is beneficially converted to energy and useful product.
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BACKGROUND OF THE INVENTION
[0001] The invention relates generally to a portable seat. In one aspect, the invention relates to a portable seat-shelter.
[0002] Portable seats are desirable for many outdoor activities, such as at sporting events, for hunting, or for relaxing, such as at the beach. At these same activities, too much sun or inclimate weather can detract from the user's enjoyment. A portable seat which provides some protection from the sun, rain or a cold wind would be very desirable.
[0003] The addition of a sheltering structure in the past has reduced the transportability of the seat. What is needed is a sheltering structure which is as easy to transport as the seat.
[0004] An object of the invention is to provide a combination seat-shelter which is easy to transport and erect, and which has a low profile to permit its use in stadiums, arenas and the like.
SUMMARY OF THE INVENTION
[0005] In accordance with one embodiment of the invention, an apparatus suitable for use as a combination seat and shelter, for use such as in a stadium, as a hunting blind, or at the beach, comprises a cushion member and a pair of sheet members. The cushion member has a first end and a second end and a length measured between the first end and the second end, and a first side edge and a second side edge extending for substantially the length. A first generally rectangularly shaped cushion member panel portion of the cushion member extends from the first end toward the second end and a second generally rectangularly shaped cushion member panel portion of the cushion member extends from the second end toward the first end. A third generally rectangularly shaped cushion member panel portion connects the first generally rectangularly shaped panel portion and the second generally rectangularly shaped panel portion. The second generally rectangularly shaped panel portion is superposed over the first generally rectangularly shaped panel portion. A first sheet member is fastened along the length of the first side edge of the cushion member and a second sheet member is fastened along the length of the second side edge of the cushion member.
[0006] When the cushion member is formed from an inflatable closure, it can be collapsed for ease in transport and inflated on-site to form a free-standing a five-sided shelter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is a pictorial representation of a seat-shelter formed in accordance with one embodiment of the invention.
[0008] [0008]FIG. 2 is a longitudinal sectional view of the seat-shelter of FIG. 1 taken along cut lines 2 - 2 .
[0009] [0009]FIG. 3 is a side view of the seat-shelter shown in FIG. 1.
[0010] [0010]FIG. 4 is a longitudinal sectional view of the seat-shelter of FIG. 1 taken along cut lines 4 - 4 .
DETAILED DESCRIPTION OF THE INVENTION
[0011] An apparatus 10 suitable for use as a combination seat and shelter comprises a cushion member 12 and a pair of sheet members 14 , 16 . The cushion member has a first end and a second end and a length measured between the first end and the second end, and a first side edge and a second side edge extending for substantially the length. A first generally rectangularly shaped cushion member panel portion 18 of the cushion member extends from the first end toward the second end and a second generally rectangularly shaped cushion member panel portion 20 of the cushion member extends from the second end toward the first end. A third generally rectangularly shaped cushion member panel portion 22 connects the first generally rectangularly shaped panel portion and the second generally rectangularly shaped panel portion. The second generally rectangularly shaped panel portion is superposed over the first generally rectangularly shaped panel portion. The first sheet member is fastened along the length of the first side edge of the cushion member and a second sheet member is fastened along the length of the second side edge of the cushion member.
[0012] In accordance with the invention, the cushion member further forms means for biasing the first generally rectangularly shaped cushion member panel portion away from the second generally rectangularly shaped panel portion. Preferably, and as illustrated, the cushion member forms means for biasing the first generally rectangularly shaped cushion member panel portion away from the second generally rectangularly shaped cushion member panel portion to straighten the first sheet member and the second sheet member and form a shelter for accommodating a person. If desired, the shelter can be made double wide to accommodate two people.
[0013] Although the cushion member could be formed from various materials, such as a resilient foam, the cushion member preferably comprises a self-supportive inflatable closed structure. A cushion member formed from a plurality of air-impermeable longitudinally-extending tubes 24 has been tested with good results. The plurality of tubes is preferably arranged with the tubes in parallel side by side relationship, and more preferably, the tubes are configured to provide the cushion with a thickness of about one inch.
[0014] Suitable materials are well known, and can be selected from thermoplastic, rubber and coated fabrics for example, as are used in beach toys, vehicle tires, and life rafts. For economy and low weight, thermoplastic is preferred. Sheets of thermoplastic can be heat welded or glued to form an interconnected array of tubes.
[0015] The cushion member preferably further comprises means 26 for inflating the tubes. Preferably, the means 26 forms a selectively sealable flow path from an outside of the cushion to an inside of the plurality of tubes. A nozzle 28 operatively associated with a valve 30 for sealing the nozzle will provide good results.
[0016] More preferably, the apparatus further comprises a second nozzle 32 associated with a second valve for selectively deflating the plurality of tubes. The second nozzle preferably provides a larger flow path than the first to permit the device to be rapidly deflated.
[0017] In a preferred embodiment, the apparatus 10 preferably comprises a covering 34 connected to an outside surface of the plurality of tubes which is stretched taut when the plurality of tubes is in an inflated condition to provide the cushion with protection and a smooth outside appearance. The sheet members 14 and 16 are preferably also stretched taut when the plurality of tubes is in an inflated condition. The covering and the sheet members can be formed from thermoplastic or fabric, for example, and are preferably constructed of a material which can be printed, such as with camouflage colors or with sports team insignia. The elements can be interconnected by heat welding, glue or stitching, as appropriate.
[0018] The sheet members are also preferably each provided with at least one means 36 , 36 ′ for forming a window. Each means for forming a window preferably comprises a clear panel 38 , 38 ′ located in a middle portion of each sheet member, each such clear panel having a periphery which is fastened to the sheet member. More preferably, each clear panel is releasably fastened to the sheet member along at least a portion of its periphery. In the illustrated embodiment, zippers are employed. Most preferably each clear panel folds toward the first generally rectangularly shaped cushion member panel portion when in a released position, to provide ventilation to permit the user to hold a conversation with a another person positioned alongside, such as in an adjacent seat-shelter.
[0019] The first generally rectangularly shaped cushion member panel portion is preferably larger than the second generally rectangularly shaped cushion member panel portion. In this embodiment, the first generally rectangularly shaped cushion member panel portion forms a seat structure and the second generally rectangularly shaped cushion member panel portion forms a roof structure. A portion of the second generally rectangularly shaped panel portion can slope toward the first generally shaped panel portion near the second end of the cushion member to form a visor 21 . The third generally rectangularly shaped cushion member panel portion connects the first generally rectangularly shaped cushion member panel portion and the second generally rectangularly shaped cushion member panel portion and preferably forms a sloping rear wall structure.
[0020] While certain preferred embodiments of the invention have been hereinabove described, the invention is not to be construed as being so limited, except to the extent that such limitations are found in the claims.
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A seat-shelter is formed from an inflatable closure can be collapsed for ease in transport and inflated on-site to form free-standing a five-sided shelter.
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This application is a continuation-in-part of U.S. patent application Ser. No. 09/597,268, filed on Jun. 20, 2000 now abandoned, which had been a continuation of U.S. patent application Ser. No. 09/287,261, filed on Apr. 7, 1999, which had been a continuation of PCT/CA97/00736 filed Oct. 7, 1997, and this application is also a continuation of PCT/CA00/00373 filed Apr. 7, 2000.
FIELD OF INVENTION
The present invention is concerned with the field of valves and actuators and relates to a pneumatic actuator. More particularly, the present invention is an improved pneumatic actuator, which includes a rotary piston that reciprocates within a housing.
BACKGROUND OF INVENTION
FIG. 1 shows a conventional pneumatic valve actuator which includes a toothed shaft 10 , an actuating shaft 20 extending through the toothed shaft 10 , two piston members 30 each having a rack member 301 engaged with the toothed shaft 10 , and a plurality of springs 302 biasedly disposed between an inner side of a housing 40 and the piston members 30 . In operation, the pneumatic valve actuator operates on the basis of cycles of air movement. At the beginning of a cycle air under pressure enters the interior of the housing 100 via two holes 41 to push the piston members 30 from a starting position away from each other to a fully separated position (as illustrated in FIG. 1) such that the toothed shaft 10 is rotated in a counter-clockwise direction by the movement of the two rack members 301 and the springs 302 are thereby compressed. By virtue of the rotation of the toothed shaft the actuating shaft 20 is also rotated. The rotation of the actuating shaft 20 is utilized for some other function (not shown). When the piston members 30 reach the fully separated position air entry into the housing is stopped, and the two holes 41 are opened to vent the housing at which time, the springs 302 push the piston members 30 back to the original starting position and thereby the toothed shaft 10 , and correspondingly, shaft 20 are rotated in a clock-wise direction. When the piston members reach the starting position, one cycle will have been completed. During operation, the force of pressurized air in the housing 100 causes leakage at the positions where the toothed shaft 10 and/or the actuating shaft 20 extend through the housing 40 (not shown in FIG. 1 ). Depending upon the construction characteristics and materials used in the valve, as well as the amount of pressure, even after using such actuators for a short period of time leakage can occur. Furthermore, the interior surfaces of the housing 40 and contact and sliding surfaces of the rack members 301 must be manufactured precisely to ensure that the rack members 301 slide smoothly along the inner surfaces of the housing 40 all of which increases the cost of manufacturing.
Another commonly used pneumatic valve actuator is illustrated in FIGS. 2 and 3. The actuator is disposed between a return spring 7400 and a valve 7200 with a shaft 6200 extending through the return spring, the actuator and the valve so that when pressurized air is injected into the actuator, the shaft is rotated to operate the valve.
The actuator includes a casing, including an upper casing 6010 , a lower casing 6020 and a vane member 6400 which is received between the upper and lower casing. The upper and lower casing are connected by bolts 6030 along flanges extending from each of the upper and lower casing wherein the lower casing has two passages 6800 defined therein so that pressurized air can be injected from the air pump and into the passages. The shaft rotatably extends through the upper casing and the lower casing and securely extends through the vane member. A seal member 6600 is disposed to the vane member so that the piston member is reciprocally moved within the casing by pressurized air entering the casing through the passages. The shaft is co-rotated with the vane member so as to control the actuator between an open and closed position. A return spring means 7400 including a spring coil 7600 is disposed above the actuator casing in accordance with a requirement to automatically return the shaft to its starting position once the pressurized air is stopped, thereby returning the vane member to its original position.
The seal member tends to become quickly worn out because the seal member slides along an inner surface of the casing whenever the piston moves. Furthermore, the inner surface of each of the upper and lower casing must be machined smooth to prolong the life of the seal. The return means including the coil spring and the machining of the inner surface of the casing results in the whole assembly being quite expensive.
SUMMARY OF THE INVENTION
The present invention avoids the above-noted problems of the prior art by providing an improved pneumatic actuator comprising a simpler, cost efficient piston, spring, and seal assembly.
Accordingly, the present invention provides a pneumatic actuator comprising a housing having an inner surface, a piston having an exterior surface and disposed within the housing, a shaft connected to piston, and a seal simultaneously engaging each of the exterior surface of the piston, the inner surface of the housing, and the shaft, and defining first and second chambers within the housing. The first chamber can be substantially isolated from the second chamber. The seal can further include aperture means for receiving the shaft. The exterior surface of the piston can be movable relative to the seal. The seal can immovably reside in a groove formed within the inner surface of the housing. Movement of the piston from a static condition to an operative condition can be effected by fluid pressure. The actuator can further comprise resilient means for biasing the piston towards a static condition. The resilient means can have a first end and a second end, the first end engaging an inner surface of the housing within the second chamber, and the second end engaging the piston, and could include a leaf spring. The actuator can be operatively connected to a valve to effect movement thereof.
In another aspect, the present invention provides a pneumatic valve actuator comprising a housing, a piston, moveable between a stable condition and an operative condition, a seal for effecting sealing between the piston and the housing, and defining first and second chambers within the housing, and resilient means disposed within the housing for biasing the piston towards a static condition. The first chamber can be substantially isolated from the second chamber. The resilient means has a first end and a second end, the first end engaging an inner surface of the housing within the second chamber, and the second end engaging the piston. The actuator can be operatively connected to a valve to effect movement thereof.
In yet another aspect, the present invention provides a pneumatic actuator comprising a housing, a piston having an exterior surface, means to introduce fluid pressure into the housing to effect movement of the piston, and a seal for effecting sealing between the piston and the housing, and defining a first chamber and a second chamber within the housing, the seal engaging the exterior surface of the piston in a substantially fluid tight arrangement in response to fluid pressure in the first chamber. The seal can have a surface exposed to fluid pressure within the first chamber, the fluid pressure acting upon the surface to effect a substantially fluid-tight engagement between the seal and the exterior surface of the piston. The surface of the seal is other than perpendicular relative to an axis defined by the exterior surface of the piston. The actuator can be operatively connected to a valve to effect movement thereof.
In a further aspect, the present invention provides a pneumatic valve actuator comprising a housing, a rotary piston having at least a top, a bottom and a peripheral wall, sealing means, wherein the sealing means is cooperatively arranged with the housing and the piston such that the sealing means is in contact with the top, bottom and peripheral wall of the piston and the housing and thereby defines a first and second chamber within the housing, means for effecting movement of at least a portion of the piston from the first chamber into the second chamber and back into the first chamber, such movement comprising one cycle of the piston, means for transferring movement of the piston to a further device, wherein the housing is comprised of two halves and the sealing means is securely received in a groove which is formed upon joining the halves of the housing, the groove defines a loop on an inside wall of the housing where the halves join, the sealing means comprising a single loop of sealing material, and wherein the sealing material is selected from the group comprising Viton, Buna N™ or polyurethane.
According to a further aspect of the present invention there is a pneumatic valve actuator comprising a housing having a first half and a second half each half containing at least one passage defined therethrough and communicating with the interior and exterior of the housing, a groove defining a loop in an inner wall of the housing and formed when the halves are joined, a first and second hole defined perpendicularly through the housing, the first and second holes located in alignment with each other and communicating with the groove, a rotary piston having a top, a bottom, a peripheral wall connected between the top and the bottom, and at least one intermediate wall connected perpendicularly between the top, the bottom and the peripheral wall, and further having two engaging holes perpendicularly defined through the top and bottom, wherein the two engaging holes each are defined by a rectangular periphery and the actuating shaft has a rectangular cross section, a seal member securely received in the groove on the inner wall of the housing, two seal member holes defined through the seal member and located to communicate with the first hole and second hole wherein the sealing means is cooperatively arranged with the housing and the piston such that the sealing means is in contact with the exterior of the piston and the housing and thereby defines a first and second chamber within the housing, means for effecting movement of at least a portion of the piston from the first chamber into the second chamber and back into the first chamber, such movement comprising one cycle of the piston, an actuating shaft rotatably extending through the first hole, the two seal member holes, the two engaging holes and the second hole, wherein the rotary piston is fixedly connected to the actuating shaft, the actuating shaft imparting movement of the piston to a further device.
According to another aspect of the present invention, there is a pneumatic actuator comprising a housing having an inner surface, a piston having exterior and interior surfaces and disposed within the housing, the piston having a first position and a second position, whereby the piston is urged from the first position to the second position by fluid pressure, a shaft connected to the piston, and resilient spring having a first end and a second end, the first end abutting against the inner surface of the housing and the second end fixedly connected to the shaft, for urging the piston from the second position to the first position, wherein the first end comprises a roller disposed against the inner surface of the housing. The shaft includes lever arms for imparting kinetic energy from the piston to the spring means, the lever arms disposed against the interior surface of the piston. The shaft comprises a two-part construction, each part having a hub with a lever arm extending from the hub and each part rotatable about an axle. The axle is a two-part axle. The piston further includes opposing first and second interior surfaces having opposing first and second recesses respectively for retaining the two-part axle, and wherein each of the hubs includes throughbores for receiving the two-part axle therethrough. The two-part axle is spring-loaded by a spring means disposed between each part of the two-part axle for urging each part of the two-part axle against the first and second recesses.
According to a further aspect of the present invention there is a pneumatic actuator comprising a housing having an inner surface and defining a chamber, a piston having exterior and interior surfaces and disposed within the housing, the piston having a first position and a second position, whereby the piston is urged from the first position to the second position by fluid pressure, a shaft connected to the piston, a spring support member extending from the inner surface of the housing, resilient spring having a first end, and a second free end, the first end connected to the shaft, the second free end extending outwardly from the shaft and into the chamber, and the second free end being biassed against the spring support member. The first end of the resilient spring can be secured to the shaft.
Other advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view, partly in section, of a conventional pneumatic actuator;
FIG. 2 is a perspective view of a pneumatic actuator comprising a conventional control means and a spring return;
FIG. 3 is an exploded view of the pneumatic actuator of FIG. 2;
FIG. 4 is an exploded view of a pneumatic actuator in accordance with the present invention;
FIG. 5 is a side elevational view, partly in section, of a pneumatic actuator in accordance with the present invention;
FIG. 6 is a top plan view, partly in section, of the pneumatic actuator to illustrate how the torsion spring works when the rotary piston is actuated;
FIG. 7 is a top plan view, partly in section, of another embodiment of the pneumatic actuator to show the rotary piston is actuated by air-flow without the torsion spring;
FIG. 8 is a top plan view, partly in section, of another embodiment of the pneumatic actuator to show the rotary piston is actuated by air-flow without the torsion spring;
FIG. 9 is a side elevation view, partly in section, of the piston assembly and spring assembly of the actuator in FIG. 10;
FIG. 10 is a top plan view, partly in section, of another embodiment of a pneumatic actuator of the present invention;
FIG. 11 is an exploded view of the piston assembly and the spring assembly of FIG. 9;
FIG. 12 is a side elevation view, partly in section, of a valve which is operatively connected to an embodiment of a pneumatic actuator of the present invention;
FIG. 13 is a top plan view, partly in section, of another embodiment of a pneumatic actuator of the present invention;
FIG. 14 is a side elevation view, partly in section, of the embodiment illustrated in FIG. 13;
FIG. 15 is an exploded view of the housing piston assembly, and seal of the embodiment illustrated in FIG. 13; and
FIG. 16 is an exploded view of the piston assembly and the spring assembly of the embodiment illustrated in FIG. 13 .
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings and initially to FIGS. 4 through 6, one embodiment of a pneumatic actuator according to the present invention comprises a housing 50 , a rotary piston 70 and a seal 60 .
The housing 50 is composed of two halves, first half 151 and second half 152 , combined with fastening means 501 and has at least two airway passages 51 , 57 (see FIGS. 6 and 7) defined therethrough which communicate between an interior 55 and exterior of the housing 50 . A retaining groove 52 is defined on an inner side wall of the housing 50 to receive a seal 60 therein. The complete retaining groove is conveniently formed when the two halves of the housing 50 are fastened together by fastening means 501 . When the first half 151 and the second half 152 are joined with piston 70 and seal 60 disposed therein, the housing 50 includes first chamber 1511 and second chamber 1512 which are substantially isolated from each other by piston 50 and seal 60 .
The housing 50 further includes a first aperture 54 a and a second aperture 54 b , or two “holes”, both of which pass through walls of the housing 50 and are located in alignment with each other to receive an actuating shaft 80 therethrough.
The seal 60 forms a band and is securely received, and immovably resides in the groove 52 and (see FIGS. 4, 5 , 6 and 7 ) forms a complete loop around the interior side walls of the closed housing 50 . The seal 60 can be made of any appropriate sealing material such as polyurethane, Viton™, or Buna N™. The placement of the seal 60 into the groove is conveniently achieved by fastening the two halves of the housing 50 together. A portion 602 of the seal 60 extends into the first chamber 1511 of the housing 50 . This portion of the seal incorporates pressure assisted seal technology to ensure complete contact between the seal 60 and the exterior of the piston 70 , as further described below. First and second apertures 62 a and 62 b , or two “holes”, are defined through the seal 60 and located to communicate with the first housing aperture 54 a and the second housing aperture 54 b respectively.
The piston 70 has a top wall 71 , a bottom wall 142 , a peripheral wall 701 connected between the top wall 71 and the bottom wall 142 , and an intermediate wall 702 joining the top wall 71 , the bottom wall 142 and the peripheral wall 701 . The piston can be open on one side such that the interior of housing 50 communicates with second chamber 1512 for facilitating the use of a biasing means to bias piston 70 to its static condition, as described below. The piston 70 receives an actuating shaft 80 through first aperture 72 a and second aperture 72 b , or two “engaging holes”, provided in top wall 71 and bottom wall 142 respectively. Each of the first aperture 72 a and second aperture 72 b can have a rectangular periphery, although any shape which is capable of engaging an actuating shaft 80 of corresponding shape is within the scope of the present invention. The actuating shaft 80 has a first base portion 81 (see FIG. 4) having a splined sleeve 810 so as to receive a splined shaft 90 to which other mechanisms can be connected.
A cylindrical second base portion 82 extends axially from the first base portion 81 , and the actuating shaft 80 extends axially from the second base portion 82 . In one embodiment, the shaft 80 is rectangular although any shape corresponding to the shape of the first aperture 72 a and second aperture 72 b is within the scope of the present invention. When assembled, (see FIG. 5) the first base portion 81 is received within and provides seating for housing 50 . The second base portion 82 extends through the first aperture 62 a and provides seating for the exterior surface of piston 70 . The actuating shaft 80 extends through the first piston aperture 72 a and second piston aperture 72 b , seal aperture 62 b , and housing aperture 54 b . Sleeve 83 is received in second housing aperture 54 b and second seal aperture 62 b , and is seated on the exterior surface of piston 70 . Sleeve 83 receives shaft 80 and, therefore, spaces shaft 80 from the side walls of each of housing aperture 54 b and seal aperture 62 b.
Referring to FIG. 4, a tubular sleeve 73 having a passage 731 defined therethrough is mounted on the actuating shaft 80 and located between the top wall 71 and bottom wall 142 of the piston 70 . In one embodiment, the passage 731 is defined by a tubular periphery. Referring to FIG. 5, when assembled, it can be seen that the rotary piston 70 rotates in unison with actuating shaft 80 . According to one embodiment, a torsion spring 85 is mounted on the sleeve 73 . The torsion spring 85 winds around sleeve 73 and has a first extending portion 801 thereof contacting against an inner surface of the intermediate wall 702 . The torsion spring 85 further has a second extending portion 802 , extending from piston 70 and contacting against an inner side of the housing 50 in second chamber 1512 . First extending portion 801 is joined to second extending portion 802 by intermediate portion 803 .
Referring now to FIGS. 4 and 6 it can be seen that an effective seal is created by the seal 60 . Inner surface of seal 60 engages the exterior wall of piston 70 and outer surface 604 (FIG. 4) engages housing 50 . More particularly, seal 60 contacts the top 71 and the bottom 142 of the piston 70 while the central portion 63 contacts the peripheral wall of the rotary piston 70 . A portion of the seal 60 directly opposite the central portion (not shown in FIG. 4) is shown in cross-section in FIGS. 6 and 7 as 640 and this portion 640 is in contact with the extended wall portion 720 of intermediate wall 702 . As well, the apertures in the seal 60 contact the piston where the shaft parts 82 , 83 are located. In this respect, an effective seal is created between chambers 1511 and 1512 . By virtue of this same arrangement, an effective seal is created between actuating shaft 80 and first chamber 1511 , and between housing 50 and its external environment.
In summary, one seal provides all of the sealing necessary to provide two substantially isolated chambers 1511 and 1512 .
As can be seen in FIG. 6, the contact between the seal member and the external surface of the piston 70 creates an effective seal and provides two chambers 1511 and 1512 thereby making it possible for air pressure to rise in chamber 1511 which provides a driving force for movement of the piston 70 into chamber 1512 . As such, the exterior surface of piston 70 does not engage housing 50 . Advantageously, the inner walls of the housing 50 do not need to be manufactured precisely and machined smooth because the rotary piston 70 does not contact the inner walls, only the seal. All that is required is that the walls of the piston 70 be smoothed, which from a manufacturing cost perspective is significantly easier to do and therefore significantly less costly.
In another embodiment illustrated in FIGS. 9, 10 and 11 , a spring 200 may be provided to bias piston 70 towards a static condition, such condition being further described below. A two-part hub 206 , comprising upper and lower parts 206 a and 206 b is provided to fix one end 208 a of spring 200 . In this respect, each of upper and lower parts 206 a and 206 b include recesses 206 c and 206 d for receiving the first end 208 a of spring 200 . Each of upper and lower hub parts 206 a and 206 b rotate about spring-loaded two-part axle 212 . Further, each of the hub parts 206 a and 206 b include bores extending therethrough for receiving each member of the two-part axle 212 . Two-part axle 212 has upper and lower members 212 a and 212 b which are biased by spring 214 towards recesses 215 a and 215 b inside piston 70 and are retained therein.
The second end 208 b of spring 200 is substantially fixed in space relative to housing 50 by armature 210 so that substantially all energy imparted to spring 200 is transferred to first end 208 a . Armature 210 includes first and second ends 210 a and 210 b . First end 210 a is coupled to second end 208 b of spring 200 . Second end 210 b includes a roller 211 which is disposed against an inner wall of second chamber 1512 of housing 50 for reducing friction load as armature 210 moves in response to a reduction in diameter of the spring 200 as spring 200 is placed under tension.
To impart kinetic energy from piston 70 to the spring 200 , upper and lower drive arms 218 a and 218 b are coupled to upper and lower hub parts 206 a and 206 b respectively. Each of upper and lower drive arms 218 a and 218 b are disposed against inner walls of piston 70 . As piston 70 rotates, kinetic energy is imparted to each of drive arms 218 a and 218 b , which consequently transfers kinetic energy to hub parts 206 a and 206 b , whereby kinetic energy is finally transmitted to the first end 208 a of spring 200 .
In the embodiment illustrated in FIG. 9, stub shafts 216 a and 216 b are integrated with piston 70 . In turn, devices can be operatively connected to either of stub shaft 216 a or 216 b , to thereby be actuated by the actuator of the present invention.
In another embodiment illustrated in FIGS. 13-16, a pneumatic actuator is shown also having a two-part coil spring 400 for biasing piston 70 towards a static condition. Coil spring 400 includes an upper spring part 400 a and a lower spring part 400 b . In association with each upper and lower spring parts 400 a and 400 b , a pair of two-part bushings 406 a and 406 b is provided for spacing spring parts 400 a and 400 b from each other and from the inner wall of piston 70 . In this respect, upper and lower parts 406 a and 406 b include slots 406 c and 406 d for receiving the first end 408 a of the spring part 400 a or 400 b . The first end 408 a extends through slots 406 c or 406 d and is keyed to shaft 80 within groove 81 formed therein. In this respect, inner portion of spring parts 400 a and 400 b rotate with shaft 80 .
Shaft 80 extends through opposing and aligned throughbores 54 a and 54 b formed in piston 70 . Retaining clips 420 and 422 are provided to prevent axial movement of shaft 80 to piston 70 . Retaining clips 420 and 422 are fitted upon corresponding shoulders formed on the surface of shaft 80 . When fitted on their corresponding shoulders, retaining clips 420 and 422 extend outwardly from the shoulders and are interposed between flanges 424 and 426 , provided on respective bushings 406 a and 406 b , and inner wall portions 428 and 430 of piston 70 proximate respective throughbores 54 a and 54 b . In this respect, retaining clips 420 and 422 , acting in concert, substantially prevents axial movement of shaft 80 relative to piston 70 . Shaft 80 can further be operatively connected to a valve stem 432 .
The second outer end 408 b of each of spring parts 400 a and 400 b extends outwardly from shaft 80 and into chamber 1512 , where it is freely supported by spring support member 410 . Spring support member 410 is mounted on and extends from an inner wall of chamber 1512 . Spring support member 410 has a distal end 412 having a surface comprising an antifriction sleeve. Distal end 412 has a first side surface 414 and a second side surface 416 , both extending from an inner wall of chamber 1512 connecting to distal end 412 . Each of spring parts 400 a and 400 b proximate their respective second outer ends 408 b is biased against distal end 412 of spring support member 410 . Ends 408 b are configured to move radially relative to the spring support member 410 . In the embodiment illustrated in FIG. 13, distal end 412 is rounded to minimize frictional losses when spring parts 400 a and 400 b move across the surface of distal end 412 in response to rotation of piston 70 . Spring parts 400 a and 400 b proximate second outer ends 408 b move across the surface of distal end 412 in response to rotation of shaft 80 . Second outer ends 408 b are bent for facilitating installation of respective spring parts 400 a and 400 b.
Referring to FIG. 12, an embodiment of the pneumatic actuator may be operatively connected to a valve 300 for effecting movement of valve 300 between static and operating conditions. In this respect, shaft 80 , which is engaged to piston 70 , can include a splined sleeve 81 for receiving a spline shaft 90 which is coupled to valve 300 . Rotation of piston 70 , therefore, effects movement of valve 300 . It is understood to those skilled in the art that any other conventional means by which the movement of the piston 70 can be transferred to a further device is within the scope of the present invention.
The sealing arrangement will now be explained with reference to FIGS. 4, 10 , and 12 . The seal 60 comprises a continuous band having an outer surface 604 and an inner surface 606 . The outer surface 604 engages housing 50 . In this respect, an outer retaining ring 608 extends radially from and coextensively with the outer surface 604 , and is keyed or anchored within groove 52 of housing 50 . In this respect, groove 52 acts as a keyway having opposing locking shoulders 52 a and 52 b for locking or anchoring the outer retaining ring 608 within the keyway or groove 52 . The inner surface 606 engages piston 70 . In this respect, portion 602 has an inner retaining ring 610 extending radially from and coextensively with the inner surface 606 , and projecting into the first chamber 1511 . The outer retaining ring 608 is joined to the inner retaining ring 610 by web 612 . The inner retaining ring 610 has an outer surface 614 and an inner surface 616 . The inner surface 616 engages the exterior surface of piston 70 . The outer surface 614 faces first chamber 1511 and is disposed such that outer surface 614 is not perpendicular to an axis defined by the exterior of piston 70 . In this respect, any fluid in chamber 1511 will tend to exert forces on outer surface 614 such that a substantially fluid tight seal is formed between inner surface 616 and the exterior of piston 70 .
In one embodiment, the piston 70 can be constructed to provide biasing means for biasing the piston 70 towards a static condition and in the general direction of first chamber 1511 . Unlike the elaborate external return means of the prior art illustrated in FIGS. 2 and 3, or a multiplicity of linear coil springs as illustrated in the prior art of FIG. 1 , the torsion spring 85 can be designed to be installed inside the piston 70 . After adding one revolution (clockwise) of preload, the helical portion of the torsion spring 85 (see FIG. 6) will relax against an extended wall portion 720 of the piston 70 making the assembly safe for handling while it is being installed between the two halves of the housing 50 . As the housing halves are tightened together the helical portion will be forced clockwise about another 30 degrees adding more preload. This now removes the arm 802 from contact with the extended portion 720 , of the piston 70 .
In operation, a complete cycle of the piston 70 starts when pressurized air is allowed into the housing 50 through passage 51 (passage 57 is open to atmospheric or reduced pressure) into first chamber 1511 . By virtue of the air pressure, the rotary piston 70 rotates from a static starting position to an actuated midcycle position as shown by phantom lines in FIG. 6 . The rotary piston 70 completes the cycle upon release of air pressure into chamber 1511 by rotation back to the static starting position condition as shown by solid lines in FIG. 4 by virtue of the energy stored in the torsion spring 85 . This rotation is transferred to any external device connected to the rotary shaft 80 .
FIG. 7 shows another embodiment of an actuator valve of the present invention which differs from the embodiment in FIG. 6 by the absence of a torsion spring. In operation, a complete cycle of the piston 70 starts when pressurized air is allowed into the housing 50 through passage 51 (passage 57 is open to atmospheric or reduced pressure) in the first chamber 1511 . By virtue of the air pressure in chamber 1511 , the rotary piston 70 rotates from a static starting position to an actuated midcycle position as shown by phantom lines in FIG. 7 . The rotary piston 70 completes the cycle by rotation back to the starting position as shown by solid lines in FIG. 7 by virtue of the introduction of pressurized air via passage 57 (passage 51 is open to atmospheric or reduced pressure) into second chamber 1512 .
FIG. 8 shows a further embodiment of an actuator of the present invention. As in the embodiment shown in FIG. 7, there is no torsion spring. In this embodiment, however, intermediate wall 702 is disposed such that it contacts an intermediate part of the peripheral wall 701 of the piston 70 . The arrangement of this intermediate wall is such that in operation, a complete cycle of the piston 70 starts when pressurized air is allowed into the first chamber 1511 of the housing 50 through passage 51 (passage 57 is open to atmospheric or reduced pressure) and by virtue of the air pressure the rotary piston 70 rotates from a static starting position to a midcycle position as shown by phantom lines in FIG. 8 The rotary piston 70 completes the cycle by rotation back to the starting position as shown by solid lines in FIG. 8 by virtue of the introduction of pressurized air via passage 57 (passage 51 is open to atmospheric or reduced pressure) into second chamber 1512 .
Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.
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Disclosed is a pneumatic actuator which includes a housing comprised of two halves and having at least two passages defined therethrough, including a “loop” groove defined in an inner peripheral wall of the housing into which a seal member is inserted. A rotary piston is rotatably received in the housing. The piston has a top and a bottom with an intermediate wall connected there between, and an actuating shaft extending through the housing, which is rotated by movement of the rotary piston. The seal member extends into the housing and is in contact with the top and bottom of the rotary piston all the times. The rotary piston moves free of contact with the interior surface of the housing and this one seal member provides a seal for the joint created between the halves of the housing, the chambers of the housing as well as the actuating shaft. Movement of the piston is effected by air pressure and return motion of the piston can be air driven or spring assisted.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 10/803,169, filed Mar. 17, 2004, which application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to grill assemblies for preparing food products, and more particularly relates to electric grill assemblies and to a dual hood configuration for a grill assembly.
2. Related Art
Grill assemblies for preparing food products are well known in the art. Generally, many existing grill assemblies provide a cooking compartment that defines an enclosed cooking area (e.g., the primary cooking area). The cooking area can include one or more cooking surfaces that support the food articles during cooking. Typically, a source of thermal energy provides heat to the entire cooking area or to targeted portions of the cooking area. Most existing grill assemblies allow large amounts of heat loss to the outside environment and fail to minimize wind currents that can disrupt the cooking process within the cooking area of the grill. Further, most existing grills require a combustible fuel such as natural gas, propane, briquettes, or wood. Although burning a combustible fuel may provide additional flavor to the food being cooked, grill assemblies that combust fuel are typically not suited for use inside living structures and are prohibited in many housing complexes (e.g., condominium and apartment complexes). The use of electric cooking assemblies that generate sufficient heat for grilling purposes typically requires a 220-240V power source, which makes grilling using electricity as a source of heat impractical in many outdoor cooking situations. Improvements in cooking assemblies that address these shortcomings are, therefore, sought.
SUMMARY OF THE INVENTION
The present invention relates generally to grill assemblies for preparing food products, and more particularly relates to an electric grill assembly and to a dual hood configuration for a grill assembly.
One aspect of the invention relates to an electric cooking assembly configured for preparing food products. The cooking assembly includes a main body portion defining a cooking area including a first cooking surface and a second cooking surface, a first electric heating element arranged and configured to provide heat to at least a portion of the first cooking surface, and a second electric heating element configured to heat at least a portion of the second cooking surface. The first and second electric heating elements may be separately controlled such that only one heating element is operable at a given time, or may be controlled in any other combination or sequence of use.
Another aspect of the invention relates to a method of manufacturing a grill assembly that includes a main body portion defining a cooking area, first and second cooking surfaces, and first and second electric heating elements. The method includes the steps of arranging the first electric heating element to heat at least a portion of the first cooking surface, arranging the second electric heating element to heat at least a portion of the second cooking surface, and controlling the first and second heating elements independent from each other
A further aspect of the invention relates to a method of assembling a cooking apparatus that including a main body portion, first and second cooking surfaces, first and second electric heating elements, and a control member. The main body portion includes a base member and a hood member that together define a cooking area. The method includes positioning the first and second cooking surfaces in the cooking area, positioning the first electric heating element in the cooking area between the first cooking surface and the base member, and coupling the second electric heating element to the second cooking surface. The method also includes coupling the control member to the first and second electric elements to control current flow to the first and second electric elements to maximize heat generation in the cooking area with a minimum amount of current flow.
A further aspect of the invention relates to a cooking assembly for preparing food products that includes a main body portion having a base member and a first hood assembly that together define a cooking area, a cooking surface, and a second hood assembly. The first hood assembly is adjustable relative to the base member to provide access to the cooking area, the cooking surface is positioned within the cooking area, and the second hood assembly is positioned at least partially within the cooking area between the cooking surface and the first hood assembly. The second hood assembly may be adjustable between an open position wherein the cooking surface is accessible and a closed position wherein the second hood member covers at least a portion of the cooking surface.
Another aspect of the invention relates to an electric grill configured for cooking food products that includes a base member, an electric heating element positioned in the base member, a first hood coupled to the base member thereby defining a cooking area between the base member and the first hood, a cooking surface positioned vertically above the electric element between the base member and the first hood, and a second hood positioned at least partially within cooking area. The second hood may be adjustable between an open position wherein the cooking surface is accessible and a closed position wherein at least a portion of the cooking surface is covered.
A further aspect of the invention relates to a cooking assembly configured for preparation of food products that includes a housing having a first hood member and a base member that define a cooking area, an electric heating element positioned in the cooking area, a cooking surface positioned in the cooking area, and a second hood member positioned within the cooking area and configured to decrease heat lost from the housing during preparation of food products in the cooking area. The second hood member is configured for adjustment between an open position providing access to the cooking surface and a closed position covering at least a portion of the cooking surface.
The above summary of the present invention is not intended to describe each disclosed embodiment or every implementation of the present invention. Figures in the detailed description that follow more particularly exemplify embodiments of the invention. While certain embodiments will be illustrated and described, the invention is not limited to use in such embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
FIG. 1 is a top perspective view of an example grill assembly made in accordance with principles of the present invention with the hood in a closed position;
FIG. 2 is a top perspective view of the grill assembly shown in FIG. 1 with the hood in an open position;
FIG. 3 is an exploded top perspective view of the grill assembly shown in FIG. 1 ;
FIG. 4 is a top view of the grill assembly shown in FIG. 1 ;
FIG. 5 is a front view of the grill assembly shown in FIG. 1 ;
FIG. 6 is a cross-sectional front view of the grill assembly shown in FIG. 4 taken along cross-sectional indicators 6 - 6 ;
FIG. 7 is a side view of the grill assembly shown in FIG. 1 ;
FIG. 8 is a top view of the grill assembly shown in FIG. 2 ;
FIG. 9 is a front view of the grill assembly shown in FIG. 2 ;
FIG. 10 is a side view of the grill assembly shown in FIG. 2 ;
FIG. 11 is a bottom view of the sear plate shown in FIG. 3 ;
FIG. 12 is a front view of the sear plate shown in FIG. 3 ;
FIG. 13 is a cross-sectional view of another example sear plate according to principles of the present invention with the heating element embedded in the plate member.
FIG. 14 is a top view of an example hood assembly made in accordance with principles of the present invention with the outer hood closed;
FIG. 15 is a front view of the hood assembly shown in FIG. 14 ;
FIG. 16 is a side view of the hood assembly shown in FIG. 14 ;
FIG. 17 is a cross-sectional side view of the hood assembly shown in FIG. 14 taken along cross-sectional indicators 17 - 17 with the inner hood closed;
FIG. 18 is a cross-sectional side view of the hood assembly shown in FIG. 14 taken along cross-sectional indicators 18 - 18 with the inner hood open;
FIG. 19 is a top view of the hood assembly shown in FIG. 14 with the outer hood open and the inner hood closed;
FIG. 20 is a front view of the hood assembly shown in FIG. 19 ;
FIG. 21 is a side view of the hood assembly shown in FIG. 19 ;
FIG. 22 is a cross-sectional side view of the hood assembly shown in FIG. 18 taken along cross-sectional indicators 22 - 22 ;
FIG. 23 is a top view of the hood assembly shown in FIG. 14 with the outer hood open and the inner hood open;
FIG. 24 is a front view of the hood assembly shown in FIG. 23 ;
FIG. 25 is a side view of the hood assembly shown in FIG. 23 ;
FIG. 26 is a cross-sectional side view of the hood assembly shown in FIG. 19 taken along cross-sectional indicators 26 - 26 ; and
FIG. 27 is a front perspective view of the grill assembly shown in FIG. 1 in combination with an example grill stand assembly.
While the invention is amenable to various modifications and alternate forms, specifics thereof have been shown by way of example and the drawings, and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates generally to grill assemblies for preparing food products, and more particularly relates to an electric grill assembly and grill assemblies having a dual hood configuration. One grill assembly configuration includes first and second cooking surfaces that are heated by separate electric elements. Typically, either the first or the second electric heating element is used at a given time to heat respective first and second heating surfaces in order to provide sufficient heat when using a standard 110 to 120 V power source. The first and second electric heating elements may have different configurations that may relate directly to the structure of the cooking surfaces. For example, when the first cooking surface is a standard grilling grate, the first electric element may be a serpentine shaped electric element that is spaced vertically below the grill grate. This configuration provides heating of the food articles being cooked on top of the cooking surface by heat provided by the electric element through the space between the grate structures and with heat conducted through the grate structure material. When the second cooking surface is a sear plate made from a cast metallic material, and the second electric element may be embedded in the structure of the second cooking surface. This configuration may be well suited for providing high temperatures in the sear plate while using the same or similar amounts of power as is required for an electric element associated with a grill grate cooking structure. Thus, the grill assembly of the present invention may have different heating element configurations and different cooking surface structures while using a common source of power.
Another aspect of the invention relates to a grill hood assembly that is configured for improved containment of heat within the grill assembly. This improved hood assembly includes an outer hood member that is movable between open and closed positions, and an inner hood member that is positioned within an enclosed space defined by the outer hood member and is also movable between open and closed positions to provide access to the cooking surface covered by the outer and inner hood members. Example hood assemblies of the present invention are described below in further detail with reference to the Figures. Reference to the various embodiments does not limit the scope of the present invention, which is limited only by the scope the claims attached hereto.
As used herein, the term “hood” is defined as any structure used to cover or enclose other parts or features such as the cooking surface of a grill assembly. The term “cooking surface” is defined as any surface adapted and configured for cooking or heating different types of food articles. The term “electric element” or “electric heating element” is defined as a structure that generates heat in the presence of an applied current or voltage. The term “cooking area” is a defined space in which sufficient heat exists in order to cook or warm food articles and is typically associated with a cooking surface and a heat source. The term “food products” or “food articles” is generally meant to include any consumable products such as meats, vegetables, fruits, or other food products capable of being cooked and/or heated using a cooking assembly such as a grill.
Referring now to FIGS. 1-12 , an example grill assembly 10 is shown in various views with the hood assembly members in opened and closed positions. The grill assembly 10 includes a hood assembly 12 , a base 14 , first and second cooking structures 16 , 18 , first and second electric heating elements 20 , 22 , a spill tray 24 , and a control assembly 26 (see FIG. 3 ). The hood assembly 12 includes a hood 30 , a base 32 , and a handle 34 . The hood 30 is movable relative to the base 32 in the direction A (see FIGS. 7 and 10 ) using the handle 34 to provide access to a cooking area 46 (see FIG. 6 ) between the hood assembly 12 and the base 14 . The base 14 includes a side wall 40 defining an outer circumference of the base, a floor 42 , and an intermediate wall 44 that divides the base 14 into separate cavities sized for the first and second cooking structures 16 , 18 .
The first cooking structure 16 includes a plurality of grate members 50 that are held together with cross supports 52 . The first cooking structure 16 may be made from materials common to grilling assemblies such as, for example, stainless steel. The second cooking structure 18 is a plate-like structure having an upper surface 60 configured for searing food articles, and an opposing lower surface 62 . The second electric heating element 22 may be mounted directly to the lower surface 62 (see FIGS. 11 and 12 ). In another embodiment (see the cross-sectional view of FIG. 13 ), a heating element 222 may be embedded within or otherwise permanently coupled to a second cooking structure 218 . The second cooking structure 18 may be made of cast aluminum or other heat absorbing material such as stainless steel or other metal alloy. Preferably, the second cooking structure 18 can obtain cooking temperatures on the upper surface 60 of about 500 to about 800° F. using a power source that provides about 1,000 to 1,400 W using about 10 to about 12 A of current. More preferably, the second cooking structure 18 attains a temperature of about 700 degrees Fahrenheit using up to about 1,100 watts of power and about 10 amps of current.
The first electric element 20 preferably defines a shaped structure (for example, a contoured shaped structure) that provides a relatively even amount of heat across the first cooking structure 16 . The first electric heating element 20 is preferably spaced vertically below the first cooking structure 16 , but may be in contact with features of the first cooking structure such as the cross supports 52 (see FIG. 6 ). The first electric heating element provides cooking temperatures within the cooking area 46 in the range of about 300 to about 500° F. using up to about 1350 W of power at about 10 to 12 A of current.
According to the configuration of the first and second electric heating elements 20 , 22 , at least two separate cooking conditions can be provided within the grill assembly 10 using the same power source (e.g., a common 110 to 120 V power source). Because the available power using a 110 to 120 V source is relatively low while the desired cooking temperatures for the first and second cooking structure 16 , 18 is relatively high, it may be necessary to use only one of the first and second electric heating elements 20 , 22 at any given time. However, if a greater power source is available (e.g. 220 to 240 V power source), it may be possible to power both electric heating elements at the same time while providing the desired temperatures. A greater power source may also make possible the use of larger heating elements for a larger cooking area or a greater number of heating elements. In either case, the example grilling assemblies disclosed herein provide improved heat generating efficiency for the power source provided.
In some embodiments, the power being supplied to the first and second heating elements 20 , 22 can be regulated with, for example, a rheostat, to control the temperature being used to cook the food article. For example, the food article may require a lower or specific cooking temperature and the power can be regulated to reach that temperature.
The spill tray 24 is positioned below the first cooking structure 16 and includes a side wall 70 , a floor 72 , and a handle 74 . The spill tray 24 is configured for collecting grease and other by-products that fall from the food articles being cooked. The spill tray 24 may be made from a material having a high reflectivity so as to reflect heat that is emanating from the first electric heating element 20 towards the floor 42 of the base 14 back toward the food articles being cooked on the first cooking surface 16 . The spill tray 24 may be easily removable from the base 14 using the handle 74 . A heat reflective member (not shown) that is separate from or replaces the spill tray 24 may be positioned within the base 14 (e.g., below first electric element 20 ) or may be positioned adjacent to the hood 30 and base 32 of the hood assembly 12 to reflect heat generated by the first and second electric heating elements 20 , 22 back toward the cooking structures 16 , 18 .
The control assembly 26 includes a panel member 80 , first and second temperature controls 82 , 84 , an on/off power switch 86 and a power allocation switch 88 . The switches and controls 82 , 84 , 86 and 88 are merely exemplary of those control features that may be necessary and useful with the grill assembly 10 . The first and second temperature controls 82 , 84 may be used to control the amount of power provided to the respective first and second electric heating elements 20 , 22 . The power allocation switch 88 may be used to allocate power to one or the other or both of the first and second electric heating elements 20 , 22 . If power is allocated to both the first and second electric heating elements 20 , 22 , a differential power can be used to provide, for example, more power to the first heating element 20 to increase the temperature of the first electric heating element 20 and less power to the second electric heating element to lower the temperature of the second electric heating element 22 . The on/off power switch 86 may be used as master power control to the grill assembly 10 for safety purposes in the event that the first and second temperature controls 82 , 84 are not turned to the off position at the completion of cooking the food articles.
In some embodiments, the second electric heating element 22 may be configured so that there is no variation in the temperature of the second cooking structure 18 . In such a configuration, the power allocation switch 88 may be used to either turn the second electric heating element on or off, and when in the off position power is allocated to the first electric heating element 20 . According to this configuration, the second temperature control 84 may be a timer rather than a temperature control. In one embodiment, the timer can be used simply to measure cooking time. In another embodiment, the timer can be coupled to the power source to regulate the length of time the first and second heating elements 20 , 22 are supplying heat in the grill. For example, the timer can be set to a thirty minutes and at the end of the thirty minutes power is shut off to the first and second heating elements 20 , 22 .
In still further embodiments, the grill assembly may include a temperature gauge (not shown) that monitors the temperature within the cooking area 46 . The control assembly 26 may further include a controller that includes a programmable microprocessor and memory and is capable of automatically controlling certain features of the grill assembly 10 . For example, such a controller may be used to monitor the temperature within the cooking area 46 and automatically alter the power allocation to the first and second electric heating elements 20 , 22 to maintain a pre-determined temperature within the cooking area. In another example, the controller may be used to provide cooking options and cooking information at a display screen (e.g., options for cooking times and temperatures) that can be viewed and implemented upon selection by the user.
The grill assembly 10 may be used in combination with a grill stand assembly 90 as shown in FIG. 27 . Stand assembly 90 includes a base 92 in the form of a refrigerator, first and second trays 94 , 96 , and a light fixture 98 . The refrigerator 92 may include wheels 100 , a door 102 , a handle 104 , and a casing 106 sized to receive food articles. The refrigerator 92 and light fixture 98 may be powered by the same power source (e.g., a 110 to 120 V power source) used to power the grill assembly 10 . In order to provide the necessary power requirements for the heating elements of the grill assembly, the refrigerator 92 may be automatically powered off in when the grill assembly features are turned on. In most instances, turning off the refrigerator 92 should not be problematic for keeping the refrigerated food articles cold because grill assemblies are commonly used for only a short period of time (e.g., about an hour or less) when preparing food articles.
The first and second trays 94 , 96 may be movable between upright positions as shown in FIG. 27 and retracted positions in which they lay flat against sides of the refrigerator 92 . In other embodiments, the trays 94 , 96 may have integrated therein separate heating elements such as a hot plate style heating element for preparing food outside of the cooking area 46 . Thus, the stand assembly 90 may provide multiple functions and may be movable via the wheels 100 to convenient cooking locations both inside and outside of a living structure, while also providing additional refrigerator space.
Another example grill assembly embodiment (not shown) that incorporates principles of the present invention includes an adjustable electric heating element that is movable within the cooking area between different positions relative to the cooking structures.
Referring now to FIGS. 14-26 , an alternate hood assembly 112 is shown in various open and closed positions. Hood assembly 112 includes first and second outer hood member 120 , 122 and first and second inner hood members 130 , 132 . The first outer hood member 120 includes a handle 124 and a temperature gauge 126 mounted thereon and is movable in a direction B (see FIGS. 18 and 22 ) relative to the second outer hood member 122 . The first inner hood member 130 is movable in the direction C (see FIGS. 17 and 18 ) relative to the second inner hood member 132 and may include a flap/cover member 134 coupled to an end thereof.
FIGS. 14-18 illustrate the first outer hood member 120 in a closed position in which the first and second outer hood members 120 , 122 would preferably completely cover the cooking surfaces of the grill assembly (not shown) associated with the hood assembly 112 . For example, hood assembly 112 may take the place of hood assembly 12 and be configured to cover the first and second cooking surfaces 16 , 18 in the grill assembly 10 shown in FIGS. 1-12 described above. Hood assembly 112 may also be used with the grill assembly shown and described in U.S. patent application Ser. No. 09/885,360 filed on Jun. 20, 2001, and entitled COOKING ASSEMBLY HAVING MULTIPLE COOKING MODALITIES, which application is incorporated herein by reference in its entirety.
The first and second outer hood members 120 , 122 define a first cooking area 140 within which the first and second inner hood members 130 , 132 are positioned. When the first outer hood member 120 is in a closed position, the first inner hood member 130 is movable between a closed position as shown in FIG. 17 and an open position as shown in FIG. 18 . When both the first outer hood member 120 and first inner hood member 130 are in a closed position and the flap 134 is in a horizontal position covering the otherwise uncovered cooking surface in the space defined by distance X in FIG. 17 , the hood assembly 112 provides a dual hood configuration in which the cooking area 150 has two insulating layers. Hood assembly 112 can sustain higher temperatures within cooking area 150 with less power or heat because there is less heat loss than in typical grill assemblies. These advantages can result in shorter cooking times and lower operating costs.
To gain access to a cooking surface within the second cooking area 150 , the first outer hood member 120 must be raised as shown in FIGS. 19-22 , and then the first inner hood member 130 must be raised as shown in FIGS. 23-26 . In some types of cooking applications it may be advantageous to close one or the other of the first hood members 120 , 130 depending on a number of factors including, for example, the desired size of the cooking surface to be used, the desired cooking time and/or temperature, or the convenience or inconvenience of opening one versus two hood members to gain access to the cooking surface.
As mentioned above, the flap 134 may be used to cover specific portions of the cooking surface over which the hood assembly 112 is positioned. The flap 134 may be adjusted from a retracted position as shown in FIGS. 17-22 to a downward, covering position (not shown) to cover a portion of the cooking surface.
In some embodiments, the first and second inner hood members 130 , 132 may extend across only a portion of the hood assembly width (not shown) rather than extending across the entire width W as shown in FIGS. 14-26 . Such a reduced width inner hood assembly may be useful in combination with a grill assembly that includes separate cooking surfaces such as grill assembly 10 , wherein there may be a preference to provide a dual hood configuration for either the first or second cooking surface 16 , 18 .
The present invention should not be considered limited to the particular examples or materials described above, but rather should be understood to cover all aspects of the invention as fairly set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the present invention may be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the instant specification.
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An electric cooking assembly includes a main body portion that defines a cooking area. First and second cooking surfaces are contained within the cooking area. A first electric heating element arranged to provide heat to at least a portion of the first cooking surface, and a second electric heating element is arranged to heat at least a portion of the second cooking surface. The main body portion may include first and second hood members. The first hood member defines the cooking area and the second hood member is positioned at least partially within the cooking area and configured to decrease heat lost from the cooking assembly during preparation of food products in the cooking area. The second hood member is configured for adjustment between an open position providing access to the cooking surface and a closed position covering at least a portion of the cooking surface.
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This application is a national stage completion of PCT/FR00/02685 filed Sep. 28, 2000 which claims priority from French Application Serial No. FR 99/12332 filed Sep. 29, 1999.
FIELD OF THE INVENTION
This invention concerns a modular drainage unit intended for soil draining in general and draining around buildings and housing in particular.
BACKGROUND OF THE INVENTION
The laying of a traditional drainage system is difficult and requires considerable and expensive means. In particular, it comprises the following operations: the digging of a trench, which is then lined with a geotextile fabric; a long pierced pipe (usually made from PVC) is then laid in the trench and covered with gravel; the geotextile fabric is folded over and the trench is filled in. Such a system therefore has many drawbacks. The geotextile fabric tends to slip down the sides of the trench when the gravel is poured and is frequently buried under the gravel. The drainage pipe tends to rise in the trench as a result of its rigidity and the vibration generated by pouring the gravel. When temperatures fall below −10° C., the PVC pipe becomes brittle. Moreover, such drainage pipes are difficult to handle and therefore difficult to lay alone. The cost of laying is high, if one counts the purchase and delivery of the gravel and the labor required.
A number of solutions have been devised to solve part of these problems. Publication DE-A-22 07 216 describes a monoblock drainage unit with a square cross-section, traversed by a central longitudinal collecting conduit, made from a grainy material. This restricts the passage of the drainage water considerably and therefore does not permit effective drainage. Moreover, there is no system to direct the drainage water to the collecting conduit, and as a result part of the water is evacuated into the fill. Publication U.S. Pat No. 3,440,823 describes a drainage system with two separate components: a drainage conduit in the shape of an inverted V, placed on a impermeable base. The pipe comprises only very few side channels on the edges of the V, which are not sufficient to capture the drainage water. Moreover, the inverted-V shape is not resistant enough to crushing by the fill. Finally, publication NL-A-7 211 660 describes a drainage unit traversed by a central longitudinal collecting conduit. This unit is limited to the capture of rainwater in gutters, as it comprises openings only on its upper part.
Therefore, no existing system provides an effective, reliable, simple and economical solution to the problem of drainage.
The purpose of this invention is to supply such a solution, in the form of a drainage unit which is effective, practical, easy to use and able to capture and evacuate drainage water efficiently.
SUMMARY OF THE INVENTION
The invention comprises a modular drainage unit, characterized in that it comprises an elongated body, traversed by a longitudinal collecting conduit and comprising flow passages opening on the peripheral walls of said body and emerging into said collecting conduit, said flow passages being arranged to enable drainage water to circulate by gravity towards said collecting conduit, in that it comprises connecting means designed to assemble two consecutive drainage units and in that it comprises a water permeable outer casing.
The flow passages may take the form of peripheral grooves emerging into said collecting conduit by transverse channels, transverse channels running from said peripheral walls to said collecting conduit, peripheral baffles emerging into said collecting conduit by side channels, or the interstices of a porous structure forming said body.
In a preferred form of the invention, the connecting means comprise a coupling separate from said body, the outer dimensions of which do not exceed the bore of said collecting conduit, this coupling being designed to fit into the extremities facing the collecting conduits of two consecutive drainage units.
One possible variation is that the connecting means may comprise a coupling integral to said body, prolonging one of the extremities of the collecting conduit and designed to form a male part, the other extremity of the collecting conduit being designed to form a female part designed to receive the male part of an adjacent drainage unit.
The connecting means also advantageously comprise at least one lateral opening in said body at the same level as said collecting conduit, the dimensions of this lateral opening being more or less equal to those of said collecting conduit, emerging into the latter, and designed to receive said coupling designed to assemble two consecutive drainage units at right angles.
Depending on the preferred form of implementation, the outer casing is composed of a geotextile fabric, this fabric being wrapped around said body and being longer on one side, so as to cover partially the next drainage unit.
The body may be manufactured from a water impermeable material selected from the group comprising at least polystyrene, polyvinyl chloride, concrete, synthetic resin and any molded or extruded synthetic material.
The body may also be manufactured from a water permeable material selected from the group comprising at least expanded polystyrene and any structured or foamed synthetic material. In this case, the body may comprise a watertight area located under the collecting conduit and comprising a base made from an impermeable material incorporated in or under said body. The collecting conduit may also comprise a watertight inner casing, if necessary.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention and its advantages will appear more fully in the following (non-exhaustive) description of instances of implementation, with reference to the attached illustrations, in which:
Illustration 1 is a schematic sectional view of soil drainage around a building as performed as per the traditional former method (left) and as per the invention (right),
Illustration 2 is a plan view of a drainage unit without its casing,
Illustration 3 is a cross-sectional and perspective view of the drainage unit in Illustration 2 ,
Illustration 4 is an exploded view of two drainage units to be assembled at right angles,
Illustrations 5 A and 5 B are perspective and cross-sectional views respectively of a drainage unit with slight differences in implementation, and
Illustrations 6 and 7 are perspective views of two other variations on the drainage unit as per the invention.
DETAILED DESCRIPTION OF THE INVENTION
With reference to Illustrations 1 and 3 , the modular drainage unit 1 as per the invention is intended to drain soil, for instance, though not exclusively, around a building or dwelling. It comprises an elongated body 2 traversed by a longitudinal collecting conduit 3 , and flow passages 5 opening on the peripheral walls of the body 2 and emerging into the collecting conduit 3 , being arranged to enable drainage water to circulate by gravity to said conduit. It further comprises connecting means 6 designed to assemble two successive drainage units 1 and an outer water permeable casing 7 shown only by the dotted line in Illustration 1 .
The elongated body 2 must be able to withstand the pressure of a load of soil. For this purpose, its cross-section is preferably polygonal, or may be semicircular. Its shape defines at least one flat base 20 and one flat side wall 21 perpendicular to said base and which enables the modular drainage unit 1 to be positioned at the base and along the foundations 9 of a building.
This body 2 may be manufactured from a water impermeable material such as polystyrene, polyvinyl chloride, concrete, synthetic resin or any other equivalent material, synthetic or otherwise, molded or extruded. It made also be made from a water permeable material such as expanded polystyrene of varying density, or any other structured (e.g. honeycombed) or foamed synthetic material. What is important is that the combination of the geometry of this body and of its material or structure gives it sufficient resistance to crushing to withstand a load of soil.
In the case of a water permeable material, a watertight area may be provided under the collecting conduit 3 to prevent the drainage water from seeping into the soil. This watertight area may take the form of a base (not shown) made from an impermeable material incorporated in or under the body 2 .
The longitudinal collecting conduit 3 is preferably placed in the lower part of body 2 to collect drainage water by gravity. It is rectilinear and more or less parallel to the base 20 of said body. Its cross-section is circular but may be of another shape. Depending on requirements and the material of the body 2 , it may comprise a watertight internal casing (not shown), inserted or integrated, for instance by overmolding. This collecting conduit 3 also comprises extremities 30 larger in diameter, designed to receive the connecting means 6 described hereunder.
In this example, the flow passages 5 take the form of peripheral grooves 50 emerging into the collecting conduit 3 by transverse channels 51 on either side of said conduit. The peripheral grooves 50 are more or less identical and have a U-shaped profile, but the profile shape could be different, as well as the depth. They are located on the top 22 and side walls 21 of the body 2 . They are rectilinear and located at regular intervals along the entire length of the drainage unit 1 . The cross-section of the drainage unit 1 shown by Illustration 3 shows that in the middle of and next to the top wall 22 each channel 50 forms a summit with two slopes which enable the drainage water to circulate by gravity.
The transverse channels 51 are more or less perpendicular to the collecting conduit 3 and designed so as to emerge into said collecting conduit 3 tangent to its bottom. They are identical and have a circular cross-section, but this cross-section could be of a different shape. They may be slightly inclined towards said collecting conduit 3 to encourage the circulation of drainage water by gravity. In the example shown, each transverse channel 51 is connected to three peripheral grooves 50 . The cross-section of each transverse channel 51 is larger than that of the peripheral grooves 50 , just as the cross-section of the collecting conduit 3 is noticeably larger than that of the transverse channels 51 , so that they can accommodate the flow of the drainage water.
In the example illustrated by Illustration 4 , the connecting means 6 comprise a coupling 60 separate from the body 2 , cylindrical and with an outer diameter no larger than the bore of the extremities 30 of the collecting conduit 3 . This coupling 60 is intended to fit into the extremities 30 , facing the collecting conduits 3 of two consecutive drainage units 1 , in order to connect them in a linear manner.
These connecting means 6 also comprise a lateral opening 61 in each side wall 21 of the body 2 at the same level as the collecting conduit 3 , next to one of its extremities and emerging into this conduit. These lateral openings are circular, but may be of a different shape, and their diameter is more or less the same as that of the extremities 30 of said conduit. They are designed to receive the coupling 60 and enable two consecutive drainage units 1 to be assembled at right angles, as shown in Illustration 4 . These lateral openings 61 are defined by a precut area 62 in the side walls 21 of said body 2 . To use them, the precut area 62 must be removed, and is then used to plug extremity 30 of the corresponding collecting conduit 3 .
The outer casing 7 is made of a fabric made of a geotextile material, more or less rectangular in shape, designed to be wrapped around the body 2 and if necessary stapled to the body. The longitudinal dimensions of this fabric 7 are larger than those of the drainage unit 1 , so as to cover at least partially the following drainage unit 1 . Thus, the join area between the two consecutive drainage units 1 is also covered. This fabric 7 retains particles of soil, stones and all other materials which may block the flow passages 5 of drainage unit 1 and thus render the latter ineffective. Of course, other equivalent means may be used, such as a cover with a very fine mesh, glued, overmolded or inserted around said body 2 .
The use and implementation of modular drainage unit 1 as per the invention are very simple. The drainage units 1 , made for instance of expanded polystyrene, are inexpensive, very light, easy to handle and process, and can be laid in all weathers, even at very low temperatures. Moreover, they are nonpollutant, rotproof and do not retain the damp.
Illustration 1 enables a very clear comparison to be made between the traditional drainage method (left) and that using the drainage unit 1 as per the invention (right). A trench 90 is dug around the foundations 9 of a building. In the traditional method, the trench is covered with geotextile fabric, the pierced collecting pipe is laid, gravel is poured on top of it and covered with the two flaps of geotextile, and the trench is filled.
Using the drainage unit 1 of the invention, the drainage units 1 are positioned directly at the bottom of the slightly sloping trench 90 , they are assembled with each other using the couplings 60 , then the trench is filled in. It is obvious that the installation of a drainage system is made much easier by the fact that the drainage unit 1 combines the collecting conduit, the flow passages and the geotextile filter in a single unit.
Once in place, this drainage system ensures effective and durable drainage, as the drainage units 1 are dimensionally very stable despite potential land slip. The drainage water is filtered by the geotextile casing 7 and channeled by the peripheral grooves 50 , through which it flows by gravity to the transverse channels 51 , which centralize it in the collecting conduit 3 . It then flows into the sewerage system.
Thus, the purpose of the invention is fully met.
However, the invention is not limited to the instance of implementation described, but extends to all versions and variations obvious to a professional.
In particular, and with reference to Illustrations 5 A and 5 B, the flow passages 5 may take the form of a multitude of transverse channels 52 , rectilinear and with a small section, running directly from the peripheral walls of the body 2 of the drainage unit 1 to the collecting conduit 3 . In this instance, the connecting means 6 are composed of a coupling 63 integral to the body 2 , prolonging one of the extremities of the collecting conduit 3 and designed to form a male part. The other extremity 64 of the collecting conduit 3 is designed to form a female part intended to receive the male part 63 of an adjacent drainage unit 1 .
With reference to Illustrations 6 and 7 , the flow passages 5 may also be formed by peripheral baffles 53 emerging into the collecting conduit 3 via transverse channels 51 . These peripheral baffles 53 may take the form of shapes in relief located on the periphery of the body 2 , such as round studs 54 (see Ill. 6 ) or rectangular studs 55 (see Ill. 7 ), or any other geometrical shape.
Another solution is to manufacture the body 2 using a porous structure, the flow passages 5 being formed by the interstices of this porous structure.
Of course, the shape and dimensions of the drainage unit and its various conduits and channels may differ, without ceasing to be covered by the protection defined by the attached claims.
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An economical, efficient, practical and easy-to-use modular drainage unit capable of efficiently collecting and evacuating drainage water and designed to provide a global solution for producing a very simple drainage process. The modular drainage unit ( 1 ) is characterized in that it comprises an elongated body ( 2 ), traversed by a longitudinal collecting conduit ( 3 ), and comprising flow passages ( 5 ) opening on the peripheral walls of the body ( 2 ) and emerging into the conduit ( 3 ), the flow passages ( 5 ) being arranged to enable drainage water to circulate by gravity towards the collecting conduit ( 3 ), and it comprises connecting method ( 6 ) designed to assemble two successive drainage units ( 1 ) and further comprises an outer water permeable casing ( 7 ) to trap soil. The invention is useful for draining grounds in general and around buildings.
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TECHNICAL FIELD
The present invention relates to the field of mitigating attacks in a computer security system, where the attack may employ multiple concurrent Advanced Evasion Techniques.
BACKGROUND
Computer security systems have to contend with increasingly sophisticated attacks, or exploits from malicious persons (i.e. hackers) attempting to gain access to data or software in a computer. An Intrusion Detection System (IDS) is an information security device that monitors and analyses data to detect when security is breached, while an Intrusion Prevention System (IPS) is a device that identifies malicious activity and attempts to stop or block the activity. IDS and IPS devices are often integrated into an IDS/IPS or Intrusion Detection and Prevention System (IDPS).
Techniques of bypassing an information security device in order to deliver an attack to a target network entity without detection are known as evasions. Evasions are typically used to counter a network-based IDS/IPS but can also be used to by-pass firewalls. Just as viruses can be detected and blocked by anti-virus software, evasions can be stopped through anti-evasion solutions. However, it has recently been recognised that more advanced evasion techniques (AETs) have been developed, and it has been reported that most, if not all currently available IDS/IPS solutions are unable to detect or prevent an attack if more than one AET is used concurrently.
The present invention has been conceived with the foregoing in mind. However, before describing this further some explanation is required of the terms that will be used particularly in relation to the embodiments described.
An attack is any attempt to destroy, expose, alter, disable, steal or gain unauthorized access to or make unauthorized use of a computer asset. An exploit is a piece of software, a chunk of data, or sequence of commands that takes advantage of a bug, glitch or vulnerability in order to cause unintended or unanticipated behavior to occur on a computer. Examples might include gaining control of a computer system or allowing a privilege escalation or a denial of service attack. Malware is malicious software designed to secretly access a computer system without the owner's informed consent, and may include a variety of forms of hostile, intrusive, or annoying software or program code, such as computer viruses, worms, trojan horses, spyware, dishonest adware, scareware, crimeware, most rootkits, and other malicious or undesirable software.
As used herein, an attack may be considered also to include any of the above.
The term “vulnerability”, as used herein refers to the term defined by the Common Vulnerabilities and Exposures (CVE®). CVE defines a vulnerability as a mistake in software that can be directly used by a hacker to gain access to a system or network. CVE is a dictionary of identifiers of known vulnerabilities that makes it easier to share data across different network security databases.
Embodiments are described below in relation to network communications at certain levels, or layers, such as described in the ISO's Open Systems Interconnection (OSI) model. In the OSI model a layer is a collection of conceptually similar functions, implemented within each layer by one or more entities. Each entity interacts directly only with the layer immediately beneath it, and provides facilities for use by the layer above it. Protocols enable an entity in one host to interact with a corresponding entity at the same layer in another host. Most network protocols used today are based on TCP/IP stacks.
In at least one version of the OSI model there are seven layers. Starting at the lowest layer, layer 1, which is the physical layer, the layers above are, in order, 2—the data Link layer, 3—the Network layer, 4—the Transport layer, 5—the Session layer, 6—the Presentation layer, and 7—the Application layer. At any given layer, N, two entities (N-peers) interact by means of the N protocol by transmitting protocol data units (PDUs). A Service Data Unit (SDU) is a specific unit of data that has been passed down from one layer to a lower layer, and which the lower layer has not yet encapsulated into a protocol data unit (PDU) of its own layer. Thus, an SDU is a set of data that is sent by a user of the services of a given layer, and is transmitted semantically unchanged to a peer service user. The SDU is the ‘payload’ of a given PDU. Accordingly, where the embodiments described below refer to a particular level or layer, such as the Application level, to describe the principles of the invention, it should be understood that the same principles may be applied at other layers, and where data is referred to as payload it should not be construed as being limited to data at any particular layer.
SUMMARY
According to a first aspect of the invention, there is provided a method of identifying a potential attack in network traffic that includes payload data transmitted to a host entity in the network. The method includes: performing a first data-check on one or more data bytes of the payload data at the host entity; performing a second data-check, equivalent to the first data-check, on data of the network equivalent to the one or more bytes of payload data; and comparing the results of the first and second data-checks to determine if there is a mismatch, the mismatch being an indication of a potential attack.
The first data-check may be performed by a Host Intrusion Protection System, HIPS and the second data-check performed by an IDS/IPS. The HIPS may be provided with a communication channel to the IDS/IPS, the results of the first and/or the second data-check being transmitted over the communication channel for the comparing. The HIPS may be provided with configuration information specifying network connection types for which the method of identifying a potential attack is to be applied. The method may further comprise sending the configuration information to the IDS/IPS.
The payload data may be an application level payload, the HIPS using network hooks for accessing the payload to perform the first data-check.
The data-checks may be compared as the bytes are transmitted over the network.
The first data-check may be performed on a server monitoring traffic relating to a service, the method further comprising performing a predetermined action in response to identification of a potential attack. The predetermined action may comprise terminating the connection, or logging the attack, or both.
Alternatively, the first data-check may be performed on a client computer monitoring traffic between the client and a remote network entity, the method further comprising notifying the user of the client computer of the attack. The method may further comprise providing an option for the user to terminate the connection or to accept the payload. Alternatively, the method may comprise automatically terminating the connection.
The first and second data-checks may comprise calculating a checksum. The checksum calculation may be a sliding checksum with offset information.
The potential attack may be identified as an attack that might include a plurality of Advanced Evasion Techniques, AETs.
According to a second aspect of the invention there is provided a method of identifying an attack in network traffic that includes application level payload transmitted to/from a host over a network connection and that might include a plurality of Advanced Evasion Techniques, AETs. A Host Intrusion Protection System, HIPS, is provided, with a communication channel to an IDS/IPS. The HIPS accesses at least a portion of the application level payload and calculates a checksum thereof. The IDS/IPS performs an equivalent checksum calculation for an equivalent portion of the application level payload assembled therein. The checksums calculated by the HIPS and the IDS/IPS are compared and an attack is signalled if there is a mismatch.
According to a third aspect of the invention there is provided a system for identifying a potential attack in network traffic that includes payload data transmitted to a host entity in the network. A first data-checker is configured to perform a first data-check on one or more data bytes of the payload data. A second data-checker is configured to perform a second data-check, equivalent to the first data-check, on data of the network equivalent to the one or more bytes of payload data. A comparator compares the results of the first and second data-checks to determine if there is a mismatch, the mismatch being an indication of a potential attack.
The first data-checker may comprise a HIPS on the host entity, and the second data-checker may comprise an IDS/IPS, the system further comprising a communication channel connecting the HIPS and the IDS/IPS.
The HIPS may be installed on a server and is configured to monitor traffic relating to a service. Alternatively, the HIPS may be installed on a client computer and is configured to monitor traffic between the client and a remote network entity.
According to another aspect of the invention there is provided a system for identifying an attack in network traffic that includes application level payload and that might include a plurality of Advanced Evasion Techniques, AETs. The system comprises: a host computer that includes a network connection over which the network traffic is sent/received and a HIPS; an IDS/IPS; and a communication channel connecting the HIPS and the IDS/IPS. The HIPS is configured to access at least a portion of the application level payload and to calculate a checksum thereof. The IDS/IPS is configured to perform an equivalent checksum calculation for an equivalent portion of the application level payload assembled therein. A comparator compares the checksums calculated by the HIPS and the IDS/IPS and for signalling an attack if there is a mismatch.
According to another aspect of the invention there is provided a computer network entity. The entity comprises a data-check comparator configured to perform a comparison between a first data-check of at least a portion of a payload of network traffic destined for a host entity and a second data-check, equivalent to the first data-check, on data of the network traffic equivalent to the payload portion. The entity signals a potential attack if the data-check comparison indicates a mismatch between the first and second data-checks.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of a network host entity showing data transfer paths.
FIG. 2 is a flow diagram illustrating a procedure for identifying a potential attack network traffic.
FIG. 3 is a schematic block diagram of a network host entity suitable for implementing some embodiments of the present invention showing data transfer paths.
FIG. 4 is a schematic block diagram of a network host entity suitable for implementing some embodiments of the present invention showing data transfer paths.
DETAILED DESCRIPTION
Referring to FIG. 1 , a host computer 102 resides as an entity in a network. Host computer 102 sends and receives data in the form of network traffic to/from other entities in the network. The host computer 102 has an installed HIPS 104 . The network traffic is also monitored by an IDS/IPS 106 . The HIPS 104 and IDS/IPS 106 have a dedicated communication channel open, which, in the embodiment shown, is a TCP channel (i.e. uses the TCP protocol).
The network traffic arriving at, or being sent by host 102 is encapsulated as PDUs, the SDUs of which comprise the payload data. For example, the payload may be application level (layer 7) data, encapsulated in presentation layer (layer 6) PDUs that make up the network traffic. The HIPS 104 analyses the payload (application level) data, while the IDS/IPS analyses the network traffic.
Embodiments of the invention are based on the idea that the only way to be sure how an attack will manifest itself on a target host computer is to inspect application level traffic payload on the target host itself. This is because it is the target host computer that implements the specific TCP/IP stack particulars, and the ways that different attacks will then be interpreted by the target host will only be evident from the payload at that level. However, for the IDS/IPS of the target network to perform the task of inspecting the payload data would involve a complex and CPU-intensive analysis of the PDUs involving exploit detection logic, and updating of databases. Instead, it is proposed to perform a simple comparison to check if the picture of the payload data in the traffic that is monitored by the IDS/IPS is the same as the actual payload at the target host computer. If there is a discrepancy, it is an indication of a potential attack.
Thus, while the IDS/IPS does the actual attack detection from the application payload, the IDS/IPS is provided with feedback indicating if it has the correct picture of the application payload. If it doesn't, then a potential multi-AET attack is assumed to be in place.
According to one preferred embodiment, on the target host computer 102 the HIPS 104 has a configuration file that defines the type of connections that should be protected against a multi-AET attack. For example, the configuration file might include a list such as “HTTP, MSRPC, FTP, ARP, etc.” FIG. 2 illustrates the method of identifying a potential attack. In FIG. 2 , items shown on the left hand side are performed at the HIPS 104 on the target host computer 102 , while items shown on the right hand side are performed at the IDS/IPS 106 . The procedure starts at step 201 where the host computer identifies from the configuration file that a communication is starting through one of the protected connections. Before any traffic is sent or received, at step 202 , the HIPS 104 sends the configuration file data to the IDS/IPS 106 through the communication channel 108 , and this is received at step 204 . Receipt of the configuration file acts as an indication that the HIPS 104 and the IDS/IPS need to cooperate in the following procedure.
When traffic commences, at step 206 , the HIPS 104 accesses the application level payload bytes. In this example, this is done using network hooks, which enable access to payloads between any level/protocol layer. There are several hooking methods/APIs provided by MICROSOFT®, or for example browser software may include “hooking” functionality in the form of Browser Helper Objects that provide access to different http specific headers and payloads. The HIPS 104 then performs a check on the payload data, the result of which can be used to compare with a similar check performed on the equivalent data assembled by the IDS/IPS. In this example, at step 210 the HIPS calculates a checksum of the payload data bytes. For example, this might be a sliding checksum with offset information. Where the traffic is being sent and received by the host computer 102 , the data check is performed on the application level payload in both directions.
Meanwhile, at step 208 . the IDS/IPS assembles the equivalent application level payload data bytes from the monitored network traffic, and, at step 212 performs the same data check (i.e. checksum) calculation. In the IDS/IPS the application level data is reassembled from data fragments in the PDUs of the network traffic.
The results of the data checks performed by the HIPS 104 and IDS/IPS 106 can now be compared (step 214 ). For example, the HIPS 104 may send the result of its checksum calculation over the communication channel 108 to the IDS/IPS 106 , where the comparison is made. Alternatively, the IDS/IPS 106 could send the result of its checksum calculation to the HIPS 104 . As another alternative shown in FIG. 4 , both the HIPS 104 the IDS/IPS 106 could send the results of their checksum calculations to a checksum comparator 309 elsewhere in the network. On an on-going basis the checksums of the HIPS 104 and IDS/IPS 106 are continuously compared for payload bytes at the same time as the bytes are exchanged over the connections specified in the configuration file.
If, at step 216 , it is determined that the checksums of the HIPS 104 and the IDS/IPS 106 are the same, then no action need be taken and the process continues (step 218 ).
However, if at step 216 , it is determined that there is a mismatch between the checksums of the HIPS 104 and IDS/IPS 106 , this is an indication of a potential attack, which could be using an AET, or possibly multiple AETs. At step 220 an attack is signaled (by whatever entity has performed the checksum comparison). In that case one of the following actions may be taken.
It will be appreciated that the IDS/IPS 106 continues to perform its normal functions of monitoring and checking for attacks. Also, once the checksum comparison at step 216 identifies a potential attack, the IDS/IPS 106 can proceed to identify the particular attack (AET) being used and take steps to nullify it.
If the target host computer 102 on which the HIPS 104 is installed is a server machine inspecting traffic relating to some service, then a preconfigured action is taken at step 222 such as terminating the connection and logging the detected attack, or just logging it. Alternatively, if the target host computer 102 is a client machine with the HIPS 104 installed on it inspecting traffic to another network entity (e.g. some web site) then at step 224 a prompt dialog is displayed on the client machine informing the client that it is probably being targeted. In that case, the user may be informed of the specific nature of the attack and given the option of either terminating the connection or accepting suspicious traffic. Alternatively, the system may be configured to automatically terminate the connection and notify the user accordingly.
FIG. 3 shows a network host entity suitable for implementing the present invention. The network monitoring device 306 monitors and checks the network traffic for attacks. The data checker 304 is configured to perform a data check on one or more data bytes of the payload data of an incoming packet. The data checker 307 is configured to perform a data check on an equivalent one or more data bytes of the network equivalent of the payload data. The comparator 308 compares the results of both data checks to determine if there is a mismatch, a mismatch being an indication that the results of the network monitoring device are inaccurate. It will be appreciated by a person skilled in the art that the data checkers could be implemented in other systems, such as the data checker 304 being implemented in a HIPS, and the data checker 307 and network monitoring device 306 being implemented in an IDS/IPS as in the above embodiments.
The method described above mitigates and at least partially solves the problem of preventing attacks (exploits) that utilize multiple AETs. This is because the method nullifies AETs of a particular attack that exist on for example the TCP/IP stack level. As a consequence, only application level AETs remain available for the attacker and, depending on the application level protocol and the vulnerability in question, in most, if not all cases the attacker will be unable to utilize more than one AET at one time and so will be unable to evade the IDS/IPS. Thus, although an attacker might be able to use multiple AETs at the IP or TCP levels, for most vulnerabilities only one application level AET can be used.
The methods described above offer enhanced protection against multi-AET attacks and could be provided, for example, to Internet Service Providers as an optional or additional extra protection service for its customers. The IDS/IPS vendor will also obtain instant feedback on the type of any multi-AETs used that it has not detected. This information can then be used to develop the IDS/IPS technology further.
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A method of identifying a potential attack in network traffic includes payload data transmitted to a host entity in the network. The method includes: performing a first data-check on one or more data bytes of the payload data at the host entity; performing a second data-check, equivalent to the first data-check, on data of the network equivalent to the one or more bytes of payload data; and comparing the results of the first and second data-checks to determine if there is a mismatch, the mismatch being an indication of a potential attack.
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BACKGROUND OF THE INVENTION
Bicycles in general are very well known, and provide an exceptionally valuable mode of transportation. However, they require balance to maneuver and a certain amount of agility to keep upright and going on a straight course. For the very young--and very old--cyclists, and for people who have insufficient strength or balance to maneuver a bicycle, the tricycle provides a stabler and safer mode of transportation, while still retaining some of the advantages of a bicycle.
Most tricycles are designed for ordinary people who have reasonable use of all of their limbs, and reasonable balance for getting on and off of the tricycle, and for sitting on a conventional saddle that can be adjusted, to a limited degree, for driving the tricycle in a well known manner.
DESCRIPTION OF THE PRIOR ART
Almost all cycles are driven by the rear wheel, and by far the most common means of propulsion is foot pedals. There are only a few cycles that use hand cranks, but these are specially made and have nothing but hand cranks. A few bicycles were developed and may have been seen around the turn of the century--in the heyday of the bicycle--that used a combination of foot and hand power. However, all of these were directed towards getting more of the potential power out of any operator. Several forms of hand motion were proposed at that time to provide auxilliary power to the front wheels, or even to supplement the power to the rear wheel. However, these were all for bicycles, and were intended to increase the efficiency of an already-very-efficient form of transportation, and were for use only by an even-more agile and acrobatic operator.
None of these exotic forms of bicycle appears to be in use today, and, certainly, none of these teachings could be applied to a cycle for the use of handicapped children.
Among the few developments in tricycles for use of handicapped individuals is the "Front Wheel Drive Cycle" of Vittori; U.S. Pat. No. 3,848,891, issued Nov. 19, 1974. Vittori shows and teaches a hand-driven front-wheel-drive tricycle for use by paraplegic individuals, and, while this is certainly a noteworthy invention, it teaches only the use of hand power and front wheel drive. In addition, there is no teaching of adjustment, aside from the longitudinal position of the tiller bar, to accommodate different paraplegics or to accommodate the growth of an individual.
More important, there is no means seen in Vittori--nor is there any teaching of any means--for accommodating the feet and legs of certain types of handicapped children who may have limited use of their legs, or where there may be a need to exercise the legs to gradually develop them. This may be of very great importance in a therapeutic program towards the recovery of a handicapped individual, because at some time it may be advisable to exercise the legs even when they are not, of themselves, capable of doing any useful work.
It is therefore an object of this invention to provide a tricycle that has a crank mechanism for driving the front wheels by hand, and a pedal mechanism for driving the rear wheels by foot.
It is a further object of this invention to provide a tricycle that can be adjusted to accommodate the large majority of handicapped children at an early age, when exercise is essential, and also can be adjusted to accommodate their growth in size, as well as their improvement in muscular coordination and condition.
It is a further object of this invention to provide a tricycle that has a hand-crank front wheel drive, and an auxilliary, foot-pedal rear wheel drive, along with a completely adjustable frame for controlling the position of the driver; the distance between his body and the hand crank; and the distance between his body and the foot pedals.
SUMMARY OF THE INVENTION
A tricycle for handicapped individuals has a hand crank coupled through a chain drive linkage to the front wheel of the tricycle, and foot pedals coupled through a chain drive linkage to the rear wheels. A frame supports the front wheel and its chain drive linkage in a steerable manner; the rear wheels and their chain drive linkage; and a seat assembly. Adjustments are provided for the position of the seat with respect to the frame; the position of the hand crank with respect to the frame and the seat; and the position of the foot pedals with respect to the frame and the seat.
This tricycle is unique in its ability to be adjusted for almost any handicapped individual, and varied to accommodate his changes. It may also be adapted, at short notice, to another individual.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of one embodiment of this invention; and
FIG. 2 shows a side view of another embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more particularly to FIG. 1, a side view of a tricycle is seen with the rear wheels in alignment for simplicity--and since their alignment and orientation is not a part of this invention. This tricycle has a frame 50; a front wheel drive mechanism having upper front wheel drive linkage or assembly 10 and a lower front wheel drive linkage or assembly 20; a rear wheel drive linkage or assembly 30; and a seat assembly 40 mounted on the frame 50.
The upper front wheel drive assembly 10 has a hand crank 12 with handles 13A and 13B turning a sprocket 14, which drives another sprocket 15 by means of a chain 16. The sprockets 14 and 15 are spaced and held in position by an upper front wheel drive linkage support 18 which is secured to an upper portion 19 of a front wheel fork by a fastener 17. The front wheel fork is otherwise conventional
The lower front wheel drive linkage or assembly 20 has an upper sprocket 21, directly coupled to the sprocket 15, a lower sprocket 22 coupled to a front wheel 11, and coupled to the sprocket 21 by means of a chain 23. The sprockets are spaced and held in their relative positions by a lower front wheel drive linkage support or swing arm 24. The front wheel 11 is rotatably mounted at the lower end of the front wheel fork in the usual manner. The front wheel fork also steers the cycle.
The rear wheel drive linkage or assembly 30 has foot pedals 32A and 32B driving a sprocket 33 which is coupled to a sprocket 34 on rear wheels 31 by a chain 35. A gear-changing apparatus 36 may be provided. The sprockets 33 and 34 along with the pedals and rear wheels are spaced and held in the relative positions by a rear wheel drive linkage support 37 which, in FIG. 1 is part of the frame.
The seat assembly 40 has a seat or saddle 41, and a backrest 42 supported by a back brace or sissy bar 43 that may include a handle or handles 44. In FIG. 1, the back brace 43 is coupled to a seat brace 46, and to the frame in a well known manner.
The frame 50 couples all of these elements together in an operable manner, and includes typical frame members 51 and 52 that support and couple a housing or bushing 53, through which the front wheel fork and front wheel drive assembly pivots, to the seat assembly and the rear wheel drive assembly.
FIG. 2 shows another species of this invention, wherein most of the elements of FIG. 1 are seen and are similarly numbered. The upper and lower front wheel drive linkages or assemblies 10 and 20 and the rear wheel drive linkage or assembly 30 may be the same. The seat assembly 40 may be the same or it may include an arm rest or guard 45.
The frame assembly 50 in FIG. 2, however, has different frame members 54 and 55 that support and couple the housing or bushing 53 to the other elements of the tricycle. In FIG. 2 the frame member 54 terminates in a special bracket 56 which is slidably coupled to the rear wheel drive linkage support 37, and is secured in any desired position by the locking bolts 58. The frame member 55 terminates in another special bracket 57 which is slidably coupled to the lower end 48 of the back brace 43 to which the seat assembly 40 is securely attached. The seat assembly can be moved forward or backward and can be secured in any desired position by the locking bolts 59. The seat 41 and back rest 42 in FIG. 2 are seen to be mounted on the back brace 43 by vertical adjuster bolts 47 that permit vertical motion of the seat and backrest.
The seat 41 in both the figures may be tilted to any desired degree by conventional adjustments under the seat or saddle 41, not shown for simplicity.
In operation, the handicapped child or individual is seated comfortably in the seat assembly 40. In the preferred embodiment of FIG. 2, the height of the seat and seat assembly may be first adjusted to a comfortable height for getting in and out of the tricycle as well as for operating it. For safety sake, this will usually be relatively low to maintain a low center of gravity, to minimize the possibility of capsize, or of injury in the remote event of a fall. However, some vertical adjustment may be desirable to achieve the most effective position, and to accommodate different children and special physical conditions as well as to accommodate the growth of the child.
The slidable coupling 56 may then be adjusted to bring the pedals 32 into the most desirable position with respect to the legs and feet of the child for most effective use of, or for the prescribed exercise of the feet and legs. The slidable coupling must then be secured by the locking bolts 58 of the special bracket 56. The fastener 17 may then be released so that the upper front wheel drive linkage can be moved up or down, or forwards or backwards, until the handles 13 of the hand crank 12 are in the most comfortable and effective position with relation to the child. The fastener 17 is then secured and the child can operate the tricycle.
The seat assembly may be removeable, particularly in the species of FIG. 2, and may be replaced with any desired type of seat. The seat may be anything from a simple saddle, to the wheelchair type of seat and backrest, depending on the type and degree of the child's handicap. The optimum seat would appear to be an extra wide saddle that provides comfortable support without impeding the use of the legs. Arm rests or guards such as 45 may be an essential part of the seat, for safety sake, or may be omitted in special cases. In fact an actual wheel chair seat could be made detachable and provided with brackets to accommodate either the tricycle or the wheel chair.
This tricycle will, obviously, be geared to relatively low speeds. Speed changing gears of the deraileur type, as seen at 36, with suitable controls mounted on the frames can obviously be fit into any of the sprocket mechanisms or chain linkages. Planetary three-speed gears--preferably with a built-in back-cranking brake--should be mounted in the front wheel hub to be operated by the front wheel drive mechanism. This may be necessary to permit the child to manage certain gradients with this comparatively-heavy vehicle, or even to help him gradually develop the strength to use it.
Coaster gearing, as in conventional cycles, may also be desirable to make the tricycle more easy to push when the child tires or when it is empty. Brakes, not shown, of any standard type that can be adapted to this type of tricycle would, in any case, be provided.
Mechanisms of any standard type, not shown for simplicity, may be provided to directly engage or to permit coasting of either front or rear drive linkage, so that the tricycle can be driven by either hand or foot, or so that both must be used simultaneously for exercise or for therapeutic reasons. For example if the child's legs are virtually useless, the rear drive may be left to coast. In certain cases the pedals may be positioned side by side, in the same direction, to act as foot rests, and the rear wheel drive linkage left to coast. On the other hand, the pedals may be made to turn if it is considered that the legs should be made to exercise.
The front wheel drive mechanism has its lower drive linkage 20 pivotable about the front wheel axel, along with the sprocket 22 at its lower end. The upper front wheel drive linkage may be pivotable about the axis of its forward sprocket 15 and the upper sprocket 21 of the lower front wheel drive linkage. There must, of course, be some means for adjusting the lengths of the upper and lower front wheel drive linkage supports 18 and 24 respectively to provide the correct tension on their respective chains. Such an adjustment may also be necessary for the rear wheel drive linkage support 37.
The hand crank and foot pedal mechanisms may be of well known types, and may resemble each other except for the inevitable differences between hand-held and operated, and foot operated mechanisms. Straps or clamps of any well known type may be provided to hold the invalids feet on the pedals.
It is obvious that the sizes of the frame members 54 and 55 may be as large as necessary, or they may be doubled for additional strength. The special brackets 56 and 57 that slidably couple the rear-wheel drive and seat assemblies to the frame must be strong enough to bear the weights involved and provide a safe, rigid coupling. The special brackets may also be made as large or as long as necessary, and they may also be doubled, and additional locking bolts such as 58 and 59 may be provided. Rectangular pipe for the frame members 54 and 55 would provide additional rigidity.
It is to be understood that I do not desire to be limited to the exact details of construction shown and described since obvious modifications will occur to a person skilled in the art.
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A tricycle having both front and rear wheel drives, for hand and foot motion respectively, includes a front wheel drive assembly that is adjustable with respect to the frame of the tricycle to position a hand crank in the optimum position for almost any user. A seat assembly is also adjustable with respect to the frame, and a rear wheel drive assembly is also adjustable with respect to the frame to make the tricycle adaptable to any handicapped child or individual, to give him the maximum use of his limbs; to exercise his limbs in the best therapeutic manner; and to allow for growth and changes and improvements in this muscular coordination.
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BACKGROUND OF THE INVENTION
The object of the invention is a method of condensing and/or polymerising sulfonated lignin containing materials by means of which the viscosity, molecular weight and the efficacy of the materials may be substantially increased.
According to the invention polymers based on sulfonated lignins are being produced in a substantially dry state and at relatively low temperature and the end products thus obtained exhibit remarkably increased viscosities. The novel and surprising feature of the invention is not so much the increase in molecular weight as the simultaneous pronounced viscosity increase.
A main source of sulfonated lignin are residual pulping liquors of wood, straw or bagasse. In the sulfite pulping process the lignocellulosic material is digested with a bisulfite or sulfite salt solution, whereby a sulfonated lignin containing solution is formed, which is commonly referred to as spent sulfite liquor. In other pulping processes a spent liquor is obtained which does not contain sulfonated lignin. The lignins thus obtained can be sulfonated by additional treatment whereby sulfonated lignins, also suitable for the preparation of the material according to the invention, are obtained.
It is known that the sulfonated lignin containing products obtained by the above mentioned processes differ substantially as to their composition and the chemical structure of their various constituents. Furthermore, many of the commercially available products are prepared by enriching the sulfonated lignin material or by chemically modifying one or more of the components of the spent liquor. Although the composition of such preparations may vary in many different ways, they still constitute sulfonated lignin containing material also known as lignosulfonates. As a group of compounds the lignosulfonates are invariably polydisperse and are described with particular thoroughness in the book `Lignins` edited by K. Sarkanen & C. Ludwig, Wiley-Interscience.
Of the millions of tons of sulfonated lignin produced annually only a small fraction is currently finding industrial utilization. Furthermore, utilization for the most part is confined to whole spent sulfite liquor exhibiting viscosities of several hundred cP as 50% solutions at room temperature and containing sulfonated lignin matter that for more than 60% falls into a molecular weight range of under 5000.
Products of higher average molecular weight and viscosities are being offered on the market as premium priced specialty items. These compounds are attracting considerable attention because of their enhanced usefulness in - for instance - such diverse materials as dispersion agents for organic dyestuffs, precipitation agents for soluble protein or as additives or extenders for glues.
For the most part these relatively high molecular weight lignosulfonates are derived by costly fractionation of sulfite spent liquor. However, spent sulfite liquor solids have also been polymerised by a method described in Canadian patent 436 469. Said patent discloses acid polymerisation of lignosulfonates in an aqueous medium to produce products claimed useful for oil well drilling muds and other applications. Accordingly, highly corrosive solutions warranting very special and costly manufacturing equipment need to be handled for prolonged periods of time at temperatures up to 180° C and pH values less than 1. A further drawback severely limiting any polymerisation technique in solution is the fact that the reaction is accompanied by a simultaneous increase in the viscosity of the medium. For the reasons of technical feasibility, polymerisation in concentrated, i.e. already very viscous solutions is therefore limited to minor increases in the molecular weight while polymerisation in the dilute state would prove excessively costly and run the risk of concurrent hydrolysis to products having a lower molecular weight or being more polydisperse as they contain hydrolysed matter in addition to condensed matter.
A method for heating lignin sulfonates in the dry state is described in U.S. Pat. No. 3 476 740. Accordingly a sulfonated lignin containing material is subjected to heat treatment between temperatures of 200° and 330° C to produce products useful in drilling muds and for dispersing applications. Because the preferred temperature range employed, 230° to 270° C, is above the ignition temperature of the treated material and the energy input is is sufficiently large to cause homolytic and other breakdown of the sulfonated lignin material, it is found necessary to first stabilize the lignin sulfonate by oxidation. Similarly, German Pat. 1769903 also discloses a method for heating lignin sulfonates at temperatures above 150° C leading to useful products exhibiting lower viscosity than the starting material.
By contrast, the present invention aims at producing substantially water soluble condensation products of sulfonated lignins which are commercially attractive whereby the method is sufficiently mild as to give rise to a minimum of side reactions.
The characteristics of the invention appear from the appended Claims.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As a result of this method water and some volatile acidic substances are eliminated and the viscosity of an aqueous solution of the treated product is substantially increased. The end products of the reaction are readily identified by their viscosities and the acid condensation reaction is therefore easily monitored.
As the efficacy of the sulfonated lignin products for any given application seems to be closely related to the average molecular weight, the acid condensation reaction according to the invention provides a convenient means for "taylormaking" lignosulfonates for any specific industrial application.
While wide variations in time, temperature and pH are possible within the scope of our invention, it is judged that pH is by far the overriding factor for achieving the best possible end result in product properties as well as the economics of manufacture. Selection of the pH range to fall below 7 is based on the consideration that lower reaction temperatures and shorter heating time -- spelling better control of the reaction -- are afforded by adjusting the pH of the dried material downward before heating.
With respect to temperature and reaction time, it has been established that the higher the reaction temperature the faster the acid condensation will proceed and the shorter the reaction time will be.
Vital, if not also rate controlling, to achieving rapid and continuous increase in viscosity is the presence of small amounts of water as the condensation will not proceed under conditions of absolute dryness. Generally speaking, all commercial lignosulfonate based materials do contain several percent of water. In addition to the water of reaction formed this amount is generally sufficient to bring about a substantial increase in viscosity over prolonged periods of time if care is taken that the reaction does not run dry. For processing reasons the moisture of the solids undergoing reaction is best kept constant at between 1 to 7 percent. However, during the condensation reaction the products thus exist in the substantially dry state, i.e. in a state where their physical properties resemble that of a solid rather than that of a liquid. This is usually the case when the amount of water present is less than 15%.
While in general we prefer to operate a two step process the first step of which consists of drying the sulfonated lignin containing material in a conventional spray drying equipment followed by a second step of acid condensation under specific conditions using suitably modified belt or tray driers, it is equally possible to consolidate the drying and heating steps into a single continuous process such as by spray drying the product and immediately heating the same in a fluidized bed within the temperature range specified or by drying and heating the product in a continuous kiln.
As mentioned earlier any sulfonated lignin containing material may be used as a starting material whether the material is spent sulfite liquor containing significant amounts of carbohydrates, or constitutes purified or fractionated and therefore less polydisperse material derived from sulfonated lignin. The starting material may also contain calcium, sodium, magnesium or any other cations and may have been modified by or blended with other chemicals or materials. In turn, the acid polymerised reaction products may receive further chemical treatment as desired.
To illustrate the present invention the following more detailed examples are presented describing modes of carrying out the invention as well as the use of the products obtained thereby.
The acid condensation reaction was conducted in a 500 ml steel vessel having a small orifice and being rotated in a thermostat controlled oil bath. The charge of product generally amounted to 150 g and the temperature given denotes the temperature prevailing within the reaction charge.
Unless otherwise specified all viscosities were measured at 23° C using a Brookfield viscosimeter at 30 rpm. The viscosity measurements were made in 40% and 25%, respectively, aqueous solutions but it is self-evident that they may also be carried out e.g. in a 50% solution, as is known in the art, whereby as a general rule may be said that the more concentrated the solution is the greater will the viscosity change be. The water content was in all tests about 4% both before and after the reaction. The pH values given refer to 3% solutions in distilled water.
EXAMPLE 1
The effect of pH value and reaction temperature on the viscosity of a sulfonated lignin containing material.
To a 55% spent liquor derived from a for alcohol fermented calcium based spruce sulfite spent liquor obtained from the production of rayon grade cellulose, was added sufficient 50% sulfuric acid to give product pH values of 3.5 and 4.0. The precipitated calcium sulfate was removed and the solution taken to dryness using a Niro design laboratory spray drier. The dried products exhibited calcium contents of 6.5% and 6.7%, respectively. The results are given in the following table.
TABLE 1
Properties of products prepared according to Example 1; acid condensation 5 hours at various temperatures
______________________________________ Viscosity % pH 40 % soln. cP reducing matterSam- Reaction before/after before/after before/afterple temp. ° C heating heating heating______________________________________0 -- 3.5 -- 28 -- 15.3 --1 120 3.5 3.6 28 32 15.3 12.62 140 3.5 3.7 28 40 15.3 11.43 160 3.5 3.8 28 440 15.3 11.34 165 3.5 3.9 28 4500 15.3 11.05 170 3.5 3.9 28 >100000 15.3 11.06 -- 4.0 -- 30 -- 15.3 --7 120 4.0 4.1 30 32 15.3 13.38 140 4.0 4.2 30 36 15.3 10.79 160 4.0 4.3 30 30 15.3 10.510 165 4.0 4.3 30 500 15.3 10.011 170 4.0 4.4 30 1900 15.3 9.0______________________________________
The efficacy of the acid condensation is illustrated by the following tests for dispersions of plaster of Paris.
The testing procedure followed that given in U.S. Pat. No. 3 476 740. 500 mg of sulfonted lignin containing material was dissolved in 30 ml of distilled water and 50 g of commercial plaster of Paris was sifted into the solution. The resulting suspension was stirred in a Hamilton-Beach mixer for 10 seconds and the slurry was allowed to stand for another minute and again stirred for 15 seconds. It was then poured from a height of 10 cm onto a glass plate. The area covered by the various samples is recorded in Table 2 and is proportional to the thinning efficiency of the dispersant employed.
TABLE 2
The efficacy of compounds prepared according to Example 1 on the thinning of plaster of Paris slurries.
______________________________________Sample Area of gypsum patty in mm.sup.2______________________________________0 113051 126602 143053 201004 158305 28266 101007 122658 141009 1885910 1674011 17430______________________________________
The table shows that the best results are obtained with samples 3 and 9. By comparison with Table 1 it is seen that the best thinning effect is achieved when the viscosity is within the range of about 100 to 500 cP.
EXAMPLE 2
The effect of reaction time on the viscosity of a sodium based for Torula yeast fermented sulfite spent liquor.
To the 55% calcium based spent liquor exhibiting a reducing matter content of 7%, was added sufficient 55% sulfuric acid and sodium sulfate to precipitate all calcium as calcium sulfate and to yield a pH of 3.1. The calcium sulfate was removed by filtration and the clear solution taken to dryness by spray drying. The dried material containing 4% Na was submitted to acid condensation for various lengths of time at 140° C and the results are presented in Table 3.
TABLE 3
The acid condensation of for Torula yeast fermented sodium based spruce sulfite spent liquor at pH 3.1 and 140° C.
______________________________________ % Viscosity ofReaction pH reducing matter 40 % soln., cPSam- time hrs before/after before/after before/afterple at 140° C heating heating heating______________________________________0 0 3.1 -- 7.0 -- 28 --1 2 3.1 3.2 7.0 6.7 28 322 4 3.1 3.3 7.0 6.2 28 573 6 3.1 3.4 7.0 5.9 28 1304 8 3.1 3.5 7.0 5.7 28 8005 12 3.1 3.7 7.0 5.4 28 19006 18 3.1 3.7 7.0 5.3 28 6000______________________________________
Kaolin tests
In this test the efficacy of condensed lignosulfonates are presented for the thinning of a kaolin clay suspension and for use as extender for phenolic glues.
0.6 g of sulfonated lignin containing material are dissolved in 300 ml of distilled water and 200 g of kaolin clay are added. The suspension is stirred for 2 minutes and the pH carefully adjusted to 4.5 with 0.1N H 2 SO 4 . The mixture is stirred for another 30 minutes and the pH, if needed, again adjusted to 4.5.
The viscosities of the various slurries are recorded in the following Table 4. They are inversely proportional to the thinning efficiency of the dispersant employed.
TABLE 4
The thinning efficiency of acid condensed material prepared according to Example 2 on a 40% kaolin clay suspension.
______________________________________ Viscosity of 40 % kaolin suspension,Sample cP at 30 rpm______________________________________0 2001 1802 1503 804 205 106 35______________________________________
Plywood glue tests
The testing procedure followed that outlined by Forss and Fuhrmann in Finnish pat. appln. 2527/72.
160 g of sulfonated lignin containing material was dissolved in 300 g of water and the pH adjusted to 7.0. This solution was subsequently poured into 600 g of a commercial 40% phenol-formaldehyde precondensate resin followed by 10 g of paraformaldehyde. The glue is allowed to react for 1 h with stirring and is subsequently applied to 1.5 mm birch veneers at an amount of 150 g/m 2 . The samples were turned into 3-ply plywood employing a press time of 5 minutes at 135° C and pressures of 16 kp/cm 2 . Comparative dry and wet strength test results are presented in the following Table 5.
TABLE 5
Comparative dry and wet strengths of plywood samples glued with phenolic-formaldehyde resins extended with acid condensed sulfonated lignin prepared according to Example 2.
______________________________________Glue component Dry strength Wet strengthSample kg/cm.sup.2 kp/cm.sup.2______________________________________0 18.2 11.31 19.0 13.22 22.1 13.83 25.0 15.04 29.7 18.05 31.8 18.96 -- --______________________________________
EXAMPLE 3
The effect of reaction time on the viscosity of a calcium based high molecular weight fractionally lime precipitated sulfonated lignin.
To 10 kg of 15% calcium based spruce spent sulfite liquor derived from a paper cook was added at 60° C a sufficient amount of a lime slurry to raise the pH to 11.5. The precipitated calcium lignosulfonate was collected and washed on the filter with 500 ml of 3% lime solution. The filter cake was then transferred to a beaker to which sufficient 50% sulfuric acid was added to give a pH of 3.0. The precipitated calcium sulfate was removed by filtration and the solution taken to dryness by spray drying. The thus purified, high molecular weight sulfonated lignin fraction exhibiting a calcium content of 4% was subsequently submitted to acid condensation at pH 3.0 and 140° C for various periods of time and the respective increases in viscosity and other data are set forth in Table 6.
The effect of reaction time at 140° C and pH 3.0 on the viscosity of a calcium based high molecular weight lignin sulfonate fraction obtained from spruce spent sulfite liquor by precipitation with lime.
______________________________________ % reducing Viscosity of pH matters 25 % soln., cP Reaction before/after before/after before/afterSample time, hrs heating heating heating______________________________________0 -- 3.0 -- 7.5 7.5 17 --1 3 3.0 3.1 7.5 7.5 17 202 6 3.0 3.3 7.5 7.5 17 603 9 3.0 3.4 7.5 7.5 17 4004 12 3.0 3.5 7.5 7.5 17 800______________________________________
Comparative tests were made with limed oil well drilling muds and the results are represented in Table 7.
TABLE 7
Comparative hot-rolled lime mud test results of acid polymerised material prepared according to Example 3.
______________________________________GelsSample 10 s/10m. Yield point API water loss, ml______________________________________0 3 5 1 6.21 3 4 0 5.62 2 2 0 5.33 2 2 0 4.44 3 4 0 4.6______________________________________
The testing procedure followed that outlined for the sweet water test in the following Example 4 except that 7.8 g of Ca(OH) 2 and 7.8 ml of 25% NaOH solution are introduced into the mud immediately prior to addition of the sulfonated lignin containing material.
EXAMPLE 4
The effect of reaction time on the viscosity of an iron salt of a sulfonated lignin containing material.
Into a hot, for alcohol fermented calcium based spruce spent liquor having a dry matter content of 53%, are added 235 g of ferro sulfate, 7H 2 O/kg. The formed calcium sulfate is separated by filtering. The pH of the filtrate is adjusted to 3.0 and 2.0, respectively, and the filtrate is dried into a free flowing powder in spray drier. The materials thus obtained are acid condensed at 150° C and 100 ° C, respectively, for various lenghts of time and the viscosity increases are given in Tables 8 and 11.
TABLE 8
The effect of reaction time on the viscosity of an iron lignosulfonate prepared at 150° C and pH 3.0 according to Example 4.
______________________________________Reaction % reducing Viscosity of atime pH matter 40 % soln., cPSam- hrs at before/after before/after before/afterple 150° C heating heating heating______________________________________0 0 3.0 -- 10.7 -- 30 --1 2 3.0 3.1 10.7 10.4 30 1002 3 3.0 3.3 10.7 10.1 30 10003 4 3.0 3.6 10.7 9.7 30 19004 5 3.0 3.8 10.7 9.3 30 30005 6 3.0 3.9 10.7 8.9 30 4500______________________________________
In the following the advantageous results obtained with sweet water and gyp drilling muds are given.
Test results with a sweet water drilling mud
500 ml of a 9.5% sodium bentonite solution (yield value 77) was prepared in distilled water. It was kept for 16 hrs at 90° C. When cooled to room temperature 8.7 g of sulfonated lignin containing material is added as well as 3 ml of a 25% NaOH-solution while mixing with a Hamilton-Beach-mixer. Thereafter the mud is placed into a heating chamber and rotated therein for 16 hours at 90° C. Thereafter the mud is cooled to room temperature and stirred for 5 minutes before testing.
TABLE 9
Comparative test results of a sweet water drilling mud containing acid polymerized iron lignosulfonate prepared according to Example 4.
______________________________________GelsSample 10 s/10m. Yield point API water loss,ml______________________________________0 2 3 3 7.81 2 3 3 6.62 2 3 4 6.03 2 3 5 5.84 2 3 6 5.45 2 3 6 5.1______________________________________
Test results with a gyp containing mud
The mud was prepared in the same manner as the sweet water mud except that 7.8 g of CaSO 4 . 1/2 H 2 O was added to the mixture of lignin product and NaOH.
TABLE 10
Comparative test results of a hot-rolled gyp mud containing acid polymerised iron lignosulfonate prepared according to Example 4.
______________________________________GelsSample 10 s/10 m. Yield point API water loss, ml______________________________________0 14 26 19 16.61 10 20 10 13.62 1 3 1 5.43 1 3 1 5.64 2 3 3 4.65 2 3 3 4.6______________________________________
The testing procedures generally correspond to the methods published by the American Petroleum Institute. The viscosity measurements, the gels and the yield points have been determined with a Fann-V viscosimeter and the water loss by using 400 ml of mud and a pressure of 7 kgN 2 /cm 2 for 30 minutes.
TABLE 11
The effect of reaction time on the viscosity of an iron lignosulfonate prepared according to Example 4 at 100° C and pH 2.
______________________________________ Viscosity of pH 40% solution, cp Reaction time before/after before/afterSample min. at 100° C heating heating______________________________________1 30 2.0 2.0 30 1002 60 2.0 2.0 30 5003 90 2.0 2.0 30 50004 120 2.0 2.0 30 410005 200 2.0 2.0 30 >200000______________________________________
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A method for polymerizing sulfonated lignin containing materials by adjusting the pH of the materials to a pH below 7, adjusting the moisture content of the materials to a value sufficient to allow the conversion to proceed, but less than 15 percent, and then subjecting the thus treated materials to heating at a temperature from 80° to 225° C in a manner to maintain the moisture content of the material at a value sufficient to allow the conversion to proceed, but less than 15 percent, and for a time period sufficient to form products having a viscosity of at least 25 percent higher than the viscosity of the starting material. The products obtained are useful as dispersants and extenders.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/248,025, filed Nov. 13, 2000 and entitled “Carried-Forward Service Units and Commoditization Thereof”, hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a system wherein, in connection with a billed service package that provides a service and a number of service units to be employed for the service, unused service units that remain at the end of a service period are carried forward to the next service period. More particularly, the present invention relates to such a system wherein, in connection with a cellular telephone service package that provides cellular telephone service or the like and a number of minutes or the like to be employed for the service, unused minutes or the like left over at the end of a billing cycle are carried forward to the next billing cycle. Thus, such unused minutes do not expire at the end of a billing cycle and can be treated as a commodity.
BACKGROUND OF THE INVENTION
[0003] In one form of service as provided by a service provider, a user selects a service package from among a plurality of service packages, where the service package implements a service and defines a number of service units that may be employed in connection with the service. Typically, the service package is provided for a pre-defined period of time, such as for example monthly or quarterly, where the period of time may be characterized as a billing cycle. As is to be appreciated, the service provider bills the user for the service package on a periodic basis that may correspond to the billing cycle, such as for example at the end thereof, ten days after the end thereof, etc.
[0004] Also typically, unused service units that remain at the end of a billing cycle expire. That is, even though the user has at least indirectly paid for such unused service units, the units cease to exist.
[0005] In one particular example of the above scenario, and as should be appreciated, in cellular telephone service and the like as provided by a cellular telephone service provider, a user typically selects a cellular telephone service package from among a plurality of such service packages. The package may for example provide local service, regional service, national service, international service, or the like, and more importantly may include a pre-determined number of minutes that the user has available for use in connection with such service. Thus, one package may provide 150 minutes of local service for 25 dollars, while another may provide 100 minutes of regional service for 25 dollars, while yet another package may provide 60 minutes of national service for 25 dollars, all on a monthly basis.
[0006] Typically, the user initially agrees to obtain and pay for the cellular telephone service and the service package over several billing cycles, i.e., for a year or two, after which the user may continue with the service and service package indefinitely. Importantly, in the prior art, over the many billing cycles that the user has agreed to, unused minutes that remain at the end of each billing cycle expire. That is, even though the user has at least indirectly paid for such minutes, the units cease to exist.
[0007] Based on the expiration of minutes at the end of each billing cycle, at least two items of interest occur. One is that the user becomes annoyed with the cellular telephone service provider for the perceived loss of the minutes. Two is that the user is provided with no incentive to continue the service and service package after the initial agreement has been satisfied, and because of item one and perhaps other reasons may be in a frame of mind to shop for service and a service package from another cellular telephone service provider.
[0008] More particularly, and with regard to item one, a user over a period of time may grow to regard the provided package minutes as his/her property, and thus becomes agitated when the unused portion of his/her perceived property is unceremoniously deemed non-existent at the end of a billing cycle. While good arguments can be made that such provided package minutes both are or are not in fact the property of the user, the point that is to be appreciated is that the user is dissatisfied.
[0009] With regard to item two, once the initial agreement has been satisfied and the user is no longer obligated by such agreement to continue the service and service package, the user by nature may explore options for alternative services and service packages, especially those from other cellular telephone service providers, and especially if the user feels dissatisfied with the current service and/or service package. Of course, it would be better for the current provider to keep the user as a customer, since such user as a customer provides a continued revenue stream, and at any rate it is axiomatic that it is less expensive to keep a current customer than to find a new customer.
[0010] Incentives can be and are currently provided to a user to continue as a customer, especially once such user has satisfied his/her initial agreement. For example, the user may be given a customer loyalty credit for purchasing service-related equipment such as a cellular telephone. However, and importantly, the incentive may not always be automatically offered, and therefore the user may not be aware of the incentive. Even if automatically offered, the incentive may be offered too late, i.e., after the user has already decided to switch to an alternative service and service package. At any rate, the user is not ‘conditioned’ to automatically consider the incentive when deciding whether to switch.
[0011] Accordingly, a need exists for a system wherein unused minutes or the like left over at the end of a billing cycle are carried forward to the next billing cycle. As such, the user keeps his/her perceived property, and does not become dissatisfied based on expired minutes. Moreover, at the end of an initial service agreement, the user is automatically conditioned to consider that he/she has un-expired minutes that still exist and that might be lost if the user switches to an alternative service and service package from another cellular telephone service provider or the like. Since such unused minutes do not expire at the end of a billing cycle, the minutes can be treated as a commodity that may be bought, sold, and/or traded for services and/or goods.
SUMMARY OF THE INVENTION
[0012] The present invention satisfies the aforementioned need by setting forth a method wherein a service is provided to a customer. The service is measurable in quantifiable service units used by the customer such that billing for the service to the customer is based at least in part on a number of the service units used. The customer is allowed to obtain service unit credits to be applied against service units used by the customer, and the service is billed to the customer according to a billing cycle.
[0013] For each billing cycle, service unit credits obtained by the customer and extant are applied against the service units used by the customer during the billing cycle. If service unit credits remain after applying the service unit credits obtained by the customer and extant against the service units used by the customer, such remaining service unit credits are carried forward to be available during a subsequent billing cycle. Importantly, the customer is allowed to treat service unit credits as a commodity, whereby the commoditized service unit credits may be bought, sold, and/or traded for services and/or goods.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The foregoing summary as well as the following detailed description of the present invention will be better understood when read in conjunction with the appended drawings. For the purpose of the illustrating the invention, there are shown in the drawings embodiments which are presently preferred. As should be understood, however, the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:
[0015] FIG. 1 is a block diagram showing a cellular telephone customer database in accordance with one embodiment of the present invention;
[0016] FIG. 2 is a flow chart showing steps performed by a customer obtaining cellular telephone minutes in accordance with one embodiment of the present invention;
[0017] FIG. 3 is a flow chart showing steps performed by a third party in obtaining minutes in accordance with one embodiment of the present invention; and
[0018] FIG. 4 is a flow chart showing steps performed by a customer in expending minutes in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0019] Certain terminology may be used in the following description for convenience only and is not considered to be limiting. For example, the words “left”, “right”, “upper”, and “lower” designate directions in the drawings to which reference is made. Likewise, the words “inwardly” and “outwardly” are directions toward and away from, respectively, the geometric center of the referenced object. The terminology includes the words above specifically mentioned, derivatives thereof, and words of similar import.
[0020] Referring to the drawings in detail, wherein like numerals are used to indicate like elements throughout, there is shown in FIG. 1 a customer database 10 in accordance with one embodiment of the present invention. As may be appreciated, the customer database 10 is operated by or on behalf of a service provider providing a service to each of a plurality of customers, where each customer has a corresponding entry 12 in the customer database 10 . As may also be appreciated, the customer database 10 may in fact be a billing system or may be closely aligned with such a billing system. In one embodiment of the present invention, and as will be discussed in more detail below, the service provider is a cellular telephone service provider providing cellular telephone service to each of a plurality of cellular telephone customers.
[0021] Nevertheless, it is to be appreciated that the service provider and the service may be any type of service provider and service without departing from the spirit and scope of the present invention. For example, such service provider may be a utility providing gas or electric or cable television or Internet access utility service, a landline telephone service provider providing landline telephone service, a long-distance telephone service provider providing long-distance telephone service, a repair organization providing repair service, etc. Moreover, the service provider and service may encompass a goods provider and goods without departing from the spirit and scope of the present invention.
[0022] To continue with the example where the service provider is a cellular telephone service provider, each cellular telephone customer typically selects a cellular telephone service package 14 from among a plurality of such service packages 14 . As can be seen, the package 14 chosen is noted in the entry 12 of the database 10 for the customer. The package 14 may for example provide local cellular telephone service (i.e., where the customer ‘roams’ when outside a local area), regional service, national service, international service, or the like, and more importantly may include a pre-determined number of minute credits (‘minutes’) 16 that the customer has available for use in connection with such service. As shown, the number of minutes 16 provided is also noted in the entry 12 of the database 10 for the customer, although such number of provided minutes 16 may instead be noted elsewhere.
[0023] It is to be appreciated that minutes are but one type of quantifiable service unit that may be employed in connection with the present invention. In general, any other quantifiable unit, such as units of time, value, length, quantity, etc. may be employed without departing from the spirit and scope of the present invention.
[0024] In the course of a billing cycle, the customer employs the cellular telephone service by way of an appropriate cellular telephone, and in doing so, service usage information 18 regarding use of the service is stored in the entry 12 of the database 10 for such customer. Being as the cellular telephone service is metered according to minutes of use, it is to be appreciated that the service usage information 18 includes for each incoming and/or outgoing call a datum on a number of minutes for the call.
[0025] Thus, at the end of the billing cycle, a total number of minutes for at least some calls may be calculated and compared to the number of provided minutes 16 , and billing may then be performed based at least in part on whether the total number of minutes exceeds the number of provided minutes 16 . Note that, depending on the selected package 14 , at least some calls and the minutes thereof may not count toward the number of provided minutes 16 . For example, in most packages 14 , emergency calls to help dispatchers do not count, and in some types of package 14 , calls between a pre-determined sub-set of customers do not count. Billing for cellular telephone service is generally known or should be apparent to the relevant public and therefore need not be discussed herein in any detail. Accordingly, any particular form of billing may be employed without departing from the spirit and scope of the present invention.
[0026] If it is the case that the number of provided minutes 16 for a package 14 selected by a customer is 200 and the total number of minutes used in a billing cycle is 300, the customer is billed based on 100 extra minutes used. Importantly, for the next billing cycle, such customer is provided another 200 minutes for use. In the same case, if the total number of minutes used in a billing cycle is 100, the customer is billed based on not exceeding the 200 provided minutes. Here, though, and relevant to the present invention, the 100 minutes remaining has heretofore been negated. That is, the 100 minutes are taken away from the customer and are no longer available for use by such customer. Accordingly, and again, for the next billing cycle, such customer is provided another 200 minutes for use and has available for use only the 200 newly provided minutes.
[0027] In one embodiment of the present invention, then, minutes remaining at the end of one billing cycle are carried forward, added on, or ‘rolled over’ to the next billing cycle. Thus, the carry-forward or roll-over minutes are added on to any minutes newly provided for the next billing cycle. Thus, and to continue with the above example, if 100 minutes remain at the end of an (n) th billing cycle, the 100 minutes are rolled over to the (n+1)th billing cycle and added on to the 200 newly provided minutes to result in 300 minutes available for use by the customer. In one embodiment, and as seen in FIG. 1 , the roll-over count of available minutes is stored in the entry 12 of the database 10 for such customer as a roll-over count 20 . As such minutes are used, the roll-over count 20 may be decremented. Alternatively, the roll-over count 20 may only be adjusted at the end of each billing cycle as part of a reconciliation. Such roll-over or accumulated minutes count may also be listed on a bill sent out to the customer. Once again, billing for cellular telephone service is generally known or should be apparent to the relevant public and therefore need not be discussed herein in any detail. Accordingly, any particular form of billing may be employed without departing from the spirit and scope of the present invention.
[0028] As may be appreciated upon reflection, allowing for roll-overs of unused minutes provides several benefits. Plainly, the customer does not become annoyed anymore due to a perceived loss of unused minutes. Quite simply, the unused minutes do not expire and are not ‘taken away’ at the end of each billing cycle, and so the customer is pleased and may in fact feel more ‘secure’ since the fear of losing minutes is gone. With such security, the customer establishes a heightened sense of trust in the service provider. Note, though, that minutes need not last indefinitely while still being within the spirit and scope of the present invention. For example, minutes may expire five years after acquisition, or upon twelve months of non-use, movement to a service package 14 that does not support roll-over minutes, lack of payment of one or more bills, etc.
[0029] In addition, the non-expiring minutes may come to be viewed as a commodity by the customer, where the commodity has perceived value and therefore may be bought, sold, and/or otherwise traded. Importantly, at the end of the term of the initial agreement of the customer, when the user is no longer obligated by such agreement to continue the service and service package, such non-expired minutes and the perceived value thereof provide a strong incentive for the customer to in fact continue the service and service package and not to bother with exploring options for alternative services and service packages from other cellular telephone service providers. This is especially true if the initial agreement specifies that the non-expiring minutes will cease to exist if the customer discontinues the service and/or service package. Thus, the current provider keeps the customer, especially if the customer has built up a relatively large amount of unused minutes and does not want to lose the perceived value thereof.
[0030] Moreover, once the customer comes to perceive the unused non-expiring minutes as a commodity having value, a plethora of opportunities arise that allow the customer and the service provider to benefit. Of course, and referring now to FIG. 2 , the prerequisite for taking advantage of such opportunities is that the customer must be provided with service and an appropriate service package 14 by the service provider (step 201 ). Examples of such opportunities are set forth below.
[0031] The service provider may now sell additional minutes to the customer at any time (step 203 ). For example, the minutes may be sold to the customer if the customer perceives that the minutes will be needed in the coming month, or may be sold to the customer if the customer perceives the amount of unused minutes is becoming low. Further, the customer may be incentivized to pre-purchase additional minutes rather than be charged additional minutes (minutes charged to the customer after the customer has used all provided minutes) if the pre-purchased minutes are less expensive than the charged minutes. Notably, in selling the minutes to the customer, the service provider may also realize a profit by charging a premium for the pre-purchased minutes as compared with the cost to the service provider thereof.
[0032] In addition to selling additional minutes to the customer, the service provider may now sell additional minutes to each of one or more third parties for transfer from such from such third party to the customer (step 205 ). For example, and referring now to FIG. 3 , the third party may be a merchant, and the merchant after obtaining the minutes from the service provider (step 301 ) may give the additional minutes to the customer as part of a promotion (buy a case of motor oil and get thirty free minutes, open a bank account and get a thousand free minutes, get a minute for each dollar spent on a credit card, etc.) (step 303 ) or may sell the minutes to the customer at a discount as part of a promotion (buy a dress and get 100 minutes for a dollar, try a new food product in a store and get 10 minutes for a cent, e.g.) (step 305 ). The third party may also sell the minutes to the customer as a revenue generating operation (step 307 ), which of course requires that the minutes be purchased from the service provider at a discount and/or sold to the customer at a price above the purchase price. In any case, transfers of the minutes between parties requires a secure transferring mechanism to ensure that the minutes are properly transferred and also to ensure that unscrupulous entities do not improperly create and/or transfer minutes. As may be appreciated, the secure transferring mechanism can be entirely electronic or can allow the use of a voucher having written material and/or electronically encoded material thereon (a paper coupon, a magnetic-strip card, a stored value card, etc). Such a secure transferring mechanism is known or should be apparent to the relevant public and therefore need not be described herein in any detail. Any particular secure transferring mechanism may therefore be employed without departing from the spirit and scope of the present invention.
[0033] Note that in commoditizing minutes, and again referring to FIG. 2 , the service provider may be able to offer cellular telephone service to the customer in the form of a service package having a discounted or even free price, or even a negative price—i.e., where the service provider pays the customer to take the service package. That is, instead of offering packages with provided minutes for a set fee, the service provider may offer packages with a reduced number of provided minutes or even no minutes at the aforementioned discounted or free or negative price. In such a situation, the customer would be responsible for purchasing or otherwise obtaining the minutes from the service provider or from one or more third parties, and the service provider would operate based on a business plan wherein the sale of minutes is the main profit center and the sale of service and service packages is a subsidiary profit center, a break-even function, or even a loss-leader necessary to enhance sales of minutes. Conceivably, the customer could obtain service from the service provider for free and obtain minutes from third parties for free through various of the aforementioned promotions, with the result being that the service costs the customer nothing.
[0034] Despite the customer being provided with a number of minutes as part of a package and/or despite obtaining a number of minutes from the service provider or third parties, the customer may still use more minutes in a billing cycle than the number of minutes provided and/or obtained. In such a case, the excess minutes are an underage (step 207 ). The service provider may choose to charge the customer a premium amount for the underage in an effort to generate profit and also to urge the customer either to select another service package that provides more minutes or to obtain more minutes from third parties (step 209 ).
[0035] As an alternative, though, the service provider may choose to automatically roll over the underage to the next billing cycle to be applied against the provided minutes therefrom (step 211 ). Of course, the service provider has to make a credit decision if it appears that the underage is severe, if underages are continuously being rolled over by the customer from billing cycle to billing cycle, and/or if the underage is escalating from billing cycle to billing cycle. As another alternative, the service provider may choose to allow the customer to post-purchase minutes to be applied against the underage (step 213 ). Such post-purchased minutes may be priced at a premium also.
[0036] As heretofore discussed, the customer may obtain commoditized minutes for use in connection with a cellular telephone service and service package. As may also be appreciated, the customer may also expend provided and/or obtained commoditized minutes in other regards, for example in connection with purchasing goods and services or even as a gift to a friend or relative.
[0037] In particular, and referring now to FIG. 4 , after receiving minutes from one source or another (step 401 ), the customer may expend commoditized minutes to purchase cellular telephone equipment from the cellular telephone provider or elsewhere—a new cellular telephone, a telephone charger, etc. (step 403 ). Likewise, the customer may expend commoditized minutes to purchase goods and/or services from participating merchants, where the goods and services have nothing at all to do with cellular telephone service—a kitchen appliance, a gym membership, a toy, an automobile, etc. (step 405 ). Further, the customer may choose to simply give commoditized minutes to another customer, either as a gift or as payment in connection with a barter transaction (step 407 ). As may be appreciated, and once again, a transfer of commoditized minutes from a customer to such a merchant or other customer requires the aforementioned secure transferring mechanism to ensure that the minutes are properly transferred and also to ensure that unscrupulous entities do not improperly create and/or transfer minutes.
[0038] Note that while commoditized minutes may expire upon the customer discontinuing service from the service provider, such commoditized minutes need not necessarily expire when the customer switches from one service package to another from the service provider. In particular, the service provider may roll over the commoditized minutes from the one service package to the other. Moreover, the service provider may even choose to offer additional minutes to the customer as an incentive to switch, if such incentive is deemed desirable. Conversely, the service provider may charge the customer a number of minutes as a disincentive to switch, if such disincentive is deemed desirable.
[0039] Note, too, that in the course of transferring minutes to or from the customer, the service provider may perform such transfer, or the transfer may be effectuated by a third party acting in the manner of a transferring organization or clearinghouse (step 409 , FIG. 4 ). Such a clearinghouse is especially useful if the transfer involves different service providers, or if the transferor is transferring to obtain cash or cash equivalent value. In the former, it may for example be the case that a customer is giving minutes to a relative as a gift, and the customer and relative have different service providers. In the latter, a merchant receiving minutes from the customer in exchange for goods or services may wish to take the received minutes and exchange them for cash or credit. In either case, it is expected that the clearinghouse can effectuate the transfer and properly credit and debit all relevant parties as appropriate. Of course, in doing so, the clearinghouse may charge a small fee to the transferor, transferee, or both, and the fee may be collected in cash or cash equivalent value or even in the form of minutes. Clearinghouses and clearing operations are generally known or should be apparent to the relevant public and therefore need not be described herein in any detail. Accordingly, any type of such clearinghouses and clearing operations may be employed without departing from the spirit and scope of the present invention.
[0040] As should be understood, the present invention has heretofore been disclosed in terms of a cellular telephone service provider providing cellular telephone service in value increments of minutes. Nevertheless, and importantly, the present invention is also applicable to any other type of goods or service provider providing goods or services in value increments—a landline telephone service provider, a long-distance service provider, a utility service provider, etc. Accordingly, each other type of goods or service provider providing goods or services in value increments may be considered to be within the spirit and scope of the present invention.
[0041] Although not necessary, the present invention is likely embodied in the form of computer programming operating on a computer 22 ( FIG. 1 ). Such programming is relatively straightforward and should be apparent to the relevant public, and therefore need not be described herein in any detail. Accordingly, any particular form of programming and programming language may be employed without departing from the spirit and scope of the present invention. Likewise, any particular type or form of computer may be employed, also without departing from the spirit and scope of the present invention.
[0042] In the foregoing description, it can be seen that the present invention comprises a new and useful system wherein unused minutes or the like left over at the end of a billing cycle are carried forward to the next billing cycle, and are thus commoditizable. It should be appreciated that changes could be made to the embodiments described above without departing from the inventive concepts thereof. It should be understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.
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Methods, systems, and products are disclosed for rolling over unused credits. An available number of service units is provided during a billing cycle. The number of service units consumed during the billing cycle is compared to the available number of service units. When service units remain at an end of the billing cycle, then unused service units are rolled over to another billing cycle.
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CROSS REFERENCE TO RELATED PATENT APPLICATION
[0001] This patent application claims priority from U.S. Provisional Application No. 62/026,239, filed Jul. 18, 2014, which application is hereby incorporated in its entirety by reference.
BACKGROUND
[0002] Electronic systems produce and are susceptible to electromagnetic interference (EMI), created through either electromagnetic induction or electromagnetic radiation from an external source. In the context of radio waves, radio frequency interference (RFI), is produced. The interference created has the potential to interrupt, deteriorate, or cause other unwanted performance in many common devices ranging from radios to cellular phones to televisions. Federal Communications Commission (FCC) requirements for the mitigation RFI are extremely strict, down to microvolts, thus it is important RFI be mitigated using appropriate radio frequency (RF) grounding.
[0003] To suppress RFI radiation, many enclosures are designed to form a sealed container for whatever may be producing the RFI. For example, an integrated circuit (IC) chip generating radio frequencies for a plasma lighting system may be contained within a housing that is sealed using the correct RFI gaskets. What is more difficult is the containment of RFI that escapes through the bulb of a lighting system that uses radio waves, i.e. plasma lighting. To contain the RFI produced from the light source, complicated housings, referred to from here on as “RFI Boxes”, must be employed to contain the escaping radiation. Conventional hardware required to successfully contain RFI from a light source as described above includes a sealable cavity to which the light source is attached, a gasket, and a piece of glass which is sealed against the gasket using a fastened flange.
[0004] However, these additional materials add cost to the production process as well as time to assembly. Moreover, present RFI boxes cause a loss of total electromagnetic output per area of coverage i.e. watts per square meter, also known as irradiance. Irradiance comprises not only the visible spectrum, but UVB and infrared wavelengths as well. Additionally, glass reduces output by an additional eight percent, and blocks the beneficial UV wavelengths UVA and UVB. Some plasma technologies produce UVC, which demands the use of glass to filter this wavelength out which can cause damage on the cellular level.
[0005] Aside from these concerns, the geometry of conventional RFI boxes for lamps causes coverage area to be diminished considerably, requiring increased distance from a desired coverage plane to reach a desired coverage area. For example in terms of horticulture, coverage of a 4 foot by 4 foot area should be achievable at 12 to 18 inches from the desired plane, i.e. the canopy, to produce adequate intensity for growth. When using a conventional RFI box, this distance must be increased dramatically, causing output at the desired plane to be less than optimal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The Detailed Description is set forth with reference to the accompanying figures.
[0007] FIG. 1 is a luminaire for horticulture utilizing reflection optics to shield lamp RFI.
[0008] FIG. 2 is a side view of a lamp assembly mounted to a frame with a bracket.
[0009] FIG. 3 is a section view of an exemplary RF shielding contact between a reflector and a lamp.
[0010] FIG. 4 is a luminaire for horticulture utilizing reflection optics and a whisker assembly.
[0011] FIG. 5 is an exploded view of an exemplary luminaire for horticulture utilizing reflection optics, a whisker assembly, and a wire mesh screen to shield lamp RFI.
[0012] FIG. 6 is a section view of an exemplary wire mesh shield assembly mounted to a fixture housing.
[0013] FIG. 7 is flow diagram of an exemplary method of RFI shielding for a horticultural lighting system.
DETAILED DESCRIPTION
[0014] This disclosure describes, in part, a luminaire which utilizes an optical reflector in conjunction with a mounting system capable of shielding RFI produced by a lamp.
[0015] In various embodiments, the optical reflector may be any device, used to guide or manipulate in any way, electromagnetic output of a luminaire. Each luminaire may contain one or more light sources used in tandem, depending on the design.
[0016] In various embodiments, the lamp may be any lamp capable of generating EMI or RFI when operating. EMI would be generated by light sources such as high intensity discharge (HID), LED, incandescent, etc. whereas RFI would be generated by light sources driven by RE such as a plasma. light source.
[0017] In some embodiments, a mounting system may be any method of ensuring physical contact between conductive components in order to shield radiated electromagnetic waves from leaving the luminaire.
[0018] The luminaire of this disclosure may allow energy from radiated RF electromagnetic waves to be conducted to ground as an electrical current, thus minimizing radiated electromagnetic waves that leave the fixture after being emitted from the lighting apparatus. In various embodiments, the luminaire may be controlled by a network controller. The network controller operable to connect to a master control software program, via a communications network. The master control software program may be configured to control the horticultural light's output spectrum.
[0019] FIG. 1 is a luminaire 100 . The luminaire 100 may be a horticultural lighting fixture. The lighting fixture 100 may include a housing 102 , an optical reflector 104 , a lamp 106 , and a conductive fastener 108 . The fastener may fasten at least a one surface of the lamp 106 to be in physical contact with at least one surface the reflector 104 .
[0020] The housing 102 may be constructed of electrically conductive material, such as a metal or an engineered polymer. The housing 102 may include a housing opening, through which light may be emitted by a lamp 106 and directed by an optical reflector 104 . In some embodiments, the housing may be constructed at least partially of an engineered polymer that may contain metal fibers that make the engineered polymer conductive.
[0021] In various embodiments, the housing 102 may enclose internal components of the luminaire 100 . The housing 102 may be constructed of housing components fastened together. In alternative embodiments, the housing 102 may be constructed as one solid component.
[0022] As illustrated, a luminaire 100 may include optical reflector 104 . The optical reflector 104 may provide adequate RFT shielding by being secured to the lamp 106 using a conductive fastener 108 .
[0023] In various embodiments, the luminaire 100 may be any sort of device capable of producing visible and non-visible light, such as a light-emitting plasma luminaire. Alternatively, the luminaire 100 may produce another type of light that may use radio frequencies to produce electromagnetic energy. The optical reflector 104 may be any sort of device capable of reflecting light output produced by the lamp 106 . The optical reflector 104 may possess varying geometry. In various embodiments, the optical reflector 104 may a horizontal surface through which at least one bulb may protrude. Additionally, the horizontal surface may have holes through which prongs of a whisker assembly may protrude around the bulb in order for the prongs of the whisker assembly to serve as an added faraday cage. The whisker assembly is described in detail in FIG. 4 .
[0024] The optical reflector may additionally have a plurality of surfaces for reflecting light set at an angle of 135 degrees with respect to the horizontal surface, or set at an angle of 45 degrees with respect to the horizontal plane of the housing opening.
[0025] The lamp 106 in various embodiments may be any device capable of producing electromagnetic energy within the visible spectrum as well as beyond the visible spectrum, such as UV wavelength below 400 nm, or infrared wavelengths above 700 nm. The lamp 106 may utilize lighting technologies such as plasma, LED, HID, or any other form of lighting technology.
[0026] The lamp 106 may comprise a resonator and a bulb. The resonator may receive a radio frequency (RF) output signal from a driver and may emit a concentrated RF field based on the RE output signal. The RE field may drive a bulb to emit light through the housing opening.
[0027] The lamp 106 may be a source of stray radio waves which require shielding through the methods described herein. By conductively coupling the optical reflector 104 to the lamp 106 , the optical reflector 104 may be an RF shielding component.
[0028] In some embodiments, the optical reflector 104 is conductively coupled to a chassis, to which the lamp 106 is in turn conductively fastened to the chassis. A chassis may be constructed of electrically conductive material, such as a metal or a metal polymer. The chassis is described in further detail in the detailed description of FIG. 2 .
[0029] A conductive fastener 108 may be any fastener capable of maintaining physical contact between the optic reflector 104 and the lamp 106 to produce adequate RF grounding between the lamp and the rest of the fixture, including the housing 102 .
[0030] By ensuring contact, all components may be interconnected, allowing stray radio waves from the lamp to be captured and grounded to prevent interference with the light output and other sensitive components. The conductive fastener 108 may be a machine screw, bolt, or any other fastener capable of providing contact between the optical reflector 104 and the lamp 106 .
[0031] FIG. 2 is a side view 200 of a lamp module 202 as it is shown underneath the housing 102 . The lamp module 202 may be coupled to the lamp 106 . The lamp module 202 may be fastened to a mounting bracket 204 , which may be fastened to a chassis 206 . The chassis 206 may be in turn mounted to the housing. The chassis may include at least one electrically conductive surface.
[0032] The mounting bracket 204 may provide adequate grounding in conjunction with the optical reflector 104 by being secured to a chassis 206 using an adequate fastener 208 to ensure proper contact between metallic surfaces. The fastener 208 may be a conductive fastener, and may be machine screw, bolt, or any other fastener capable of providing contact between the optical reflector 104 and the lamp module 202 .
[0033] The lamp module 202 may be any device requiring RF grounding to function as desired, such as plasma, lighting.
[0034] In some embodiments, the mounting bracket 204 may be any device capable of securing the lamp module 202 to a chassis 206 . The bracket 204 ensures the optical reflector 104 is in continuous contact with the chassis 206 through contact with the lamp module 202 . The continuity of contact between all components may ensure that stray RF signals are grounded and that unwanted effects may be mitigated.
[0035] In some embodiments, the chassis 206 may be any device capable of supporting components as well as providing a common point for radio grounding to occur. The chassis 206 in many instances may be a metallic material or other material capable of grounding stray RF signals through contact with an EMI shield such as an optical reflector 104 .
[0036] In various embodiments, the fastener 208 may be any device capable of providing firm contact between the lamp module 202 , the bracket 204 , and the chassis 206 , or any combination of these devices. The efficacy of the optical reflector 104 as an EMI shield may be reliant on the physical contact established through all previously mentioned devices. The fastener 208 may include the combination of a nut and bolt, a threaded insert and bolt, or any other fastening method capable of providing firm contact.
[0037] FIG. 3 is a section view 300 of FIG. 2 that may provide clarity on the physical interaction between previously described components. The optical reflector 104 and the lamp 106 are described above in detail with regard to FIG. 1 . The lamp module 202 , the mounting bracket 204 , the chassis 206 , and the fastening method 208 are described in detail above with regard to FIG. 2 . As previously described, the physical contact made between the optical reflector 104 and the lamp module 202 is made possible by the conductive fastener 108 .
[0038] The Whisker assembly 302 may be coupled to the chassis 206 by a conductive fastener 108 . The whisker assembly 302 may have a metallic base and an array of metallic prongs perpendicularly extending from the metallic base. Each metallic prong may be a steel wire at least one inch long and may be between 0.04″ and 0.06′ in diameter. The whisker assembly 302 may act as a faraday cage and may shield or absorb a portion of RFI.
[0039] FIG. 4 is an exemplary horticultural luminaire 400 utilizing an optical reflector 104 , a whisker assembly 302 , and a wire mesh frame 402 . The optical reflector 104 is described in detail above with regard to FIG. 1 . The whisker assembly 302 is described in detail above with regard to FIG. 3 . The wire mesh frame 402 may be used to allow wire mesh screen to extend across the housing opening, thus increase performance of RFI shielding while allowing greater than 80% light transmission.
[0040] In some embodiments, the metallic base may be coupled between the optical reflector 104 and the lamp module 202 . The array of metallic prongs may positioned so that the bulb is positioned within the array. The array of metallic prongs may protruding through a corresponding set of holes in the optical reflector 104 .
[0041] Alternatively, the metallic base may be clipped onto an exposed surface of optical reflector 104 surrounding the bulb, and the array of metallic prongs positioned so that the bulb is positioned within the array. In some embodiments, the array of metallic prongs may comprise at least three metallic prongs equally spaced.
[0042] In some embodiments, the whisker assembly may be at least partially constructed of aluminum.
[0043] FIG. 5 is an exploded view 500 of an exemplary luminaire for horticulture utilizing an optical reflector 104 , a whisker assembly 302 , a bracket 406 , and a wire mesh screen 508 to shield lamp RFI.
[0044] The wire mesh screen 508 may be coupled to the housing 102 . The wire mesh screen may be fastened to a wire mesh frame 502 . The wire mesh screen may extend across the housing opening and may be configured to absorb at least a portion of the RF field emitted by the resonator.
[0045] The wire mesh screen may be configured to have a transparency of 88% ( 50 openings per inch [OPI]). In some embodiments, the wire mesh screen may have a transparency as low as 100 OPI, which may more effectively shield RFI and EMI.
[0046] In some embodiments, the wire mesh screen may be at least partially constructed from a ferrous material or a nickel alloy.
[0047] FIG. 6 is a section view 600 of an exemplary wire mesh shield assembly mounted to a fixture housing.
[0048] The wire mesh screen 508 may be coupled to a conductive gasket 602 . The conductive gasket 602 may be configured to hold a portion of the wire mesh screen 508 into a corresponding gasket groove in the bracket 406 . A wire mesh frame 402 may mount to at least one bracket 406 in a plurality of locations. In several embodiments, the number of mounting locations may be more than seven. A conductive adhesive may bond the perimeter of the wire mesh screen 508 to the wire mesh frame 402 utilizing the corresponding gasket groove.
[0049] FIG. 7 is flow diagram of an exemplary method 700 of RFI shielding for a horticultural lighting system.
[0050] At 702 , the chassis 206 may be coupled to the housing 102 .
[0051] At 704 , the lamp module 202 may be coupled to the chassis 206 with a conductive fastener.
[0052] At 706 , the optical reflector 104 may be coupled to chassis 206 with a conductive fastener 108 .
[0053] At 708 , whisker assembly 302 may be coupled to chassis 206 with conductive fastener 108 , positioned between the lamp module 202 and the optical reflector 104 .
[0054] At 710 , the whisker assembly 302 may be positioned so that the array of metallic prong protrudes through a corresponding set of holes in the optical reflector.
[0055] At 712 , mounting bracket 204 may be coupled to the housing 102 along at least one side of the housing opening.
[0056] At 714 , a wire mesh screen 508 may be coupled to the mounting bracket by an additional conductive fastener. The wire mesh screen may be formed of woven conductive strands extending across the housing opening.
[0057] Accordingly, an RF grounding path may be provided from each shielding component to the housing.
CONCLUSION
[0058] Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.
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Shielding radio frequency interference (RFI) using reflector optics is disclosed. A simplified non-sealed reflector is used in conjunction with a mounting system, resulting in desired amounts of visible and non-visible light using radio frequency driven luminaries and emitters without sacrificing output or coverage area. Configurations are disclosed such that achieved RF grounding is compliant with FCC regulations. Accordingly, the disclosed RFI shielding improves optical design options, increased output, and decreased manufacturing costs over traditional sealed enclosures.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority of U.S. Provisional Patent Application No. 60/576,626 filed Jun. 4, 2004, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to photovoltaic cells and modules thereof, such as solar cells and solar cell modules. More particularly, the present invention relates to structural stiffening of solar modules through geometric shaping, including corrugation.
BACKGROUND OF THE INVENTION
[0003] Solar modules for generating electricity are well known in the art. The most common solar modules employ a glass superstrate that provides rigidity to the module, but also greatly increases the mass of the module and makes transportation difficult. To create a large solar module, the thickness of the glass is increased to provide sufficient strength to ensure the integrity of the module. If the glass is too thin, and does not provide sufficient rigidity, it can crack and the module will be useless.
[0004] Conventional photovoltaic modules can produce 200 W (with a surface area of approximately two square meters), but at such capacity their weight approaches 50 pounds. This weight limits the utility of these laminates for use in products that require simplified installation. This weight is mainly due to the requirement for thicker glass as surface area increases, in order to meet wind load requirements. Thinner glass is more susceptible to being fractured and is also susceptible to shear and torsion. A small fracture in the glass of a conventional solar module effectively renders the module useless, as the glass is typically safety glass and a small fracture will result in the rapid fracturing of the entire module. One skilled in the art will appreciate that substituting another material for glass in a conventional solar module is undesirable due to the characteristics of other transparent media.
[0005] Flexible solar modules are known in the field. These modules typically make use of thin film cells or cells using spherical silicon elements as the photovoltaic element, and are bonded between flexible superstrates and substrates by an encapsulant. These solar modules are, by their very nature, lighter weight than the conventional glass modules, but offer no support and cannot bear a load.
[0006] Flexible solar modules can typically be manufactured at a lower cost than glass photovoltaic (PV) modules and offer many benefits related to portability and durability but cannot be incorporated as structural elements in construction as they cannot support a load.
[0007] By making flexible modules more rigid, they could be incorporated as structural elements in place of glass PV modules. This would allow a reduction in weight and allows for better scalability, as the mass per watt of generating capacity would not necessarily need to increase as it does with glass modules. Although using multiple smaller glass modules can often overcome the increase in the mass per waft, it increases the number of connections needed and amount of cable, which increases the overall cost and results in a more complex installation process.
[0008] Large glass PV modules also cause installation difficulties as the PV module adds to the weight of any pre-assembled component and thus requires heavy machinery to hoist modules onto roofs.
[0009] A mechanism to incorporate a rigid structure into flexible PV modules would address many of the downfalls of glass PV modules including the fragile nature of the modules, the Increased weight due to the thick glass, and the added installation difficulties.
[0010] Numerous pieces of prior art have been directed to creating standard roofing elements with integrated solar modules. A discussion of a sampling of the art is provided below.
[0011] U.S. Pat. No. 5,935,343 to Hollick teaches affixing solar cells to the top of a corrugate. The cells are Illustrated as being bolted to the top surface of the corrugate or affixed across the openings in the top surface. Hollick uses this configuration to allow air flow beneath the module to promote cooling. Hollick's teachings do not result in an integral unit, and would thus be difficult to implement using flexible modules, as the areas of the module not supported by the corrugate would not adequately bear wind loads. Above all, Hollick does not teach a method for constructing a stand alone module which can be rack mounted.
[0012] U.S. Pat. No. 6,201,179 to Dalacu discloses an array of modules installed on an interlocking corrugated support. The Dalacu reference also describes attaching modules to an interlocking corrugated roofing bed, using techniques similar to those taught by Hollick. As a result, the system taught in the Dalacu reference does not result in a stand alone module which can be rack mounted and in which system modules can be added or removed with ease.
[0013] U.S. Pat. No. 5,338,369 to Rawlings discloses an extruded corrugated core PV panel. The Rawlings reference describes an interlocking array of modules for use as an integrated roofing system. Though this system provides some structural integrity for the module, it requires the panels to be installed in an interlocking fashion, which can complicate installation and replacement of the modules. Additionally, as shown in FIG. 2 , the modules are individually wired together at a combiner box, which is more complicated than simple inter-module connections. This adds to the installation complexity and cost.
[0014] U.S. Pat. No. 5,505,788 to Dinwoodie discloses a corrugated pan to hold phase change material against modules. As illustrated in the Dinwoodie reference, modules are simply affixed to the top of a corrugate or other structure, as a means of attachment to a horizontal surface. As a result, this approach would be required to use stand alone modules which have passed wind load requirements prior to attachment to said mounting structure.
[0015] U.S. Pat. No. 5,092,939 to Nath discloses PV cells laminated on a metal coil for field forming to make a standing seam roof construction. Significant shading of areas of the modules is likely on a seasonal basis, as the seams stand above the solar cell plane, creating reliability issues. Ease of replacement for individual modules is quite questionable for a system of this design.
[0016] U.S. Pat. No. 5,232,518 to Nath et al. discloses a roofing system similar to that disclosed in the '939 patent. The '518 patent teaches the interconnection of all installed modules so that a single connection to the module array is utilized. As noted above, shading and ease of module replacement are major issues with such designs.
[0017] U.S. Pat. No. 4,433,200 to Jester et al, discloses a roll formed pan on which conventional fragile silicon wafer-based cells are mounted. Without any internal reinforcement in this design, simply a frame around the perimeter, this approach fails to provide any improvement over glass superstrate designs as weight per area must significantly increase as module size increases, since much thicker substrates will be required to sustain wind load requirements. As a result, the approach taught by Jester is not suitable for large area modules.
[0018] U.S. Pat. No. 6,606,830 to Nagao et al is directed to reducing the number of connections to a house that a solar array requires. As disclosed in the Nagao reference, the PV modules are interlocking and they form a serial connection to each other. As such, individual modules are not easily replaced and also cannot withstand wind load requirements without first attachment to a roof deck.
[0019] U.S. Patent Application Publication No. 2002/0112419 to Dorr et al. is directed to affixing PV modules to a corrugate by use of an adhesive, and draws connecting cables from each individual module. That the specified corrugate structure is filled with insulating foam is a significant problem as inadequate dissipation of heat severely limits device performance. Additionally, this design suffers from shading by corrugate elements above the plane of the attached modules.
[0020] U.S. Pat. No. 6,498,289 to Mori et al. teaches a roofing element having a PV cell. A PV cell is attached to a backing whose sides are then bent into flanges. Elements are then added to the backing to space the structure from the roof. These spacers are then affixed to the roof, allowing for air ventilation behind the panel. Though bending the edges of the backing and affixing spacers provides support to the flexible PV panel, Mori admits that the panels cannot bear loads as the areas between spacers are not supported and thus can bend under loads.
[0021] One skilled in the art will appreciate that the interconnection of the solar modules as taught by many prior art references results in a large solar array that is physically interlocked. Should one of the modules fail most of this prior art does not provide for ease of replacement or removal from the circuit, to circumvent performance and reliability issues.
[0022] It Is, therefore, desirable to provide a supporting structure for flexible solar modules that provides rigidity and strength to allow the flexible solar module to bear loads for a variety of installation methods. It is also desirable to provide a modular structural element having a flexible solar panel capable of being removed or replaced with relative ease.
SUMMARY OF THE INVENTION
[0023] It is an object of the present invention to obviate or mitigate at least one disadvantage of previous photovoltaic panel structured elements.
[0024] In a first aspect of the present invention there is provided a rigid solar module having a flexible solar module prelaminate. The module comprises a metal backing, a corrugated backing and a junction box. The metal backing is affixed to the prelaminate. Preferably, this provides a degree of rigidity to the prelaminate. The corrugated backing is affixed to the metal backing to provide rigidity to the combination of the metal backing and the prelaminate. The junction box is connected to the prelaminate, for transferring power to a load.
[0025] In an embodiment of the present invention, the metal backing is laminated to the prelaminate, and its edges are preferably folded over the edges of the corrugate backing to affix the corrugate backing to the metal backing. In another embodiment, a flexible backing is interposed between the metal backing and the prelaminate in a laminate. In a further embodiment, the corrugated backing and the metal backing are integral. In another embodiment, the edges of the corrugated backing are folded over the edges of the prelaminate to affix the corrugated backing to the metal backing. In a further embodiment, the junction box is positioned inside a trough in the corrugate.
[0026] In a second aspect of the present invention, there is provided a method of forming a rigid photovoltaic module from a flexible photovoltaic module. The method comprises the steps of affixing the flexible photovoltaic module to a rigid backing and structuring the rigid backed photovoltaic module to provide increased strength in at least one direction.
[0027] In embodiments of the second aspect of the present invention, the rigid backing is a metal backing, such as an aluminum backing. In another embodiment, the step of affixing can include at least one of gluing the flexible module to the backing, laminating the flexible photovoltaic module to the rigid backing, and integrally affixing the module to the backing.
[0028] In another embodiment, the step of structuring the metal backing Includes bending the rigid backed photovoltaic module to create a curve. This embodiment preferably includes adding supports in a hollow portion of the curve, connecting a junction box to the photovoltaic module and locating the junction box between supports in the hollow portion of the curve.
[0029] In a further embodiment, the step of structuring the metal backing includes corrugating the rigid backed photovoltaic module and affixing a junction box under a flat section of the corrugated rigid backed photovoltaic module.
[0030] In another embodiment, the step of structuring includes affixing the rigid backed photovoltaic module to a corrugate. This embodiment preferably includes folding the edges of one of the corrugate and the photovoltaic module over the edges of the other one of the corrugate and the photovoltaic module, connecting a junction box to the photovoltaic module and locating the junction box in a trough of the corrugate.
[0031] In a further embodiment, the step of structuring the metal backing includes bending the rigid backed photovoltaic module to create standing seams beneath the plane of the flexible photovoltaic module. This embodiment preferably includes connecting a junction box to the photovoltaic module and locating the junction box between two of the standing seams.
[0032] Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art, upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] Embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:
[0034] FIG. 1 is a block diagram of a section of a flexible PV prelaminate of the present invention;
[0035] FIG. 2 is a block diagram of a section of a flexible PV cell of the present invention;
[0036] FIG. 3 is a block diagram of a section of a PV module of the present invention prior to being corrugated;
[0037] FIG. 4 is a block diagram of an open corrugated section of the PV module of FIG. 3 ;
[0038] FIG. 5 is a block diagram of an closed corrugated section of the PV module of FIG. 3 ;
[0039] FIG. 6 is a perspective view of a rigid PV module of the present invention attached to a corrugated backing;
[0040] FIG. 7 is a perspective view of the bottom of the assembly of FIG. 6 ;
[0041] FIG. 8 is a perspective view of a rigid PV module of the present invention formed to a curve;
[0042] FIG. 9 is a perspective view of the bottom of the assembly of FIG. 8 ;
[0043] FIG. 10 is a perspective view of corrugated backed modules of the present invention nesting;
[0044] FIG. 11 is a perspective view of an embodiment of the present invention;
[0045] FIG. 12 is a perspective view of a detail of the embodiment of FIG. 11 ;
[0046] FIG. 13 is a flowchart illustrating a method of the present invention;
[0047] FIG. 14 is a flowchart illustrating an embodiment of the method of FIG. 11 ;
[0048] FIG. 15 is a flowchart illustrating an embodiment of the method of FIG. 11 ; and
[0049] FIG. 16 is a flowchart illustrating an embodiment of the method of FIG. 11 .
DETAILED DESCRIPTION
[0050] Generally, the present invention provides a method and system for simplified installation of affordable and low weight photovoltaic (PV) modules that can be prepared in advance for modular installation. PV modules of the present invention use lower cost flexible laminates but can serve as replacements to conventional glass modules as they are rigid and have a planar surface much as glass PV modules do.
[0051] The present invention provides a flexible solar module that has sufficient structure and rigidity to be used in place of conventional glass superstrate photovoltaic (PV) modules. The flexible solar module can use either thin film PV cell-based panels or spherical silicon element-based panels. Those skilled In the art will appreciate the operation, manufacture and characteristics of these cells.
[0052] By eliminating the glass in conventional PV modules, it is possible to build products with areas of more than four square meters that do not exceed 50 pounds in weight. This allows for a reduction in overall production costs, as fewer parts have to be finished to produce the same equivalent energy. It also allows for a reduction in installation costs as fewer parts need to be installed. It is possible to install lighter modules using fewer construction workers and overhead cranes are not necessary. Although these designs are particularly useful for flexible PV modules, some of the designs disclosed below can be used with standard wafer technology when the backing designs have adequate rigidity to prevent cell breakage.
[0053] Most crystalline silicon wafer PV technologies use a glass superstrate and aluminum frame with a polymer backing film to encapsulate the solar cells, providing the needed moisture barrier and structural strength for stand alone modules. Flexible modules allow elimination of the weight of the glass cover by replacing it with a polymer film such as Ethylene/Tetrafluoroethylene Copolymer (ETFE). Although this eliminates the excessive weight of the glass, it is often necessary to provide a structural backing to support this flexible sandwich. Many materials that are used for building construction, truck trailer construction, and even signage are designed to be lightweight yet resist wind loading and uplift forces. The challenge is to find materials that are lighter than glass but do not significantly increase production costs. A number of designs which appear to meet these requirements have been found and their configuration as well as methods for construction will be detailed below as they apply to the present invention.
[0054] Typically a flexible solar module is composed of an array of cells. As illustrated in FIG. 1 , each cell 100 is a sandwich of layers. A superstrate 102 , typically ETFE, serves to protect a layer 104 of PV elements that function as PV diodes. This is the layer 104 that generates the electrical potential, it can be composed of silicon beads or a thin film of silicon or other semiconductor materials. The PV diode, or diodes, is typically encased in an encapsulent 106 that bonds the elements to the superstrate 102 . As a product, at this point, the cell assembly can be referred to as a prelaminate as it has not yet been affixed to a substrate, but can be used to generate power.
[0055] The prelaminate can be affixed to a substrate 108 such as a film or fiber backing, as shown in FIG. 2 . This can then be affixed to a metal backing 110 . The metal backing 110 is preferably included with the superstrate 102 , the encapsulants 106 and the substrate 108 in a single step lamination process. In an alternate embodiment, a laminate is formed without the metal layer 110 and is then affixed to the metal layer 110 . Contacts (not shown) from each cell 100 are connected to the other cells in the laminate as is common.
[0056] After creating an integral PV laminate on a backing, such as metal layer 110 , the backing can then be given a structural form. The structural forming can include corrugating the backing to create either an open or a closed corrugate.
[0057] In the embodiment of an open corrugate, as shown in FIGS. 3 and 4 , the solar cells 100 can be spaced on the module 112 so that only the flat portions 114 of the corrugate structure 116 have PV elements 104 . The corrugations preferably remain below the cell plane to preclude shading and the associated performance and reliability issues it creates.
[0058] In other embodiments, a flexible solar sheet can be attached to the surface of a corrugate structure. The lamination of the solar sheet can be performed either before or after attachment of a corrugate structure. The corrugate structure can consist of open corrugations, as shown In FIG. 4 , in which troughs 118 are left between rows of cells 100 , or it can consist of closed corrugations, as shown in FIG. 5 , in which the top surface 120 of the corrugate 122 becomes a continuous plane. The closed troughs 124 in the sheet can be tubular, triangular or other standard forms, where the corrugations 124 are pinched off at their top surface to create a plane. In another embodiment, a mix of open and closed corrugations can be formed in either regular or irregular shapes.
[0059] One approach of forming these corrugations is very much like a standing seam roof in which pinched-off areas of the sheet are pressed completely flat and have little cross-sectional open area, but extend below rather than above the cell plane. This embodiment will be discussed below with relation to a figure. Another variation of this approach is to simply laminate PV modules to narrow strips of metal (approx. 18-24″ wide) and roll the edges in a standard seam roof coil converter. These pieces can then be assembled together using conventional assembly hardware or other such standard means to provide a structurally rigid module having a large surface area, but again the edges are formed below rather than above the cell plane. In many of these embodiments, a frame is preferably formed at the edges of the sheet to allow for simplified installation of the modules into a structural framework. End caps may also be placed on the assembly to create a complete frame and control air flow.
[0060] Many other embodiments preferably include at least one additional sheet of material for the additional structural support. This additional support can be provided by attaching a flat solar sheet to an existing corrugate or even an extruded three-dimensional sheet. The structure preferably provides a planar face of PV cells though the face can be either interrupted, as shown with the open corrugate, or curved to fit a structured form.
[0061] One such design, as illustrated in FIGS. 6 and 7 , involves attaching a sheet of corrugated metal 126 to the back of a PV laminate 128 which has as part of its construction a metal layer and a plurality of PV cells 100 . This attaching can be done using any one of, or a combination of, screws, rivets, tabs, glue, adhesive tapes, and other conventional means. This structure has excellent strength along the direction of the rolled corrugation but can be bent to conform to the curvature of a building surface in the other direction. Junction boxes 130 can be used to connect the module to other modules or to the power system. Preferably the cables 132 are quick connect cables that allow for rapid installation without requiring sophisticated installation teams. This structure allows airflow 134 to aid in the dissipation of heat as air is drawn through the corrugations.
[0062] In another embodiment, a flexible sheet with a metal layer backing is curved or bent to fit with a structured form that supports the new shape. FIGS. 8 and 9 provide top and bottom perspective views of one such embodiment. A flexible PV module 113 having cells 100 is formed with a rigid back that provides both strength and rigidity. The module is then bent to take a shape, such as the illustrated curve. This bent module can be attached to structural supports 136 . Supports 136 serve to further reinforce the structure and provide rigidity. The spaces 138 between supports 136 , can be used to hold a junction box connected to the PV cells 100 . This allows for a finished product that can be easily deployed and installed by affixing the module to the desired location using standard construction techniques, and simply connecting the junction boxes either to other modules or to a power conditioner/inverter. The structured module can be easily moved to the installation site, as it is durable, resistant to fracture, and lighter weight than a standard glass module of the equivalent size.
[0063] In another embodiment a complex corrugation pattern, similar to that used in high strength cardboard that can provide strength along both axes of the sheet is used. Some of these complex designs require more advanced rolling techniques and preferably involve providing a wave pattern, such as herringbone, in the roll direction.
[0064] One feature of the corrugated designs, of the above described figures, is that air can flow directly against the back surface of the laminate. This provides cooling to the solar sheet, which is desirable to limit cell efficiency losses caused by heating. In one embodiment, the corrugate backing is preferably perforated, or even expanded material, which allows for the maximization of airflow while minimizing the weight of the corrugate with little detriment to structural integrity.
[0065] With corrugated designs, it is presently preferable to provide a nesting feature with a recessed junction box. This design allows two modules to be nested back-to-back thus minimizing shipment volume. Additionally, with the two sheet design of FIGS. 6 and 7 , the edges of the metal backed PV laminate 128 or the corrugate 126 can be rolled over the other, improving edge strength and protecting the installer from cuts.
[0066] An extruded three-dimensional sheet of material such as polypropylene or even aluminum serving as a corrugate 126 behind the PV module 128 allows for airflow 134 , though it may not offer the same cooling efficiencies as the air would not be in direct contact with the backing of the module and instead makes contact with the metal layer.
[0067] In another embodiment, the PV prelaminate can be affixed to a rigid metal backing that forms the top layer of a sandwich. Two metal layers, one of which carries the PV module, can sandwich a polymer core such as polypropylene (PP) or polyethylene (PE). The end product is essentially a standard architectural product with integrated energy generating potential. After creating the PV module, grooves can be routed into the back surface of the product. By folding along the routed lines, the module can be bent to form three dimensional structures such as a frame around the perimeter of the module.
[0068] The corrugated laminates of the present invention allow for a modular design with one or two junction boxes per module. The use of quick-connect cable terminations eliminates much of the on site wiring and assembly that some of the prior art requires. As a result, the product can be treated like a standard photovoltaic module for installation. As opposed to most of the prior art, no special installation training is required, the module is simply installed using standard photovoltaic module Installation techniques.
[0069] The corrugate construction provides a strong module that is both light weight and cost effective. In comparison to glass modules, the modules of the present invention avoid increased weight per watt of generating capacity, as thicker corrugate or thicker superstrates are not required as the module size increases. Additionally, the installation is simplified as the modules are more robust and are not prone to shattering if another object impacts the module surface. The inclusion of the corrugate sufficiently strengthens the module so that it is as strong as conventional glass modules. In comparison to prior art systems employing flexible modules, the modules of the present invention are consistently rigid and do not have unsupported areas that cannot bear a load. Additionally, the modular nature of the present invention avoids the prior art problem of requiring a specially trained installation crew, or requiring on-site module assembly. This reduces the installation costs and allows quality control to be exercised by the manufacturer. Assembly in a controlled environment is not possible with the prior art systems that require interconnected elements or provide the solar modules separately from the structural elements.
[0070] FIG. 10 illustrates a the nesting of modules so that cells 100 face opposite directions, and the corrugated sections of backing 126 nest within each other. Junction boxes 130 by being in one of the covered troughs do not interfere with the nesting of the modules. This allows for a smaller shipping volume to an installation site.
[0071] FIGS. 11 and 12 illustrate a solar module constructed to form standing seams. Whereas many prior art implementations are directed to affixing solar cells to a standing seam, the embodiment illustrated in FIG. 11 has cells 100 spaced apart from each other, with a gap at fixed intervals. These gaps are folded into standing seams 140 that both increase the strength of the module, and raise the portions of the module bearing solar cells 100 . By raising cells 100 , seams 140 allow airflow under the module and provide a location for placing junction boxes and other such connectors. One skilled in the art will appreciate that the standing seam modules can also be nested, although the location of junction boxes will determine the orientation of the panels when nested back to back. This nesting allows for tighter packing In transit and a reduction in the shipping volume of the module. FIG. 12 illustrates the encircled detail of FIG. 11 and clearly shows the placement of cells 100 with respect to seam 140 .
[0072] One skilled in the art will appreciate that there are many ways that the structured modules of the present invention can be manufactured. One such method will now be discussed with relation to the flowchart of FIG. 13 . In step 150 a flexible solar module is affixed to a metal backing. In the interests of reducing the mass of the module it is preferable to use a low density and strong metal such as aluminum. In addition to providing rigidity, the metal backing can serve as a heat sink to aid in the dissipation of heat buildup caused during the operation of the module. The flexible solar module can be attached to the metal backing in a number of ways including the use of a fastener, an adhesive, or the metal backing can be affixed by including the metal backing in the laminating process. It is preferable, though not required, that the module be integral with the backing, so that no folds or distortions occur later in the process.
[0073] In step 152 , the metal backing is structured to allow for greater strength and rigidity. This results in a module that has a rigid backing and a structure. The structure of the module provides strength, in at least one direction, and allows the module to serve as a replacement for conventional glass modules at lower cost and weight.
[0074] FIG. 14 illustrates an embodiment of the above method, where the step of structuring the metal backing is performed by corrugating the metal backing in step 154 . In this embodiment of the method, it is preferable that the flexible solar module is affixed to the rigid backing in step 150 with spaces between cells to allow for the corrugations.
[0075] FIG. 15 illustrates a further embodiment, where the step of structuring in step 152 includes attaching the rigid backed module to a corrugate in step 156 . The attaching of the rigid module is preferably done by gluing, spot welding, or fastening the rigid backed module to the corrugate. In one embodiment, the edges of the corrugate are folded over the edges of the rigid backed module to strengthen the edges of the product. In other embodiments, the edges of the module are bent back to fold over the edges of the corrugate, or end caps are used to clamp the corrugate and the module together. End caps may be added to strengthen ends of the module and/or to control air flow.
[0076] FIG. 16 illustrates a further embodiment of the present invention, where the rigid backed module is bent to a structured form in step 158 , as described above in conjunction with FIGS. 8 and 9 or FIGS. 11 and 12 . The rigid backed module is preferably bent to a structural form in step 158 and then secured to a frame that provides additional support and structure.
[0077] The above-described embodiments of the present invention are intended to be examples only. Alterations, modifications and variations may be effected to the particular embodiments by those of skill in the art without departing from the scope of the invention, which is defined solely by the claims appended hereto.
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A flexible solar module is provided sufficient rigidity for use in construction, and comparable rigidity to a glass based solar module, by incorporation of a metal backing to the module, preferably in the laminated module. The rigidity of the construction is enhanced by the inclusion of a corrugation, either in the metal backing, or in a structure that is affixed to the backing. The resulting structure is a modular unit that has connection points and does not need to be connected to other modules to operate. A connection point is provided by an integrated junction box that allows for a simpler installation and the use of standard building techniques for the installation on a roof or wall.
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FIELD OF THE INVENTION
The present invention relates to agricultural machines such as combine harvesters or forage harvesters, provided with an engine driving the machine and operating its crop-processing parts, such as cutting drums and blowing fans.
STATE OF THE ART
The aforementioned machines traditionally operate at high fixed RPM, a variable, usually a hydrostatic, drive being provided for the control of the travel speed. The high, fixed engine RPM is maintained in order to ensure homogeneous processing of the crops and also in order to absorb load fluctuations without the crop flow through the machine becoming jammed. This way of operating does, however, lead to a high consumption of fuel and to the generation of a high level of noise by the machines. In many situations, for example when the machine is at a standstill, when it is travelling on flat ground, or when the crop-processing elements are immobilised, the load is low and engine efficiency diminishes when the machine is running at high RPM.
A number of documents already describe this problem and propose numerous solutions, as follows.
EP-A-1236389 describes a machine wherein the (constant) RPM at which the engine is running can be set by the operator within the limits of the sub-range of the total RPM range. The former may depend on different parameters, such as the quantity of crops, or the preset engine parameters, this taking place on the switch to running at a constant RPM. The operator sets the RPM and there can accordingly be no automatic RPM reduction when the load decreases. The present document describes a system in which the range wherein the operator can set the RPM changes automatically, according to circumstances.
EP-A-1609349 describes a machine wherein the engine RPM is controlled as a function of a measurement of crop throughput. The drawback is a complex set-up with different sensors for measuring throughput.
GB-A-2205179 describes a system wherein the engine shaft torque is measured and serves as input of a system to control the engine speed, allowing said speed to fall or to rise depending on load. The adjustment of RPM only takes place when torque fluctuation has exceeded a given threshold value, the crop-processing elements being maintained at constant RPM by means of speed converters. In one particular embodiment of the invention, use is made of an indirect modification of RPM in cases where a central gear transmission is used.
EP-A-1658765 describes a machine wherein the engine RPM is controlled by the measurement of external parameters such as the height or the throughput of the crop. If said measurements yield the required information, the engine RPM is raised from “low load” to “high load”. Since said measurements can be made sufficiently early on, the control has sufficient time to set the RPM rapidly enough and a rise of RPM can be implemented sufficiently early on. Once again, the drawback is the need for complex sensors.
EP-A-2057881 describes a machine running at various fixed values of RPM depending on the load being measured on the engine shaft, the speed of the crop-processing elements being kept constant. No details are given concerning the transition between different values of RPM.
SUMMARY OF THE INVENTION
The present invention provides a solution of the aforementioned problems using the control to be provided and described in the appended claims.
The present invention concerns a self-propelled agricultural machine, such as a combine harvester, or a forage harvester comprising:
elements for gathering and/or processing crops; an engine operable to travel the machine through a first driving mechanism and to drive the operation of said elements through a second driving mechanism; and a control unit for controlling engine RPM,
characterised in that the control unit is configured for controlling the engine RPM on the basis of a target RPM, which is in turn based on an assessment of the imposed engine load, wherein in at least in one sub-range between 0% and 100% of the maximum load, the target RPM is a constantly rising function of said engine load.
The imposed engine load is preferably derived from a measurement of engine RPM and of fuel consumption, for example by the control unit (ECU) of the engine itself.
According to a preferred embodiment of the present invention, the rate of change of the target RPM within said sub-range is itself a rising function of the extent to which the imposed load respectively exceeds the sub-range upper limit or undershoots the sub-range lower limit.
According to an embodiment of the present invention, the control unit is configured for keeping the RPM equal to a constant target value within two or more non-overlapping sub-ranges of the total load range, the lowest sub-range beginning at 0% of said total load range, and wherein:
said constant target value is lowest for the lowest of said sub-ranges and rises for higher ranges; in the transition zone between the sub-ranges of constant target value, the target RPM is a continuously rising function of the engine load, as stated in claim 1 .
The difference between the constant target values of two neighbouring sub-ranges can be constant. Setting means can be provided enabling the machine operator to set engine RPM corresponding to a sub-range having a constant setting value, or an RPM between two sub-ranges with a continuously rising target value.
Said total range can advantageously comprise:
a transition zone between a medium and a high load range, where the control unit raises the target RPM continuously to a maximum value; a high load range where the control unit keeps the target RPM at maximum value and the current RPM of the engine is determined by the torque curve of said engine.
At full machine load, for example in order to achieve full harvesting capacity, this enables high engine RPM, whilst another element of the control unit varies the travel speed of the machine, in order to keep the load at its present level.
According to an embodiment of the present invention, said range is divided up as follows:
a low load range where RPM remains at a constant target value; a medium load range where the target RPM is a continuously rising function of the load; a high load range where the current RPM is determined by the torque curve of the engine; and
a transition zone between medium and high load ranges where the target RPM is a continuously rising function of the load.
According to another embodiment of the present invention said range is divided up as follows:
a low load range where RPM remains at a constant target value; a medium load range where the RPM remains at a constant target value which is higher than the target value of the low load range; a high load range where the RPM is determined by the torque curve of the engine; and transition zones respectively between low and medium load and between medium and high load where the target RPM is a continuously rising function of the load.
The present invention also relates to a method of controlling the RPM of a machine according to the invention, wherein the method comprises the following steps:
assessing the imposed engine load; and setting the RPM in accordance with the imposed engine load and in accordance with a curve providing the target RPM as a function of the load, wherein said curve comprises at least one sub-range of the total range between 0% and 100% of the maximum load and wherein the target RPM is a continuously rising function of the engine load.
According to the method of the present invention, the rate of change of the target RPM in said sub-range is itself a rising function of the extent to which the imposed load respectively exceeds the sub-range upper limit or undershoots the sub-range lower limit.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic view of the main components of a machine according to the present invention.
FIGS. 2 to 5 show different variants of control of the engine RPM as a function of load, compared with the existing control with fixed RPM (curve 11 ).
FIG. 6 shows a method of control of the engine RPM in a range where RPM is continuously rising with rising load.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 is a schematic representation of a number of components of the machine to which the invention refers. The internal combustion engine 1 drives the wheels 2 of the machine via a hydrostatic drive 3 . The crop-processing components 5 such as cutting drums, feed rollers, blower and the like in the case of forage harvesters, are driven by a mechanical drive 4 consisting of, for example, gears and/or belt drives. Said drives are not shown in detail here and can be constructed according to the state of the art.
A control unit 6 is also shown schematically. Control unit 6 can be embodied by a programmable electronic module according to the state of the art. It is preferably a control unit linked to the engine control unit 7 (ECU). The ECU is a control module commonly present on contemporary engines, which provides a number of signals during engine operation, indicative of parameters such as fuel consumption, engine RPM (n i ), as well as derived parameters such as current power, or the current percentage of maximum available power or engine torque (T i ) (on the basis of curves or tables pre-programmed into the ECU). Control unit 6 , sometimes called in the art ‘Vehicle Control Module’ (‘FCM’ in forage harvesters), assesses the operating state of the machine on the basis of said parameters. A module 9 of the FCM 6 calculates the setting value of RPM (n s ) and transmits the necessary control data to ECU 7 in order to command the engine to run at the set RPM value. The present invention concerns a method of controlling the RPM of the engine of the machine, as well as an agricultural machine wherein the control unit 6 is programmed to control the engine according to said method.
Another module 8 of FCM 6 controls the travel speed of the machine through control of the elements of a hydrostatic drive. In a certain work mode (PowerCruise) this module uses the data of current RPM n i and load T i for calculating the power currently delivered, and, on the bases of the result, modifying the travel speed of the machine according to the load of engine 1 . This mode is used during harvesting in order to have the machine running as much as possible at its maximum load. The power offtake depends partly on the power needed for the travel of the machine, but primarily on the power needed for harvesting and processing the crop. The power needed rises and falls according to the quantity of crop being processed per unit of time (T/h) and hence to the travel speed of the machine. Variations of the local density of crops in the field (T/ha), or of the width (m) over which the header harvests the crop, also influence crop throughput and cause engine power variations. A controller in the FCM will compensate these variations by adjusting the travel speed of the machine, so that the quantity of crop per unit of time shall remain stable and the required power remains as close as possible to the available maximum of engine power.
The control unit according to the present invention is configured to rotate the engine at a target RPM n s which in at least one sub-range of the torque or power range of the engine will be a continuously rising function of the imposed engine load (expressed as the imposed engine torque or power).
The RPM control described above is illustrated in FIGS. 2 to 6 and covers a number of possible embodiments of the present invention. Curve 10 in FIG. 2 is the engine torque curve showing the maximum available torque according to the current RPM, for example for the engine of a forage harvester. In this example the torque reaches its maximum value at 1500 RPM. The aforementioned torque range covers the area between the indicated values of 0% and 100%. The vertical 11 shows how RPM is controlled using the known method: the RPM is kept constant at a high value such as 2100 RPM. It then is the intention to operate the machine at this RPM under as many harvesting conditions as possible, in order to ensure that the cutting drums and blower are working properly. Only when the threshold load of +−73% has been exceeded (for example in the event of an increase of the travel speed, driving uphill), the speed will drop in accordance with engine torque curve 10 . In the present context the word ‘constant’ does not mean that the actual RPM n i is at all times equal to a pre-determined value, but that the RPM is controlled with this constant value n s as the target value. In normal operation, the RPM will accordingly lie in a restricted sector around the target value.
Curve 12 in FIG. 2 shows a control according to the present invention. In the range between 0% and 73% the target RPM n s varies according to a continuously rising function of the engine torque from 1800 RPM to 2100 RPM. This function can be the linear function shown, but can also be some other rising function. This function is programmed into the control unit 6 , ensuring that in the case of a change of the load in the range 0 to 73% the RPM assumes a value determined by the rising function. Above the 73% load, it is the engine torque curve which imposes the RPM.
FIG. 3 shows another variant of the present invention, wherein the RPM is kept constant at a fixed target value of 1850 RPM in a first range 13 between a zero and a 43% load, and then in the sub-range 14 changes with the load according to a rising function up to the limit of 73%.
A specific embodiment of the present invention concerns a control wherein the range from a 0 to a 100% load is split into three sub-ranges, respectively corresponding to ‘low’, ‘medium’ and ‘high’ load as shown in FIGS. 4 and 5 . FIG. 4 shows:
a low load range 20 : between a 0 and a 43% load with a constant target RPM ns of 1850 RPM; a medium load range 21 : between 43% and 73% with a continuously rising target RPM; a transition zone 22 : between 73% and 85% (from 1900 RPM) with a continuously rising target RPM (up to 1950 RPM); and a high load range 23 , with an RPM according to engine torque curve 10 .
FIG. 5 is an example of the embodiment of the present invention, wherein the control unit 6 is configured for controlling the engine RPM according to engine load in such a way that the RPM is kept constant in two or more non-overlapping sub-ranges of the engine torque range, according to whether the engine torque lies in a lower or a higher sub-range. In FIG. 5 one distinguishes:
a low load range 30 : between a 0 and a 43% load with a constant target RPM ns of 1850 RPM; a transition zone 31 : between 43% and 55% with a continuously rising target RPM; a medium load range 32 : between 55% and 73% with a continuously rising target RPM; a transition zone 33 : between 73% and 85% (from 1900 RPM) with a continuously rising target RPM (up to 1950 rpm); and a high load range 34 , with an RPM according to the engine torque curve.
In the context of the present invention the relation between the target RPM and power may comprise several constant RPM ranges in combination with several RPM ranges, in which the target RPM is a rising function of power. The present invention is characterised in that at least one sub-range is present where the imposed RPM is a rising function of the delivered torque or power as assessed (for example) in the ECU.
According to the preferred embodiment of the present invention, the rate at which the target RPM changes within such a sub-range, is itself a rising function (at least over a portion of the sub-range) of the extent to which the imposed load respectively exceeds the sub-range upper limit or undershoots the sub-range lower limit. In other words, the higher the imposed engine torque, the more rapidly will the RPM will rise to the desired value of RPM and the lower the imposed engine torque, the more rapidly will the RPM fall to its desired value. A preferred embodiment of this type of control is shown in FIG. 6 relating to range 21 in FIG. 4 . In range 21 the target RPM rises from 1850 RPM to 1900 RPM for a load of between 43% and 73%. FIG. 6 shows the rate at which the target RPM n s changes within range 21 according to the imposed load and the current engine RPM n i . The reaction at a current RPM of 1850 RPM is shown in curve 40 and that at a current RPM of 1900 in curve 41 . The portion of the curves above the x axis shows the rate of rise of the target RPM with the rise of the load, whilst the portion of the sector below the x axis shows the rate of the fall of the target RPM with the fall of the load. For example, the situation is considered in which the actual RPM n i is equal to 1850 RPM at a load T i of 20%. From this situation, the load rises suddenly to 60%. It follows from curve 40 that the target RPM rises at a rate of +−13 rpm/s. Nevertheless, from the moment the actual RPM n i rises, curve 40 is no longer decisive for the rise of RPM, but a curve located between curves 40 (corresponding to 1850 RPM) and 41 (corresponding to 1900 RPM). A possible position of the interpolated curves 42 to 45 corresponding to current RPM values of 1860, 1870, 1880 and 1890 RPM is shown in FIG. 6 . According to these curves, the rate at which the RPM rises will consistently diminish until an RPM value is reached at which the corresponding curve intersects the x axis at the imposed load level of 60%. The current engine RPM n i then corresponds to the target RPM n s and the engine rotates at this RPM for as long as the load remains constant.
The curves 40 and 41 corresponding to the RPM interval (in the present case 1850 RMP to 1900 RPM), can be freely chosen by the programmer of the control unit. The interpolated curves 42 to 45 preferably follow automatically from the chosen boundary curves 40 and 41 according to a predetermined formula. The position of an interpolation curve belonging to a current RPM between 1850 RPM and 1900 RPM in the case of FIG. 6 is determined by the distance (expressed in RPM/s) between curves 40 and 41 , by multiplying said distance by the percentage position of the RPM n i in the RPM interval between curves 40 and 41 and deducting the result from the value of curve 40 . For example, with a 53% load:
curve 40 (1850 RPM)→7.5 RPM/s curve 41 (1900 RPM)→−15 RPM/s distance between curves 40 - 41 =22.5 RPM/s percentage RPM rise for 1860 RPM=10 RPM=20% of the interval 1850-1900 RPM
→curve at 1860 RPM passes through (7.5−22.5)×20%=3 RPM/s
By applying this formula to all points of the x axis and at 1860 RPM, 1870 RPM, 1880 RPM and 1890 RPM it is possible to generate the curves 42 to 45 shown in FIG. 6 .
It can be seen that at a starting RPM of 1850 RPM and a rise from a 20% load to a higher load, it is possible to distinguish different possibilities, namely:
with a rise to a load of between 43% and 73%, a rise to a target RPM between 1850 RPM and 1900 RPM, as described above; with a rise to a load of between 73% and +−85%, a rise from the target RPM with falling rate, to 1900 RPM and thereafter with constant rate further still to 1950 RPM (range 22 , FIG. 4 ). The higher the load, the more rapidly will the target value of RPM rise from 1900 to 1950 RPM; with a rise to a load above +−85%, a rise of the target RPM at a rising rate to 1900 RPM and further at constant rate to 1950 RPM (range 22 ). The current RPM drops according to torque curve 10 , but the target value remains 1950 RPM; with a rise to a load of +−85%, a rise from 1850 to 1950 RPM at a constant rate of 15 RPM/s.
What takes place when the target speed of 1900 RPM has been reached and when the load is rising further, is determined by the following control algorithm. In the case of FIG. 4 , the control switches to a different mode (range 22 ) where the target RPM remains 1950 RPM. The progress of this value can be determined from the curves shown in FIG. 6 . In another case, a switch takes place from 1900 RPM to a mode where the RPM is kept constant for a medium load (as shown in FIG. 5 ).
Control unit 6 retains the high target value of 1950 RPM for as long as the machine is working in the high load mode. In the case of FIG. 4 , this is as long as the imposed load remains above 73% (ranges 22 and 23 ). As soon as the load falls below this value, the target RPM also falls, as shown in the lower half of the bundle of curves 40 - 45 in FIG. 6 . With a load of between 43 and 73%, the target RPM becomes stabilised at a value between 1850 and 1900 RPM. With a lower load, the target RPM assumes a value of 1850 RPM. The greater the decrease of the load, the greater the commencing rate at which the target RPM falls. However, the rate of the decrease diminishes as the current RPM decreases.
As shown in FIG. 6 , the curves 40 and 41 are limited to maximum rate values of 15 RPM/s, 25 RPM/s and −15 RPM/s (flat parts). It goes without saying that the form of curves 40 - 45 can vary within the context of the present invention. It is, for instance, possible to choose a control, which contains no intersection (as in the case of 85% load in FIG. 6 ), or where the curves 40 and 41 exhibit no flat portions.
In the control shown in FIG. 4 or 5 the high load mode is preferably operated with a current fixed engine RPM of 1900. This lies below the target RPM value of 1950 RPM, which is outputted by the control unit 6 , because the load exceeds 85%. The current RPM falls along the engine torque curve 10 . The control unit 6 can now automatically adjust the travel speed when the imposed load changes. This ‘PowerCruise’ mode described earlier is already known in the art. The transition zone 22 ( FIG. 4 ) or 33 ( FIG. 5 ) is a preliminary phase of the transition to PowerCruise mode for high load conditions. It is aimed for said transition zone to be traversed as rapidly as possible.
The machine preferably receives a default set value for the engine RPM, which can be adjusted by the operator. This concerns, for example, the set RPM of the PowerCruise mode. The control system of the present invention can be set around this set value; for example in the case of FIGS. 4 and 5 , the set value is 1900 RPM. In case the set value is changed, the control curve automatically shifts along to higher or lower RPM values. In this way the operator can adjust the machine in the light of changing circumstances. Some crops require a greater speed of the processing elements, for example the blower. The operator can adjust said speed by modifying the set speed of the engine.
In a control module 6 according to the present invention the sub-ranges, the constant target values of engine RPM and the curves 40 and 41 (and interpolation curves) are pre-programmed in the module itself, using programming methods known in the art. Communication between the control module 6 and the engine 1 also takes place by known means.
The control unit 6 is accordingly configured for controlling the engine RPM using the following method:
assessing the imposed engine load; and setting of the RPM in accordance with the imposed engine load and in accordance with a curve showing the target RPM as a function of the load, wherein said curve comprises at least one sub-range of the range between 0% and 100% of maximum load and in that the target RPM is a continuously rising function of the engine load.
The assessment of the imposed engine load preferably takes place by measuring fuel consumption and the current RPM, for example on the basis of a signal delivered by the ECU
According to a preferred embodiment of the present method, the rate of change of the target RPM within said sub-range is itself a rising function of the extent to which the imposed load either respectively exceeds the sub-range upper limit or undershoots the sub-range lower limit, as described in relation to FIG. 6 .
The curve can provide to keep the RPM equal to constant target values within two or more non-overlapping sub-ranges of said total load, the lowest sub-range beginning at 0% and wherein:
said constant target value is lowest for the lowest of said sub-ranges and rises for higher sub-ranges, in the transition zone between the sub-ranges of constant target value the target RPM is a continuously rising function of the engine torque, as stated in claim 1 .
According to an embodiment of the present invention, the difference between the target values of two neighbouring sub-ranges is constant.
According to an embodiment of the present invention, the method also comprises a step, in which the engine RPM is set corresponding to a sub-range with a constant target value, or an RPM between two zones with a continuously rising target RPM.
According to an embodiment, said curve comprises
a low load range ( 20 ) where the target RPM retains a constant value; a medium load range ( 21 ) where the target RPM is a continuously rising function of the load; a high load range ( 23 ) where the current RPM is determined by the engine torque curve; a transition zone ( 22 ) between the medium and high load ranges, where the target RPM continuously rises to a maximum value.
According to another embodiment, said curve comprises:
a low load range ( 30 ) where the target RPM retains a constant value; a medium load range ( 32 ) where the target RPM retains a constant value higher than the target value of the low load range, a high load range ( 34 ) where the actual RPM is determined by the engine torque curve; the transition zones ( 31 , 33 ) between the low and the medium load ranges and between the medium and high load ranges, where the target RPM is a continuously rising function of the load.
The control method of the present invention has the advantage that the machine does not continuously rotate at a high RPM, but only switches to high RPM when the load requires it. This leads to a substantial fuel economy, as well as a reduction of machine noise generated. The control method where the RPM varies more rapidly the higher the imposed load modification, has the advantage that the machine changes more rapidly to a new value in the case of rapid changes of load and more slowly when said changes are gradual. In this way, the machine works in a flexible manner.
Said control method also enables a smooth changeover from manual control of the travel speed by the operator to an automatic speed control, keeping the machine load at a maximum. Both the control of the engine target RPM and the travel speed of the machine, make use of the measured load and of the current engine RPM.
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The present invention relates to a self-propelled agricultural machine, comprising:
elements ( 5 ) for gathering and/or processing crops; an engine ( 1 ) operable to travel the machine through a first driving mechanism ( 3 ) and to drive the operation of said elements through a second driving mechanism ( 4 ); and a control unit ( 6 ) for controlling engine RPM, characterized in that the control unit ( 6 ) is configured for controlling the engine RPM (n i ) on the basis of a target RPM (ns), which is in turn based on an assessment of the imposed engine load (Ti), wherein in at least in one sub-range between 0% and 100% of the maximum load, the target RPM is a constantly rising function of said engine load. The present invention relates also to a method of controlling the RPM of the engine.
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FIELD OF THE INVENTION
The present invention relates to a process for producing an antimicrobial compound consisting of a specific phosphate containing a metal ion having antibacterial, antifungal or antialgal activity such as silver, copper, zinc, tin, mercury, lead, iron, cobalt, nickel, manganese, arsenic, antimony, bismuth, cadmium or chromium ion. The antimicrobial compound obtained by the process of the present invention can be used in antimicrobial compositions which comprise the antimicrobial compound mixed with various binders, for coating compositions, adhesives or fillers, or as antimicrobial shaped products which comprise the antimicrobial compound supported on carriers such as fibers, films, papers, or plastics.
BACKGROUND OF THE INVENTION
Ions such as silver, copper, zinc, tin, mercury, lead, iron, cobalt, nickel, manganese, arsenic, antimony, bismuth, barium, cadmium and chromium ions have been known for a long time as metal ions which exhibit antifungal, antibacterial and antialgal activities (hereinafter referred to as "antimicrobial metal ions"), and particularly silver ion has been widely used in the form of an aqueous silver nitrate solution as bactericides or disinfectants. However, the above-mentioned metal ions having antifungal, antibacterial and antialgal activities are, in many cases, toxic for human bodies and have various restrictions in methods of use, storage and disposal, and their uses are limited.
Recently, it has become clear that application of a slight amount of an antimicrobial metal to subjects is enough to exhibit antifungal, antibacterial and antialgal activities, and organic microbicides or antimicrobial compounds comprising antimicrobial metals supported on ion exchange resins or chelate resins, and inorganic microbicides or antimicrobial compounds comprising antimicrobial metals supported on clay minerals, inorganic ion exchangers or porous materials have been proposed as microbicides having antifungal, antibacterial and antialgal activities.
Among the above microbicides, the inorganic microbicides are generally higher in safety, have longer period of time showing antimicrobial effect and are superior in heat resistance as compared with the organic microbicides.
As one of the inorganic microbicides, there are microbicides prepared by replacing an alkali metal ion such as sodium ion in clay minerals such as montmorillonite and zeolite with silver ion, but the skeleton structure of the clay minerals per se is inferior in acid resistance, and therefore the silver ion readily flows away into an acidic solution and the microbicides have no durable antimicrobial effect. Furthermore, silver ion is unstable against exposure to heat and light and is immediately reduced to metallic silver to cause coloration. Thus, these microbicides lack long-term stability.
In order to enhance the stability of silver ion, an attempt has been made to support both silver ion and ammonium ion on zeolite by ion exchanging, but the problem of coloration has not yet been solved to practically acceptable level and fundamental solution has not yet been attained.
Furthermore, as other inorganic microbicides, those which comprise antimicrobial metals supported on active carbons having adsorbability have been proposed. However, in these microbicides soluble antimicrobial metal salts are merely physically adsorbed or deposited, and hence the antimicrobial metal ions rapidly dissolve away upon contact with water and the microbicides have no prolonged antimicrobial effect.
Recently, it has been proposed to use as a microbicide an antimicrobial compound comprising an antimicrobial metal ion supported on a specific zirconium phosphate such as Ag 0 .01 H 0 .95 Li 0 .04 Zr 2 (PO 4 ) 3 . This microbicide is chemically and physically stable and is known as a material which has long-term antifungal and antibacterial activities (Japanese Patent Kokai No. 3-83905).
However, the process for preparing the antimicrobial compound proposed in Japanese Patent Kokai No. 3-83905 uses a phosphate prepared by a dry process and according to the dry process, the antimicrobial ion can be uniformly supported on the zirconium phosphate only after a mixture of starting material powders has been fired to obtain a lumpy zirconium phosphate and then this has been crushed and ground to fine powders. Therefore, this process has the problems that it is low in productivity; additionally it is difficult to obtain a phosphate compound having uniform and fine particle size.
Moreover, this antimicrobial compound tends to color slightly when used under severe conditions such as exposure to sunlight under high temperature and high humidity. Accordingly, there is a great need to inhibit even the slight coloration for uses in which coloration must be avoided as much as possible.
The object of the present invention is to provide a process for easily producing an antimicrobial compound having uniform and fine particle size and usable as a microbicide which undergoes substantially no coloration even under severe conditions such as exposure to sunlight or high temperature or contact with acidic solutions and which can exhibit antifungal, antibacterial and antialgal activities for a long period of time, without using crushing and grinding steps which are required for preparing the phosphates by a dry process.
SUMMARY OF THE INVENTION
As a result of intensive research conducted by the inventors in an attempt to attain the above object, it has been found that in preparing an antimicrobial compound by supporting an antimicrobial metal ion on a phosphate, an antimicrobial compound which is excellent in chemical and physical stability and has long-term antifungal, antibacterial and antialgal activities can be obtained by using a phosphate compound produced by a wet process as a starting material and by firing the phosphate compound before or after supporting thereon the antimicrobial metal ion. Thus, the present invention has been accomplished.
That is, the present invention relates to a process for producing an antimicrobial compound represented by the following formula [1]:
M.sup.1.sub.a H.sub.b A.sup.1.sub.c M.sup.2.sub.2 (PO.sub.4).sub.3.H.sub.2 O[1]
wherein M 1 is at least one metal ion selected from silver, copper, zinc, tin, mercury, lead, iron, cobalt, nickel, manganese, arsenic, antimony, bismuth, barium, cadmium and chromium, A 1 is at least one ion selected from alkali metal ion and alkaline earth metal ion, M 2 is a tetravalent metal, n is a number which satisfies 0≦n≦6, a and b are positive numbers and c is 0 or a positive number, and a, b and c satisfy ka+b+mc=1 where k is a valence of M 1 and m is a valence of A 1 , by supporting at least one metal ion selected from silver, copper, zinc, tin, mercury, lead, iron, cobalt, nickel, manganese, arsenic, antimony, bismuth, barium, cadmium and chromium on a phosphate represented by the following formula [2]:
A.sup.2.sub.d M.sup.2.sub.2 (PO.sub.4).sub.3.nH.sub.2 O [2]
wherein A 2 is at least one ion selected from alkali metal ion, alkaline earth metal ion and ammonium ion, M 2 and n are as defined above and d is 1/m' where m' is a valence of A 2 , characterized in that said phosphate is synthesized by a wet process and furthermore characterized in that a step of supporting hydrogen ion and a step of firing at 500° to 1300° C. are employed.
DETAILED DESCRIPTION OF THE INVENTION
The starting material, firing method and other procedures used in the present invention are explained in detail below.
Phosphates
The phosphate compounds used as a starting material in the present invention are those which are represented by the above formula [2], and are amorphous compounds or crystalline compounds belonging to the space group R3c in which the constituting ions form a three-dimensional network structure.
As the phosphates used in the present invention, preferred are the crystalline compounds having the three-dimensional network structure in view of less discoloration upon exposure to sunlight.
A 2 in the above formula is an alkali metal ion, an alkaline earth metal ion, or ammonium ion, and preferred examples of the alkali metal ion and the alkaline earth metal ion are lithium, sodium, potassium, magnesium and calcium.
Preferred ions as A 2 are lithium ion, sodium ion and ammonium ion in consideration of stability of the resulting compounds and their cheapness, and sodium ion is especially preferred.
M 2 in the formula [2] is a tetravalent metal and is preferably zirconium, titanium or tin, and zirconium and titanium are especially preferred in consideration of stability of the resulting compounds.
Examples of the phosphate represented by the above formula [2] [hereinafter referred to as "phosphate (2)"] are as follows:
Li 1 Zr 2 (PO 4 ) 3
(NH 4 ) 1 Zr 2 (PO 4 ) 3
Na 1 Zr 2 (PO 4 ) 3
K 1 Ti 2 (PO 4 ) 3
The phosphate (2) used in the present invention is a compound synthesized by a wet process. By employing the wet synthesis process, the phosphate (2) having uniform and fine particle size can be easily obtained only by light disintegration without grinding step, and an antimicrobial compound having uniform and fine particle size can be obtained by supporting an antimicrobial metal ion on the resulting phosphate (2).
All of the known wet synthesis processes can be employed. Specifically, for example, there is a wet process conducted under atmospheric pressure or under application of pressure.
The tetravalent metal phosphate compounds are obtained by reacting phosphate ion with a tetravalent metal ion in water in the presence of at least one ion selected from an alkali metal ion, an alkaline earth metal ion and ammonium ion.
Compounds having alkali metal ion, alkaline earth metal ion or ammonium ion are unlimited as far as they have said ion, but preferred are hydroxides, sulfates, nitrates, chlorides, carbonates, hydrogen-carbonates, phosphates and borates.
The reaction of phosphate ion with a tetravalent metal ion can be performed by merely reacting compounds having these ions. However, for promoting this reaction, it is preferred to previously form a mixture of a compound having a tetravalent metal ion (hereinafter referred to as "tetravalent metal compound") and a carboxylic acid or a salt thereof and to react this mixture with a compound having phosphate ion.
The mixing ratio of the carboxylic acid or salt thereof and the tetravalent metal compound is preferably 1 equivalent of the carboxylic acid or salt thereof (molecular weight per carboxyl group) per equivalent of the trivalent metal compound (formula weight per tetravalent metal atom).
The tetravalent metal compounds usable for the above-mentioned process are suitably those which are water-soluble or acid-soluble. Examples of the preferred tetravalent metal compounds containing zirconium as a tetravalent metal are zirconium nitrate, zirconium acetate, zirconium sulfate, basic zirconium sulfate, zirconium oxysulfate and zirconium oxychloride.
The carboxylic acid or salt thereof is preferably an aliphatic polycarboxylic acid having at least two carboxyl groups or salt thereof. Examples thereof are shown below.
That is, they include aliphatic dibasic acids such as oxalic acid, maleic acid, malonic acid and succinic acid, salts of aliphatic dibasic acids such as sodium oxalate, sodium hydrogen oxalate, lithium hydrogen oxalate, ammonium oxalate and ammonium hydrogen oxalate, and aliphatic hydroxycarboxylic acids such as citric acid, tartaric acid and malic acid and salts thereof.
Among them, oxalic acid and sodium and ammonium salts thereof are especially preferred.
The phosphoric acid or salt thereof used as a compound having phosphate ion is preferably in the form of an aqueous solution previously prepared.
As the preferred phosphates there are ammonium phosphate and alkali metal phosphates which are water-soluble or acid-soluble salts. Examples thereof are sodium dihydrogenphosphate, disodium hydrogenphosphate, trisodium phosphate, diammonium hydrogenphosphate, ammonium dihydrogenphosphate and dipotassium hydrogenphosphate.
In carrying out the reaction, the ratio of the tetravalent metal ion and the phosphate ion is preferably 0.4-4.0 equivalents, more preferably 0.6-2.0 equivalents and most preferably 0.6-0.8 equivalent of the tetravalent metal ion per equivalent of the phosphate ion.
When the equivalent ratio is less than 0.4 or more than 4.0, there is a possibility of producing a compound having the structure which is not preferred to be used in the present invention.
A particulate tetravalent metal phosphate is precipitated by the above-mentioned reaction to give a slurry of the reaction product. Then, preferably the pH of the slurry is adjusted to 7 or less by addition of an acid or an alkali. In order to obtain a tetravalent metal phosphate of high crystallinity, it is desired that the pH of the slurry is adjusted to preferably 1-6, more preferably 2-6 and the slurry is heated to preferably 80° C. or higher, more preferably 95° C. or higher. When the slurry is heated to lower than 80° C., there is a possibility of producing a compound having the structure which is not preferred, but when it is heated to higher than 95° C., crystallization proceeds in a short time. Since the crystallization rate increases with increase in the temperature, the heating temperature is more preferably 97°-100° C. under atmospheric pressure and further preferably 110°-200° C. under pressure, namely, under saturated water vapor pressure. Within this range of the temperature, the crystallization is completed usually in 2-50 hours.
In consideration of agitatability of the slurry of the reaction product, the solid concentration of the slurry is preferably 15% by weight or less.
The reaction product is separated from the liquid phase by the known separation means such as filtration, decantation, centrifugal separation, filter press and cross flow filtration system, washed and dried by conventional methods and, if necessary, disintegrated to obtain a tetravalent metal phosphate.
An actual example of synthesis of the phosphate (2) used in the present invention is as follows: 9 g of oxalic acid is dissolved in an aqueous solution prepared by dissolving 46.1 g of zirconium oxychloride in 252 g of pure water under stirring. To the resulting solution is added 24.7 g of 85% phosphoric acid to produce a precipitate. The reaction mixture is adjusted to pH 3 with 15% aqueous sodium hydroxide solution and heated and refluxed at 97° C. for 10 hours. Then, the precipitate is subjected to filtration and washing with water until the electric conductivity EC reaches 100 μS/cm or less, and dried at 110° C. This is further disintegrated to primary particles by a disintegrator.
Supporting of Antimicrobial Metal Ions
At least one antimicrobial metal ion selected from silver, copper, zinc, tin, mercury, lead, iron, cobalt, nickel, manganese, arsenic, antimony, bismuth, barium, cadmium and chromium is supported on the phosphate (2) obtained as mentioned above, before or after firing.
These antimicrobial metal ions M 1 are all known as metal ions having antifungal, antibacterial and antialgal activities. Among them, silver ion is especially effective from the point of safety and besides, as a metal ion capable of enhancing antifungal, antibacterial and antialgal activities.
For supporting the antimicrobial metal ion on the phosphate (2), there is used, for example, ion-exchange reaction which utilizes ion-exchange characteristics of the phosphate.
The ion-exchange reaction can be carried out according to conventionally well known methods, and can be allowed to easily proceed by immersing a phosphate compound in an aqueous nitric acid solution containing a suitable concentration of the antimicrobial metal ion. The amount a of the antimicrobial metal ion to be supported can be readily adjusted depending on the necessary properties and the conditions for use by increasing the concentration of the antimicrobial metal ion in the aqueous solution in which the phosphate compound before or after firing is immersed. Furthermore, the amount to be supported can be somewhat increased by carrying out adjustments such as prolongation of the period for which the phosphate compound is immersed in the antimicrobial metal ion-exchanging solution or increase of the immersing temperature.
More specific conditions for the ion exchange reaction are as follows. The tetravalent metal phosphate is immersed in an aqueous solution of an antimicrobial metal ion set at 0°-100° C. preferably 40°-100° C. for several minutes to several ten minutes, preferably for a longer time (for example, 1 to several hours) so that the solution reaches such a solid concentration as the solution can be smoothly agitated, for example, 40% by weight or less, preferably 5-20% by weight. Further specifically, for example, the antimicrobial phosphate can be prepared in the following manner; 10% by weight of a phosphate compound is added to 1% by weight of aqueous silver nitrate solution and the mixture is stirred at 40° C. for 4 hours and then filtrated. The residue is washed with water until the electric conductivity EC reaches 100 μS/cm or less and dried at 110° C. for 12 hours.
For exhibiting the antifungal, antibacterial and antialgal activities, the larger value a is preferred, but when the value a is 0.001 or more, the antifungal, antibacterial and antialgal activities can be sufficiently exhibited. However, in consideration of the fact that when the value a is smaller than 0.01, it may become difficult to exhibit the antifungal, antibacterial and antialgal activities for a prolonged period of time, and furthermore from the economical viewpoint, the value a is preferably in the range of 0.01 to 0.5, more preferably 0.10 to 0.30.
The antimicrobial compound obtained by supporting the antimicrobial metal ion on the phosphate (2) is represented by the formula [1], and is an amorphous compound or a crystalline compound belonging to the space group R3c in which the constituting ions form a three-dimensional network structure.
As the antimicrobial phosphate compounds obtained in the present invention, preferred are the crystalline compounds having the three-dimensional network structure in view of less discoloration when exposed to sunlight.
Examples of the antimicrobial phosphate obtained by supporting the antimicrobial metal are enumerated below.
Ag 0 .005 H 0 .995 Zr 2 (PO 4 ) 3
Ag 0 .01 (NH 4 ) 0 .99 Zr 2 (PO 4 ) 3
Ag 0 .05 Na 0 .95 Zr 2 (PO 4 ) 3
Ag 0 .2 K 0 .8 Ti 2 (PO 4 ) 3 , and
compounds having the above formulas in which Ag is replaced with Zn, Mn, Ni, Pb, Hg, Sn or Cu so that they have the same electric charge amount as that of the silver ion per mol of the compounds.
Firing Method
It is necessary in the present invention to fire the phosphate (2) or the antimicrobial compound obtained by supporting the antimicrobial metal ion at 500°-1300° C., preferably 600°-1000° C., more preferably 700°-900° C. Through this firing step, chemical and physical stability of microbicides consisting of said antimicrobial compounds can be markedly improved and thus, microbicides having extremely excellent weathering resistance can be obtained.
If the firing is carried out at a temperature lower than 500° C. or higher than 1300° C., the antimicrobial activity decreases or it becomes difficult to sufficiently exhibit the effect to improve the chemical and physical stability. Accordingly, it is utterly impossible to exhibit the effect of the present invention, when a mere drying step which is generally conducted at 70°-130° C. is carried out after synthesis of the phosphate by a wet process.
The firing time is not critical and the effect of the present invention can be sufficiently exhibited by carrying out the firing usually for 1-20 hours.
Heating rate and cooling rate are not critical either and can be readily adjusted in consideration of the capability and productivity of a firing furnace.
Supporting of Hydrogen Ion
In order to obtain microbicides extremely excellent in antimicrobial activity and weather resistance, it is necessary to support hydrogen ion together with the antimicrobial metal ion.
When the starting tetravalent metal phosphate contains ammonium ion, the ammonium ion is thermally decomposed by carrying out the firing step to leave hydrogen ion, and therefore the microbicides on which hydrogen ion is supported can be obtained merely by carrying out the firing step. Preferable firing conditions in this case are a firing temperature in the range of 600°-1100° C. and a firing time in the range of about 0.5-2 hours.
On the other hand, when the tetravalent metal phosphate does not contain ammonium ion, a step for supporting hydrogen ion must be added and the typical methods include a method of immersing the tetravalent metal phosphate or a microbicide containing no hydrogen ion in an acid solution. This method is higher in productivity than the above-mentioned method of firing the tetravalent metal phosphate containing ammonium ion.
Preferred examples of the acid solution in which the tetravalent metal phosphate or a microbicide containing no hydrogen ion is immersed, are hydrochloric acid and sulfuric acid, and especially preferred is nitric acid. Acid concentration of the acid solution, immersing temperature and immersing time are unlimited, but generally hydrogen ion can be supported in a short time at a higher acid concentration and at a higher temperature. Therefore, the acid concentration is preferably 0.1N or higher and more preferably 0.3N or higher, the treating temperature is preferably 40° C. or higher and more preferably 60°-100° C., and the immersing time is preferably 10 minutes or more and more preferably 60 minutes or more.
The amount (b) of hydrogen ion to be supported is preferably 0.3 or more, more preferably 0.40-0.70, most preferably 0.50-0.60.
The order of the step of supporting hydrogen ion, the step of supporting the antimicrobial ion and the step of firing has no special limitation, but it is preferred to carry out the steps in the above-mentioned order or to simultaneously carry out the supporting of hydrogen ion and that of antimicrobial ion and then carry out the firing.
Examples of the antimicrobial compounds of the formula [1] are as follows.
Ag 0 .16 H 0 .84 Zr 2 (PO 4 ) 3
Ag 0 .05 H 0 .05 Na 0 .90 Zr 2 (PO 4 ) 3
Ag 0 .05 H 0 .55 NaO 0 .40 Zr 2 (PO 4 ) 3 , and
compounds having the above formulas in which Ag is replaced with Zn, Mn, Ni, Pb, Hg, Sn or Cu so that they have the same electric charge amount as that of the silver ion per mol of the compounds.
The microbicides obtained in this way are stable against exposure to heat and light and undergo no change in structure and composition even after heated to 500° C. and 800°-1100° C. in some cases, and furthermore show no discoloration by irradiation with ultraviolet rays.
Furthermore, no change is seen in the skeleton structure even in an acidic solution. Therefore, the antimicrobial phosphates of the present invention are not restricted by conditions such as heating temperature and light-proof conditions when they are processed for obtaining various molded products and are stored and used, while the conventional microbicides have been restricted by them.
The form of the antimicrobial compounds of the present invention in use is unlimited, and they can be optionally mixed with other components or formed into composites with other materials depending on uses.
For example, the antimicrobial compounds of the present invention can be used in various forms such as powders, powder-containing dispersions, powder-containing particles, powder-containing paints, powder-containing fibers, powder-containing papers, powder-containing plastics, powder-containing films and powder-containing aerosols. Furthermore, if necessary, they can be used in combination with various additives or materials for deodorizers, flame-proof agents, corrosion-proof agents, fertilizers and building materials.
The microbicides containing the antimicrobial compound obtained by the present invention as an active ingredient can exhibit antifungal, antibacterial and antialgal activities for any use against fungi, bacteria and algae on which the antimicrobial metal ions such as silver ion effectively act, and can be effectively used, for example, for the following uses: fibers such as working clothes, medical clothes, medical beddings, medical appliances, sports wear, medical dressings, fishing nets, curtains, carpets, underwears, and air filters; papers such as wall papers; daily sundries made of resin shaped articles of kitchen utensils such as strainers and resin chopping boards; films such as food-packaging films, medical films, and synthetic leathers; paints such as paints for sterilizers, corrosion-resistant paints, and antifungal paints; powders such as agricultural soil; and liquid compositions such as shampoo.
According to the present invention, the phosphate compounds are prepared by a wet process, and therefore microbicides having a uniform and fine particle size can be easily obtained, and the grinding step which is needed for synthesis of phosphate compounds by a dry process is not needed, and lightly disintegrating the fired product after the firing step is sufficient in the present invention.
Since the antimicrobial compounds obtained by the process of the present invention are chemically and physically very stable, various shaped products comprising mixtures of various resins with these compounds as microbicides show substantially no coloration even under severe conditions such as exposure to sunlight or an atmosphere of high temperatures or contact with acidic solutions, and have long-term antifungal, antibacterial and antialgal activities. Thus, they have excellent effects and are very useful.
In the following examples and comparative examples, analysis of the composition, weathering test and antimicrobial activity test of the microbicides were conducted under the following conditions.
Analysis of Composition
The zirconium phosphate salt containing silver ion was dissolved in a small amount of hydrofluoric acid to prepare a test solution. Then, silver and sodium concentrations in the test solution were measured by atomic absorption spectrometry.
Furthermore, concentration of ammonium ion in the test solution was measured by indophenol absorption spectrophotometry.
Weathering Test
In Examples 1-3 and Comparative Example 1, a plate of 5 mm thickness consisting of a commercially available polyethylene resin [HIZEX 2100JP (tradename for high-density polyethylene powders manufactured by Mitsui Petrochemical Industries, Ltd.)] which contained 10 parts by weight of the microbicide per 100 parts by weight of the resin, was prepared and subjected to 3 cycles of weathering test (1 cycle comprising the steps of irradiating the sample with ultraviolet ray for 1 hour at 60° C. and then leaving it for 1 hour at 40° C. and a humidity of 95%). Then, the weathering resistance was evaluated by measuring the color of the sample before and after the test by a calorimeter.
In Examples 4-6 and Comparative Examples 2-4, in order that discoloration of the plate in the weathering test can be evaluated at high sensitivity, the content of the microbicide in the plate and the thickness of the plate were changed. That is, a plate of 3 mm thickness of the same commercially available polyethylene resin as above which contained 5 parts by weight of the microbicide per 100 parts by weight of the resin, was prepared. The resulting antimicrobial plates were subjected to 3 cycles of weathering test using a weathering tester UC-1 manufactured by Toyo Seiki Mfg. Co. (one cycle of the test using UC-1 was conducted for 2 hours and comprised the step of irradiating the sample with ultraviolet radiation of not more than 350 nm at 60° C. for 1 hour and the step of leaving the sample in an atmosphere of 95% or higher in humidity at 40° C. for 1 hour). The color of the sample before and after the test was measured by color-difference meter SZ-Σ80 manufactured by Nihon Denshoku Kogyo Co., Ltd., and color difference (ΔE) was obtained from the following formula.
ΔE={(L.sub.0 -L.sub.1).sup.2 +(a.sub.0 -a.sub.1).sup.2 +(b.sub.0 -b.sub.1).sup.2 }.sup.1/2
L 0 , a 0 , b 0 : Color before the test
L 1 , a 1 , b 1 : Color after the test
Antimicrobial Activity Test
Antimicrobial activity test of silver zirconium phosphate against Escherichia coli was conducted in accordance with the standard method of Japan Chemical Remedy Society to measure the minimum inhibitory concentration (MIC).
REFERENTIAL EXAMPLE 1
80 g of 6% aqueous oxalic acid solution was added to an aqueous solution prepared by dissolving 116.5 g of zirconium oxychloride (ZrOCl 2 .8H 2 O) and 2.9 g of ammonium chloride in 183 g of pure water under stirring, and 19 g of 85% phosphoric acid was further added. The reaction mixture was adjusted to pH 3.5 with an aqueous ammonia solution and heated and refluxed at 97° C. for 78 hours. Then, the precipitate was subjected to filtration and washing with water until the electric conductivity EC of the filtrate reached 100 μS/cm or less. The residue was dried at 110° C. for 12 hours and then disintegrated to a given particle size by a disintegrator to obtain zirconium phosphate [(NH 4 )Zr 2 (PO 4 ) 3 ] having a network structure.
EXAMPLE 1
10 g of the phosphate compound obtained in the Referential Example 1 was fired at 800°, 900° or 1000° C. for 4 hours in a firing furnace (heating rate: 200° C./Hr). The fired product was stirred in 100 cc of 1% aqueous silver nitrate solution for 4 hours and then washed with water until the electric conductivity reached 100 μS/cm or less and dried at 105° C. for 12 hours to obtain the three antimicrobial compounds having the following compositional formula (a).
Ag.sub.0.16 H.sub.0.84 Zr.sub.2 (PO.sub.4).sub.3 (a)
These antimicrobial compounds were subjected to the weathering test as microbicides. As clear from Table 1 which shows the value L before and after the test, all of them were excellent in weathering resistance as microbicides.
Furthermore, as a result of the antimicrobial activity test, it was found that the minimum inhibitory concentration (MIC) for Escherichia coli was 125 ppm for all of the microbicides.
TABLE 1______________________________________Firing Firingtemperature time L.sub.0 L.sub.1______________________________________ 800° C. 4 hr 76 67 900° C. 4 hr 80 771000° C. 4 hr 81 77______________________________________
EXAMPLE 2
The compound having the above composition formula (a) prepared in accordance with the Referential Example 1 and Example 1 except that the firing was not carried out, was fired at 800°, 900° or 1000° C. for 4 or 10 hours in a firing furnace and disintegrated by a disintegrator to obtain three antimicrobial compounds.
These antimicrobial compounds were subjected to the weathering test. As apparent from Table 2 which shows the value L before and after the test, all of the microbicides were excellent in weathering resistance.
As a result of the antimicrobial activity test, it was found that the minimum inhibitory concentration (MIC) for Escherichia coli was 125 ppm for all of the microbicides.
TABLE 2______________________________________Firing Firingtemperature time L.sub.0 L.sub.1______________________________________ 800° C. 4 hr 86 67 900° C. 4 hr 86 801000° C. 10 hr 87 81______________________________________
Example 3
The following phosphate obtained in the same manner as in Example 2 was fired at 800°, 900° or 1000° C. for 4 hours in a firing furnace and then disintegrated by a disintegrator to obtain three antimicrobial compounds.
Ag.sub.0.16 (NH.sub.4).sub.0.84 Zr.sub.2 (PO.sub.4).sub.3
These antimicrobial compounds were subjected to the weathering test. As apparent from Table 3 which shows the value L before and after the test, all of the microbicides were excellent in weathering resistance.
As a result of the antimicrobial activity test, it was found that the minimum inhibitory concentration (MIC) for Escherichia coli was 125 ppm for all of the microbicides.
TABLE 3______________________________________Firing Firingtemperature time L.sub.0 L.sub.1______________________________________ 800° C. 4 hr 78 73 900° C. 4 hr 73 701000° C. 4 hr 83 80______________________________________
COMPARATIVE EXAMPLE 1
The following phosphate compound was subjected to the weathering test without subjecting it to the firing. The value L o before the weathering test was 68 and the value L 1 after the test was 28, and coloration was seen.
Ag.sub.0.16 (NH.sub.4).sub.0.84 Zr.sub.2 (PO.sub.4).sub.3
As a result of the antimicrobial activity test, the minimum inhibitory concentration (MIC) for Escherichia coli was 125 ppm.
REFERENTIAL EXAMPLE 2
Preparation of K Type Zirconium Phosphate Salt
Oxalic acid (0.1 mol) was added to an aqueous solution of zirconium oxychloride (0.2 mol) with stirring, and thereto was further added phosphoric acid (0.3 mol) (equivalent of zirconium ion per equivalent of phosphate ion was 0.67). The reaction mixture was adjusted to pH 3.5 with aqueous potassium hydroxide solution and heated and refluxed at 95° C. for 20 hours and then, the precipitate was subjected to filtration, washing with water and drying to obtain potassium zirconium phosphate [KZr 2 (PO 4 ) 3 .1.2H 2 O] having a network structure (average particle size: 0.4 μm).
REFERENTIAL EXAMPLE 3
Preparation of NH 4 Type Zirconium Phosphate Salt
Ammonium chloride (0.1 mol) and oxalic acid (0.1 mol) were added to an aqueous solution of zirconium oxychloride (0.2 mol) with stirring, and thereto was further added phosphoric acid (0.3 mol). The reaction mixture was adjusted to pH 4.0 with aqueous ammonia solution and heated and refluxed at 95° C. for 48 hours and then, the precipitate was subjected to filtration, washing with water and drying to obtain ammonium zirconium phosphate [NH 4 Zr 2 (PO 4 ) 3 .1.1H 2 O] having a network structure (average particle size: 0.7 μm).
REFERENTIAL EXAMPLE 4
Preparation of Na Type Zirconium Phosphate Salt
Oxalic acid (0.1 mol) was added to an aqueous solution of zirconium oxychloride (0.2 mol) with stirring and thereto was further added phosphoric acid (0.3 mol). The reaction mixture was adjusted to pH 3.5 with aqueous sodium hydroxide solution and heated and refluxed at 95° C. for 10 hours and then, the precipitate was subjected to filtration, washing with water and drying to obtain sodium zirconium phosphate [NaZr 2 (PO 4 ) 3 .1.1H 2 O] having a network structure (average particle size: 0.8 μm).
EXAMPLE 4
Each of the K type zirconium phosphate powder prepared in Referential Example 2 and the Na type zirconium phosphate powder prepared in Referential Example 4 was added to a 1N nitric acid solution containing silver ion and stirred at 60° C. for 10 hours. Thereafter, the resulting slurry was filtered and the residue was sufficiently washed with pure water, further heated and dried at 110° C. overnight and then fired at 750° C. for 4 hours to obtain a microbicide (Sample Nos. 1 and 3).
EXAMPLE 5
The NH4 type zirconium phosphate powder prepared in Referential Example 3 was fired at 700° C. for 4 hours to obtain a hydrogen type zirconium phosphate [HZr 2 (PO 4 ) 3 ]. This was added to a 1N nitric acid solution containing silver ion and stirred at 60° C. for 10 hours. Thereafter, the resulting slurry was filtered, and the residue was sufficiently washed with pure water, further heated and dried at 110° C. overnight and then fired at 750° C. for 4 hours to obtain a microbicide (Sample No. 2).
EXAMPLE 6
The Na type zirconium phosphate powder prepared in Referential Example 4 was added to a 0.1N nitric acid solution containing silver ion and stirred at 60° C. for 10 hours. Thereafter, the resulting slurry was filtered and the residue was sufficiently washed with pure water, further heated and dried at 110° C. overnight and then fired at 750° C. for 4 hours to obtain a microbicide (Sample No. 4).
COMPARATIVE EXAMPLE 2
The Na type zirconium phosphate powder prepared in Referential Example 4 was added to a 1N nitric acid solution containing a given amount of silver nitrate and stirred at 60° C. for 10 hours. Thereafter, the resulting slurry was filtered and the residue was sufficiently washed with pure water. This was only heated and dried at 110° C. overnight and subjected to no firing to obtain a microbicide (Sample No. 5).
COMPARATIVE EXAMPLE 3
Hydroxyapatite [Ca 10 (PO 4 ) 6 (OH) 2 ] or an A type zeolite (composition: 0.94Na 2 O.Al 2 O 3 .1.92SiO 2 .xH 2 O*) was added to an aqueous solution of silver nitrate alone or of silver nitrate and ammonium nitrate, stirred at room temperature for 10 hours, then sufficiently washed with water and dried at 110° C. to obtain antimicrobial hydroxyapatite (average particle size: 1.2 μm) and antimicrobial zeolite (average particle size: 2.6 μm) (Sample Nos. 6 to 8). (*: x=1 to 4)
COMPARATIVE EXAMPLE 4
The antimicrobial hydroxyapatite powder (Sample No. 6) and antimicrobial zeolite powder (Sample No. 7) obtained in Comparative Example 3 were fired at 750° C. for 4 hours (Sample Nos. 9 and 10).
The microbicides prepared as mentioned above are shown in the following Table 4.
TABLE 4______________________________________SampleNo. Microbicides______________________________________1 Ag.sub.0.05 K.sub.0.75 H.sub.0.20 Zr.sub.2 (PO.sub.4).sub.32 Ag.sub.0.10 H.sub.0.90 Zr.sub.2 (PO.sub.4).sub.33 Ag.sub.0.19 Na.sub.0.47 H.sub.0.34 Zr.sub.2 (PO.sub.4).sub.34 Ag.sub.0.20 Na.sub.0.7 H.sub.0.10 Zr.sub.2 (PO.sub.4).sub.35 Ag.sub.0.19 Na.sub.0.47 H.sub.0.34 Zr.sub.2 (PO.sub.4).sub.3.1.2H.su b.2 O6 Ag.sub.0.16 Ca.sub.9.92 (PO.sub.4).sub.6 (OH).sub.27 0.04Ag.sub.2 O.0.9Na.sub.2 O.Al.sub.2 O.sub.3.1.9SiO.sub.2.2.2H.sub. 2 O8 0.04Ag.sub.2 O.0.02(NH.sub.4).sub.2 O.0.8Na.sub.2 O.Al.sub.2 O.sub.3.1.9SiO.sub.2.2.7H.sub.2 O9 (Fired product of Sample No. 6)10 (Fired product of Sample No. 7)______________________________________
Preparation of Antimicrobial Plates and Evaluation Thereof
Antimicrobial plates were prepared using the various microbicides prepared in Examples 4 to 6 and Comparative Examples 2 to 4 in the manner as mentioned in the above item of weathering test.
The results of the antimicrobial activity test and the weathering test on these antimicrobial plates are shown in the following Table 5.
TABLE 5__________________________________________________________________________ ColorColor Color differ-Sample(before test) (after test) ence MICNo. L.sub.0 a.sub.0 b.sub.0 L.sub.1 a.sub.1 b.sub.1 ΔE (ppm)__________________________________________________________________________1 52.68 -1.83 -4.20 51.89 -1.46 -3.46 1.9 2502 55.23 -1.21 -5.12 55.07 -1.40 -3.00 2.1 2503 54.64 -1.07 -4.71 54.39 -1.06 -2.42 2.3 62.54 55.69 -0.69 -5.71 53.90 -0.88 1.76 7.7 62.55 62.54 -1.51 -3.59 37.92 7.38 16.63 33.1 2506 37.49 -0.60 7.25 24.57 0.92 3.80 13.5 2507 53.59 -1.90 -1.52 30.43 7.50 9.51 27.3 2508 53.27 -1.50 -1.78 30.29 6.89 10.52 27.4 2509 48.48 -0.74 -1.29 47.42 -0.53 0.05 1.7 >200010 35.73 -1.05 -0.38 37.37 -0.75 2.88 3.7 >2000__________________________________________________________________________
As clear from the results of the above Table 5, the microbicides of the present invention (Sample Nos. 1, 2, 3 and 4) are excellent in both the antimicrobial activity and the weathering resistance.
On the other hand, the microbicide (Sample No. 5) which was not subjected to the firing even though prepared by supporting silver ion on the zirconium phosphate salt, has problem in the weathering resistance.
In the case of the antimicrobial hydroxyapatite, the unfired product (Sample No. 6) colored just after molded into an antimicrobial plate, and furthermore had problem in the weathering resistance, and the fired product (Sample No. 9) was very low in the antimicrobial activity.
In the case of the antimicrobial zeolite, the unfired product (Sample Nos. 7 and 8) had problem in the weathering resistance, and the fired product (Sample No. 10) colored just after molded into an antimicrobial plate and furthermore was very low in the antimicrobial activity.
EXAMPLE 7
Zirconium sulfate (0.12 mol), ammonium sulfate (0.04 mol), phosphoric acid (0.18 mol) and sodium hydroxide (0.018 mol) under mixing were added to pure water (40 g) to prepare a homogeneous aqueous solution. This reaction mixture was heated for 4 hours under saturated water vapor pressure at 120° C., and the precipitate was subjected to filtration, washing with water and drying to obtain a zirconium phosphate salt having a network structure. This was added to an aqueous silver nitrate solution containing a given amount of silver ion and stirred at 60° C. for 10 hours. Then, the slurry was filtrated, and the residue was sufficiently washed with pure water, heated and dried at 110° C. overnight and fired at 900° C. for 4 hours to obtain a microbicide having the following composition (Sample No. 11).
Ag.sub.0.15 Na.sub.0.05 (NH.sub.4).sub.0.80 Zr.sub.2 (PO.sub.4).sub.3
The microbicide of Sample No. 11 obtained above was evaluated on the weathering resistance and the antimicrobial activity in the same manner as the evaluation of the microbicide obtained in Example 4, and the results are shown in Table 6.
COMPARATIVE EXAMPLE 5
A microbicide (Sample No. 12) was prepared in the same manner as in Example 7 except that the firing at 900° C. was not carried out.
The microbicide of Sample No. 12 obtained above was evaluated on the weathering resistance and the antimicrobial activity in the same manner as the evaluation of the microbicide obtained in Example 4 and the results are shown in Table 6.
TABLE 6__________________________________________________________________________ ColorColor Color differ-Sample(before test) (after test) ence MICNo. L.sub.0 a.sub.0 b.sub.0 L.sub.1 a.sub.1 b.sub.1 ΔE (ppm)__________________________________________________________________________11 70.92 1.24 5.74 66.18 2.15 11.01 7.2 25012 71.69 0.37 5.18 40.49 8.27 10.96 32.9 250__________________________________________________________________________
As apparent from the above Table 6, also when the zirconium phosphate was synthesized by a hydrothermal process, the weathering resistance of the microbicide could be improved by carrying out the firing.
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A process for producing an antimicrobial compound represented by the following formula [1]:
M.sup.1.sub.a H.sub.b A.sup.1.sub.c M.sup.2.sub.2 (PO.sub.4).sub.3.nH.sub.2
O [1]
wherein M 1 is at least one metal ion selected from silver, copper, zinc, tin, mercury, lead, iron, cobalt, nickel, manganese, arsenic, antimony, bismuth, barium, cadmium and chromium, A 1 is at least one ion selected from alkali metal ion and alkaline earth metal ion, M 2 is a tetravalent metal, n is a number which satisfies 0≦n≦6, a and b are positive numbers and c is 0 or a positive number, and a, b and c satisfy ka+b+mc=1 where k is a valence of M 1 and m is a valence of A 1 , by supporting at least one metal ion selected from silver, copper, zinc, tin, mercury, lead, iron, cobalt, nickel, manganese, arsenic, antimony, bismuth, barium, cadmium and chromium on a phosphate represented by the following formula [2]:
A.sup.2.sub.d M.sup.2.sub.2 (PO.sub.4).sub.3.nH.sub.2 O [2]
wherein A 2 is at least one ion selected from alkali metal ion, alkaline earth metal ion and ammonium ion, M 2 and n are as defined above and d is 1/m' where m' is a valence of A 2 , characterized in that said phosphate is synthesized by a wet process and furthermore characterized in that a step of supporting hydrogen ion and a step of firing at 500° to 1300° C. are employed.
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TECHNICAL FIELD
The present invention broadly relates to method and apparatus for forming joints between two sheets of material, and deals more particularly with a method and apparatus for mechanically forming so-called clinch joints between two sheets of material by mechanically deforming into interlocking relationship mutually opposing areas of the sheets.
BACKGROUND ART
In connection with many types of manufacturing processes, it is desirable, and sometimes required to join two sheets of material, by forming clinch joints therebetween. Clinch joints obviate the need for welding or special fasteners, are highly effective in holding two sheets of material together and can be formed using relatively simple apparatus. Clinch joints may be of the so-called pierce type in which one or both sheets of material are pierced in order to form an interlocking joint, or may be of the so-called waterproof type in which an interlocking joint is formed without piercing either sheet.
Apparatus for forming clinch joints, of both the pierced and non-pierced types, are well-known in the art. Such apparatus normally includes a punch for forming a cup in the two sheets of material, a die which cooperates with the punch to form the cup, and an anvil which cooperates with the punch to complete the deformation process. Previous types of known apparatus employ cams and/or various types of camming mechanisms to move the die, anvil and/or punch in synchronism with each other. Such types of apparatus are not only relatively difficult to manufacture, because in part they require trip levers to trip the cams, but also require frequent adjustment, especially under high production conditions, since cam wear results in deterioration of the quality of the clinch joint.
The present invention is intended to overcome the foregoing problems.
SUMMARY OF THE INVENTION
According to the present invention, a method and apparatus is provided for forming a clinch joint between two sheets of deformed material, such as sheet metal, for example. The invention eliminates the use of or need for a camming mechanism to sequentially displace an anvil and die relative to a punch in order to form the clinch joint. The apparatus includes a motor member consisting of a hydraulic or pneumatic cylinder having a reciprocable output shaft pivotally coupled to one end of a drive lever. The opposite end of the drive lever is pivotally connected to both an anvil driving slide which is drivingly connected to the anvil, and a pair of die slides which drive the die relative to the anvil. The die slides are disposed on opposite sides of the anvil slide, and are connected to the latter by means of a pivot pin which extends through an elongate slot in the anvil slide. The pivot pin in turn is pivotally connected to the drive lever. In the illustrated embodiment, the punch is stationarily mounted on a support and the die and anvil are reciprocated relative to the stationary punch. In a first portion of the workstroke, both the die and the anvil move downwardly toward the punch, with the two sheets of material positioned therebetween. During this first portion of the workstroke, the die is spaced from the anvil in a direction of travel toward the punch, and functions to deform the two sheets of material over the punch to form a cup. During a second portion of the workstroke, the die retracts slightly while the anvil continues advancing toward the punch and eventually engages and forms the portion of the two sheets which defines the cup, so that at least sections of the deformed portions overlap each other to form a clinch joint. During a retraction workstroke, the anvil and die are retracted so that the finished clinch joint and sheets of material may be removed from the punch.
It is therefore a primary object of the invention to provide apparatus for forming clinch joints which obviates the need for cams, cam trip levers, and various types of cam adjustments heretofore required.
It is a further object of the present invention to provide apparatus as described above which is especially simple in construction and therefore economical to fabricate.
A further object of the invention is to provide apparatus as described above which may be employed to form either pierced or nonpierced type clinch joints.
A still further object of the invention is to provide apparatus as mentioned above which is relatively simple and light-weight, and is therefore relatively portable.
Another object of the invention is to provide a method of forming an improved clinch joint.
These, and further objects and features of the invention will be made clear or will become apparent during the course of the following description of a preferred embodiment of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, which form an integral part of the specification and should be read in conjunction therewith, and in which like references numerals are employed to designate identical components in the various views:
FIG. 1 is a front view of apparatus for forming clinch joints in accordance with the preferred embodiment of the present invention, a portion of the motor member being broken away in section;
FIG. 2 is a side view of the apparatus shown in FIG. 1, the positions of the components depicted in FIGS. 1 and 2 corresponding to a third portion of the workstroke in which the anvil deforms a portion of the two sheets of material;
FIG. 3 is an exploded, perspective view of the primary components of the apparatus;
FIG. 4 is a view similar to FIG. 2 with portions broken away in cross-section for clarity, the drive mechanism, anvil and die being shown in the starting position before a clinch joint is formed;
FIG. 5 is a side view depicting the relationships of the drive members, anvil and die, when the apparatus completes the first portion of the workstroke;
FIG. 6 is an enlarged, cross-sectional view showing the relationship of the die, anvil, punch and sheets of material immediately before the apparatus has completed the first portion of its workstroke;
FIG. 7 is a view similar to FIG. 5, but depicting the relationship of the components when the apparatus has completed a second portion of the workstroke;
FIG. 8 is a view similar to FIG. 6, but depicting the relationship of the die and anvil when the apparatus has completed a second portion of its workstroke;
FIG. 9 is a view similar to FIG. 6, but depicting the relationship between the anvil and die when the apparatus has completed a third portion of its workstroke; and,
FIG. 10 is a view similar to FIG. 9, but depicting a subsequent portion of the workstroke during the initial retraction of the die and anvil to their starting positions.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIGS. 1 through 4, the present invention broadly relates to a method and apparatus for forming clinch joints between two sheets of deformable ductile material, such as sheet metal. A number of types of clinch joints can be formed using the method and apparatus of the present invention, however, for illustrative purposes, a so-called pierceless or waterproof type of clinch joint is formed, in which neither sheet of material is pierced.
The apparatus broadly includes a motor member 24, a pair of side plates 20, 22, and a punch support 28. The motor member 24 may be of a pneumatic or hydraulic type, consisting of a cylinder having a reciprocable output shaft 26. The motor member 24 operates a drive assembly, described below, which in turn shifts an anvil 86 and die 94 relative to each other, and toward and away from a punch 30, and particularly an upstanding punch element 32. The punch element 32 cooperates with the anvil 86 and die 94 to form the clinch joint, as will become apparent hereinbelow.
The reciprocable output shaft 26 is connected to one end of an elongate drive lever 40 by means of a clevis 38 having an elongated slot 44 therein, and a drive pin 42 which extends through a hole 46 in the drive lever 40 and the elongate slot 44 in the clevis 38. One end of the drive lever is thus pivotally connected to the outer end of the output shaft 26, and has its pivot point shiftable somewhat as a result of the elongate mounting slot 44. The opposite end of the drive lever 40 is provided with three apertures therein, 48, 50 and 52 respectively. The drive lever 40 is pivotally mounted between the plates 20, 22 by means of a clevis link 54 which includes a pair of connecting links 54a, 54b. The connecting clevis 54 is mounted between the two plates 20, 22 by means of a pivot pin 56. The lever 40 is connected to the connecting links 54a, 54b by means of a pivot pin 62.
An anvil slide 68 includes a pair of clevis-like ears 72 each provided with through holes 74. Ears 72 are pivotally mounted on drive lever 40 by means of pivot pin 76 which extends through holes 74 and aperture 52 in the drive lever 40. The anvil slide 68 includes a lower bearing portion 90 which engages and bears on the head 88 of a cylindrical shaft 84 which includes a reduced diameter portion defining the anvil 86. The anvil slide 68 also includes another through hole 70 therein which is elongated in the direction of the longitudinal axis of the anvil slide 68.
A pair of die slides 78, 80 are respectively mounted between opposite sides of the anvil slide 68, and the plates 20, 22. The die slides 78, 80 are each connected to a die 92. An anvil retainer 82 is secured to the anvil slide 68 and includes a through hole 83 therein, through which the cylindrical portion 84 of the anvil 86 extends. The die 92 has an apertured die button 94 through which the anvil 86 may extend. The die slide assembly, consisting of slides 78, 80, and die 92 is slideably shiftable relative to anvil slide 68 and anvil 86, toward and away from the punch 30 by means which will now be described. Each of two elongate connecting links 58, 60 is pivotally connected to the outermost end of drive lever 40 by means of a pivot pin 64 which extends through hole 50 in lever 40. The opposite ends of the connecting links 58, 60 are pivotally connected to the upper ends of die slides 78 and 80, by means of a pivot pin 66 which extends through the elongate clearance hole 70. It may thus be appreciated that the pivot point between the upper ends of the die slides 78, 80 and the connecting links 58, 60 is longitudinally slideable relative to the anvil slide 68, in the direction in which both the anvil slide 68 and the die slides 78 travel relative to the punch 30. The clearance hole 70 is provided merely to allow unimpeded shifting of the pivot pin 66.
Having described the construction of the apparatus, its method of operation will now be discussed, particularly with reference to FIGS. 4-10. In FIG. 4, the components of the apparatus are shown in their initial starting position, with the output shaft 26 retracted, immediately prior to commencement of a workstroke. With the components in this position, the anvil 86 and die 94 are retracted to their raised position, spaced from the punch 32 so that the overlapping sheets 34 and 36 may be placed therebetween. The motor member 24 is then actuated to commence a workstroke. During a first portion of the workstroke, drive lever 40 is driven by output shaft 26 and is caused to rotate in a clockwise direction, as viewed in FIGS. 4, 5 and 7. This clockwise rotation of the drive link 40 is guided in part by the connecting links 54 which connect the drive lever 40 to the stationary supporting structure. During this first portion of the workstroke, it can be seen that the pivot points (designated by the same numerals corresponding to the respective pivot pins) 64, 66 and 76 move downwardly, with the pivot pin 66 positioned near the bottom of the hole 70. Thus, during this first portion of the workstroke, both the die 94 and the anvil 86 move downwardly in unison with each other, with the anvil 86 spaced from the outer end of the die 94. As this first portion of the workstroke is completed, the lower end of the die 94 engages the top sheet 34 and deforms the two sheets 34, 36 over the punch element 32 to form a "cup" in the two sheets 34, 36.
The output shaft 26 continues to move downwardly through a second portion of the workstroke, causing the drive lever 40 to continue to rotate in a clockwise direction. During this second portion of the workstroke, pivot point 64 rotates clockwise (FIGS. 5 and 7) and moves upwardly, thus, links 60 draw the die slides 78, 80 upwardly to retract the die 94 away from the sheets 34, 36. Simultaneously, continued clockwise motion of the drive lever 40 during the second portion of the workstroke drives pivot point 76 downwardly and therefore causes the anvil 86 to move toward the punch element 32, as shown in FIG. 8. As the second portion of the workstroke is completed (see FIGS. 7 and 9), the die is retracted above the outer end of the anvil 86, so that the anvil 86 engages and deforms a portion of the sheets 34, 36 in overlapping relationship to each other to form a joint therebetween. Notice that the periphery of the deformed material of the joint extends laterally outward beyond the sides of the anvil 86, in clearing relationship to the die 94. It should be noted here that, during the first portion of the workstroke, the die 94 is driven downwardly toward the punch 32 as a result of the lever 40 driving links 58, 60. However, during a later part of the second portion of the workstroke, continued clockwise motion of the drive lever 40 causes the pivot pin 66 to move upwardly within the hole 70, while at the same time, pivot pin 76 moves downwardly which in turn drives the anvil 86 toward the punch element 32.
The positions of the parts during the first portion of the return stroke of the shaft 26 are depicted in FIG. 10. Initial reverse movement of the drive lever 40 in the counterclockwise direction results in the die 94 once again moving downwardly a short distance, while the anvil 86 moves upwardly. This results in a further deformation of the peripheral edges of the joint, as shown in FIG. 10 which increases the strength of the resulting clinch joint. During the final portion of the workstroke, the output shaft 26 is further retracted, causing both the anvil 86 and the die 94 to return to their starting position, depicted in FIG. 4. It should be noted here parenthetically that as shown in FIGS. 2 and 4, the punch 30 may be provided with an elastic, e.g. urethane, sleeve 31 which surrounds the punch and functions to eject the joint from the punch 30.
From the foregoing, it can be appreciated that the present invention not only provides for the reliable accomplishment of the objects of the invention but does so in a particularly effective and economical manner. It is recognized, of course, that those skilled in the art may make various modifications or additions to the preferred embodiment chosen to illustrate the invention without departing from the spirit and scope of the present contribution to art. Accordingly, it is to be understood that the protection sought and to be afforded hereby should be deemed to extend to the subject matter claimed and all equivalents thereof fairly within the scope of the invention.
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A method and apparatus for forming pierce type or pierceless clinch joints in two sheets of material, such as sheet metal, employs a drive system which eliminates the need for camming mechanisms and periodic adjustment of worn cams. A die and anvil are relatively moveable and are displaced relative to a punch by means of a single drive lever which is driven by the output shaft of a hydraulic or pneumatic cylinder. A slide which drives the die is pivotally connected both to the drive lever and to a second slide which drives the anvil. The anvil slide is pivotally connected to the drive lever. The anvil and die are displaced in synchronism with each other and with the punch to form a clinch joint in a single workstroke of the cylinder motor.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] The present application claims priority under Title 35, United States Code §119 of U.S. Provisional Application Serial No. 60/364,347 filed Mar. 13, 2002.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] The present invention was developed with funds from a grant by the National Institute of Health, Grant Number 5R01GM052964-07.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] Pateamine A was first isolated from the marine sponge Mycale found off the shores of New Zealand. Northcote, P. T. et al, Tetrahedron Lett., 32:6411-6414 (1991). The natural form bears a thiazole and an E,Z-dienoate within a 19-membered macrocycle and a trienylamine side chain. Two additional pateamines, pateamines B and C, were also isolated. Their structures differ from pateamine A only in the nature of the terminal group of the trienylamine side chain. The structure for all three isolated natural forms is shown below:
[0005] Isolated pateamine A (“native pateamine A”) is a novel marine product that promises to be quite useful as a biochemical probe and which displays potent imunosuppressive properties with low cytotoxicity. Northcote, P. T.; Blunt, J. W.; Munro, M. H. G. Tetrahedron Lett. 1991, 32, 6411; Alexander Akhiezer, Ph. D. Thesis, Massachusetts Institute of Technology, 1999. In MLR (mixed lyphocyte reaction) assay, IC 50 =2.6 nM while the LCV (lymphocyte viability assay)/MLR ratio is >1000. In comparing native pateamine A to cyclosporin A in a mouse skin graft rejection assay, native pateamine A resulted in a 15 day survival period as opposed to cyclosporin A having only a 10 day survival of the skin graft. Additionally, at high doses, toxicity was at 17% in these studies. For other dose levels, there was no toxicity. All doses were active.
[0006] More recently, it was found that native pateamine A specifically inhibits an intracellular step of the T-cell receptor signal transduction pathway leading to IL-2 transcription. Romo, D. et al., J. Am. Chem. Soc., 120:12237-12254 (1998). Two syntheses of native pateamine A have been reported. Rzasa, R. M., et al., J. Am. Chem. Soc., 120:591-592 (1998), Remuinan, M. J. and Pattenden, G., Tetrahedron Lett., 41:7367-7371 (2000). The utility of these molecules as an immunosuppressant or immunostimulant is severely restricted because the molecule lacks stability. Additionally, natural sources of the molecule are limited. Thus, continuous development of synthetic pateamine derivatives having the same or lower toxicity, potent activity and increased stability is required.
[0007] Preliminary studies by a group at PharmMar showed potent activity of native pateamine A in the mixed lymphocyte reaction and also in the mouse skin graft rejection assay. Native pateamine A originally showed activity in a mixed lymphocycte reaction, (IC 50 2.6 nM) and in the mouse skin graft rejection assay. Native pateamine A was found to be more potent than cyclosporin A with only low toxicity at high doses but all doses were active. More recent studies, indicate that native pateamine A inhibits a specific intracellular signaling pathway involved in T cell receptor-mediated IL-2 production. Romo, D.; Rzasa, R. M.; Shea, H. A.; Park, K.; Langenhan, J. M.; Sun, L.; Akhiezer, A.; Liu, J. O. J. Am. Chem. Soc. 1998, 120, 12237-12254. In addition to its effect on TCR signaling pathway, native pateamine A has been found to induce apoptosis in certain mammalian cell lines, especially those that are transformed with the oncogene Ras. Hood, K. A.; West, L. M.; Northcote, P. T.; Berridge, M. V.; Miller, J. H. Apoptosis 2001, 6, 207-219.
[0008] Analysis of the native pateamine A structure reveals a rigid eastern half (C6-C24) including the thiazole, dienoate, and the triene sidechain, due to extended conjugation, and a more flexible western half (C1-C5). Furthermore, C3-Boc-PatA was found to have only 3-4 fold lower activity than native pateamine A. Id.
[0009] 2. Description of the Related Art
[0010] Natural products have proven to be extremely useful as probes of biological processes. Schreiber, S. L.; Hung, D. T.; Jamison, T. F. Chem. Biol. 1996, 3, 623-639. Examples include the immunosuppressive, microbial secondary metabolites, cyclosporin A, FK506, and rapamycin. Hung, D. T.; Jamison, T. F.; Schreiber, S. L. Chemistry & Biology 1996, 3, 623-639. Marine organisms have also been a rich source of bioactive compounds, which are proving useful as drug leads and biological probes. Newmann, d. J.; Cragg, G. M.; Snader, K. M. Nat. Prod. Rep. 2000, 17, 215-234. For example, bryostatin, epithilone, discodermolide and ecteinascidin show great potential as anti-cancer agents and have revealed novel biological mechanisms of action. Hung, D. T.; Nerenberg, J. B.; Schreiber, S. L. J. Am. Chem. Soc. 1996, 118, 11054-11080; Cvetkovic, R. S.; Figgitt, D. P.; Plosker, G. L. Drugs 2002, 62, 1185-1192.
[0011] Marine life has been the source for the discovery of compounds having varied biological activities. The following United States patents have issued for inventions, such as: U.S. Pat. No. 6,057,333, directed to Discorhabdin compounds derived from marine sponges of the genus Batzella or prepared by synthetic methods. These compounds, and pharmaceutical compositions containing them as active ingredients, are useful as immunomodulatory, antitumor agents, and/or caspase inhibitors.
[0012] Other patents with compounds from marine organisms include: U.S. Pat. No. 4,548,814, which uses didemnins having antiviral activity that were isolated from a marine tunicate; U.S. Pat. No. 4,729,996, which discloses compounds, having antitumor properties isolated from marine sponges Teichaxnella morchella and Ptilocaulis walpersi ; U.S. Pat. No. 4,808,590, which discloses compounds, having antiviral, antitumor, and antifungal properties from the marine sponge Theonella sp.; and U.S. Pat. No. 4,737,510, which discloses compounds having antiviral and antibacterial properties, isolated from the Caribbean sponge Agelas coniferin.
[0013] Immunomodulators are useful for treating systemic autoimmune diseases, such as lupus erythematosus and diabetes, as well as immunodeficiency diseases. Immunomodulators are also useful for immunotherapy of cancer or to prevent rejections of foreign organs or other tissues in transplants, e.g., kidney, heart, or bone marrow. Examples of immunomodulators include: FK506, muramylic acid dipeptide derivatives, levamisole, niridazole, oxysuran, flagyl, and others from the groups of interferons, interleukins, leukotrienes, corticosteroids, and cyclosporins. Many of these compounds, however, have undesirable side effects and/or high toxicity. New immunomodulator compounds are needed to provide a wider range of immunomodulator function for specific areas with a minimum of undesirable side effects.
[0014] Many of the immunomodulators available currently, however, have undesirable side effects and/or high toxicity and are often difficult to synthesize in pharmacologically effective amounts. What is needed is one or more immunomodulative compounds that may be synthetically produced in effective amounts that provide a wider range of immunomodulator function with increased stability and with less undesirable side effects.
BRIEF SUMMARY OF THE INVENTION
[0015] The present invention is a compound of Formula I as set out below:
[0016] and its pharmaceutically accepted salts, wherein
[0017] A-B is ethane, (E) and (Z)-ethene, (E) and (Z)-substituted ethene, ethyne,
[0018] K is hydrogen or C 1 -C 3 alkyl,
[0019] Q=NH or O,
[0020] X is hydrogen, hydroxy, alkoxy, alkyl, aminocarbonyl, amino, alkylamino, dialkylamino, alkoxycarbonylamino,
[0021] Y is S, NH, or O,
[0022] Z is hydrogen, hydroxy, aminocarbonyl, alkylamino, dialkylamino, alkoxycarbonylamino, but not t-butoxycarbonylamino when R 4 is dimethylamino,
[0023] R 1 is hydrogen or C 1 -C 3 alkyl, and
[0024] R is selected from the following:
[0025] (a) Alkene of the formula:
[0026] wherein R2 is optionally substituted with one or more substituents selected from alkyl, alkylhydroxy, alkylalkoxy, alkylamino, alkylaminoalkyl, or alkylaminodialkyl;
[0027] (b) Alkenylaryl of the formula:
[0028] wherein R 3 is optionally substituted with one or more substituents selected from hydrogen, alkyl, alkyenyl, ankynyl, hydroxy, alkoxy, amino, alkylamino, dialkylamino, trifluromethane, or fluoro; and
[0029] (c) Methyldienylpentyl of the formula:
[0030] wherein R 4 is optionally substituted with one or more substituents selected from hydrogen, alkyl, alkyenyl, alkynyl, hydroxy, alkoxy, amino, alkylamino, or dialkylamino; and
[0031] (d) Methylalkenylpentyl of the formula:
[0032] wherein R 4 is optionally substituted with one or more substituents selected from hydrogen, alkyl, alkyenyl, alkynyl, hydroxy, alkoxy, amino, alkylamino, or dialkylamino.
[0033] More particularly, the present invention includes a compound with the formula:
[0034] and its pharmaceutically accepted salts.
[0035] Yet another embodiment may be a compound having the formula:
[0036] and its pharmaceutically accepted salts, wherein R1 is selected from the following:
[0037] Another embodiment of the present invention is a compound comprising the formula:
[0038] and its pharmaceutically accepted salts, wherein R1 is selected from hydroxyalkene, methoxyalkene, dimethyl amino alkene and dimethyl amino methyldiene;
[0039] R2 is selected from amino, t-butoxycarbonylamino, hydrogen, phenoxycarbonylamino, and trifluromethylacetamide; and
[0040] R3 is selected from methyl and hydrogen.
[0041] Preferred combinations are set out in Table 1 immediately below:
TABLE 1 R 1 R 2 R 3 NH 2 Me NHBoc Me H H NHBoc Me NHBoc Me NHBoc Me NHC(O)OPh Me NHC(O)CF 3 Me
[0042] In Table 1, the following abbreviations are used: NH 2 is amino, NHBoc is t-butoxycarbonylamino, H is hydrogen, NHC(O)OPh is phenoxycarbonylamino, NHC(O)CF 3 is tri-fluromethylacetamide, and Me is methyl.
[0043] Further embodiments of the present invention are the following compounds:
[0044] and its pharmaceutically accepted salts.
[0045] The present invention also includes a method of making a biotinylated derivative of PatA, comprising the steps of:
[0046] The present invention includes pharmaceutical compositions and methods of treatment by administering to a person in need thereof the compounds of the present invention. The compounds of the subject invention are useful as an immunoregulator having anti-tumor, anti-fungal or anti-cancer properties. The compounds are also useful in graft versus host rejection therapy, autoimmune diseases, chemotherapy and/or treatment of infectious diseases. The compounds of the present invention overcome the limitation of the native molecule (as produced in nature), having potent activity and increased stability with the same or lower toxicity.
[0047] Pateamine A (“native pateamine A”), a marine metabolite from Mycale sp., is a potent inhibitor of the intracellular signal transduction pathway emanating from the T-cell receptor leading to the transcription of cytokines such as interleukin (IL-2). Based on the structure of native pateamine A, initial biological results, and molecular modeling studies, the presence of distinct binding and scaffolding domains in the native pateamine A structure with respect to interactions with its putative cellular receptor(s) has been shown. A simplified PatA derivative (desmethyl, desamino PatA, DMDA PatA, 3 as shown in FIG. 1) was prepared by employing a convergent Hantzsch coupling strategy via total synthesis of the molecule. This derivative was prepared in 10 fewer synthetic steps relative to native pateamine A and was found to exhibit equal to greater potency (IC 50 0.81±0.27 nM) in inhibition of IL-2 production relative to native pateamine A (IC 50 4.01±0.94 nM). In addition, as a means to find more stable derivatives and gain further insights into structure-activity relationships, PatA derivatives have been synthesized and studied in the IL-2 reporter gene assay. Many of these derivatives displayed lower potency but marked stability relative to the natural product and provide further insights into the nature of the binding domain required for activity.
[0048] A hypothesis was developed regarding a potential binding and scaffolding domain in the immunosuppressive marine natural product, pateamine A (“native pateamine A”). Premised on preliminary biological and molecular modeling studies, an analysis of the native pateamine A structure was prepared. A simplified derivative, DMDA PatA, devoid of the C3-amino and C5-methyl groups was found to have greater potency than native pateamine A in the IL-2 reporter gene assay. As evidenced in the analysis, the sector of the molecule (C1-C5) serves as a scaffold for the remaining conformationally rigid sectors (C6-C24) of the molecule including the thiazole, the dienoate, and the triene sidechain. This result is reminiscent of similar receptor binding proposals put forth in early studies of other cyclic peptide and macrocyclic immunosuppressive natural products, namely cyclosporin A, FK506, and rapamycin. Hung, D. T.; Jamison, T. F.; Schreiber, S. L. Chemistry & Biology 1996, 3, 623-639. However, in those cases, the domains were renamed effector and binding domains because these natural products were found to bind two cellular proteins acting as a molecular “glue.”
[0049] Importantly, the synthesis of this derivative (14 versus 24 steps from crotyl alcohol; longest linear sequence) is greatly simplified relative to PatA (1 as shown in FIG. 1), native pateamine A. As previously observed, C3-amino acylated derivatives retain activity in the IL-2 reporter gene assay. In addition, a subtle interplay between the dienoate sector (C18-C22) and the triene sidechain was revealed when dienoate versus enynoate-containg macrocycles were compared. The importance of macrocycle conformation and sidechain functionality in binding of native pateamine A to its putative cellular receptor is evidenced.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0050] For better understanding of the invention and to show by way of example how the invention may be carried into effect, reference is now made to the detail description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
[0051] [0051]FIG. 1 shows the chemical structure of native pateamineA, boc pateamine A and novel demda PatA.
[0052] [0052]FIG. 2 depicts the synthesis of DMDA PatA using Scheme 1.
[0053] [0053]FIG. 3 shows the synthesis of additional PatA derivatives using Scheme 2.
[0054] [0054]FIG. 4 shows the required stannanes for side chain-modified PatA derivatives using Scheme 3.
DETAILED DESCRIPTION OF THE INVENTION
[0055] The present invention is a compound of Formula I as set out below.
[0056] and its pharmaceutically accepted salts, wherein
[0057] A-B is ethane, (E) and (Z)-ethene, (E) and (Z)-substituted ethene, ethyne,
[0058] K is hydrogen or C1-C3 alkyl,
[0059] Q=NH or O,
[0060] X is hydrogen, hydroxy, alkoxy, alkyl, aminocarbonyl, amino, alkylamino, dialkylamino, alkoxycarbonylamino,
[0061] Y is S, NH, or O,
[0062] Z is hydrogen, hydroxy, aminocarbonyl, alkylamino, dialkylamino, alkoxycarbonylamino, but not t-butoxycarbonylamino when R 4 is dimethylamino,
[0063] R 1 is hydrogen or C 1 -C 3 alkyl, and
[0064] R is selected from the following:
[0065] (a) Alkene of the formula:
[0066] wherein R2 is optionally substituted with one or more substituents selected from alkyl, alkylhydroxy, alkylalkoxy, alkylamino, alkylaminoalkyl, or alkylaminodialkyl;
[0067] (b) Alkenylaryl of the formula:
[0068] wherein R 3 is optionally substituted with one or more substituents selected from hydrogen, alkyl, alkyenyl, ankynyl, hydroxy, alkoxy, amino, alkylamino, dialkylamino, trifluromethane, or fluoro; and
[0069] (c) Methyldienylpentyl of the forumula:
[0070] wherein R 4 is optionally substituted with one or more substituents selected from hydrogen, alkyl, alkyenyl, alkynyl, hydroxy, alkoxy, amino, alkylamino, or dialkylamino; and
[0071] (d) Methylalkenylpentyl of the formula:
[0072] wherein R 4 is optionally substituted with one or more substituents selected from hydrogen, alkyl, alkyenyl, alkynyl, hydroxy, alkoxy, amino, alkylamino, or dialkylamino.
[0073] Native pateamine A consists of separate binding (C6-C24) and scaffolding (C1-C5) domains. Molecular modeling studies and the total synthesis and biological analysis of a simplified derivative, devoid of the C3-amino and C5-methyl groups (DMDA PatA) is provided. The synthesis of DMDA PatA incorporates a convergency-building strategy involving a Hantzsch thiazlole coupling. In addition, the synthesis and biological testing of other pateamine A derivatives are provided having the stability in comparison to the native pateamine A structure. In particular, stabilization of the acid sensitive triallylic acetate moiety (i.e. C10 position) is provided in such derivatives.
[0074] Molecular Modeling Studies of Native Pateamine A and DMDA PatA
[0075] The presence of binding and scaffolding domains in native pateamine A were verified using molecular mechanics/dynamics (MM/MD) calculations. Simulated annealing was used to determine the conformational space of native pateamine A. An overlay of the 100 structures obtained from the simulated annealing, in which the C11-C16 segment of the triene moiety is overlaid, shows a “mushroom” structure. From the 100 structures, 13 unique conformers (Table 1) were identified within 3 kcal/mol of the lowest energy conformer. Extensive NMR studies of native pateamine A by the Munro and Blunt groups revealed a key cross-ring nOe in CDCl 3 between H C3 and H C21 (see FIG. 1 for numbering scheme), indicating that these two hydrogen atoms should be less than approximately 3 Å of one another. Robert, G. C. K., Ed.; Osford Univ. Press, 1993, Ch. 10. The MM/MD calculations gave conformers that had H C3 -H C21 distances ranging from 3.2 to 7.1 Å, and a distance of 4.3 Å for the lowest energy conformation.
[0076] To obtain better energetics and refined structures, the 13 unique conformations determined at the MM/MD level of theory, were optimized at the DFT level of theory using the B3LYP functional. Frequency calculations were performed to obtain free energies and ensure that each structure had zero imaginary frequencies. Table 2 lists the CVFF relative energies (ΔE(OK)) and H C3 -H C2 , bond distances, and B3LYP relative free energies (ΔG 0 ) and H C3 -H C21 bond distances for the 13 unique conformers.
TABLE 2 Energetics (kcal/mol) and H C3 -H C21 bond distances (Å) for the 12 unique PatA (DMDA PatA) conformers at the CVFF and B3LYP levels of theory. CVFF B3LYP a ΔE (0K) H C3 -H C21 ΔG o H C3 -H C21 Conformer (kcal/mol) Distance (Å) (kcal/mol) Distance (Å) A 0.0 4.34 9.0 (7.9) 4.96 (4.83) B 0.3 4.24 8.1 4.92 C 0.4 3.23 4.8 3.28 D 0.8 6.09 10.1 6.10 E 1.3 3.94 0.0 (0.0) 4.52 (4.37) F 1.4 6.17 13.0 5.99 G 1.4 3.24 3.3 (2.3) 3.30 (3.26) H 2.0 3.78 3.3 3.57 I 2.0 3.75 9.3 3.37 J 2.1 3.22 7.5 3.50 K 2.5 3.78 8.2 3.43 L 2.8 5.72 4.6 5.81 M 2.8 3.79 3.2 3.54
[0077] In Table 2, the following abbreviations are used: CVFF is Consistent Valence Force Field, DFT is Density Functional Theory, and B3LYP is is Becke three parameter hybrid exchange functional and the Lee-Yang-Parr correlation functional.
[0078] A large discrepancy between the CVFF and B3LYP energies with an underestimation of the difference in conformational energy by CVFF is evident. While CVFF energies were quite different from B3LYP, the structures were similar. An overlay of the 13 B3LYP optimized conformations was made. Inspection of the overlay revealed two basic conformations: 1) lower energy extended structures, leaving the majority of the triene moiety exposed and 2) higher energy conformations having the macrocycle folded over the triene moiety. DFT is known to underestimate van der Waal interactions; therefore, the H C3 -H C21 distance appeared to be underestimated.
[0079] The lowest energy conformer identified at the B3LYP level, H C3 -H C21 , has a distance of 4.5 Å, longer than anticipated in light of the cross-ring nOe. Another conformer has only 3.3 kal/mol higher in energy than the lowest energy conformer having an H C3 -H C21 distance of 3.3 Å, in much better agreement with the cross-ring nOe.
[0080] Of the 13 conformations studied, four have an H C3 -H C21 , distance less than 4 Å, and within 5 kcal/mol of the lowest energy conformer. An overlay of the conformations are within 5 kcal/mol of the lowest energy conformer and have an H C3 -H C21 , distance consistent with the NMR data. As shown in FIG. 1, the extended conformations differ primarily in the C1-C5 region, indicating a flexible region, while the thiazole, triene, and dienoate regions (C6-C22) are relatively rigid in nature. The thiazole has two conformations that are approximately 180 degrees from each other i.e. simultaneous rotation around C5-C6 and C8-C9. Therefore, the relative position of the plane containing the thiazole ring atoms in these conformations changes very little, but the nitrogen and sulfur atoms exchange positions.
[0081] Simulated annealing was also used to investigate the conformational space of DMDA PatA. An overlay of the 100 structures obtained from the simulated annealing, in which the C11-C16 segment of the triene moiety is overlaid, shows a “mushroom” structure similar to that found for native pateamine A. Due to the computational cost of the B3LYP calculations and the similar results obtained from the CVFF calculations, only three conformations (A, E, and G) were optimized at the B3LYP level of theory for DMDA PatA. The relative free energies for DMDA PatA are similar to those found for native pateamine A (Table 2) with the difference in free energy between conformations being about 1 kcal/mol less than that for native pateamine A. An overlay of the lowest energy conformer of native pateamine A and the corresponding DMDA PatA conformer was used. In addition, an overlay of the lowest energy conformer that also satisfies the nOe constraint for native pateamine A and the corresponding DMDA PatA conformer was used. As can be seen by this analysis, native pateamine A and DMDA PatA have similar structures and energetics using similar minimization parameters.
[0082] These structural studies, in combination with the previously reported potent biological activity of acylated C3-amine derivatives (e.g. 2, R=Boc), suggested the presence of possible separate binding (C6-C24) and scaffolding (C1-C5) domains in the native pateamine A structure. Romo, D.; Rzasa, R. M.; Shea, H. A.; Park, K.; Langenhan, J. M.; Sun, L.; Akhiezer, A.; Liu, J. O. J. Am. Chem. Soc. 1998, 120, 12237-12254. Many protein ligands are known to change conformations on binding to their receptors or alternatively, the binding event leads to a more defined conformation. Rosen, M. K.; Belshaw, P. J.; Alberg, D. G.; Schreiber, S. L. Bio. Med. Chem. Lett. 1992, 2, 747-753. The preliminary biological data and the modeling described above, allows synthesis of a simplified PatA derivatives including DMDA PatA that are devoid of the C3-amino and C5-methyl groups.
Synthesis of PatA Derivatives
[0083] For the synthesis of DMDA PatA 3, a more convergent strategy to the C1-12 thiazole-containing fragment employing a Hantzsch coupling reaction (FIG. 2, Scheme 1). Pattenden made use of a related-strategy in the synthesis of native pateamine A. Remuinan, M. J.; Pattenden, G. Tetrahedron Lett. 2000, 41, 7367-7371. As shown in FIG. 2, the synthesis of the requisite bromoketone 6 commenced with esterification and bromination of 6-oxoheptanoic acid (4). Hantzsch thiazole coupling between this bromoketone and the previously described thioamide 7 using modified Meyers' conditions provided thiazole 9 in good overall yield (64%). Romo, D.; Rzasa, R. M.; Shea, H. A.; Park, K.; Langenhan, J. M.; Sun, L.; Akhiezer, A.; Liu, J. O. J. Am. Chem. Soc. 1998, 120, 12237-12254; Aguilar, E.; Meyers, A. I. Tetrahedron Lett. 1994, 35, 2473-2476. A critical prerequisite for optimal yields in this coupling was purification of the intermediate thiazoline 8 prior to the dehydration step in contrast to our previous applications of this reaction, in which this process could be performed in a single pot. Romo, D.; Rzasa, R. M.; Shea, H. A.; Park, K.; Langenhan, J. M.; Sun, L.; Akhiezer, A.; Liu, J. O. J. Am. Chem. Soc. 1998, 120, 12237-12254. Deprotection of the TIPS ether followed by a Mitsunobu coupling with the TIPS protected version of the previously described enyne acid 11 gave the macrocyclic precursor 12. Id. Deprotection of the TIPS ether and trichloroethyl ester of diester 12 followed by Yamaguchi macrocyclization gave macrocycle 15. Dong, Q.; Anderson, C. E.; Ciufolini, M. A. Tetrahedron Lett. 1995, 36, 5681-5682; Inanaga, J.; Hirata, K.; Saeki, H.; Katsuki, T.; Yamaguchi, M. Chem. Soc. Japan 1979, 52, 1989-1993. Subsequent Lindlar reduction gave E,Z-diene 16 and Stille coupling with the previously described dienyl stannane 17 gave DM DAPatA (3) in 11 steps from thioamide 7. Id., see also, Farina, V.; Krishnan, B. J. Am. Chem. Soc. 1991, 113, 9585-9595.
[0084] The synthesis of additional PatA derivatives with only minor structural variations began with the previously described β-lactam 18 (FIG. 3, Scheme 2). The synthesis of all derivatives in this series mirrored that previously reported for the total synthesis of native pateamine A. Romo, D.; Rzasa, R. M.; Shea, H. A.; Park, K.; Langenhan, J. M.; Sun, L.; Akhiezer, A.; Liu, J. O. J. Am. Chem. Soc. 1998, 120, 12237-12254. Introduction of side chain via a Stille coupling reaction as the final step in the synthesis is preferred partly to the polarity introduced by the tertiary amine, but primarily due to the instability associated with the triallylic ester moiety.
[0085] Derivatives 23-25 and 26-28 were prepared to determine the structural flexibility tolerated on the sidechain of PatA and also to improve stability of the acid labile triallylic acetate moiety by removal of one unsaturation. For this purpose, the required stannanes for sidechain-modified PatA derivatives were prepared by standard conditions and stannylcupration was performed as described previously for vinyl stannane 17 (FIG. 4, Scheme 3). Romo, D.; Rzasa, R. M.; Shea, H. A.; Park, K.; Langenhan, J. M.; Sun, L.; Akhiezer, A.; Liu, J. O. J. Am. Chem. Soc. 1998, 120, 12237-12254. The C3-Boc protecting group had previously been found to have a minor effect on activity (2-3 fold decrease in activity), therefore for ease of handling, this group was retained in all derivatives. PatA derivatives bearing a dienyl alcohol (23 and 26) and a dienyl methyl ether (26 and 27) were synthesized. In addition, derivative 25 bearing the identical side-chain found in PatA with the exception of one unsaturation and the C16 methyl group was prepared. The effect of a more rigid macrocycle (i.e. enyne vs dienoate) on biological activity was investigated by synthesis of enynes 26-29. These derivatives were readily prepared by omission of the Lindlar reduction step (FIG. 3, Scheme 2).
[0086] Due to the aforementioned activity of C3-Boc PatA, two additional C3-amino derivatives were prepared with the expectation that they should have similar potency. In this regard, the C3-phenyl carbamate 32 and the C3-trifluoroacetamide 33 were synthesized by deprotection of Boc-macrocycle 21 followed by acylation to give macrocycles 30 and 31. Subsequent Lindlar reduction and Stille reaction gave the C3-acylated derivatives 32 and 33.
[0087] The ability of these derivatives to inhibit T cell receptor-mediated IL-2 production was analyzed using an IL-2 reporter gene assay. In this assay, a plasmid encoding a reporter gene (luciferase) under the control of the IL-2 promoter was first introduced into Jurkat T cells by transfection. The transfected Jurkat T cells are then stimulated with two pharmacological agents, phorbol myristyl acetate (PMA), which activates protein kinase C, and inonmycin, which allows calcium ion to enter T cells to activate calmodulin and calcineurin. Together, PMA and ionomycin recapitulate T cell receptor signaling, leading to the activation of the luciferase reporter gene by activating the IL-2 promoter. The ability of PatA and its analogs to block T cell receptor-mediated IL-2 expression was measured by their effects on this reporter gene assay. Su, B.; Jacinto, E.; Hibi, M.; Kallunki, T.; Karin, M.; Ben-Neriah, Y. Cell 1994, 77, 727-736.
[0088] Most derivatives were in general less potent than native pateamine A, PatA (1). As expected, the C3-phenyl carbamate derivative 32 was found to have comparable activity (˜15 nM) to BocPatA (2, 16-17 nM). However, the reduced activity of the trifluoroacetamide 33 (˜303 nM) may be due to the increased polarity of this substituent leading to poorer cell permeability. However, a possible trend was observed upon comparison of dienoate macrocyclic (23-25) versus enynoate macrocyclic (26-29) derivatives. Enyne derivatives having an a more rigid macrocycle than the natural product and bearing oxygen rather than nitrogen at the terminus of the side chain (i.e. 26 and 27) were found to have activities in the IL-2 reporter gene assay ranging from 55-335 nM. However, enyne derivatives (i.e. 28 and 29) with side chains more closely resembling the natural product (i.e. amino end groups) had no activity. Futhermore, the dienoate derivatives (i.e. 23 and 24) having macrocycle conformations similar to the natural product but bearing oxygen rather than nitrogen at the terminus of the side chain had very low activity. However, once nitrogen is introduced into the sidechain, as in derivative 25, activity is restored (328 nM). Thus, it would appear that an oxygenated side-chain compensates for the change in macrocycle conformation that occurs upon introduction of an enyne. However, oxygen rather than nitrogen on the side chain leads to low activity when coupled to the natural dienoate-containing macrocycle. It is imaginable that changes in the conformation of the macrocycle results in a reorientation of the sidechain that cannot be accommodated by the protein receptor. However, replacement of a charged tertiary amino group with a neutral and smaller hydroxyl or methoxy groups allows for the binding of the derivative with these two structural alterations.
[0089] The derivative providing direct support for the binding/scaffolding hypothesis is DMDA PatA 3. This derivative displayed similar to greater potency (IC 50 0.8±0.3 nM) relative to natural pateamine PatA (IC 50 4.0±0.9 nM) in its ability to inhibit expression of the IL-2 reporter gene in stimulated Jurkat T cells. The hypothesis that the C1-C5 segment of native pateamine A does not interact directly with its putative cellular receptor but may serve as a scaffold to define and maintain the macrocyclic conformation is supported in accordance with the results above. Importantly, DMDA PatA 3 is more stable than native pateamine A (stable in CDCl 3 for 3-4 weeks at 25° C.). Native pateamine A decomposes in CDCl 3 at 25° C. in <10 minutes.
TABLE 3 IL-2 reporter gene assay (transfected Jurkat cells) activity of pateamine A and derivatives. cmpd. R 1 IC 50 (nM) cmpd. R 1 R 2 R 3 IC 50 (mM) 26 335 ± 183 PatA (1) NH 2 Me 4.01 ± 0.938 27 55.1 ± 15.5 3 ″ H H 0.808 ± 0.274 28 NA a 23 NHBoc Me >1000 b 29 NA a 24 NHBoc Me >1000 b 25 NHBoc Me 328 ± 119 32 ″ NHC(O) Me 15.4 ± 6.05 OPh 33 ″ NHC(O) Me 303 ± 93.2 CF 3
[0090] The present invention also encompasses pharmaceutically acceptable salts of Formula I where they can be formed. Pharmaceutically acceptable salts may be formed from Formula B compounds and a pharmaceutically acceptable organic or inorganic acid including, but not limited to hydrochloric acid, sulfuric acid, phosphoric acid, acetic acid, maleic acid, fumaric acid, toluenesulfonic acid, benzoic acid, succinic acid and the like. Such salts may be formed during or after the synthesis of the compound of Formula I.
[0091] In general, a pharmaceutically acceptable salt of the present invention may be administered in a pharmaceutically acceptable carrier to an animal or a human. In order to obtain systemic immune suppression, injection of the compound in a liquid carrier such as saline may prove suitable. For local effects, topical administration in an ointment or cream may have better function. All carriers should be chosen so as not to counteract the desired effects of the compound (immunosuppression or immunostimulation). Additionally, carriers should be chosen to promote the stability of the compound. In both in vitro and in vivo applications, more than one compound of Formula I may be combined with another compound of Formula I or a different compound all together to achieve multiple effects or a synergistic effect.
[0092] Immunosuppressive compounds of Formula I may be used to prevent long-term or short-term transplant rejection. Immunostimulant compounds may be used to counter autoimmune diseases, provide chemotherapy or other cancer treatments and to fight infections, including fungal infections.
[0093] The active compounds disclosed herein may be orally administered, for example, with an inert diluent or with an assimilable edible carrier, or they may be enclosed in hard or soft shell gelatin capsule, or they may be compressed into tablets, or they may be incorporated directly with the food of the diet. For oral therapeutic administration, the active compounds may be incorporated with excipients and used in the form of ingestible tablets, buccal tables, troches, capsules, elixirs, suspensions, syrups, wafers, and the like. Such compositions and preparations should contain at least 0.1% of active compound. The percentage of the compositions and preparations may, of course, be varied and may conveniently be between about 2 to about 60% of the weight of the unit. The amount of active compounds in such therapeutically useful compositions is such that a suitable dosage will be obtained.
[0094] The tablets, troches, pills, capsules and the like may also contain the following: a binder, as gum tragacanth, acacia, cornstarch, or gelatin; excipients, such as dicalcium phosphate; a disintegrating agent, such as corn starch, potato starch, alginic acid and the like; a lubricant, such as magnesium stearate; and a sweetening agent, such as sucrose, lactose or saccharin may be added or a flavoring agent, such as peppermint, oil of wintergreen, or cherry flavoring. When the dosage unit form is a capsule, it may contain, in addition to materials of the above type, a liquid carrier. Various other materials may be present as coatings or to otherwise modify the physical form of the dosage unit. For instance, tablets, pills, or capsules may be coated with shellac, sugar or both. A syrup of elixir may contain the active compounds sucrose as a sweetening agent methyl and propylparabens as preservatives, a dye and flavoring, such as cherry or orange flavor. Of course, any material used in preparing any dosage unit form should be pharmaceutically pure and substantially non-toxic in the amounts employed. In addition, the active compounds may be incorporated into sustained-release preparation and formulations.
[0095] The active compounds may also be administered parenterally or intraperitoneally. Solutions of the active compounds as free base or pharmacologically acceptable salts 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 and in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
[0096] 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 exists. It must be stable under the conditions of manufacture and storage and must be preserved against the contaminating action of microorganisms, such as bacteria and fungi. The carrier can be a solvent or dispersion medium containing, for example, water, ethanol, polyol (for example, glycerol, propylene glycol, and liquid polyethylene glycol, and the like), suitable mixtures thereof, and vegetable oils. The proper fluidity can be maintained, for example, by the use of a coating, such as lecithin, by the maintenance of the required particle size in the case of dispersion and by the use of surfactants. The prevention of the action of microorganisms can be brought about by various antibacterial ad antifungal agents, for example, parabens, chlorobutanol, phenol, sorbic acid, thimerosal, and the like. In many cases, it will be preferable to include isotonic agents, for example, sugars or sodium chloride. Prolonged absorption of the injectable compositions can be brought about by the use in the compositions of agents delaying absorption, for example, aluminum monostearate and gelatin.
[0097] Sterile injectable solutions are prepared by incorporating the active compounds in the required amount in the appropriate solvent with various of the other ingredients enumerated above, as required, followed by filtered sterilization. Generally, dispersions are prepared by incorporating the various sterilized active ingredients into a sterile vehicle which contains the basic dispersion medium and the required other ingredients from those enumerated above. In the case of sterile powders for the preparation of sterile injectable solutions, the preferred methods of preparation are vacuum-drying and freeze-drying techniques which yield a powder of the active ingredient plus any additional desired ingredient from a previously sterile-filtered solution thereof.
[0098] As used herein, “pharmaceutically acceptable carrier” includes any and all solvents, dispersion media, coatings, antibacterial and antifungal agents, isotonic and absorption delaying agents and the like. The use of such media and agents for pharmaceutical active substances is well known in the art. Except insofar as any conventional media or agent is incompatible with the active ingredient, its use in the therapeutic compositions is contemplated. Supplementary active ingredients can also be incorporated into the compositions.
[0099] For oral prophylaxis the polypeptide may be incorporated with excipients and used in the form of non-ingestible mouthwashes and dentifrices. A mouthwash may be prepared incorporating the active ingredient in the required amount in an appropriate solvent, such as a sodium borate solution (Dobell's Solution). Alternatively, the active ingredient may be incorporated into an antiseptic wash containing sodium borate, glycerin and potassium bicarbonate. The active ingredient may also be dispersed in dentifrices, including: gels, pastes, powders and slurries. The active ingredient may be added in a therapeutically effective amount to a paste dentifrice that may include water, binders, abrasives, flavoring agents, foaming agents, and humectants.
EXAMPLES
Example 1
Synthesis of Biotin-PEO-macrocycle
[0100] [0100]
[0101] To a stirred solution of amino diene macrocycle (6 mg, 0.0117 mmol) in DMF were added biotin-PEO-iodide (6.3 mg, 0.017 mmol) and K 2 CO 3 (3.2 mg, 0.0234 mmol). After 15 h, an additional amount of biotin-PEO-iodide (6.3 mg, 0.0117 mmol) was added. The resulting solution was stirred at 25° C. for 16 h and concentrated in vacuo. Purification of the residue by directly loading on a flash column containing SiO 2 and eluting with EtOAc:n-Hex.:Et 3 N (45:52:8) to CHCl 3 :MeOH (9:1) gave 8.5 mg (78%) of biotin-PEO-diene macrocycle as a pale yellowish oil: 1 H-NMR (500 MHz, CDCl 3 ) δ 7.69 (t, J=6 Hz, 1H), 7.01 (d, J=7.2 Hz, 1H), 6.77 (s, 1H), 6.72 (dd, J=6.6, 7.2 Hz, 1H), 6.52 (br s, 1H), 6.01 (dt, J=2, 9.5 Hz), 5.94 (d, J=9.5 Hz, 1H), 5.79 (br s, 2H), 5.42 (d, J=6.6 Hz, 1H), 5.12 (br s, 1H), 5.08-5.04 (m, 1H), 4.51-4.48(m, 1H), 4.33-4.30 (m, 1H), 3.61-2.84 (m, 15H), 2.45 (s, 3H), 2.33-1.21 (m, 18H), 1.99 (s, 5H), 1.80 (s, 3H); MS (ESI) m/z 927 [M+H] + .
Example 2
Biotin-PEO-Pateamine A
[0102] [0102]
[0103] To a flask charged with Pd 2 dba 3 .CHCl 3 (1.7 mg, 0.0016 mmol) and triphenyl arsine (4.1 mg, 0.013 mmol) was added 0.1 mL of degassed THF (by several freeze/thaw cycles). The final concentration of this palladium catalyst stock solution was 0.031 M. To a solution of Biotin-PEO-diene macrocycle (7 mg, 0.0075 mmol) and tributylstannyl dimethyl amino diene (9.3 mg, 0.0225 mmol) in 0.1 ml of THF was added 0.024 mL of palladium catalyst. The resulting solution was stirred at 25° C. for 14 h. and concentrated in vacuo. Purification of the residue by directly loading on a C18 reverse phase chromatography eluting with H 2 O:CH 3 CN:AcOH:Et 3 N (65:35:3 mmol:1.5 mmol) gave 2.1 mg of biotin-PEO-pateamine A as a pale yellowish oil. The residue was loaded on an amino cartridge pre-equilibrated with MeOH and eluted with MeOH to give 2.1 mg (29%) of biotin-PEO-pateamine A as a pale yellowish oil: 1 H-NMR (500 MHz, benzene-d6) δ 7.78 (br t, 1H), 6.67-6.60 (m, 1H), 6.53 (s, 1H), 6.51 (dd, J=12, 6.5 Hz, 1H), 6.37 (br s, 1H), 6.28 (d, J=16 Hz, 1H), 6.18 (d, J=16 Hz, 1H), 5.66 (br t, 1H), 5.61 (d, J=12 Hz, 1H), 5.46 (d, J=9 Hz, 1H), 5.04-4.98 (m, 1H), 4.80 (br s, 1H), 3.06-2.07 (m, 22H), 2.07 (s, 6H), 1.93-0.78 (m, 12H), 1.84 (s, 3H), 1.75 (s, 3H), 1.66 (s, 3H), 1.51 (s, 3H), 1.31 (d, J=6.5 Hz, 3H), 1.01 (d, J=6.5 Hz, 3H); HRMS (ESI) Calcd for C 49 H 75 N 7 O 9 S 2 [M+H]: 970.5145 Found: 970.5135
Example 3
Molecular Modeling Details
[0104] Molecular mechanics and dynamics calculations were performed using the OFF (Open Force Field) program with CVFF 950 (Consistent Valence Force Field) as implemented in Cerius 4.6 (Accelrys, Inc., San Diego, Calif.). Simulated annealing was carried out for 280.0 ps, over a temperature range of 300-500 K, using the Nose temperature thermostat, a relaxation time of 0.1 ps, and a time step of 0.001 ps. After each annealing step, the structure was minimized, leading to 100 minimized structures. A dielectric constant of 86.75 was used to simulate bulk solvation in water. A rigid body least squares fit algorithm (as implemented in Cerius 4.6) was used to overlay the 100 structures obtained from the simulated annealing and the 16 B3LYP optimized structures. The carbons belonging to the triene region were the only atoms used in the least squares fit. After all molecules were overlayed, a visual inspection of the 24 structures within 3 kcal/mol of the lowest energy structure was used to extract 13 unique conformations of the flexible ring portion of the molecule. Full geometry optimizations (gas phase) and frequency calculations were performed for the 13 unique conformations using Density Functional Theory (DFT) with the Becke three parameter hybrid exchange functional and the Lee-Yang-Parr correlation functional (B3LYP) as implemented in the Gaussian 98 suite of programs. Parr, R. G.; Yang, W. Density-functional theory of atoms and molecules Oxford Univeristy Press, Oxford, 1989; Becke, A. D.; Phys. Rev. A. 1988, 38, 3098; Becke, A. D. J. Chem. Phys. 1993, 98, 1372; Becke, A. D. J. Chem. Phys. 1993, 98, 5648; Lee, C.; Yang, W.; Parr, R. G. Physical Review B 1988, 37, 785; Gaussian 98 (Rev. A.9), Frisch, M. J.; Trucks, G. W.; Schlegel, H. B.; Scuseria, G. E.; Robb, M. A.; Cheeseman, J. R.; Zakrzewski, V. G.; Montgomery, J. A.; Stratmann, R. E.; Burant, J. C.; Dapprich, S.; Millam, J. M.; Daniels, A. D.; Kudin, K. N.; Strain, M. C.; Farkas, O.; Tomasi, J.; Barone, V.; Cossi, M.; Cammi, R.; Mennucci, B.; Pomelli, C.; Adamo, C.; Clifford, S.; Ochterski, J.; Petersson, G. A.; Ayala, P. Y.; Cui, Q.; Morokuma, K.; Malick, D. K.; Rabuck, A. D.; Raghavachari, K.; Foresman, J. B.; Cioslowski, J.; Ortiz, J. V.; Stefanov, B. B.; Liu, G.; Liashenko, A.; Piskorz, P.; Komaromi, I.; Gomperts, R.; Martin, R. L.; Fox, D. J.; Keith, T.; Al-Laham, M. A.; Peng, C. Y.; Nanayakkara, A.; Gonzalez, C.; Challacombe, M.; Gill, P. M. W.; Johnson, B. G.; Chen, W.; Wong, M. W.; Andres, J. L.; Head-Gordon, M.; Replogle E. S.; Pople, J. A.; Gaussian, Inc., Pittsburgh Pa., 1998. A double-ζ quality basis set was used to describe C, N, O, and H (6-31 G) and a double-ζ quality basis set with a polarization function was used to describe S (6-31G*). Hehre, W. J.; Ditchfield, R.; Pople, J. A. J. Chem. Phys. 1972, 56, 2257; Francl, M. M.; Petro, W. J.; Hehre, W. J.; Binkley, J. S.; Gordon, M. S.; DeFrees, D. J.; Pople, J. A. J. Chem. Phys. 1982, 77, 3654.
Example 4
Trichloroethyl Ester 5
[0105] To a stirred solution of 6-oxoheptanoic acid (2.0 g, 12.58 mmol) in benzene (40 mL) was added trichloroethanol (1.08 mL, 11.32 mmol) and SOCl 2 (1.1 mL, 15.1 mmol). The solution was refluxed for 8 h and then evaporated and diluted with 30 mL of EtOAc. The layers were separated and the aqueous layer was extracted with EtOAc. The combined organic layers were washed with brine, dried over MgSO 4 and concentrated in vacuo. Purification of the residue by flash column chromatography on SiO 2 eluting with EtOAc:hexanes (20:80) gave 2.1 g (61%) of ester 5 as a light yellow oil: 1 H NMR (300 MHz, CDCl 3 ) δ 4.71(s, 2H), 2.46-2.42 (m, 4H), 2.11 (s, 3H), 1.65-1.62 (m, 4H); C NMR (75 MHz, CDCl 3 ) δ 208.4, 171.8, 95.6, 74.1, 43.2, 33.8, 30.1, 24.3, 23.2; IR (neat) 2956, 1762, 1720 cm −1 .
Example 5
α-Bromoketo Ester 6
[0106] To a cooled (0° C.), stirred solution of 6-oxoheptanoic ester (1.00 g, 3.62 mmol) in CHCl 3 (20 mL) was slowly added bromine (0.20 mL, 3.98 mmol) in CCl 4 over a 1 h period and the solution was stirred at 0° C. for 3 h. The reaction mixture was diluted with 30 mL of CH 2 Cl 2 . The organic layer was washed with satd. aqueous NaHCO 3 solution, brine, and then dried over MgSO 4 and concentrated in vacuo. Rapid purification of the residue by flash column chromatography on SiO 2 eluting with EtOAc:hexanes (10:90) gave 465 mg (36%) of α-bromoester 6 as a yellow oil:H NMR (300 MHz, CDCl 3 ) δ 4.78 (s, 2H), 3.92 (s, 2H), 2.79-2.72 (m, 2H), 2.59-2.48 (m, 2H), 1.81-1.71 (m, 4H)); C NMR (75 MHz, CDCl 3 ) δ 201.7, 171.7, 95.2, 74.1, 39.4, 34.4, 33.8, 24.2, 23.2; IR (neat) 2934, 1753, 1710 cm −1 ; HRMS (ESI) Calcd for C 9 H 12 BrCl 3 O 3 [M+H]: 376.8903 Found: 376.8901. Schreiber, S. L.; Hung, D. T.; Jamison, T. F. Chem. Biol. 1996, 3, 623-639.
Example 6
Thiazole 9
[0107] To a cooled (−5° C.), stirred solution of α-bromoketo ester 6 (354 mg, 1.0 mmol) in CH 2 Cl 2 (20 mL) was added 2,6-lutidine (0.232 mL, 2.0 mmol) and thioamide 7 (380 mg, 1.0 mmol). The solution was stirred at 25° C. for 12 h and then diluted with 30 mL of CH 2 Cl 2 . The organic layer was washed with brine, dried over MgSO 4 and concentrated in vacuo. Rapid purification of the residue by flash column chromatography on SiO 2 eluting with EtOAc:hexanes (20:80) gave 528 mg of the intermediate thiazoline 8 as a colorless oil and as a mixture of diastereomers which was used directly in the next step. Some spectral data is provided: 1 H NMR (300 MHz, CDCl 3 ) δ 5.91 (dt, J=1.8, 9 Hz, 1H), 4.82-4.77 (m, 1H), 4.77(s, 2H), 3.29 (s, 2H), 2.91-2.81 (m, 2H), 2.72 (ddd, J=7.2, 8.7, 14.1, 1H), 2.53 (t, J=7.5 Hz, 2H), 2.29 (s, 2H), 1.89 (t, J=9.3 Hz, 2H), 1.78 (t, J=7.2 Hz, 2H), 1.63-1.48 (m, 4H); C NMR (75 MHz, CDCl 3 ) δ 172.1, 134.9, 108.5, 74.1, 68.9, 68.6, 43.6, 43.5, 43.4, 43.2, 40.9, 34.1, 25.2, 24.7, 23.7, 18.3. 18.1, 12.5. To a cooled (0° C.), stirred solution of thiazoline (528 mg, 0.807 mmol) in CH 2 Cl 2 (10 mL) was added Hünig's base (1.26 mL, 7.26 mmol), pyridine (200 μL, 2.42 mmol) and TFAA (341 μL, 2.42 mmol) and the solution was stirred at 25° C. for 3 h and then diluted with 30 mL of CH 2 Cl 2 . The organic layer was washed with satd. aqueous NaHCO 3 , brine, dried over MgSO 4 and concentrated in vacuo. Purification of the residue by flash column chromatography on SiO 2 eluting with EtOAc:hexanes (20:80) gave 405 mg (80%) of thiazole 9 as a yellow oil: 1 H NMR (300 MHz, CDCl 3 ) δ 6.78 (s, 1H), 5.89 (dd, J=0.6, 8.7 Hz, 1H), 4.80 (dt, J=6.0, 9.0 Hz, 1H), 4.76 (s, 2H), 3.25 (dd, J=6.3, 14.1 Hz, 1H), 3.13 (dd, J=6.3, 14.1 Hz, 1H), 2.80-2.75 (m, 2H), 2.54-2.50 (m, 2H), 2.11 (s, 3H), 1.85-1.72 (m, 4H), 1.04 (s, 21H); C NMR (75 MHz, CDCl 3 ) δ 172.1, 165.4, 156.6, 135.1, 121.5, 113.4, 95.2, 74.1, 70.3, 42.2, 33.9, 31.3, 28.8, 24.5, 24.2, 18.2, 12.5; HRMS (ESI) Calcd for C 24 H 40 BrCl 3 NO 3 SSi [M+H]: 634.0717 Found: 634.0748.
Example 7
Thiazole Enyne 12
[0108] To a cooled (−20° C.), stirred solution of thiazole 8 (53 mg, 3.62 mmol) in THF (1.0 mL) was added 0.20 mL of 1M TBAF (0.20 mmol) buffered with 20 mol % AcOH and the solution was stirred at −20° C. for 3 h. The reaction mixture was diluted with 10 mL of CH 2 Cl 2 . The organic layer was washed with satd. aq. NaHCO 3 , brine, dried over MgSO 4 and concentrated in vacuo. Crude purification of the residue by flash column chromatography on SiO 2 eluting with EtOAc:hexanes (20:80→50:50) gave 38 mg of alcohol 10 as a light yellow oil which was used directly in the next step. To a solution of DIAD (0.032 mL, 0.167 mmol) in THF (0.5 mL) was added PPh 3 (35 mg, 0.1336 mmol) as a solid and the solution was stirred at ambient temperature for 30 min. The resulting heterogeneous mixture was cooled (−20° C.) and the solution of acid (30 mg, 0.0935 mmol) in THF (0.2 mL) was added. After 20 min, a solution of alcohol (32 mg, 0.0668 mmol) in THF (0.2 mL) was added and stirring was continued for 1 h. The reaction was quenched by addition of 2 mL pH 7 buffer followed by warming to 25° C. and diluting with 20 mL of EtOAc. The layers were separated and the aqueous layer was extracted with EtOAc. The combined organic layers were washed with brine, dried over Na 2 SO 4 and concentrated in vacuo. Purification of the residue by flash column chromatography on SiO 2 eluting with EtOAc:hexanes (10:90) gave 37 mg (71%) of thiazole enyne 12 as a light yellow oil: 1 H NMR (300 MHz, CDCl 3 ) δ 6.77 (s, 1H), 5.87 (dd, J=1.2, 9.6 Hz, 1H), 5.79-5.72 (m, 1H), 5.38 (d, J=1.2 Hz, 1H), 4.71 (s, 2H), 4.13-4.07 (m, 1H), 3.36 (dd, J=6.9, 14.7 Hz, 1H), 3.24 (dd, J=6.9, 14.7 Hz, 1H), 2.74 (t, J=6.9 Hz, 1H), 2.48 (t, J=6.9 Hz, 2H), 2.39 (dd, J=5.4, 14.7 Hz, 1H), 2.23 (dd, J=5.4, 14.7 Hz, 1H), 2.26 (d, J=1.2 Hz, 1H), 1.99 (d, J=1.5 Hz, 3H), 1.77-1.69 (m, 4H), 1.24-1.22 (m, 2H), 1.11 (d, J=6.3 Hz, 3H), 1.03 (s, 21H); HRMS (ESI) Calcd for C 33 H 50 BrCl 3 NO 5 SSi [M+H]: 784.1428 Found: 784.1434.
Example 8
Alcohol 13
[0109] To a stirred solution of silylether (30 mg, 0.038 mmol) in THF (0.5 mL) was added 20 mol % AcOH/TBAF (0.095 mL, 0.095 mmol). The resulting solution was stirred at 25° C. for 12 h. The reaction mixture was diluted with 10 mL of CH 2 Cl 2 . The combined organic layers were washed with satd. aqueous NaHCO 3 , brine, dried over MgSO 4 and concentrated in vacuo. Purification of the residue by flash column chromatography on SiO 2 eluting with EtOAc:hexanes (50:50) gave 18 mg (75%) of alcohol 13 as a pale yellow oil:H NMR (500 MHz, CDCl 3 ) δ6.84 (s, 1H), 5.92 (dd, J=1.2, 6.9 Hz, 1H), 5.86-5.79 (m, 1H), 5.48 (s, 1H), 4.77 (s, 2H), 4.07-4.01 (m, 1H), 3.43 (dd, J=6.9, 14.7 Hz, 1H), 3.29 (dd, J=6.9, 14.7 Hz, 1H), 2.81 (t, J=6.6 Hz, 2H), 2.54 (t, J=6.9 Hz, 1H), 2.32 (d, J=1.5 Hz, 3H), 2.07 (d, J=1.2 Hz, 3H), 1.80-1.76 (m, 4H), 1.26 (d, J=6.3 Hz, 3H); C NMR (125 MHz, CDCl 3 ) δ 172.1, 171.4, 163.7, 158.5, 156.9, 153.2, 128.6, 128.1, 113.8, 105.2, 85.6, 83.7, 74.1, 71.6, 65.9, 48.9, 38.0, 33.9, 31.2, 28.7, 24.5, 23.6, 20.7, 14.4; HRMS (ESI) Calcd for C 24 H 39 BrCl 3 NO 5 S [M+H]: 628.0094 Found: 628.0073.
Example 9
Macrocycle 15
[0110] To a stirred solution of alcohol 13 (10 mg, 0.0158 mmol) in THF (0.2 mL) and 1M NH 4 OAc (0.2 mL) was added 10% Cd/Pd couple (5.0 mg) The resulting solution was stirred at 25° C. for 2 h. The reaction mixture was diluted with 10 mL of EtOAc and then filtered through a celite pad. The organic layer was washed with brine, dried over MgSO 4 and concentrated in vacuo. The crude hydroxy acid 14 was submitted directly to macrocyclization conditions without purification. To a cooled (0° C.) stirred solution of hydroxy acid 14 (8 mg, 0.016 mmol) in THF (0.5 mL) was added Et 3 N (13 μL, 0.096 mmol) and 2,4,6-trichlorobenzoyl chloride (12.5 μL, 0.08 mmol). The resulting solution was stirred at 0° C. for 20 min and then added to a solution of DMAP (19.5 mg, 0.16 mmol) in toluene (8 mL) at 25° C. and stirred for 2 h. The reaction mixture was diluted with 10 mL of EtOAc. The organic layer was washed with brine, dried over MgSO 4 and concentrated in vacuo. Purification of the residue by flash column chromatography on SiO 2 eluting with EtOAc:hexanes (30:70) gave 7.0 mg (92%, 2 steps) of macrocycle 15 as a pale yellow oil: 1 H NMR (300 MHz, CDCl 3 ) δ 6.82 (s, 1H), 6.06 (dd, J=1.2, 9.3 Hz, 1H), 5.93-5.86 (m, 1H), 5.35 (s, 1H), 5.33-5.26 (m, 1H), 3.34 (br d, J=7.5 Hz, 2H), 2.81-2.61 (m, 2H), 2.46-2.39 (m, 1H), 2.43 (d, J=1.5 Hz, 3H), 2.30 (d, J=6.9 Hz, 2H), 1.96 (d, J=1.2 Hz, 3H), 1.90-1.68 (m, 3H), 1.57-1.45 (m, 3H), 1.28 (d, J=6.3 Hz, 3H); HRMS (ESI) Calcd for C 22 H 27 Br Cl 3 NO 4 S [M+H]: 480.0844 Found: 480.0760.
Example 10
DMDA PatA (3)
[0111] A slurry of Pd/CaCO 3 poisoned with Pb (5.0 mg) and macrocycle 15 (5.0 mg, 0.0104 mmol) in 0.3 mL of MeOH was evacuated under water aspirator pressure and purged with H 2 . After stirring at 25° C. for 12 h under 1 atm of H 2 , the reaction was filtered through Celite, concentrated in vacuo. Passage through a plug of SiO 2 eluting with EtOAc:hexanes (50:50) gave 4.6 mg (92%) of E,Z-macrocycle 16 as a colorless oil: 1 H NMR (300 MHz, CDCl 3 ) δ 7.02 (d, J=11.7 Hz, 1H), 6.72 (s, 1H), 6.71 (dd, J=11.7 Hz, 1H), 6.08 (dt, J=4.5, 16.5 Hz, 1H), 5.97 (dq, J=1.2, 9.6 Hz, 1H), 5.36 (d, J=11.7 Hz, 1H), 5.23-5.12 (m, 1H), 3.27-3.14 (m, 2H), 2.93-2.83 (m, 1H), 2.60 (ddd, J=4.5, 10.5, 1.4 Hz, 1H), 2.53-2.47 (m, 1H), 2.51 (s, 3H), 2.41-2.13 (m, 4H), 1.86 (s, 3H), 1.77-1.61 (m, 2H), 1.44-1.29 (m, 2H), 1.27 (d, J=6.6 Hz, 3H). This material was directly used in the next reaction without further purification. To a flask charged with Pd 2 dba 3 .CHCl 3 (1.7 mg, 0.0016 mmol) and triphenyl arsine (4.1 mg, 0.013 mmol) was added 0.1 mL of degassed THF prepared by several freeze/thaw cycles. The final concentration of this palladium catalyst stock solution was ˜0.031 M. To a solution of macrocycle 16 (4.0 mg, 0.0083 mmol) and stannane 17 (7.0 mg, 0.0166 mmol) in 0.1 mL of THF was added 0.027 mL (0.000837 mmol, 10 mol %) of palladium catalyst stock solution. The resulting solution was stirred at 25° C. for 2 h and concentrated in vacuo. Purification of the residue by flash column chromatography on SiO 2 eluting with EtOAc:hexanes:Et 3 N (45:52:8) gave 2.1 mg (49%) of DMDAPatA (3) as a pale yellow oil: 1 H NMR (500 MHz, C 6 D 6 ) δ 7.47 (d, J=12.0 Hz, 1H), 6.71 (app dt, J=5.0, 9.0 Hz, 1H), 6.45 (app t, J=11.5 Hz, 1H), 6.32 (d, J=16.0 Hz, 1H), 6.21 (d, J=16.0 Hz, 1H), 6.17 (s, 1H), 5.69 (t, J-7 Hz, 1H), 5.55 (d, J=11.5 Hz, 1H), 5.49 (d, J=9.0 Hz, 1H), 5.19-5.11 (m, 1H), 3.08-3.01 (m, 2H), 2.91 (d, J=6.5 Hz, 2H), 2.78 (dt, J=4.5, 14.0 Hz, 1H), 2.48-2.42 (m, 1H), 2.33 (ddd, J=4.0, 10.0, 14.5 Hz, 1H), 2.11 (s, 6H), 2.16-2.03 (m, 2H), 1.90 (d, J=1.0 Hz, 3H), 1.71 (2, 3H), 1.64-1.61 (m, 1H), 1.56-1.43 (m, 2H), 1.54 (s, 3H), 0.96-0.81 (m, 2H), 0.95 (d, J=6.5 Hz, 3H); HRMS (ESI) Calcd for C 30 H 43 N 2 O 4 S [M+H]: 527.2944 Found: 527.2927.
[0112] The complete content of all publications, patents and patent applications cited in this description are herein incorporated by reference as if each individual publication, patent or patent application.
[0113] The foregoing invention has been described above in some detail by way of illustration and example for the purposes of clarity of understanding. The above examples are provided for exemplification purposes only and are not intended to limit the scope of the invention, which has been described in broad terms before the examples. It will be readily apparent to one skilled in the art in light of the teachings of this invention that changes and modifications can be made without departing from the spirit and scope of the present invention.
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The present invention provides a compound of Formula I, all of its related stereoisomers, and their pharmaceutically acceptable salts, wherein A-B, K, Q, X, Y, Z, R and R1 are as defined in claim 1. The present invention also provides processes for the preparation thereof, the use thereof in treating immune mediated disease and conditions, and pharmaceutical compositions for use in such therapy.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. patent application Ser. No. 10/157,787, filed May 29, 2002, which claims priority to U.S. patent application Ser. No. 10/092,021, filed Mar. 6, 2002, which claims priority to U.S. Provisional Patent Application Nos. 60/288,032, filed May 2, 2001; and 60/273,724, filed Mar. 6, 2001, all of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the production of the alkyl sulfate of sulfated dextrin, the production of the alkyl sulfate of sulfated dextran, and to the use of these compounds to provide antiviral activity, particularly in the treatment and prevention of sexually-transmitted diseases.
[0004] 2. Description of Related Art
[0005] Compounds exhibiting activity against viruses may function by a number of mechanisms: they may kill or disable the disease pathogens, they may inhibit the entry of the pathogen into cells, or they may prevent replication of the pathogen once it has entered a cell. All of these mechanisms are being studied to prevent and treat viral infection, including those resulting in diseases that can be sexually transmitted, such as Acquired Immunodeficiency Disease Syndrome (AIDS).
[0006] The generally accepted theory is that AIDS is caused by the Human Immunodeficiency Virus (HIV). There are two different versions of HIV: HIV-1 and HIV-2. These viruses are believed, on the basis of their genetic sequences, to have evolved from the Simian Immunodeficiency Virus (SIV), with HIV-2 being much more similar to SIV. Several years after the initial HIV infection, the immune system is weakened to the point where opportunistic infections occur, resulting in the syndrome of AIDS.
[0007] Research has revealed a great deal of valuable medical, scientific, and public health information about HIV and AIDS. HIV molecules whose structures are known include reverse transcriptase (RT), proteases of HIV-1 and HIV-2, the catalytic domain of HIV integrase (INT), the HIV matrix protein, the HIV capsid protein and several fragments of CD4. HIV macromolecules whose structures are being investigated include the surface glycoproteins (gp160, gp120, gp41), and the regulatory proteins (tat, rev, vpr, tar).
[0008] The ways in which HIV can be transmitted have been clearly identified. HIV is spread by sexual contact with an infected person, by sharing needles and/or syringes (primarily for drug injection) with someone who is infected, or through transfusions of infected blood or blood clotting factors. Babies born to HIV-infected women may become infected before or during birth or through breast-feeding after birth. In the health care setting, workers have been infected with HIV after being stuck with needles containing HIV-infected blood or, less frequently, after infected blood gets into a worker's open cut or a mucous membrane (for example, the eyes or inside of the nose). HIV is found in varying concentrations or amounts in blood, semen, vaginal fluid, breast milk, saliva, and tears.
[0009] In recent years, medical science has made great progress in the ability to successfully treat the opportunistic infections associated with HIV infection. Wider use of medications for preventing tuberculosis, Pneumocystis carinii pneumonia (PCP), toxoplasmosis, and Mycobacterium avium complex (MAC), for example, has helped reduce the number of people with HIV who develop serious illness and die from AIDS.
[0010] Also, several classes of compounds have been federally approved to treat HIV infection. These include nucleoside RT inhibitors (AZT, ddI, ddC, d4T and 3TC), non-nucleoside RT inhibitors (alpha-APA, TSAO, costatolide, TIBO, UC10), protease inhibitors (indinavir, saquinavir, KNI 272), attachment inhibitors (sulfate polysaccharides, sulfonated dyes) and neutralizing antibodies. Combinational therapy with these drugs seems to produce the best results, reducing the level of HIV particles circulating in the blood (viral load) to very low levels in many individuals.
[0011] Though treatment results using these drugs have been encouraging, the virus is not eliminated, these drugs do not work for all people, there are adverse interactions with other medications, toxicity to the drugs is problematic, dosing protocols are complex, resistance to treatment develops, and expense is extremely high. Furthermore, long-term effectiveness and safety are completely unknown. Clearly, there remains a need for new therapies.
[0012] Attempts to develop a vaccine have not been successful to this point.
[0013] Testing facilities perform in vitro analyses to identify compounds with antiviral activity. Therapeutic indices of active compounds are evaluated using several viral strains. Many viruses are routinely available for the testing of compounds for antiviral activity in viruses other than HIV, including the herpesviruses HSV-1, HSV-2, HCMV, VZV and EBV; the respiratory viruses Flu A, Flu B, RSV, Paraflu 3 and Ad5; measles and hepatitis B virus. Anti-HIV assays are routinely performed in established cell culture lines. Recently fresh human peripheral blood lymphocytes (PBMCs) have been introduced as test media.
[0014] Assays measure the ability of compounds to directly inactivate the HIV virus and inhibit HIV-induced cell killing through numerous enzyme-inhibiting mechanisms (Reverse Transcriptase, RNaseH, Integrase, Protease, Tat, Rev and Nef), by preventing attachment and internalization (inhibit gp120-CD4 interaction) or by inhibiting regulatory protein expression, or by inhibiting maturation and budding, or by preventing Syncytical formation. Toxicity of the test compounds to host cells is also measured. It is generally accepted that if the test compound is highly toxic to cells, then it will have little value despite anti-HIV activity.
[0015] Infectious virus levels are measured by viral titers, quantitation of p24 (a viral protein found to be proportional to viral concentration) or measurement of the activity of the viral enzymes.
[0016] Several parameters are routinely varied to more completely understand the potential of a particular drug. The concentration of a drug is varied to calculate the ED50 (Effective Dose at 50% inhibition), LD50 (Lethal Dose at 50% cell death), and TI50 (Therapeutic Index, which is the Effective Dose divided by the Lethal Dose).
[0017] The concentration of the initial viral load is varied in the cell system used for testing to help determine drug potency. The time of drug addition to the cell system, either pre- or post-infection, is varied to identify strengths and weaknesses in the drug mechanism of action. Another test is to add the drug to the cell system and then wash it away before infection. This gives insight into cell-drug mechanisms of action. Topical assays test drugs which may be of use as preventive barriers. Both viral killing and cellular toxicity are measured in these assays.
[0018] Active anti-HIV compounds will likely be used in combination with other anti-HIV agents, with agents that inhibit opportunistic agents, or with other therapies. Therefore, the compounds are tested with all known useful drugs to determine beneficial synergistic effects or possible harmful combinatorial toxicity.
[0019] Drugs that prove to be successful in in vitro testing are selected for animal testing. Several animal models have proven to be helpful including systems using the mouse, cat, and rhesus macaque. The test compound and virus can be administered by a variety of methods and routes in addition to the variables discussed above. Animal mucosal models of HIV transmission may be useful for the evaluation of possible therapeutic agents. Test compounds that may have limited effectiveness in fully developed HIV may be effective at the time of initial infection. Models are useful in exploring this possibility. Animal models traditionally have been used for the pre-clinical evaluation of lead compounds to determine mechanism of action, distribution, toxicity, and efficacy.
[0020] Antiviral compounds are also being investigated for use as microbicides. A “microbicide” is any substance that can substantially reduce transmission of sexually transmitted infections (STIs) when applied either in the vagina or rectum. Target viruses include herpes viruses such as cytomegalovirus and herpes simplex, hepatitis agents, and the papilloma virus. Proposed forms for microbicides include gels, creams, suppositories, films, and sponges or vaginal rings that slowly releases the active ingredient over time. Microbicides are not currently available commercially, but a number of compounds, including nonoxynol-9, cellulose sulfate, carrageenan, cyanovirin, the sulfated polysaccharide PRO2000 and dextrin sulfate, are currently being evaluated. Dextrin sulfate has been found to have a high level of toxicity. Nonoxynol-9 has been found to cause inflammation of mucosa that may actually enhance the chance of infection. There remains a need for a proven effective nonirritant antiviral compound of low toxicity for use as a microbicide.
[0021] Polysulfonated polysaccharides (PSP) have been previously proposed to be used to treat HIV infection. The most studied include curdlan sulfate (CDS), dextrin sulfate, dextran sulfate (DS), and heparin sulfate. Many of these, including dextran sulfate, curdlan sulfate and dextrin 2-sulfate, have been studied in human trials. Many other naturally occurring isolated sulfates have been shown to inhibit the AIDS virus. Smaller non-polymeric sulfated sugar based compounds included pentosan sulfate and glucosamine sulfate.
[0022] Though the results indicate that sulfates are a viable lead for the development of an anti-HIV drug, several problems remain. Firstly, the large anionic structures of the PSPs show very poor absorption or no absorption from oral administration. Secondly, when PSP's are given intravenously the toxic effects of seriously decreasing the amount of platelets and decreasing the ability of blood to clot become limiting factors. Oral administration is also related to serious gastrointestinal toxic effects including the possible development of cancers demonstrated in rodents. Furthermore, there is no protection of the compounds from sulfatase enzymes which rapidly degrade these compounds and shorten the half-life.
[0023] The use of dextrin-2 sulfate as an anti-HIV compound versus generically sulfated dextrin (that is sulfates at any or all of the 2, 3 or 6 positions of the glucose units) has also been proposed. The use of dextrin-2 sulfate is an attempt to decrease toxicity while maintaining anti-HIV activity. Recent attempts to administer dextrin-2 sulfate by intra-peritoneal administration (that is, infusion into the body cavity by a catheter passing through the abdominal wall as done in peritoneal dialysis) shows some promise in decreasing HIV infection while decreasing intravenous-type side effects. However, the intra-peritoneal method introduces extremely little if any drug to the systemic circulation and relies upon the lymphatic circulation to expose circulating HIV infected white blood cells to the drug as they pass through the peritoneal cavity. Evaluation of dextrin 2-sulfate shows that the anti-platelet effect and anti-coagulant effect persists and there is no attempt at chemical inhibition of the hydrolysis of the drug by hydrolyzing enzymes. Consequently, dextrin 2-sulfate has not been shown to provide significant advantages over dextrin sulfate.
[0024] Accordingly, there remains a need to identify and synthesize a compound with minimized toxicity, providing antiviral activity including, but not limited to, microbicidal activity. There remains a need for a pharmaceutical composition incorporating this compound, and for methods of treatment, inhibition of viral transmission, and elimination of virus in blood, blood products, organs and whole body preparations incorporating this compound.
SUMMARY OF THE INVENTION
[0025] The present invention is directed to a new class of compounds, methods for their synthesis, and to the use of these compounds in providing antiviral activity. This class of compounds is produced by alkylsulfation (alkylsulfonation) and sulfation (sulfonation) of dextrin or dextran. The reaction used introduces aliphatic alkyl groups and sulfur groups onto a carbohydrate or polysaccharide. This reaction randomly replaces the reactive hydrogen atoms with a methylsulfate group or a sulfate group and allows for a combinatorial production of sulfate and methylsulfate substitution of dextrin or dextran. The variables of this reaction that can be controlled include the choice of dextrin or dextran as a reactant, the polymeric size of the starting material, the degree of total methylsulfation and sulfation, the degree of methylsulfation and sulfation per saccharide, and position of methylsulfation and sulfation (sulfonation) and the character of the counter ion. Control of these variables, along with the polymeric size of the starting material and degree of hydrolysis during the reaction or work-up, produces a wide range of polymeric compounds. These new compounds are distinctly different from other compounds introduced for anti-HIV therapy. These compounds have a unique synthesis, unique chemical properties and a unique pattern of activity against HIV. Use of these compounds overcomes the absorption obstacles, toxicity obstacles, and efficacy obstacles presented by prior art compounds while retaining the anti-HIV properties of sulfated saccharides. Use of the compounds of the present invention, incorporating alkyl sulfonate groups, embodies the realization that these obstacles are related to the linear sulfated structures and the non-attenuated high degree of anionicity characteristic of these sulfated compounds, and the lack of the presence of an inhibitor to enzymatic sulfate hydrolysis.
[0026] The invention introduces four important changes. First, the crucial structural element required for anti-HIV activity is recognized to be the cluster of sulfate groups presented on the branch point structures. Second, the structural element of toxic side effects is recognized as the sulfate groups on the linear portions. Elimination of linear portions and amplification of branch point sulfated structures decreases toxic side effects and increases therapeutic effects. Third, introduction of the methylsulfate group in synergy with the sulfate group increases efficacy by several possible mechanisms, including the providing of an inhibitor to sulfate hydrolyzing enzymes, the attenuation of the large negative charge and the proposed increase in oral, systemic and cellular absorption and efficacy. Finally, the number of sulfated structures or combinations of structures provides variable sites for binding and enzyme inhibition.
[0027] The antiviral activity of the compounds of the present invention is explained here in relation to, but is not limited to, the Human Immunodeficiency Virus (HIV). The generally accepted theory is that Acquired Immunodeficiency Disease Syndrome (AIDS) is caused by the Human Immunodeficiency Virus (HIV) and that the prevention of the reproduction of HIV will prevent AIDS. The reproduction of the virus relies on the function of the reverse transcriptase enzyme (RT). RT function requires the binding protein Trans Activating Transcriptor (TAT). The present invention prevents the reproduction of HIV by binding with the TAT protein and preventing the proper function of RT.
[0028] The comparatively low toxicity and comparative absence of detrimental effects on body tissue allow the use of the compounds of the present invention in a number of applications calling for compounds exhibiting antiviral activity. The compounds may be used directly, alone or in combination with other therapy, as an antiviral or anti-HIV drug. The compounds of the present invention may also be used in preventative treatments for HIV or other viruses. Routes of administration for these uses include oral and topical administration, and sub-cutaneous, muscular, intraperitoneal or intravenous injection. The compounds of the present invention may be used in bound and unbound form to eliminate HIV or other viruses from blood products during dialysis of organ or whole body preparations. They may also be used alone or in combination in cell culture systems or organ preservation systems to destroy or prevent HIV or other viral growth.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a pictorial illustration of dextrin;
[0030] FIG. 2 is a pictorial illustration of a limit dextran;
[0031] FIG. 3 is one exemplary chemical structure for polysulfated polymethylsulfated dextrin;
[0032] FIG. 4 shows Structure 1 of a polysulfated polymethylsulfated dextrin compound linked to a branch point glucose molecule with an α 1→6 linkage;
[0033] FIG. 5 shows Structure 2 of a polysulfated polymethylsulfated dextrin compound linked to a branch point maltose molecule with an α 1→6 linkage;
[0034] FIG. 6 shows Structure 3 of a polysulfated polymethylsulfated dextrin compound linked to a branch point maltose molecule with an α 1→6 linkage and linked to a branch point glucose molecule with an α1→4 linkage;
[0035] FIG. 7 shows Structure 4 shows a polysulfated polymethylsulfated dextrin compound linked to a branch point glucose molecule with an α1→6 linkage and linked to a branch point glucose molecule with an α 1→4 linkage;
[0036] Table 1 lists the various chemical moieties that can be substituted on carbons 2-4 and 6 of the different glucose molecules for Structure 1;
[0037] Table 2 lists the various chemical moieties that can be substituted on carbons 2-4 and 6 of the different glucose molecules for Structure 2;
[0038] Table 3 lists the various chemical moieties that can be substituted on carbons 2-4 and 6 of the different glucose molecules for Structure 3;
[0039] Table 4 lists the various chemical moieties that can be substituted on carbons 2-4 and 6 of the different glucose molecules for Structure 4; and
[0040] Table 5 shows the resulting p24 values (pg/ml) as a measurement of HIV concentration for the indicated concentrations of three separate efficacy tests.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] The starting material for synthesis of the product of the present invention is common corn starch or dextrin, pictorially illustrated in FIG. 1 . Dextrin is chemically characterized as a glucose polymer. The polymer consists of linear chains having glucose units linked with alpha (1-4) glycocidic bonds. Multiple linear chains are linked with alpha (1-6) glycosidic bonds along the length of any other given linear chain. The resulting structure increases in size as more glucose molecules are added increasing the length of the linear chains and increasing the number of the branches. The group of glucose molecules having both alpha (1-4) and alpha (1-6) glycosidic bonds is termed the branch point or branch point structure.
[0042] Degradation of the starting dextrin with enzymes has been discussed in the scientific literature. The process involves treatment of the dextrin with starch-digesting enzymes called amylases. Beta-amylase is an exo-glycosidase which hydrolyzes polysaccharides at alpha-(1-4) links from the non-reducing end liberating two glucose units or maltose. The cleavage continues until the enzyme encounters an alpha-(1-6) link and then stops. The branch point glucose molecules will have either none or one glucose molecule remaining attached to each of the exposed non-reducing number four carbons. This resulting highly branched starch molecule is called a beta-limit dextrin. Alpha-amylase is an endo-glycosidase which hydrolyzes polysaccharides at alpha-(1-4) links from the reducing end. The enzyme requires a polymer of seven glucose molecules to attach so the next glucose molecule can be cleaved. The alpha-amylase will not hydrolyze alpha-(1-6) links and has decreased activity at alpha-(1-4) links located next to the alpha-(1-6) links. However, the hydrolysis will occur between two neighboring alpha-(1-6) branch points if the required number of seven alpha-(1-4) links are present. Branch points are separated by about twenty-five glucose molecules in starch amylopectin. Hydrolysis by alpha-amylase would result in a branch point with short linear portions of seven to twenty-five glucose molecules attached to the non-reducing carbon number four of the branch point glucose molecules and a glucose polymer of zero to eighteen (that is 25 minus 7) glucose molecules attached to the reducing carbon one of the branch point glucose. This resulting collection of molecules is called an alpha-limit dextrin. A representative pictorial illustration of a limit dextran is shown in FIG. 2 .
[0043] Exhaustive enzymolysis of the starch results in the production of pure branch points or branch points with short linear segments of glucose alpha-(1-4) polymers attached to the branch point. The branch point structures vary by the number of glucose units and availability of substitution position. As a result of the processes which produce the branch point structures, the number of glucose units at the non-reducing end of the branch point will be necessarily very short and contain either no extra glucose units or one unit in the most commonly occurring situation, two glucose units as the next most common situation and three glucose units in the least likely situation. The presence of four or more glucose units at the non-reducing end of the branch point indicates incomplete reaction hydrolysis. The length of glucose linear polymer at the reducing end of the branch point will range from no extra glucose units to seven glucose units in the most commonly occurring situation. Chain lengths of eight to eighteen glucose units are possible but the abundance falls as the length increases. The most preferred branch points have either none or one extra glucose molecule at either of the non-reducing branch point carbon four positions and a short polymer of eight or less glucose molecules at the reducing carbon one of the branch point. A third method of obtaining branch point structures, discussed in the scientific literature, is to synthesize the branch point structures from individual glucose units.
[0044] There are two possible synthetic paths to obtain the branch point polysulfated polymethylsulfated dextrin product starting with dextrin. The first path involves enzymatic or chemical degradation of the starting material dextrin into a structure which will expose the branch point structures followed by chemical replacement of the hydroxyl groups with sulfate and methylsulfate groups. The second path involves chemical replacement of the hydroxyl groups with sulfate and methylsulfate groups as the first step, followed by enzymatic or chemical degradation to eliminate non-branch point structures.
[0045] Chemical replacement of the hydroxyl groups with charged sulfate groups and non-charged methylsulfate groups is performed by a simultaneous competitive reaction of reagents such as chlorosulfonic acid, methylchlorolsulfonate, and a sulfurtrioxide pyridine complex on the limit dextrin or branch point structure starting material. This chemical replacement, however, can be performed in two individual steps. Also, there are changes that can be made in the choice of reagent or solvent. These changes may alter the purification techniques required to obtain end product suitable for use in clinical studies.
[0046] The total sulfate composition of the polysulfate polymethysulfate dextrin is about 12 to 21 percent sulfation. It is proposed that, because of the increased reactivity of the sulfation reagent over the methylsulfation reagent, the ratio of sulfate to methylsulfate will favor sulfate by about 2 to 1. It is also proposed that the exposed or primary branch point carbon groups will have the highest degree of sulfation. The secondary branch points, defined as the second branch from the exposed surface, react at a decreased rate and are less sulfated. Position 6 is the most exposed and the most highly susceptible to substitution. Position 2 and position 3 are the least likely for sulfate substitution and would be expected to be present in a low proportion. Position 4, if hydrolyzed, has a high probability of substitution.
[0047] To obtain active product with the least number of side effects the length of linear chains should be minimized and the number of sulfate and methylsulfate groups should be minimized. As the parameters are limited the potency of the drug may decrease. The potency of sulfated polysaccharides has been shown to be related to the degree of sulfation and size of the polymer. The minimum number of glucose units with strategically located methylsulfate and sulfate groups is the most preferred. For example, one methylsulfate group located at the carbon-6 position of the leading glucose unit and one sulfate group at the carbon-2 position of the base glucose of the branchpoint is a preferred arrangement.
[0048] The synthetic strategy is to ultimately obtain a collection of branch point structures with varying amounts of combinatorial chemical alteration. The chemical alteration is the replacement of the hydroxyl groups of the individual glucose molecules in the branch point structure with either a negatively charged sulfate groups accompanied with a suitable counter ion or a non-charged methylsulfate group. The number of possible differing chemical structures is large and is calculated from the variability of the branch point structure, the number of charged versus non-charged sulfate groups on a particular branch point structure, the position of the charged versus non-charged groups on the branch point structure, and the nature of the counter ions. FIG. 3 shows one exemplary chemical structure for the polysulfated polymethylsulfated dextrin compound of the present invention. FIGS. 4-7 show four polysulfated polymethylsulfated dextrin compounds, each one differing in their branch point structures. For example, Structure 1 is a polysulfated polymethylsulfated dextrin compound linked to a branch point glucose molecule with an α 1→6 linkage, as shown in FIG. 4 . Structure 2 is a polysulfated polymethylsulfated dextrin compound linked to a branch point maltose molecule with an α 1→6 linkage, as shown in FIG. 5 . Structure 3 is a polysulfated polymethylsulfated dextrin compound linked to a branch point maltose molecule with an α 1→6 linkage and linked to a branch point glucose molecule with an α 1→4 linkage, as shown in FIG. 6 . Structure 4 is a polysulfated polymethylsulfated dextrin compound linked to a branch point glucose molecule with an α 1→6 linkage and linked to a branch point glucose molecule with an α 1→4 linkage, as shown in FIG. 7 . Tables 1-4 list the various chemical moieties that can be substituted on carbons 2-4 and 6 of the different glucose molecules for Structures 1-4, respectively.
[0049] Applicant believes, without wishing to be bound by the statement, that the alkylsulfate of limit dextrin contributes to the activity of the alkyl sulfate of sulfated dextrin of the present invention.
[0050] The methylsulfate group and other alkylsulfate groups, such as ethylsulfate or propylsulfate groups, may also be added to any other sulfates that have been tested for antiviral activity, such as cyclodextrin sulfate and other non-polymeric structures. The resulting compounds include saccharides containing both sulfate and alkylsulfate groups. Dextrin, dextran and cyclodextrin may serve as the saccharides.
[0051] Numerous mechanisms of action have been proposed for the observed anti-HIV activity of the sulfated saccharides. These previously proposed mechanisms of actions support the demonstrated anti-HIV activity of the invention. In addition, unique mechanisms of action are proposed to explain the function of the invention.
[0052] The large and highly negatively charged polymeric polysulfates are not believed to be capable of entering the cell. The mechanism of action of these large sulfates involve processes at the surface of the cell. These include the prevention of viral absorption into the cell or prevention of budding of the reproduced virus from the cell. As opposed to the linear binding array as represented by dextran sulfate and curdlan sulfate, the invention places the proposed active branch points, or alpha 1-6 gycosidic linkages, on the surface of the molecule creating a three dimensional surface which enhances the binding the invention and the proteins at the cell surface.
[0053] However, in the cellular based testing results presented of the proposed compound, the virus was first placed in the cell before addition of the test compound. Therefore, because the virus was already in the cell, reproduction within the cell did not depend on entry. If the test compound simply prevented the HIV particle from entering the cell then it should show no activity in this type of assay. This is evidence that the mechanism of action is intracellular which is different from the known mechanism of action of dextran sulfate.
[0054] Binding to internal enzymes of the virus has to be considered as a possible mechanism. Experiments with HIV inhibition demonstrate that viral reproduction is inhibited by intracellular mechanisms. The route of absorption of a compound of the present invention may be enhanced because of the lipophilic characteristics of the methylsulfate group. This lipophilic characteristic of the compound may shield the electrostatic repulsion between the compound and the outer wall of the cell so that the compound can pass into the interior of the cell. Inhibition of intracellular reverse transcriptase or protease enzymes is known to effectively inhibit viral reproduction. Other enzymes may also be effected.
[0055] The TAT protein is a unique protein in that it plays both an extracellular and intracellular role in viral reproduction. TAT binds with RT to allow accelerated DNA synthesis and is thought to be the reason for the great increase in viral load during active infection. This protein is manufactured in large numbers and is released from the infected cell. The TAT protein then enters uninfected cells awaiting the arrival of the virus. Once infected, the newly functioning RT is able to immediately function at the accelerated level. The binding of the sulfate group to an active site arginine on the TAT protein is proposed to be the mechanism of inhibition. This proposed mechanism would explain the ability of the invention to prevent systemic viral conversion during the initial periods of infection.
[0056] The polysulfated polymethysulfate exhibits an increased antiviral activity in comparison to dextrin sulfate. A proposed explanation is that the high concentrations of enzymes in the white blood cells called sulfatases, which hydrolyze the sulfate group, inactivates polysulfated compounds. The polymethylsulfate derivative of polysulfate dextrin retains activity, possibly because the methylsulfate moiety acts as an inhibitor of the sulfatase enzyme. This prevents drug decomposition or deactivation.
[0057] A number of routes of administration are suitable for the compounds of the present invention. These compounds are included, for therapeutic evaluation, in antiviral compositions containing excipients appropriate to the route of administration. The route of administration of a drug may be oral, topical, intra-peritoneal/-muscular/-cutaneous or intravenous. The route used depends on the ability to achieve therapeutic results along with minimization of side effects and eventually compliance. As a drug of the nature of the drug of the present invention is developed, the optimum goal is to develop an oral dosing medication.
[0058] The early stage of testing may find success in either topical mucosal application or intravenous route of administration. These routes of delivery are chosen because they eliminate or minimize many of the variables of absorption, distribution, metabolism and elimination. The topical application places the drug directly on the mucosal membrane. Systemic side effects can be minimized and local toxic effects can be observed. The therapeutic effect is measured in the population response as decrease in disease rate of spread.
[0059] Intravenous administration places the drug directly into the blood. However, toxic effects may be amplified because of this route. To minimize toxic side effects a slow continuous infusion or a multiple bolus dosing can be used. The serum drug concentration is monitored to develop a concentration response curve. The infusion rate or bolus dose and frequency is altered to maintain a drug concentration or to increase levels. The effect or therapeutic benefit is measured by periodic measurement of total viral load and p24 concentration. A common known reversible side effect of polymeric sulfates is an increase in the APTT or bleeding time. Therefore, in tests involving compounds of the present invention, the APTT is monitored and maintained at pre-selected values. The platelet count is also monitored in that thrombocytopenia is a possible expected reversible side effect.
[0060] Experimental results indicate that the compounds of the present invention provide unexpected and extended modes of action. Therefore, it is expected that the antiviral activity of the compounds of the present invention is not limited to a single viral agent. Target viruses for the evaluation of prior art antimicrobials include HIV, herpes viruses such as cytomegalovirus and herpes simplex, hepatitis agents, and the papilloma virus. Efficacy of the compounds of the present invention in treatment of these species is therefore not unexpected.
[0061] The object of antiviral drug therapy, such as anti-HIV drug therapy, is to produce and maintain a therapeutic response. The response may be as vague as a feeling of improvement or the precise measurement of a parameter such as viral load or serum p24 levels. Attempts have to be made to minimize toxic side effects while achieving the goal of a therapeutic response. Adjustments in the dosing form, amount, dosing interval, adjuvant therapy, supportive chemotherapeutics and expected response window.
[0062] Pharmacokinetic parameters relate the amount of drug in the body or serum concentration to desired effect rather than relating the dose amount or dose frequency to the desired effect. However, the practical matter is to first determine the dose amount and frequency which produces the desired effect and then to describe this by determining the drug serum concentration. In-vitro experiments help to describe a rough estimate of concentration of active drug which produces a specific response. In-vitro experiments also demonstrate, on a cellular level, toxicity. The ratio of the concentration which produces a therapeutic response and the concentration which produces a toxic response is termed the therapeutic index.
[0063] The goal, however, is to determine the therapeutic concentration in a patient with disease. The goal is to reverse disease. Toxic effects are judged with regard to the therapeutic benefit. The goal is to place in check toxic effects so that the drug concentration can be increased and maintained. A patient population must be studied to overcome the natural variability of response traditionally observed from patient to patient when treating disease. The goal of maintaining a therapeutic response can then be achieved.
EXAMPLES
Example 1
Purification of Dextrin
[0064] Type I corn starch dextrin of USP grade having a molecular weight distribution of approximately 30% of 2,000 to 4,000 daltons and 60% of 8,000 to 10,000 daltons as determined by gel permeation chromatography is supplied. The dextrin is purified by dissolving into sufficient purified water and dialyzing against purified water. The dialysis membrane has a pore size of 3000 to 6000 daltons so that smaller size dextrin and impurities are eliminated. The purified starting material is then dried by lyophilization and is obtained as a white fluffy solid, melting point 266-274° C. with decomposition.
Example 2
Synthesis of Polysulfate Polymethylsulfate Dextrin
[0065] To 10 mL of dry pyridine is added 1.0 mL of methanesulfonyl chloride and 1.0 mL of chlorosulfonic acid. To this is added 500 mg of dextrin. The mixture is heated to 55° C. for a period of twelve hours. Ten grams of sodium hydroxide in 100 mL of water is then added. The aqueous layer is transferred to a dialysis membrane and dialysed against water until the pH is neutral. The polysulfate polymethylsulfate dextrin is obtained as a fluffy white solid by removal of the water by lyophylization. Weight 455 mg; melting point 185-215 degrees Celsius with decomposition 215-220 degrees Celsius. Elemental analysis shows carbon 31.27%, hydrogen 6.38%, and sulfur 11.28%. The 300 MHZ NMR in deuterium shows a broad singlet at 5.8 to 5.4 ppm and a broad quartet at 4.5 to 3.2 ppm.
[0066] The methysulfate group may be added to any other sulfates that have been tested for antiviral activity such as dextrin sulfate, dextran sulfate, cyclo-dextrin sulfate, or other non-polymeric sulfated structures using this reaction.
Example 3
Synthesis and Purification of Polysulfate Polymethylsulfate Dextrin from Sulfated Dextrin
[0067] To 10 mL of clean dry pyridine is added 1.0 mL of methanesulfonyl chloride. The addition requires stirring and cooling. This mixture is then heated to 55° C. To this is added 500 mg of sulfated dextrin with stirring. The mixture is heated to 55° C. and stirred for a period of twelve hours. The mixture is then cooled and ten grams of cooled sodium hydroxide in 100 mL of water is slowly added with stirring and cooling.
[0068] The aqueous layer is allowed to separate and is transferred to a dialysis membrane and dialyzed against purified water until the pH of the water remains neutral. The polysulfate polymethylsulfate dextrin is obtained as a solid by removal of the water by lyophilization.
[0069] The above synthesis can be applied to any form of sulfated dextrin such as dextrin-2-sulfate, dextrin-3-sulfate, dextrin-6-sulfate or multiple sulfates. Any molecular weight of sulfate dextrin can be used such as those with a molecular weight of 3000 to 10,000 and higher polymers with a molecular weight of, for example, 10,000 to 500,000.
Example 4
Synthesis of Polysulfate Polymethylsulfate Dextrin with Sulfurtrioxide Pyridine Complex and Purification Thereof
[0070] (a) Production of the Solid Product: 300 mL of dry pyridine is added to a reaction flask heated to 20° C. 120 mL of chlorosulfonic acid is slowly added to the flask, keeping the temperature no higher than 20° C. 120 mL of methanesulfonyl chloride is added over 15 minutes, keeping the temperature below 30° C. Another 300 mL pyridine is added to the mixture, and then 95 g of sulfurtrioxide pyridine complex (PySO 3 ) is added, keeping the temperature below 40° C. The presence of any solids is determined and then the mixture is heated to 55-60° C. If a bulk of un-dissolved salts are present in the mixture, then 50 mL of pyridine is added every 2-3 minutes up to a maximum of 300 mL of additional pyridine. When the mixture is homogeneous, 152.93 g of dry dextrin is stirred into the mixture and the mixture is heated to between 55-60° C. for one hour. After one hour, the mixture is cooled and stirred overnight at room temperature. The final product is a solid. The pyridine is decanted from the solids and retained. Then the solids then are removed using a first wash solution, described below. The solids are filtered using a Buchner funnel and Whatner filter paper # 4. To assist drying of the solids, a latex sheet can be placed over the solids in the Buchner funnel during the filtration process. The solid product then is washed with two wash solutions in the following order: The first wash is made up of ice cold 97.5% acetone and 2.5% HCl (v/v). The volume of this wash should be approximately 500-1000 mL. This removes most of the pyridine and deactivates the remaining reagent. The second wash is made up of about 500 mL ice cold 100% acetone. This removes excess acid.
[0071] (b) Neutralization and Purification of the Solid Product: The solid product first is made basic by dissolving it in 10% NaOH. The pH of the solution should be between 10 and 11. The solution then is transferred to a dialysis membrane for dialysis. The amount of base is determined by the pH reading and the amount of water is determined by the dialysis step. A large amount of excess base is not favorable and dialysis limits the amount of water that can be used. Purification of the product is achieved by dialysis against a 1000 MW cut off membrane. The dialysis membrane thus has a smaller pore size than the purification step. Dialysis proceeds with water exchanges until the exchange water pH is neutral, which takes about 72 hours and requires about 6 water changes done about every 6-8 hours. After the exchange water has neutralized, it may be assumed that the product also has a neutral pH. The product then is removed from the dialysis membrane and placed on a lyophilizer for immediate freeze-drying. The water is removed by the freeze-drying method so as not to destroy the product. The polysulfate polymethylsulfate dextrin product is obtained as a slightly acrid, tan solid by removal of the water by lyophilization. Weight: 125 g; pH: 7.5; melting point: 185-215° C. with decomposition at about 215-220° C. Elemental analysis shows carbon: 18.24%; hydrogen: 3.42%; nitrogen: 0.38%; sulfu:r 15.91%; and oxygen: 49.45%. Percentage organic matter: 67% (ash: 33%).
Example 5
In Vivo Toxicity Study of Polysulfate Polymethylsulfate Dextrin with Sulfurtrioxide Pyridine Complex in Rats
[0072] (a) Intraperitoneal Administration: Sprague-Dawley rats weighing approximately 250 g were injected i.p. with increasing amounts of polysulfate polymethylsulfate dextrin dissolved in sterile water. The LD 50 , calculated by semi-log plot of the data, was 47 mg/kg body weight.
[0073] (b) Oral Administration: Sprague-Dawley rats weighing approximately 250 g were orally gavaged with increasing amounts of polysulfate polymethylsulfate dextrin dissolved in sterile water up to a dose of 2 g/kg body weight. No toxic effects of the compound was observed, thus indicating that oral administration was “non-toxic.”
Example 6
Anti-HIV Testing of Polysulfate Polymethylsulfate Dextrin
[0074] Anti-HIV activity of polysulfate polymethylsulfate dextrin was demonstrated in cell culture by inhibition of cell-to-cell transmission of the Human Immunodeficiency Virus as measurement of the p24 protein production in the presence of increasing drug concentration. The average of three separate tests demonstrated that the calculated 50% inhibition (IC50) is 1.16 μM. Testing was performed independently at the NIH using standard testing protocol. Results are shown in Table 5.
Example 6
Oral Administration of Antiviral Compound for Treatment of HIV
[0075] Oral administration is the most preferred route of administration for general distribution of the invention allowing ease of dose manufacturing and dispensing. Absorption through the gut wall is substantial and adequate because of the increase in lypophilic character of the methylsulfate groups compared to the sulfate groups alone. The decrease in molecular weight by elimination of the linear polymer connecting the branch point structure also increases transport across the gut wall as compared to the limit dextrin. Formulation of the invention with solubilizing lipid carriers, buffered excipients, and dissolution enhancers maximizes absorption. The first pass hepatic clearance is expected to be substantial and should be overcome by increasing the oral dose amount and dosing frequency.
[0076] Formulation for oral absorption may include any of the following excipients: glycerin USP, microcrystalline cellulose, methylcellulose, starch, paraben, methylparaben, colloidal silicon dioxide, magnesium stearate, simethicone, sorbitol, water, FD&C color, and flavor.
[0077] EXAMPLE FORMULATION: 1 gram of antiviral composition of the present invention in a soft gel capsule.
[0078] EXAMPLE DOSAGE: 1 capsule four times a day.
[0079] PURPOSE: To determine the effectiveness of the antiviral composition of the present invention towards the treatment of HIV as the drug is administered orally.
[0080] METHODOLOGY: The study is an open label study. Subjects are given monthly supplies of the medication. The subjects self-administer the medication and make records in a daily journal. The subjects are medically examined monthly, which may include serum blood drug levels, viral titer or anti-body measurement, serum chemistry measurements, and serum bleeding parameters.
[0081] Patients take medication at a starting dose which is adjusted on a monthly basis. If the medication is tolerated and the viral load has not decreased, then the medication is increased from 10% to 1000%. If the medication is not tolerated the medication will be decreased 10% to 100%.
[0082] INCLUSION CRITERIA: HIV infection as documented by ELISA or EIA and confirmed by a Western blot analysis.
[0083] EXCLUSION CRITERIA: Known allergy to the medication.
[0084] END POINT: Elimination of HIV infection.
Example 8
Intravenous Administration of Antiviral Compound for Treatment of HIV
[0085] Intravenous administration is the most preferred route of administration for initial clinical trials because it ensures that the invention reaches the systemic circulation. Administration is best accomplished through a large catheter in the femoral or sub-clavian vein to avoid the complication of small vein irritation. Dosing protocol is variable to include one time bolus dosing, multiple dosing protocols which vary the amount of the drug and/or the time interval between dosing, or continuous infusion.
[0086] Formulation for intravenous administration may contain any of the following excipients: sterile water, saline, phosphate buffer, dextran, and sodium hydroxide.
[0087] EXAMPLE FORMULATION: Sterile solution 15 mg/mL “antiviral composition” in 0.9% sodium chloride adjusted to pH 6.0 to 7.5 with 0.01N sodium hydroxide sterilized with a 0.2 μm filter.
[0088] EXAMPLE DOSAGE: 100 mg of “antiviral composition” per 24 hour period delivered over a four hour infusion.
[0089] PURPOSE: To determine the effectiveness of the invention “antiviral composition” towards the treatment of HIV as the drug is administered intravenously.
[0090] METHODOLOGY: The study is an open label study. Subjects are given daily doses of the medication. The medication is given in a medical setting and records in a daily chart are kept. The subjects are medically assessed daily, as need be, which may include serum blood drug levels, viral titer or anti-body measurement, serum chemistry measurements, and serum bleeding parameters.
[0091] Patients are administered medication at a starting dose which is adjusted on a daily basis. If the medication is tolerated and the viral load has not decreased then the medication is increased from 10% to 1000%. If the medication is not tolerated the medication is decreased 10% to 100%.
[0092] INCLUSION CRITERIA: HIV infection as documented by ELISA or EIA and confirmed by a Western blot analysis.
[0093] EXCLUSION CRITERIA: Known allergy to the medication.
[0094] END POINT: Elimination of HIV infection.
Example 9
Intraperitoneal Administration of Antiviral Composition for the Treatment of HIV
[0095] Intraperitoneal administration is the least preferred route of administration used for general use or for initial clinical trials. The benefit of intraperitoneal administration is the possible reduction of systemic toxic side-effects: circulating white blood cells are exposed to the drug invention. The drug invention is formulated in a phosphate buffer, a pH adjusted saline solution, a dextrin solution, a lipid emulsion or a combination.
[0096] Formulation for intraperitoneal administration may contain any of the following excipients: sterile water, saline, dextrin, icodextrin, phosphate buffer.
[0097] EXAMPLE FORMULATION: 0.015% w/v of “antiviral composition” in 4% icodextrin solution.
[0098] EXAMPLE DOSAGE: 100 mg of “antiviral composition” per 24 hour period delivered the intraperitoneal cavity.
[0099] PURPOSE: To determine the effectiveness of the invention “antiviral composition” towards the treatment of HIV as the drug is administered intraperitoneally.
[0100] METHODOLOGY: The study is an open label study. Subjects are given daily doses of the medication. The medication is given in a medical setting and records in a daily chart are kept. The subjects are medically assessed daily, as need be, which may include serum blood drug levels, viral titer or anti-body measurement, serum chemistry measurements, and serum bleeding parameters.
[0101] Patients are administered medication at a starting dose which is adjusted on a daily basis. If the medication is tolerated and the viral load has not decreased then the medication is increased from 10% to 1000%. If the medication is not tolerated the medication is decreased 10% to 100%.
[0102] INCLUSION CRITERIA: HIV infection as documented by ELISA or EIA and confirmed by a Western blot analysis.
[0103] EXCLUSION CRITERIA: Known allergy to the medication.
[0104] END POINT: Elimination of HIV infection.
Example 9
Topical Administration of Antiviral Composition for Prevention of HIV
[0105] Topical administration is a possible preferred route of administration for initial clinical trials because it may eliminate systemic absorption difficulties and toxicities. Administration is controlled by the subject; the formulation is self-administered. Dosing protocol is variable to include one time bolus dosing as well as multiple dosing protocols which vary the amount of the drug and/or the time interval between dosing.
[0106] Formulation for topical administration may contain any of the following excipients: petroleum jelly, petroleum ointment mixture, sterile water, saline, phosphate buffer, and dextran.
[0107] EXAMPLE FORMULATION: 0.1% ointment; petroleum based ointment with a pH buffer of 6.8.
[0108] EXAMPLE DOSAGE: 0.5 gram of ointment within one hour before and one hour after intercourse to vaginal mucosa.
[0109] PURPOSE: To determine the effectiveness of the invention “antiviral composition” towards the prevention of HIV as the drug is administered topically.
[0110] METHODOLOGY: The study is an open label study. The study population contains 1000 females who are sexually active with a high risk male population. A known population transmission rate or an untreated group may act as controls. Subjects are given a supply of individual doses of the medication. The medication is self-administered. The subjects are medically assessed weekly, as need be, which may include physical and pelvic examination, serum blood drug levels, viral titer or anti-body measurement, serum chemistry measurements, and serum bleeding parameters.
[0111] Patients are administered medication at a starting dose which is adjusted on a daily basis. If the medication is tolerated and the viral load has not decreased then the medication is increased from 10% to 1000%. If the medication is not tolerated the medication is decreased 10% to 100%.
[0112] INCLUSION CRITERIA: Free of HIV infection as documented by ELISA or EIA.
[0113] EXCLUSION CRITERIA: Presence of HIV infection and known allergy to the medication.
[0114] END POINT: Presence of acquired HIV infection.
[0115] The above invention has been described with reference to the preferred embodiment. Other modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
TABLE 1 Various chemical moieties for Structure 1. COMBINATIONS FOR STRUCTURE 1 2 3 4 6 1 A, E or H B, For I C or G D or J K 1 SO2Me SO2Me SO2Me SO2Me POLYMER 2 SO2Me SO2Me SO2Me SO3—X+ POLYMER 3 SO2Me SO2Me SO2Me H POLYMER 4 SO2Me SO2Me SO3—X+ SO2Me POLYMER 5 SO2Me SO2Me SO3—X+ SO3—X+ POLYMER 6 SO2Me SO2Me SO3—X+ H POLYMER 7 SO2Me SO2Me H SO2Me POLYMER 8 SO2Me SO2Me H SO3—X+ POLYMER 9 SO2Me SO2Me H H POLYMER 10 SO2Me SO3—X+ SO2Me SO2Me POLYMER 11 SO2Me SO3—X+ SO2Me SO3—X+ POLYMER 12 SO2Me SO3—X+ SO2Me H POLYMER 13 SO2Me SO3—X+ SO3—X+ SO2Me POLYMER 14 SO2Me SO3—X+ SO3—X+ SO3—X+ POLYMER 15 SO2Me SO3—X+ SO3—X+ H POLYMER 16 SO2Me SO3—X+ H SO2Me POLYMER 17 SO2Me SO3—X+ H SO3—X+ POLYMER 18 SO2Me SO3—X+ H H POLYMER 19 SO2Me H SO2Me SO2Me POLYMER 20 SO2Me H SO2Me SO3—X+ POLYMER 21 SO2Me H SO2Me H POLYMER 22 SO2Me H SO3—X+ SO2Me POLYMER 23 SO2Me H SO3—X+ SO3—X+ POLYMER 24 SO2Me H SO3—X+ H POLYMER 25 SO2Me H H SO2Me POLYMER 26 SO2Me H H SO3—X+ POLYMER 27 SO2Me H H H POLYMER 28 SO3—X+ SO2Me SO2Me SO2Me POLYMER 29 SO3—X+ SO2Me SO2Me SO3—X+ POLYMER 30 SO3—X+ SO2Me SO2Me H POLYMER 31 SO3—X+ SO2Me SO3—X+ SO2Me POLYMER 32 SO3—X+ SO2Me SO3—X+ SO3—X+ POLYMER 33 SO3—X+ SO2Me SO3—X+ H POLYMER 34 SO3—X+ SO2Me H SO2Me POLYMER 35 SO3—X+ SO2Me H SO3—X+ POLYMER 36 SO3—X+ SO2Me H H POLYMER 37 SO3—X+ SO3—X+ SO2Me SO2Me POLYMER 38 SO3—X+ SO3—X+ SO2Me SO3—X+ POLYMER 39 SO3—X+ SO3—X+ SO2Me H POLYMER 40 SO3—X+ SO3—X+ SO3—X+ SO2Me POLYMER 41 SO3—X+ SO3—X+ SO3—X+ SO3—X+ POLYMER 42 SO3—X+ SO3—X+ SO3—X+ H POLYMER 43 SO3—X+ SO3—X+ H SO2Me POLYMER 44 SO3—X+ SO3—X+ H SO3—X+ POLYMER 45 SO3—X+ SO3—X+ H H POLYMER 46 SO3—X+ H SO2Me SO2Me POLYMER 47 SO3—X+ H SO2Me SO3—X+ POLYMER 48 SO3—X+ H SO2Me H POLYMER 49 SO3—X+ H SO3—X+ SO2Me POLYMER 50 SO3—X+ H SO3—X+ SO3—X+ POLYMER 51 SO3—X+ H SO3—X+ H POLYMER 52 SO3—X+ H H SO2Me POLYMER 53 SO3—X+ H H SO3—X+ POLYMER 54 SO3—X+ H H H POLYMER 55 H SO2Me SO2Me SO2Me POLYMER 56 H SO2Me SO2Me SO3—X+ POLYMER 57 H SO2Me SO2Me H POLYMER 58 H SO2Me SO3—X+ SO2Me POLYMER 59 H SO2Me SO3—X+ SO3—X+ POLYMER 60 H SO2Me SO3—X+ H POLYMER 61 H SO2Me H SO2Me POLYMER 62 H SO2Me H SO3—X+ POLYMER 63 H SO2Me H H POLYMER 64 H SO3—X+ SO2Me SO2Me POLYMER 65 H SO3—X+ SO2Me SO3—X+ POLYMER 66 H SO3—X+ SO2Me H POLYMER 67 H SO3—X+ SO3—X+ SO2Me POLYMER 68 H SO3—X+ SO3—X+ SO3—X+ POLYMER 69 H SO3—X+ SO3—X+ H POLYMER 70 H SO3—X+ H SO2Me POLYMER 71 H SO3—X+ H SO3—X+ POLYMER 72 H SO3—X+ H H POLYMER 73 H H SO2Me SO2Me POLYMER 74 H H SO2Me SO3—X+ POLYMER 75 H H SO2Me H POLYMER 76 H H SO3—X+ SO2Me POLYMER 77 H H SO3—X+ SO3—X+ POLYMER 78 H H SO3—X+ H POLYMER 79 H H H SO2Me POLYMER 80 H H H SO3—X+ POLYMER 81 H H H H POLYMER 82 SO2Me SO2Me SO2Me SO2Me POLYMER 83 SO2Me SO2Me SO2Me SO3—X+ POLYMER 84 SO2Me SO2Me SO2Me H POLYMER 85 SO2Me SO2Me SO3—X+ SO2Me POLYMER 86 SO2Me SO2Me SO3—X+ SO3—X+ POLYMER 87 SO2Me SO2Me SO3—X+ H POLYMER 88 SO2Me SO2Me H SO2Me POLYMER 89 SO2Me SO2Me H SO3—X+ POLYMER 90 SO2Me SO2Me H H POLYMER 91 SO2Me SO3—X+ SO2Me SO2Me POLYMER 92 SO2Me SO3—X+ SO2Me SO3—X+ POLYMER 93 SO2Me SO3—X+ SO2Me H POLYMER 94 SO2Me SO3—X+ SO3—X+ SO2Me POLYMER 95 SO2Me SO3—X+ SO3—X+ SO3—X+ POLYMER 96 SO2Me SO3—X+ SO3—X+ H POLYMER 97 SO2Me SO3—X+ H SO2Me POLYMER 98 SO2Me SO3—X+ H SO3—X+ POLYMER 99 SO2Me SO3—X+ H H POLYMER 100 SO2Me H SO2Me SO2Me POLYMER 101 SO2Me H SO2Me SO3—X+ POLYMER 102 SO2Me H SO2Me H POLYMER 103 SO2Me H SO3—X+ SO2Me POLYMER 104 SO2Me H SO3—X+ SO3—X+ POLYMER 105 SO2Me H SO3—X+ H POLYMER 106 SO2Me H H SO2Me POLYMER 107 SO2Me H H SO3—X+ POLYMER 108 SO2Me H H H POLYMER 109 SO3—X+ SO2Me SO2Me SO2Me POLYMER 110 SO3—X+ SO2Me SO2Me SO3—X+ POLYMER 111 SO3—X+ SO2Me SO2Me H POLYMER 112 SO3—X+ SO2Me SO3—X+ SO2Me POLYMER 113 SO3—X+ SO2Me SO3—X+ SO3—X+ POLYMER 114 SO3—X+ SO2Me SO3—X+ H POLYMER 115 SO3—X+ SO2Me H SO2Me POLYMER 116 SO3—X+ SO2Me H SO3—X+ POLYMER 117 SO3—X+ SO2Me H H POLYMER 118 SO3—X+ SO3—X+ SO2Me SO2Me POLYMER 119 SO3—X+ SO3—X+ SO2Me SO3—X+ POLYMER 120 SO3—X+ SO3—X+ SO2Me H POLYMER 121 SO3—X+ SO3—X+ SO3—X+ SO2Me POLYMER 122 SO3—X+ SO3—X+ SO3—X+ SO3—X+ POLYMER 123 SO3—X+ SO3—X+ SO3—X+ H POLYMER 124 SO3—X+ SO3—X+ H SO2Me POLYMER 125 SO3—X+ SO3—X+ H SO3—X+ POLYMER 126 SO3—X+ SO3—X+ H H POLYMER 127 SO3—X+ H SO2Me SO2Me POLYMER 128 SO3—X+ H SO2Me SO3—X+ POLYMER 129 SO3—X+ H SO2Me H POLYMER 130 SO3—X+ H SO3—X+ SO2Me POLYMER 131 SO3—X+ H SO3—X+ SO3—X+ POLYMER 132 SO3—X+ H SO3—X+ H POLYMER 133 SO3—X+ H H SO2Me POLYMER 134 SO3—X+ H H SO3—X+ POLYMER 135 SO3—X+ H H H POLYMER 136 H SO2Me SO2Me SO2Me POLYMER 137 H SO2Me SO2Me SO3—X+ POLYMER 138 H SO2Me SO2Me H POLYMER 139 H SO2Me SO3—X+ SO2Me POLYMER 140 H SO2Me SO3—X+ SO3—X+ POLYMER 141 H SO2Me SO3—X+ H POLYMER 142 H SO2Me H SO2Me POLYMER 143 H SO2Me H SO3—X+ POLYMER 144 H SO2Me H H POLYMER 145 H SO3—X+ SO2Me SO2Me POLYMER 146 H SO3—X+ SO2Me SO3—X+ POLYMER 147 H SO3—X+ SO2Me H POLYMER 148 H SO3—X+ SO3—X+ SO2Me POLYMER 149 H SO3—X+ SO3—X+ SO3—X+ POLYMER 150 H SO3—X+ SO3—X+ H POLYMER 151 H SO3—X+ H SO2Me POLYMER 152 H SO3—X+ H SO3—X+ POLYMER 153 H SO3—X+ H H POLYMER 154 H H SO2Me SO2Me POLYMER 155 H H SO2Me SO3—X+ POLYMER 156 H H SO2Me H POLYMER 157 H H SO3—X+ SO2Me POLYMER 158 H H SO3—X+ SO3—X+ POLYMER 159 H H SO3—X+ H POLYMER 160 H H H SO2Me POLYMER 161 H H H SO3—X+ POLYMER 162 H H H H POLYMER 163 SO2Me SO2Me SO2Me SO2Me POLYMER 164 SO2Me SO2Me SO2Me SO3—X+ POLYMER 165 SO2Me SO2Me SO2Me H POLYMER 166 SO2Me SO2Me SO3—X+ SO2Me POLYMER 167 SO2Me SO2Me SO3—X+ SO3—X+ POLYMER 168 SO2Me SO2Me SO3—X+ H POLYMER 169 SO2Me SO2Me H SO2Me POLYMER 170 SO2Me SO2Me H SO3—X+ POLYMER 171 SO2Me SO2Me H H POLYMER 172 SO2Me SO3—X+ SO2Me SO2Me POLYMER 173 SO2Me SO3—X+ SO2Me SO3—X+ POLYMER 174 SO2Me SO3—X+ SO2Me H POLYMER 175 SO2Me SO3—X+ SO3—X+ SO2Me POLYMER 176 SO2Me SO3—X+ SO3—X+ SO3—X+ POLYMER 177 SO2Me SO3—X+ SO3—X+ H POLYMER 178 SO2Me SO3—X+ H SO2Me POLYMER 179 SO2Me SO3—X+ H SO3—X+ POLYMER 180 SO2Me SO3—X+ H H POLYMER 181 SO2Me H SO2Me SO2Me POLYMER 182 SO2Me H SO2Me SO3—X+ POLYMER 183 SO2Me H SO2Me H POLYMER 184 SO2Me H SO3—X+ SO2Me POLYMER 185 SO2Me H SO3—X+ SO3—X+ POLYMER 186 SO2Me H SO3—X+ H POLYMER 187 SO2Me H H SO2Me POLYMER 188 SO2Me H H SO3—X+ POLYMER 189 SO2Me H H H POLYMER 190 SO3—X+ SO2Me SO2Me SO2Me POLYMER 191 SO3—X+ SO2Me SO2Me SO3—X+ POLYMER 192 SO3—X+ SO2Me SO2Me H POLYMER 193 SO3—X+ SO2Me SO3—X+ SO2Me POLYMER 194 SO3—X+ SO2Me SO3—X+ SO3—X+ POLYMER 195 SO3—X+ SO2Me SO3—X+ H POLYMER 196 SO3—X+ SO2Me H SO2Me POLYMER 197 SO3—X+ SO2Me H SO3—X+ POLYMER 198 SO3—X+ SO2Me H H POLYMER 199 SO3—X+ SO3—X+ SO2Me SO2Me POLYMER 200 SO3—X+ SO3—X+ SO2Me SO3—X+ POLYMER 201 SO3—X+ SO3—X+ SO2Me H POLYMER 202 SO3—X+ SO3—X+ SO3—X+ SO2Me POLYMER 203 SO3—X+ SO3—X+ SO3—X+ SO3—X+ POLYMER 204 SO3—X+ SO3—X+ SO3—X+ H POLYMER 205 SO3—X+ SO3—X+ H SO2Me POLYMER 206 SO3—X+ SO3—X+ H SO3—X+ POLYMER 207 SO3—X+ SO3—X+ H H POLYMER 208 SO3—X+ H SO2Me SO2Me POLYMER 209 SO3—X+ H SO2Me SO3—X+ POLYMER 210 SO3—X+ H SO2Me H POLYMER 211 SO3—X+ H SO3—X+ SO2Me POLYMER 212 SO3—X+ H SO3—X+ SO3—X+ POLYMER 213 SO3—X+ H SO3—X+ H POLYMER 214 SO3—X+ H H SO2Me POLYMER 215 SO3—X+ H H SO3—X+ POLYMER 216 SO3—X+ H H H POLYMER 217 H SO2Me SO2Me SO2Me POLYMER 218 H SO2Me SO2Me SO3—X+ POLYMER 219 H SO2Me SO2Me H POLYMER 220 H SO2Me SO3—X+ SO2Me POLYMER 221 H SO2Me SO3—X+ SO3—X+ POLYMER 222 H SO2Me SO3—X+ H POLYMER 223 H SO2Me H SO2Me POLYMER 224 H SO2Me H SO3—X+ POLYMER 225 H SO2Me H H POLYMER 226 H SO3—X+ SO2Me SO2Me POLYMER 227 H SO3—X+ SO2Me SO3—X+ POLYMER 228 H SO3—X+ SO2Me H POLYMER 229 H SO3—X+ SO3—X+ SO2Me POLYMER 230 H SO3—X+ SO3—X+ SO3—X+ POLYMER 231 H SO3—X+ SO3—X+ H POLYMER 232 H SO3—X+ H SO2Me POLYMER 233 H SO3—X+ H SO3—X+ POLYMER 234 H SO3—X+ H H POLYMER 235 H H SO2Me SO2Me POLYMER 236 H H SO2Me SO3—X+ POLYMER 237 H H SO2Me H POLYMER 238 H H SO3—X+ SO2Me POLYMER 239 H H SO3—X+ SO3—X+ POLYMER 240 H H SO3—X+ H POLYMER
[0116]
TABLE 2
Various chemical moieties for Structure 2.
COMBINATIONS FOR STRUCTURE 2
2
3
4
6
1
A, D, H or K
B, E, I or L
F or J
C, G or M
N
1
SO2Me
SO2Me
SO2Me
SO2Me
POLYMER
2
SO2Me
SO2Me
SO2Me
SO3—X+
POLYMER
3
SO2Me
SO2Me
SO2Me
H
POLYMER
4
SO2Me
SO2Me
SO3—X+
SO2Me
POLYMER
5
SO2Me
SO2Me
SO3—X+
SO3—X+
POLYMER
6
SO2Me
SO2Me
SO3—X+
H
POLYMER
7
SO2Me
SO2Me
H
SO2Me
POLYMER
8
SO2Me
SO2Me
H
SO3—X+
POLYMER
9
SO2Me
SO2Me
H
H
POLYMER
10
SO2Me
SO3—X+
SO2Me
SO2Me
POLYMER
11
SO2Me
SO3—X+
SO2Me
SO3—X+
POLYMER
12
SO2Me
SO3—X+
SO2Me
H
POLYMER
13
SO2Me
SO3—X+
SO3—X+
SO2Me
POLYMER
14
SO2Me
SO3—X+
SO3—X+
SO3—X+
POLYMER
15
SO2Me
SO3—X+
SO3—X+
H
POLYMER
16
SO2Me
SO3—X+
H
SO2Me
POLYMER
17
SO2Me
SO3—X+
H
SO3—X+
POLYMER
18
SO2Me
SO3—X+
H
H
POLYMER
19
SO2Me
H
SO2Me
SO2Me
POLYMER
20
SO2Me
H
SO2Me
SO3—X+
POLYMER
21
SO2Me
H
SO2Me
H
POLYMER
22
SO2Me
H
SO3—X+
SO2Me
POLYMER
23
SO2Me
H
SO3—X+
SO3—X+
POLYMER
24
SO2Me
H
SO3—X+
H
POLYMER
25
SO2Me
H
H
SO2Me
POLYMER
26
SO2Me
H
H
SO3—X+
POLYMER
27
SO2Me
H
H
H
POLYMER
28
SO3—X+
SO2Me
SO2Me
SO2Me
POLYMER
29
SO3—X+
SO2Me
SO2Me
SO3—X+
POLYMER
30
SO3—X+
SO2Me
SO2Me
H
POLYMER
31
SO3—X+
SO2Me
SO3—X+
SO2Me
POLYMER
32
SO3—X+
SO2Me
SO3—X+
SO3—X+
POLYMER
33
SO3—X+
SO2Me
SO3—X+
H
POLYMER
34
SO3—X+
SO2Me
H
SO2Me
POLYMER
35
SO3—X+
SO2Me
H
SO3—X+
POLYMER
36
SO3—X+
SO2Me
H
H
POLYMER
37
SO3—X+
SO3—X+
SO2Me
SO2Me
POLYMER
38
SO3—X+
SO3—X+
SO2Me
SO3—X+
POLYMER
39
SO3—X+
SO3—X+
SO2Me
H
POLYMER
40
SO3—X+
SO3—X+
SO3—X+
SO2Me
POLYMER
41
SO3—X+
SO3—X+
SO3—X+
SO3—X+
POLYMER
42
SO3—X+
SO3—X+
SO3—X+
H
POLYMER
43
SO3—X+
SO3—X+
H
SO2Me
POLYMER
44
SO3—X+
SO3—X+
H
SO3—X+
POLYMER
45
SO3—X+
SO3—X+
H
H
POLYMER
46
SO3—X+
H
SO2Me
SO2Me
POLYMER
47
SO3—X+
H
SO2Me
SO3—X+
POLYMER
48
SO3—X+
H
SO2Me
H
POLYMER
49
SO3—X+
H
SO3—X+
SO2Me
POLYMER
50
SO3—X+
H
SO3—X+
SO3—X+
POLYMER
51
SO3—X+
H
SO3—X+
H
POLYMER
52
SO3—X+
H
H
SO2Me
POLYMER
53
SO3—X+
H
H
SO3—X+
POLYMER
54
SO3—X+
H
H
H
POLYMER
55
H
SO2Me
SO2Me
SO2Me
POLYMER
56
H
SO2Me
SO2Me
SO3—X+
POLYMER
57
H
SO2Me
SO2Me
H
POLYMER
58
H
SO2Me
SO3—X+
SO2Me
POLYMER
59
H
SO2Me
SO3—X+
SO3—X+
POLYMER
60
H
SO2Me
SO3—X+
H
POLYMER
61
H
SO2Me
H
SO2Me
POLYMER
62
H
SO2Me
H
SO3—X+
POLYMER
63
H
SO2Me
H
H
POLYMER
64
H
SO3—X+
SO2Me
SO2Me
POLYMER
65
H
SO3—X+
SO2Me
SO3—X+
POLYMER
66
H
SO3—X+
SO2Me
H
POLYMER
67
H
SO3—X+
SO3—X+
SO2Me
POLYMER
68
H
SO3—X+
SO3—X+
SO3—X+
POLYMER
69
H
SO3—X+
SO3—X+
H
POLYMER
70
H
SO3—X+
H
SO2Me
POLYMER
71
H
SO3—X+
H
SO3—X+
POLYMER
72
H
SO3—X+
H
H
POLYMER
73
H
H
SO2Me
SO2Me
POLYMER
74
H
H
SO2Me
SO3—X+
POLYMER
75
H
H
SO2Me
H
POLYMER
76
H
H
SO3—X+
SO2Me
POLYMER
77
H
H
SO3—X+
SO3—X+
POLYMER
78
H
H
SO3—X+
H
POLYMER
79
H
H
H
SO2Me
POLYMER
80
H
H
H
SO3—X+
POLYMER
81
H
H
H
H
POLYMER
82
SO2Me
SO2Me
SO2Me
SO2Me
POLYMER
83
SO2Me
SO2Me
SO2Me
SO3—X+
POLYMER
84
SO2Me
SO2Me
SO2Me
H
POLYMER
85
SO2Me
SO2Me
SO3—X+
SO2Me
POLYMER
86
SO2Me
SO2Me
SO3—X+
SO3—X+
POLYMER
87
SO2Me
SO2Me
SO3—X+
H
POLYMER
88
SO2Me
SO2Me
H
SO2Me
POLYMER
89
SO2Me
SO2Me
H
SO3—X+
POLYMER
90
SO2Me
SO2Me
H
H
POLYMER
91
SO2Me
SO3—X+
SO2Me
SO2Me
POLYMER
92
SO2Me
SO3—X+
SO2Me
SO3—X+
POLYMER
93
SO2Me
SO3—X+
SO2Me
H
POLYMER
94
SO2Me
SO3—X+
SO3—X+
SO2Me
POLYMER
95
SO2Me
SO3—X+
SO3—X+
SO3—X+
POLYMER
96
SO2Me
SO3—X+
SO3—X+
H
POLYMER
97
SO2Me
SO3—X+
H
SO2Me
POLYMER
98
SO2Me
SO3—X+
H
SO3—X+
POLYMER
99
SO2Me
SO3—X+
H
H
POLYMER
100
SO2Me
H
SO2Me
SO2Me
POLYMER
101
SO2Me
H
SO2Me
SO3—X+
POLYMER
102
SO2Me
H
SO2Me
H
POLYMER
103
SO2Me
H
SO3—X+
SO2Me
POLYMER
104
SO2Me
H
SO3—X+
SO3—X+
POLYMER
105
SO2Me
H
SO3—X+
H
POLYMER
106
SO2Me
H
H
SO2Me
POLYMER
107
SO2Me
H
H
SO3—X+
POLYMER
108
SO2Me
H
H
H
POLYMER
109
SO3—X+
SO2Me
SO2Me
SO2Me
POLYMER
110
SO3—X+
SO2Me
SO2Me
SO3—X+
POLYMER
111
SO3—X+
SO2Me
SO2Me
H
POLYMER
112
SO3—X+
SO2Me
SO3—X+
SO2Me
POLYMER
113
SO3—X+
SO2Me
SO3—X+
SO3—X+
POLYMER
114
SO3—X+
SO2Me
SO3—X+
H
POLYMER
115
SO3—X+
SO2Me
H
SO2Me
POLYMER
116
SO3—X+
SO2Me
H
SO3—X+
POLYMER
117
SO3—X+
SO2Me
H
H
POLYMER
118
SO3—X+
SO3—X+
SO2Me
SO2Me
POLYMER
119
SO3—X+
SO3—X+
SO2Me
SO3—X+
POLYMER
120
SO3—X+
SO3—X+
SO2Me
H
POLYMER
121
SO3—X+
SO3—X+
SO3—X+
SO2Me
POLYMER
122
SO3—X+
SO3—X+
SO3—X+
SO3—X+
POLYMER
123
SO3—X+
SO3—X+
SO3—X+
H
POLYMER
124
SO3—X+
SO3—X+
H
SO2Me
POLYMER
125
SO3—X+
SO3—X+
H
SO3—X+
POLYMER
126
SO3—X+
SO3—X+
H
H
POLYMER
127
SO3—X+
H
SO2Me
SO2Me
POLYMER
128
SO3—X+
H
SO2Me
SO3—X+
POLYMER
129
SO3—X+
H
SO2Me
H
POLYMER
130
SO3—X+
H
SO3—X+
SO2Me
POLYMER
131
SO3—X+
H
SO3—X+
SO3—X+
POLYMER
132
SO3—X+
H
SO3—X+
H
POLYMER
133
SO3—X+
H
H
SO2Me
POLYMER
134
SO3—X+
H
H
SO3—X+
POLYMER
135
SO3—X+
H
H
H
POLYMER
136
H
SO2Me
SO2Me
SO2Me
POLYMER
137
H
SO2Me
SO2Me
SO3—X+
POLYMER
138
H
SO2Me
SO2Me
H
POLYMER
139
H
SO2Me
SO3—X+
SO2Me
POLYMER
140
H
SO2Me
SO3—X+
SO3—X+
POLYMER
141
H
SO2Me
SO3—X+
H
POLYMER
142
H
SO2Me
H
SO2Me
POLYMER
143
H
SO2Me
H
SO3—X+
POLYMER
144
H
SO2Me
H
H
POLYMER
145
H
SO3—X+
SO2Me
SO2Me
POLYMER
146
H
SO3—X+
SO2Me
SO3—X+
POLYMER
147
H
SO3—X+
SO2Me
H
POLYMER
148
H
SO3—X+
SO3—X+
SO2Me
POLYMER
149
H
SO3—X+
SO3—X+
SO3—X+
POLYMER
150
H
SO3—X+
SO3—X+
H
POLYMER
151
H
SO3—X+
H
SO2Me
POLYMER
152
H
SO3—X+
H
SO3—X+
POLYMER
153
H
SO3—X+
H
H
POLYMER
154
H
H
SO2Me
SO2Me
POLYMER
155
H
H
SO2Me
SO3—X+
POLYMER
156
H
H
SO2Me
H
POLYMER
157
H
H
SO3—X+
SO2Me
POLYMER
158
H
H
SO3—X+
SO3—X+
POLYMER
159
H
H
SO3—X+
H
POLYMER
160
H
H
H
SO2Me
POLYMER
161
H
H
H
SO3—X+
POLYMER
162
H
H
H
H
POLYMER
163
SO2Me
SO2Me
SO2Me
SO2Me
POLYMER
164
SO2Me
SO2Me
SO2Me
SO3—X+
POLYMER
165
SO2Me
SO2Me
SO2Me
H
POLYMER
166
SO2Me
SO2Me
SO3—X+
SO2Me
POLYMER
167
SO2Me
SO2Me
SO3—X+
SO3—X+
POLYMER
168
SO2Me
SO2Me
SO3—X+
H
POLYMER
169
SO2Me
SO2Me
H
SO2Me
POLYMER
170
SO2Me
SO2Me
H
SO3—X+
POLYMER
171
SO2Me
SO2Me
H
H
POLYMER
172
SO2Me
SO3—X+
SO2Me
SO2Me
POLYMER
173
SO2Me
SO3—X+
SO2Me
SO3—X+
POLYMER
174
SO2Me
SO3—X+
SO2Me
H
POLYMER
175
SO2Me
SO3—X+
SO3—X+
SO2Me
POLYMER
176
SO2Me
SO3—X+
SO3—X+
SO3—X+
POLYMER
177
SO2Me
SO3—X+
SO3—X+
H
POLYMER
178
SO2Me
SO3—X+
H
SO2Me
POLYMER
179
SO2Me
SO3—X+
H
SO3—X+
POLYMER
180
SO2Me
SO3—X+
H
H
POLYMER
181
SO2Me
H
SO2Me
SO2Me
POLYMER
182
SO2Me
H
SO2Me
SO3—X+
POLYMER
183
SO2Me
H
SO2Me
H
POLYMER
184
SO2Me
H
SO3—X+
SO2Me
POLYMER
185
SO2Me
H
SO3—X+
SO3—X+
POLYMER
186
SO2Me
H
SO3—X+
H
POLYMER
187
SO2Me
H
H
SO2Me
POLYMER
188
SO2Me
H
H
SO3—X+
POLYMER
189
SO2Me
H
H
H
POLYMER
190
SO3—X+
SO2Me
SO2Me
SO2Me
POLYMER
191
SO3—X+
SO2Me
SO2Me
SO3—X+
POLYMER
192
SO3—X+
SO2Me
SO2Me
H
POLYMER
193
SO3—X+
SO2Me
SO3—X+
SO2Me
POLYMER
194
SO3—X+
SO2Me
SO3—X+
SO3—X+
POLYMER
195
SO3—X+
SO2Me
SO3—X+
H
POLYMER
196
SO3—X+
SO2Me
H
SO2Me
POLYMER
197
SO3—X+
SO2Me
H
SO3—X+
POLYMER
198
SO3—X+
SO2Me
H
H
POLYMER
199
SO3—X+
SO3—X+
SO2Me
SO2Me
POLYMER
200
SO3—X+
SO3—X+
SO2Me
SO3—X+
POLYMER
201
SO3—X+
SO3—X+
SO2Me
H
POLYMER
202
SO3—X+
SO3—X+
SO3—X+
SO2Me
POLYMER
203
SO3—X+
SO3—X+
SO3—X+
SO3—X+
POLYMER
204
SO3—X+
SO3—X+
SO3—X+
H
POLYMER
205
SO3—X+
SO3—X+
H
SO2Me
POLYMER
206
SO3—X+
SO3—X+
H
SO3—X+
POLYMER
207
SO3—X+
SO3—X+
H
H
POLYMER
208
SO3—X+
H
SO2Me
SO2Me
POLYMER
209
SO3—X+
H
SO2Me
SO3—X+
POLYMER
210
SO3—X+
H
SO2Me
H
POLYMER
211
SO3—X+
H
SO3—X+
SO2Me
POLYMER
212
SO3—X+
H
SO3—X+
SO3—X+
POLYMER
213
SO3—X+
H
SO3—X+
H
POLYMER
214
SO3—X+
H
H
SO2Me
POLYMER
215
SO3—X+
H
H
SO3—X+
POLYMER
216
SO3—X+
H
H
H
POLYMER
217
H
SO2Me
SO2Me
SO2Me
POLYMER
218
H
SO2Me
SO2Me
SO3—X+
POLYMER
219
H
SO2Me
SO2Me
H
POLYMER
220
H
SO2Me
SO3—X+
SO2Me
POLYMER
221
H
SO2Me
SO3—X+
SO3—X+
POLYMER
222
H
SO2Me
SO3—X+
H
POLYMER
223
H
SO2Me
H
SO2Me
POLYMER
224
H
SO2Me
H
SO3—X+
POLYMER
225
H
SO2Me
H
H
POLYMER
226
H
SO3—X+
SO2Me
SO2Me
POLYMER
227
H
SO3—X+
SO2Me
SO3—X+
POLYMER
228
H
SO3—X+
SO2Me
H
POLYMER
229
H
SO3—X+
SO3—X+
SO2Me
POLYMER
230
H
SO3—X+
SO3—X+
SO3—X+
POLYMER
231
H
SO3—X+
SO3—X+
H
POLYMER
232
H
SO3—X+
H
SO2Me
POLYMER
233
H
SO3—X+
H
SO3—X+
POLYMER
234
H
SO3—X+
H
H
POLYMER
235
H
H
SO2Me
SO2Me
POLYMER
236
H
H
SO2Me
SO3—X+
POLYMER
237
H
H
SO2Me
H
POLYMER
238
H
H
SO3—X+
SO2Me
POLYMER
239
H
H
SO3—X+
SO3—X+
POLYMER
240
H
H
SO3—X+
H
POLYMER
[0117]
TABLE 3
Various chemical moieties for Structure 3.
COMBINATIONS FOR STRUCTURE 3
2
3
A, D, H,
B, E, M,
4
6
1
L or N
I or O
F or J
C, G, K, or P
Q
1
SO2Me
SO2Me
SO2Me
SO2Me
POLYMER
2
SO2Me
SO2Me
SO2Me
SO3—X+
POLYMER
3
SO2Me
SO2Me
SO2Me
H
POLYMER
4
SO2Me
SO2Me
SO3—X+
SO2Me
POLYMER
5
SO2Me
SO2Me
SO3—X+
SO3—X+
POLYMER
6
SO2Me
SO2Me
SO3—X+
H
POLYMER
7
SO2Me
SO2Me
H
SO2Me
POLYMER
8
SO2Me
SO2Me
H
SO3—X+
POLYMER
9
SO2Me
SO2Me
H
H
POLYMER
10
SO2Me
SO3—X+
SO2Me
SO2Me
POLYMER
11
SO2Me
SO3—X+
SO2Me
SO3—X+
POLYMER
12
SO2Me
SO3—X+
SO2Me
H
POLYMER
13
SO2Me
SO3—X+
SO3—X+
SO2Me
POLYMER
14
SO2Me
SO3—X+
SO3—X+
SO3—X+
POLYMER
15
SO2Me
SO3—X+
SO3—X+
H
POLYMER
16
SO2Me
SO3—X+
H
SO2Me
POLYMER
17
SO2Me
SO3—X+
H
SO3—X+
POLYMER
18
SO2Me
SO3—X+
H
H
POLYMER
19
SO2Me
H
SO2Me
SO2Me
POLYMER
20
SO2Me
H
SO2Me
SO3—X+
POLYMER
21
SO2Me
H
SO2Me
H
POLYMER
22
SO2Me
H
SO3—X+
SO2Me
POLYMER
23
SO2Me
H
SO3—X+
SO3—X+
POLYMER
24
SO2Me
H
SO3—X+
H
POLYMER
25
SO2Me
H
H
SO2Me
POLYMER
26
SO2Me
H
H
SO3—X+
POLYMER
27
SO2Me
H
H
H
POLYMER
28
SO3—X+
SO2Me
SO2Me
SO2Me
POLYMER
29
SO3—X+
SO2Me
SO2Me
SO3—X+
POLYMER
30
SO3—X+
SO2Me
SO2Me
H
POLYMER
31
SO3—X+
SO2Me
SO3—X+
SO2Me
POLYMER
32
SO3—X+
SO2Me
SO3—X+
SO3—X+
POLYMER
33
SO3—X+
SO2Me
SO3—X+
H
POLYMER
34
SO3—X+
SO2Me
H
SO2Me
POLYMER
35
SO3—X+
SO2Me
H
SO3—X+
POLYMER
36
SO3—X+
SO2Me
H
H
POLYMER
37
SO3—X+
SO3—X+
SO2Me
SO2Me
POLYMER
38
SO3—X+
SO3—X+
SO2Me
SO3—X+
POLYMER
39
SO3—X+
SO3—X+
SO2Me
H
POLYMER
40
SO3—X+
SO3—X+
SO3—X+
SO2Me
POLYMER
41
SO3—X+
SO3—X+
SO3—X+
SO3—X+
POLYMER
42
SO3—X+
SO3—X+
SO3—X+
H
POLYMER
43
SO3—X+
SO3—X+
H
SO2Me
POLYMER
44
SO3—X+
SO3—X+
H
SO3—X+
POLYMER
45
SO3—X+
SO3—X+
H
H
POLYMER
46
SO3—X+
H
SO2Me
SO2Me
POLYMER
47
SO3—X+
H
SO2Me
SO3—X+
POLYMER
48
SO3—X+
H
SO2Me
H
POLYMER
49
SO3—X+
H
SO3—X+
SO2Me
POLYMER
50
SO3—X+
H
SO3—X+
SO3—X+
POLYMER
51
SO3—X+
H
SO3—X+
H
POLYMER
52
SO3—X+
H
H
SO2Me
POLYMER
53
SO3—X+
H
H
SO3—X+
POLYMER
54
SO3—X+
H
H
H
POLYMER
55
H
SO2Me
SO2Me
SO2Me
POLYMER
56
H
SO2Me
SO2Me
SO3—X+
POLYMER
57
H
SO2Me
SO2Me
H
POLYMER
58
H
SO2Me
SO3—X+
SO2Me
POLYMER
59
H
SO2Me
SO3—X+
SO3—X+
POLYMER
60
H
SO2Me
SO3—X+
H
POLYMER
61
H
SO2Me
H
SO2Me
POLYMER
62
H
SO2Me
H
SO3—X+
POLYMER
63
H
SO2Me
H
H
POLYMER
64
H
SO3—X+
SO2Me
SO2Me
POLYMER
65
H
SO3—X+
SO2Me
SO3—X+
POLYMER
66
H
SO3—X+
SO2Me
H
POLYMER
67
H
SO3—X+
SO3—X+
SO2Me
POLYMER
68
H
SO3—X+
SO3—X+
SO3—X+
POLYMER
69
H
SO3—X+
SO3—X+
H
POLYMER
70
H
SO3—X+
H
SO2Me
POLYMER
71
H
SO3—X+
H
SO3—X+
POLYMER
72
H
SO3—X+
H
H
POLYMER
73
H
H
SO2Me
SO2Me
POLYMER
74
H
H
SO2Me
SO3—X+
POLYMER
75
H
H
SO2Me
H
POLYMER
76
H
H
SO3—X+
SO2Me
POLYMER
77
H
H
SO3—X+
SO3—X+
POLYMER
78
H
H
SO3—X+
H
POLYMER
79
H
H
H
SO2Me
POLYMER
80
H
H
H
SO3—X+
POLYMER
81
H
H
H
H
POLYMER
82
SO2Me
SO2Me
SO2Me
SO2Me
POLYMER
83
SO2Me
SO2Me
SO2Me
SO3—X+
POLYMER
84
SO2Me
SO2Me
SO2Me
H
POLYMER
85
SO2Me
SO2Me
SO3—X+
SO2Me
POLYMER
86
SO2Me
SO2Me
SO3—X+
SO3—X+
POLYMER
87
SO2Me
SO2Me
SO3—X+
H
POLYMER
88
SO2Me
SO2Me
H
SO2Me
POLYMER
89
SO2Me
SO2Me
H
SO3—X+
POLYMER
90
SO2Me
SO2Me
H
H
POLYMER
91
SO2Me
SO3—X+
SO2Me
SO2Me
POLYMER
92
SO2Me
SO3—X+
SO2Me
SO3—X+
POLYMER
93
SO2Me
SO3—X+
SO2Me
H
POLYMER
94
SO2Me
SO3—X+
SO3—X+
SO2Me
POLYMER
95
SO2Me
SO3—X+
SO3—X+
SO3—X+
POLYMER
96
SO2Me
SO3—X+
SO3—X+
H
POLYMER
97
SO2Me
SO3—X+
H
SO2Me
POLYMER
98
SO2Me
SO3—X+
H
SO3—X+
POLYMER
99
SO2Me
SO3—X+
H
H
POLYMER
100
SO2Me
H
SO2Me
SO2Me
POLYMER
101
SO2Me
H
SO2Me
SO3—X+
POLYMER
102
SO2Me
H
SO2Me
H
POLYMER
103
SO2Me
H
SO3—X+
SO2Me
POLYMER
104
SO2Me
H
SO3—X+
SO3—X+
POLYMER
105
SO2Me
H
SO3—X+
H
POLYMER
106
SO2Me
H
H
SO2Me
POLYMER
107
SO2Me
H
H
SO3—X+
POLYMER
108
SO2Me
H
H
H
POLYMER
109
SO3—X+
SO2Me
SO2Me
SO2Me
POLYMER
110
SO3—X+
SO2Me
SO2Me
SO3—X+
POLYMER
111
SO3—X+
SO2Me
SO2Me
H
POLYMER
112
SO3—X+
SO2Me
SO3—X+
SO2Me
POLYMER
113
SO3—X+
SO2Me
SO3—X+
SO3—X+
POLYMER
114
SO3—X+
SO2Me
SO3—X+
H
POLYMER
115
SO3—X+
SO2Me
H
SO2Me
POLYMER
116
SO3—X+
SO2Me
H
SO3—X+
POLYMER
117
SO3—X+
SO2Me
H
H
POLYMER
118
SO3—X+
SO3—X+
SO2Me
SO2Me
POLYMER
119
SO3—X+
SO3—X+
SO2Me
SO3—X+
POLYMER
120
SO3—X+
SO3—X+
SO2Me
H
POLYMER
121
SO3—X+
SO3—X+
SO3—X+
SO2Me
POLYMER
122
SO3—X+
SO3—X+
SO3—X+
SO3—X+
POLYMER
123
SO3—X+
SO3—X+
SO3—X+
H
POLYMER
124
SO3—X+
SO3—X+
H
SO2Me
POLYMER
125
SO3—X+
SO3—X+
H
SO3—X+
POLYMER
126
SO3—X+
SO3—X+
H
H
POLYMER
127
SO3—X+
H
SO2Me
SO2Me
POLYMER
128
SO3—X+
H
SO2Me
SO3—X+
POLYMER
129
SO3—X+
H
SO2Me
H
POLYMER
130
SO3—X+
H
SO3—X+
SO2Me
POLYMER
131
SO3—X+
H
SO3—X+
SO3—X+
POLYMER
132
SO3—X+
H
SO3—X+
H
POLYMER
133
SO3—X+
H
H
SO2Me
POLYMER
134
SO3—X+
H
H
SO3—X+
POLYMER
135
SO3—X+
H
H
H
POLYMER
136
H
SO2Me
SO2Me
SO2Me
POLYMER
137
H
SO2Me
SO2Me
SO3—X+
POLYMER
138
H
SO2Me
SO2Me
H
POLYMER
139
H
SO2Me
SO3—X+
SO2Me
POLYMER
140
H
SO2Me
SO3—X+
SO3—X+
POLYMER
141
H
SO2Me
SO3—X+
H
POLYMER
142
H
SO2Me
H
SO2Me
POLYMER
143
H
SO2Me
H
SO3—X+
POLYMER
144
H
SO2Me
H
H
POLYMER
145
H
SO3—X+
SO2Me
SO2Me
POLYMER
146
H
SO3—X+
SO2Me
SO3—X+
POLYMER
147
H
SO3—X+
SO2Me
H
POLYMER
148
H
SO3—X+
SO3—X+
SO2Me
POLYMER
149
H
SO3—X+
SO3—X+
SO3—X+
POLYMER
150
H
SO3—X+
SO3—X+
H
POLYMER
151
H
SO3—X+
H
SO2Me
POLYMER
152
H
SO3—X+
H
SO3—X+
POLYMER
153
H
SO3—X+
H
H
POLYMER
154
H
H
SO2Me
SO2Me
POLYMER
155
H
H
SO2Me
SO3—X+
POLYMER
156
H
H
SO2Me
H
POLYMER
157
H
H
SO3—X+
SO2Me
POLYMER
158
H
H
SO3—X+
SO3—X+
POLYMER
159
H
H
SO3—X+
H
POLYMER
160
H
H
H
SO2Me
POLYMER
161
H
H
H
SO3—X+
POLYMER
162
H
H
H
H
POLYMER
163
SO2Me
SO2Me
SO2Me
SO2Me
POLYMER
164
SO2Me
SO2Me
SO2Me
SO3—X+
POLYMER
165
SO2Me
SO2Me
SO2Me
H
POLYMER
166
SO2Me
SO2Me
SO3—X+
SO2Me
POLYMER
167
SO2Me
SO2Me
SO3—X+
SO3—X+
POLYMER
168
SO2Me
SO2Me
SO3—X+
H
POLYMER
169
SO2Me
SO2Me
H
SO2Me
POLYMER
170
SO2Me
SO2Me
H
SO3—X+
POLYMER
171
SO2Me
SO2Me
H
H
POLYMER
172
SO2Me
SO3—X+
SO2Me
SO2Me
POLYMER
173
SO2Me
SO3—X+
SO2Me
SO3—X+
POLYMER
174
SO2Me
SO3—X+
SO2Me
H
POLYMER
175
SO2Me
SO3—X+
SO3—X+
SO2Me
POLYMER
176
SO2Me
SO3—X+
SO3—X+
SO3—X+
POLYMER
177
SO2Me
SO3—X+
SO3—X+
H
POLYMER
178
SO2Me
SO3—X+
H
SO2Me
POLYMER
179
SO2Me
SO3—X+
H
SO3—X+
POLYMER
180
SO2Me
SO3—X+
H
H
POLYMER
181
SO2Me
H
SO2Me
SO2Me
POLYMER
182
SO2Me
H
SO2Me
SO3—X+
POLYMER
183
SO2Me
H
SO2Me
H
POLYMER
184
SO2Me
H
SO3—X+
SO2Me
POLYMER
185
SO2Me
H
SO3—X+
SO3—X+
POLYMER
186
SO2Me
H
SO3—X+
H
POLYMER
187
SO2Me
H
H
SO2Me
POLYMER
188
SO2Me
H
H
SO3—X+
POLYMER
189
SO2Me
H
H
H
POLYMER
190
SO3—X+
SO2Me
SO2Me
SO2Me
POLYMER
191
SO3—X+
SO2Me
SO2Me
SO3—X+
POLYMER
192
SO3—X+
SO2Me
SO2Me
H
POLYMER
193
SO3—X+
SO2Me
SO3—X+
SO2Me
POLYMER
194
SO3—X+
SO2Me
SO3—X+
SO3—X+
POLYMER
195
SO3—X+
SO2Me
SO3—X+
H
POLYMER
196
SO3—X+
SO2Me
H
SO2Me
POLYMER
197
SO3—X+
SO2Me
H
SO3—X+
POLYMER
198
SO3—X+
SO2Me
H
H
POLYMER
199
SO3—X+
SO3—X+
SO2Me
SO2Me
POLYMER
200
SO3—X+
SO3—X+
SO2Me
SO3—X+
POLYMER
201
SO3—X+
SO3—X+
SO2Me
H
POLYMER
202
SO3—X+
SO3—X+
SO3—X+
SO2Me
POLYMER
203
SO3—X+
SO3—X+
SO3—X+
SO3—X+
POLYMER
204
SO3—X+
SO3—X+
SO3—X+
H
POLYMER
205
SO3—X+
SO3—X+
H
SO2Me
POLYMER
206
SO3—X+
SO3—X+
H
SO3—X+
POLYMER
207
SO3—X+
SO3—X+
H
H
POLYMER
208
SO3—X+
H
SO2Me
SO2Me
POLYMER
209
SO3—X+
H
SO2Me
SO3—X+
POLYMER
210
SO3—X+
H
SO2Me
H
POLYMER
211
SO3—X+
H
SO3—X+
SO2Me
POLYMER
212
SO3—X+
H
SO3—X+
SO3—X+
POLYMER
213
SO3—X+
H
SO3—X+
H
POLYMER
214
SO3—X+
H
H
SO2Me
POLYMER
215
SO3—X+
H
H
SO3—X+
POLYMER
216
SO3—X+
H
H
H
POLYMER
217
H
SO2Me
SO2Me
SO2Me
POLYMER
218
H
SO2Me
SO2Me
SO3—X+
POLYMER
219
H
SO2Me
SO2Me
H
POLYMER
220
H
SO2Me
SO3—X+
SO2Me
POLYMER
221
H
SO2Me
SO3—X+
SO3—X+
POLYMER
222
H
SO2Me
SO3—X+
H
POLYMER
223
H
SO2Me
H
SO2Me
POLYMER
224
H
SO2Me
H
SO3—X+
POLYMER
225
H
SO2Me
H
H
POLYMER
226
H
SO3—X+
SO2Me
SO2Me
POLYMER
227
H
SO3—X+
SO2Me
SO3—X+
POLYMER
228
H
SO3—X+
SO2Me
H
POLYMER
229
H
SO3—X+
SO3—X+
SO2Me
POLYMER
230
H
SO3—X+
SO3—X+
SO3—X+
POLYMER
231
H
SO3—X+
SO3—X+
H
POLYMER
232
H
SO3—X+
H
SO2Me
POLYMER
233
H
SO3—X+
H
SO3—X+
POLYMER
234
H
SO3—X+
H
H
POLYMER
235
H
H
SO2Me
SO2Me
POLYMER
236
H
H
SO2Me
SO3—X+
POLYMER
237
H
H
SO2Me
H
POLYMER
238
H
H
SO3—X+
SO2Me
POLYMER
239
H
H
SO3—X+
SO3—X+
POLYMER
240
H
H
SO3—X+
H
POLYMER
[0118]
TABLE 4
Various chemical moieties for Structure 4.
COMBINATIONS FOR STRUCTURE 4
2
3
4
6
1
A, E, I, or K
B, F, J or L
G or C
D, H or M
Q
1
SO2Me
SO2Me
SO2Me
SO2Me
POLYMER
2
SO2Me
SO2Me
SO2Me
SO3—X+
POLYMER
3
SO2Me
SO2Me
SO2Me
H
POLYMER
4
SO2Me
SO2Me
SO3—X+
SO2Me
POLYMER
5
SO2Me
SO2Me
SO3—X+
SO3—X+
POLYMER
6
SO2Me
SO2Me
SO3—X+
H
POLYMER
7
SO2Me
SO2Me
H
SO2Me
POLYMER
8
SO2Me
SO2Me
H
SO3—X+
POLYMER
9
SO2Me
SO2Me
H
H
POLYMER
10
SO2Me
SO3—X+
SO2Me
SO2Me
POLYMER
11
SO2Me
SO3—X+
SO2Me
SO3—X+
POLYMER
12
SO2Me
SO3—X+
SO2Me
H
POLYMER
13
SO2Me
SO3—X+
SO3—X+
SO2Me
POLYMER
14
SO2Me
SO3—X+
SO3—X+
SO3—X+
POLYMER
15
SO2Me
SO3—X+
SO3—X+
H
POLYMER
16
SO2Me
SO3—X+
H
SO2Me
POLYMER
17
SO2Me
SO3—X+
H
SO3—X+
POLYMER
18
SO2Me
SO3—X+
H
H
POLYMER
19
SO2Me
H
SO2Me
SO2Me
POLYMER
20
SO2Me
H
SO2Me
SO3—X+
POLYMER
21
SO2Me
H
SO2Me
H
POLYMER
22
SO2Me
H
SO3—X+
SO2Me
POLYMER
23
SO2Me
H
SO3—X+
SO3—X+
POLYMER
24
SO2Me
H
SO3—X+
H
POLYMER
25
SO2Me
H
H
SO2Me
POLYMER
26
SO2Me
H
H
SO3—X+
POLYMER
27
SO2Me
H
H
H
POLYMER
28
SO3—X+
SO2Me
SO2Me
SO2Me
POLYMER
29
SO3—X+
SO2Me
SO2Me
SO3—X+
POLYMER
30
SO3—X+
SO2Me
SO2Me
H
POLYMER
31
SO3—X+
SO2Me
SO3—X+
SO2Me
POLYMER
32
SO3—X+
SO2Me
SO3—X+
SO3—X+
POLYMER
33
SO3—X+
SO2Me
SO3—X+
H
POLYMER
34
SO3—X+
SO2Me
H
SO2Me
POLYMER
35
SO3—X+
SO2Me
H
SO3—X+
POLYMER
36
SO3—X+
SO2Me
H
H
POLYMER
37
SO3—X+
SO3—X+
SO2Me
SO2Me
POLYMER
38
SO3—X+
SO3—X+
SO2Me
SO3—X+
POLYMER
39
SO3—X+
SO3—X+
SO2Me
H
POLYMER
40
SO3—X+
SO3—X+
SO3—X+
SO2Me
POLYMER
41
SO3—X+
SO3—X+
SO3—X+
SO3—X+
POLYMER
42
SO3—X+
SO3—X+
SO3—X+
H
POLYMER
43
SO3—X+
SO3—X+
H
SO2Me
POLYMER
44
SO3—X+
SO3—X+
H
SO3—X+
POLYMER
45
SO3—X+
SO3—X+
H
H
POLYMER
46
SO3—X+
H
SO2Me
SO2Me
POLYMER
47
SO3—X+
H
SO2Me
SO3—X+
POLYMER
48
SO3—X+
H
SO2Me
H
POLYMER
49
SO3—X+
H
SO3—X+
SO2Me
POLYMER
50
SO3—X+
H
SO3—X+
SO3—X+
POLYMER
51
SO3—X+
H
SO3—X+
H
POLYMER
52
SO3—X+
H
H
SO2Me
POLYMER
53
SO3—X+
H
H
SO3—X+
POLYMER
54
SO3—X+
H
H
H
POLYMER
55
H
SO2Me
SO2Me
SO2Me
POLYMER
56
H
SO2Me
SO2Me
SO3—X+
POLYMER
57
H
SO2Me
SO2Me
H
POLYMER
58
H
SO2Me
SO3—X+
SO2Me
POLYMER
59
H
SO2Me
SO3—X+
SO3—X+
POLYMER
60
H
SO2Me
SO3—X+
H
POLYMER
61
H
SO2Me
H
SO2Me
POLYMER
62
H
SO2Me
H
SO3—X+
POLYMER
63
H
SO2Me
H
H
POLYMER
64
H
SO3—X+
SO2Me
SO2Me
POLYMER
65
H
SO3—X+
SO2Me
SO3—X+
POLYMER
66
H
SO3—X+
SO2Me
H
POLYMER
67
H
SO3—X+
SO3—X+
SO2Me
POLYMER
68
H
SO3—X+
SO3—X+
SO3—X+
POLYMER
69
H
SO3—X+
SO3—X+
H
POLYMER
70
H
SO3—X+
H
SO2Me
POLYMER
71
H
SO3—X+
H
SO3—X+
POLYMER
72
H
SO3—X+
H
H
POLYMER
73
H
H
SO2Me
SO2Me
POLYMER
74
H
H
SO2Me
SO3—X+
POLYMER
75
H
H
SO2Me
H
POLYMER
76
H
H
SO3—X+
SO2Me
POLYMER
77
H
H
SO3—X+
SO3—X+
POLYMER
78
H
H
SO3—X+
H
POLYMER
79
H
H
H
SO2Me
POLYMER
80
H
H
H
SO3—X+
POLYMER
81
H
H
H
H
POLYMER
82
SO2Me
SO2Me
SO2Me
SO2Me
POLYMER
83
SO2Me
SO2Me
SO2Me
SO3—X+
POLYMER
84
SO2Me
SO2Me
SO2Me
H
POLYMER
85
SO2Me
SO2Me
SO3—X+
SO2Me
POLYMER
86
SO2Me
SO2Me
SO3—X+
SO3—X+
POLYMER
87
SO2Me
SO2Me
SO3—X+
H
POLYMER
88
SO2Me
SO2Me
H
SO2Me
POLYMER
89
SO2Me
SO2Me
H
SO3—X+
POLYMER
90
SO2Me
SO2Me
H
H
POLYMER
91
SO2Me
SO3—X+
SO2Me
SO2Me
POLYMER
92
SO2Me
SO3—X+
SO2Me
SO3—X+
POLYMER
93
SO2Me
SO3—X+
SO2Me
H
POLYMER
94
SO2Me
SO3—X+
SO3—X+
SO2Me
POLYMER
95
SO2Me
SO3—X+
SO3—X+
SO3—X+
POLYMER
96
SO2Me
SO3—X+
SO3—X+
H
POLYMER
97
SO2Me
SO3—X+
H
SO2Me
POLYMER
98
SO2Me
SO3—X+
H
SO3—X+
POLYMER
99
SO2Me
SO3—X+
H
H
POLYMER
100
SO2Me
H
SO2Me
SO2Me
POLYMER
101
SO2Me
H
SO2Me
SO3—X+
POLYMER
102
SO2Me
H
SO2Me
H
POLYMER
103
SO2Me
H
SO3—X+
SO2Me
POLYMER
104
SO2Me
H
SO3—X+
SO3—X+
POLYMER
105
SO2Me
H
SO3—X+
H
POLYMER
106
SO2Me
H
H
SO2Me
POLYMER
107
SO2Me
H
H
SO3—X+
POLYMER
108
SO2Me
H
H
H
POLYMER
109
SO3—X+
SO2Me
SO2Me
SO2Me
POLYMER
110
SO3—X+
SO2Me
SO2Me
SO3—X+
POLYMER
111
SO3—X+
SO2Me
SO2Me
H
POLYMER
112
SO3—X+
SO2Me
SO3—X+
SO2Me
POLYMER
113
SO3—X+
SO2Me
SO3—X+
SO3—X+
POLYMER
114
SO3—X+
SO2Me
SO3—X+
H
POLYMER
115
SO3—X+
SO2Me
H
SO2Me
POLYMER
116
SO3—X+
SO2Me
H
SO3—X+
POLYMER
117
SO3—X+
SO2Me
H
H
POLYMER
118
SO3—X+
SO3—X+
SO2Me
SO2Me
POLYMER
119
SO3—X+
SO3—X+
SO2Me
SO3—X+
POLYMER
120
SO3—X+
SO3—X+
SO2Me
H
POLYMER
121
SO3—X+
SO3—X+
SO3—X+
SO2Me
POLYMER
122
SO3—X+
SO3—X+
SO3—X+
SO3—X+
POLYMER
123
SO3—X+
SO3—X+
SO3—X+
H
POLYMER
124
SO3—X+
SO3—X+
H
SO2Me
POLYMER
125
SO3—X+
SO3—X+
H
SO3—X+
POLYMER
126
SO3—X+
SO3—X+
H
H
POLYMER
127
SO3—X+
H
SO2Me
SO2Me
POLYMER
128
SO3—X+
H
SO2Me
SO3—X+
POLYMER
129
SO3—X+
H
SO2Me
H
POLYMER
130
SO3—X+
H
SO3—X+
SO2Me
POLYMER
131
SO3—X+
H
SO3—X+
SO3—X+
POLYMER
132
SO3—X+
H
SO3—X+
H
POLYMER
133
SO3—X+
H
H
SO2Me
POLYMER
134
SO3—X+
H
H
SO3—X+
POLYMER
135
SO3—X+
H
H
H
POLYMER
136
H
SO2Me
SO2Me
SO2Me
POLYMER
137
H
SO2Me
SO2Me
SO3—X+
POLYMER
138
H
SO2Me
SO2Me
H
POLYMER
139
H
SO2Me
SO3—X+
SO2Me
POLYMER
140
H
SO2Me
SO3—X+
SO3—X+
POLYMER
141
H
SO2Me
SO3—X+
H
POLYMER
142
H
SO2Me
H
SO2Me
POLYMER
143
H
SO2Me
H
SO3—X+
POLYMER
144
H
SO2Me
H
H
POLYMER
145
H
SO3—X+
SO2Me
SO2Me
POLYMER
146
H
SO3—X+
SO2Me
SO3—X+
POLYMER
147
H
SO3—X+
SO2Me
H
POLYMER
148
H
SO3—X+
SO3—X+
SO2Me
POLYMER
149
H
SO3—X+
SO3—X+
SO3—X+
POLYMER
150
H
SO3—X+
SO3—X+
H
POLYMER
151
H
SO3—X+
H
SO2Me
POLYMER
152
H
SO3—X+
H
SO3—X+
POLYMER
153
H
SO3—X+
H
H
POLYMER
154
H
H
SO2Me
SO2Me
POLYMER
155
H
H
SO2Me
SO3—X+
POLYMER
156
H
H
SO2Me
H
POLYMER
157
H
H
SO3—X+
SO2Me
POLYMER
158
H
H
SO3—X+
SO3—X+
POLYMER
159
H
H
SO3—X+
H
POLYMER
160
H
H
H
SO2Me
POLYMER
161
H
H
H
SO3—X+
POLYMER
162
H
H
H
H
POLYMER
163
SO2Me
SO2Me
SO2Me
SO2Me
POLYMER
164
SO2Me
SO2Me
SO2Me
SO3—X+
POLYMER
165
SO2Me
SO2Me
SO2Me
H
POLYMER
166
SO2Me
SO2Me
SO3—X+
SO2Me
POLYMER
167
SO2Me
SO2Me
SO3—X+
SO3—X+
POLYMER
168
SO2Me
SO2Me
SO3—X+
H
POLYMER
169
SO2Me
SO2Me
H
SO2Me
POLYMER
170
SO2Me
SO2Me
H
SO3—X+
POLYMER
171
SO2Me
SO2Me
H
H
POLYMER
172
SO2Me
SO3—X+
SO2Me
SO2Me
POLYMER
173
SO2Me
SO3—X+
SO2Me
SO3—X+
POLYMER
174
SO2Me
SO3—X+
SO2Me
H
POLYMER
175
SO2Me
SO3—X+
SO3—X+
SO2Me
POLYMER
176
SO2Me
SO3—X+
SO3—X+
SO3—X+
POLYMER
177
SO2Me
SO3—X+
SO3—X+
H
POLYMER
178
SO2Me
SO3—X+
H
SO2Me
POLYMER
179
SO2Me
SO3—X+
H
SO3—X+
POLYMER
180
SO2Me
SO3—X+
H
H
POLYMER
181
SO2Me
H
SO2Me
SO2Me
POLYMER
182
SO2Me
H
SO2Me
SO3—X+
POLYMER
183
SO2Me
H
SO2Me
H
POLYMER
184
SO2Me
H
SO3—X+
SO2Me
POLYMER
185
SO2Me
H
SO3—X+
SO3—X+
POLYMER
186
SO2Me
H
SO3—X+
H
POLYMER
187
SO2Me
H
H
SO2Me
POLYMER
188
SO2Me
H
H
SO3—X+
POLYMER
189
SO2Me
H
H
H
POLYMER
190
SO3—X+
SO2Me
SO2Me
SO2Me
POLYMER
191
SO3—X+
SO2Me
SO2Me
SO3—X+
POLYMER
192
SO3—X+
SO2Me
SO2Me
H
POLYMER
193
SO3—X+
SO2Me
SO3—X+
SO2Me
POLYMER
194
SO3—X+
SO2Me
SO3—X+
SO3—X+
POLYMER
195
SO3—X+
SO2Me
SO3—X+
H
POLYMER
196
SO3—X+
SO2Me
H
SO2Me
POLYMER
197
SO3—X+
SO2Me
H
SO3—X+
POLYMER
198
SO3—X+
SO2Me
H
H
POLYMER
199
SO3—X+
SO3—X+
SO2Me
SO2Me
POLYMER
200
SO3—X+
SO3—X+
SO2Me
SO3—X+
POLYMER
201
SO3—X+
SO3—X+
SO2Me
H
POLYMER
202
SO3—X+
SO3—X+
SO3—X+
SO2Me
POLYMER
203
SO3—X+
SO3—X+
SO3—X+
SO3—X+
POLYMER
204
SO3—X+
SO3—X+
SO3—X+
H
POLYMER
205
SO3—X+
SO3—X+
H
SO2Me
POLYMER
206
SO3—X+
SO3—X+
H
SO3—X+
POLYMER
207
SO3—X+
SO3—X+
H
H
POLYMER
208
SO3—X+
H
SO2Me
SO2Me
POLYMER
209
SO3—X+
H
SO2Me
SO3—X+
POLYMER
210
SO3—X+
H
SO2Me
H
POLYMER
211
SO3—X+
H
SO3—X+
SO2Me
POLYMER
212
SO3—X+
H
SO3—X+
SO3—X+
POLYMER
213
SO3—X+
H
SO3—X+
H
POLYMER
214
SO3—X+
H
H
SO2Me
POLYMER
215
SO3—X+
H
H
SO3—X+
POLYMER
216
SO3—X+
H
H
H
POLYMER
217
H
SO2Me
SO2Me
SO2Me
POLYMER
218
H
SO2Me
SO2Me
SO3—X+
POLYMER
219
H
SO2Me
SO2Me
H
POLYMER
220
H
SO2Me
SO3—X+
SO2Me
POLYMER
221
H
SO2Me
SO3—X+
SO3—X+
POLYMER
222
H
SO2Me
SO3—X+
H
POLYMER
223
H
SO2Me
H
SO2Me
POLYMER
224
H
SO2Me
H
SO3—X+
POLYMER
225
H
SO2Me
H
H
POLYMER
226
H
SO3—X+
SO2Me
SO2Me
POLYMER
227
H
SO3—X+
SO2Me
SO3—X+
POLYMER
228
H
SO3—X+
SO2Me
H
POLYMER
229
H
SO3—X+
SO3—X+
SO2Me
POLYMER
230
H
SO3—X+
SO3—X+
SO3—X+
POLYMER
231
H
SO3—X+
SO3—X+
H
POLYMER
232
H
SO3—X+
H
SO2Me
POLYMER
233
H
SO3—X+
H
SO3—X+
POLYMER
234
H
SO3—X+
H
H
POLYMER
235
H
H
SO2Me
SO2Me
POLYMER
236
H
H
SO2Me
SO3—X+
POLYMER
237
H
H
SO2Me
H
POLYMER
238
H
H
SO3—X+
SO2Me
POLYMER
239
H
H
SO3—X+
SO3—X+
POLYMER
240
H
H
SO3—X+
H
POLYMER
[0119]
TABLE 5
P24 values (pg/ml) as a measurement of HIV concentration.
RESULTING P24 VALUES (pg/ml) AS MEASUREMENT OF HIV
CONCENTRATION FOR THE INDICATED CONCENTRATIONS
OF THREE SEPARATE EFFICACY TESTS
CONC (μM)
0.0
0.32
1.0
3.2
10
32
100
SAMPLE 1
594.8
665.0
356.1
2.6
−21
−29
−42
SAMPLE 2
809.6
672.3
407.1
0.8
−7.1
0.2
−26
SAMPLE 3
669.2
654.6
351.2
13.0
10.0
3.3
−13
MEAN
691.2
664.0
371.5
5.5
−6.1
−8.8
−27
% VIRAL
100.0
96.1
53.7
0.8
−0.9
−1.3
−3.9
CONCENTRATION
RESULTING AVERAGE INHIBITORY CONCENTRATION 50% (μM) = 1.16
|
Chemical compounds, being the alkyl sulfate of sulfated saccharides, particularly, dextrin, dextran, and cyclodextrin, and pharmaceutical compositions containing these compounds. The compounds of the invention provide antiviral activity, particularly in the treatment and prevention of sexually-transmitted diseases. Methods of treating viral infection and preventing viral transmission include administration include administration of the compounds of the invention orally, topically, subcutaneously, by muscular injection, by intraperitoneal injection and by intravenous injection.
| 2
|
FIELD OF THE INVENTION
[0001] This invention relates to a thermoplastic polymer which can be thermoformed into electrically conductive packaging for the electronics industry. This thermoplastic polymer can be beneficially utilized in manufacturing trays for supporting disk drive head suspension assemblies during storage, transportation, cleaning and manufacturing procedures.
BACKGROUND OF THE INVENTION
[0002] In many industries, component parts used in the assembly of a larger item of equipment are often shipped to an assembler in either disposable or recyclable packages. Typically, the manufacturer removes the component from the shipping package, and places the component into a processing fixture. The processing fixture holds the component sufficiently rigid such that certain processes can be performed on the component. Removal of a component from its shipping tray and placement into the processing fixture can be done either by automation or manually.
[0003] While the foregoing describes a common method of assembling component parts into a larger whole, it also describes a process infused with complexity and cost. If the components are removed with automation, the capital cost of such equipment and related overhead adds cost to the manufacturer. If the components are removed manually, the labor rate of the operators performing this act also increases the manufacturer's cost. Further, in many cases, the processing fixtures employed by manufacturers are complex and costly. Finally, where the components are fragile or otherwise easily damaged, the removal of the component from its shipping package and its installation into a processing fixture, whether by hand or through some automated procedure, may result in costly component damage from the handling of the component
[0004] As an illustration of the foregoing methods and processes and the problems associated therewith, the hard disk drive industry can be considered. A hard disk drive is the device most predominantly used for long term memory/data storage in modern computer systems. In overview, a hard disk drive comprises a disk that is rotated at high speeds. The disk has a magnetic coating or read/write media that can be selectively magnetized with the application of a magnetic field thereto. A “read/write” device, commonly called a head, is attached to and held closely adjacent the disk by a head suspension assembly and is moved radially relative to the rotating disk, that is, from the edge of the disk toward the center and back. Electric current is provided to the head which creates and applies a magnetic field to the disk as the head moves relative thereto. Selective areas of the disk are preferentially magnetized as the magnetic field is applied to the disk. Each magnetized area consists of a north and south pole selectively oriented in one of two preferred directions. Magnetized areas having a north pole pointing in one of the two direction are designated as a “0” and in the other direction as a “1.” In this way the binary language of computers consisting of zeroes and ones is assembled on the magnetized disk coating and data and programs, which comprise zeroes and ones in binary computer language, are stored on the hard disk.
[0005] Continuing with the example of the disk drive industry, head suspension assemblies are shipped in disposable vacuum-formed trays to manufacturers who may attach the read/write head thereto. The manufacturers remove the head suspension assembly from its shipping tray and place it into an intricate processing fixture, referred to as a “head bond fixture.” Typically, head bond fixtures are precise, machined metal fixtures with several moving parts. Often times, these fixtures include a small clamping mechanism to hold the suspension assembly sufficiently rigid during the assembly process. The surface of the fixture which mates with the suspension assembly is ground to complex geometries with very tight tolerances, thus making them very costly. Once placed within the head bond fixture, the suspension assembly is held in such a manner that a read/write head can be bonded to it.
[0006] As in any industry, manufacturing costs in the hard disk drive industry are carefully monitored. The hard disk provides large amounts of storage capability at relatively low cost. As the technology continually matures, the storage density per unit of cost, that is, the quantity of data stored per dollar, is continuously increasing, as is the reliability of the hard disk and its related components, (collectively called the hard disk drive, hard drive, or disk drive) and the rate at which data can be transferred to and from the disk. That is, advancing hard disk technology is resulting in the storage of increasing amounts of information at decreasing unit costs. Yet, in spite of the rapid advance in storage technology, the technology continues to face cost pressures as competition in the marketplace intensifies and computer programs grow in size. It would be helpful if the cost pressures arising out of damage that occurs during the assembly process could be reduced as well as the cost pressures that result from labor or inflexible tooling intensive processes.
[0007] Head suspension assemblies are extremely fragile and susceptible to damage from handling such as that occurring during the assembly process. That is, the act of removing a head suspension assembly from its packaging and installing it in a processing fixture can result in the destruction of the assembly or damage it so as to degrade seriously the suspension's later operational performance.
[0008] One source of possible damage to the components stems from electrostatic discharge (ESD) or electrical overstress (EOS), collectively referred to as ESD/EOS. ESD/EOS usually results from touching an object and causing a build-up of static charges. Prior to the time that the head suspension assembly is installed into a disk drive, the electrical interconnect is electrically connected to the read and write elements, but is not connected to the drive electronics. As a result, the individual conductors that make up the electrical interconnect, can easily be charged by stray voltages, thereby creating a voltage potential across the sensitive magnetoresistive or giant magnetoresistive read elements of the read/write head, which when discharged results in damaging current transients through the read element.
[0009] The components used in hard disk drives are small and continually decreasing in size. Consequently, any tolerance for ESD/EOS damage of the components during the assembly process is also continuously decreasing while their susceptibility to damage during assembly is increasing. The present methods of assembly, however, are the source for the creation of much static potential charge, whether through direct handling of the component parts or because of the human assemblers doing some normal activity such as shuffling their feet or wiping their brow. Minimizing the handling of the head suspension assembly is thus desirable, yet present packaging, transportation and assembly methods result in the need for an undesirable amount of such handling.
[0010] The small size of the components and their continually decreasing size also reduces any tolerance for misalignment of the components during the assembly process while increasing their susceptibility to damage during assembly. Current disk drive assembly includes expensive, labor intensive processes, particularly the assembly of the flex circuit to the suspension assembly. The labor intensive nature of the assembly process has several consequences. First, the labor increases the final cost of the assembled suspension. Second, because of the heavy use of labor in the assembly, there is a meaningful quantity of handling of the components by the assembler, which increases the likelihood of damage to the components. Third, the assemblers are limited in both the precision and speed with which the flex circuits can be assembled to the suspensions. Fourth, even though human assemblers are used, the assembly process is quite tooling intensive. Fifth, as the part geometries change as the technology advances, the costs also increase because of the need for new tooling in the assembly of the new parts; that is, the tooling used is either not adaptable or not readily adaptable to new part geometries.
[0011] Additional costs that are not included in calculation of the cost of the use of human assemblers are those of the consumer whose hard drive fails, perhaps due to damage to a component by a human assembler. Though data backups are always advised, such advice is often unheeded. When a hard drive fails the consumer may lose valuable data that is either not easily replaced or is replaced only at some cost in terms of time and effort, if not actual cash outlays.
[0012] Many of the foregoing deficiencies in the employment of human assemblers could be reduced or eliminated with a precision automated assembly apparatus and method for attaching flex circuits to suspensions. Automated assembly machines and methods should result in lower costs, reduced component handling and possible damage, and have greater flexibility to accommodate variations in component types, geometries and improved placement tolerances. Simple automation of the actual assembly of the flex circuit to the suspension will not, however, eliminate the problems associated with removing the components from their shipping trays and placing them in an assembly apparatus.
[0013] For the reasons delineated above, there was a need for an inexpensive packaging tray that can also be utilized as a processing fixture. This approach has several advantages over the processes and apparatus described above. First, because the components need not be removed from the shipping tray during subsequent manufacturing processes, the likelihood of damage resulting from handling is significantly reduced. Second, the costs associated with the removal of the component from the shipping package are eliminated. Finally, this approach eliminates the need for costly processing fixtures. Disk drive head suspension assembly trays that can be used in storage, transportation, cleaning and manufacturing procedures are described in U.S. Pat. No. 7,191,512.
[0014] U.S. Pat. No. 7,191,512 more specifically describes a tray system for holding and positioning head suspensions as components, the tray system comprising: a first tray comprising a first side having at least one component receptacle and an opposite second side having at least one component receptacle, wherein at least one of the component receptacles of the first side of the first tray comprises a base plate seat positioned adjacent a first load beam seat, and at least one of the component receptacles of the second side of the first tray comprises a base plate collar seat adjacent a second load beam seat; and a second tray engageable with the first tray, the second tray comprising a first side having at least one component receptacle and an opposite second side having at least one component receptacle, wherein at least one of the component receptacles of the first side of the second tray comprises a base plate seat positioned adjacent a first load beam seat, and at least one of the component receptacles of the second side of the second tray comprises a base plate collar seat adjacent a second load beam seat, wherein the second side of the first tray is adjacent the first side of the second tray so that the at least one component receptacle of the first side of the second tray is substantially aligned with the at least one component receptacle of the second side of the first tray for cooperatively restraining the motion of at least one component, of the components, positioned therein.
[0015] U.S. Pat. No. 7,360,653 describes a tray for supporting a plurality of disk drive suspension assemblies that either have a first configuration or a second configuration that is generally a mirror image of the first configuration, each disk drive suspension assembly having a load beam with a proximal mounting region having an aperture and a tail member extending proximally from the mounting region, the tray comprising: a frame; a first member extending across the frame and having a plurality of first support features, each first support feature, adapted to support the mounting region of a suspension assembly of the first configuration and of the second configuration; and a second member extending across the frame and having a plurality of tail support features, each adapted to support a portion of a tail member proximal to the mounting region and constrain lateral movement of the supported portion of the tail member, wherein each tail support feature is positioned relative to a respective first support feature so as to support and laterally contain the portion of the tail member of a disk drive suspension assembly of the first configuration or the portion of the tail member of a disk drive suspension assembly of the second configuration.
[0016] U.S. Pat. No. 7,360,653 also describes a tray for supporting a plurality of disk drive suspension assemblies each having a flexible load beam with a proximal mounting region, wherein the load beam in a neutral position extends from the proximal mounting region and wherein deflection of the load beam from the neutral position beyond a plastic deformation position causes plastic deformation of the load beam, the tray comprising: a frame; a first member extending across the frame and adapted to support the proximal mounting regions of the plurality of suspension assemblies; and a second member extending across the frame, the second member being spaced apart from the load beams in their neutral position and for contacting the load beams before the load beams are in their plastic deformation position.
[0017] The disk drive head suspension assembly trays of the prior art have typically been made by injection molding, vacuum forming, or thermoforming a blend of polyethylene terephthalate glycol (PETG) with an inherently dissipative polymer (IDP) based on a polyamide or a copolyester-amide. However, polymer blends of this type are far from optimal as a material for use in automated manufacturing of disk drive head suspension assembly trays. For instance, it would be desirable for the thermoplastic polymer used in making such head suspension assembly trays to offer improved stiffness, good dimensional tolerances, improved chemical resistance, to be capable of enduring more washing cycles, to be capable of being dried at higher temperatures, to display improved cleanliness, and to exhibit higher electrical conductivity.
SUMMARY OF THE INVENTION
[0018] This invention relates to a thermoplastic polymer composition that exhibits excellent characteristics for being thermoformed into disk drive head suspension assembly trays. More specifically, these trays are applicable as packaging material for head suspension assembly and offer conductivities in the range of antistatic to electrostatic dissipation (ESD). For instance, the thermoplastic polymer composition of this invention offers improved stiffness, good dimensional tolerances, improved chemical resistance, the capability of enduring more washing cycles, the capability of being dried at higher temperatures, improved cleanliness, and better electrical conductivity that conventional PETG/IDP polymer blends. Additionally, the thermoplastic polymer compositions of this invention are inherently black in color which is critical for laser-driven automated processes.
[0019] The thermoplastic polymer composition of this invention is comprised of (1) a polyethylene terephthalate glycol copolyester, (2) from 1 weight percent to 6 weight percent carbon nanotubes, (3) from 2 weight percent to 30 weight percent of a copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 1 weight percent to 10 weight percent of a functionalized rubbery polymer, (5) from 1 weight percent to 10 weight percent of an acrylic based core-shell polymer, and (6) from 0.5 weight percent to 6 weight percent of a lubricant selected from the group consisting of high density polyethylene and polyester wax, where the polyethylene terephthalate glycol copolyester makes up the balance of the composition and wherein all weight percentages are based upon the total weight of the thermoplastic polymer composition.
[0020] The present invention also relates to a disk drive head suspension assembly tray which is comprised of an exterior frame having substantially perpendicularly adjacent sides, frame sides having essentially planar top and bottom surfaces, at least two feet, at least two foot seats, at least one support rib, and a repository that is adapted to seat and retain a disk drive head suspension, wherein the disk drive head suspension assembly tray is comprised of (1) a polyethylene terephthalate glycol copolyester, (2) from 1 weight percent to 6 weight percent carbon nanotubes, (3) from 2 weight percent to 30 weight percent of a copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 1 weight percent to 10 weight percent of a functionalized rubbery polymer, (5) from 1 weight percent to 10 weight percent of an acrylic based core-shell polymer, and (6) from 0.5 weight percent to 6 weight percent of a lubricant selected from the group consisting of high density polyethylene and polyester wax, where the polyethylene terephthalate glycol copolyester makes up the balance of the composition and wherein all weight percentages are based upon the total weight of the thermoplastic polymer composition.
[0021] The subject invention also specifically reveals a tray system for holding and positioning head suspensions as components, the tray system comprising: a first tray comprising a first side having at least one component receptacle and an opposite second side having at least one component receptacle, wherein at least one of the component receptacles of the first side of the first tray comprises a base plate seat positioned adjacent a first load beam seat, and at least one of the component receptacles of the second side of the first tray comprises a base plate collar seat adjacent a second load beam seat; and a second tray engageable with the first tray, the second tray comprising a first side having at least one component receptacle and an opposite second side having at least one component receptacle, wherein at least one of the component receptacles of the first side of the second tray comprises a base plate seat positioned adjacent a first load beam seat, and at least one of the component receptacles of the second side of the second tray comprises a base plate collar seat adjacent a second load beam seat, wherein the second side of the first tray is adjacent the first side of the second tray so that the at least one component receptacle of the first side of the second tray is substantially aligned with the at least one component receptacle of the second side of the first tray for cooperatively restraining the motion of at least one component, of the components, positioned therein; wherein the first tray and/or the second tray are comprised of (1) a polyethylene terephthalate glycol copolyester, (2) from 1 weight percent to 6 weight percent carbon nanotubes, (3) from 2 weight percent to 30 weight percent of a copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 1 weight percent to 10 weight percent of a functionalized rubbery polymer, (5) from 1 weight percent to 10 weight percent of an acrylic based core-shell polymer, and (6) from 0.5 weight percent to 6 weight percent of a lubricant selected from the group consisting of high density polyethylene and polyester wax, where the polyethylene terephthalate glycol copolyester makes up the balance of the composition and wherein all weight percentages are based upon the total weight of the thermoplastic polymer composition.
[0022] The present invention also reveals a tray for supporting a plurality of disk drive suspension assemblies each having a flexible load beam with a proximal mounting region, wherein the load beam in a neutral position extends from the proximal mounting region and wherein deflection of the load beam from the neutral position beyond a plastic deformation position causes plastic deformation of the load beam, the tray comprising: a frame; a first member extending across the frame and adapted to support the proximal mounting regions of the plurality of suspension assemblies; and a second member extending across the frame, the second member being spaced apart from the load beams in their neutral position and for contacting the load beams before the load beams are in their plastic deformation position; wherein the tray is comprised of (1) a polyethylene terephthalate glycol copolyester, (2) from 1 weight percent to 6 weight percent carbon nanotubes, (3) from 2 weight percent to 30 weight percent of a copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 1 weight percent to 10 weight percent of a functionalized rubbery polymer, (5) from 1 weight percent to 10 weight percent of an acrylic based core-shell polymer, and (6) from 0.5 weight percent to 6 weight percent of a lubricant selected from the group consisting of high density polyethylene and polyester wax, where the polyethylene terephthalate glycol copolyester makes up the balance of the composition and wherein all weight percentages are based upon the total weight of the thermoplastic polymer composition.
[0023] The subject invention further reveals a tray for supporting a plurality of disk drive suspension assemblies each having a flexible load beam with a proximal mounting region, wherein the load beam in a neutral position extends from the proximal mounting region and wherein deflection of the load beam from the neutral position beyond a plastic deformation position causes plastic deformation of the load beam, the tray comprising: a frame; a first member extending across the frame and adapted to support the proximal mounting regions of the plurality of suspension assemblies; and a second member extending across the frame, the second member being spaced apart from the load beams in their neutral position and for contacting the load beams before the load beams are in their plastic deformation position; wherein the tray is comprised of (1) a polyethylene terephthalate glycol copolyester, (2) from 1 weight percent to 6 weight percent carbon nanotubes, (3) from 2 weight percent to 30 weight percent of a copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 1 weight percent to 10 weight percent of a functionalized rubbery polymer, (5) from 1 weight percent to 10 weight percent of an acrylic based core-shell polymer, and (6) from 0.5 weight percent to 6 weight percent of a lubricant selected from the group consisting of high density polyethylene and polyester wax, where the polyethylene terephthalate glycol copolyester makes up the balance of the composition and wherein all weight percentages are based upon the total weight of the thermoplastic polymer composition.
[0024] The present invention also discloses a process for making a thermoplastic polymer composition which comprises (1) mixing a polyethylene terephthalate glycol copolymer and carbon nanotubes in a first mixing step to produce a PETG/carbon nanotube premix, and (2) mixing additional polyethylene terephthalate glycol copolymer, a copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, a functionalized rubbery polymer, an acrylic based core-shell polymer, and a lubricant selected from the group consisting of high density polyethylene and polyester wax throughout the PRTG/carbon nanotube premix made in step (1), wherein from 25 weight percent to 70 weight percent of the total constituents of the thermoplastic polymer composition are added in step (1) to make the premix.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The polyethylene terephthalate glycol copolymer (PETG) used in the thermoplastic polymer compositions of this invention has repeat units that are derived from terephthalic acid, ethylene glycol, and an additional glycol selected from the group consisting of 1,4-cyclohexanedimethanol, 1,2-propanediol, 1,3-propanediol, 1,4-butanediol, 2,2-dimethyl-1,3-propanediol, 1,6-hexanediol, 1,2-cyclohexanediol, 1,4-cyclohexanediol, 1,2-cyclohexanedimethanol, and 1,3-cyclohexanedimethanol. Ethylene glycol will typically constitute from about 60% to 90% of the glycol component used in synthesizing the PETG and the additional glycol will accordingly make up the remaining 10% to 40% of the glycol component. Ethylene glycol will more typically constitute from about 70% to 80% of the glycol component used in synthesizing the PETG and the additional glycol will accordingly make up the remaining 20% to 30% of the glycol component. It is typically preferred to utilize 1,4-cyclohexanedimethanol as the additional glycol. Such a PETG would accordingly be comprised of polymer chains that are derived from terephthalic acid, ethylene glycol, and 1,4-cyclohexanedimethanol.
[0026] The PETG used in the practice of this invention can also be made by polymerizing a second dicarboxylic acid in addition to terephthalic acid therein. Such amorphous PETG will accordingly have repeat units that are derived from terephthalic acid, ethylene glycol, and the additional dicarboxylic acid. The repeat units that are derived from the additional dicarboxylic acid will act to inhibit crystallization in such polymers. The additional dicarboxylic acids that can be used for this purpose will typically contain from 8 to 16 carbon atoms. Some representative examples of aromatic dicarboxylic acids that can be used include isophthalic acid, orthophthalic acid, 1,8-naphthalenedicarboxylic acid, 1,7-naphthalenedicarboxylic acid, 1,6-naphthalenedicarboxylic acid, 1,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, 2,7-naphthalenedicarboxylic acid, 1,7-anthracenedicarboxylic acid, 2,6-anthracenedicarboxylic acid, 2,7-anthracenedicarboxylic acid, 2,6-phenalenedicarboxylic acid, 1,6-phenalenedicarboxylic acid, 1,7-phenalenedicarboxylic acid, 2,8-naphthacenedicarboxylic acid, 2,9-naphthacenedicarboxylic acid, 1,7-naphthacenedicarboxylic acid, 1,10-naphthacenedicarboxylic acid, 2,7-pyrenedicarboxylic acid, 2,6-pyrenedicarboxylic acid, and 2,8-pyrenedicarboxylic acid. Isophthalic acid and 2,6-naphthalenedicarboxylic acid are preferred dicarboxylic acids for utilization in the acid component of such amorphous PETG polyesters in conjunction with the terephthalic acid. It should also be understood that the PETG can be modified with both a glycol in addition to ethylene glycol and with a diacid in addition to terephthalic acid.
[0027] The PETG used in the practice of this invention is thermoformable and typically has a melt viscosity which is within the range of 0.8 to 10 grams per 10 minutes. The PETG used in the practice of this invention preferably has a melt viscosity which is within the range of 0.9 to 5 grams per 10 minutes, and most preferably has a melt viscosity which is within the range of 1 to 3 grams per 10 minutes.
[0028] The carbon nanotubes used in making the thermoplastic polymer compositions of this invention normally have a diameter which is within the range of 5 to 20 nanometers and have a length which is within the range of 1 to 5 microns. The carbon nanotubes used in making the thermoplastic polymer compositions of this invention more typically have a diameter which is within the range of 7 to 15 nanometers and have a length which is within the range of 1 to 3 microns. The carbon nanotubes used in making the thermoplastic polymer compositions of this invention preferably have a diameter which is within the range of 8 to 13 nanometers and have a length which is within the range of 1 to 2 microns. Such carbon nanotubes typically have an aspect ratio which is within the range of 80 to 180 and more typically have an aspect ratio which is within the range of 90 to 150. The carbon nanotubes used in making the thermoplastic polymer compositions of this invention preferably have an aspect ratio which is within the range of 95 to 120.
[0029] The copolymer of ethylene with a higher α-olefin used in making the thermoplastic polymer compositions of this invention has from about 0.5 weight percent to 2.5 weight percent of maleic anhydride or glycidyl methacrylate grafted onto it. It is typically preferred for the level of maleic anhydride or glycidyl methacrylate grafted onto the backbond of the polymer to be within the range of 0.9 weight percent to 1.5 weight percent. The higher α-olefin will typically contain from 2 to about 12 carbon atoms and will preferably contain form 6 to 10 carbon atoms. The α-olefin will preferably be 1 -octene and it is normally preferred for the grafting agent to be maleic anhydride. Fusabond® MN-493D is a maleic anhydride grafted ethylene-octene copolymer having a melting point of 48° C. and a density of 0.87 which is commercially available from DuPont that can be used in the practice of this invention.
[0030] The functionalized rubbery polymer will generally be a compatibilizing ethylene copolymer of the formula E/X/Y, where E is about 55-75%, X is about 15-35%, and Y is about 2-15% by weight of the compatibilizing ethylene copolymer, and E is ethylene, X is an α,β-ethylenically unsaturated monomer derived from at least one of alkylacrylate, alkylmethacrylate, alkyl vinyl ether, carbon dioxide, sulfur dioxide, or mixtures thereof, where the alkyl groups contain 1- 12 carbon atoms, such as vinyl acetate, methylacrylate, butylacrylate, and methyl vinyl ether. X can, for example, be a moiety derived from at least one of alkyl acrylate, alkyl methacrylate, alkyl vinyl ether, carbon monoxide, sulfur dioxide, or mixtures thereof. More specifically, X can, for example, consist of 0-35 weight percent of a moiety derived from at least one alkyl acrylate, alkyl methacrylate, or mixtures thereof where the alkyl groups contain 1-8 carbon atoms. Y is an α,β-ethylenically unsaturated monomer containing a reactive group, such as epoxide, maleic anhydride, isocyanate, or oxazoline, for example, that forms a covalent bond with said first polymeric component. In one preferred embodiment, Y is selected from the group consisting of glycidyl methacrylate and glycidyl acrylate, maleic anhydride, and isocyanato-ethylmethacrylate.
[0031] The functionalized rubbery polymer will typically contain repeat units that are derived from an acrylate monomer of the structural formula:
[0000]
[0000] wherein R represents a hydrogen atom, an alkyl group containing from 1 to about 8 carbon atoms, or a moiety containing an epoxy group, and wherein R 1 represents a hydrogen atom or an alkyl group containing from 1 to about 8 carbon atoms. Some representative examples of monomers that can be used include methyl methacrylate, butyl acrylate, dimethylsiloxane. In many cases, R will represent an alkyl group containing from 1 to 4 carbon atoms. The moiety containing an epoxy group will typically be of the structural
[0000]
[0000] wherein n represents an integer from 1 to about 6. In most cases, n will represent 1.
[0032] The functionalized rubbery polymer will generally also contain repeat units that are derived from a conjugated diolefin monomer, such as 1,3-butadiene or isoprene, a vinyl aromatic monomer, such as styrene or α-methyl styrene, a monoolefin monomer, such as ethylene or propylene, and/or a dialkylsiloxane monomer, such as dimethylsiloxane.
[0033] The functionalized rubbery polymer can optionally contain repeat units in its backbone which are derived from an anhydride group containing monomer, such as maleic anhydride. In another scenario, the functionalized rubbery polymer can contain anhydride moieties which are grafted onto the polymer in a post polymerization step. Lotader® 8900 is a terpolymer of ethylene, methyl methacrylate and glycidyl methacrylate that can be used as the functionalized rubbery polymer in the practice of this invention.
[0034] The acrylic based core-shell polymer will typically have an acrylic core and a shell that is comprised of polymethylmethacrylate. Durastrength®440 is core-shell acrylic based impact modifier that can be used as the acrylic based core-shell polymer in the practice of this invention.
[0035] The lubricant used in making the thermoplastic polymer compositions of this invention is either high density polyethylene or a polyester wax, such as Glycolube wax. It is frequently preferred to use a combination of high density polyethylene and a polyester wax in making the thermoplastic polymer compositions of this invention. For example, from 0.5 weight percent to 6 weight percent of polyester wax can be used as a lubricant in conjunction with 0.5 weight percent to 3 weight percent of high density polyethylene which is used to improve surface finishing characteristics.
[0036] The thermoplastic polymer compositions of this invention are made by a two step process. In the first step a portion of the polyethylene terephthalate glycol copolymer is mixed with the carbon nanotubes and optionally additional components of the composition being made. The first mixing step results in the production of a PETG/carbon nanotube premix. Then in the second step additional polyethylene terephthalate glycol copolymer, the grafted copolymer of ethylene with a higher α-olefin, the functionalized rubbery polymer, the acrylic based core-shell polymer, and the lubricant selected from the group consisting of high density polyethylene and polyester wax are dispersed throughout the PETG/carbon nanotube premix made in step (1). In this mixing procedure from 25 weight percent to 70 weight percent of the total constituents of the thermoplastic polymer composition are added in step (1) to make the premix. It is typically preferred for from 30 weight percent to 55 weight percent of the total constituents of the thermoplastic polymer composition to be added in step (1) to make the premix.
[0037] This mixing will typically be done by melt blending the components of the thermoplastic polymer composition. This can be done in a suitable mixing device for melt blending, such as a single or twin screw extruder or multiple mixing devices with controlled specific energy input via control of feed rate (15 to 95% torque), RPM (60 to 900 rpm), process temperature and residence time distribution. The specific energy input will typically be within the range of 0.15 to 0.5 kilowatt hours per kilogram and will more typically be within the range of 0.2 to 0.4 kilowatt hours per kilogram.
[0038] The thermoplastic polymer compositions of this invention will typically contain (1) the polyethylene terephthalate glycol copolyester, (2) from 1 weight percent to 6 weight percent of the carbon nanotubes, (3) from 2 weight percent to 30 weight percent of the copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 1 weight percent to 10 weight percent of the functionalized rubbery polymer, (5) from 1 weight percent to 10 weight percent of the acrylic based core-shell polymer, and (6) from 0.5 weight percent to 6 weight percent of the lubricant selected from the group consisting of high density polyethylene and polyester wax. It should be noted that the polyethylene terephthalate glycol copolyester makes up the balance of the composition and that all weight percentages are based upon the total weight of the thermoplastic polymer composition. The thermoplactic polymer compositions of this invention will preferably contain (1) the polyethylene terephthalate glycol copolyester, (2) from 1.5 weight percent to 5 weight percent of the carbon nanotubes, (3) from 4 weight percent to 25 weight percent of the copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 2 weight percent to 8 weight percent of the functionalized rubbery polymer, (5) from 2 weight percent to 8 weight percent of the acrylic based core-shell polymer, and (6) from 0.8 weight percent to 4 weight percent of the lubricant selected from the group consisting of high density polyethylene and polyester wax. The thermoplactic polymer compositions of this invention will most preferably contain (1) the polyethylene terephthalate glycol copolyester, (2) from 2 weight percent to 4 weight percent of the carbon nanotubes, (3) from 6 weight percent to 15 weight percent of the copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 3 weight percent to 6 weight percent of the functionalized rubbery polymer, (5) from 3 weight percent to 6 weight percent of the acrylic based core-shell polymer, and (6) from 1 weight percent to 3 weight percent of the lubricant selected from the group consisting of high density polyethylene and polyester wax. This thermoplastic polymer composition can optionally contain small amounts (level of less than about 1 weight percent) of thermal stabilizers, UV stabilizers, antioxidants, and/or flame retardants.
[0039] The thermoplastic polymer compositions of this invention can then be thermoformed into disk drive head suspension assembly trays of various desired designs. Disk drive head suspension assembly trays that can be made by thermoforming the thermoplastic polymer compositions of this invention are described in U.S. Pat. No. 7,191,512 and U.S. Pat. No. 7,360,653. The teachings of U.S. Pat. No. 7,191,512 and U.S. Pat. No. 7,360,653 are incorporated herein by reference for the purpose of illustrating disk drive head suspension assembly trays that can be beneficially made by thermoforming the thermoplastic polymer compositions of this invention.
[0040] This invention is illustrated by the following examples that are merely for the purpose of illustration and are not to be regarded as limiting the scope of the invention or the manner in which it can be practiced. Unless specifically indicated otherwise, parts and percentages are given by weight.
EXAMPLE 1
[0041] The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at a rate of 350 rpm and a set temperature profile of 35° C. (feed), 230° C. (Zone 2), 255° C. (Zone 3), 260° C. (Zone 4), 260° C. (Zone 5), 260° C. (Zone 6), 260° C. (Zone 7), 255° C. (Zone 8), 255° C. (die), was charged with 77.8 parts of Skygreen PETG, 3.0 parts of Lotader 8900 terpolymer of ethylene, methyl methacrylate and glycidyl methacrylate, 3.0 parts of Durastrength®400 core-shell acrylic based impact modifier, 0.2 parts of phenolic antioxidant, 6.0 parts of Nanocyl 7000 multi-walled carbon nanotubes (9.5 nanometer diameter, 1.5 micron length, and an aspect ratio of ˜100), 3.0 parts of cyclic polybutylene terephthalate, 2.0 parts of high density polyethylene, and 5 parts of Fusabond® MN-493D polyethylene-polyoctene copolymer grafted with maleic anhydride. This mixing procedure resulted in the production of a PETG/carbon nanotube premix.
[0042] In a subsequent mixing step the extruder was charged with an additional 47 parts of Skygreen PETG, an additional 4.0 parts of Lotader 8900 terpolymer of ethylene, methyl methacrylate and glycidyl methacrylate, an additional 3.0 parts of Durastrength®400 core-shell acrylic based impact modifier, 38 parts of the PETG/carbon nanotube premix, 1.0 parts of Glycolube P polyester wax, an additional 8 parts of Fusabond( MN-493D polyethylene-polyoctene copolymer grafted with maleic anhydride, and an additional 1 part of high density polyethylene.
[0043] Characterization of the thermoplastic polymer composition made in this experiment show that it had excellent characteristics for being thermoformed into electrically conductive packaging for electronic components, such as disk drive head suspension assembly trays. More specifically, the polymer compound made in this experiment was determined to have the characteristics shown in the Table below:
[0000]
TABLE 1
Characteristic
Value
Surface resistivity
2.6 × 10 5 Ω/sq.
Izod impact strength at 23° C.
2.96 foot-pounds per inch
Flexural modulus (stiffness)
1,215.9 MPa
Tensile strength at break
22 MPa
Processability (sheet extrusion and
Excellent
thermoformability);
Retention of characteristics from (1) to (5)
Excellent
after sheet extrusion and thermoforming
EXAMPLES 2-8
[0044] In the following experiments thermoplastic polymer compositions were made utilizing the general procedure described in Example 1. However, the components used and the amounts of these components were varied as shown in Tables 2 and 3. The characteristics of this series of thermoplastic polymer compositions are also depicted in Tables 2 and 3.
[0045] Carbon nanotube masterbatch formulations were made in the first mixing step. In the following tables these carbon nanotube masterbatches are designated by an asterisk (*) and includes all of the materials identified above them in the table. Materials which were subsequently added to the carbon nanotube masterbatches are in the rows following the items designated with asterisks in the tables. The materials used in the following Examples are as follows:
[0000]
PETG (Skygreen)
Polyethylene terephthalate glycol
HDPE 511051
Polycarbonate with melt flow index of 25
grams per 10 minutes at 190° C. and
2.16 kg
C150P, NC7000,
Multi-walled carbon nanotubes
2040 CNT
CBT100
Cyclic polyethylene terephthalate
Lotader 8900, Lotader
Terpolymer of ethylene, methyl methacrylate
4700
and glycidyl methacrylate
Glycolube P
Polyester wax
D440
Core-shell acrylic based impact modifier
PBS 2010
Polyether sulfone
PP/LDPE Blend
Blend of polypropylene with low density
polyethylene
TOHO A201
Carbon fiber
PBT CX11051
Medium viscosity polybutylene terephthalate
Printex XE2
High surface area conductive carbon black
Fusabond 493D
Polyethylene-polyoctene copolymer grafted
with maleic anhydride
Fusabond 226DE
Polyethylene graft maleic anhydride
AO 1010
Phenolic antioxidant
A0 626
Phosphate antioxidant
AO 412S
Amine antioxidant
Surlyn ® 8920
Ethylene methacrylic acid plastic (EMMA)
Entira MK400, Sunova
Inherently dissipated polymer
80HP, Pelestat NC 6321
APET 5005
Amorphous polyethylene terephthalate
Sodium stearate
lubricant
Kraton 1901X
Styrene ethylene butadiene styrene grafted with
maleic anhydride
Pearlthane D11T93
Thermoplastic polyurethane
Ninor
Stabilizer
Bruno Bock PETMP
Thiol based crosslinker
PC 1225L
High density polyethylene with melt flow index
of 10 grams per 10 minutes at 300° C.
and 1.2 kg
Engage 8180
Polyolefin plastomer
LDPE and LDPE NA520
Low density polyethylene
Bayon YM312, CYRO
Acrylic polymer additive
H15
LLDPE (120 FPLDPE)
Linear low density polyethylene
CB900
Medium surface area carbon black
[0046] The thermoplastic polymer compositions made in this series of experiments were prepared utilizing a ZE 25 twin screw extruder (L/D=44). The main feeder of the ZE 25 twin screw extruder was operated at a rate of 400 rpm and with a set temperature profile of 40° C. (feed), 260° C. (Zone 2), 285° C. (Zone 3), 300° C. (Zone 4), 310° C. (Zone 5), 310° C. (Zone 6), 290° C. (Zone 7), 290° C. (Zone 8), and 285° C. (die). The components used in making such thermoplastic polymer compositions and the levels utilized in reported in the following tables.
[0000]
TABLE 2
CP 292 (PETG Antistat - HSA Trays)
Material
EXAMPLE 2
EXAMPLE 3
PETG Skygreen
42
47
Lotader 8900
5
4
D440
5
4
CP 290 X1*
38
38
Glycolube P
1
1
Fusabond 493D
8
5
HDPE 511051
1
1
Properties
Tensile Modulus (Mpa)
1036.3
1155.5
Tensile Str. @ YLD (Mpa)
26.4
30.2
Tensile Str. @ BRK (Mpa)
20.5
22
Tensile Str. @ BRK (%)
22.3
23.8
Flex Modulus (Mpa)
1073.8
1215.9
Flex Stress (Mpa)
37.4
42.1
Izod Impact @RT (ft-lb/in)
9.48 PB
2.96 (3CB)
6.76 (2PB)
Resistance - Strand (Ohms/sq)
1.80E+04
2.60E+04
Resistance - Tensile (Ohms/sq)
8.30E+09
3.66E+09
[0000]
TABLE 3
CP 300 (PETG Antistat - HSA Trays)
Material
EXAMPLE 4
EXAMPLE 5
EXAMPLE 6
EXAMPLE 7
EXAMPLE 8
EXAMPLE 9
PETG Skygreen
79.8
30
37
25
35
79.8
Lotader 8900
3
5
5
5
5
3
D440
3
5
5
5
5
3
AO 1010
0.2
0.2
CP 300 X6*
45
C150P
6
CP 300 X1*
50
43
55
NC 7000
6
CBT 100
1
1
HDPE 511051
2
1
1
1
1
2
Fusabond 493D
5
8
8
8
8
5
Glycolube P
1
1
1
1
Properties
Tensile Modulus
1660.3
1085
1093.2
1100.6
1186.8
(Mpa)
Tensile Str. @
39.2
27.1
27.3
26.3
30.2
YLD (Mpa)
Tensile Str. @
27.5
25.3
27.6
21.8
28.7
BRK (Mpa)
Tensile Str. @
13.3
130
156.5
69.6
113
BRK (%)
Flex Modulus
1916.2
1274.5
1229.4
1226.9
1214.9
(Mpa)
Flex Stress
59
40.9
40.1
39.6
38.4
(Mpa)
Izod Impact
1.89 CB
15.9 NB
15.4 NB
12.2 NB
17.6 NB
@RT (ft-lb/in)
HDT @66 psi
66.1
63.9
66
64.2
68.4
(° C.)
Resistance -
7.37E+03
7.03E+11
2.09E+11
8.27E+05
1.6E+04
Strand
(Ohms/sq)
Resistance -
4.82E+09
6.74E+12
7.6E+12
5.52E+12
Tensile
(Ohms/sq)
COMPARATIVE EXAMPLES 10-139
[0047] In this series of experiments thermoplastic polymer compositions were again made utilizing the general procedure described in Example 1. The components used and the amounts of these components were varied as shown in Table 4-40. The characteristics of this series of thermoplastic polymer compositions are also depicted in Tables 4-40. As can be seen, the properties of the polymer compositions made in this series of experiments were not optimal for utilization in manufacturing head suspension trays for one or more reasons.
[0000]
TABLE 4
CP 197 (PETG Antistat)
EXAMPLE
EXAMPLE
Material
EXAMPLE 10
11
12
PETG Skygreen
75
70
71
Lotader 8900
2
Surlyn 8920
2
Entira MK 400
25
30
25
Properties
Tensile Modulus (Mpa)
1247
1146
1059
Tensile Str. @ YLD (Mpa)
21
28.3
28
Tensile Str. @ BRK (Mpa)
24
28.3
28
Tensile Str. @ BRK (%)
2.3
3.1
3.4
Flex Modulus (Mpa)
1332
1154
1036
Flex Stress (Mpa)
50
46.3
41.5
Izod Impact @RT (ft-lb/in)
0.26 CB
0.43 CB
0.45 CB
Resistance (ohms/sq)
3.04E+12
3.04E+12
2.44E+12
[0000]
TABLE 5
CP 198 (PETG Antistat)
EXAMPLE
EXAM-
EXAMPLE
EXAM-
Material
13
PLE 14
15
PLE 16
APET 5005
75
71
69
PETG Skygreen
69
Lotader 8900
2
2
2
D440
2
2
Surlyn 8920
2
2
2
Entira MK 400
25
25
25
25
Properties
Resistance - Strand
1.62E+13
2.64E+12
5.08E+12
1.90E+12
(ohms/sq)
[0000]
TABLE 6
CP 199 (PETG & APET Antistat)
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
Material
17
18
19
20
21
22
APET 5005
75
71
69
PETG
75
71
69
Skygreen
Lotader 8900
2
2
2
2
D440
2
2
Surlyn 8920
2
2
2
2
Sunova 80HP
25
25
25
25
25
25
Properties
Resistance -
1.02E+12
1.21E+12
4.47E+12
1.90E+12
1.21E+12
2.52E+12
Strand
(ohms/sq)
[0000]
TABLE 7
CP 202 (PETG & APET Antistat)
EXAM-
EXAM-
EXAM-
EXAM-
EXAM-
EXAM-
PLE
PLE
PLE
PLE
PLE
PLE
Material
23
24
25
26
27
28
PETG
69.5
65.5
63
63
64.5
64.5
Skygreen
Lotader
2
3.5
8900
Surlyn 8920
2
3
3
5
Na Stearate
0.5
0.5
0.5
0.5
0.5
0.5
Sunova
30
30
30
30
30
30
80HP
Kraton
3.5
5
1901X
No Properties
[0000]
TABLE 8
CP 203 (PETG Antistat)
EXAM-
EXAM-
EXAM-
EXAM-
EXAM-
Material
PLE 29
PLE 30
PLE 31
PLE 32
PLE 33
PETG Skygreen
65.5
65.5
65.5
65
65
Lotader 8900
2
2
2
Surlyn 8920
2
2
2
5
5
Na Stearate
0.5
0.5
0.5
Pelestat NC 6321
30
Sunova 80HP
30
30
30
30
No Properties
[0000]
TABLE 9
CP 204 (PETG Antistat)
Material
EXAMPLE 34
PETG Skygreen
70.8
Lotader 8900
2
D440
2
Pearlthane D11T93
25
AO 1010
0.2
No Properties
[0000]
TABLE 10
CP 205 (PETG Antistat)
EXAM-
EXAM-
EXAM-
EXAM-
EXAM-
EXAM-
PLE
PLE
PLE
PLE
PLE
PLE
Material
35
36
37
38
39
40
Lotader
1
2
1
2
8900
Surlyn 8920
1
2
1
2
Sunova
25
25
25
30
30
30
80HP
CP 204 X1*
75
73
71
70
68
66
No Properties
[0000]
TABLE 11
CP 206 (PETG Antistat)
Material
EXAMPLE 41
EXAMPLE 42
EXAMPLE 43
PETG Skygreen
10
20
30
Lotader 8900
1
1
1
Surlyn 8920
1
1
1
Sunova 80HP
30
30
30
CP 201 X1*
58
48
38
No Properties
[0000]
TABLE 12
CP 207P (PETG Antistat)
Material
EXAMPLE 44
PETG Skygreen
20
Lotader 8900
1
Surlyn 8920
1
Sunova 80HP
30
CP 201 X1*
48
Properties
Izod Impact @RT (ft-lb/in)
16.0 NB
Resistance - Disk (ohms/sq)
3.07E+10
[0000]
TABLE 13
CP 208 (APET Antistat)
Material
EXAMPLE 45
APET 5005
70.8
Lotader 8900
2
D440
2
Pearlthane D11T93
25
AO 1010
0.2
No Properties
[0000]
TABLE 14
CP 209 (APET Antistat)
Material
EXAMPLE 46
EXAMPLE 47
APET 5005
20
Lotader 8900
1
1
Surlyn 8920
1
1
Sunova 80HP
30
30
CP 204 X1*
20
CP 208 X1*
48
48
No Properties
[0000]
TABLE 15
CP 210P (APET Antistat)
Material
EXAMPLE 48
APET 5005
70.8
Lotader 8900
2
D440
2
Pearlthane D11T93
25
AO 1010
0.1
AO 626
0.1
No Properties
[0000]
TABLE 16
CP 211P (APET Antistat)
Material
EXAMPLE 49
Lotader 8900
1
Surlyn 8920
1
Sunova 80HP
30
AO 412S
0.1
Ninor
0.1
CP 204 X1*
20
CP 210 X1*
47.8
Properties
Tensile Modulus (Mpa)
394
Tensile Str. @ YLD (Mpa)
11.3
Tensile Str. @ BRK (Mpa)
11
Tensile Str. @ BRK (%)
11.2
Flex Modulus (Mpa)
452
Flex Stress (Mpa)
18.4
Izod Impact @RT (ft-lb/in)
0.39 HB
HDT @66 psi (° C.)
50.9
Resistance - Bars (Ohms/sq)
1.14E+10
[0000]
TABLE 17
CP 213P (APET CNT)
Material
EXAMPLE 50
APET 5005
95.8
Lotader 8900
1
NC 7000
3
AO 412S
0.1
Ninor
0.1
Properties
Tensile Modulus (Mpa)
2623
Tensile Str. @ YLD (Mpa)
52.9
Tensile Str. @ BRK (Mpa)
52.9
Tensile Str. @ BRK (%)
2.7
Flex Modulus (Mpa)
2888
Flex Stress (Mpa)
101
Izod Impact @RT (ft-lb/in)
0.28
Specific Gravity
1.383
[0000]
TABLE 18
CP 214 (PETG & PC CNT)
EXAMPLE
EXAMPLE
EXAMPLE
Material
51
52
53
PETG Skygreen
95
PC 1225L
95.5
93
Lotader 8900
1
1
1
NC 7000
4
3.5
6
Properties
Tensile Modulus (Mpa)
1841
Tensile Str. @ YLD (Mpa)
50.8
Tensile Str. @ BRK (Mpa)
30
Tensile Str. @ BRK (%)
17.6
Flex Modulus (Mpa)
2326
Flex Stress (Mpa)
75.5
Izod Impact @RT (ft-lb/in)
1.07
Specific Gravity
1.2823
[0000]
TABLE 19
CP 228 (APET Antistat)
EXAM-
EXAM-
EXAM-
EXAM-
PLE
PLE
PLE
PLE
Material
54
55
56
57
APET 5005
95.9
95.9
93.8
93.9
Lotader 8900
2
2
2
2
D440
2
2
2
Surlyn 8920
2
2
2
Bruno Bock PETMP
0.1
AO 412S
0.1
0.1
0.1
0.1
Properties
Tensile Modulus (Mpa)
1992.4
2157.4
2031.8
2101.1
Tensile Str. @ YLD (Mpa)
49
59.2
60
60.4
Tensile Str. @ BRK (Mpa)
49.4
58.9
38
42.2
Tensile Str. @ BRK (%)
3.3
4.3
20.6
13.8
Flex Modulus (Mpa)
2147.5
2433.3
2201.1
2361.7
Flex Stress (Mpa)
81.9
94.1
88
87.8
Izod Impact @RT (ft-lb/in)
0.85 CB
0.76 CB
0.77 CB
0.64 CB
[0000]
TABLE 20
CP 229 (APET Antistat)
EXAMPLE
EXAMPLE
EXAMPLE
Material
58
59
60
APET 5005
89.9
86.9
79.9
Lotader 8900
5
5
5
D440
5
8
5
Pearlthane D11T93
10
AO 412S
0.1
0.1
0.1
Properties
Tensile Modulus (Mpa)
1580.2
1633.7
1575.6
Tensile Str. @ YLD (Mpa)
41.9
47.6
40.6
Tensile Str. @ BRK (Mpa)
28
30
Tensile Str. @ BRK (%)
175
21.9
19.4
Flex Modulus (Mpa)
1879.2
1681.4
1587.5
Flex Stress (Mpa)
60
61.9
57.6
Izod Impact @RT (ft-lb/in)
3.36 CB
2.99 CB
1.91 CB
[0000]
TABLE 21
CP 230P (APET Antistat Base)
Material
EXAMPLE 61
APET 5005
87.9
Lotader 8900
7
D440
5
AO 412S
0.1
No Properties
[0000]
TABLE 22
CP 231P (APET CNT)
Material
EXAMPLE 62
EXAMPLE 63
EXAMPLE 64
Lotader 8900
2.5
2.5
2.5
CP 230P*
94.9
94.9
94.5
C150P
2.6
3
3.42
CBT 100
1.84
HDPE 511051
0.92
Glycolube P
0.92
No Properties
[0000]
TABLE 23
CP 232P (APET CNT)
Material
EXAMPLE 65
Lotader 8900
2.5
CP 230P*
90
2040 CNT
3.6
CBT 100
2
HDPE 511051
1
Glycolube P
0.9
Properties
Tensile Modulus (Mpa)
1636.4
Tensile Str. @ YLD (Mpa)
41
Tensile Str. @ BRK (Mpa)
41.1
Tensile Str. @ BRK (%)
4.2
Flex Modulus (Mpa)
1874.2
Flex Stress (Mpa)
67.9
Izod Impact @RT (ft-lb/in)
0.69 CB
Specific Gravity
1.2988
[0000]
TABLE 24
CP 237 (APET Antistat Base)
EXAM-
EXAM-
EXAM-
EXAM-
EXAM-
EXAM-
PLE
PLE
PLE
PLE
PLE
PLE
Material
66
67
68
69
70
71
APET 5005
87.9
78.9
78.9
57.9
77.9
Lotader 8900
7
6
5
5
5
5
D440
5
15
5
20
7
7
AO 412S
0.1
0.1
0.1
0.1
0.1
0.1
PC 1225L
75
Engage 8180
11
CP 237 X4*
30
LDPE
10
Properties
Tensile
1852.3
Modulus
(Mpa)
Tensile Str. @
52.7
YLD (Mpa)
Tensile Str. @
50.4
BRK (Mpa)
Tensile Str. @
8.3
BRK (%)
[0000]
TABLE 25
CP 239 (APET Antistat Base)
EXAM-
EXAM-
EXAM-
EXAM-
Material
PLE 72
PLE 73
PLE 74
PLE 75
EXAMPLE 76
APET 5005
57.9
43.9
Lotader 8900
5
5
8
D440
20
7
8
2
2
AO 412S
0.1
0.1
PC 1225L
75
NC 7000
5
5
CP 239 X1*
30
40
CP 239 X2*
93
CP 239 X3*
93
No Properties
[0000]
TABLE 26
CP 253 (PETG Antistat - HSA Trays)
EXAM-
EXAM-
EXAM-
EXAM-
EXAM-
Material
PLE 77
PLE 78
PLE 79
PLE 80
PLE 81
PETG Skygreen
70.8
19.8
Lotader 8900
2
1
D440
2
Pearlthane D11T93
25
AO 1010
0.2
Surlyn 8920
1
Sunova 80HP
30
30
30
CP 253 X1*
48
69
67
CB 900
0.2
CP 253 X2*
98
NC 7000
2
1
Bayon YM312
3
No Properties
[0000]
TABLE 27
CP 255 (PETG Antistat - HSA Trays)
EXAM-
EXAM-
EXAM-
EXAM-
EXAM-
Material
PLE 82
PLE 83
PLE 84
PLE 85
PLE 86
PETG Skygreen
69.8
Lotader 8900
2
1
1
1
1
D440
2
3
Pearlthane D11T93
25
AO 1010
0.2
Surlyn 8920
1
Sunova 80HP
30
30
30
30
CP 253 X1*
66
66
65
65
NC 7000
1
1
Bayon YM312
3
CYRO H15
3
3
No Properties
[0000]
TABLE 28
CP 256 (PETG Antistat - HSA Trays)
EXAM-
EXAM-
EXAM-
EXAM-
PLE
PLE
PLE
PLE
Material
87
88
89
90
PETG Skygreen
93
16.8
Lotader 8900
2
3
D440
3
Pearlthane D11T93
15
AO 1010
0.2
Surlyn 8920
2
Sunova 80HP
CP 255 X1*
60
40
CP 256 X1*
40
60
60
NC 7000
5
Properties
Tensile Modulus (Mpa)
1577.4
1835.3
1505.7
Tensile Str. @ YLD (Mpa)
42.7
44.9
40.7
Tensile Str. @ BRK (Mpa)
33.2
44.5
40.3
Tensile Str. @ BRK (%)
99
3.3
3.8
Izod Impact @RT (ft-lb/in)
1.16 CB
1.34 CB
1.68 CB
MI @240 C., 5.0 Kg
25.03
16.07
10.63
(g/10 min)
Resistance (Ohms/sq)
4.07E+12
8.39E+09
1.65E+09
[0000]
TABLE 29
CP 265 (PETG Antistat - HSA Trays)
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
Material
91
92
93
94
95
96
PETG
87
11.8
16.8
13
Skygreen
Lotader 8900
2
3
2
3
3
3
D440
3
3
2
3
3
3
Pearlthane
15
13.8
15
15
D11T93
AO 1010
0.2
0.2
0.2
0.2
0.2
Surlyn 8920
2
2
2
2
2
CP 255 X1*
31.8
CP 265 X1*
65
80
60
60
60
CBT 100
2
3.8
C150P
6
Properties
Tensile
1549.8
1714.8
1464.5
Modulus
(Mpa)
Resistance -
3.6E+06
1.5E+03
2.9E+03
Mid-HighE+03
Strand
(Ohms/sq)
[0000]
TABLE 30
CP 266 (PETG Antistat - HSA Trays)
Material
EXAMPLE 97
PETG Skygreen
11.8
Lotader 8900
3
D440
3
AO 1010
0.2
Surlyn 8920
2
CP 255 X1*
20
CP 265 X1*
60
Properties
Tensile Modulus (Mpa)
1744.5
Tensile Str. @ YLD (Mpa)
41.6
Tensile Str. @ BRK (Mpa)
35.7
Tensile Str. @ BRK (%)
7.8
Flex Modulus (Mpa)
1800.8
Flex Stress (Mpa)
60.3
[0000]
TABLE 31
CP 269 (PETG Antistat - HSA Trays)
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
Material
98
99
100
101
102
103
PETG
87
11.8
11.8
72
52.5
Skygreen
Lotader 8900
2
3
3
3
3
D440
3
CBT 100
2
3.8
AO 1010
0.2
0.2
0.2
0.2
Surlyn 8920
2
2
LDPE NA520
15
85
PP 6310
15
CP 269 X1*
65
65
CP 269 X4*
15
40
C150P
6
10
3
1.25
Lotader 4700
3
Fusabond
3
5
3
3
226DE
Properties
Tensile
1340.5
1047.5
1210.8
849.4
Modulus
(Mpa)
Tensile Str. @
30.6
25
32
24.2
YLD (Mpa)
Tensile Str. @
27.3
21.2
23.1
23.8
BRK (Mpa)
Tensile Str. @
6.11
7.4
39.2
5.6
BRK (%)
Flex Modulus
1554.3
1197
1360
769.9
(Mpa)
Flex Stress
46.7
39.4
47
30.4
(Mpa)
Izod Impact
1.13 CB
1.14 CB
1.07 CB
0.94 PB
@RT (ft-
lb/in)
MI @240 C,
7.3
3.6
6.7
0 No Flow
5.0 Kg
(g/10 min)
Resistance -
1.6E+04
2.0E+04
5.3E+08
4.40E+12
Strand
(Ohms/sq)
Resistance -
5.26E+12
3.99E+11
2.7E+10
1.73E+12
Probe
(2)
(Ohms/sq)
4.1E+07
(1)
[0000]
TABLE 32
CP 270 (PETG Antistat - HSA Trays)
EXAM-
EXAM-
EXAM-
EXAM-
PLE
PLE
PLE
PLE
Material
104
105
106
107
PETG Skygreen
8.8
7.8
21.8
30.3
Lotader 8900
3
3
3
3
D440
3
3
3
3
AO 1010
0.2
0.2
0.2
0.2
Surlyn 8920
2
2
2
2
CP 255 X1*
20
20
20
20
CP 265 X1*
60
60
50
41.5
HDPE 511051
3
2
Glycolube P
2
Properties
Tensile Modulus (Mpa)
1507.8
1474
1509.7
1382.1
Tensile Str. @ YLD
38.2
36.4
35.9
36.6
(Mpa)
Tensile Str. @ BRK
28.3
29.9
32.8
25.9
(Mpa)
Tensile Str. @ BRK (%)
11.7
8.9
5.9
13.1
Flex Modulus (Mpa)
1850.3
1721.2
1899.7
1624.3
Flex Stress (Mpa)
60.7
57
59.3
56.1
Izod Impact @RT
1.06 CB
0.77 CB
0.53 CB
0.86 CB
(ft-lb/in)
MI @240 C., 5.0 Kg
8.3
5.3
9.8
31.5
(g/10 min)
Resistance - Strand
4.16E+03
2.36E+03
4.48E+03
8.76E+05
(Ohms/sq)
Resistance - Probe
4.60E+06
3.99E+07
7.61E+08
3.98E+12
(Ohms/sq)
[0000]
TABLE 33
CP 273 (PETG Antistat - HSA Trays)
Material
EXAMPLE 108
PETG Skygreen
28
Lotader 8900
3.8
D440
3
AO 1010
0.2
CP 255 X1*
20
CP 265 X1*
42
HDPE 511051
3
Properties
Tensile Modulus (Mpa)
1551.4
Tensile Str. @ YLD (Mpa)
37.4
Tensile Str. @ BRK (Mpa)
37.4
Tensile Str. @ BRK (%)
3.3
Flex Modulus (Mpa)
1666
Flex Stress (Mpa)
55.2
Izod Impact @RT (ft-lb/in)
1.19 CB
Resistance - Strand (Ohms/sq)
1.51E+06
[0000]
TABLE 34
CP 288 (PETG Antistat - HSA Trays)
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
Material
109
110
111
112
113
PETG Skygreen
77.8
32
32
33
42
Lotader 8900
3
4
5
5
D440
3
4
2
5
AO 1010
0.2
Pearlthane 11T93
15
CP 255 X1*
20
20
CP 288 X1*
38
38
38
38
NC 7000
6
CBT 100
3
HDPE 511051
2
1
1
1
1
Fusabond 493D
5
8
5
8
Glycolube P
1
1
1
1
Properties
Tensile Modulus
1444.6
1350
1135.3
996.9
(Mpa)
Tensile Str. @ YLD
37.8
34.9
29.6
26.9
(Mpa)
Tensile Str. @ BRK
23.3
22.5
20.6
21.3
(Mpa)
Tensile Str. @ BRK
13
11.1
21.2
31.3
(%)
Flex Modulus (Mpa)
1531.1
1425.5
1202.9
1032.8
Flex Stress (Mpa)
55.3
50.4
41.8
37
Izod Impact @RT (ft-
3.41 CB
2.57 CB
4.43 CB
25.3 NB
lb/in)
Resistance - Strand
7.43E+05
1.23E+05
5.17E+04
4.17E+04
(Ohms/sq)
Resistance - Tensile
4.72E+12
1.82E+11
1.57E+12
5.68E+12
(Ohms/sq)
[0000]
TABLE 35
CP 290 (PETG Antistat - HSA Trays)
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
Material
114
115
116
117
118
PETG Skygreen
77.8
47
42
52
52
Lotader 8900
3
4
5
3
D440
3
4
5
AO 1010
0.2
CP 290 X1*
38
38
38
38
NC 7000
6
CBT 100
3
HDPE 511051
2
1
1
1
1
Fusabond 493D
5
5
8
5
8
Glycolube P
1
1
1
1
Properties
Tensile Modulus
1171.9
1015.2
1233.8
1279.7
(Mpa)
Tensile Str. @ YLD
31.3
27.5
34.8
36.9
(Mpa)
Tensile Str. @ BRK
23
21.8
23.9
24.4
(Mpa)
Tensile Str. @ BRK
20.8
26.7
16.8
13.3
(%)
Flex Modulus (Mpa)
1175
1050.7
1305.5
1386.7
Flex Stress (Mpa)
42.1
37.5
47.3
50.1
lzod Impact @RT (ft-
3.23 CB
8.55 PB
2.05 CB
1.99 CB
lb/in)
Resistance - Strand
1.57E+04
1.77E+04
1.40E+04
4.57E+04
(Ohms/sq)
Resistance - Tensile
5.85E+11
9.70E+10
7.62E+10
2.88E+11
(Ohms/sq)
[0000]
TABLE 36
CP 291 (PETG Antistat - HSA Trays)
Material
EXAMPLE 119
EXAMPLE 120
PETG Skygreen
74.1
76.4
Lotader 8900
4
4
D440
6
6
NC 7000
2.3
CBT 100
1.1
1.1
HDPE 511051
1.5
1.5
Fusabond 493D
10
10
Glycolube P
1
1
Properties
Tensile Modulus (Mpa)
1085.1
1069.9
Tensile Str. @ YLD (Mpa)
28.1
28.4
Tensile Str. @ BRK (Mpa)
20.4
30.1
Tensile Str. @ BRK (%)
19.6
304.1
Flex Modulus (Mpa)
1162.8
1114.7
Flex Stress (Mpa)
40.3
38.7
Izod Impact @RT (ft-lb/in)
6.91 NB
19.2 NB
Resistance - Tensile (Ohms/sq)
1.02E+03
6.42E+12
[0000]
TABLE 37
CP 294 (PETG Antistat - HSA Trays)
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
Material
121
122
123
124
125
126
PETG
84.1
78.1
74.1
80.1
74.1
67.1
Skygreen
Lotader 8900
4
4
4
4
5
D440
6
6
6
10
10
2
NC 7000
2.3
2.3
2.3
2.3
2.3
2.3
CBT 100
1.1
1.1
1.1
1.1
1.1
1.1
HDPE 511051
1.5
1.5
1.5
1.5
1.5
1.5
Fusabond
10
10
6
5
493D
Glycolube P
1
1
1
1
1
1
Pearlthane
15
11T93
Properties
Tensile
1403.7
1369.4
1103.9
1277.4
1116.2
1117.3
Modulus
(Mpa)
Tensile Str. @
39.2
35.7
28.8
34.5
29.6
30.2
YLD (Mpa)
Tensile Str. @
25.3
23.8
20.6
23.8
21.1
20.2
BRK (Mpa)
Tensile Str. @
14.1
10.6
22.2
18.3
16.4
19
BRK (%)
Flex Modulus
1587.3
1569.4
1205.5
1541.7
1208
1291.8
(Mpa)
Flex Stress
54.2
49.2
42
52.9
42.8
44.9
(Mpa)
lzod Impact
1.27 CB
1.56 CB
2.98 CB
1.73 CB
2.63 CB
2.40 CB
@RT (ft-lb/in)
Resistance -
9.63E+04
1.02E+04
7.37E+05
1.43E+04
5.30E+05
1.11E+12
Strand
(Ohms/sq)
Resistance -
7.82E+09
1.40E+06
4.98E+12
3.94E+08
7.08E+12
1.04E+13
Tensile
(Ohms/sq)
[0000]
TABLE 38
CP 296 (PETG Antistat - HSA Trays)
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
Material
127
128
129
130
PETG
77.8
50
47
47
Skygreen
Lotader 8900
3
5
5
D440
3
5
5
AO 1010
0.2
CP 290 X1*
38
38
38
NC 7000
6
CBT 100
3
HDPE 511051
2
1
1
1
Fusabond 493D
5
8
8
Glycolube P
1
1
1
No Properties
[0000]
TABLE 39
CP 297 (PETG Antistat - HSA Breaker Plate)
EXAM-
EXAM-
EXAM-
EXAM-
PLE
PLE
PLE
PLE
Material
131
132
133
134
PETG Skygreen
77.8
42
42
30
Lotader 8900
3
5
5
5
D440
3
5
5
5
AO 1010
0.2
LLDPE (120FPLDPE)
2
CP 297 X1*
38
38
50
NC 7000
6
CBT 100
3
HDPE 511051
2
1
1
1
Fusabond 493D
5
8
8
8
Glycolube P
1
1
Properties
Tensile Modulus (Mpa)
1015
948
Tensile Str. @ YLD
26
23.7
(Mpa)
Tensile Str. @ BRK
19.4
18.4
(Mpa)
Tensile Str. @ BRK
34.6
37.9
(%)
Flex Modulus (Mpa)
1064
986
Flex Stress (Mpa)
37
33
HDT @66 psi (° C.)
63.7
61.4
Specific Gravity
1.1805
1.1665
Resistance - Strand
2.43E+12
2.37E+12
(Ohms/sq)
[0000]
TABLE 40
CP 299 (PETG Antistat - HSA Trays)
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
Material
135
136
137
138
139
PETG Skygreen
85.7
83
83
78.8
79.9
Lotader 8900
4.2
4.2
4.2
4.2
D440
4.2
4.2
4.2
4.2
C150P
2.3
2.3
2.3
2.3
2.3
CBT 100
1.1
1.1
1.1
1.1
HDPE 511051
1.5
1.5
1.5
1.5
1.5
Fusabond 493D
6.9
6.9
6.9
6.9
Glycolube P
1
1
1
1
1
Properties
Tensile Modulus
1464
1383
1309.7
1211.3
1207.1
(Mpa)
Tensile Str. @ YLD
39.6
36
34.8
32.4
31.9
(Mpa)
Tensile Str. @ BRK
23.2
21.9
21.7
21.2
22.1
(Mpa)
Tensile Str. @ BRK
20.1
17.4
57.1
35.7
65.2
(%)
Flex Modulus (Mpa)
1645
1480
1375
1285
1269
Flex Stress (Mpa)
56
51
49
46
45
HDT @66 psi (° C.)
65.3
65.8
68.3
65.7
68.1
Specific Gravity
1.2423
1.221
1.2178
1.2095
1.2105
[0048] While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention.
|
This invention relates to a thermoplastic polymer composition that exhibits excellent characteristics for being thermoformed into a wide variety of packaging trays for electronics, including the disk drive and semiconductor industries. More specifically, these trays are applicable as packaging material for head suspension assembly and offer conductivities in the range of antistatic to electrostatic dissipation (ESD). For instance, the thermoplastic polymer composition of this invention offers improved stiffness, improved chemical resistance, the capable of enduring more washing cycles, the capability of being dried at higher temperatures, improved cleanliness, and better electrical conductivity that conventional PETG/IDP polymer blends. The thermoplastic polymer composition of this invention is comprised of (1) a polyethylene terephthalate glycol copolyester, (2) from 1 weight percent to 6 weight percent carbon nanotubes, (3) from 2 weight percent to 30 weight percent of a copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 1 weight percent to 10 weight percent of a functionalized rubbery polymer, (5) from 1 weight percent to 10 weight percent of an acrylic based core-shell polymer, and (6) from 0.5 weight percent to 6 weight percent of a lubricant selected from the group consisting of high density polyethylene and polyester wax, where the polyethylene terephthalate glycol copolyester makes up the balance of the composition and wherein all weight percentages are based upon the total weight of the thermoplastic polymer composition.
| 2
|
BACKGROUND OF THE INVENTION
This invention relates to electric irons and in particular to a nozzle assembly for spraying water onto the garments being ironed while the iron is being used.
In the field of electric irons of the type that are commonly used in the modern household, many of the irons include means to emit a spray of water droplets onto the object to be ironed which is positioned in the path of movement of the iron. This spray function is used when ironing certain fabrics and the spray function is controlled by the user of the iron. The spray of water tends to relax the fabric being ironed and assists in removing wrinkles from the garment.
Prior spray nozzle assemblies typically have used either a nozzle having an integral check valve or a separate check valve generally located adjacent to the spray pump. In both instances, the check valve comprises a valve seat sealed by a spring loaded ball which is displaced to allow water flow from the pump through the spray nozzle. The spring returns the ball to the seated position to prevent reverse flow when the user discontinues the spray function.
Assembly of the spray nozzles can be made complicated due to the check valve including the spring loaded ball. The spring and ball are generally small parts and are somewhat difficult to assemble.
As shown in U.S. Pat. No. 5,209,407, some nozzle assemblies contain a plurality of raised pads to create circular water flow through the orifice. The fluid is directed through the raised pads by a substantially flat disc-like member. The present nozzle assembly provides an improvement over the assembly disclosed in the cited United States patent.
It is therefore an object of this invention to provide an electric iron having a spray nozzle which eliminates the separate spring loaded check valve and results in a three piece nozzle assembly which is relatively easy to assemble during manufacture of the iron.
SUMMARY OF THE INVENTION
The foregoing object and other objects of the invention are obtained in a spray nozzle for an electric iron including a nozzle cap having an outlet orifice formed in a first end wall thereof. The cap includes an axially extending cylindrical wall defining an axially extending bore. A fluid flow coupling is inserted into a second end wall of the cap and includes a valve seat. A movable valve member is disposed within the bore and operates to direct fluid through said outlet orifice when fluid flows through said bore towards said outlet. The valve member moves within the bore into engagement with the valve seat when the flow of fluid through the bore is discontinued.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an exploded perspective view illustrating the iron, the water cassette, and the base for the iron and cassette;
FIG. 1A is an exploded perspective view of the cassette and portion of the base illustrating further details thereof;
FIG. 2 is a side elevational view, partially in section, of the iron being placed on the base;
FIG. 3 is a view similar to FIG. 2 with the iron on the base;
FIG. 4 is a side elevational view of the iron, with parts broken away for clarity, illustrating the iron on the soleplate thereof;
FIG. 5 is a view similar to FIG. 4 with the iron on its heel rest;
FIG. 6 is a view similar to FIGS. 4 and with the iron in the base;
FIG. 7 is a side elevational view of the iron, partially in section, with the iron on the soleplate;
FIG. 8 is an enlarged sectional view of the steam control assembly employed in the iron;
FIG. 9 is an exploded perspective view of the steam control assembly;
FIG. 10 is a side elevational view with parts broken away to illustrate a thermostat control used in the iron;
FIG. 11 is a top plan view of the iron further illustrating the thermostat control;
FIG. 12 is an enlarged sectional view of a portion of the iron illustrating the thermostat control;
FIG. 13 is a side perspective view of the iron with parts broken away to illustrate a spray nozzle assembly employed on the iron;
FIG. 14 is an enlarged perspective view of the spray nozzle assembly;
FIG. 15 is an enlarged perspective view of the nozzle assembly;
FIG. 16 is a side perspective view of the iron with parts broken away to illustrate a reservoir fill control for the iron;
FIG. 17 is a partial sectional view of the iron illustrated in FIG. 16;
FIG. 18 is an exploded perspective view of the iron and base illustrating details of the water reservoir of the iron; and
FIG. 19 is a plan view partially in section and partially broken away of the water reservoir.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the various figures of the drawing, a preferred embodiment of the present invention shall now be described in detail. In referring to the various figures of the drawing, like numerals shall refer to like parts.
Referring specifically to FIGS. 1, 1A, 2 and 3, there is shown an iron assembly 10 embodying the present invention. Iron assembly 10 includes an iron 11, a water cassette 16, and a base 14. Base 14 includes a generally planar platform member 15 terminating in a downwardly inclined portion 41 at its rear end. Base 14 includes an upwardly extending rim 17. Platform 15 includes three standoffs 18 formed from nonabrasive material such as rubber or the like. Standoffs 18 contact the bottom surface of soleplate 54 of the iron when the iron is placed on the base. As standoffs 18 are made from nonabrasive material, the standoffs will not scratch the surface of the soleplate. Further, the standoffs are made from high temperature resistant material so that the iron may be placed directly in base 14 immediately after ironing is discontinued.
Base 14 includes a pair of inwardly extending hook-like projections 20 formed at the top of rim 17 and located at the front of platform 15. Hook-like projections 20 extend into a groove 55 formed between the top of soleplate 54 and the bottom of skirt 58 of the iron when iron 11 is placed on the base. A rectangular slot 26 and a generally circular opening 28 are formed in platform 15 to enable base 14 to be placed on a mounting bracket for enabling iron assembly 10 to be stored on a wall or similar surface when iron 11 is not in use.
Base 14 further includes a pivotal latch 22 having a hook-like portion 27 at one end and an elongated finger 25 extending from hook-like portion 27. The latch is preferably L or reverse J shaped. A handle 23 is connected to latch 22 to pivot the latch between locking and unlocking positions. As shown in FIGS. 2 and 3, latch 22 further includes a spring 24 which keeps the latch in its iron engaged position when the iron is placed on base 14. As illustrated in FIG. 3, a somewhat rectangular slot 29 is formed at the rear face of the iron between soleplate 54 and skirt 58. Hook-like portion 27 projects within slot 29 to retain iron 11 on base 14.
When the iron is not located on the base, for example when the iron is being used, finger 25 extends upwardly above the surface of platform 15. As iron 11 is moved towards the base, as shown in FIG. 2, finger 25 extends into the path of movement of the iron. When the iron is placed on the base, the rear portion of soleplate 54 contacts finger 25. The force developed by soleplate 54 engaging finger 25 rotates latch 22 counterclockwise into its locking position. When the user desires to remove iron 11 from base 14, the user rotates handle 23 clockwise to pivot latch 22 clockwise to release the iron. Even if engaging finger 25 is moved below the plane of platform 15 when the iron is not in the base, when the front of the iron is placed in the base so that projections 20 are inserted into groove 55, the rear face of skirt 58 will contact portion 27 and rotate the latch clockwise until finger 25 contacts 54 of iron 11. Further movement of the iron into the base will result in the latch pivoting counterclockwise into its locking position.
As shown in FIGS. 1 and 1A, base 14 includes a rear section 34 defining the rear wall of the base. Rear section 34 includes a vertically extending inwardly projecting abutment member 30 and a tail portion 32 extending upwardly from the top face 33 of rear section 34. Tail portion 32 comprises a generally horizontal extending floor member 35, a pair of inwardly inclined sidewalls 37 and an inwardly inclined front wall 39. The rear of tail section 32 is open.
Water cassette 16 includes a bottom wall 36 having a generally rectangularly shaped slot 43 formed therein. Slot 43 is configured to complement the shape of tail portion 32 so that the tail portion may be slid within the slot to join the cassette to the base. Slot 43 terminates in a vertical wall 45 which mates with vertical wall 39 of tail portion 32 when the tail portion is inserted into the slot. Cassette 16 further includes a plurality of horizontally extending ribs 38 to give rigidity to the wall 49 of cassette 16. The ribs also function as a cordwrap for power cord 59 when the iron is stored. A cap 51 is threadably received on the spout (not shown) of the cassette.
Housing 12 includes a nose portion 50. Housing 12 is attached to skirt 58 which, in turn, is attached to soleplate 54. Groove 55 is formed between the top surface of soleplate 54 and the bottom surface of skirt 58. Groove 55 enables the user to readily iron garments having buttons and also functions to receive projections 20 as previously described. Skirt 58 is generally L-shaped and comprises a horizontal leg 58A and a substantially vertical leg 58B.
Spray nozzle 52 extends forwardly of nose portion 50 of housing 12. Nose portion 50 further includes fill opening 48. Housing 12 further includes handle 40. Steam control valve 42 extends upwardly from handle 40. Handle 40 further includes spray pump control 44. Control 44 activates pump 44A (See FIG. 17).
An on/off switch 46 is positioned on the saddle portion 47 of housing 12. An arcuate opening 62 is formed in saddle portion 47. The arcuate opening forms a track for thermostat control knob 60. Arcuate opening 62 is inclined downwardly about 2° from its rear to its forward faces. The inclination of the track follows the general contour of saddle portion 47.
A rear cover 56 is attached to the outer surface of vertical leg 58B of skirt 58. An opening is formed between the outer surface of leg 58B and the opposed surface of cover 56. A cord bushing 57 extends outwardly through the opening. Cord bushing 57 surrounds power cord 59. Power cord 59 is connected to a source of electrical power for delivering electrical power to the iron for actuating among other components the electrical resistance heater (shown in FIG. 18) associated with the soleplate in heat transfer relation as is conventional in the art. A rotatable foot-like member 70 is attached to cover 56 for a reason to be more fully explained hereinafter.
Referring now in detail to FIGS. 4-9, the function of foot member 70 in conjunction with the steam control, on/off switch, and base shall be more fully explained.
As illustrated, foot member 70 is pivotally connected to cover 56 at pivot 72. As shown in FIG. 4, when the soleplate is placed in a horizontal plane and the iron is supported on an underlying garment or the surface of the ironing board, foot member 70 lies generally parallel to the soleplate and is spaced above the underlying support surface. An actuator arm 102 of steam control assembly 100 extends within the pivotal path of movement of foot member 70. When the iron is positioned as shown in FIG. 4, actuator arm 102 is urged towards cover 56.
Further as illustrated in FIG. 4, on/off switch 46 is in its on position connecting iron 11 to the source of electrical power. On/off switch 46 is pivotally connected to skirt 58 via bracket 76. On/off switch 46 includes a trigger member 78. Rotatable actuator 80 is positioned in the path of movement of foot member 70 when the iron is placed on base 14 as illustrated in FIG. 6. Movement of actuator 80 results in contact between the actuator and trigger member 78.
FIG. 5 illustrates the iron supported on its heel rest. The rear surface of cover 56 defines the heel rest for the iron. As the iron is rotated from its horizontal position to its heelrest position, the weight of the iron provides a force to rotate foot member 70 in a counterclockwise direction to achieve the position illustrated in FIG. 5. The weight of the iron also provides a force which causes the foot member to translate parallel to the soleplate in the direction of the arrow shown in FIG. 5. When so translated in the direction shown, notch 81 of the foot member engages a complementary surface 82 on the cover to latch the foot member in the position illustrated. Spring 83 is compressed as a consequence of the rotational movement of foot member 70.
When foot member 70 has been rotated to the position illustrated in FIG. 5, the foot member extends the effective length of the heel rest. It should be noted that iron 11 has a rather unique shape. Particularly, it should be noted that the upwardly extending leg 58B of skirt 58 is at an obtuse angle relative to horizontal leg 58A of the skirt. Typically, the upwardly extending leg of a skirt is perpendicular or at an acute angle to the horizontally extending leg of the skirt. Thus, the cover of the iron attached to the upwardly extending leg readily provides a suitable support for the iron when the iron is placed in the heel rest position. Due to the rather unique shape of the present iron 11, and in the absence of foot member 70, the weight of the iron will cause the iron to rotate in a counterclockwise direction if the iron were placed on cover 56. Foot member 70 when extended in the position shown in FIG. 5, increases the length of cover 56 so that the fulcrum or pivot point for the iron is shifted to the left (towards the soleplate) as viewed in FIG. 5 so that the clockwise moment arm tending to maintain the iron on its heel rest increases in magnitude and the counterclockwise moment arm decreases in magnitude. A relatively light weight 86 may be added to the handle to increase the magnitude of the clockwise moment arm to further insure the stability of the iron when the iron is placed on its heel rest. Since the fulcrum has been moved as a consequence of the extension of foot member 70, weight 86 may be relatively light so as not to unduly increase the total weight of the iron.
As illustrated in FIG. 5, the rotational movement of foot member 70 results in leg 70A thereof contacting actuator arm 102 of steam valve assembly 100. The force provided by leg 70A moving into contact with actuator arm 102 of steam valve 100 moves the actuator to the left as viewed in FIG. 4 or upwardly as viewed in FIG. 5. As shall be more fully explained hereinafter, this movement of the actuator arm results in the stoppage of flow of water from water reservoir 120 into steam chamber 122.
When iron 11 is moved from the heel rest position illustrated in FIG. 5 to the ironing position illustrated in FIG. 4, notch 81 disengages from surface 82, enabling foot member 70 to rotate in a clockwise direction as viewed in FIG. 4. Spring 83 provides the force to rotate foot member 70 from its heel rest position (FIG. 5) to the ironing position (FIG. 4). If the foot member is jammed into its heel rest position when the iron is returned to its ironing position, the lower edge 70D of foot member 70 extends below the bottom surface of soleplate 54. Edge 70D contacts the underlying support surface (ironing board or garment) and the force of such engagement triggers the foot member to translate in the direction opposite to the arrow illustrated in FIG. 5. This movement releases notch 81 from surface 82.
Referring now to FIG. 6, iron 11 is shown mounted on base 14. When the iron is placed on its base, abutment member 30 of rear section 34 of the base engages foot member 70 to rotate foot member 70 in a counterclockwise direction. As noted previously, the foot member is rotated in a counterclockwise direction when the iron is placed on its heel rest; however the shape of abutment member 30 causes the foot member to have a larger arc of rotation when the iron is placed on base 14 than when the iron is placed on its heel rest.
Foot member 70 is rotated counterclockwise when iron 11 is placed on the base, to move actuator arm 102 of steam valve assembly 100 to the left as shown in FIG. 6. Further, upper face 70C of the foot member engages actuator 80 associated with on/off switch 46. The actuator in turn engages trigger member 78 of the switch to rotate the switch in a counterclockwise direction from its on position to its off position. Thus, when iron 11 is placed on base 14, engagement of foot member 70 with abutment member 30 results in the foot member moving the actuator arm 102 to discontinue flow of water into steam chamber 122 and also results in the electrical power to the iron being interrupted since the on/off switch is moved into its off position. Inclined portion 41 of platform member 15 enables foot member to rotate to the position shown in FIG. 6 when the iron is placed on base 14. Inclined portion 41 accepts the extended portion of foot member 70 terminating in edge 70D.
Referring now to FIGS. 7, 8, 9, and 18, steam control assembly 100 shall now be described in detail. Steam control assembly 100 is mounted in a track 124 formed in the top surface 126 of skirt 58 and includes a longitudinally extending actuator arm 102 which, has one end as previously described extending into the path of travel of foot member 70. As shown in FIG. 9, actuator arm 102 is connected to a rib 106 which in turn is connected to an actuator fork 108 having a U-shaped slot 110 formed therein. One end 112 of a spring bellows 114 extends within slot 110.
The other end of spring bellows 114 terminates in a longitudinally extending pin 116. As shown in FIGS. 7 and 8, the pin and associated end of the spring bellows extend into an orifice 130 of conduit 132. Conduit 132 extends outwardly from the sidewall 134 of valve housing 136. Valve housing 136 includes a chamber 128. Passageway 140 communicates orifice 130 with chamber 128. Passageway 140 also communicates chamber 128 with outlet 142. Pin 116 extends through the passageway into the chamber to clean the passageway and meter the flow of water from the chamber into the passageway. End 112 of bellows 114 closes the passageway when the bellows is moved to the left as viewed in FIG. 8 and interrupts flow between chamber 128 and outlet 142. Actuator arm 102 moves bellows 114 to terminate the flow of water from water reservoir 120 into steam chamber 122.
Housing 14 includes steam control valve 42 for enabling the user to operate iron 11 in either dry or steam modes. FIG. 7 illustrates control valve 42 when the iron is being operated in its steam mode. Steam control valve 42 is connected via valve stem 144 to valve 146. As shown, when valve 146 is spaced above chamber 128, water will flow from water reservoir 120 into valve chamber 128 and thence into outlet 142 and steam chamber 122. When in the position shown, iron 11 may be used to steam and iron a garment. If dry ironing is desired, control valve 42 is moved downwardly to move valve stem 144 and attached valve 146 downwardly to close off the flow of water from reservoir 120 into chamber 122.
When the iron is rotated into its heel rest position, foot member 70 is rotated in a counterclockwise direction which, in turn, moves actuator arm 102 to the left as viewed in FIGS. 7 and 8. Movement of the actuator arm in this manner results in end 112 of bellows 114 closing the orifice to discontinue the flow of water from the water reservoir through chamber 128 and then into outlet 142. The same movement of the foot member and actuator arm occurs when the iron is placed in the base and the foot member engages abutment member 30.
Referring now to FIGS. 10-12, there is disclosed a preferred embodiment of the thermostat control for iron 11. As noted previously, saddle 47 of the iron includes an arcuate track 62 in which control knob 60 is movably mounted. Track 62 extends arcuately in a horizontal plane through the saddle portion and, as shown in FIG. 12 has a vertical slope so that track 62 is angled downwardly from the rear end of iron 11 towards nose portion 50 thereof. The slope of the track is substantially 2° and the arcuate travel of knob 60 in track 62 is substantially 10°.
As shown in FIG. 12, control knob 60 is connected to a vertically extending pin 150. The vertical axis of pin 150 is offset inwardly towards the center of iron 11 with respect to a vertical plane passing through the center of knob 60. Pin 150 extends within horizontally extending slot 152 of actuator lever 154. Lever 154 is integrally formed with rotatable actuator 156. Actuator 156 is attached to upwardly extending shaft 149 of thermostat 148. Thermostat 148 senses the temperature of soleplate 54. Pin 150 and actuator lever 154 comprise a linkage connecting control knob 60 to actuator 156, which in turn controls the operation of thermostat 148. The length of the radius establishing arcuate track 62 is substantially larger when compared to the length of the radius establishing the rotational path of movement of actuator 156. Movement of control knob 60 through a 10° arcuate path of travel results in substantially a 120° rotational movement of actuator 156 and shaft 149 of thermostat 148.
As shown in FIG. 11, as control knob 60 is arcuately moved along track 62, pin 150 transfers the force developed by movement of the knob to the actuator lever 154 and then to actuator 156 for establishing a set or operating point for thermostat 148. As the arcuate path for travel of knob 60 is substantially less than the arcuate path of travel of actuator 156, the distance between pin 150 and the center of rotation of actuator 156 is constantly changing. Further, the vertical position of the pin relative to slot 152 changes during movement of knob 60 due to the inclination of track 62. Pin 150 slides within slot 152 of lever 154 as a consequence of the movement of the control knob. In effect, the slot compensates for the vertical movement of pin 150 relative to lever 154 and also enables the distance between pin 150 and the center of rotation of actuator 156 to change. The described control enables thermostat control knob 60 to be mounted on a saddle having a rather complex geometrical shape.
Referring now to FIGS. 13-15, there is disclosed a preferred embodiment of the spray nozzle assembly 52 as used in the present iron assembly 10. Spray nozzle assembly 52 is mounted at the nose portion 50 of iron 11. Spray pump control 44 extends upwardly from handle 40 of iron 11. When the user desires to spray an underlying garment, the user presses downwardly on pump control 44 which creates a pumping action to pump water via pump 44A (See FIG. 17) from water reservoir 120 through line 182 and then through nozzle 52A of nozzle assembly 52. Nozzle assembly 52 includes nozzle 52A having a generally frusto-conically shaped outer wall 162 and an end wall 164 having a spray opening 166 generally located at the center thereof. Outer wall 162 defines a longitudinally extending bore 168. A spreader element 170 is disposed within the bore for reciprocating movement therein. Spreader element 170 includes a generally enlarged cylindrical head 172, a longitudinally extending body portion 174 and a spherical spreader end 176. A coupling 178 extends within an open end 180 of nozzle assembly 52. Line 182 is fitted over the outer end of coupling 178 to communicate bore 184 with water reservoir 120. Coupling 178 includes a valve seat 188 facing towards spherical end 176 of spreader element 170.
In operation, when the user desires to spray a garment being ironed, the user pumps control 44 to pump water from water reservoir 120 via pump 44A through line 182, thence into bore 168. The force of the water moves the spreader to the left as viewed in FIG. 14 so that surface 190 of the spreader contacts the inwardly extending pads 192 of nozzle assembly 52. Cylindrical head 172 of spreader element 170 directs the water in bore 168 towards the perimeter. Raised pads 192 comprise a plurality of circumferentially spaced members disposed on the interior surface of end wall 164. The water forced to the perimeter of bore 168 flows under the spreader and then radially inwardly between the raised pads to the centrally located orifice 166. The water is then sprayed in a desired pattern onto the garment.
When the user ceases pumping control 44, the return action of pump 44A creates a suction on line 182 moving spreader element 170 to the right as shown in FIG. 14 which results in spherical end 176 engaging seat 188 to create a seal. The seal prevents air from being sucked into the discharge side of pump 44A.
Referring now to FIGS. 16 and 17, the details of the fill system for water reservoir 120 shall be described in detail. A somewhat elliptically shaped opening 48 is formed in housing 12 at the nose portion or front end thereof 50. Opening 48 communicates with a water flow passage 194 defined between downwardly extending ribs 196. Ball valve or float valve 198 is disposed within flow passage 194. The specific gravity of ball valve 198 is less than one so that the valve floats on water. Lower wall 208 of reservoir 120 and the ribs entrap the ball valve. When the ball valve is moved upwardly within the passage, the ball valve seats against valve seat 202 to prevent water from splashing outwardly through opening 48.
When the user is filling water reservoir 120, a source of water is placed in communication with flow opening 48. For example, flow opening 48 may be placed beneath a faucet or cassette 16 may be used to add water to reservoir 120. Water fills the water reservoir causing float valve 198 to move upwardly in passage 194. When the iron is in normal use and water is in the reservoir, the float valve again is moved upwardly since its specific gravity is less than one. Valve 198 is forced against seat 202 to prevent the water from splashing outwardly through opening 48 during normal ironing use.
Further, when the iron is placed in a vertical position, for example when it is desired to steam or iron a garment held in a vertical position, if water level in the reservoir is relatively high, the water will cause ball valve 198 to remain seated, preventing water from splashing out when the iron is held upright.
Referring now to FIGS. 18 and 19, the structure of reservoir 120 shall now be more fully described. Reservoir 120 includes a plurality of walls 204 and 206 which extend upwardly part way from the top of lower or bottom wall 208 of reservoir 120. Walls 204 and 206 serve as dam means or as weir means to separate the reservoir into a forward compartment 210 and a rear compartment 211. It should be noted opening 212 in bottom wall 208 is located at the rear of forward compartment 210. In effect, walls 204 and 206 serve as dam means to provide a head of water above opening 212 when the iron is held in a vertical position. The head of water in forward compartment 210 enables iron 11 to be used as a steamer while the iron is held in a vertical position. By trapping water in the forward compartment when the iron is turned vertical, water will continue to flow from reservoir 120, through opening 212, steam valve chamber 128 and then into steam chamber 122. The iron will generate steam for a period of time until the supply of trapped water in compartment 210 is exhausted.
To replenish the supply of water in forward compartment 210, the user need only tip the iron forward and water in rear compartment 211 will flow into the forward compartment. When the iron is returned to its vertical position, divider walls 204 and 206 will retain the water in the forward compartment.
A water window 214 is disposed on saddle portion 47 and in alignment with rear compartment 211. When the iron is placed on its heel rest or held vertical, the user may look at the water window which, since it is in vertical alignment with the rear compartment provides an accurate indicator of the amount of water remaining in the water reservoir. If there is insufficient water in the reservoir to satisfy the steaming function, additional water can be added to reservoir 120 from cassette 16 or from a sink faucet.
While a preferred embodiment of the present invention has been described and illustrated, the invention should not be limited thereto but may be otherwise embodied within the scope of the following claims.
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A spray nozzle for an electric iron includes a nozzle cap having an outlet orifice formed in a first end wall thereof. The cap includes an axially extending cylindrical wall defining an axially extending bore. A fluid flow coupling is inserted into a second end wall of the cap and includes a valve seat. A movable valve member is disposed within the bore and is operable to direct fluid through the outlet orifice when fluid flows through the bore towards the outlet. The valve member moves within the bore into engagement with the valve seat when flow of fluid through the bore is terminated.
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This application is a continuation of Ser. No. 212,308, Mar. 14, 1994, U.S. Pat. No. 5,612,318, which is a continuation of Ser. No. 35,897, Mar. 18, 1993, abandoned, which is a continuation of Ser. No. 633,626, Dec. 20, 1990, abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to methods of controlling gene expression by radiation responsive genetic constructs. This invention also relates to methods and compositions for destroying, altering, or inactivating target tissues. These tissues may be disease-related, for example, tumors, or blood clots, or they may have a metabolic deficiency or abnormality. An aspect of this invention is to deliver radiation responsive genetic constructs to target tissues and to activate the genes in said constructs by exposing the tissues to external ionizing radiation.
2. Description of the Related Art
Certain genes may play a role in the cellular response to stress or DNA-damaging agents. For example, metallothionein I and II, collagenase, and plasminogen activator are induced after UV irradiation (Angel, et al., 1986; 1987; Fornace, et al., 1988a and b; Miskin, et al., 1981). B2 polymerase III transcripts are increased following treatment by heat shock (Fornace, et al., 1986; 1989a). Furthermore, although the level of DNA polymerase β mRNA is increased after treatment with DNA-damaging agents, this transcript is unchanged following irradiation, suggesting that specific DNA-damaging agents differentially regulate gene expression (Fornace, et al., 1989b). Protooncogene c-fos RNA levels are elevated following treatment by UV, heat shock, or chemical carcinogens (Andrews, et al., 1987; Hollander, et al., 1989a). In this regard, the relative rates of fos transcription during heat shock are unchanged, suggesting that this stress increased c-fos RNA through posttranscriptional mechanisms (Hollander, et al., 1989b).
Investigations of the cytotoxic effects of ionizing radiation has focused on the repair of DNA damage or the modification of radiation lethality by hypoxia (Banura, et al., 1976; Moulder, et al., 1984). In prokaryotes and lower eukaryotes, ionizing radiation has been shown to induce expression of several DNA repair genes (Little, et al., 1982); however, induction of gene expression by ionizing radiation has not been described in mammalian cells. DNA-damaging agents other than x-rays induce expression of a variety of genes in higher eukaryotes (Fornace, et al., 1988, 1989; Miskin, et al., 1981).
What is known about the effects of ionizing radiation is that DNA damage and cell killing result. In many examples, the effects are proportional to the dose rate. Ionizing radiation has been postulated to induce multiple biological effects by direct interaction with DNA or through the formation of free radical species leading to DNA damage (Hall, 1988). These effects include gene mutations, malignant transformation, and cell killing. Although ionizing radiation has been demonstrated to induce expression of certain DNA repair genes in some prokaryotic and lower eukaryotic cells, little is known about the effects of ionizing radiation on the regulation of mammalian gene expression (Borek, 1985). Several studies have described changes in the pattern of protein synthesis observed after irradiation of mammalian cells. For example, ionizing radiation treatment of human malignant melanoma cells is associated with induction of several unidentified proteins (Boothman, et al., 1989). Synthesis of cyclin and coregulated polypeptides is suppressed by ionizing radiation in rat REF52 cells but not in oncogene-transformed REF52 cell lines (Lambert and Borek, 1988). Other studies have demonstrated that certain growth factors or cytokines may be involved in x-ray-induced DNA damage. In this regard, platelet-derived growth factor is released from endothelial cells after irradiation (Witte, et al., 1989).
Initiation of mRNA synthesis by DNA is a critical control point in the regulation of cellular processes and depends on bindings of certain transcriptional regulatory factors to specific DNA sequences. However, little is known about the regulation of transcriptional control by ionizing radiation exposure in eukaryotic cells. The effects of ionizing radiation on posttranscriptional regulation of mammalian gene expression are also unknown.
Many diseases, conditions, and metabolic deficiencies would benefit from destruction, alteration, or inactivation of affected cells, or by replacement of a missing or abnormal gene product. In certain situations, the affected cells are focused in a recognizable tissue. Current methods of therapy which attempt to seek and destroy those tissues, or to deliver necessary gene products to them, have serious limitations. For some diseases, e.g., cancer, ionizing radiation is useful as a therapy. Methods to enhance the radition, thereby reducing the necessary dose, would greatly benefit cancer patients. Therefore, methods and compositions were sought to enhance radiation effects by investigating effects of radiation on gene expression. A goal was to provide new types of therapy using radiation, and to explore other uses of radiation.
SUMMARY OF THE INVENTION
In this invention, control exerted over gene expression by a promoter-enhancer region, which is responsive to ionizing radiation, is used as a switch to selectively introduce gene products to distinct tissue targets, providing opportunities for therapeutic destruction, alteration, or inactivation of cells in target tissues. These promoter-enhancer regions control gene expression through application of a radiation trigger.
More particularly, this invention relates to methods and compositions for treating diseases and conditions for which destruction, alteration or inactivation of cells in affected tissues would alleviate the disease or condition. The methods comprise delivering a genetic construct to cells of the host tissue and subsequently exposing the tissue to ionizing radiation. A region of the genetic construct is capable of being induced by ionizing radiation. Exposing the tissue to ionizing radiation, therefore, induces the expression of the genetic construct. The gene product is then capable of destroying, altering, or inactivating the cells in the tissue. The gene product chosen for treatment of factor deficiencies or abnormalities, is one that provides the normal n factor.
An illustrative embodiment of the genetic construct comprises a combination of a radiation responsive enhancer-promoter region and a region comprising at least one structural gene. The enhancer-promoter region drives the expression of a structural gene in the form of a reporter-effector gene appropriate for the disease or condition in the host.
The general composition of the construct comprises a radiation inducible promoter-enhancer region and a structural gene region. In an illustrative embodiment, the promoter is 5' to the structural gene region. In this embodiment, amplification of the final response does not occur. Rather there is a direct correlation between regulation of the radiation sensitive region and the structural gene. The inducible region is turned on by radiation exposure, but will turn off at some point after the radiation exposure ceases. Expression of the structural gene region is limited by exposure time and the inherent quantitative limits of the expression region.
In a preferred embodiment, to amplify the expression of the gene construct and to extend expression beyond exposure time, a cascade of promoters and expressing genes are contemplated, for example, two plasmids. The first plasmid comprises the radiation sensitive promoter 5' of an appropriate transcription factor. In an embodiment of a transcription factor, the first plasmid comprises a powerful activation domain, for example, that obtained from the herpes virus VP16. This domain contains many negatively charged residues. A chimeric protein is contemplated in this embodiment comprising the VP16 activation domain and a DNA binding domain of a known protein, for example, the lac repressor. The chimeric protein/gene construct (a fusion gene) is driven from a radiation sensitive promoter.
The second plasmid construct in the preferred embodiment comprises several binding sites for the lac repressor DNA binding domain. These binding sites are placed upstream of a reporter-effector gene, for example, TNF. Alternatively, the two plasmids described above could be merged into one construct.
The use of a cascade of promoters and two expressing genes as the genetic construct has several advantages:
(1) the promoter does not have to provide strong activation because amplification of the initial radiation sensitive promoter effect is provided through action of the subsequent genetic cascade;
(2) several genes may be included in the construct to provide more complex or more extensive action. In an illustrative embodiment, several toxin producing genes may be placed 3' of the appropriate DNA binding sites. An embodiment of a multiple gene construct comprises the DNA binding domain of the lac repressor followed by several genes which produce various regulators of cell growth; and
(3) the effect due to the initial ionizing radiation may be temporarily prolonged; that is, if the half-life of the chimeric lac repressor protein were long, for example, hours or day, compared to the radiation exposure time during which promoter RNA is released, the effect of the genetic construct on the cell is prolonged.
The genetic construct of this invention is incorporated into the cells of a target tissue by any method which incorporates the construct without inhibiting its desired expression and control over that expression by radiation. These methods comprise electroporation, lipofection, or retroviral methodology.
Retroviruses used to deliver the constructs to the host target tissues generally are viruses in which the 3' LTR (linear transfer region) has been inactivated. That is, these are enhancerless 3'LTR's, often referred to as SIN (self-inactivating viruses) because after productive infection into the host cell, the 3'LTR is transferred to the 5' end and both viral LTR's are inactive with respect to transcriptional activity. A use of these viruses well known to those skilled in the art is to clone genes for which the regulatory elements of the cloned gene are inserted in the space between the two LTR's. An advantage of a viral infection system is that it allows for a very high level of infection into the appropriate recipient cell, e.g., LAK cells.
For purposes of this invention, a radiation responsive enhancer-promoter which is 5' of the appropriate structural gene region, for example, a lymphokyne gene, or a transcriptional activator, may be cloned into the virus.
The constructs are delivered into a host by any method that causes the constructs to reach the cells of the target tissue, while preserving the characteristics of the construct used in this invention. These methods comprise delivering the construct by intravenous injection, injection directly into a target tissue, or incorporation into cells which have been removed from the host. In the latter case, after in vitro incorporation of the constructs into the recipient cells, the cells containing the construct are reintroduced into the host. Depending on the type of recipient cell, the distribution of the cells in the host will vary--in some cases being focused to a specific area, for example, where cells are directed to a tumor or clot, in other cases diffusing through an entire system such as the bone marrow. Even when the cells carrying the genetic construct have dispersed over a wide area of the host, focusing the desired action of the construct on a target tissue can be provided by directing the ionizing radiation used to switch on the construct, to a limited area. Only the cells within the beam will react and cause expression of the construct genes.
Another method of focusing the genetic action of the construct, or homing it into particular body regions, is to tag the construct with a radioisotope or other label and determine when the construct bearing cells have reached the target tissue by detecting the label geographically. The radiation is turned on when the construct reaches the target, and directed to the labelled direction.
The type of recipient cells used to incorporate the radiation inducible genetic constructs are selected based on the objective of the treatment. In an exemplary embodiment, LAK cells are used for patients in which tumor-directed attack is the main objective. In another embodiment, endothelial cells are used to deliver genes for gene therapy, for example, to treat genetically abnormal fetuses with a metabolic deficiency or abnormality. Cells derived from peripheral blood are also suitable recipient cells.
In an exemplary embodiment of the genetic construct, there are several steps leading to expression of the structural gene in the host tissues. In these constructs, there is a radiation sensitive promoter which causes (drives) the expression of a transcription factor. The transcription factor activates a reporter construct which includes an effector appropriate for the disease or condition of the host. The expression production of the effector gene interacts in a therapeutic fashion with the diseased, deficient or abnormal cells without a target tissue.
In an exemplary embodiment, toxins which are capable of killing tumor cells are put into LAK cells or other cellular/molecular vehicles by incorporating into the cells a vector comprising a radiation inducible or responsive promoter-enhancer region and a structural gene region. Examples of a radiation responsive promoter-enhancer region comprise that derived from, for example, c-jun or TNF-α. Examples of structural genes comprise those expressed as tumor necrosis factor (TNF), ricin, or various growth factors including, but not limited to, IL-1-6, PDGF (platelet derived growth factor) or FGF (fibroblast growth factor). Diseases for which this embodiment of a construct is useful comprise cancers. Types of cancers which would benefit from this form of treatment comprise solid and hematologic malignancies. Specific cancers include head and neck adenocarcinomas.
An embodiment of genetic construct comprises a radiation sensitive promoter coupled to an appropriate reporter, for example, β-galactosidase. The construct is transferred to a recipient cell. In general, many recipient cells are prepared in this fashion. The recipient cells are then introduced into a mammal. In an illustrative example, endothelial cells are used as the recipient cells. These cells are then transplanted into an appropriate blood vessel in which the action of the construct within the cells is desired. Radiation is delivered to an area of the body including that blood vessel. Expression of the β-galactosidase is monitored by chromogenic assays such as Xgal.
An embodiment of a structural gene which acts as a reporter-effector gene comprises that which is expressed as the tumor necrosis factor (TNF). Increased TNF-α production by human sarcomas after x-irradiation is evidence for the direct cytotoxic effects of this polypeptide on human tumor cells (Sugarman, 1985; Old, 1985). The intracellular production of TNF-α within irradiated tumor cells results in lethality to the cell after x-ray exposure that is greater than the lethality produced by the direct effects of ionizing radiation alone.
The additive and synergistic effects, the latter occurring if TNF is provided before radiation, of TNF-α on tumor killing by radiation supports potential applications for the use of TNF-α in clinical radiotherapy. TNF-α potentiates the cellular immune response (Bevelacqua, et al., 1989; Sersa, et al., 1988). In vivo studies have shown that TNF-α enhances tumor control by x-rays in mice with implanted syngeneic tumors by the augmentation of the host's immune system (Sersa, et al., 1988). Therefore, TNF-α may reverse immune suppression, which often accompanies radiotherapy. TNF-α also causes proliferation of fibroblasts and endothelial destruction, suggesting that TNF-α production by tumors may be one component responsible for the late radiation effects in surrounding normal tissue. Turning on this gene within a genetic construct by radiation allows directed attack on diseased tissues.
In addition to killing tumor cells by treatment with TNF, a goal is to protect normal tissues adjacent to the target tissue from radiation effects and deleterious action of various cytotoxins during cancer or other therapy. Solid and hemologic malignancies and aplastic anemia, are conditions for which this is a concern. Genes in the structural region of the genetic construct of this invention that are appropriate for this protective goal, include lymphokines, GCSF, CMSF, and erythropoietin.
The goal of cancer treatment is not only to kill cells at a specific target, but to inhibit metastasis. For this purpose, one of the genes appropriate for inclusion in the genetic construct is NM23.
Prevention of secondary malignancies which are and unfortunate side effect of standard radiotherapy and chemotherapy, is assisted by treatment with a construct comprising tumor suppressor genes.
This invention has uses in diseases and conditions other than cancer. For patients with clotting disorders, Factor VIII or other factors necessary for the complex process of clot formation, may be introduced into cells deficient for the missing factor.
Conversely, in conditions such as myocardial infarction, central nervous system or peripheral thrombosis, anticlotting factors introduced via the genetic constructs of this invention, are used to dissolve the clots. Embodiments of the expression products of such genes include streptokinase and urokinase.
Other categories of diseases or conditions for which there is a deficiency due to either a genetic or environmental factor, include the hemoglobinopathies such as sickle cell anemia, for which genes producing normal hemoglobin are included in the treatment construct; neurodegenerative diseases such as Alzheimer's disease for which genes expressed as nerve growth factors are included in the construct; and diabetes, for which insulin producing genes may be included in the construct.
Genetic diseases caused by defects in the genetic pathways effecting DNA repair, e.g., ataxia telangiectasia, xeroderma pigmentosum, are treated by the introduction of genes such as ERCC-1 or XRCC-1.
Although the practice of this invention requires exposure to radiation, an agent which in itself may adversely affect cells, the dose is relatively low, administered for brief periods of time, and focused. For many of the diseases and conditions for which this invention is appropriate, radiation treatment is standard, and practice of this invention will reduce the necessary dose, which reduces risk of the radiation treatment per se. For diseases which usually do not require radiation, use of radiation in the methods described in this invention will replace another therapy. Decision on use of this invention will be based on a risk/benefit analysis.
Definitions
Effector Gene--a gene whose expression product produces the desired effect in the recipient cells and target tissues.
Enhancer Gene or Element--a cis-acting nucleic acid sequence that increases the ulitization of some eukaryotic promoters, and can function in either orientation and in any location (upstream or downstream) relative to the promoter.
LAK Cells--lymphocyte activated killer cells.
Promoter--a region of DNA involved in binding RNA polymerase to initiate transcription.
Reporter Gene--a gene whose expression product is readily detectable and serves as a marker for the expression of induction.
Structural Gene--a gene coding for a protein with an effector function. This protein might be an enzyme, toxin, ligand for a specific receptor, receptor, nucleic acid binding protein or antigen. The protein could also serve as a reporter to monitor induction by ionizing radiation. The gene coding for these proteins could be derived from eukaryotes or prokaryotes.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:
FIG. 1. A schematic drawing of the basic genetic construct comprising a radiation sensitive promoter driving an effector gene.
FIGS. 2A-2B. A schematic drawing of a more complex genetic construct than that shown in FIG. 1, comprising an "amplification system."
FIG. 3. A schematic drawing comprising the basic system of a retroviral mode of infection of a genetic construct into a cell.
FIGS. 4A-4B. Effects of irradiation on TNF-α gene expression.
FIGS. 5A-5C. Influence of TNF-α on radiation lethality of TNF-α-producing human sarcomas and TNF-α-nonproducing human tumor cells.
FIGS. 6A1-6B2. Effects of ionizing radiation on c-jun RNA levels in human HL-60 cells.
FIGS. 7A-7B. Effects of ionizing radiation on c-jun RNA levels in U-937 cells and in human AG-1522 diploid fibroblasts.
FIG. 8. Effects of ionizing radiation on rates of c-jun gene transcription.
FIG. 9A-9B. Effects of cycloheximide on c-jun mRNA levels in ionizing radiation-treated HL-60 cells.
FIG. 10A-10B. Effects of ionizing radiation on C-fos and jun-B mRNA levels in HL-60 cells.
FIG. 11. Effects of dose rate on the induction of c-jun expression by ionizing radiation.
While the invention is susceptible to various modifications and alternative forms, a specific embodiment thereof has been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DESCRIPTION OF THE PREFERRED EMBODIMENT
This invention relates to methods and compositions of controlling expression of a gene by exposure of a construct, including the gene, to ionizing radiation. The genes to be controlled are preferably incorporated within a genetic construct which includes a region which is sensitive to ionizing radiation. A schematic diagram of such a construct is shown in FIG. 1 wherein an enhancer-promoter region 10 of a radiation response gene, e.g., c-jun, drives 16 the expression of a structural gene, e.g., a reporter-effector gene such as TNF 14. The product of the structural gene expression is then capable of acting on a cell which has incorporated it, to produce a desired effect on the cell.
A more complex genetic construct is shown schematically in FIG. 2. In FIG. 2A, a region 20 comprising an enhancer-promoter of a radiation responsive gene, is coupled to, and drives 28 the expression of, a DNA binding domain 26, e.g., of a LAC repressor gene, and a gene 24 producing a transcription factor, e.g., from VP16. The chimeric protein resulting from the expression of that fusion gene, 40, 42 is capable of binding to a DNA sequence 30 illustrated in FIG. 2B. Binding of this sequence by the transcription factor 40, 42 activates 38 a structural gene 36, e.g., a reporter-effector gene such as TNF. A "minimal promoter" 32 containing CCAAT and the TATA boxes, e.g., from the c-fos oncogene, is placed between the binding sequence 30 and the genes 36 to be expressed. The gene product 34 is capable of acting on a cell which has incorporated the genetic constructs, to produce a desired effect.
An example showing details of the multiple gene form of genetic construct is shown in FIG. 2. This figure is predicated on strong induction of the c-jun gene in various different cell types by ionizing radiation at a transcriptional level. A large piece of 5' genomic sequence from the jun gene is ligated to an appropriate reporter such as β-galactosidase. Such a construct is then transfected into a recipient cell and checked for radiation responsiveness. Various truncations of this initial large 5' piece may be used.
Methods of incorporating constructs into recipient cells comprise electroporation, lipofection, and viral infection. This latter method comprises a SIN (self-inactivating virus) with two LTR's 50, 56. Nestled between the LTR's is a genetic construct comprising a radiation sensitive element 52 and a structural gene region 54. A U3 enhancer deletion is shown at 58.
Examples of elements used for the constructs follow.
Radiation Regulates TNF-α Expression
Combinations of tumor necrosis factor α (TNF-α), a polypeptide mediator of the cellular immune response with pleiotropic activity, and radiation produce synergistic effects and are useful for clinical cancer therapy. TNF-α acts directly on vascular endothelium to increase the adhesion of leukocytes during the inflammatory process (Bevelacqua, et al., 1989). This in vivo response to TNF-α was suggested to be responsible for hemorrhagic necrosis and regression of transplantable mouse and human tumors (Carswell, 1975). TNF-α also has a direct effect on human cancer cell lines in vitro, resulting in cell death and growth inhibition (Sugarman, et al., 1985; Old, 1985). The cytotoxic effect of TNF-α correlates with free-radical formation, DNA fragmentation, and microtubule destruction (Matthews, et al., 1988; Rubin, et al., 1988; Scanlon, et al., 1989; Yamauchi, et al., 1989; Matthews, et al., 1987; Neale, et al., 1988). Cell lines that are resistant to oxidative damage by TNF-α also have elevated free-radical buffering capacity (Zimmerman, et al., 1989; Wong, et al., 1988).
TNF-α causes hydroxyl radical production in cells sensitive to killing by TNF-α (Matthews, et al., 1987). Cell lines sensitive to the oxidative damage produced by TNF-α have diminished radical-buffering capacity after TNF-α is added (Yamauchi, et al., 1989). Lower levels of hydroxyl radicals have been measured in cells resistant to TNF-α cytotoxicity when compared with cells sensitive to TNF-α killing (Matthews, et al., 1987).
Tumor necrosis factor α is increased after treatment with x-rays in certain human sarcoma cells. The increase in TNF-α mRNA is accompanied by the increased production of TNF-α protein.
The induction of a cytotoxic protein by exposure of cells containing the TNF gene to x-rays was suspected when medium decanted from irradiated cultures of some human sarcoma cell lines was found to be cytotoxic to those cells as well as to other tumor cell lines. The level of TNF-α in the irradiated tumor cultures was elevated over that of nonirradiated cells when analyzed by the ELISA technique (Saribon, et al., 1988). Subsequent investigations showed that elevated TNF-α protein after irradiation potentiates x-ray killing of cells by an unusual previously undescribed mechanism (see Example 1).
FIG. 4 illustrates the effects of irradiation on TNF-α gene expression. RNA from untreated cells (control) and irradiated cells was size-fractionated and hybridized to 32 p-labeled TNF-α cDNA (STSAR-13) and PE4 plasmid containing TNF-α cDNA (STSAR-48). Autoradiograms showed increased expression of TNF-α mRNA 3 hr after irradiation in cell line STSAR-13 and at 6 hr in cell line STSAR-48. 7S RNA was hybridized to show the pattern for equally loaded lanes. The conclusion from these results is that there is increased TNF-α gene expression after radiation.
The next question was what the effects of TNF-α and radiation would be on cell killing. FIG. 5 exhibits the influence of TNF-α on radiation lethality of TNF-α-producing human sarcomas and TNF-α-nonproducing human tumor cells. The solid lines indicate the effects of radiation alone, and the dashed lines indicate the effects of both TNF-α and irradiation. Representative survival data for cell line STSAR-33 are shown in the graph to the left, A. The lower dashed line represents survival of cells with TNF-α at 1000 units/ml, corrected for a plating efficiency (PE) of 30%. The survival of human epithelial tumor cells (SQ-20B) irradiated with TNF-α (10 units/ml and 1000 units/ml) is shown in the middle graph, B. Survival data for SQ-20B show an additive effect of TNF-α (1000 units/ml). Survivals with TNF-α are corrected for 85% killing with TNF-α alone. Radiation survival data for HNSCC-68 is shown in the graph to the right, C. A nonlethal dose of TNF-α (10 units/ml) was added 24 hr before irradiation.
As can be seen from these results and from information discussed in Example 1, the tumor necrosis factor α is increased after treatment with x-rays. Both mRNA and TNF-α proteins were increased.
Although DNA-damaging agents other than ionizing radiation have been observed to induce expression of variety of prokaryotic and mammalian genes, the TNF-α gene is the first mammalian gene found to have increased expression after exposure to ionizing radiation. This gene is not categorized as a DNA repair gene.
To determine the mechanisms responsible for regulation of c-jun gene expression by ionizing radiation, run-on transcriptional assays were performed in isolated nuclei. The action gene was constitutively transcribed in untreated HL-60 cells as a positive control (FIG. 8).
Negative control was provided by the β-globin gene transcript. As shown in FIG. 8, a low level of c-jun transcription was detectable in HL-60 untreated by radiation. Dramatic increased transcription (7.2 fold) occurred after exposure to ionizing radiation. The conclusion from this study was that ionizing radiation induced c-jun expression, at least in part by a transcriptional mechanism.
FIG. 9 illustrates the effects of cycloheximide on c-jun mRNA levels in ionizing radiation treated HL-60 cells. The columns headed XRT shows expression of mRNA after 20 Gy radiation exposure of the cells. In the columns CHX, cycloheximide has been added. The additive effects of CHX and CHX/XRT are a 3.6 fold increased expression compared to XRT alone.
Effects of cycloheximide on c-jun mRNA levels in ionizing radiation-treated HL-60 cells. HL-60 cells were treated with 20 Gy of ionizing radiation (XRT) and/or 5 μg of cycloheximide (CHX) per ml. Total cellular RNA (20 μg per lane) was isolated after 1, 3 and 6 h and analyzed by hybridization to the 32 P-labeled c-jun or actin probe.
FIG. 10. Effects of ionizing radiation on C-fos and jun-B mRNA levels in HL-60 cells. (A) HL-60 cells were treated with varying doses of ionizing radiation (XRT) or 32 nM 12-0-tetradecanoylphorbol 13-acetate (TPA; positive control) for 3 h. Total cellular RNA (20 μg) was hybridized to the 32 P-labeled c-fos probe. (B) HL-60 cells were treated with 20 Gy of ionizing radiation. Total cellular RNA (20 μg per lane) was isolated at the indicated times and analyzed by hybridization to the 32 P-labeled jun-B probe.
FIG. 11. Effects of dose rate on the induction of c-jun expression by ionizing radiation. HL-60 cells were treated with 10 or 20 Gy of ionizing radiation at the indicated dose rates. After 3 h, total cellular RNA (20 μg) was isolated and hybridized to the 32 P-labelled c-jun probe.
Targeting Tissues for Incorporation of a Genetic Construct Responsive to Ionizing Radiation
Depending on the application in question, the recipient cells are targeted in various ways. In an exemplary embodiment, LAK cells which tend to home in on the tumor site in question with some degree of preference though as is well known, they will also distribute themselves in the body in other locations, may be used to target tumors. Indeed, one of the most important advantages of the radiation inducible system is that only those LAK cells, which are in the radiation field will be activated and will have their exogenously introduced lymphokine genes activated. Thus, for the case of LAK cells, there is no particular need for any further targeting. In other applications, the appropriate cells in question have had appropriate genes from monoclonal antibodies introduced in them or appropriate antibodies expressed on their cell surface by other means such as by cell fusion. These monoclonal antibodies, for example, are targeted towards specific cells in the body and thus allow the recipient cells to home in on that particular region so that then radiation could be used for the activation of the appropriate toxins within them. This enables local delivery of the "drug," wherein the "drug" is defined as the expression product of the genes within the radiation responsive genetic construct. Illustrative embodiments of types of radiation inducible constructs and their applications are presented in Table 1 and EXAMPLE 4.
TABLE 1__________________________________________________________________________ILLUSTRATIVE EMBODIMENTS OF TYPES OFRADIATION INDUCIBLE GENETIC CONSTRUCTS AND THEIR USESAction of Expression Products Examples of Structural Applications to Diseasesof Genes in the Construct Genes Used in the Construct Conditions, and Tissues__________________________________________________________________________Kill tumor cells Toxins Solid & Hematologic TNF Malignancies Growth Factors (IL-1-6 PDGF, FGF)Protect normal tissues from Lymphokines GCSF, CMCSF Solid & Hematologicradiation and other cytotoxins Erythropoietin Malignancies,during cancer therapy Aplastic AnemicInhibit Metastasis NM23 Cancer MetastasisTumor Suppressor Gene Products Rb p53 Prevention of Malignancy Following Standard Radio- therapy and ChemotherapyRadiosensitization TNF Solid & HematologicChemosensitization Malignancies(enhance routine treatment effects)Correct Defects in Factor B Clotting DisordersClotting FactorsIntroduce Anticlotting Factors Streptokinase Myocardial Infarction, Urokinase CNS Thrombosis. Pheripheral ThrombosisCorrect Defects Characterizing Normal Hemoglobin Sickle Cell AnemiaHemoglobinopathyCorrect Deficiencies Leading to Nerve Growth Factor Alzheimer's DiseaseNeurodegenerative DiseaseProvide Treatment Component for Insulin DiabetesDiabetesDisease of DNA Repair ERCC-1, XRCC-1 Ataxia TelangiectasiaAbnormalities Xeroderma Pigmentosum__________________________________________________________________________
EXAMPLES
Example 1
Increased Tumor Necrosis Factor α mRNA After Cellular Exposure to Ionizing Radiation
A. Protein Products
To investigate TNF-α protein production after x-irradiation, the levels of TNF-α in the medium of human tumor cell lines and fibroblasts were quantified by the ELISA technique (Saribon, et al., 1988) before and after exposure to 500-cGy x-rays (Table 1). Five of 13 human bone and soft tissue sarcoma cell lines (STSAR-5, -13, -33, -43, and -48) released TNF-α into the medium after irradiation, whereas TNF-α levels were not elevated in supernatant from normal human fibroblast cell lines (GM-1522 and NHF-235) and four human epithelial tumor cell lines (HN-SCC-68, SCC-61, SCC-25, and SQ-20B) after exposure to radiation. The assay accurately measures TNF-α levels between 0.1 and 2.0 units per ml (2.3×10 6 units/mg) (Saribon, et al., 1988). Tumor cell line STSAR-13 produced undetectable amounts of TNF-α before x-irradiation and 0.35 units/ml after x-ray exposure. Cell lines STSAR-5 and -33 responded to x-irradiation with increases in TNF-α concentrations of >5- to 10-fold; however quantities above 2 units/ml exceeded the range of the assay (Saribon, et al., 1988). Cell lines STSAR-43 and -48 demonstrated increases in TNF-α of 1.5- to 3-fold (Table 1). TNF-α protein in the medium was first elevated at 20 hr after x-ray treatment, reached maximal levels at 3 days, and remained elevated beyond 5 days. Furthermore, supernatant from irradiated, but not control STSAR-33, was cytotoxic to TNF-α-sensitive cell line SQ-20B.
TABLE 2______________________________________PRODUCTION OF TNF-A IN HUMAN SARCOMA CELL LINES TNF-α level, units/ml,Cell Line Origin Control X-ray______________________________________STSAR-5 MFH 0.4 >2.0STSAR-13 Liposarcoma 0.0 0.34STSAR-33 Ewing sarcoma 0.17 >2.0STSAR-43 Osteosarcoma 0.41 1.3STSAR-48 Neurofibrosarcoma 0.28 0.43______________________________________ TNF-α levels were measured in medium from confluent cell cultures (control) and in irradiated confluent cells (xray). TNFα levels increased as measured by the ELISA technique. MFH, malignant fibrous histiocytoma.
B. RNA Analysis.
Increased levels of TNF-α mRNA were detected in the TNF-α-producing sarcoma cell lines after irradiation relative to unirradiated controls (FIG. 4). For example, TNF-α transcripts were present in unirradiated STSAR-13 and -48 cell lines. TNF-α mRNA levels in cell line STSAR-13 increased by >2.5-fold as measured by densitometry 3 hr after exposure to 500 cGy and then declined to baseline levels by 6 hr (FIG. 4). These transcripts increased at 6 hr after irradiation in cell line STSAR-48, thus indicating some heterogeneity between cell lines in terms of the kinetics of TNG-α gene expression (FIG. 4). In contrast, irradiation had no detectable effect on 7S RNA levels (FIG. 4) or expression of the polymerase β gene.
C. Interaction Between TNF-α and X-Irradiation.
To investigate the influence of TNF-α on radiation-induced cytotoxicity in TNF-α-producing cell lines, recombinant human TNF-α was added to cultures before irradiation (FIG. 5). Recombinant human TNF-α (1000 units/ml) (2.3×10 6 units/mg) was cytotoxic to four of five TNF-α-producing sarcomas (STSAR-5, -13, -33, and -43). The plating efficiency (PE) was reduced by 60-90% at 1000 units/ml in these lines. Radiation-survival analysis of cell line STSAR-33 was performed with TNF-α (10 units/ml). The radiosensitivity (D 0 ), defined as the reciprocal of the terminal slope of the survival curves was 80.4 cGy for cell line STSAR-33. When TNF-α was added 20 hr before irradiation, the D 0 was 60.4 cGy. Surviving fractions were corrected for the reduced PE with TNF-α. Thus, the interaction between TNF-α and radiation in STSAR-33 cells was synergistic (Dewey, 1989). Sublethal concentrations of TNF-α (10 units/ml) enhanced killing by radiation in cell line STSAR-33, suggesting a radiosensitizing effect of TNF-α The surviving fraction of cell line STSAR-5 at 100-700 cGy was lower than expected by the independent killing of TNF-α and x-rays, although the D 0 values were similar. Thus, the interaction between TNF-α and radiation is additive (Dewey, 1979) in STSAR-5 cells. Cell lines STSAR-13 and STSAR-43 were independently killed with x-rays and TNF-α, and no interaction was observed.
To determine the possible interactions between TNF-α and x-rays in non-TNF-α producing cells, human epithelial tumor cells (SQ-20B and HNSCC-68) were irradiated 20 hr after TNF-α was added. These cell lines do not product TNF-α in response to ionizing radiation. TNF-α (1000 units/ml) was cytotoxic to SQ-20B and SCC-61 cells, reducing the PE by 60-80%. The radiation survival of SQ-20B cells with and without TNF-α is shown in FIG. 5. The D 0 for cell line SQ-20B is 239 cGy. With TNF-α (1000 units/ml) added 24 hr before x-rays, the D 0 was 130.4 cGy. Therefore, a synergistic interaction (Dewey, 1979) between TNF-α and x-rays was demonstrated in this cell line. TNF-α added after irradiation did not enhance cell killing by radiation in cell lines SQ-20B. Nonlethal concentrations of TNF-A (10 units/ml) resulted in enhanced radiation killing in cell line HNSCC-68 (FIG. 5), providing evidence that TNF-α may sensitize some epithelial as well as mesenchymal tumor cell lines to radiation.
The following specific methods were used in Example 1.
Cell Lines. Methods of establishment of human sarcoma and epithelial cell lines have been described (Weichselbaum, et al., 1986; 1988). Culture medium for epithelial tumor cells was 72.5% Dulbecco's modified Eagle's medium/22.5% Ham's nutrient mixture F-12 DMEM/F-12 (3:1)!5% fetal bovine serum (FBS), transferrin at 5μg/ml/10 -10 M cholera toxin/1.8×10 -4 M adenine, hydrocortisone at 0.4 μg/ml/2×10 -11 M triodo-L-thyronine/penicillin at 100 units/ml/streptomycin at 100 μg/ml. Culture medium for sarcoma cells was DMEM/F-12 (3:1)/20% FBS, penicillin at 100 units/ml/streptomycin at 100 μg/ml.
TNF-α Protein Assay. Human sarcoma cells were cultured as described above and grown to confluence. The medium was analyzed for TNF-α 3 days after feeding and again 1-3 days after irradiation. Thirteen established human sarcoma cell lines were irradiated with 500-centigray (cGy) x-rays with a 250-kV Maxitron generator (Weichselbaum, et al., 1988). TNF-α was measured by ELISA with two monoclonal antibodies that had distinct epitopes for TNF-α protein (Saribon, et al., 1988); the assay detects TNF-α from 0.1 to 2.0 units/ml.
RNA Isolation and Northern (RNA) Blot Analysis. Total cellular RNA was isolated from cells by using the guanidine thiocyanate-lithium chloride method (Cathala, et al., 1983). RNA was size-fractionated by formaldehyde-1% agarose gel electrophoresis, transferred to nylon membranes (GeneScreenPlus, New England Nuclear), hybridized as previously described to the 1.7-kilobase (kb) BamHI fragment of the PE4 plasmid containing TNF-α cDNA (19, 23), and autoradiographed for 16 days at -85° C. with intensifying screens. Northern blots were also hybridized to 7S rRNA and β-polymerase plasmids as described (Fornace, et al., 1989). Ethidium bromide staining revealed equal amounts of RNA applied to each lane. RNA blot hybridization of TNF-α was analyzed after cellular irradiation with 500 cGy. Cells were washed with cold phosphate-buffered saline and placed in ice at each time interval. RNA was isolated at 3, 6, and 12 hr after irradiation.
Treatment of Cells with X-Irradiation and TNF-α. Exponentially growing cells were irradiated by using a 250-kV x-ray generator. The colony-forming assay was used to determine cell survival (Weichselbaum, et al., 1988). The multitarget model survival curves were fit to a single-hit multitarget model S=1-(-e -D/D0 ) n !. Concentrations of recombinant human TNF-α (10 units/ml) (2:3×10 6 units/mg) and (1000 units/ml) (Asahi Chemical, New York) were added 24 hr before irradiation.
Example 2
Increased c-jun Expression After Exposure to Ionizing Radiation
The following methods were used in this example.
Radiation Regulates c-jun Expression
Another embodiment of a genetic construct derives from the c-jun protooncogene and related genes. Ionizing radiation regulates expression of the c-jun protooncogene, and also of related genes c-fos and jun-β. The protein product of c-jun contains a DNA binding region that is shared by members of a family of transcription factors. Expression level after radiation is dose dependent. The c-jun gene encodes a component of the AP-1 protein complex and is important in early signaling events involved in various cellular functions. AP-1, the product of the protooncogene c-jun recognizes and binds to specific DNA sequences and stimulates transcription of genes responsive to certain growth factors and phorbol esters (Bohmann, et al., 1987; Angel, et al., 1988). The product of the c-jun protooncogene contains a highly conserved DNA binding domain shared by a family of mammalian transcription factors including jun-β, jun-D, c-fos, fos-β, fra-1 and the yeast GCN4 protein.
In addition to regulating expression of the c-jun gene, c-jun transcripts are degraded posttranscriptionally by a labile protein in irradiated cells. Posttranscriptional regulation of the gene's expression is described in Sherman, et al., 1990.
Contrary to what would be expected based on previous DNA damage and killing rates for other agents, decreasing the dose rate, for example, from 14.3 Gy/min to 0.67 Gy/min. was associated with increased induction of c-jun transcripts.
FIG. 6. Effects of ionizing radiation on c-jun RNA levels in human HL-60 cells. (A) Northern blot analysis of total cellular RNA levels was performed in HL-60 cells after treatment with 20 Gy of ionizing radiation (XRT). Hybridization was performed using a 32 P-labeled c-jun or actin DNA probe. (B) HL-60 cells were treated with the indicated doses of ionizing radiation. RNA was isolated after 3 hours and hybridizations were performed using 32 P-labeled c-jun or β-actin DNA probes. The column labelled HL-60 represents RNA from untreated cells.
Maximum c-jun mRNA levels were detectable after 50 Gy of ionizing radiation (FIG. 6B).
Similar kinetics of c-jun induction were observed in irradiated human U-937 monocytic leukemia cells (FIG. 7A) and in normal human AG-1522 diploid fibroblasts (FIG. 7B). Treatment of AG-1522 cells with ionizing radiation was also associated with the appearance of a minor 3.2-kb c-jun transcript.
Cell Culture. Human HL-60 promyclocytic leukemia cells, U-937 monocytic leukemia cells (both from American Type Culture Collection), and AG-1522 diploid foreskin fibroblasts (National Institute of Aging Cell Repository, Camden, N.J.) were grown in standard fashion. Cells were irradiated using either Philips RT 250 accelerator at 250 kV, 14 mA equipped with a 0.35-mm Cu filter or a Gammacell 1000 (Atomic Energy of Canada, Ottawa) with a 137 Cs source emitting at a fixed dose rate of 14.3 Gy/min as determined by dosimetry. Control cells were exposed to the same conditions but not irradiated.
Northern Blot Analysis. Total cellular RNA was isolated as described (29). RNA (20 μg per lane) was separated in an agarose/formaldehyde gel, transferred to a nitrocellulose filter, and hybridized to the following 32 P-labeled DNA probes: (i) the 1.8-kilobase (kb) BamHI/EcoRI c-jun cDNA (30); (ii) the 0.91-kb Sca I/Nco I c-fos DNA consisting of exons 3 and 4 (31); (iii) the 1.8-kb EcoRI jun-B CDNA isolated from the p465.20 plasmid (32); and (iv) the 2.0-kb PstI β-actin cDNA purified from pA1 (33). The autoradiograms were scanned using an LKB UltroScan XL laser densitometer and analyzed using the LKB GelScan XL software package. The intensity of c-jun hybridization was normalized against β-actin expression.
Run-On Transcriptional Analysis. HL-60 cells were treated with ionizing radiation and nuclei were isolated after 3 hours. Newly elongated 32 P-labeled RNA transcripts were hybridized to plasmid DNAs containing various cloned inserts after digestion with restriction endonulceases as follows: (i) the 2.0-kb Pst I fragment of the chicken β-actin pAl plasmid (positive control); (ii) the 1.1-kb BamHI insert of the human β-globin gene (negative control, ref.34); and (iii) the 1.8-kb BamHI/EcoRI fragment of the human c-jun cDNA from the pBluescript SK(+) plasmid. The digested DNA was run in a 1% agarose gel and transferred to nitrocellulose filters by the method of Southern. Hybridization was performed with 10 7 cpm of 32 P-labeled RNA per ml of hybridization buffer for 72 h at 42° C. Autoradiography was performed for 3 days and the autoradiograms were scanned as already described.
Example 3
Radiation Induced Transcription of JUN and EGR1
There was increased mRNA expression for different classes of immediate early response to radiation genes (JUN, EGR1) within 0.5 to 3 hours following cellular x-irradiation. Preincubation with cycloheximide was associated with superinduction of JUN and EGR1 in x-irradiated cells. Inhibition of protein kinase C (PKC) activity by prolonged stimulation with TPA or the protein kinase inhibitor H7 prior to irradiation attenuated the increase in EGR1 and JUN transcripts. These data implicated EGR1 and JUN as signal transducers during the cellular response to radiation injury and suggested that this effect is mediated in part by a protein kinase C (PKC) dependent pathway.
JUN homodimers and JUN/FOS heterodimers regulate transcription by binding to AP1 sites in certain promoter regions (Curran and Franza, 1988). The JUN and FOS genes are induced following x-ray exposure in human myeloid leukemia cells suggests that nuclear signal transducers participate in the cellular response to ionizing radiation.
EGR1 (also known as zif/268, NGFI-1, Krox-24, TIS-8) (Christy, et al., 1988; Milbrant, 1987; Lemaire, et al., 1988; Lim, et al., 1987) encodes a nuclear phosphoprotein with a Cys 2 -His 2 zinc-finger motif which is partially homologous to the corresponding domain in the Wilms' tumor susceptibility gene (Gessler, 1990). The EGR1 protein binds with high affinity to the DNA sequence CGCCCCCGC in a zinc-dependent manner (Christy and Nathans, 1989; Cao, 1990). EGR1 represents an immediate early gene which is induced during tissue injury and participates in signal transduction during cellular proliferation and differentiation.
The EGR1 and JUN genes are rapidly and transiently expressed in the absence of de novo protein synthesis after ionizing radiation exposure. EGR1 and JUN are most likely involved in signal transduction following x-irradiation. Down regulation of PKC by TPA and H7 is associated with attenuation of EGR1 and JUN gene induction by ionizing radiation, implicating activation of PKC and subsequent induction of the EGR1 and JUN genes as signaling events which initiate the mammalian cell phenotypic response to ionizing radiation injury.
Control RNA from unirradiated cells demonstrated low but detectable levels of EGR1 and JUN transcripts. In contrast, EGR1 expression increased in a dose dependent manner in irradiated cells. Levels were low but detectable after 3 Gy and increased in a dose dependent manner following 10 and 20 Gy. Twenty Gy was used in experiments examining the time course of gene expression so that transcripts were easily detectable. Cells remained viable as determined by trypan dye exclusion during this time course. A time dependent increase in EGR1 and JUN mUNA levels was observed. SQ-20B cells demonstrated coordinate increases in EGR1 and JUN expression by 30 minutes after irradiation that declined to baseline within 3 hours. In contrast, EGR1 transcript levels were increased over basal at 3 hours while JUN was increased at one hour and returned to basal at 3 hours in AG1522. JUN levels were increased at 6 hours in 293 cells while EGR1 was increased at 3 hours and returned to basal levels by 6 hours.
To determine whether EGR1 and JUN participated as immediate early genes after x-irradiation, the effects of protein synthesis inhibition by CHI were studied in cell lines 293 and SQ-20B after x-ray exposure. CHI treatment alone resulted in a low but detectable increase in EGR1 and JUN transcripts normalized to 7S. In the absence of CHI, the level of EGR1 and JUN expression returned to baseline. In contrast, SQ-20B cells pretreated with CHI demonstrated persistent elevation of EGR1 at 3 hours and 293 cells demonstrated persistent elevation of JUN mRNA at 6 hours after irradiation thus indicating superinduction of these transcripts.
mRNA levels of transcription factors EGR1 and JUN increased following ionizing radiation exposure in a time and dose dependent manner. The potential importance of the induction of EGR1 and JUN by ionizing radiation is illustrated by the recent finding that x-ray induction of the PDGF alpha chain stimulates proliferation of vascular endothelial cells (Witte, et al., 1989). PDGF has AP-1 and EGR1 binding domains while TNF has elements similar to AP-1 and EGR1 target sequences (Rorsman, et al., 1989; Economou, et al., 1989). X-ray induction of PDGF and TNF appears to be regulated by EGR1 and JUN.
The following is a method used in Example 3:
Kinase Inhibitors
Cell line SQ-20B was pretreated with 1 μM TPA for 40 hours to down regulate PKC and then stimulated with TPA, serum, or x-ray (20 Gy). Controls included x-ray without TPA pretreatment, TPA (50 nM) without TPA pretreatment and untreated cells. RNA was isolated after one hour and hybridized to EGR1. SQ-20B cells were preincubated with 100 μM H7 (1-(5-isoquinolinylsulfonyl)-2-methyl piperazine) or 100 μM HA1004 (N- 2-methyl-amino! ethyl)-5-isoquino-linesulfonamide) Seikagaku America, Inc., St. Petersberg, Fla.) for 30 minutes or TPA pretreatment (1 μM) for 40 hours and followed by exposure to 20 Gy x-irradiation. RNA was extracted one hour after irradiation. Positive control cells treated under the same conditions but in the absence of inhibitor also received 20 Gy, while negative control cells received neither H7 nor X-ray. RNA was extracted at one hour after 20 Gy without inhibitor. Northern blots were hybridized to EGR1 or 7S. 293 cells pretreated with the above inhibitors were irradiated, RNA was extracted after 3 hours and the Northern blot was hybridized to JUN and 7S probes.
Example 4
Protocol for Treatment of Head and Neck Cancer with X-ray Induced TNF and Therapeutic X-rays
For treatment of patients with head and neck cancer, the following steps are followed:
1. Prepare a genetic construct according to the general scheme illustrated in FIGS. 1 or 2.
This construct comprises AP-1 as the element which is responsive to x-rays, coupled to a sequence of DNA to which the lac repressor binds, and to the gene for the tumor necrosis factor. This construct is designated "construct A" for purposes of this example.
2. "Construct A" is put into a retrovirus that is self-inactivating (see FIG. 3).
3. Lymphokine activated killer (LAK) cells are infected with the retrovirus bearing "construct A." The cells are to be directed against the malignant cells in the head and neck.
4. The lymphocytes are infused into the patient to be treated.
5. The head and neck region is irradiated.
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Reference 50. van Straaten, F., Muller, R., Curran, T., van Beveren, C. and Verma, I. M. (1983) Proc. Natl.
Acad. Sci. USA 80:3183-3187.
Reference 51. Wang, A. M., Creasg, A. A., Lander, M. B., Lin, L. S., Strickler, J., Van Arsdell, J. N., Yanamotot, R. and Mark, D. F. (1985) Science 228:149-154.
Reference 52. Weichselbaum, R. R., Nove, J. and Little, J. B. (1980) Cancer Res. 40:920-925.
Reference 53. Weichselbaum, R. R., Dahlberg, W., Beckett, M. A., Karrison, T., Miller, D., Clark, J. and Ervin, T. J. (1986) Proc. Natl. Acad. Sci. USA 83:2684:2688.
Reference 54. Weichselbaum, R. R., Beckett, M. A., Simon, M. A., McCowley, C., Haraf, D., Awan, A., Samuels, B., Nachman, J. and Drtischilo, A. (1988) Int. J. Rad. Oncol. Biol. Phys. 15:937-942.
Reference 55. Wilson, J. T., Wilson, L. B., deRiel, J. K., Villa-Komaroff, L., Efstratiadis, A., Forget, B. G. and Weissman, S. M. (1978) Nucleic Acids Res. 5:563-580.
Reference 56. Witte, L., Fuks, Z., Haimovitz-Friedman, A., Vlodavsky, I., Goodman, D. S. and Eldor, A. (1989) Cancer Res. 49:5066-5072.
Reference 57. Woloschak, G. E., Chang-Liu, C. M., Jones, P. S. and Jones, C. A. (1990) Cancer Res. 50:339-344.
Reference 58. Wong, G. W. H. and Goeddel, D. V. (1988) Science 242:941-943.
Reference 59. Wong, G. H. W., Elwell, J. H., Oberly, L. H., Goeddel, D. V. (1989) Cell 58:923-931.
Reference 60. Yamuchi, N., Karizana, H., Watanabe, H., Neda, H., Maeda, M. and Nutsu, Y. (1989) Cancer Res. 49:1671-1675.
Reference 61. Zimmerman, R. J., Chan, A. and Leadon, S. A. (1989) Cancer Res. 49:1644-1648.
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This invention relates to genetic constructs which comprise an enhancer-promoter region which is responsive to radiation, and at least one structural gene whose expression is controlled by the enhancer-promoter. This invention also relates to methods of destroying, altering, or inactivating cells in target tissue by delivering the genetic constructs to the cells of the tissues and inducing expression of the structural gene or genes in the construct by exposing the tissues to ionizing radiation. This invention is useful for treating patients with cancer, clotting disorders, myocardial infarction, and other diseases for which target tissues can be identified and for which gene expression of the construct within the target tissues can alleviate the disease or disorder.
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BACKGROUND OF THE INVENTION
This invention relates generally to automatically opening doors. More particularly, the present invention relates to apparatus for testing the door controller and door sensors of an automatic door system.
Automatic door systems of a type which are automatically operable for initiating an opening sequence upon sensing the motion or the presence of traffic at the doorway or receiving a command from a push plate, card reader, mat or other operation initiating device are now commonplace. A number of automatic door systems employ infrared sensors to initiate the door opening sequence. The sensors sense traffic approaching the doorway by detecting changes in received active or passive infrared radiation. Infrared sensors also function as safety devices to ensure that the doors do not inadvertently close.
Some conventional door applications employ multiple sensor units. For example, an approach sensor unit may be positioned at each side of the door to sense approaching traffic. The approach sensors may be conventional microwave field distortion devices or active infrared motion sensing devices. For one-way doors, a single approach sensor may be positioned to detect traffic approaching from the approved direction. A threshold or safety sensor may be positioned to cover the threshold area. Such safety sensors are conventionally presence sensing devices such as pulsed infrared beams.
The controller for the automatic door system must be capable of performing sophisticated signal processing. The controller typically must open the door upon receipt of an appropriate signal from an approach sensor, hold the door open for a predetermined period of time or until the safety sensor no longer senses a presence in the threshold area, and close the door. It should be noted that because of the movement of the doors, the controller and sensors which are employed in the automatic door system must take into account the movement of the door itself. In addition, the sensor and controller must accommodate changes in the background environment.
Periodically, the automatic door system must be tested to ensure that the doors will operate as required. In the event of a component or system failure, testing is also required to troubleshoot and repair the system. With the increasing complexity of the control systems and the sensors, the equipment required to perform such testing has grown in complexity and expense.
SUMMARY OF THE INVENTION
Briefly stated, the invention in a preferred form is a device for testing automatic door systems which has a test circuit, including a display, a micro-controller, a memory for storing data and a test program, and a control switch for controlling operation of the test program by the micro-controller. The test device is installed by connecting the data and power connector of the controller and the data connector of the sensors to the test circuit. A selector switch on the test device is moveable between first and second positions. When the selector switch is in the first position, it completes a data path between the test circuit and the controller and blocks the exchange of data between the sensors and the test circuit and the first connector. When the selector switch is in the second position, it completes a data path between the test circuit and the second connector and blocks the exchange of data between the controller and the test circuit and the second connector.
The automatic door system provides power to the test device via its connection with the controller. The test circuit includes a first voltage comparator for monitoring the automatic door system power and the display comprises an LED for indicating the status of the automatic door system power. A second and third voltage comparator of the test circuit are used to monitor the voltage of the controller and sensor clock lines and data lines during testing. The display also includes an alphanumeric indicator for displaying the test results.
When the test device is installed between the controller and the sensors, the first voltage comparator senses the controller voltage and lights the LED if the sensed voltage is above a predetermined value. The test device micro-controller then prompts the test personnel to place the selector switch in the first position to test the controller. Pressing the control switch steps the micro-controller through the test program such that the second voltage comparator monitors first the voltage of the controller clock line and then the third voltage comparator monitors the data line and provides an indication on the alphanumeric indicator whether or not the sensed voltage is above or below a predetermined minimum value. Next the micro-controller is directed to monitor the signals on the clock line and the data line and provide an indication whether or not the sensed signals correspond to signals which are stored in the memory, thereby completing the testing of the controller.
The micro-controller then prompts the test personnel to move the selector switch to the second position. Pressing the control switch continues to step the micro-controller through the test program such that the second and third voltage comparators monitor the voltage of the sensor clock line and data line and provides an indication on the alphanumeric indicator whether or not the sensed voltage is above or below a predetermined minimum value.
The software then directs the micro-controller to test each sensor. The micro-controller establishes communication with a designated sensor and causes the sensor emitter to emit a signal into a detection zone. If an object is within the zone, the sensor detector detects a return signal. The micro-controller then provides an indication on the alphanumeric indicator whether or not the sensor detector detects the return signal. If the detector is not receiving a return signal, the test personnel places an object in the zone. The sensor performance is satisfactory if the indication changes to show that the detector is now receiving the return signal. If the detector is receiving a return signal, the test personnel covers the emitter or the receiver. The sensor performance is satisfactory if the indication changes to show that the detector is no longer receiving the return signal.
It is an object of the invention to provide a new and improved device and method for testing an automatic door system.
It is also an object of the invention to provide a new and improved device for testing an automatic door system which device has an efficient construction.
It is further an object of the invention to provide a new and improved method of testing an automatic door system which method is simple and takes a minimum of time.
Other objects and advantages of the invention will become apparent from the drawings and specification.
BRIEF DESCRIPTION OF THE DRAWINGS
The present 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 in which:
FIG. 1 is a schematic diagram of a test device in accordance with the present invention installed in an automatic door system;
FIG. 2 is a top plan view of the test device of FIG. 1;
FIG. 3 is a cross-section view of the test device taken along line 3--3 of FIG. 2;
FIG. 4 is a schematic diagram of the test device of FIG. 1;
FIGS. 5a, 5b and 5c are a flow diagram illustrating the operation of the test device of FIG. 1;
FIG. 6 is a flow diagram illustrating a first optional test performed by the test device of FIG. 1; and
FIG. 7 is a flow diagram illustrating a second optional test performed by the test device of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawings wherein like numerals represent like parts throughout the several figures, an automatic door test device in accordance with the present invention is generally designated by the numeral 10. The test device 10 is interposed between the controller 12 and the sensors 14 of an automatic door system, as shown in FIG. 1. In a preferred embodiment, the test device 10 is a hand-held unit which is removed after the testing is complete. Alternatively, the test device 10' may be permanently installed in the automatic door system.
With reference to FIGS. 2 and 3, the hand-held test device 10 includes a housing 16 having externally accessible fiber optic or electrical connectors 18 for connecting the device 10 to the automatic door system. For example, a test device 10 for use with a Stanley Access Technologies Sentrex 3™ automatic door system will include a first connector 17 for connecting to the sensor Flex Link™ cable 19 and a second connector 21 for connecting to the controller TB2 connector 23. The test device includes two externally-visible indicators, an LED 20 and a four digit alphanumeric display 22. The operators for a two-position selector switch 24 and a push-button switch 26 extend through the housing 16 and are externally accessible.
A circuit board 28 mounted within the housing 16 includes an electrical circuit 30 which is electrically connected to the connectors 18, the LED 20, the alphanumeric display 22, the selector switch 24 and the push-button switch 26. The electrical circuit 30 includes a micro-controller 32 and a memory 34 for storing test data and control programs. The memory 34 may be integral with the micro-controller 32 or comprise one or more separate memory units. Preferably, the test device 10 receives its power from the automatic door system and does not require an internal power supply. As a personnel and equipment safety precaution, power to the automatic door system is secured until the test device 10 has been completely installed.
The electrical circuit 30 includes a first voltage comparator 36 which monitors the power supply voltage and lights the LED 20 when the power being received by the test device 10 is above a preset level. The LED 20 will not turn on if the voltage is below the value required to supply the automatic door system sensors 14. The value of the preset voltage level may be adjusted with a potentiometer to accommodate the range of sensors 14 that may be used by the automatic door system.
With reference to FIGS. 2 and 3, the test device 10 may be used to test either the automatic door system controller 12 or the automatic door system sensors 14, but not both at the same time. The micro-controller 32 is programmed to sequentially test the automatic door system controller 12 first and the sensors 14 second. Consequently, the micro-controller 32 will scroll a "SWITCH TO MICRO" message 38 across the alphanumeric display 22, indicating that the two-position selector switch 24 should be toggled to the micro-controller position. This action selects the automatic door system controller 12 for testing and isolates the data signals from the sensors 14. Such isolation is required to isolate failures between the controller 12 and the sensors 14.
The push-button switch 26 is used to step the test device 10 through the various tests. With reference to the operational diagram of FIGS. 5a-5c as employed for a Sentrex 3™ automatic door system, pressing 40 the push-button switch 26 causes a second voltage comparator 42 portion of the circuit 30 to monitor 44 the voltage on the controller clock line. The micro-controller 32 will send a signal to the display to indicate whether the clock line voltage (V2) is above (V20K) 46 or below (V2NG) 48 a predetermined minimum level. Pressing 50 the push-button 26 steps the micro-controller to monitor 52 the data line voltage with the third voltage comparator 53. The micro-controller will send a signal to the display to indicate whether the data line voltage (V3) is above (V30K) 54 or below (V3NG) 56 a predetermined minimum level. If either V2NG 48 or V3NG 56 is displayed, the controller 12 is defective.
Pressing 58 the push-button 26 again steps the micro-controller 32 to monitor 60 the signals on the clock and data lines. If the signals being sent by the automatic door system controller correspond to correct signals, the micro-controller will send a signal to the display to indicate that the controller communications are good (CMOK) 62. If the signals do not correspond to correct signals the micro-controller will send a signal to the display to indicate that the controller communications are no good (CMNG) 64. On the completion of this test, pressing 66 the push-button 26 will cause the micro-controller to scroll a "SWITCH TO SENSOR" message 68 across the alphanumeric display 22, indicating that the two-position selector switch 24 should be toggled to the sensor position.
The test device 10 may optionally perform two additional tests on the automatic door system controller 12. With reference to FIG. 6, the micro-controller 32 can be programmed to send a signal 118 which is equivalent to the "operate" signal which is normally transmitted by the automatic door system sensors 14. If the signal is accepted 120 by the controller 12, the micro-controller 32 will send a "OPER" signal 122 to the display 22. With reference to FIG. 7, the micro-controller 32 can be programmed to send a signal 124 which is equivalent to the "stall" signal which is normally transmitted by the automatic door system sensors 14. If the signal is accepted 126 by the controller 12, the micro-controller 32 will send a "STAL" signal 128 to the display 22.
Toggling the selector switch 24 to the sensor position will isolate the data signals of the controller 12 from the test device 10 and allow the test device 10 to test the sensors 14. Pressing 70 the push-button switch 26 causes the second voltage comparator circuit 42 to monitor 72 the voltage on the sensor clock line. The micro-controller 32 will send a signal to the display 22 to indicate whether the clock line voltage (V2) is above (V20K) 74 or below (V2NG) 76 a predetermined minimum level. Pressing 78 the push-button 26 steps the micro-controller 32 to monitor 80 the sensor data line voltage with the third voltage comparator 53. The micro-controller will send a signal to the display 22 to indicate whether the data line voltage (V3) is above (V30K) 82 or below (V3NG) 84 a predetermined minimum level. If either V2NG 76 or V3NG 84 is displayed, either the Flex-Link™ cable is shorted or a sensor 14 is defective.
After verifying that the voltages are correct, the push-button switch 26 is pressed 86 to initiate a test 88 of each individual sensor. For each sensor 14, the test comprises a first part where the micro-controller 32 sends a first data signal 90 addressing a specific sensor. When communication with the sensor 14 has been established, the micro-controller 32 sends a second data 92 signal directing the sensor 14 to output a specific zone pattern 94 for detecting the presence of a person/object 96. When the sensor 14 initiates output of the zone pattern 94, an object 96 may or may not be within the zone 94. If the sensor 14 detects the presence of an object 96, the micro-controller 32 will send a "SXON" signal 98 (where "X" is the sensor number) to the display 22 to indicate the presence of an object detection signal from the sensor 14. Conversely, if the sensor 14 does not detect the presence of an object 96, the micro-controller 32 will send a "SXNC" signal 100 to the display 22 to indicate the absence of an object detection signal from the sensor 14.
The sensor 14 is tested by attempting to change the status of the object detection signal. That is, if the "SXNC" signal 100 is being displayed, the operator will introduce an object 96, such as his hand, into the zone 94. If the sensor 14 is operating satisfactorily, the sensor receiver 102 will receive a return signal 104 from the object 96 and thereby sense the presence of this object 96 and send a signal to the test device 10. Upon receipt of this signal, the micro-controller 32 sends a "SXON" signal 98 to the display 22. Conversely, if the "SXON" signal 98 is being displayed, the operator will cover the emitter lens 106 or receiver 102. Since the receiver 102 will no longer receive a return signal 104 from the object 96 in the zone 94, it will appear as if the object 96 has been removed from the zone 94. Consequently, the sensor 14 will cease sending a signal to the test device 10 and the micro-controller 32 will send the "SXNC" signal 100 to the display 22. Pushing 108 the push-button switch 26 will cause the test device to advance to the next sensor 110. When the micro-controller 32 determines 112 that all of the sensors 14 have been tested, pushing 114 the push-button 26 will cause the micro-controller 32 to display a "END" message 116 on the alphanumeric display 22.
It should be appreciated that the test device 10' may be permanently installed in the automatic door system. Since the controller 12 and the sensors 14 must be isolated from each other during testing, a permanently installed test device 10' must include controls and circuitry for inserting the test device 10' between the controller 12 and the sensors 14 during testing and for removing the test device 10' when testing is complete so that the sensors 14 may once again communicate with the controller 12.
It should also be appreciated that the test device 10 is simple to manufacture and operate, resulting in low acquisition and operating costs. The installation and removal of the portable test device 10 of the subject invention is relatively easy to accomplish and does not require complex tools or training to accomplish. In addition, use of the test device 10, 10' requires only the operation of two switches 24, 26. The test results are obtained by observation of a single LED 20 which is either on or off and an alphanumeric display 22 which provides easily understood four digit test result messages.
It should be further appreciated that the test data and control program stored in memory 34 may be customized for each type and manufacture of automatic door system. For example, the program described above is for a standard Sentrex 3™ automatic door system. Consequently, the program includes information on each sensor 14 and component of the controller 12 to ensure that they are properly tested. The test data includes normative data for comparison to the parameters which are sensed by the test device 10, 10' when the sensors 14 and controller 12 are tested. The program and test data also include steps and data necessary to transmit "operate" and "stall" signals to the controller 12 and the first and second data signals for testing the sensors 14.
While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation.
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A test device for testing automatic door systems has a test circuit including a display, a micro-controller, a memory for storing data and a test program, and a control switch for controlling operation of the test program by the micro-controller. The test device is installed by interposing the test circuit between the controller and sensors of the automatic door system. A selector switch on the test device is moveable between first and second positions. When the selector switch is in the first position, it completes a data path between the test circuit and the controller and blocks the exchange of data between the sensors and the test circuit and the first connector. When the selector switch is in the second position, it completes a data path between the test circuit and the second connector and blocks the exchange of data between the controller and the test circuit and the second connector. Pushing the control switch steps the micro-controller through the test program to individually test the controller and each of the sensors.
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This application claims priorty to Provisional application Ser. No. 60/019,22 filed 6 Jun. 1996.
FIELD OF THE INVENTION
The present invention is in the field of human medicine, particularly in the treatment of viral infections. More particularly, the present invention relates to the treatment of rhinoviral, enteroviral and flaviviral inventions.
BACKGROUND OF THE INVENTION
The incidence of viral upper respiratory disease, the common cold, is immense. It has been estimated that nearly a billion cases annually appear in the United States alone. Rhinovirus, a member of the picornaviridae family, is the major cause of the common cold in humans. Because more than 110 strains of rhinoviruses have been identified, the development of a practical rhinovirus vaccine is not feasible, and chemotherapy appears to be the more desirable approach. Another member of the picornavirus family is the enterovirus, which includes approximately eighty human pathogens. Many of these enteroviruses cause cold-like symptoms; others can cause more serious diseases such as polio, conjunctivitis, aseptic meningitis and myocarditis.
Illness related to rhinovirus infection is evidenced by nasal discharge and obstruction Furthermore, it has been implicated in otitis media, predisposes the development of bronchitis, exacerbates sinusitis, and has been implicated in the precipitation of asthmatic altoclis. Although it is considered by many to be a mere nuisance, its frequent occurrence in otherwise healthy individuals and the resulting economic importance in terms of employee absenteeism and physician visits have made it the subject of extensive investigation.
The ability of chemical compounds to suppress the growth of viruses in vitro may be readily demonstrated using a virus plaque suppression test or a cytopathic effect test (CPE). Cf Siminoff, Applied Microbiology, 9(1), 66 (1961). Although a number of chemical compounds that inhibit picornaviruses such as rhinoviruses have been identified, many are unacceptable due to 1) limited spectrum of activity, 2) undesirable side effects or 3) inability to prevent infection or illness in animals or humans. See Textbook of Human Virology, edited by Robert B. Belshe, chapter 16, "Rhinoviruses," Roland A. Levandowski, 391-405 (1985). Thus, despite the recognized therapeutic potential associated with a rhinovirus inhibitor and the research efforts expended thus far, a viable therapeutic agent has not yet emerged. For example, anti-viral benzimidazole compounds have been disclosed in U.S. Pat. Nos. 4,008,243, 4,018,790, 4,118,573, 4,118,742, 4,174,454 and 4,492,708.
In general, the compounds disclosed in the above patents do not have a desirable pharmacological profile for use in treating rhinoviral infections. Specifically, these compounds do not possess satisfactory oral bioavailability or a high enough inhibitory activity to compensate for their relatively low oral bioavailability to permit their widespread use. In addition, it is widely accepted in the art that compounds used to treat rhinoviral infections should be very safe from a toxicological standpoint.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of this invention to provide novel benzimidazole compounds which inhibit the growth of picornaviruses, such as rhinoviruses, enteroviruses such as polioviruses, coxsackieviruses of the A and B groups, or echo virus and which have a desirable pharmacological profile. The benzimidazole compounds may also be used to inhibit flaviviruses such as hepatitis C and bovine diarrheal virus (BVDV).
The present invention provides compounds of formula I ##STR1## wherein: a is 0, 1, 2 or 3;
each R is independently hydrogen, halo, cyano, amino, halo(C 1 -C 4 )alkyl, di(C 1 -C 4 )alkylamino, azido, C 1 -C 6 alkyl, carbamoyl, carbamoyloxy; carbamoylamino, C 1 -C 4 alkoxy, C 1 -C 4 alkylthio, C 1 -C 4 alkylsulfinyl, C 1 -C 4 alkylsulfonyl, pyrrolidino, piperidino or morpholino;
R 0 is hydrogen, halo, C 1 -C 4 alkyl or C 1 -C 4 alkoxy;
R 1 is halo, cyano, hydroxy, methyl, ethyl, methoxy, ethoxy, methylthio, methylsulfinyl or methylsulfonyl;
R 2 is hydrogen, amino or --NHC(O)(C 1 -C 6 alkyl);
R 3 is dimethylamino, C 1 -C 10 alkyl, halo(C 1 -C 6 )alkyl, C 3 -C 7 cycloalkyl, substituted C 3 -C 7 cycloalkyl, phenyl, substituted phenyl, naphthyl, thienyl, thiazolidinyl, furyl, pyrrolidino, piperidino, morpholino or a group of the formula: ##STR2## R 4 and R 5 are independently hydrogen or C 1 -C 4 alkyl; or a pharmaceutically acceptable salt thereof.
The present invention also provides pharmaceutical formulations comprising a compound of the present invention, or a pharmaceutically acceptable salt thereof, in combination with a pharmaceutically acceptable carrier, diluent or excipient therefor.
The present invention also provides a method for inhibiting a picornavirus comprising administering to a host in need thereof, an effective amount of a compound of formula I, or a pharmaceutically acceptable salt thereof, wherein a, R, R 0 , R 1 , R 2 , R 3 , R 4 and R 5 are as defined above.
DETAILED DESCRIPTION
The present invention relates to benzimidazole compounds of formula I, as described above, that are useful as antiviral agents.
All temperatures stated herein are in degrees Celsius (°C.). All units of measurement employed herein are in weight units except for liquids which are in volume units.
As used herein, the term "C 1 -C 10 alkyl" represents a straight or branched alkyl chain having from one to ten carbon atoms. Typical C 1 -C 10 alkyl groups include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, t-butyl, pentyl, neo-pentyl, hexyl, 2-methylhexyl, heptyl and the like. The term "C 1 -C 10 alkyl" includes within its definition the terms "C 1 -C 6 alkyl" and "C 1 -C 4 alkyl."
"Halo" represents chloro, fluoro, bromo or iodo.
"Halo(C 1 -C 4 )alkyl" represents a straight or branched alkyl chain having from one to four carbon atoms with 1, 2 or 3 halogen atoms attached to it. Typical halo(C 1 -C 4 )alkyl groups include chloromethyl, 2-bromoethyl, 1-chloroisopropyl, 3-fluoropropyl, 3-bromobutyl, 3-chloroisobutyl, iodo-t-butyl, trichloromethyl, trifluoromethyl, 2,2-chloro-iodoethyl, 2,3-dibromopropyl and the like.
"C 1 -C 4 alkylthio" represents a straight or branched alkyl chain having from one to four carbon atoms attached to a sulfur atom. Typical C 1 -C 4 alkylthio groups include methylthio, ethylthio, propylthio, isopropylthio, butylthio and the like.
"C 1 -C 4 alkoxy" represents a straight or branched alkyl chain having from one to four carbon atoms attached to an oxygen atom. Typical C 1 -C 4 alkoxy groups include methoxy, ethoxy, propoxy, isopropoxy, butoxy and the like.
"Di(C 1 -C 4 )alkylamino" represents two straight or branched alkyl chains having from one to four carbon atoms attached to a common amino group. Typical di(C 1 -C 4 )alkylamino groups include dimethylamino, ethylmethylamino, methylpropylamino, ethylisopropylamino, butylmethylamino, sec-butylethylamino and the like.
"C 1 -C 4 alkylsulfinyl" represents a straight or branched alkyl chain having from one to four carbon atoms attached to a sulfinyl moiety. Typical C 1 -C 4 alkylsulfinyl groups include methylsulfinyl, ethylsulfinyl, propyl-sulfinyl, isopropyl-sulfinyl, butylsulfinyl and the like.
"C 1 -C 4 alkylsulfonyl" represents a straight or branched alkyl chain having from one to four carbon atoms attached to a sulfonyl moiety. Typical C 1 -C 4 alkylsulfonyl groups include methylsulfonyl, ethylsulfonyl, propylsulfonyl, isopropyl-sulfonyl, butylsulfonyl and the like.
"Substituted phenyl" represents a phenyl ring substituted with 1-3 substituents selected from the following: halo, cyano, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, amino or halo(C 1 -C 4 )alkyl.
"Substituted C 3 -C 7 cycloalkyl" represents a cycloalkyl ring substituted with 1-3 substituents selected from the following: halo, cyano, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, amino or halo (C 1 -C 4 ) alkyl.
The claimed compounds can occur in either the cis or trans isomer. For the purposes of the present application, cis refers to those compounds where the carboxamide moiety is cis to the benzimidazole ring and trans refers to those compounds where the carboxamide moiety is trans to the benzimidazole ring. Both isomers are included in the scope of the claimed compounds.
As mentioned above, the invention includes the pharmaceutically acceptable salts of the compounds defined by formula I. A compound of this invention can possess a sufficiently acidic, a sufficiently basic, or both functional groups, and accordingly react with any of a number of inorganic bases, and inorganic and organic acids, to form a pharmaceutically acceptable salt.
The term "pharmaceutically acceptable salt" as used herein, refers to salts of the compounds of the above formula which are substantially non-toxic to living organisms. Typical pharmaceutically acceptable salts include those salts prepared by reaction of the compounds of the present invention with a mineral or organic acid or an inorganic base. Such salts are known as acid addition and base addition salts.
Acids commonly employed to form acid addition salts are inorganic acids such as hydrochloric acid, hydrobromic acid, hydroiodic acid, sulfuric acid, phosphoric acid, and the like, and organic acids such as p-toluenesulfonic, methanesulfonic acid, ethanesulfonic acid, oxalic acid, p-bromophenylsulfonic acid, carbonic acid, succinic acid, citric acid, benzoic acid, acetic acid and the like.
Examples of such pharmaceutically acceptable salts are the sulfate, pyrosulfate, bisulfate, sulfite, bisulfite, phosphate, monohydrogenphosphate, dihydrogenphosphate, metaphosphate, pyrophosphate, chloride, bromide, iodide, acetate, propionate, decanoate, caprylate, acrylate, formate, isobutyrate, caproate, heptanoate, propiolate, oxalate, malonate, succinate, suberate, sebacate, fumarate, maleate, butyne-1,4-dioate, hexyne-1,6-dioate, benzoate, chlorobenzoate, methylbenzoate, dinitrobenzoate, hydroxybenzoate, methoxybenzoate, phthalate, sulfonate, xylenesulfonate, phenylacetate, phenylpropionate, phenylbutyrate, citrate, lactate, γ-hydroxybutyrate, glycollate, tartrate, methanesulfonate, ethanesulfonate, propanesulfonate, naphthalene-1-sulfonate, napththalene-2-sulfonate, mandelate and the like. Preferred pharmaceutically acceptable acid addition salts are those formed with mineral acids such as hydrochloric acid and sulfuric acid, and those formed with organic acids such as maleic acid and methanesulfonic acid.
Base addition salts include those derived from inorganic bases, such as ammonium or alkali or alkaline earth metal hydroxides, carbonates, bicarbonates, and the like. Such bases useful in preparing the salts of this invention thus include sodium hydroxide, potassium hydroxide, ammonium hydroxide, potassium carbonate, sodium carbonate, sodium bicarbonate, potassium bicarbonate, calcium hydroxide, calcium carbonate, and the like. The potassium and sodium salt forms are particularly preferred.
It should be recognized that the particular counterion forming a part of any salt of this invention is not of a critical nature, so long as the salt as a whole is pharmacologically acceptable and as long as the counterion does not contribute undesired qualities to the salt as a whole.
Preferred compounds of this invention are those compounds of the formula: ##STR3## where: a is 0, 1 or 2;
each R is independently hydrogen, halo, C 1 -C 4 alkyl, C 1 -C 4 alkoxy or di(C 1 -C 4 )alkylamino;
R 0 is hydrogen;
R 2 is amino;
R 3 is dimethylamino, C 1 -C 6 alkyl, halo(C 1 -C 6 )alkyl, C 3 -C 7 cycloalkyl, substituted C 3 -C 7 cycloalkyl, thienyl, thiazolidinyl, pyrrolidino, piperidino or morpholino;
R 4 is hydrogen, methyl or ethyl;
R 5 is hydrogen, methyl or ethyl;
or a pharmaceutically acceptable salt thereof.
Of these preferred compounds, more preferred are those compounds of formula I where:
a is 0 or 1;
each R is independently hydrogen, fluoro, methyl, ethyl, methoxy, ethoxy, dimethylamino;
R 0 is hydrogen;
R 3 is dimethylamino, C 1 -C 4 alkyl, C 3 -C 7 cycloalkyl or pyrrolidino;
or a pharmaceutically acceptable salt thereof.
Of these compounds, the most preferred compounds are: ##STR4## or a pharmaceutically acceptable salt thereof.
The compounds of formula I may be prepared by reacting a suitably substituted acetamide with a base to provide the corresponding anion which is then reacted with a suitably substituted ketone of formula IA to provide a carbinol intermediate. The reactions are typically carried out in an organic solvent for one to twelve hours at a temperature of from about -90° C. to room temperature using an excess of the base and acetamide reactant relative to the ketone reactant. The acetamide is preferably protected with a suitable protecting group prior to use in the reaction. Typical bases include sodium hydride, lithium diisopropylamide (LDA) and n-butyllithium. A preferred base is n-butyllithium. Solvent choice is not critical so long as the solvent employed is inert to the ongoing reaction and the reactants are sufficiently solubilized to effect the desired reaction. A solvent that is suitable for use in this reaction is tetrahydrofuran although the acetamide reactant can also be used as a solvent. The carbinol intermediate is generally prepared in from about one to eighteen hours when the reaction is initiated at -78° C. and allowed to slowly warm to room temperature. The reaction may be monitored by HPLC and quenched by the addition of an acid when it is substantially complete. Typical acids include hydrochloric acid, hydrobromic acid, formic acid and the like. A preferred acid is concentrated hydrochloric acid. The resultant carbinol intermediate is preferably dehydrated without prior isolation or purification.
In particular, the carbinol intermediate is reacted with an acid for thirty minutes to twelve hours at a temperature of from about room temperature to the reflux temperature of the mixture to provide the desired compound of formula I. Typical acids include hydrochloric acid, hydrobromic acid, formic acid, acetic acid and combinations of acids. A preferred acid combination is formic acid containing 1-6% concentrated hydrochloric acid. The desired compound is generally prepared in from about thirty minutes to seven hours when the reaction is carried out at the reflux temperature of the mixture. The reaction is preferably monitored by HPLC, for example, to ensure that the reaction goes to completion.
The compounds of formula I are preferably isolated and the resulting cis/trans isomers separated using procedures known in the art. For example, the cis and trans forms of the isolated compounds may be separated using column chromatography, for example reverse phase HPLC. The compounds may be eluted from the column using an appropriate ratio of acetonitrile and water or methanol and water. The cis form of the compound may be converted to a cis/trans mixture by exposure to hν irradiation and recycled through the above-mentioned purification process.
The ketone intermediates of formula IA used in the above reaction may be prepared substantially as detailed in the art. For example, the ketone intermediates may be prepared according to the following Reaction Scheme I. ##STR5## where: X is cyano or --COOR', where R' is C 1 -C 4 alkyl;
X' is halo; and
a, R, R 0 , R 1 , R 2 and R 3 are defined above.
Reaction Scheme I, above, is accomplished by carrying out reactions 1-4. Once a reaction is complete, the intermediate compound may be isolated, if desired, by procedures known in the art. For example, the compound may be crystallized and then collected by filtration, or the reaction solvent may be removed by extraction, evaporation or decantation. The intermediate compound may be further purified, if desired, by common techniques such as crystallization or chromatography over solid supports such as silica gel or alumina, before carrying out the next step of the reaction scheme.
Reaction I.1 is accomplished by first exposing an appropriately substituted halo-nitroaniline, preferably fluoro- or chloro-nitroaniline and an appropriately substituted phenylacetonitrile or benzoate to a base in an organic solvent for one to twenty four hours at a temperature of from about -10° C. to about 40° C. to provide a ketone precursor. The reaction is typically carried out using equimolar proportions of the reactants in the presence of two equivalents of the base. Typical bases include sodium hydride, potassium t-butoxide, lithium diisopropylamide (LDA). A preferred base is potassium t-butoxide. Examples of solvents suitable for use in this reaction include dimethylformamide, dimethylacetamide and the like. Solvent choice is not critical so long as the solvent employed is inert to the ongoing reaction and the reactants are sufficiently solubilized to effect the desired reaction. The ketone precursor is generally prepared in from about one to fifteen hours when the reaction is initiated at 0° C. and allowed to progress at room temperature. The ketone precursor is preferably oxidized in the same reaction mixture without prior isolation or purification.
In particular, the ketone precursor is reacted with an oxidizing agent for thirty minutes to fifteen hours at a temperature of from about 0° C. to about 30° C. to provide the corresponding ketone compound. Typical oxidizing agents include hydrogen peroxide, oxygen and air. The oxygen and air are typically bubbled through the reaction mixture. A preferred oxidizing agent is hydrogen peroxide, preferably in a 30% solution. The ketone is generally prepared in from about thirty to five hours when the reaction is carried out between 0° C. and room temperature. The reaction is preferably monitored by TLC, for example, to ensure that the reaction goes to completion.
In reaction I.2, the nitro substituent on the ketone is reduced according to procedures known in the art to provide the corresponding diaminobenzophenone compound. For example, the nitro substituent may be reduced by catalytic hydrogenation, for example by combining the ketone isolated from reaction II.1 with hydrogen gas in ethanol or tetrahydrofuran and a catalyst. A preferred catalyst is palladium-on-carbon or Raney nickel. Solvent choice is not critical so long as the solvent employed is inert to the ongoing reaction and the nitro reactant is sufficiently solubilized to effect the desired reaction. The hydrogen gas is typically used at a pressure of up to 60 psi, preferably at or about 30 psi. The reaction is generally substantially complete after about 1 to 24 hours when conducted at a temperature in the range of from about 0° C. to about 40° C. The reaction is preferably conducted at a temperature in the range of from about 20° C. to about 30° C. for about 2 to 5 hours.
In reaction I.3, the diaminobenzophenone compound isolated from reaction I.2 may be sulfonylated with an appropriately substituted sulfonyl halide of the formula R 4 -SO 2 -halide substantially in accordance with the procedure detailed above to provide the corresponding sulfonamido benzophenone compounds.
In reaction I.4, the compound isolated from reaction I.3 is cyclized via a nitrile intermediate by first exposing the sulfonamido benzophenone compound to a base in an alcoholic solvent such as isopropanol followed by reaction with cyanogen bromide. Typically, the sulfonamido benzophenone and base are reacted at a temperature of from about 0° C. to about 30° C. A preferred base is sodium hydroxide, preferably added in the form of an aqueous solution (about 1-4M). When the sulfonamido benzophenone is completely dissolved, the resultant solution is combined with cyanogen bromide. The cyanogen bromide is typically added in the form of a solution (3-7M for example in acetonitrile). The reaction is generally complete after one to eighteen hours when the reaction mixture is stirred at room temperature. However, in certain instances nitrile intermediate will precipitate out of the reaction mixture. In order to form the desired ketone, this precipitate is isolated and then refluxed in an alcoholic solvent such as isopropanol for one to four hours to provide the desired ketone compound of formula I.
Alternatively, the compound isolated from reaction I.3 is cyclized via a nitrile intermediate by exposing the sulfonamido benzophenone compound to a base in a chlorinated solvent such as methylene chloride followed by reaction with cyanogen bromide. Typically, the sulfonamido benzophenone and base are reacted at a temperature of from about 0° C. to about the reflux temperature of the mixture. A preferred base is lithium methoxide. The sulfonamido benzophenone and the base typically form a slurry which is then combined with cyanogen bromide. The cyanogen bromide is typically added in the form of a solution (3-7M for example in methylene chloride). The reaction is generally complete after one to eighteen hours when the reaction mixture is stirred at a temperature range of 0° C. to the reflux temperature.
The compounds of formula I where R 2 is --NHC(O)(C 1 -C 6 alkyl) may be prepared by acylating a compound of formula I, where R 2 is amino, according to procedures known in the art. For example, the amine compound may be acylated with a suitable acyl halide, isocyanate or chloroformate, preferably in the presence of an acid scavenger such as a tertiary amine, preferably triethylamine. A preferred acylating agent is acetic anhydride. The reaction is typically carried out at a temperature of from about -20° C. to about 25° C. Typical solvents for this reaction include ethers and chlorinated hydrocarbons, preferably diethylether, chloroform or methylene chloride. The amine reactant is generally employed in equimolar proportions relative to the acylating reactant, and preferably in the presence of equimolar quantities of an acid scavenger such as a tertiary amine. A preferred acid scavenger for this reaction is N-methylmorpholine (NMM).
The compounds employed as initial starting materials in the synthesis of the compounds of this invention are known in the art, and, to the extent not commercially available are readily synthesized by standard procedures commonly employed in the art.
It will be understood by those in the art that in performing the processes described above it may be desirable to introduce chemical protecting groups into the reactants in order to prevent secondary reactions from taking place. Any amine, alcohol, alkylamine or carboxy groups which may be present on the reactants may be protected using any standard amino-, alcohol or carboxy-protecting group which does not adversely affect the remainder of the molecule's ability to react in the manner desired. The various protective groups may then be removed simultaneously or successively using methods known in the art.
The pharmaceutically acceptable salts of the invention are typically formed by reacting a compound of formula I with an equimolar or excess amount of acid or base. The reactants are generally combined in a mutual solvent such as diethylether, tetrahydrofuran, methanol, ethanol, isopropanol, benzene and the like, for acid addition salts, or water, an alcohol or a chlorinated solvent such as methylene chloride for base addition salts. The salts normally precipitate out of solution within about one hour to about ten days and can be isolated by filtration or other conventional methods.
The following Preparations and Examples further illustrate specific aspects of the present invention. It is to be understood, however, that these examples are included for illustrative purposes only and are not intended to limit the scope of the invention in any respect and should not be so construed.
In the following Preparations and Examples, the terms melting point, nuclear magnetic resonance spectra, electron impact mass spectra, field desorption mass spectra, fast atom bombardment mass spectra, infrared spectra, ultraviolet spectra, elemental analysis, high performance liquid chromatography, and thin layer chromatography are abbreviated "m.p.", "NMR", "EIMS", "MS(FD)", "MS(FAB)", "IR", "UV", "Analysis", "HPLC", and "TLC", respectively. The MS(FD) data is presented as the mass number unless otherwise indicated. In addition, the absorption maxima listed for the IR spectra are only those of interest and not all of the maxima observed.
In conjunction with the NMR spectra, the following abbreviations are used: "s" is singlet, "d" is doublet, "dd" is doublet of doublets, "t" is triplet, "q" is quartet, "m" is multiplet, "dm" is a doublet of multiplets and "br.s", "br.d", "br.t", and "br.m" are broad singlet, doublet, triplet, and multiplet respectively. "J" indicates the coupling constant in Hertz (Hz). Unless otherwise noted, NMR data refers to the free base of the subject compound.
The NMR spectra were obtained on a Bruker Corp. 250 MHz instrument or on a General Electric QE-300 300 MHz instrument. The chemical shifts are expressed in delta, δ values (parts per million downfield from tetramethylsilane). The MS(FD) spectra were taken on a Varion-MAT 731 Spectrometer using carbon dendrite emitters. EIMS spectra were obtained on a CEC 21-110 instrument from Consolidated Electrodynamics Corporation. IR spectra were obtained on a Perkin-Elmer 281 instrument. UV spectra were obtained on a Cary 118 instrument. TLC was carried out on E. Merck silica gel plates. Melting points are uncorrected.
EXAMPLE 1
A. 3-Amino-4-nitro-4'-fluorobenzophenone
To a cold (0° C.) solution of 17.25 g (100 mmol) of 5-chloro-2-nitroaniline and 12 ml (100 mmol) of 4-fluorophenylacetonitrile in 200 ml of dimethylformamide, was added 22.44 g (200 mmol) of potassium t-butoxide, under nitrogen. The reaction mixture was warmed to room temperature and reacted overnight. When the reaction was substantially complete, as indicated by TLC (eluent of 40% ethyl acetate in hexane), the reaction mixture was cooled to 0° C. followed by the addition of 30 ml of hydrogen peroxide (30% solution in water). When the reaction was substantially complete, as indicated by TLC (eluent of 40% ethyl acetate in hexane), the reaction mixture was poured into 1 liter of 1N hydrochloric acid (aqueous) which resulted in the formation of a yellow/orange precipitate.
This precipitate was isolated by filtration. Yield: 23.3 g (89%).
B. 3,4-Diamino-4'-fluorobenzophenone
To a solution of 21 g of Example 1A in 250 ml of tetrahydrofuran and 250 ml of ethanol, was added 3.0 g of Raney Nickel catalyst. The reaction mixture was stirred overnight under 30 psi of hydrogen (gas) and then filtered. The filtrate was concentrated in vacuo to provide a yellow solid which was used without further purification.
C. 4-Amino-3-isopropylsulfonamido-4'-fluorobenzophenone
To a solution of 18.14 g (79 mmol) of Example 1B in 160 ml of anhydrous methylene chloride and 32 ml of anhydrous pyridine, was added 13.25 ml (118 mmol) of isopropylsulfonylchloride. The reaction mixture was reacted at room temperature for 5 hours, under nitrogen. When the reaction was substantially complete, as indicated by TLC (eluent of ethyl acetate), the reaction mixture was poured into 400 ml of 1N hydrochloric acid (aqueous). The resulting mixture was diluted with 300 ml of ethyl acetate and the resulting layers were separated, the organic layer dried over magnesium sulfate, filtered and concentrated in vacuo to provide a dark red gum. This gum was purified using Preparatory HPLC (gradient eluent of 30-60% ethyl acetate in hexane). The fractions containing the desired compound were combined and dried in vacuo to provide 17.11 g of a yellow gum that was used without further purification. Yield: 65% ##STR6##
To a solution of 17.11 g (51 mmol) of Example 1C and 25 ml of 2N sodium hydroxide (aqueous) in 100 ml of isopropanol, was added 10 ml of a 5M cyanogen bromide in acetonitrile. The reaction mixture was reacted at room temperature for 30 minutes resulting in the formation of a precipitate. This precipitate was isolated by filtration to provide 11.68 g of a solid. This solid was resuspended in 250 ml of isopropanol and the resultant mixture was refluxed until all of the material had dissolved and then cooled to provide 10.0 g of the desired compound.
Yield: 55%.
Analysis for C 17 H 16 FN 3 O 3 S: Calcd: C, 56.50; H, 4.46; N, 11.63; Found: C, 56.71; H, 4.48; N, 11.82.
MS(FD): 361.
1 H NMR (300 MHz; d 6 -DMSO): δ 1.32 (d, J=7 Hz, 6H); 3.96 (septet, J=7.0 Hz, 1H); 7.34-7.44 (m, 5H); 7.63 (dd, J=1.6,8.3 Hz, 1H); 7.79-7.83 (m, 2H); 7.95 (d, J=1.5 Hz, 1H). ##STR7##
To a cold (-78° C.) solution of bis(trimethylsilyl)acetamide (8 equivalents) in tetrahydrofuran, was slowly added a solution of 2.5M n-butyllithium (8 equivalents) in hexane. To the resultant mixture was added Example 1D (1 equivalent). The reaction mixture was stirred for 8 hours at -78° C. and then allowed to warm to room temperature. When the reaction was substantially complete, as indicated by HPLC, the reaction was quenched by the addition of concentrated hydrochloric acid (approximately 1 equivalent) and then concentrated in vacuo to provide an oil which was then redissolved in formic acid containing 1% concentrated hydrochloric acid. The resultant mixture was allowed to react for 4 hours at 95° C. When the reaction was substantially complete, as indicated by HPLC, the mixture was concentrated in vacuo to provide an oil. This oil was separated using reverse phase HPLC (eluent of acetonitrile in water) to provide the cis and trans isomers.
cis
not characterized
trans
Analysis for C 19 H 19 N 4 O 3 SF: Calcd: C, 56.71; H, 4.76; N, 13.92; S, 7.97; F, 4.72; Found: C, 56.96; H, 4.76; N, 13.90; S, 7.96; F, 4.90.
MS(FD): 402 (M + ).
1 H NMR (300 MHz; d 6 -DMSO): δ 1.20 (d, 6H); 3.80 (m, 1H); 6.35 (s, 1H); and 7.10 (m, 11H).
IR (CHCl 3 ): ν 3465, 3140, 1680, 1658, 1600, 1554, 1395, 1353, 1265, 1216, 1157, 1139, 1047, 689, 593 and 425 cm -1 .
UV/VIS (95% EtOH): λ max =312.50 nm (E=15680.556); 245.00 nm (E=26956.305).
The compounds described in Examples 2-4 were prepared substantially as detailed in Example 1A-E, using N-methyl-N-trimethylsilylacetamide instead of bis(trimethylsilyl)acetamide.
EXAMPLE 2 ##STR8## cis
Analysis for C 20 H 21 N 4 O 3 SF: Calcd: C, 57.68; H, 5.08; N, 13.45; Found: C, 57.69; H, 5.07; N, 13.36.
MS(FD): 416 (M + )
1 H NMR (300 MHz; d 6 -DMSO): δ 1.23 (d, J=7 Hz, 6H); 2.59 (d, J=5 Hz, 3H); 3.86 (septet, J=7 Hz, 1H); 6.13 (s, 1H); 6.85 (dd, J=8,1 Hz, 1H); 7.07 (s, 2H); 7.08-7.31 (m, 4H); 7.32-7.50 (m, 2H) and 8.01 (d, J=5 Hz, 1H).
IR (CHCl 3 ): ν 3450, 3410, 3350, 2996, 1659, 1639, 1608, 1548, 1359 and 1155 cm -1 .
UV/VIS (95% EtOH): λ max =296.0 nm (E=12272); 252.0 nm (E=21329).
trans
Analysis for C 20 H 21 N 4 O 3 SF: Calcd: C, 57.68; H, 5.08; N, 13.45; Found: C, 57.91; H, 5.07; N, 13.47.
MS(FD): 416 (M + ).
1 H NMR (300 MHz; d 6 -DMSO): δ 1.25 (d, J=7 Hz, 6H); 2.59 (d, J=5 Hz, 3H); 3.82 (septet, J=7 Hz, 1H); 6.58 (s, 1H); 7.04 (dd, J=8,1 Hz, 1H); 7.14-7.21 (m, 6H); 7.37-7.42 (m, 2H) and 8.01 (d, J=5 Hz, 1H).
IR(CHCl 3 ): ν 3460, 3310, 2990, 1639, 1603, 1547 and 1360 cm -1 .
UV/VIS (95% EtOH): λ max =313.0 nm (E=21062); 240.0 nm (E=18068).
EXAMPLE 3 ##STR9## cis
Analysis for C 20 H 20 N 4 O 3 SF 2 : Calcd: C, 55.29; H, 4.64; N, 12.89; Found: C, 55.29; H, 4.89; N, 12.96.
MS(FD): 434.2 (M + ).
1 H NMR (300 MHz; d 6 -DMSO): δ 1.23 (d, J=7 Hz, 6H); 2.57 (d, J=5 Hz, 3H); 3.83 (septet, J=7 Hz, 1H); 6.17 (s, 1H); 6.82 (d, J=8.1 Hz, 1H); 6.99-7.39 (m, 6H); 7.42 (s, 1H) and 7.98 (d, J=5 Hz, 1H).
IR (KBr): ν 3412, 1662, 1639, 1550, 1445, 1357, 1264 and 1136 cm -1 .
UV/VIS (95% EtOH): λ max =300.0 nm (E=11944); 252.0 nm (E=20932).
trans
Analysis for C 20 H 20 N 4 O 3 SF 2 : Calcd: C, 55.29; H, 4.64; N, 12.89; Found: C, 55.45; H, 4.70; N, 12.77.
MS(FD): 434.2 (M + ).
1 H NMR (300 MHz; d 6 -DMSO): δ 1.22 (d, J=7 Hz, 6H); 2.59 (d, J=5 Hz, 3H); 3.83 (septet, J=7 Hz, 1H); 6.58 (s, 1H); 6.99-7.23 (m, 7H); 7.42 (s, 1H) and 8.08 (d, J=5 Hz, 1H).
IR (KBr): ν 3424, 1664, 1658, 1601, 1553, 1506, 1383, 1229, 1152 and 1138 cm -1 .
UV/VIS (95% EtOH): λ max =315.0 nm (E=20986); 242.0 nm (E=17916); 214.0 nm (E=29973).
EXAMPLE 4 ##STR10## cis
Analysis for C 20 H 20 N 4 O 3 SF 2 : Calcd: C, 55.29; H, 4.64; N, 12.89; Found: C, 55.47; H, 4.71; N, 12.84.
MS(FD): 434.2 (M + ).
1 H NMR (300 MHz; d 6 -DMSO): δ 1.22 (d, J=7 Hz, 6H); 2.58 (d, J=5 Hz, 3H); 3.84 (septet, J=7 Hz, 1H); 6.13 (s, 1H); 6.82 (d, J=8 Hz, 1H); 7.01-7.20 (m, 5H); 7.45 (m, 1H); 7.52 (s, 1H); and 8.08 (d, J=5 Hz, 1H).
IR(CHCl 3 ): ν 1660, 1638, 1606, 1547, 1465, 1359 and 1004 cm -1 .
UV/VIS (95% EtOH): λ max =307.0 nm (E=13613); 246 nm (E=18327).
trans
Analysis for C 20 H 20 N 4 O 3 SF 2 : Calcd: C, 55.29; H, 4.64; N, 12.89; Found: C, 55.04; H, 4.56; N, 12.77.
MS(FD): 434.2 (M + ).
1 H NMR (300 MHz; d6-DMSO): δ 1.23 (d, J=7 Hz, 6H); 2.58 (d, J=5 Hz, 3H); 3.83 (septet, J=7 Hz, 1H); 6.71 (s, 1H); 7.01-7.19 (m, 5H); 7.21 (d, J=8 Hz, 1H); 7.43 (q, J=8 Hz, 1H); 7.44 (s, 1H); and 8.18 (d, J=5 Hz, 1H).
IR (KBr): ν 3466, 3427, 1662, 1604, 1554, 1464, 1379, 1229, 1174, 1046, 1001 and 687 cm -1 .
UV/VIS (95% EtOH): λ max =317.0 nm (E=20136); 242.0 nm (E=17889).
The compounds described below were prepared substantially as detailed in Example 1A-E, below, unless otherwise indicated.
EXAMPLE 5 ##STR11## cis
Analysis for C 19 H 19 FN 4 O 3 S: Calcd: C, 56.71; H, 4.76; N, 13.92; Found: C, 56.62; H, 4.60; N, 13.86.
MS(FD): 402.1 (M + ).
1 H NMR (300 MHz; d 6 -DMSO): δ 1.22 (d, J=6.8 Hz, 6H); 3.81 (septet, J=6.8 Hz, 1H); 6.16 (s, 1H); 6.90 (dd, J=8.1,1.2 Hz, 1H); 6.99 (s, 2H); 7.11 (s, 1H); 7.14-7.42 (m, 6H) and 7.47 (s, 1H).
IR (KBr): ν 3438, 3142, 1685, 1654, 1624, 1605, 1554, 1384, 1350, 1297, 1147, 1038 and 764 cm -1 .
UV/VIS (95% EtOH): λ max =254.0 nm (E=21819)
trans
Analysis for C 19 H 19 FN 4 O 3 S: Calcd: C, 56.71; H, 4.76; N, 13.92; Found: C, 56.90; H, 4.69; N, 13.85.
MS(FD): 402.1 (M + ).
1 H NMR (300 MHz; d 6 -DMSO): δ 1.22 (d, J=6.8 Hz, 6H); 3.82 (septet, J=6.8 Hz, 1H); 6.57 (s, 1H); 6.86 (s, 1H); 7.02-7.22 (m, 7H) and 7.36-7.43 (m, 3H).
IR(KBr): ν 3460, 1678, 1667, 1600, 1552, 1394, 1271 cm -1 .
UV/VIS (95% EtOH): λ max =285.0 nm (E=3801); 254.0 nm (E=10511); 218.0 nm (E=29782).
EXAMPLE 6 ##STR12## cis
Analysis for C 20 H 21 FN 4 O 4 S: Calcd: C, 55.55; H, 4.89; N, 12.96; Found: C, 55.72; H, 4.89; N, 12.86.
MS(FD): 432.0 (M + ).
1 H NMR (300 MHz; d 6 -DMSO): δ 1.23 (d, J=6.8 Hz, 6H); 3.78 (s, 3H); 3.79 (septet, J=6.8 Hz, 1H); 6.12 (s, 1H); 6.78-6.90 (m, 5H); 6.98 (s, 1H); 7.10 (d, J=2.2 Hz, 1H); 7.12 (d, J=7.8 Hz, 1H); 7.35 (s, 1H) and 7.44 (d, J=1.4 Hz, 1H).
IR (KBr): ν 3443, 3411, 3093, 1659, 1637, 1622, 1611, 1601, 1575, 1565, 1508, 1437, 1394, 1356, 1324, 1278, 1250, 1172, 1153, 1138, 1097, 1040, 1029, 844 and 821 cm -1 .
UV/VIS (95% EtOH): λ max =285.0 nm (E=18629); 260.0 nm (E=20801).
trans
Analysis for C 20 H 21 FN 4 O 4 S.H 2 O: Calcd: C, 53.32; H, 5.15; N, 12.24; Found: C, 53.23; H, 5.11; N, 12.24.
MS(FD) 432.1 (M + ).
1 H NMR (300 MHz; d 6 -DMSO): δ 1.23 (d, J=6.8 Hz, 6H); 3.80 (s, 3H); 3.83 (septet, J=6.8 Hz, 1H); 6.48 (s, 1H); 6.76 (s, 2H); 6.77 (dd, J=20.0, 2.5 Hz, 1H); 6.84 (s, 1H); 7.02 (dd, J=8.7,1.8 Hz, 1H); 7.07 (s, 1H); 7.18 (d, J=8.3 Hz, 1H); 7.37 (s, 2H) and 7.42 (d, J=1.3 Hz, 1H).
IR (CHCl 3 ): ν 3400, 1661, 1639, 1624, 1603, 1580, 1547, 1508, 1466, 1443, 1386, 1360, 1323, 1291, 1268, 1174, 1156, 1043 and 1033 cm -1 .
UV/VIS (95% EtOH): λ max =312.0 nm (E=19477).
EXAMPLE 7 ##STR13##
The compound was prepared substantially as detailed in Example 1A-E, using N-methyl-N-trimethylsilylacetamide instead of bis(trimethylsilyl)acetamide.
cis
Analysis for C 21 H 23 N 4 O 4 SF: Calcd: C, 56.59; H, 5.19; N, 12.55; Found: C, 56.42; H, 5.24; N, 12.36.
MS(FD): 446.1 (M + ).
1 H NMR (300 MHz; d 6 -DMSO): δ 1.23 (d, J=6.8 Hz, 6H); 2.56 (d, J=4.5 Hz, 3H); 3.79 (s, 3H); 3.83 (septet, J=6.8 Hz, 1H); 6.10 (s, 1H); 6.86-6.78 (m, 4H); 6.99 (s, 2H); 7.15 (d, J=8.7 Hz, 1H); 7.43 (d, J=1.0 Hz, 1H); 7.93 (d, J=4.5 Hz, 1H).
IR (CHCl 3 ): ν 3360, 3250, 1638, 1620, 1547, 1507, 1358 and 1157 cm -1 .
UV/VIS (95% EtOH): λ max =283.0 nm (E=19090); 259.0 nm (E=21760).
trans
Analysis for C 21 H 23 N 4 O 4 SF: Calcd: C, 56.59; H, 5.19; N, 12.55; Found: C, 56.52; H, 5.20; N, 12.45.
MS(FD): 446 (M + ).
1 H NMR (300 MHz; d 6 -DMSO): δ 1.23 (d, J=6.8 Hz, 6H); 2.56 (d, J=4.6 Hz, 3H); 3.80 (s, 3H); 3.83 (septet, J=6.8 Hz, 1H); 6.46 (s, 1H); 6.76 (s, 1H); 6.77 (dd, J=21.2, 2.4 Hz, 2H); 7.00 (dd, J=8.5,2.0 Hz 1H); 7.07 (s, 2H); 7.17 (d, J=8.5 Hz, 1H); 7.44 (d, J=2.0 Hz, 1H); 7.94 (d, J=4.6 Hz, 1H).
IR (CHCl 3 ): ν 3510, 3400, 1638, 1603, 1579, 1546, 1508, 1360 and 1156 cm -1 .
UV/Vis (95% EtOH): λ max =310.0 nm (E=20794).
EXAMPLE 8 ##STR14## cis
Analysis for C 19 H 18 N 4 O 3 SF 2 : Calcd: C, 54.28; H, 4.32; N, 13.33; Found: C, 54.19; H, 4.47; N, 13.53.
1 H NMR (300 MHz, DMSO-d 6 ): δ 7.47 (d, J=1.3 Hz, 1H); 7.42 (s, 1H); 7.30 (m, 3H); 7.13 (d, J=8.2 Hz, 1H); 7.05 (s, 1H); 7.00 (s, 2H); 6.88 (dd, J=8.4 Hz, 1H); 6.15 (s, 1H); 3.81 (septet, J=6.8 Hz, 1H); 1.23 (d, J=6.8 Hz, 6H).
IR (KBr): 3449, 1655, 1637, 1615, 1595, 1553, 1349, 1264, 1154 and 690 cm -1 .
MS(FD): 420.1 (M + ).
UV/Vis (95% EtOH): λ max =253.0 nm (E=17236).
trans
Analysis for C 19 H 18 N 4 O 3 SF 2 .0.5H 2 O: Calcd: C, 53.14; H, 4.46; N, 13.05; Found: C, 53.52; H, 4.41; N, 13.05.
1 H NMR (300 MHz, DMSO-d 6 ): δ 7.48 (s, 1H); 7.40 (d, J=1.4 Hz, 1H); 7.21-7.11 (m, 4H); 7.09 (s, 2H); 7.04 (dd, J=6.8,1.4 Hz, 1H); 6.89 (s, 1H); 6.58 (s, 1H); 3.83 (septet, J=6.8 Hz, 1H); 1.23 (d, J=6.8 Hz, 6H).
IR (KBr): 3470, 3280, 1670, 1651, 1635, 1599, 1589, 1535 and 1394 cm -1 .
MS(FD): 420 (M + ).
UV/Vis (95% EtOH): λ max =316.0 nm (E=19702); 240.0 nm (E=16497).
EXAMPLE 9 ##STR15## cis not characterized
trans
Analysis for C 20 H 22 N 4 O 4 S: Calcd: C, 57.96; H, 5.35; N, 13.52; Found: C, 57.91; H, 5.19; N, 13.35.
1 H NMR (300 MHz, DMSO-d 6 ) δ 7.37 (s, 1H); 7.31 (m, 1H); 7.14 (d, 1H); 7.10 (s, 1H); 7.02 (m, 5H); 6.95 (m, 1H); 6.73 (s, 1H); 6.44 (s, 1H); 3.79 (septet, 1H); 3.58 (s, 3H); 1.19 (d, 6H).
IR (CHCl 3 ): 3399, 3009, 1658, 1639 and 1386 cm -1 .
MS(FD): 414 (M + ).
UV/Vis (95% EtOH): λ max =312 nm (E=19305).
EXAMPLE 10 ##STR16##
The compound was prepared substantially in accordance with the procedure detailed in Example 1A-E, with the exception that n-butyllithium (15.85 mmol) was slowly added to a solution that was prepared as follows. A cold (-78° C.) solution of lithium bis(trimethylsilyl)amide (15.84 mmol) and N-ethylacetamide (15.85 mmol) in tetrahydrofuran was stirred for 1 hour followed by the addition of chlorotrimethylsilane (15.84 mmol). The resultant solution was stirred for 15 minutes and then allowed to warm slowly to room temperature.
NOTE: The solution was cooled to -78° C. before the addition of the n-butyllithium.
cis
Analysis for C 21 H 22 N 4 O 3 SF 2 : Calcd: C, 56.24; H, 4.94; N, 12.49; Found: C, 56.11; H, 5.09; N, 12.24.
1 H NMR (300 MHz, DMSO-d 6 ): δ 8.05 (t, 1H); 7.35-7.55 (m, 2H); 6.9-7.3 (m, 5H); 6.88 (dd, 1H); 6.18 (s, 1H); 3.85 (septet, 1H); 3.05 (p, 2H); 1.25 (d, 6H); 0.95 (t, 3H).
IR (CHCl 3 ): 2986, 1664, 1602, 1514 and 1482 cm -1 .
MS(FD): 447.9 (M + ).
UV/Vis (95% EtOH): λ max =255.0 nm (E=13119.76).
trans;
Analysis for C 21 H 22 N 4 O 3 SF 2 : Calcd: C, 56.24; H, 4.94; N, 12.49; Found: C, 56.46; H, 4.85; N, 12.20.
1 H NMR (300 MHz, DMSO-d 6 ): δ 8.10 (t, 1H); 7.25-7.48 (m, 2H); 7.02-7.25 (m, 4H); 6.97 (dd, 1H); 6.86 (t, 1H); 6.57 (s, 1H); 3.81 (septet, 1H); 3.02 (p, 2H); 1.20 (d, 6H); 0.95 (t, 3H).
IR (CHCl 3 ): 3397, 3001, 1639, 1604, 1478, 1359 and 1270 cm -1 .
MS(FD): 448.1 (M + ).
UV/Vis (95% EtOH): λ max =316 nm (E=11399.60); 245.00 nm (E=10149.71); 214 nm (E=17027.16).
EXAMPLE 11 ##STR17## cis
Analysis for C 18 H 17 N 5 O 3 SF 2 : Calcd: C, 51.30; H, 4.07; N, 16.62; Found: C, 50.94; H, 4.00; N, 16.63.
1 H NMR (300 MHz, DMSO-d 6 ): δ 7.51 (s, 1H); 7.47 (s, 1H); 7.26 (m, 2H); 7.13 (m, 3H); 6.98 (s, 2H); 6.90 (d, 1H); 6.20 (s, 1H); 2.83 (s, 6H).
IR (KBr): 3461, 3438, 1667, 1645, 1384, 1173 and 577 cm -1 .
MS(FD): 421 (M + ).
UV/Vis (95% EtOH): λ max =286 nm (E=12460); 256 nm (E=19979.71); 217.5 nm (E=36270.16).
trans
Analysis for C 18 H 17 N 5 O 3 SF 2 : Calcd: C, 51.30; H, 4.07; N, 16.62; Found: C, 51.35; H, 4.03; N, 16.68.
1 H NMR (300 MHz, DMSO-d 6 ): δ 7.55 (s, 1H); 7.33 (s, 1H); 7.23 (m, 3H); 7.14 (d, 1H); 7.07 (s, 2H); 6.97 (m, 1H); 6.94 (s, 1H); 6.63 (s, 1H); 2.80 (s, 6H).
IR (KBr): 3472, 3448, 3118, 1666, 1557, 1388 and 580 cm -1 .
MS(FD): 421 (M + ).
UV/Vis (95% FtOH): λ max =319.5 nm (E=19736); 244 nm (E=15653); 218.5 nm (E=29125).
EXAMPLE 12 ##STR18## cis
Analysis for C 19 H 17 N 4 O 3 SF 3 : Calcd: C, 52.05; H, 3.91; N, 12.77; Found: C, 52.09; H, 3.96; N, 12.61.
1 H NMR (300 MHz, DMSO-d 6 ): δ 7.48 (d, J=7.0 Hz, 1H), 7.35 (q, J=9.0 Hz, 1H), 7.15 (d, J=8.2 Hz, 1H), 7.13 (dd, J=8.7,1.8 Hz, 1H), 7.03 (s, 2H), 6.91 (d, J=8.3 Hz, 1H), 6.21 (s, 1H), 3.82 (septet, J=6.8 Hz, 1H), 1.23 (d, J=6.8 Hz, 6H).
IR (CHCl 3 ): 3490, 3360, 1667, 1639, 1607, 1547, 1509, 1474, 1385 and 1357 cm -1 .
MS(FD): 438.0 (M + ).
UV/Vis (95% EtOH): 298.8 nm (E=9947.5); 254.5 nm (E=21502); 212.8 nm (E=36486).
trans
Analysis for C 19 H 17 N 4 O 3 SF 3 : Calcd: C, 52.05; H, 3.91; N, 12.77; Found: C, 51.76; H, 4.21; N, 12.47.
1 H NMR (300 MHz, DMSO-d 6 ): δ 7.57 (s, 1H), 7.44 (s, 2H), 7.30 (q, J=8.4 Hz, 1H); 7.20 (d, J=8.4 Hz, 1H); 7.12 (s, 2H); 7.03 (dd, J=8.4,1.6 Hz, 1H); 6.97 (s, 1H); 6.64 (s, 1H); 3.86 (septet, J=6.8 Hz, 1H); 1.24 (d, J=6.8 Hz, 6H).
IR (CHCl 3 ): 3399, 1677, 1639, 1603, 1583, 1546, 1510, 1476, 1442, 1388, 1360, 1325, 1273, 1264, 1155 and 1043 cm -1 .
MS(FD): 438 (M + ).
UV/Vis (95% EtOH): λ max =319.0 nm (E=27794); 244.0 nm (E=24112).
EXAMPLE 13 ##STR19## cis not characterized
trans
Analysis for C 19 H 16 N 4 O 3 SF 4 : Calcd: C, 50.00; H, 3.53; N, 12.28; Found: C, 49.97; H, 3.59; N, 12.03.
1 H NMR (300 MHz, DMSO-d 6 ) δ 7.94 (m, 1H); 7.71 (s, 1H); 7.60 (dd, J=5.6,1.6 Hz, 1H); 7.23 (d, J=8.5 Hz, 1H); 7.17-7.06 (m, 3H); 6.95 (d, J=6.8 Hz, 1H); 6.84 (s, 1H); 3.85 (septet, J=6.8 Hz, 1H); 1.25 (d, J=6.8 Hz, 6H).
IR (KBr): 3452, 1679, 1660, 1641, 1638, 1551, 1496, 1399, 1382, 1358, 1270, 1175, 1154, 1044, 936, 687 cm -1 .
MS(FD): 456.0 (M + ).
UV/Vis (95% EtOH): λ max =320.0 nm (E=15355) 248.0 nm (E=17540).
EXAMPLE 14 ##STR20##
The compound was prepared substantially as detailed in Example 7.
cis
Analysis for C 20 H 20 N 4 O 3 SF 2 : Calcd: C, 55.29; H, 4.64; N, 12.89; Found: C, 55.27; H, 4.67; N, 12.77.
1 H NMR (300 MHz, DMSO-d 6 ) δ 8.00 (m, 1H); 7.45 (s, 1H); 7.0-7.35 (m, 6H); 6.85 (d, 1H); 6.17 (s, 1H); 3.80 (septet, 1H); 2.57 (d, 3H); 1.20 (d, 6H).
IR (KBr): 3415, 1666, 1551, 1353, 1173 and 1040 cm -1 .
MS(FD): 434 (M + ).
UV/Vis (95% EtOH): λ max =254 nm (E=20592); 214.5 nm (E=36320).
trans
Analysis for C 20 H 20 N 4 O 3 SF 2 : Calcd: C, 55.29; H, 4.64; N, 12.89; Found: C, 55.00; H, 4.56; N, 13.02.
1 H NMR (300 MHz, DMSO-d 6 ) δ 8.13 (m, 1H); 7.43 (s, 1H); 7.19-7.24 (m, 3H); 7.13 (s, 2H); 6.93-7.05 (m, 2H); 6.6 (s, 1H); 2.58 (d, 3H); 1.22 (d, 6H).
IR (KBr): 3440, 3120, 1664, 1551, 1233 and 1038 cm -1 .
MS(FD): 434 (M + ).
UV/Vis (95% EtOH): λ max =316.5 nm (E=20895); 241.5 nm (E=17229); 215.5 nm (31108).
EXAMPLE 15 ##STR21## cis
Analysis for C 19 H 18 N 4 O 3 SF 2 : Calcd: C, 54.28; H, 4.32; N, 13.33; Found: C, 54.50; H, 4.25; N, 13.14.
1 H NMR (300 MHz, DMSO-d 6 ) 7.44 (m, 2H); 7.22 (m, 2H); 7.11 (m, 4H); 7.00 (m, 1H); 6.88 (d, 1H); 6.18 (s, 1H); 3.79 (septet, 1H); 1.20 (d, 6H).
13 C NMR (75 MHz, DMSO-d 6 ): 166.9, 159.4, 157.3, 156.3, 154.0, 153.4, 142.4, 142.0, 131.6, 130.7, 130.1, 126.1, 125.1, 117.4, 116.5, 115.0, 112.9, 55.5 and 15.5.
IR (KBr): 3441, 3148, 1656, 1486, 1350, 1154, 1037 and 689 cm -1 .
MS(FD): 420 (M + ).
UV/Vis (95% EtOH): λ max =256 nm (E=20450); 214.5 nm (E=37022).
trans
Analysis for C 19 H 18 N 4 O 3 SF 2 : Calcd: C, 54.28; H, 4.32; N, 13.33; Found: C, 54.40; H, 4.34; N, 13.54.
1 H NMR (300 MHz, DMSO-d 6 ) δ 7.50 (s, 1H); 7.38 (s, 1H); 7.18 (m, 43H); 7.08 (s, 2H); 6.99 (m, 3H); 6.57 (s, 1H); 3.80 (septet, 1H); 1.19 (d, 6H).
13 C NMR (75 MHz, DMSO-d 6 ): 165.8, 159.2, 156.9, 156.1, 153.7, 143.4, 142.8, 131.7, 131.5, 129.1, 123.6, 122.1, 117.3, 116.1, 115.7, 115.4, 110.3, 55.8 and 15.6.
IR (KBr): 3163, 1677, 1427, 1269, 1043 and 687 cm -1 .
MS(FD): 420 (M + ).
UV/Vis (95% EtOH): λ max =318.5 nm (E=19751); 239.5 nm (E=16318); 215 nm (E=31509).
EXAMPLE 16 ##STR22## cis
Analysis for C 19 H 18 N 4 O 3 SF 2 : Calcd: C, 54.28; H, 4.31; N, 13.33; Found: C, 54.51; H, 4.56; N, 13.41.
1 H NMR (300 MHz, DMSO-d 6 ) δ 7.49 (s, 2H); 7.46 (m, 1H); 7.22 (m, 1H); 7.05-7.15 (m, 4H); 7.04 (s, 1H); 6.91 (d, 1H); 6.21 (s, 1H); 3.82 (septet, 1H) and 1.23 (d, J=7 Hz, 6H).
IR (KBr): 3438, 3141, 1685, 1656, 1606, 1477, 1352 and 1275 cm -1 .
MS(FD): 420 (M + ).
UV/Vis (95% EtOH): λ max =300 nm (E=10339); 254 nm (E=21435).
trans
Analysis for C 19 H 18 N 4 O 3 SF 2 : Calcd: C, 54.28; H, 4.32; N, 13.33; Found: C, 54.31; H, 4.37; N, 13.22.
1 H NMR (300 MHz, DMSO-d 6 ) δ 7.55 (s, 1H); 7.42 (s, 1H); 7.39 (m, 1H); 7.18 (m, 2H); 7.11 (s, 2H); 7.02 (d, 1H); 6.93 (s, 1H); 6.91 (m, 1H); 6.63 (s, 1H); 3.85 (septet, 1H) and 1.21 (d, 6H).
IR (KBr): 2982, 1694, 1659, 1555, 1473, 1349 and 1265 cm -1 .
MS(FD): 420 (M + ).
UV/Vis (95% EtOH): λ max =318 nm (E=19511); 241 nm (E=16526).
The compounds in Examples 17 and 18 were prepared substantially as detailed in Example 7.
EXAMPLE 17 ##STR23## cis
Analysis for C 20 H 20 N 4 O 3 SF 2 : Calcd: C, 55.29; H, 4.64; N, 12.90; Found: C, 55.48; H, 4.54; N, 12.79.
1 H NMR (300 MHz, DMSO-d 6 ) δ 8.05 (d, J=5 Hz, 1H); 7.58-7.41 (m, 2H); 7.32-7.01 (m, 5H); 6.84 (dd, J=8,1 Hz, 1H); 6.20 (s, 1H); 3.83 (septet, J=7 Hz, 1H); 2.59 (d, J=5 Hz, 3H); 1.23 (d, J=7 Hz, 6H).
IR (CHCl 3 ): 3450, 2910, 1656, 1638, 1608, 1547, 1479, 1359 and 1273 cm -1 .
MS(FD): 434 (M + ).
UV/Vis (95% EtOH): λ max =300.0 nm (E=11012); 254.0 nm (E=22088).
trans
Analysis for C 20 H 20 N 4 O 3 SF 2 : Calcd: C, 55.29; H, 4.64; N, 12.90; Found: C, 55.53; H, 4.65; N, 12.96.
1 H NMR (300 MHz, DMSO-d 6 ) δ 8.13 (d, J=5 Hz, 1H); 7.42 (d, J=1 Hz, 1H); 7.40 (q, J=8 Hz, 1H); 7.22-7.13 (m, 4H); 7.05 (dd, J=8,1 Hz, 1H); 6.92 (d, J=8 Hz, 1H); 6.61 (s, 1H); 3.83 (septet, J=7 Hz, 1H); 2.59 (d, J=5 Hz, 3H); 1.25 (d, J=7 Hz, 6H).
IR (CHCl 3 ): 3401, 2992, 1662, 1638, 1603, 1546, 1478, 1359 and 1271 cm -1 .
MS(FD): 434 (M + ).
UV/Vis (95% EtOH): λ max =316.0 nm (E=19543); 244 nm (E=17677).
EXAMPLE 18 ##STR24## cis
Analysis for C 20 H 19 N 4 O 3 SF 3 : Calcd: C, 53.09; H, 4.23; N, 12.38; Found: C, 52.97; H, 4.38; N, 12.37.
1 H NMR (300 MHz, DMSO-d 6 ) δ 8.08 (m, 1H); 7.49 (s, 1H); 7.37 (m, 1H); 6.95-7.20 (m, 4H); 6.87 (d, 1H); 6.19 (s, 1H); 3.84 (septet, 1H); 2.58 (d, 3H) and 1.22 (d, 6H).
IR (CHCl 3 ): 2995, 1656, 1638, 1606, 1509 and 1474 cm -1 .
MS(FD): 452 (M + ).
UV/Vis (95% EtOH): λ max =311 nm (E=12010); 244 nm (E=19690).
trans
Analysis for C 20 H 19 N 4 O 3 SF 3 : Calcd: C, 53.09; H, 4.23; N, 12.38; Found: C, 53.31; H, 4.29; N, 12.50.
1 H NMR (300 MHz, DMSO-d 6 ) δ 8.18 (m, 1H); 7.49 (s, 1H); 7.29 (m, 1H); 7.18 (m, 3H); 6.98 (m, 2H); 6.61 (s, 1H); 3.87 (septet, 1H); 2.58 (d, 3H); 1.23 (d, 6H).
IR (CHCl 3 ): 3022, 1662, 1638, 1604, 1510, 1477 and 1040 cm -1 .
MS(FD): 452 (M + ).
UV/Vis (95% EtOH): λ max =317 nm (E=20108); 244 nm (E=18099).
The present compounds appear to inhibit replication of plus-strand viral RNA by interfering with the structure and/or function of the viral replication complex (a membrane-bound complex of viral and cellular proteins). Mutant rhinovirus and enterovirus have been isolated which demonstrate very low levels of drug tolerance. These mutants contain a single amino acid substitution in the protein that is expressed by the viral gene known as "3A". Therefore, the compounds of the present invention inhibit the rhinovirus and enterovirus by inhibiting a 3A function. The 3A gene encodes a hydrophobic protein which serves as the scaffolding protein that attaches the proteins of the replication complex to intracellular membranes.
The replicative strategy of flaviviruses such as hepatitis C virus (HCV) and bovine diarrheal virus (BVDVB) is similar to that of the rhinovirus and enterovirus, discussed above. In particular, both families of virus contain single-stranded, messenger-sense RNA that replicates in a cytoplasmic complex via a minus-strand RNA intermediate. In addition, both families of virus translate their genome into a polyprotein that is subsequently cleaved. Furthermore, the replication complexes of both viruses are tightly associated with intracellular membranes. Finally, both families of virus have analogous genomic structures including the presence of a 5' and 3' non-translated region which are required by the viruses for replication. There are two HCV proteins that have been implicated with this intracellular association: NS2 and NS4. It is postulated that either NS2 or NS4 is analogous to the picornavirus 3A protein.
Accordingly, another embodiment of the present invention is a method of treating or preventing a flavivirus infection comprising administering to a host in need thereof an effective amount of a compound of formula I or a pharmaceutically acceptable salt thereof. It is preferred to inhibit hepatitis C.
As noted above, the compounds of the present invention are useful as antiviral agents. They have shown inhibitory activity against various enterovirus and rhinovirus. An embodiment of the present invention is a method of treating or preventing picornaviridae infection comprising administering to a host in need thereof an effective amount of a compound of formula I or a pharmaceutically acceptable salt thereof.
The term "effective amount" as used herein, means an amount of a compound of formula I which is capable of inhibiting viral replication. The picornaviridae inhibition contemplated by the present method includes either therapeutic or prophylactic treatment, as appropriate. The specific dose of compound administered according to this invention to obtain therapeutic or prophylactic effects will, of course, be determined by the particular circumstances surrounding the case, including, for example, the compound administered, the route of administration, the condition being treated and the individual being treated. A typical daily dose will contain a dosage level of from about 0.01 mg/kg to about 50 mg/kg of body weight of an active compound of this invention. Preferred daily doses generally will be from about 0.05 mg/kg to about 20 mg/kg and ideally from about 0.1 mg/kg to about 10 mg/kg.
The compounds can be administered by a variety of routes including oral, rectal, transdermal, subcutaneous, intravenous, intramuscular and intranasal. The compounds of the present invention are preferably formulated prior to administration. Therefore, another embodiment of the present invention is a pharmaceutical formulation comprising an effective amount of a compound of formula I or a pharmaceutically acceptable salt thereof and a pharmaceutically acceptable carrier, diluent or excipient therefor.
The active ingredient in such formulations comprises from 0.1% to 99.9% by weight of the formulation. By "pharmaceutically acceptable" it is meant that the carrier, diluent or excipient is compatible with the other ingredients of the formulation and not deleterious to the recipient thereof.
The present pharmaceutical formulations are prepared by known procedures using well-known and readily available ingredients. In making the compositions of the present invention, the active ingredient will usually be admixed with a carrier, or diluted by a carrier, or enclosed within a carrier which may be in the form of a capsule, sachet, paper or other container. When the carrier serves as a diluent, it may be a solid, semi-solid or liquid material which acts as a vehicle, excipient or medium for the active ingredient. Thus, the compositions can be in the form of tablets, pills, powders, lozenges, sachets, cachets, elixirs, suspensions, emulsions, solutions, syrups, aerosols, (as a solid or in a liquid medium); ointments containing, for example, up to 10% by weight of the active compound, soft and hard gelatin capsules, suppositories, sterile injectable solutions, sterile packaged powders and the like.
The following formulation examples are illustrative only and are not intended to limit the scope of the invention in any way. The term "active ingredient" means a compound according to formula I or a pharmaceutically acceptable salt thereof.
Formulation 1
Hard gelatin capsules are prepared using the following ingredients:
______________________________________ Quantity (mg/capsule)______________________________________Active ingredient 250Starch, dried 200Magnesium stearate 10Total 460 mg______________________________________
Formulation 2
A tablet is prepared using the ingredients below:
______________________________________ Quantity (mg/capsule)______________________________________Active ingredient 250Cellulose, microcrystalline 400Silicon dioxide, fumed 10Stearic acid 5Total 665 mg______________________________________
The components are blended and compressed to form tablets each weighing 665 mg.
Formulation 3
An aerosol solution is prepared containing the following components:
______________________________________ Weight______________________________________Active ingredient 0.25Methanol 25.75Propellant 22(Chlorodifluoromethane) 70.00Total 100.00______________________________________
The active compound is mixed with ethanol and the mixture added to a portion of the propellant 22, cooled to 30° C. and transferred to a filling device. The required amount is then fed to a stainless steel container and diluted with the remainder of the propellant. The valve units are then fitted to the container.
Formulation 4
Tablets, each containing 60 mg of active ingredient, are made as follows:
______________________________________ Quantity (mg/tablet)______________________________________Active ingredient 60Starch 45Microcrystalline cellulose 35Polyvinylpyrrolidone 4(as 10% solution in water)Sodium carboxymethyl starch 4.5Magnesium stearate 0.5Talc 1Total 150______________________________________
The active ingredient, starch and cellulose are passed through a No. 45 mesh U.S. sieve and mixed thoroughly. The aqueous solution containing polyvinylpyrrolidone is mixed with the resultant powder, and the mixture then is passed through a No. 14 mesh U.S. sieve. The granules so produced are dried at 50° C. and passed through a No. 18 mesh U.S. sieve. The sodium carboxymethyl starch, magnesium stearate and talc, previously passed through a No. 60 mesh U.S. sieve, are then added to the granules which, after mixing, are compressed on a tablet machine to yield tablets each weighing 150 mg.
Formulation 5
Capsules, each containing 80 mg of active ingredient, are made as follows:
______________________________________ Quantity (mg/capsule)______________________________________Active ingredient 80 mgStarch 59 mgMicrocrystalline cellulose 59 mgMagnesium stearate 2 mgTotal 200 mg______________________________________
The active ingredient, cellulose, starch and magnesium stearate are blended, passed through a No. 45 mesh U.S. sieve, and filled into hard gelatin capsules in 200 mg quantities.
Formulation 6
Suppositories, each containing 225 mg of active ingredient, are made as follows:
______________________________________Active ingredient 225 mgSaturated fatty acid glycerides 2,000 mgTotal 2,225 mg______________________________________
The active ingredient is passed through a No. 60 mesh U.S. sieve and suspended in the saturated fatty acid glycerides previously melted using the minimum heat necessary. The mixture is then poured into a suppository mold of nominal 2 g capacity and allowed to cool.
Formulation 7
Suspensions, each containing 50 mg of active ingredient per 5 ml dose, are made as follows:
______________________________________Active ingredient 50 mgSodium carboxymethyl cellulose 50 mgSyrup 1.25 mlBenzoic acid solution 0.10 mlFlavor q.v.Color q.v.Purified water to total 5 ml______________________________________
The active ingredient is passed through a No. 45 mesh U.S. sieve and mixed with the sodium carboxymethyl cellulose and syrup to form a smooth paste. The benzoic acid solution, flavor and color are diluted with a portion of the water and added, with stirring. Sufficient water is then added to produce the required volume.
Formulation 8
An intravenous formulation may be prepared as follows:
______________________________________Active ingredient 100 mgIsotonic saline 1,000 ml______________________________________
The solution of the above ingredients generally is administered intravenously to a subject at a rate of 1 ml per minute.
The following experiment was carried out to demonstrate the ability of the compounds of formula I to inhibit certain virus.
Test Method for Anti-picornaviral Assay
African green monkey kidney cells (BSC-1) or Hela cells (5-3) were grown in 25 cc Falcon flasks at 37° C. in medium 199 with 5 percent inactivated fetal bovine serum (FBS); penicillin (150 units 1 ml) and streptomycin (150 micrograms per milliliter (μg/ml)). When confluent monolayers were formed, the supernatant growth medium was removed and 0.3 mL of an appropriate dilution of virus (echo, Mengo, Coxsackie, polio or rhinovirus) were added to each flask. After absorption for one hour at room temperature, the virus infected cell sheet was overlaid with a medium comprising one part of 1 percent Ionagar No. 2 and one part double strength Medium 199 with FBS, penicillin and streptomycin which contains drug at concentrations of 100, 50, 25, 12, 6, 3 and 0 μg/ml. The flask containing no drug served as the control for the test. The stock solutions of vinyl acetylene benzimidazole compounds were diluted with dimethylsulfoxide to a concentration of 10 4 μg/ml. The flasks were then incubated for 72 hours at 37° C. for polio, Coxsackie, echo and Mengo virus and 120 hours at 32° C. for rhinovirus. Virus plaques were seen in those areas were the virus infected and reproduced in the cells. A solution of 10 percent formalin and 2 percent sodium acetate was added to each flask to inactivate the virus and fix the cell sheet to the surface of the flask. The virus plaques, irrespective of size, were counted after staining the surrounding cell areas with crystal violet. The plaque count was compared to the control count at each drug concentration. The activity of the test compound was expressed as percentage plaque reduction, or percent inhibition. Alternatively, the drug concentration which inhibits plaque formation by 50 percent can be used as a measure of activity. The 50 percent inhibition is indicated by the symbol IC50.
In vitro CPE/XTT anti-BVDV Assay
MDBK cells were dispersed in the 96-wells microtiter plate at 10,000 cells per well with Minimum Essential Medium containing Earl's balanced salt solution (EBSS), 2% horse serum, penicillin (100 units/ml) and streptomycin (100 μg/ml). Plates were grown at 37° C. CO 2 incubator overnight. The MDBK cells were then infected with .sup.˜ 0.02 moi (multiplicity of infection) of bovine viral diarrhea virus (BVDV, ATCC VR-534). After allowing the virus to adsorb to the cells for 1-2 hours, medium containing serial dilutions of drug or medium alone was added to the wells. After further incubating for 3-4 days (when extensive cpe was apparent in medium alone wells), the antiviral effect of testing drugs were assessed by performing a XTT assay as described below.
XTT 2,3-bis(methoxy-4-nitro-5-sulfophenyl)-2H-tetraazolium-5-carboxanilide, inner salt, sodium salt! at 1 mg/ml for warm medium without FBS were freshly prepared and used immediately. For each 5 ml of the XTT solution, 25 μl of 5 mM of PMS (phenazine methosulfate) in phosphate buffer saline was added. Then 50 μl of the freshly prepared XTT/PMS mixture was added to each of the microtiter wells. Incubate at 37° C. (CO 2 ) for 3-4 hours or until color change is prominent. Read absorptance at 450 nm/ref. 650 nm in a spectrophotometer. The concentration of drug required to cause 50% cytotoxic effect as compared to the no drug no virus control (TC 50 ) and which to inhibit the development of virus cytopathic effect (cpe) by 50% (IC 50 ) was then determined from the liner portion of each dose response curve.
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The present application provides a series of benzimidazole compounds which inhibit the growth of picornaviruses, such as rhinoviruses, enteroviruses, polioviruses, coxsackieviruses of the A and B groups, echo virus and Mengo virus and flaviviruses such as hepatitis C and bovine diarrheal virus.
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BACKGROUND THE INVENTION
This invention relates to water crafts and particularly to sailboats having keel structures for improving the lateral stability of the sailboats when pointing the sailboats. The lateral stability provided by the keel structure enables a sailboat to better hold its course.
The keel structure includes a keel member and a wing member attached thereto. In one embodiment the keel member is slidably attached to the sailboat, and the wing member is fixed to the keel member. In a second embodiment the keel member is pivotally attached to the sailboat, and the wing member is pivotally attached to the keel member.
Keels are commonly provided on the bottom of sailboats to add stability to the sailboats by preventing the sailboats from heeling. Larger sailboats have been provided with fixed keels, while smaller sailboats have been provided with vertically moveable keels or dagger boards. While these fixed keels and dagger boards do increase the stability of the sailboats to which they are attached, the stability is not always sufficient to allow these sailboats to hold their course when pointing, and especially when pointing high, i.e. sailing close to the wind. Additionally, because of the fixed keels of the larger sailboats, these sailboats cannot be sailed in shallow water. Also, in deeper water the size of the fixed keels limits the speed of the sailboats. Whether sailing for recreational purposes or competitive purposes, the most enjoyment can be obtained when the sailboat is stable and versatile, such that it can be controlled as desired by its captain in changing water depths and wind conditions.
OBJECTS OF THE INVENTION
It is a primary object of the invention to improve the lateral stability of a sailboat when pointing the sailboat.
It is another object of the invention to enable a sailboat to easily be sailed in shallow water.
It is a further object of the invention to enable a sailboat to be sailed in deeper water at increased speeds.
SUMMARY OF THE INVENTION
The water craft of the present invention is preferably a sailboat provided with a wing keel. In a first embodiment of the invention the wing keel comprises a keel member that is pivotally attached to the bottom of the sailboat, and a wing member that is pivotally attached to the bottom of the keel member. As the sailboat is being sailed the force of the water will pivot the keel member towards the bottom of the sailboat, and also pivot the wing member such that it is generally parallel to the water surface. When the wing member pivots such that it is generally parallel to the water surface, a greater generally horizontal surface area is presented to the water, whereby the sailboat is provided with enhanced stability in all water depths and wind conditions while performing sailing maneuvers, such as pointing. Also, because the keel member pivots towards the bottom of the sailboat the draft is reduced, whereby the sailboat can be sailed in shallow water. This reduced draft also enables the sailboat to be sailed at greater speeds in deeper water.
In a second embodiment of the invention the sailboat includes a vertically adjustable keel member having a wing member fixed to the bottom thereof. The wing member is fixed to the bottom of the keel member such that the wing member extends generally parallel to the water surface during sailing of the sailboat, whereby stability of the sailboat is improved as with the first embodiment. And, because the keel member is vertically adjustable the draft can be reduced, whereby the sailboat can be sailed in shallow water and can also be sailed in deeper water at a greater speed, like in the first embodiment
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the keel of the first embodiment of the invention.
FIG. 2 is a plan view of a wing member of the keel of the first embodiment of the invention.
FIG. 3 is a plan view of an alternative wing member of the keel of the first embodiment of the invention.
FIG. 4 a is a schematic side view of a sailing water craft having the keel of the first embodiment of the invention attached thereto.
FIG. 4 b is a view similar to that of FIG. 4 a , but showing a different position of the keel.
FIG. 4 c is a view similar to that of FIG. 4 a , but showing another different position of the keel.
FIG. 5 a is a front view of the water craft shown in FIG. 4 c.
FIG. 5 b is a front view of the water craft as shown in FIG. 4 a.
FIG. 6 is a schematic view showing a keel and water craft in accordance with a second embodiment of the invention.
FIG. 7 is a figure similar to FIG. 6 but showing the keel in its retracted condition.
FIG. 8 a is a front view of the water craft as shown in FIG. 6 .
FIG. 8 b is a front view of the water craft as shown in FIG. 7 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown a keel 20 , having a keel member 1 and a wing member 2 . The keel member 1 is pivotally attachable to the bottom of a water craft or sailboat by passing a pivot pin through hole 4 and corresponding portions of the sailboat (not shown). The wing member 2 is pivotally attached to the keel member 1 as generally shown at 3 by passing a hinge pin 6 of the wing member 2 , as shown in FIG. 2, through a hole in protrusion 8 of the keel member 1 . The wing member 2 projects laterally from both sides of the keel member 1 .
Referring to FIG. 2, the wing member 2 of this specific embodiment comprises a member having a first surface defined by two intersecting planes, a second opposite surface, and two side surfaces that interconnect the first surface with the second surface. The wing member 2 can have a cross-sectional shape that tapers from the first surface towards the second surface. In the first surface there is provided a recess 7 , and spanning this recess is the hinge pin 6 . The hinge pin 6 is received within the opening of the protrusion 8 such that the recess 7 receives the protrusion 8 . When the wing member 2 is subjected to a fluid flow it pivots relative to the keel member 1 . Accordingly, during sailing of the sailboat the wing member 2 attains a generally horizontal or parallel position relative to the water surface, with the first surface defining a leading edge of the wing member 2 . This generally horizontal or parallel position will be attained irrespective of the orientation of the keel member 1 relative to the sailboat, as shown in FIGS. 4 a - 4 c , that depict a sailboat while being sailed. During sailing, the force of the water flowing past the keel will pivot the keel member 1 towards the bottom of the boat, and will also pivot the wing member 2 such that it becomes oriented generally parallel to the water surface or the bottom of the sailboat 9 as explained previously. When not subjected to a fluid flow, the wing member 2 is allowed to pivot away from this generally horizontal or parallel orientation.
Because the wing member 2 attains a generally horizontal orientation during sailing of the sailboat 9 , a greater surface area is presented to the water which enhances the stability of the sailboat 9 in any water depth and wind condition. This enhanced stability enables the sailboat to hold its course when pointing, and especially when pointing high, i.e. sailing close to the wind.
FIG. 3 shows an alternative embodiment or shape of the wing member. In the specific embodiment of FIG. 3, wing member 2 ′ has its first surface defined by a single plane as opposed to the two intersecting planes of wing member 2 as depicted in FIG. 2 . Like wing member 2 , wing member 2 ′ has a recess 7 ′ and a hinge pin 6 ′. Hinge pin 6 ′ is received in the opening in the protrusion 8 of the keel member 1 such that wing member 2 ′ pivots relative to keel member 1 , as does wing member 2 described above. Accordingly, wing member 2 ′ attains a generally horizontal or parallel position relative to the bottom of the sailboat during sailing of the sailboat, regardless of the position of keel member 1 relative to the bottom of the sailboat. As such, the enhanced stability as discussed above is also realized for wing member 2 ′.
As explained above, because the wing member 2 , 2 ′ attains a generally horizontal or parallel position relative to the bottom of the sailboat, stability of the sailboat is improved during the sailing thereof. Furthermore, because the keel member 1 pivots relative to the bottom of the sailboat during sailing thereof, the speed at which the sailboat 9 sails can be increased due to the reduced draft. This reduced draft also allows the sailboat to be sailed in shallow water. Additionally, because the wing member 2 , 2 ′ attains a generally horizontal or parallel position relative to the bottom of the sailboat and the water surface, additional lift can be generated, which also can increase the speed of the sailboat.
Should the water depth or speed of the sailboat not be a factor, then the keel can be locked in the position shown in FIG. 4 a . In this regard, the keel member 1 is provided with an opening 5 , which opening receives a pin 10 that cooperates with the sailboat 9 to lock the keel member 1 in the position shown in FIG. 4 a . Because the draft in this arrangement is maximized, the speed of the sailboat is less than it could be were the pin 10 removed and the keel member 1 allowed to freely pivot as shown in FIGS. 4 b and 4 c . On the other hand, this increased draft further enhances the stability of the sailboat.
Referring to FIG. 6, there is shown a second embodiment of the invention. In FIG. 6 is shown a keel 30 that is slidably attached to the sailboat. This keel 30 includes a keel member 1 ′ and a fixed wing member 2 ″ projecting laterally therefrom. The bottom of the sailboat 9 ′ is provided with an opening that receives the keel member 1 ′. The keel member 1 ′ can be locked in its lowest position as shown in FIG. 6 by passing a rope or strap 12 through a hole 11 provided in a top portion of the keel member 1 ′, and then tying or otherwise securing the rope or strap to a cleat or other fastening structure carried by the sailboat. When sailing in deeper water, and when speed of the sailboat is not an issue, locking the keel 30 in this lowest position will provide the greatest stability of the sailboat.
The wing member 2 ″ of the specific embodiment of FIG. 6 is oriented generally orthogonal to the keel member 1 ′. Accordingly, the wing member 2 ″ is oriented generally parallel or horizontal relative to the bottom of the sailboat or the water surface, during sailing of the sailboat. Thus, as explained with regard to the first embodiment, this orientation enhances the stability of the sailboat.
When desiring to increase the speed of the sailboat, or when sailing in shallow water, the keel 30 can be raised to its upper most position as shown in FIG. 7 . In this regard, the rope or strap 12 is untied or removed from the cleat 13 such that the keel member 1 ′ can be raised to its upper most position.
In each embodiment, the keel member and wing member can be fiberglass, foam surrounded by fiberglass, or any other suitable material.
While preferred embodiments of this invention have been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined in the appended claims.
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This invention pertains to a retractable wing keel for sailboats. A keel member is movably attached to the bottom of the sailboat, and a wing member is attached to the bottom of the keel member. In a first embodiment, the keel member is pivotally attached to the bottom of the sailboat and the wing member is pivotally attached to the bottom of the keel member. In a second embodiment, the keel member is slidably attached to the bottom of the sailboat and the wing member is fixedly attached to the bottom of the keel member.
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BACKGROUND OF THE INVENTION
The present invention relates to a new and improved construction of apparatus for monitoring yarn travel at a multiple spindle spinning machine equipped with a suction device servicing at least one group of the spindles, a probe being arranged in a collecting channel of the suction device, this probe, upon passage therepast of fiber flocks or the like delivering an electrical signal to an evaluation circuit. The evaluation circuit contains a periodically resettable signal counter having a pre-set counter value or state, the evaluation circuit being operatively coupled with an alarm device.
Now in German Pat. No. 1,685,885, and equally in the earlier German patent publication 26 43 453 there is disclosed for instance such general construction of monitoring device. With this state-of-the-art equipment there are described special measures in order that there is infed to the evaluation circuit with the greatest probability only such signals which, in fact, are predicated only upon fiber flocks which move through the collecting channel. Fiber flocks which travel in the suction channel however, in turn, are an indicia that an irregular operating state prevails at the monitored spinning machine, for instance that there has arisen rupture of a yarn or roving. With the prior art equipment there is thus not directly detected the presence or absence of an intact yarn at the spindles. Rather, based upon the material existing within the suction device a decision is reached as to the operating state of the spinning machine. Equipment of this type therefore basically is different from other, likewise prior art equipment, for instance of the type disclosed in German Pat. No. 1,907,990 or German patent publication 22 62 425, wherein by means of stationary or migrating monitoring elements there is directly detected the presence or absence, as the case may be of intact yarn at the spindles.
With the previously mentioned prior art monitoring apparatus the periodically resettable signal counter triggers the alarm device then if during one or two successive counting periods the counter value which has been pre-set at the counter has been reached or exceeded. This pre-set counter value allows determinations to be made regarding the number of yarn ruptures which have occurred. This is so because each yarn rupture--depending upon the quality and nature of the roving or the like processed at the spinning machine and as long as the spinning machine continues to operate--serves to form a sequence of timewise successive fiber flocks which are produced due to the disintegration of the still infed roving, and the recurrence within a certain time period, i.e., so-to-speak the "frequency" of the moving flocks is within comparatively narrow limits for each yarn rupture. The greater the number of yarn ruptures which have occurred that much greater is the recurrence or frequency (per counting period) of the flocks which are moving past.
As already mentioned, with the state-of-the-art monitoring device the alarm device is then first triggered, for instance for calling an operator or for turning-off the machine, when this recurrence exceeds a predetermined value, namely the counter value set at the signal counter. The system is designed with the view of first then undertaking corrective measures during the operation of the machine if, based upon the detected number of fiber flocks which move past, there can be determined such a number of yarn ruptures that the economies of further operating the spinning machine when these conditions have arisen becomes questionable. If, however, the operator takes corrective action and eliminates the yarn rupture at the spindles which require servicing during the further operation of the spinning machine, the prior art equipment does not afford for the operator any indication as to when the servicing and corrective work has progressed to an extent such that an economical further operation of the machine can be again carried out notwithstanding possibly still uncorrected yarn ruptures or yarn ruptures which have newly arisen in the meantime.
This is especially then disdadvantageous if, as is presently oftentimes the case, a single operator is responsible for the monitoring of an entire series of spinning machines. In such case the operator is not informed that the servicing or corrective work at the one spinning machine has sufficiently been accomplished so that he can discontinue his or her efforts and proceed to pay attention to a further spinning machine where likewise there has been triggered the alarm device.
Additionally, the prior art equipment is not capable of detecting all of the operating conditions which are desirable for the operator to take corrective action. For instance if per chance a yarn rupture arises at only a few spindles, at the remaining spindles however no such yarn rupture occur, then it is quite possible that this operating state can continue for a limited period of time. Since the prior art equipment only however detects the recurrence or frequency of the flocks per counting period, the flocks which are produced by the few yarn ruptures are not even capable of attaining the recurrence threshold needed for triggering the alarm device, even if the machine remains in operation over a longer period of time.
SUMMARY OF THE INVENTION
Hence, with the foregoing in mind it is a primary object of the present invention to provide an improved apparatus for monitoring yarn travel at a multiple spindle spinning machine in a manner which is not associated with the aforementioned drawbacks and limitations of the prior art proposals.
Another and more specific object of the present invention aims at the provision of a new and improved construction of apparatus of the previously mentioned type which not only more exactly monitors the operating condition or state of the spinning machine, but also is capable of indicating to the operator responsible for the maintenance when the momentary state of the maintenance or corrective work allows for the further economical operation of the spinning machine, even then if not all of the yarn ruptures have been eliminated.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the proposed apparatus of the present development is manifested by the features that the alarm device can be switched-in by means of a further, cumulative counter with a higher, pre-set counter value, and this cumulative counter is coupled by means of a logic circuit with the periodically resettable signal counter in such a manner that the cumulative counter is reset whenever there is an absence of one or two signals at the signal counter.
With the proposed equipment the alarm device is thus triggered by the further cumulative counter having a higher preset counter value, which counter, however, is not periodically reset. On the other hand, the periodically resettable signal counter serves in the first instance to reset the cumulative counter and, thus, also to turn-off the alarm device.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a block circuit diagram of a preferred exemplary embodiment of apparatus for monitoring yarn travel at a multiple spindle spinning machine and constructed according to the teachings of the present invention; and
FIG. 2 is a diagram showing different signal curves during operation of the apparatus according to the showing of FIG. 1 at certain locations of the circuitry thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, with the apparatus 10 shown by way of example in FIG. 1 there will be recognized a merely schematically illustrated collecting channel or duct 11 of a conventional suction device, schematically generally indicated by reference character 100 in FIG. 1, of a spinning machine (not shown). Within the collecting channel or duct 11 there is arranged a probe or sensor 12 which is coupled by means of a coupling capacitor 13 to a digitizing discriminator stage 14. The discriminator stage 14 can be constructed, in principle, in the manner disclosed in the aforementioned German patent publication 26 43 453, to which reference may be readily had and the disclosure of which is incorporated herein by reference, and can comprise, for instance, an impedance converter 15, an amplifier 16, a filter element 17 and an amplitude discriminator 18. At the output 19 of the discriminator stage 14 there appears for each fiber flock which moves in the direction of the arrow 20 in the collecting channel or duct 11 a digital pulse of a predetermined duration, for instance of several μs.
The discriminator stage-output 19 is connected both with the counter input 21 of a cumulative counter or adder 22 and with the counter input 23 of a signal counter 24. The counter 22 which has, for instance, four or five counter decades is operatively connected with an adjustment or setting device 25 by means of which there can be pre-set a given counter value, for instance between 40,000 and 50,000 at the counter 22. The signal counter 24 which can possess, for instance, two or three counter decades, is likewise connected to a suitable adjustment or setting device 26. The reset input 27 of the signal counter 24 is connected with the output 28 of a clock generator 29, which, in turn, can contain an oscillator 30, a frequency divider 31 and a monostable multivibrator or a monoflop 32. The clock generator 29 thus, for instance, produces one pulse every ten seconds, which therefore periodically resets the signal counter 24 by means of the reset input 27. The signal counter 24 can be equipped with a display device 33 which displays the counter state attained at the moment of resetting the counter 24 during the following counting period.
Both the counter 22 as well as also the signal counter 24 deliver at their respective outputs 34 and 44 a signal as soon as and as long as their counter state has reached or exceeded the counter value which has been pre-set at the adjustment or setting devices 25 and 26 respectively.
The output 34 of the counter 22 is connected with the input 35 of a monoflop 36, whose output 36a is connected by means of a line 37 with the set or pre-set input 38 of a bistable multivibrator or RS-flip-flop 39. At the output 40 of this RS-flip-flop 39 there is connected by means of a line or conductor a an alarm device 41, which, in turn, can comprise a relay 42 and an optical or acoustical display or indicator element 43.
From what has been discussed above it will be apparent that if there is only considered the full-line illustrated circuit elements of FIG. 1, then the alarm device 41 will be triggered as soon as there has been reached at the counter 22 the relevant, pre-set counter value, and specifically, initially independent of whether or not there has been delivered a signal by the signal counter 24.
Both the counter 22 as well as also the RS-flip-flop 39 each possess a reset input 45 and 46, respectively, which are connected in parallel with a line or conductor k constituting the output of a logic circuit 47 shown within the phantom line block.
The inputs of this logic circuit 47 are formed by the lines a, b and c, which, in turn, are connected with the output 40 of the RS-flip-flop 39, with the output 44 of the signal counter 24 and with the output 28 of the clock generator 29.
The line b leads to a monostable multivibrator 48 which responds without delay and flops over with delay. The multivibrator 48 thus delivers a signal at its output line or conductor d whenever and as long as a signal from the signal counter 24 appears and after its disappearance still during its flop over time. The lines a and d are connected with the inputs 49a and 49b, respectively, of a first AND-gate 49, the output e of which is directly connected with the one input 50a of a second AND-gate 50 and by means of an inversion element 51 and the line or conductor f is connected with the one input 52a of a third AND-gate 52. The other inputs 50b and 52b of the AND-gates 50 and 52, respectively, are directly connected with the line or conductor c, i.e., with the output 28 of the clock generator 29.
The output of the AND-gate 52 has been designated by reference character g and is connected with the set or pre-set input 53 of a RS-flip-flop 54, whereas the output h of the AND-gate 50 is connected with the reset input 55 of such RS-flip-flop 54. The output i of this flip-flop 54 is connected with the input 56a of a monoflop 56 having a certain flop over time and responsive to ascending signal flanks or edges. The output of the monoflop 56 constitutes the output k of the logic circuit 47.
Now based upon the graphs shown in FIG. 2 there will be explained the function of the circuitry portrayed in FIG. 1 to the extent that there is only considered at this time the circuit components illustrated with full lines. Now in FIG. 2 there have been illustrated along the lines a to k of the graphs the signal trains which appear at the lines or conductors designated by the corresponding reference characters in FIG. 1. These lines are subdivided into counting periods which have been designated by 1 to 6, n-2, n-1, n and n+1 and n+2. The counting periods are limited by the pulses of the clock generator 29 (line c) and amount to, for instance, 10 seconds.
There will be seen from FIG. 2, line b, that the signal counter 24 first reaches its pre-set value or state during the counting period 1 and thus delivers a logic "1"-signal which then again disappears during the next following reset pulse (line c). On the other hand, the counter 22 has not yet reached its pre-set counter value, so that the alarm device 41 initially is not yet triggered and the AND-gate 49 still remains blocked or non-conductive, and the signals (line d) delivered by the monostable multivibrator 48 are not switched-through. During the counting period 5 the counter state of the counter 22 attains its pre-set value and the RS-flip-flop 39 switches-through i.e., becomes conductive, so that there appears at the conductor a (line a of FIG. 2) a logic "1"-signal, which, in turn, triggers the alarm device 41, and, furthermore prevails as long as there is not delivered a reset pulse to the RS-flip-flop 39.
Now there is also switched-through to the AND-gate 49 the signals appearing at the line d, as has been illustrated by the line e of the graph of FIG. 2. Due to the delayed flop over of the monostable multivibrator 48 there appears during the duration of each logic "1"-signal at the line or conductor d and therefore also at the line e a clock pulse, so that these clock pulses only then appear at the output h of the AND-gate 50 (line h of the graph of FIG. 2) when there simultaneously appears at its input 50a i.e., the line or conductor e also a logic "1"-signal or pulse (line e of the graph of FIG. 2).
As long as there does not appear any signal at the output of the logic gate 49, the inversion element 51 delivers a logic "1"-signal and vice versa (line f of the graph of FIG. 2). The AND-gate 52 thus switches-through all of the clock pulses appearing at its input 52b i.e., the line or conductor c to its output g (line g of the graph of FIG. 2), which, in turn, insures that the RS-flip-flop 54 remains switched-through or conductive for such length of time as there does not appear at the line e a logic "1"-signal. This has been illustrated in line i of the graph of FIG. 2. As soon as however there appears at the line e a logic "1"-signal, then the AND-gate 52, by virtue of the inversion element 51, blocks the incoming clock pulses, whereas the clock pulses (line h, end of the counting period 5) appearing at the output of the AND-gate 50 reset the RS-flip-flop 54. This condition prevails for such length of time as the signal counter 24 reaches, during the counting periods dictated by the clock generator 29, the pre-set value, i.e., as long as the frequency or recurrence of the flocks which move past the probe or center 12 constitute an indication that the corrective or servicing work has not yet reached an operating state of the machine which allows for an economical further operation of the monitored spindles of the spinning machine. During further progression of the corrective or repair work of course such flock frequency or recurrence decreases, so that the value pre-set at the signal counter 24 increasingly is reached towards the end of a counting period. This leads to the appearance at the line b of signals of progressively shorter duration, as such has been illustrated in line b of the graph of FIG. 2, counting periods (n-2) and (n-1). It is now assumed that at the end of the counting period n the signal counter 24 no longer reaches the pre-set counter value, so that the corresponding signal at the line b and therefore also at the lines d and e disappears. As a result, the AND-gate 52 (by virtue of the inversion element 51) becomes conductive and the clock pulse (line c of the graph of FIG. 2) appearing at the end of the counting period n is switched-through by the AND-gate 52 to the line or conductor g, with the result that the RS-flip-flop 54 is again switched-through, i.e, at its output the signal state flips over from the logic signal "0" to the logic signal "1". Since the monoflop 56 only responds to ascending signal flanks or edges, there now appears at its output a signal (line k of the graph of FIG. 2) which by means of the line k resets both the counter 22 as well as also the RS-flip-flop 39. The counter 22 may have attained in the meantime a state which far exceeds the pre-set value, which possibly exceeds the inherent counter capacity. However, this is irrelevant because there appears at the output of the RS-flip-flop 39 a logic "1"-signal for such time as there is not delivered to the flip-flop 39 any reset signal.
In certain situations it may be desired that for triggering the alarm device 41 there not only be fulfilled the condition that the counter 22 has reached the counter value which has been pre-set thereat, rather also the additional condition that the signal counter 24 delivers a signal. In other words: the alarm should be triggered if, on the one hand, there has been reached the absolute value of the flocks detected by the probe or sensor 12 since the last resetting of the counter 22, and, on the other hand, the frequency or recurrence of the flocks appearing during a counting period has exceeded the value pre-set at the signal counter 24. This can be simply accomplished by virtue of the fact that the input 35 of the monoflop 36 is not directly connected with the output 34 of the counter 22, rather with the output 57a of an AND-gate 57 shown in phantom lines in FIG. 1, the inputs 57b and 57c of which are connected with the output 34 of the counter 22 and with the output 44 of the signal counter 24, respectively. The only change which would then arise for the signal train or sequence shown in the graphic illustrations of FIG. 2 would be a delay in the triggering of the alarm device 41 in the counting period 5 as has been shown in line a of the graph of FIG. 2 by the broken lines.
Equally, it may be desired that the resetting of the counter 22 and the alarm device 41 is not accomplished during the first absence of a signal at the counter 24, rather upon the absence of such signal during two successive counting periods. This can be accomplished, by way of example, by augmenting the logic circuit 47 within the broken line block in that the line or conductor g also is connected with the set or pre-set input 58 of a RS-flip-flop 59 having delayed switching-through action and that the output of the monoflop 56 is connected with the reset input 60 of such flip-flop 59. The output 59a of this flip-flop 59 is connected with a further monoflop 61 responsive to ascending edges or flanks, and the output 61a of such monoflop 61 is connected with the reset inputs 45 and 46 of the counter 22 and the RS-flip-flop 39, respectively. In this case the reset pulse first appears at the end of the counting period n+1.
Finally, it is to be mentioned that the counter 22 as well as the alarm device 41 can be connected with a service hour counter 62 having a printer (not shown) where there can be recorded the frequency and the duration of the alarm conditions.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. ACCORDINGLY,
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An apparatus for monitoring yarn travel at a multiple spindle spinning machine which is equipped with a suction device servicing at least one group of the spindles. In a collecting channel of the suction device there is arranged a probe which upon passage therepast of fiber flocks or the like delivers an electrical signal to an evaluation circuit equipped with a periodically resettable signal counter having pre-settable counter value and an alarm device. The alarm device can be switched-in by means of a further cumulative counter with a higher, pre-set counter value. This further cumulative counter is coupled by means of a logic circuit with the periodically resettable signal counter in such a manner that the cumulative counter is reset whenever there is missing once or twice a signal from the periodically resettable signal counter.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of and claims priority to U.S. patent application Ser. No. 10/628,129, filed Jul. 24, 2003.
BACKGROUND
[0002] Lithography is used in the fabrication of semiconductor devices. In lithography, a light-sensitive material, called a “photoresist”, coats a wafer substrate, such as silicon. The photoresist may be exposed to light reflected from a mask to reproduce an image of the mask that is used to define a pattern on the wafer. When the wafer and mask are illuminated, the photoresist undergoes chemical reactions and is then developed to produce a replicated pattern of the mask on the wafer.
[0003] Extreme Ultraviolet (EUV) a promising future lithography techniques. EUV light may be produced using a small, hot plasma which will efficiently radiate at a desired wavelength, e.g., in a range of from 11 nm to 15 nm. The plasma may be created in a vacuum chamber, typically by driving a pulsed electrical discharge through the target material, or by focusing a pulsed laser beam onto the target material. The light produced by the plasma is then collected by nearby mirrors and sent downstream to the rest of the lithography tool.
[0004] The hot plasma tends to erode materials nearby, e.g., the electrodes in electric-discharge sources or components of the gas delivery system in laser-produced plasmas. The eroded material may coat the collector optics, resulting in a loss of reflectivity and reducing the amount of light available for lithography.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 shows a lithography system according to an embodiment of the invention.
[0006] FIG. 2 shows components in a light source chamber according to an embodiment of the invention.
[0007] FIG. 3 shows components in a light source chamber according to an alternative embodiment of the invention.
DETAILED DESCRIPTION
[0008] FIG. 1 shows a lithography system 100 . A wafer, coated with a light sensitive coating, and a mask are placed in a lithography chamber 105 . The pressure in the lithography chamber may be reduced to a near vacuum environment by vacuum pumps 110 . A light source chamber 115 , which houses a light source, is connected to the lithography chamber 105 . The pressure in the light source chamber may also be reduced to a near vacuum environment by the vacuum pumps 110 . The light source chamber and lithography chamber may be separated by a valve 120 which may be used to isolate the chambers. This allows for different environments within the different chambers.
[0009] The light source chamber 115 may be an EUV chamber, which houses an EUV light source. A power supply 125 is connected to the EUV chamber to supply energy for creating an EUV photon emitting plasma, which provides EUV light for lithography. The EUV light may have a wavelength in a range of 11 nm to 15 nm, e.g., 13.5 nm. The source may be a plasma light source, e.g., a laser plasma source or a pinch plasma source. Plasma-producing components, e.g., electrodes, in the EUV source may excite a gas, e.g., Xenon, to produce EUV radiation. The EUV chamber may be evacuated by the vacuum pumps 110 .
[0010] FIG. 2 shows components in a light source chamber according to an embodiment of the invention. The light source 205 and collector mirrors 210 for collecting and directing the light for use in the lithography chamber 105 are inside the EUV chamber.
[0011] Tungsten (W) or other refractory metal or alloy of same may be used for components in the EUV source because it is relatively resistant to plasma erosion. However, plasma-erosion may still occur, and the debris produced by the erosion may be deposited on the collector mirrors 210 . Debris may be produced from other sources, e.g., the walls of the chamber. Debris particles may coat the collector mirrors, resulting in a loss of reflectivity. Fast atoms produced by the electric discharge (e.g., Xe, Li, Sn, or In) may sputter away part of the collector mirror surfaces, further reducing reflectivity.
[0012] Debris-contaminant “foil traps”, e.g., foil elements in a collimator-type geometry 215 , may be positioned between the source 205 and the collector mirrors 210 . The foil elements may be small, thin foils spaced apart from each other by, e.g., 1 mm and spaced apart from the source by, e.g., 10-20 mm. Typically, the debris particles travel in a jagged path characteristic of Brownian motion. This path makes the debris particles susceptible to striking, and being captured by, the foil traps.
[0013] In an embodiment, a relatively low-energy secondary plasma 220 may be created between the EUV source 205 and the foil traps 215 . The secondary plasma may ionize debris particles and Xenon atoms. Electrical and magnetic forces may then be provided to effect the motion of the particles more strongly toward the foil traps. An electric field which produces such forces may be created by, e.g., alternating the potential of the foil traps themselves. The ionized Xenon atoms and debris particles are drawn to the foil traps. As a result, less debris reaches collector mirrors.
[0014] Typically, the gas densities in the EUV chamber are high enough that even though debris particles may be initially charged when created near the source plasma, many quickly become neutralized.
[0015] A plasma source may be used to generate the secondary plasma 220 . For example, in the embodiment shown in FIG. 2 , an antenna (e.g., a coil) 225 , with a radio frequency (RF) power supply 150 ( FIG. 1 ) to supply power to the coil. Other plasma sources may include, e.g., a helicon or ECR plasma source, DC glow discharge, or capacitive plate system.
[0016] The plasma source may include “Faraday shields” 250 or other means to lessen the voltage on the coil itself, thereby minimizing sputtering of the coil.
[0017] The timing to create the secondary plasma and ionize the particles may be very short, e.g., on the order of tens of microseconds. High volume manufacturing (HVM) source repetition rates may be of the order of 10 Khz, which is a period of 100 μs, with an individual pulse event lasting less than 1 μs. Thus more than 99 microseconds may be available between pulses to produce the secondary plasma. The secondary plasma may be triggered to occur between source pulses, minimizing interference with the source discharge. In some embodiments, this may not be necessary. For example, in an embodiment the secondary plasma may be left on during and between source pulses.
[0018] A pressure gradient may be established on either side of the foil trap to allow for a high gas pressure on the source side, to help stop debris, and a lower pressure on the collector side, to minimize absorption of EUV. In an embodiment, the foil trap geometry, inlet gas flow, and vacuum pumping may be chosen to optimize the post-collector pressure for the RF plasma, while still maintaining a minimal amount of EUV absorption.
[0019] In an embodiment, the coil 225 may be operated at an overall DC bias to produce an axial magnetic field. This may deflect the path of an ion or debris particle so that it travels in a generally circular or spiral path, making it more likely to strike the plates of the foil trap. This may be especially useful when operating the source in a low-pressure environment, where debris particles are less likely to be deflected by the background gas.
[0020] As shown in FIG. 3 , an additional (secondary) coil 300 may be positioned immediately after the foil trap to re-ionize any debris that makes it through the trap or that is re-emitted by the trap. An additional foil trap 305 may be positioned between the secondary coil 300 and the collector mirrors to trap the re-ionized and re-emitted debris.
[0021] In an embodiment, the electrode surface may be coated with a material that is easily ionizable. For example, a tungsten electrode may be coated with an alkali metal coating, e.g., cesium (Cs). More of the cesium debris particles may become ionized than would tungsten debris particles, and hence more of the cesium debris particles may be captured by the foil traps.
[0022] The electrode surface may be coated with a material that is easily ablated. This may assist in the cooling of the electrode, as heat energy would be carried away by the vaporization of the material. Again, alkali metal coatings, e.g., cesium, may be used.
[0023] The elements of the foil trap itself may be operated in a miniature plasma mode, either as a DC or at an RF potential driven by a power supply to produce a secondary plasma for ionizing debris particles. This would serve to both ionize particles as well as to draw them to a plate in the foil trap.
[0024] The plasma debris mitigation technique may be applied to other uses where debris needs to be blocked from a discharge-produced plasma device, e.g., lithography using wavelengths besides EUV and other areas where a high current is driven through electrodes in a vacuum and the resultant debris needs to be blocked.
[0025] A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, the ionization might be assisted by a laser pulse focused onto the region to be ionized. Accordingly, other embodiments are within the scope of the following claims.
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A light source chamber in an Extreme Ultraviolet (EUV) lithography system may include a secondary plasma to ionize debris particles created by the light source and a foil trap to trap the ionize particles to avoid contamination of the collector optics in the chamber.
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BACKGROUND OF THE INVENTION
The present invention relates to a new grain-oriented magnetic steel sheet with an electrically insulating coating which is applied after final annealing in order to ensure electrical insulation of the individual layers of sheet, for use of the grain-oriented magnetic steel sheet e.g. in transformers. The invention also relates to a method for producing the grain-oriented magnetic steel sheet with an electrically insulating coating.
For further use, e.g. in transformers, it is important to reduce the hysteresis loss. One measure for this which is frequently used is to add by alloying silicon which results in an increase in the specific electrical resistance and thus in a reduction in eddy-current losses. By means of modifications in the chemical composition and the cold-rolling and annealing processes, crystal orientation {110} <001> is set and enhanced. By means of a reduction in the thickness of the sheet, the loss is further improved. Moreover, by improving the purity of the steel, it is possible to avoid precipitated particles in the finished product which as undesirable traps impair the Bloch wall movement during magnetic reversal.
Types of magnetic steel sheet with particularly enhanced orientation and thus high permeability can be still further improved regarding the hysteresis in that the production process is controlled such that limitation of the size of the secondary recrystallised grains, and, respectively a large ratio of grain boundary length to grain surface, is ensured, and thus the Bloch wall spacing is reduced. The state of the art also includes additional improvement of the domain structure by way of applying an insulation layer which exerts a permanent tensile stress on the sheet substrate, and additionally by treatments which generate lines of local tension across or inclined to the direction of rolling. Among other things these can be local mechanical deformations (EP 0 409 389 A2), laser beam or electron treatments (EP 0 008 385 B1; EP 0 100 638 B1; EP 0 571 705 A2) or the etching-in of grooves (EP 0 539 236 B1).
This method of producing types of magnetic steel sheets with particular low-loss characteristics is associated with a disadvantage in that the combination of measures for forming the insulating layer and further domain refining is expensive. There is a further disadvantage in that the insulation layer is usually constructed in a series of complicated process steps which are carefully attuned to each other. This provides very little scope for undertaking still further parameter variations for economical and qualitative process optimisation.
The hitherto commonly used tension-applying layer is implemented in that the strip which has been cold-rolled to final thickness is subjected to annealing for primary recrystallisation and decarburising, wherein in a targeted way the surface is oxidised, then coated with MgO and suitable additives as a non-stick layer, and dried, and subsequently coiled and again annealed for the purpose of secondary recrystallisation and subsequent cleaning of the steel of precipitation-forming elements. During this annealing step, the non-stick layer reacts with the oxides on the strip surface and forms a forsterite layer (Mg 2 SiO 4 ) which is also referred to as a “glass film”. This film becomes rooted in the base material, a characteristic which enhances its adhesion.
In a further process step, as is for example known from DE 22 47 269 C3, solutions based on magnesium phosphate or aluminium phosphate or mixtures of the two with various additives such as for example chromium compounds and Si-oxide are applied to said film and burned-in at temperatures above 350° C. The tensile stress which the finished insulation layer transfers to the base material can be up to approx. 5 MPa. The improvements in hysteresis loss achieved in this way are of a magnitude of approx. 5%. Furthermore, magnetostriction is reduced.
The achievable improvement in loss is limited by the fact that, for forming the layer, oxidation processes are inevitable during which non-ferromagnetic particles and inhomogeneities form at the surface or in the surface zones, with said particles and inhomogeneities impeding the mobility of the Bloch walls during magnetic reversal, thus causing increased energy losses.
In newer developments, attempts have therefore been made to produce magnetic steel sheet without a glass film and with a surface which is as smooth as possible; and afterwards to apply tension applying insulation layers which do not require surface oxidation as a base. For example, sol-gel methods for layers with oxidic substances have been tried, as described in EP 0 555 867 A2. In this arrangement, the layer tensions have been created on the basis of the difference in the thermal expansion coefficients of the steel and the layer, and on the basis of the high temperature of between 800° C. and 1000° C. during formation of the layer. Other known methods include the application of thin layers onto sheet substrates made of magnetic steel sheet of extremely smooth surface by means of CVD or PVD methods such as electron beam evaporation, magnetron sputtering or vacuum arc evaporation, wherein layers or multiple layers of metal nitrides or metal carbides (e.g. TiN, BN, ZrN, AlN, Ti(CN), Cr2N, TiC, ZrC, WC) are produced, as described in EP 0 193 324 B1 or EP 0 910 101 A1.
With these types of layers it is possible to create tensile stress in the magnetic steel sheet of for example 8 MPa, however, their inadequate electrical insulation effect is disadvantageous so that they have to be covered by an additional insulating layer as described in EP 0 215 134 B1.
SUMMARY OF THE INVENTION
It is the object of the invention to generate highly permeable grain-oriented magnetic steel sheet which is suitable as the core material for particularly silent low-loss transformers.
This object is met by a grain-oriented magnetic steel sheet including an electrically insulating coating made of an amorphous carbon-hydrogen network.
Grain-oriented magnetic steel sheet according to the invention comprises a coating which exerts such tensile stress on the sheet and improves the hysteresis loss to such an extent that additional measures for refining the magnetic domain structure become redundant. The coating which according to the invention is formed from an amorphous carbon-hydrogen network adheres safely to the strip surface and provides high surface insulation resistance.
It is well-known that amorphous carbon-hydrogen networks, also known as a:C—H or diamond-like carbon (DLC) are very hard, chemically inert and provide good adhesion to steel alloys, as is for example described in EP 0 600 533 B1. Up to now, as e.g. described in DE 198 34 968 A1 or WO 99/47346 A1, these characteristics have been utilised for coatings of tools, which coatings must meet particular requirements in regard to their adhesion effect. The same suitability is at the centre of the state of the art, known from DE 198 25 860 A1, which deals with the coating of piston rings.
Surprisingly it has been found that magnetic steel sheet which in the way according to the invention has been provided with a layer of an amorphous carbon-hydrogen network features considerably improved magnetic properties such as reduced hysteresis loss and increased magnetic polarisation. Presumably, this is due to the observed refinement in the magnetic domain structure which renders any additional treatment of the magnetic steel sheet for domain refining redundant.
Furthermore, magnetic steel sheet according to the invention achieves insensitivity of the magnetic characteristics to the sort of compressive strains that can occur in transformer cores. A further advantage associated with this is the reduced magnetostriction which makes it possible to construct more silent transformers. Moreover, the layer system according to the invention is thinner than conventional layer systems, thus permitting a higher stacking factor in the transformer core.
The electrically insulating coating of the grain-oriented magnetic steel sheet can be doped with one or several of the elements Si, O, N, B or F, preferably each ranging from 1 to 20 atomic per cent.
Particularly good magnetic characteristics of the magnetic steel sheet are achieved in that the electrically insulating coating exerts a tensile stress of at least 8 MPa on the sheet substrate.
To further improve adhesion between the sheet substrate and the amorphous carbon-hydrogen network, it is advantageous to arrange at least one adhesion-improving intermediate layer between the electrically insulating coating and the sheet substrate. This adhesion-improving intermediate layer can for example consist of an Si—C—O—H network or an Si—C—H network.
Further adhesion-improving intermediate layers that may be considered include titanium or titaniferous compounds, in particular titanium nitride, whereby the tensile stress on the sheet substrate can be further increased.
Preferably, the layer of magnetic steel sheet according to the invention comprises a surface insulation resistance of at least 10 Ohm*cm 2 , as a result of which the necessary insulation effect is ensured.
With corresponding optimisation, at a sheet thickness of 0.30 mm, grain-oriented magnetic steel sheet according to the invention has a hysteresis loss (at a frequency of 50 Hertz and a polarisation of 1.7 Tesla) of P 1.7 =0.90 W/kg; at a sheet thickness of 0.27 mm, of P 1.7 =0.80 W/kg; and at a sheet thickness of 0.23 mm, of P 1.7 =0.70 W/kg.
In a typical composition, the sheet substrate contains 2.5 weight % to 4.0 weight % silicon, up to 0.20 weight % manganese, up to 0.50 weight % copper, up to 0.065 weight % aluminium, up to 0.0150 weight % nitrogen, and at least 90 weight % iron. Furthermore, additionally one or several of the elements Cr, Ni, Mo, P, As, Sn, Sb, Se, Te, B or Bi, each with mass fractions of up to 0.2 weight % can be present.
The sheet substrate is produced from a steel melt as it is typically used in the production of grain-oriented magnetic steel sheet, with said steel melt comprising 2.5 weight % to 4.0 weight % Si, up to 0.100 weight % C, up to 0.20 weight % Mn, up to 0.50 weight % Cu, up to 0.035 weight % S, up to 0.065 weight % Al, up to 0.0150 weight % N, with the remainder being mainly Fe and the usual impurities as well as the above-mentioned additional alloying elements Cr, Ni, Mo, P, As, Sn, Sb, Se, Te, B or Bi, each with mass fractions of up to 0.2 weight %, by way of strip casting or continuous casting of slabs of between 20 and 300 mm in thickness. These slabs are subsequently rolled to hot strip, after which optional annealing of the hot strip can take place. Subsequent cold rolling, in one or several passes, takes place with intermediate annealing to an end thickness of 0.15 to 0.50 mm. This is followed by a primarily recrystallising annealing at decarburising conditions, as long as the mass fraction of carbon in the steel exceeds 0.005 weight A, as well as if need be by the application of a non-stick layer, followed by annealing for secondary recrystallisation and Goss texture formation (coarse-grain annealing), annealing for cleaning the steel of elements which are no longer required for controlling recrystallisation and texture formation (final annealing), if need be removal of any residue from the non-stick layer and removal from the strip surfaces of the oxides formed during previous annealing processes. Process conditions which ensure a surface of the sheet substrate which is free of any glass film are particularly advantageous in order to prevent the formation and subsequently necessary removal of the glass film after coarse-grain annealing.
Annealing for secondary recrystallisation with Goss texture formation, which is carried out as a continuous annealing process with a maximum of 15 min duration in the continous strip furnace, is a further preferred variant in the production of the sheet substrate. In this context, preferably annealing for cleaning the steel is also carried out as a continuous annealing process with a maximum of 15 min duration in the continuous strip furnace. In regard to process optimisation, these process steps achieve the best result if the formation of surface layers according to the invention is carried out directly in line with annealing in the continuous strip furnace.
The sheet substrate used can also be favourably influenced in that it is subjected to nitrogenizing annealing conditions between the first cold rolling and the secondary recrystallisation. This can take place by adding NH 3 to the annealing gas. As an alternative to this, the strip can be nitrogenized by means of suitable nitrogen-supplying additives to provide a non-stick layer.
A suitable method for producing grain-oriented magnetic steel sheet according to the invention with an electrically insulating coating from an amorphous carbon-hydrogen network consists of the formation of the coating of the strip-shaped sheet substrate with the electrically insulating coating taking place in a continuous strip method. Expediently, the application of adhesion-improving intermediate layers also takes place in a continuous strip method which is preferably arranged upstream of the continuous coating with the amorphous carbon-hydrogen network.
Both for coating with an amorphous carbon-hydrogen network and for the application of the adhesion-improving intermediate layers, either CVD (chemical vapour deposition) methods or PVD (physical vapour deposition) methods can be considered as coating methods. In the case of CVD methods, methods involving thermal activation or plasma activation and particularly preferred hollow-cathode glow-discharge methods can be considered. In the case of PVD methods, thermal evaporation, sputtering, or laser, electron beam or arc evaporation are suitable. Plasma-activated high-rate electron beam vaporisation is considered a particularly preferred embodiment of the PVD method. It is also possible for the individual coating steps to be carried out using different methods.
Advantageously, prior to coating, the roughness Ra of the surface of the steel substrate should be max. 0.5 μm as this contributes to a significant improvement in the magnetic characteristics.
BRIEF DESCRIPTION OF THE DRAWINGS
Below, the invention is explained in more detail by means of exemplary embodiments. The following are shown:
FIG. 1 the hysteresis loss plotted against the external pressure/tensile stresses of sheet which has been coated with a tension applying surface coating, for sheet coated with a conventional coating system, and for sheet coated according to the invention; and
FIG. 2 a diagrammatic view of a device for double-sided coating of grain-oriented magnetic steel sheet comprising an adhesion-improving intermediate layer and a subsequent electrically insulating coating from an amorphous carbon-hydrogen network in a continuous strip method.
DETAILED DESCRIPTION OF THE INVENTION
Table 1 shows for samples 1 to 4: the respective coating state; the respective tensile stress calculated from the curvature of a sample coated on one side (in the case of DLC, coated on one side; in the case of conventional insulation, subsequently freed of insulation on one side); the respective sheet thickness; the hysteresis loss P 1.7 (determined at a frequency of 50 Hz and a polarisation of 1.7 Tesla); and the magnetic polarisation at a magnetic field strength of 800 A/m.
TABLE 1
Tensile
Sheet
stress**)
thickness
P 1.7
J 800
Sample
State
[MPa]
[mm]
W/kg
T
1
Reference
5
0.213
0.89
1.90
(conventional
insulation)
2*)
DLC coating
12
0.220
0.84
1.90
1 μm
3*)
DLC coating
24
0.216
0.69
1.92
2 μm
4*)
DLC coating
24
0.221
0.71
1.93
2 μm
*)examples according to the invention
**)calculated from the curvature of a sample coated on one side (in the case of DLC, coated on one side; in the case of conventional insulation, subsequently freed of insulation on one side).
The sheet substrates were taken from factory production of highly-permeable grain-oriented magnetic steel strip with conventional glass film and phosphate layers (sample 1). The phosphate layer was removed with 25 weight % of NaOH at 60° C., while the glass film beneath it was removed with a HCl/HF mixture. Subsequently the surface was smoothed by means of a chemical polish in H 2 O 2 /HF mixture.
The production of the coatings of samples 2 was carried out as follows:
By means of an intensive glow-discharge, generated by a hollow-cathode discharge method, in an argon-acetylene mixture, a plasma is generated from which on both sides of the magnetic steel sheet an amorphous carbon-hydrogen layer of great hardness and high residual compressive stress is deposited. Prior to the application of this layer, an adhesion-providing amorphous layer, approx. 0.5 μm in thickness, consisting of silicon, carbon and hydrogen (Si—C:H), is deposited by means of the same hollow-cathode based glow-discharge method. Instead of acetylene, TMS (tetramethylsilane) is used as a starting substance to deposit this layer.
The amorphous carbon-hydrogen layer created in this way, in Table 1 abbreviated as the DLC layer, of sample 2 is 1 μm in thickness. From the deflection of a reference sample which is coated only on one side, a residual compressive stress of 3 GPa is determined. Consequently, in the magnetic steel sheet of 0.25 mm in thickness, a tensile stress of approx. 12 MPa is generated. By means of a Franklin tester, an area resistance of ≧20 Ωcm was determined for this layer.
The production of the coatings of samples 3 and 4 was carried out as follows:
By means of high-frequency glow-discharge in an argon-acetylene mixture, a plasma is generated from which on both sides of the magnetic steel sheet an amorphous carbon-hydrogen layer of great hardness and high residual compressive stress is deposited. Prior to the application of this layer, an adhesion-providing titanium layer, approx. 0.5 μm in thickness, is deposited by means of cathode sputtering. The transition from the titanium layer to the amorphous carbon-hydrogen layer takes place without interrupting the vacuum.
The amorphous carbon-hydrogen layer of samples 3 and 4 is 2 μm in thickness. From the deflection of a reference sample which was coated only on one side, a residual compressive-stress of 3 GPa is determined for the layer. Consequently, in the magnetic steel sheet of 0.25 mm thickness, a tensile stress of approx. 25 MPa is generated. By means of a Franklin tester, an area resistance of >20 Ωcm is determined for this layer.
The illustration of the domain structure in the same position of a sample, before and after coating according to the invention with an amorphous carbon-hydrogen network, shows a slightly domain-refining effect of an amorphous carbon-hydrogen layer 1 μm in thickness, and a highly domain-refining effect of an amorphous carbon-hydrogen layer 2 μm in thickness.
In order to determine the insensitivity to compressive strains, the hysteresis loss was measured depending on external tensile stress (positive values) and compressive stress (negative values). The results are shown in FIG. 1 . The values determined for non-coated sheet are shown by lozenges; the values determined for sheet with a conventional layer system of glass film+phosphate are shown by triangles; and the values determined for sheet according to the invention are shown by squares.
FIG. 2 diagrammatically shows an example of a plant for double-sided coating of grain-oriented magnetic steel sheet with an adhesion-improving intermediate layer and a subsequently applied electrically insulating coating consisting of an amorphous carbon-hydrogen network in a continuous strip method.
After being uncoiled and transferred to a high-vacuum zone which is closed off by locks 1 , a strip B of magnetic steel sheet first passes through a device 2 for plasma fine-purification in which fine purification takes place e.g. by means of magnetic field reinforced glow-discharge in an Ar atmosphere.
The adhesion-improving intermediate layer is applied by high-rate electron beam vaporisation in a vaporisation plant 3 through which the strip B subsequently passes. These adhesion-improving layers consist of e.g. Ti or TiN. In the latter case it is advantageous if a reactive variant of electron beam vaporisation is applied, in which in a targeted way nitrogen is introduced as a reactive gas to the vacuum recipient. The use of plasma activation during vaporisation can also be advantageous.
Deposition of the electrically insulating coating consisting of an amorphous carbon-hydrogen network then takes place in a hollow-cathode glow-discharge device 4 without interruption, while the vacuum continues to be maintained. The use of a band hollow cathode is particularly advantageous in this context.
Thereafter, the coated strip B is removed from the vacuum zone by way of a lock 5 and is then coiled.
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The invention relates to a grain-oriented magnetic steel sheet including an electrically insulating coating made of an amorphous carbon-hydrogen network, which is applied after final annealing in order to ensure electrical insulation of the individual layers of the sheet. The grain-oriented magnetic steel sheet including the electrically insulating coating made of an amorphous carbon-hydrogen network can be used in transformers.
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RELATED APPLICATION
[0001] This is a continuation-in-part of U.S. application Ser. No. 09/516,934 filed Mar. 1, 2000 (pending).
FIELD OF THE INVENTION
[0002] This invention relates to high-security removal of data from information bearing disks, especially high-security removal of data from ordinary CDs, CDRs, CDRWs and DVDs.
BACKGROUND OF THE INVENTION
[0003] Compact disks (CDs) include three types: ordinary CDs, CDRs and CDRWS. These disks store data in little pits burned into the disk, or optically in a very thin light-sensitive dye layer on the disk. The information is stored in a very thin layer under the label. That stored information theoretically can be scraped off into small enough pieces so that the data cannot be read. That is, the data can be mechanically disintegrated. CDRs are also known as WORMs, i.e., Write Once Read Many. Relatively speaking, for different kinds of CDs, high-security-grade deletion or erasure of data from CDRs is the most difficult to accomplish. CDRWs are the modern equivalent of floppy disks. Actual writing is by a laser, and the stored data is covered by a metallized reflective layer which is the back side of the label. Rewriteables tend to have the reflective label come off in flakes. Also, there is a remote possibility that a mirror image of the data might come off with the label. Flakes are big enough fragments that such data might still be read. Ordinary CDs, CDRs and CDRWs are sometimes collectively referred to herein as CDs. DVDs (digital versatile disks, also previously known as “digital video disks”) are almost exactly the same thickness, diameter, and general shape as CDs and in many ways resemble CDs. Generally a disk can be determined to be a DVD by the edge having a central seam or joint between the two halves.
[0004] DVDs are manufactured somewhat like a sandwich, with an extremely thin reflective layer and one or two extremely thin layers of a special light-sensitive dye in the middle, located between the two thick clear plastic covers. A “double-sided” DVD can hold twice as much data as the equivalent-type “single-sided” DVD.
[0005] A “single-sided” DVD consists of a thick clear plastic cover, an extremely thin dye layer, an extremely thin reflective layer and a thick clear plastic cover. The read/write laser “looks through” and “shoots through” the clear plastic towards the data layer and finally the reflector layer, from ONE side.
[0006] A “double-sided” DVD consists of a thick clear plastic cover, an extremely thin dye layer, an extremely thin reflective layer which is reflective on both sides, an extremely thin dye layer, and a thick clear plastic cover. The read/write laser “looks through” and “shoots through” the clear plastic towards the data layer and finally the reflector layer from EITHER side, thus providing double storage capacity.
[0007] Currently, in the year 2001, the highest commercially available DVD (“double-sided”) capacity is about 9.4 gigabytes, with even higher capacity DVD's on the horizon. The highest capacity CD is currently about 0.8 gigabytes. With their vastly superior storage capacity one can only conclude that DVD's will become increasingly popular.
[0008] Destruction of data from such CDs and DVDs may be further complicated by the fact that particular manufacturers may use different adhesive systems, with some systems more prone to flaking upon removal of the data layer. Thus, flaking is a variable problem for which provision must be made, but which is not easily solved, when undertaking data removal.
[0009] In certain applications, erasing or removing sensitive data from disks can be critical for security reasons or necessary for business reasons. As devices for putting information onto disks such as CDs and DVDs are becoming more common, so, too, the problem of how to effectively remove that stored information from the disks is becoming even more of a concern.
[0010] Certain devices for performing such data erasure are known, but respectively suffer from drawbacks.
[0011] For example, Proton Engineering Inc. has a declassification system that is a CD-ROM Eraser/Declassifier, for CD-ROMS, WORM CDs and other optical media, that according to its literature reportedly declassifies CD-ROMS in 12 seconds. It is a mini-tower of 18″×18″×9″, 75 lbs, and its power requirements are 120 vac. 50/60 Hz., 8 amperes. Another example of a known data-erasure device is SEM's model 1200 weighing 75 lbs. The DX-CDE CD destruction device is 59.4 lbs, 24″ high, 7.5″ in diameter, weighing 50 lbs. with electrical operation. These declassification machines, weighing 75 lbs, almost 60 lbs and 50 lbs, disadvantageously are relatively heavy and not easily portable. A further example is the DX-CDm™ CD Destruction Device, which is a manual field portable unit that is intended for mounting on the inside wall of a vehicle, bracketed to the side of a vessel, or securely fastened to the bulkhead of an ocean going vessel. The machine is 20 lbs, 10″ high, of 7″ diameter. The inner hub of the erased disk remains intact. The machine operates by mechanical operation with a rotating handle. Although this declassification machine is relatively light-weight, 30 seconds is the operating time, which may be disadvantageously long. In addition, this machine disadvantageously MUST be firmly secured to a robust mounting surface, because considerable force is exerted on the rotary handle to operate it. Further this machine disadvantageously requires considerable manual effort, resulting in rapid operator fatigue, and consequent difficulty in performing the critically important high-security-grade removal of data.
[0012] Another conventional device that purports to provide secure CD destruction is that of U.S. Pat. No. 6,039,637 to Hutchison et al. (issued Mar. 21, 2000) for “Security device for destroying the information bearing layer and data of a compact disc.”
[0013] Another example of a device that purports to provide secure CD destruction is that of U.S. Pat. No. 6,189,446, to Olliges et al. (issued Feb. 20, 2001) is for a “System for the secure destruction of compact disc data.” Olliges discloses a system for use on gold or aluminum information bearing surfaces (IBS's), especially those of CDs but also mentioning DVDs. Olliges et al.'s system includes at least one pair of rollers, with each roller rotatably mounted between rigid support plates. A CD passes between the rollers under pressure. The roller exteriors contain raised patterns. After passing through the roller system, the disk is said to be characterized by lines of distortion that are about 0.25 mm apart. Olliges et al. attempts to distort a CD sufficiently to prevent a laser from reading information stored in groove-like patterns, by distorting the shape of pits in which data were stored, moving pits from their original positions, displacing the reflective layer of the CD at the base of the pits so that the laser beam does not reflect back properly to the optical sensor, “filling in” the pits, and production of imperfections. Such a method that leaves data on the disk is subject to drawbacks, such as the fact that there may be technology, now or developed in the future, for making sense of the remains. Especially where so much data is all in one place (e.g., still on the one disk), Olliges et al.'s methods may be risky.
[0014] A commercial example of such a machine is the Security Engineered Machinery (SEM) Model 1250B. Examination of the results of the operation of this machine reveals that it disadvantageously leaves considerable contiguous recorded information, easily visible under an ordinary microscope, on the disk. Thus it disadvantageously does not perform the high-security data removal to Dept. of Defense standards, or even common-sense industrial security standards.
[0015] Another consideration introduced into this data destruction area is that in many applications the declassified disk cannot be entirely destroyed, because verification of declassification is needed for the particular exact original disk. Such verification is accomplished by a data destruction method that retains only the disk's inner-hub which bears its identifying information, such as a serial number. A method which destroys the entire disk does not permit this verification of destruction.
[0016] There is a need, which has not heretofore been met, for a data erasure machine that declassifies data-containing disks such as CDs and DVDs that meets the following characteristics: short (e.g., less than 10 seconds) cycle time; small size (e.g., such as 10×12×8 inches); pluggable into a wall outlet; light-weight (e.g., less than about 20 lbs); mechanically simple; and, capable of destroying all confidential data on the disk while maintaining intact only the inner hub of the disk, so that the serial number or identifying disk number remains visible to confirm data destruction on the original product. Also, high-security destruction of data stored on a disk is extremely important to government, military, and commercial users. Especially considering the large amount of data that can be stored on a solitary DVD, and the likelihood that DVD use will be increased, high-security data destruction suited to DVDs is a particular concern.
SUMMARY OF THE INVENTION
[0017] After much evaluation by the inventor of potential ways to remove and handle stored material on information bearing disks such as CDs and DVDs, including evaluating cutting, grinding and destroying the whole disk, the present inventor arrived at the following inventive products for removing data from disks while leaving the inner-hub data intact and further arrived at the following inventive methods and machines. Also, the invention advantageously provides for easy removal of data from CD's (wherein the data is on one side, at the surface), by a device or apparatus into which can be fed a split DVD (wherein the data is also on one side at the surface), so that all type of CDs (CDs, CDRs, CDRWs and DVDs) can be processed with a single data destruction device or apparatus.
[0018] The invention in a first preferred embodiment provides a method for security declassification of a disk (such as an ordinary CD, a CDR, a CDRW, a DVD etc.), comprising the step of contacting a data-containing disk with a rotating cutter having a patterned surface to provide a declassified disk. In one embodiment of the invention, the contacting step provides dust; in another embodiment, the contacting step provides dust and flakes. Where flakes are provided, the invention provides for further reducing the flakes to dust. In a particularly preferred embodiment of the invention, the contacting step is performed for about 3-10 seconds. In an especially preferred embodiment of the invention, the disk is rotating while the cutter is contacting the disk. In a particularly preferred embodiment of the invention, the rotating cutter is provided in a desk-top, portable machine pluggable into a wall outlet.
[0019] Additionally, the invention in a second preferred embodiment provides a high-security, high-speed disk declassification machine, comprising a patterned-surface cutter, wherein the cutter is of length about corresponding to the exterior data band of a disk; a motor connected to the cutter for rotating the patterned-surface cutter at 10,000-30,000 rpm; and a system for capturing and positioning the disk to press the rotating patterned-surface cutter parallel to the disk with the cutter length aligned with a disk external data radius for sweeping the disk external data surface.
[0020] In a third preferred embodiment, the invention provides a high-security, high-speed disk declassification machine, comprising: a patterned-surface cutter; a motor connected to the cutter for rotating the patterned-surface cutter at 10,000-30,000 rpm; and a system for capturing and positioning a batch of disks comprising CDs and split DVDs to press the rotating patterned-surface cutter parallel to the disk with the cutter length aligned with a disk exterior ring radial length for sweeping the disk external data surface.
[0021] In a fourth preferred embodiment, the invention provides a production method for minimizing the size and weight of a high-speed CD or DVD-disk declassification motorized machine to as small as about 8 inches by 10 inches by 12 inches and as light as about 17 pounds, comprising the steps of: (A) providing a housing of about 8 inches high, with a base of about 10 by 12 inches, and having an opening on a side into which a CD or split DVD may be inserted; (B) in the housing interior, securely disposing a system for capturing and positioning a CD or split disk, such that the capturing/positioning system is secured to the housing base; (C) mechanically connecting to the capturing/positioning system, a system for disposing a patterned-surface cutter of length about 1.52 inches with the cutter parallel to and below where the CD or split DVD will be held by the capturing/positioning system for cutting, with the cutter length aligned with the CD or DVD exterior data band radial width; and (D) to the cutter, connecting a motor for rotating the cutter at 10,000-30,000 rpm. The most preferred embodiment of such a production method provides a CD or DVD declassification machine that outputs a verifiable center-ring-intact declassified CD or DVD.
[0022] In a fifth preferred embodiment, the invention provides a DVD splitter system, comprising: a housing with a circular nest of diameter only slightly larger than a DVD diameter, the nest having a height of about half the thickness of a DVD; and a blade attached to the housing.
[0023] In a sixth preferred embodiment, the invention provides a method for security declassification of a disk having at least one interior information-bearing surface, comprising (a) lengthwise-splitting the to-be-split disk into a number of thinner split-disk fragments; and, (b) contacting each interior surface of the split-disks with a rotating cutter having a patterned surface to provide a declassified disk surface. In a most preferred exemplary method, the to-be-split disk is a DVD, and the DVD is split into two DVD halves each of about ½ thickness of the to-be-split DVD. In an especially preferred embodiment of the invention, the cutter has a length equal to or about corresponding to an exterior data ring radial length of the disk. In another especially preferred embodiment, before splitting the DVD, each exterior face of the to-be-split disk is marked with a marking that directs contact of the split disk with the rotating cutter.
[0024] In a seventh preferred embodiment, the invention provides a high-security, high-speed DVD declassification machine, comprising: a patterned-surface cutter; a motor connected to the cutter for rotating the patterned-surface cutter at 10,000-30,000 rpm; and a system for capturing and positioning a lengthwise split half-DVD to press the rotating patterned-surface cutter parallel to the DVD surface with the cutter length aligned with a disk exterior ring radial length for sweeping the disk external data surface. An especially preferred embodiment includes a cutter of length about corresponding to the exterior data ring radial length of a disk. Another particularly preferred embodiment includes a housing having disposed therein the cutter, with a DVD splitter device detachably contacting an exterior surface of the housing.
[0025] In an eighth preferred embodiment, the invention provides a digital versatile disk (DVD) comprising at least one interior surface onto which information has been recorded or is recordable, and including on an exterior of the DVD a marking directing entry of the DVD into a data destruction machine. In an especially preferred embodiment, the marking has been applied before information-recording onto the interior surface.
[0026] Some further details of the inventive methods, machines, apparatuses, devices and processes are as follows, without the invention being limited thereto.
[0027] In a particularly preferred embodiment of the invention, the declassified disk has an intact center ring (such as an intact center ring comprising disk identifying information). In a particularly preferred embodiment, the cutter has a length equal to or about corresponding to an exterior data band of the disk, and preferably the cutter length exceeds the exterior data band. In a particularly preferred embodiment of the invention, a disk is declassified in as little as 3-6 seconds, to provide products consisting essentially of a declassified disk with intact center-ring and security-standard dust.
[0028] In a particularly preferred embodiment of the invention, the cutter may be cylindrical shaped. The cutter rotation may be provided by a motor. The patterned cutter surface preferably comprises a pattern selected from the group consisting of a rotary file, herring bone, cross-cut rotary file, intersecting spiral and non-cross-cut interleave file, most preferably a cross-cut herringbone pattern. The cutter diameter preferably may be about ½ inch. In a particularly preferred embodiment of the invention, the cutter is operated at about 10,000-30,000 rpm.
[0029] The cutter may be driven by a motor run on a timing cycle (such as a timing cycle initiated by an arm-actuated microswitch). In a preferred embodiment of the invention, the microswitch is triggered by the disk before the contacting step. A particularly preferred embodiment of the invention provides a machine wherein the cutter-driving motor is on a timing cycle controlled by a microswitch, wherein the cycle is triggered on by a disk being inserted past the microswitch's actuator arm. A particularly preferred embodiment of the invention provides for (1) disposing a microswitch system comprising a microswitch such that the microswitch is positioned with respect to the opening into which the disk is inserted to detect entry of a disk into the housing; and (2) electrically connecting the microswitch to a timing circuit and disposing the timing circuitry in the housing interior.
[0030] In an especially preferred embodiment of the invention, dust is vacuum-collected, such as by a dust collection system for collecting dust formed when the cutter contacts the disk. In a particularly preferred embodiment, the dust collection system comprises a vacuuming system positioned near the cutter and a dust collection bag connected to the vacuuming system. Another preferred embodiment provides for disposing a motorized vacuum dust collection system in the housing interior. The motorized vacuum dust collection system may comprise a motor separate from the cutter motor. The motorized vacuum dust collection system may comprise a dust collection bag connected to a vacuum exhaust which is connected to a vacuuming device directed to vacuum dust from where the cutter contacts the disk.
[0031] In a further especially preferred embodiment of the invention, flakes are captured. Flake capturing preferably comprises providing a screen disposed near the rotating patterned cutter. In a most preferred embodiment, the invention further comprises further cutting the captured flakes into dust. An inventive machine preferably may comprise a means for flake collection (such as a screen) disposed near the cutter. A particularly preferred embodiment of the invention provides for shaping and positioning a flake-capturing screen under the cutter and close to the cutter without contacting the cutter and also under the CD or DVD support, and to completely block access by flakes to the vacuum dust collection bag.
[0032] In an especially preferred embodiment of the invention, a vacuum system is applied to hold the disk in contact with the rotating cutter having a patterned surface. In a further embodiment, the disk is held in contact with the patterned cutter surface entirely by the vacuum system.
[0033] In another particularly preferred embodiment of the invention, the system for capturing and positioning the disk comprises a spring-loaded pinch roller. In a further embodiment, the pinch roller comprises a pinch roller (driven by a motor), squeezing the disk against a ball bearing. The system for capturing and positioning the disk may comprise a means for rotating the disk being declassified. The means for rotating the disk being declassified may comprise a roller mechanism.
[0034] Additionally, in another embodiment of the invention, the system for capturing and positioning the disk may comprise ball bearings against which the disk to be declassified rests, such as three ball bearings positioned in a triangle with one ball bearing positioned on a pressure arm which captures the disk to position for holding and rotating. In another embodiment, the system for capturing and positioning the disk comprises a pivot with a non-rotating guidepost at the bottom of the pivot, wherein the guidepost is located exactly across from the center of the roller. Also, in a particularly preferred embodiment of the invention, the disk capturing/positioning system comprises a platform of about 6 inches wide by 5½ inches long for supporting the disk during high-speeding cutting (such as a platform having a minimized cut-out section for the cutter under the disk to contact the disk data surface).
[0035] Where a pinch roller is used, a further preferred embodiment provides a brush for brushing the pinch roller. Also, the pinch roller may be easily replaceable. In an exemplary embodiment, the capturing/positioning system comprises a motorized pinch roller system in which the pinch roller is positioned above and in close contact with the CD or DVD, and there is a pinch roller motor separate from the cutter motor and separate from the vacuum motor.
[0036] In a preferred embodiment, the motorized pinch roller system further comprises a brush disposed above the pinch roller with the brushing end contacting the pinch roller.
[0037] In a particularly preferred embodiment, the invention provides multi-disk processing, such as a data declassification machine comprising a multi-disk processing system.
SUMMARY OF THE DRAWINGS
[0038] [0038]FIG. 1 is a top view of a standard CD showing the respective surface areas for the data area and the serial number.
[0039] [0039]FIG. 2 shows an enlarged, partial detail view of the cutter and the parts around the cutter in a machine in which the cutter is used.
[0040] [0040]FIG. 3 is a profile view of the cutter.
[0041] [0041]FIG. 4 is a fragmentary diagram of the interior of a partially-disassembled inventive machine in which the cutter of FIG. 2 is used and in which, for clarity of viewing, a vacuum bag is not included.
[0042] [0042]FIG. 5 is along the lines of FIG. 4, but with the vacuum bag added.
[0043] [0043]FIG. 6 is along the lines of FIG. 5, but with a CD inserted and the vacuum bag inflated during use of the machine.
[0044] [0044]FIG. 7 shows a flake-trapping screen in relation to the cutter.
[0045] FIGS. 8 ( a ) and 8 ( b ) are exterior side-views of a desk-top machine according to the invention, for accomplishing high-speed, high-security disk erasure, with FIG. 8(a) showing the front of the machine and FIG. 8( b ) showing the rear.
[0046] [0046]FIG. 9 is a front view of the mechanism of FIGS. 4, 5 and 6 removed from the cabinet.
[0047] [0047]FIG. 10 is the same side view as FIG. 9, with a CD inserted and the vacuum bag inflated during use.
[0048] [0048]FIG. 11 is a circuit diagram.
[0049] [0049]FIG. 12 shows a vacuum belt drive system in which a single motor drives both the cutter and the vacuum system.
[0050] [0050]FIG. 13A is a top view of a splitter according to the invention, with a to-be-split DVD nested in the splitter. FIG. 13B is top view, x-ray style, of a splitter. FIG. 13C is a cross-sectional view of the splitter of FIG. 13B in operation showing a DVD partially split. FIG. 13D is a magnified view of part of FIG. 13C.
[0051] [0051]FIG. 14A is a perspective view of a DVD before being split with an arrow showing an exemplary place on the DVD at which the DVD may be split according to the invention. FIG. 14B is a perspective view of a partly-split DVD. FIG. 14C shows two pieces of a DVD after being split according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0052] Before being processed according to the invention, a disk (such as a CD or DVD) 1 encoded with data, referring to FIG. 1, has a circumferential edge 1 a, a center ring 1 b , a shiny top surface 1 c , and a data area 1 d under the shiny top surface 1 c . The inner center ring 1 b of the disk is essentially data-less, usually having a serial or control number for identifying the disk but no confidential information. About the exterior 1.52 inches of the radius of the disk, the outer band 1 d of the disk has recorded information. Herein that data-containing part of the disk sometimes is referred to as the disk “exterior data band”. Serial number area 1 e shown in FIG. 1 and FIG. 14 is typical of where a serial number may appear on the disk. In the case of a DVD, as may be appreciated from FIGS. 14 A- 14 C, there may be two data areas 101 c.
[0053] The desired “declassifying” of the disk means that the processed disk and any remaining dust and particles meet the U.S. government NSA/DOD declassification standard. Declassifying the disk may be accomplished in one aspect of the invention by a process in which the unprocessed disk 1 is contacted with a rotating cutter with a patterned surface. By the action of the patterned rotating cutter, the data area of the disk is forcibly removed from the disk in the form of particles sufficiently small to meet security destruction standards. The disk that is subjected to such a declassification procedure may be a CD, a DVD, or a DVD that has been split in half. If a DVD is split before declassification, the same piece of equipment may be used, without adjustment, for declassifying a CD or a split DVD.
[0054] Because a DVD carries its data in the middle of the disk (see FIGS. 14 B- 14 C), the most expeditious way to remove the data from a DVD is to expose this middle portion of the DVD disk (so that the removal process may be applied), by splitting the disk into two disk-shaped halves (see FIG. 14C), to split DVD of thickness 2t (see FIG. 14A) to half-DVD of thickness t (see FIGS. 14B, 14C). In this fashion, the DVD data may be exposed and then contacted with a rotating cutter according to the invention and the data may be removed from the DVD half-disk, while the clear plastic covers (such as plastic cover 102 on FIGS. 14 A-B) remain.
[0055] For splitting a DVD, optimally the DVD is subjected to application of force at its rim at half of its thickness, as shown in FIG. 14A. Any force application that splits the DVD into two essentially equal disks of half-thickness may be used, with application of a blade being particularly preferred.
[0056] During force application to the DVD, preferably the DVD is situated in a holding device that avoids manual holding of the DVD. An exemplary DVD-holder and device for application of splitting force is shown in FIG. 13A. A body 140 is provided, with a circular nesting spot 141 that is just slightly larger in diameter than a DVD to accommodate a DVD and is sized for a relatively snug fit. Preferably, the height of the nest is half the thickness of a DVD, minus an appropriate allowance for the thickness and style of the blade 143 . A blade 143 is provided so that a corner of the blade may be forcibly contacted with the midline of the circumferential edge of the DVD to start the splitting action on the DVD. Considerable force is required to start the splitting action, and this is facilitated by the high operating leverage (over 7:1 in a preferred embodiment) designed into the machine. Once the initial split is started, finishing the complete split is much easier, and is accomplished with little or no leverage. An example of a blade 143 is a 0.028″ thick ordinary “steel-rule die” material, well known in the materials cutting art. In a preferred embodiment, the blade is ground sharp on both long edges, and is dimensioned, along with other elements of the device, so that when the first edge is worn or damaged, the blade may be removed and turned end-for-end, allowing the second edge to be used. In a preferred embodiment, the blade 143 is sharpened with a single bevel, to provide a simpler, lower-precision mechanism, needing no adjustments during manufacture or use. The blade 143 preferably is flat, such as a flat 1″ wide blade. The blade 143 also preferably is beveled at its cutting edge, most preferably a bevel which aids in the splitting aid (such as a long bevel, which provides a gradual wedging/slicing entry). A blade also preferably may be two-sided, such as a two-sided beveled blade, thus providing a “spare” blade edge.
[0057] As shown in FIG. 13A, a handle 144 guards the operator from coming in contact with the blade. The blade 143 and its associated handle 144 are secured to the housing 140 by a pivot 145 . The blade 143 is shown in a starting position in FIG. 13A. The pivot 145 permits the blade 143 to be swung away from the DVD (i.e., counterclockwise in FIG. 13A) and towards the DVD (i.e., clockwise in FIG. 13). The particular arrangement in FIG. 13A is preferable for a right-handed operator; a left-handed splitter arrangement may be easily adapted therefrom. The DVD is manually loaded into the nest 141 and the operator holds the DVD in the nest with one hand while moving the handle 144 to activate the blade 143 and split the DVD.
[0058] In a preferred embodiment (as illustrated in FIG. 13A) the splitting device may be fitted with two ball-nosed spring-loaded plungers 146 and 147 . The two small locknuts for these plungers are shown in FIG. 13A. The outer plunger 146 contacts the disk prior to the blade 143 contacting the disk, and holds the edge of the disk down during the initial (first phase) penetration by the corner of the blade 143 (counter-clockwise (CCW) handle 144 rotation). The ball-nose style of plunger is preferable, because it tends to roll across the disk surface under pressure, rather than slide and drag across it. This ball-nose plunger feature makes overall operation easier. During clockwise (CW) handle 144 rotation (secondary and final penetration) the inner plunger 147 contacts the disk prior to the blade 143 , and holds the edge of the disk down during the beginning of penetration. During this second phase, the blade enters at the small starting split formed during the first phase, and the blade contacts the disk much nearer the midpoint of the blade edge.
[0059] In a preferred embodiment (as illustrated in FIGS. 13A, 13B), the end of the handle 144 is fitted with a knob which is free to rotate, enhancing operator ease, comfort, safety, and convenience. An exemplary example of using a DVD splitting device, such as the device of FIG. 13B, is to follow the following operation sequence. First, marking of each side of the to-be-split DVD is carried out, such as by using a felt-tip writing marker or crayon, marking EACH side of the to-be-split DVD “TOP” or “UP”. Such a marking step is highly preferred, as the markings indicate which side should face in which direction (for example, which side faces up) when each half-DVD is inserted into a high-security disk data removal machine. It is especially preferred that the to-be-split DVD be marked immediately prior to splitting and data destruction. It will be appreciated that the marking should correspond to the configuration of data destruction to be subsequently used. For example, both sides of a to-be-split DVD may be marked “TOP” when they are to be inserted into a data removal machine in which the rotating cutter is underneath the to-be-classified disk. Marking to be placed on the DVD may vary depending on the configuration of the rotating cutter, disk insertion system, etc. When a split DVD has not been marked, or where a split DVD has markings the accuracy of which may be doubted, it is suggested to apply the cutting surface against both sides of the split DVD, to ensure that the information bearing surface has contacted the cutting surface. Preferably the DVD-splitting apparatus or device includes a receptable or attachment containing at least one marker, such as a pouch containing at least one marker, at least one clipped-on marker, at least one marker on an extendible cord, etc.
[0060] Optionally, the disks, destruction devices and machines according to the invention may be marked, such as with directive markings and/or instructions, so that the inventive methods, apparatuses and devices may be used by operators having relatively little skill, knowledge or training. It will be appreciated that a DVD-marking method advantageously reduces the data destruction time by minimizing the number of non-information-bearing-surfaces that are contacted with a data-destroying cutter. Additionally, pre-marking of DVDs and/or CDs may be provided, such as pre-marking DVDs during manufacture with appropriate marking to correspond to a particular data destruction apparatus. When DVDs are pre-marked during disk manufacture, preferably a notation also is included to the effect that the DVD must be split, such as a marking “when split, ‘TOP’ for certain listed models”, such “when split, ‘TOP’ for Datastroyer.” A corresponding instruction may be prominently included on the data destruction machine, such as “split DVDs before insertion”.
[0061] The to-be-split DVD having been marked or confirmed to be marked, referring again to FIG. 13B, next, the handle 144 is moved to the “start” position, by lining up the handle 144 with the thick black line 140 A. The handle 140 is shown in the “start” position in FIG. 13B. The disk is then loaded into the circular nest 141 . (Half of the disk falls below the main flat machine surface.)
[0062] While the operator holds the disk down firmly with his or her left hand, the operator with his or her right hand moves the handle 144 counterclockwise (CCW) (towards the instruction label 140 D) to the stop 140 B. This movement causes the end-corner of the sharp blade 143 to just slightly penetrate the disk edge, in the middle, making a starting-point for the splitting operation. The blade end-corner penetrates the disk about ¼″.
[0063] Ball plunger 146 also inscribes a small arc-shaped mark 141 B on the top surface of the disk, at the edge.
[0064] Handle 144 is returned to the start position. Then the disk DVD′ is rotated about 15 degrees clockwise so that the small arc-shaped mark 141 B just made at the edge of the disk lines up with the inner small nut 147 on the handle 140 . This positioning establishes a set-up in which blade 143 can enter at the point started on the disk DVD′ in the above-mentioned penetration. Holding the disk down steady, the operator swings the handle 140 clock-wise (away from the label 140 D) all the way to the stop 140 C. The blade passes through the midline of the disk, completely splitting it. FIG. 13C (and FIG. 13D, which is a magnified view of part of FIG. 13C) show a partly-split DVD′. As shown in FIGS. 13C and 13D, the corner of the blade has made the starter split and is being withdrawn. The handle is returning to “START” position, and the blade is still partly inside the disk. Considerable vertical space is present between the handle and the blade, allowing room for the upper half of the splitting disk to angle upwards (initial separation), curve over towards horizontal, and finally slip between the blade and the handle. After the DVD has been split, the operator uses the center hole to grasp and slide out the two disk halves.
[0065] Thus the invention provides for easily splitting a DVD (such as a 0.05″ DVD) into two half-thickness disks (“half-disks”). Using the invention, a DVD may be split into two half-disks in as little as five seconds.
[0066] DVD disks that have been so processed into DVD disk halves may be run through a data destruction machine such as an exemplary inventive data destruction machine discussed herein with the “TOP” marked sides UP. It will be appreciated that the “TOP” (i.e., the exterior of the to-be-split DVD) is not the data-bearing surface. The declassification methods of the present invention may be applied to a DVD disk, in its split form. It further will be appreciated that whether a particular information-bearing disk is suitable for splitting before declassification may be determined from the construction of the disk (such as from the general appearance of the disk suggesting that it is a DVD, and/or the presence of a central seam on the disk edge or joint between the two halves, etc.). It will be readily appreciated that the reason for splitting a DVD is to expose the information-bearing surface so that the information-bearing surface may be contacted with a data-removing cutter according to the invention. Most preferably, both halves of a split-DVD are contacted with a data-removing cutter, even for a “single-sided” DVD, as information may stick to or be present on either surface after splitting.
[0067] As for declassification according to the present invention, a preferred embodiment uses a cylindrical-shaped cutter, as in cutter 2 in FIGS. 2, 3, 4 . In a preferred embodiment, as shown in FIG. 4, the cutter 2 rotation is provided by a motor 3 .
[0068] The cutter surface is not necessarily limited, and may be an abrasive, rotary file, herring bone, cross-cut rotary file, intersecting spiral pattern, non-cross-cut interleave file, or other pattern. For providing these surfaces, a commercially available cutter from a machinery supply house may be used. The present inventor has experimented with some of these cutters and abrasives, and has found that non-cross-cut interleave works relatively well, but because of its helical shape tends to put a side force on the disk and tends to move the disk in or out. Preferably, the cutter should not load up with dust or partially-melted residue. The most preferred embodiment uses a cross-cut herring-bone pattern for the cutter surface. Such a cross-cut herring-bone patterned cutter may be made by purchasing part no. 60469665 from Manhattan Supply Corp. and then cutting its shank down to the desired length.
[0069] The cutter length should be equal to or exceed the length of the exterior data band, i.e., about 1.52 inches. When a commercially available cutter is used, the shaft may be cut and positioned as needed to align with the radial width of the exterior data band. If the cutter length is less than radial width of the exterior data band, one knowledgeable in the art will easily appreciate that complications would be introduced in that data destruction may not proceed properly. If the cutter swath is too much greater than the radial width of the exterior data band, the serial number-containing center-ring undesirably may be destroyed. Having a longer-than-necessary cutter swath is to be avoided both to preserve the center-ring identification information and also to avoid unnecessary energy expenditure (and consequent heat build up) cutting away a part of the disk that does not require destruction. Thus, in the most preferred embodiment, the cutter length just exceeds the radial width of the exterior data band.
[0070] As to size, the cutter diameter may be about ½ inch, but is not required to be a particular diameter.
[0071] The cutter must be positioned with respect to the disk so as to effect disk declassification. The rotating cutter must be positioned sufficiently near to the disk so that the data will be removed by the action of the rotating cutter against the disk surface.
[0072] A vacuum system may be used for forcing the disk and rotating cutter together in sufficiently close contact.
[0073] “Speed” is the rate at which the cutter is rotating. The cutter typically is operated at about 10,000-30,000 rpm, which is a relatively high speed. That high-speed cutter rotation is provided by a motor. Such a speed translates into a certain number of cutting surface feet per minute. “Feed” is the rate at which the disk surface passes by the cutter.
[0074] It will further be appreciated that the cutter is rotating so as to help the disk to rotate. The cutter rotation augments the disk rotation, such that a reduced amount of force is required by the roller motor driving the disk.
[0075] At the high-speed motorized operation of the cutter, disk declassification is accomplished in as little as about 3-1 0 seconds.
[0076] In a preferred embodiment, the motor for driving the cutter may be run on a timing cycle. The timing cycle may be initiated by a microswitch 7 as shown in FIG. 4, which may be triggered by the to-be-processed disk.
[0077] In the declassification, the cutter must be positioned so as to come in contact with the disk surface so as, referring to FIG. 1, to mechanically remove the shiny top surface 1 c and data area 1 d and separate them from the inserted disk 1 being processed. The cutter is disposed in relation to the disk so that the disk center ring 1 b is not removed.
[0078] The cutting operation comprises the application of the patterned cutter that is rotating to the data surface of a rotating disk.
[0079] During the cutting operation, one by-product is dust that is of a sufficiently small size to meet security declassification standards (hereinafter “dust”). The dust that is formed may be collected. Preferably, the dust is collected so that dust will not interfere with operation of moving parts.
[0080] Additionally, if the dust is collected in a disposable bag, there need be no operator contact with the dust. This is advantageous in that certain types of CDs or DVDs may contain dyes or other materials which might be hazardous for operators to contact or inhale.
[0081] In a preferred embodiment, as shown in FIGS. 5, 6 and 7 , a vacuum dust collection system is used for dust collection. The vacuum dust collection may be operated simultaneously with the cutting operation. In the machine shown in FIG. 5, the dust created from the removal process is collected in vacuum bag 4 .
[0082] Optionally, the vacuum bag may be a reusable fabric vacuum pouch.
[0083] During the cutting operation, in addition to dust formation, another byproduct that may form for certain types of disks is flakes which may not meet security declassification standards (hereinafter “flakes”). Flakes that may form require capturing and further destruction efforts, i.e., regrinding or re-cutting. Those in the art will appreciate that only certain types of disks may flake.
[0084] In a particularly preferred embodiment, importantly, the flake capturing system is as simple and integrated with the initial cutting operation as possible, so that no further parts, such as a separate re-grinder or re-cutting mechanism, are required.
[0085] To avoid clogging and to minimize the number of parts (with the corresponding concern about either requiring close fits or separate machinery) are features of the invention. Advantageously, the present invention for its flake capturing system and re-cutting, provides for reusing the precision high speed cutter.
[0086] The high speed cutter may be re-used for re-cutting the flakes by trapping the flakes by a carefully shaped screen.
[0087] The flake-capturing screen should have openings of sufficient size to permit the dust to pass through without clogging, but to prevent the flakes from passing. A suitable raw screen material for using is commercially available from McMaster-Carr, part no. 936OT21, which is about 0.018 inches thick. A suitable raw size for the screen is 3½ inches long by 3½ inches wide. The screen may be cut and formed as needed.
[0088] As shown in FIG. 7, the screen 5 may be positioned around and under the rotating cutter 2 so as to capture the flakes. The screen 5 is of ordinary brass, about 0.01 8 inches thick, and dead soft. Holes in the screen 5 are about 0.045 inches in diameter, closely spaced. In screen 5 , the “open area” (i.e., the area comprised of holes) is about 50% of the total screen area. The screen 5 is used to prevent the flakes from leaving the area of the cutter 2 prior to re-cutting. Preferably, the screen 5 is disposed so that it gradually approaches the cutter 2 , and at its closest point to the cutter 2 , the cutter 2 clears the screen 5 by about 0.025 inches. The rotating cutter 2 should clear the screen 5 and not contact the screen 5 , to provide for smooth mechanical performance. While a maximum closest distance between the screen 5 and cutter 2 is not exactly established, it will be appreciated that providing the smallest distance possible in a practical, economically manufacturable machine is generally advantageous for achieving the objective of minimizing the dimensions occupied by the screen 5 and cutter 2 and associated parts. Also, the closeness of the cutter 2 to the flake-capturing screen 5 enhances the ability of the rotating cutter 5 to pick up and carry the flakes via the spaces in the cutter's patterned surface.
[0089] In a preferred embodiment, such as one as shown in FIGS. 2, 4, 5 and 6 using flake-capturing screen 5 , flakes generated from the cutting of the cutter 2 against the disk surface being processed travel so that they come into contact with and situate on and near the rotating cutter 2 . Once a flake situates on the rotating cutter 2 , such as in a space on the patterned surface of the cutter, the flake travels via the rotating cutter 2 back to the contact of the rotating cutter 2 and the disk surface, and the flake is drawn between the patterned cutter surface and the disk surface, and the flake is thereby cut down further.
[0090] It is not necessary that a flake travel on the rotating cutter 2 before re-cutting. Also, flakes that have separated from the disk surface directly may be drawn back through the air, without riding on the rotating cutter 2 , to the juncture of the rotating cutter 2 and the disk surface and thereby re-cut into dust. Some of these rather fragile flakes may also be broken down simply by coming into air-borne contact with the high-speed cutter.
[0091] The movement of the flakes in returning for re-cutting between the rotating cutter 2 and disk surface may be assisted by a vacuum system, disposed to vacuum from below the screen.
[0092] Flakes that are re-cut into dust then travel, as dust, through the screen 5 (as does the originally produced dust). The patterned cutting surface parallel to the disk must be kept parallel to the disk, otherwise the cutter 2 may penetrate unevenly and leave gaps of data remaining on the disk.
[0093] Also, the patterned cutting surface must be brought into sufficient contact with the disk so that all of the data will be removed from the disk.
[0094] It will be appreciated that the inventive declassification processes described herein may be modified in various ways without departing from the spirit of the invention.
[0095] In one embodiment of the invention, the declassification process may be accomplished using a single-disk machine. The operation of the machine is first set forth and discussed with reference to FIGS. 4, 6, 8 ( a ), 9 , 10 and 11 .
[0096] An unprocessed disk 1 is loaded into the single-disk machine through an opening 6 to trigger a microswitch 7 . A suitable microswitch for use in the invention is the “SNAP-ACTION SWITCH”. Other microswitches also may be used.
[0097] The triggering of microswitch 7 starts a timing cycle. A circuit as shown in FIG. 11, including such a timing cycle, may be used. A timing relay 21 (shown in FIG. 4) may be used inside the machine, and the timing relay 21 may be controlled by an exterior timing knob (shown in FIG. 8( b )) on the outside of the machine.
[0098] In the preferred embodiment of the single-disk machine, the disk is drawn into the machine when a spring-loaded pinch roller mechanism, which comprises a pressure roller or pinch roller 8 riding on a big ball bearing 8 b (shown on FIG. 5), pinches the inserted to-be-processed disk 1 and pulls it into the machine. The pinch mechanism is driven by a first motor 10 . Thus, the roller mechanism functions first to draw the disk into the machine. Once the disk has been drawn into the machine, the roller mechanism keeps rotating the disk.
[0099] The motor 10 driving the pinch mechanism starts at the same time as a second motor 3 which drives a cutter or grinder 2 . Although most simply, both motors start at the same time, such simultaneous starting of the motors is not necessary. The motors are started automatically by insertion of the disk after switching ON the exterior on/off switch 23 (shown in FIG. 8( a )). Power is supplied via power cord 24 (shown in FIG. 4).
[0100] The pinch roller/motor combination mentioned above and shown in the figures has THREE functions using only ONE mechanism: (1) to draw the partially inserted disk into position for cutting; (2) to rotate the disk to cause the cutter/grinder to sweep the entire data band; and (3) to eject the declassified disk from the machine. These aspects of the invention are innovative, economical, and provide maximum simplicity, considering that the machine is fully automatic.
[0101] Minimizing the number of motors needed is advantageous, in several perspectives, including reducing the number of parts and thereby simplifying the machine, minimizing the weight, and minimizing the dimensions.
[0102] As part of the mechanism for capturing the inserted disk, a pivot may be provided with a non-rotating guidepost at the bottom of the pivot. The guidepost is exactly across from the center of the roller. Disk capture is facilitated by passing the guidepost.
[0103] The to-be-processed disk upon being fully inserted into the machine is positioned against ball bearings. In a preferred embodiment of the invention, as shown in FIG. 4, there are three ball bearings 9 a, 9 b and another that is not visible in FIG. 4 and is under the actuator 25 . The ball bearings 9 a, 9 b and the third ball bearing are positioned in a triangle, with the third ball bearing positioned on a pressure arm, which captures the disc 1 to position the disc for holding and rotating. The three ball bearings define where the disc center 1 b is ultimately located. This machine makes use of the fact that disks necessarily are uniform and circular for operation in normal use for data retrieval devices.
[0104] In the machine shown in FIGS. 9 and 10, the positioning and capturing of the disk are further accomplished by the following features.
[0105] A pivot is provided, with a guidepost at the bottom of the pivot. The guidepost does not rotate and is geometrically located with the guidepost exactly across from the center of the roller. By passing the guidepost, the disk is partially captured.
[0106] In a preferred embodiment, the time cycle is set for 2 revolutions of the disk. Other numbers of revolutions, such as 1, 3, 5 or other numbers of revolutions may be used. Providing 2 revolutions is believed to be the best combination of low heat and reasonable performance. In actual practice, for example, the machine might be adjusted at the factory so as to perform the required security function in one revolution, yet have its timer set for two revolutions, to provide an extra margin of safety. Advantageously, the user will only want the data destruction machine to run as long as necessary.
[0107] In using a machine as shown in the figures, the pinch roller 8 operates until the disk no longer remains in the machine to contact the switch actuator arm.
[0108] The ejection of the disk from the machine may be accomplished by the use of a circuit as in FIG. 11. Using that circuit, when the time cycle ends, the main (cutter) motor 3 shuts down and the roller (pinch) motor 10 reverses, causing the disk to exit the machine. This occurs partly because upon conclusion of the timed cycle, drag on the disk during deceleration of the cutter motor 3 makes exiting of the disk easier.
[0109] Optionally a front swing actuator arm spring 30 (shown in FIG. 4) can be set to fling the declassified disk completely out of the machine. This feature advantageously enables the fastest possible processing of a plurality of disks, which could be very important in an emergency.
[0110] As set forth above, it will be appreciated that the data destruction machine may be used to have three phases of operation, including disk insertion, disk rotation for a certain time, and disk exiting.
[0111] During operation of the data destruction machine, cutting proceeds such that the shiny top surface 1 c and data area are removed and separated from the inserted disk 1 . The center ring 1 b is not removed.
[0112] For accomplishing the cutting operation, and removing the top surface 1 c and data area from the disk 1 , the machine provides the cutter 2 .
[0113] For positioning the respective parts of the machine 2 in a reduced-space configuration, two pressure springs 11 a and 11 b may be used, as shown in FIG. 2.
[0114] The disposition of the high-speed drive motor 3 for the cutter 2 may be accomplished by using, for attachment, a collet.
[0115] In a preferred embodiment, the whole roller motor pivots as a unit to allow for wear on the pinch roller 8 (which rotates the disk) and changes in temperature. The workings of the pinch roller may be appreciated from FIG. 10, in which pinch roller 8 is above and contacts disk 1 under which is a ball bearing 8 b . The ball bearing freewheels during the cutting operation, and the pinch roller 8 moves. Those in the art are familiar with pinch rollers. A ball bearing was used in a preferred embodiment because it is precise and long-wearing, but alternatives may be used, such as bushings.
[0116] A brush 12 as shown in FIGS. 4, 5 and 6 is provided to brush from the pinch roller 8 dust that otherwise accumulates during operation.
[0117] For providing sufficient contact between the disk and the rotating cutter, in the embodiment shown in FIG. 7, a leading tension roller 14 a and a following tension roller 14 b are used for forcing the disk 1 against the rotating cutter 2 . Each tension roller is floppily mounted on two independent bars 26 a and 26 b, and 27 a and 27 b, respectively, with an arm pivot 28 and 29 , respectively, provided for each tension roller. There is a lower limit for how far down the tension rollers 14 a and 14 b can be pushed. The tension roller system conforms the disk to the cutter surface that it must contact, and acts as a pressure equalization/leveling device and also as the limit device. A vertical-limit-setting nut and equalizer bar are provided as part of the tension roller system.
[0118] The tension rollers 14 a and 14 b spin when on the disk surface. To permit such spinning, in mounting the tension roller to each arm, a loose, floppy mount is provided. Using a tension roller assembly is preferred and provides several advantages. First, the tension roller self-aligns to force the disk evenly against the rotating cutter. This allows for normal machine assembly without ultra-precision fits, tolerances, or adjustments. Second, the tension roller provides a balanced downward limit. The tension roller stays parallel as it descends to the lower limit. The limit bar allows this level limiting with one part, i.e., one adjustment for the two arms. Third, the tension roller is pushed down by a spring. The spring force is adjustable by a screw or nut. The spring position is adjustable by pivoting the spring arm mount, thus adding more or less tension roller pressure toward the center or edge of the disk as necessary. Fourth, the use of a second tension roller helps to mold the disk, which is slightly flexible, over the cutter, enhancing cutting efficiency and speed. Fifth, the use of the second tension roller also suppresses vibration of the disk, which otherwise could cause it to bounce away from the cutter.
[0119] A pinch force spring 8 a (as shown in FIGS. 4 and 10) may be provided to apply downwards pressure to the motor frame and to increase the pressure between the pinch roller 8 and the disk. In one embodiment, a moveable nut can be provided to decrease or increase the pressure of the pinch force spring 8 a . However, in another embodiment, spring pressure may be a non-adjustable feature.
[0120] With wear, a pinch roller becomes smaller. Accordingly, being able to change pinch rollers is an advantage. The machine provided herein provides for easy replaceability of the pinch roller.
[0121] During the cutting operation, the disk sits on a support platform 13 (shown in FIG. 4) which is a flat surface.
[0122] During the cutting operation, dust is formed. The dust, being sufficiently small-sized, as shown in FIG. 7, passes through the flake-capturing screen 5 and travels in the vacuum dust collection system into a dust collection bag 4 . A vacuum system may be provided, including an intake system, a discharge system and an auxiliary system. For gathering the dust before its vacuuming, as shown in FIG. 7, a dust collector cup 16 may be provided below the screen 5 , with the bottom of the cup 16 going through a hose 18 to vacuum intake (not shown on FIG. 7)
[0123] During the cutting operation, in addition to dust, flakes may be formed and require capturing. In a preferred embodiment, the flake capturing system is as simple as possible, so as to avoid the need to provide and drive a separate re-grinder or re-cutter, to avoid clogging, and to avoid providing more parts requiring close fits. Advantageously, the present invention for its flake capturing system and re-cutting reuses the precision high speed cutter 2 . The flakes get trapped by a screen 5 which is positioned under the rotating cutter 2 . The screen prevents the flakes from leaving the area of the cutter 2 . The flakes come into contact with and situate on the rotating cutter and thus, when that point on the cutter next contacts a disk surface, the flake is further cut down in size. Once the flakes are reduced to dust, they travel as does the originally produced dust in the dust collection system into the dust collection bag 4 .
[0124] In a data destruction machine such as that shown in FIG. 4, keeping the disk in cutting position is accomplished by tension rollers 14 a and 14 b and a balancing mechanism. When actual cutting is proceeding, the tension roller mechanism helps to keep the disk in contact with the cutting surface.
[0125] The machine configuration shown in FIGS. 2 and 4- 10 addresses, inter alia, the important requirements of: keeping the cylindrical cutting surface absolutely parallel to the disk so that the cutter 2 will penetrate sufficiently and data gaps will not be left; keeping the disk in flat, direct contact with the roller line and avoiding angular contact so that data gaps will not occur; avoiding bounce problems by forcing the disk in contact with the rest of the roller, using the flexibility of the disk itself.
[0126] The machine in the embodiments mentioned above advantageously has minimal mechanisms. However, it will be easily appreciated that mechanisms can be added to the machine.
[0127] The declassified disk that exits the machine has its center ring 1 b intact, but has been stripped of its shiny top surface 1 c and data area. The top surface 1 c and data area have been converted to dust and material consistent with security declassification standards from which data cannot be recovered.
[0128] Providing a data destruction method whereby the center ring 1 b remains after destruction of the data on the disk is significant. Typically, the center ring does not contain data but does contain a serial number by which the disk may be identified and controlled. Typically, security personnel responsible for controlling a disk on which was contained sensitive data will want to be able to have direct evidence that the particular disk with the particular serial number in question has been declassified.
[0129] In a preferred embodiment, an optional, detachable vacuum attachment is provided, for vacuuming from inside the machine dust that may have accumulated. During vacuuming using the optional vacuum accessory, the cutter is not operating. The optional vacuum accessory may make use of the vacuum system that already is provided as part of the vacuum dust-collection system. The optional on-board vacuum connection may include a hose and a small nozzle adapter. The life and proper mechanical functioning of the declassification machine may be enhanced by such optional further vacuuming.
[0130] Also as to dust control, filters may be provided for the motors (such as the cutter or vacuum motor) used in a declassification machine according to the invention, by providing filters over the air inlets of the motors, to prevent dust from entering the motor.
[0131] The invention provides for at least one disk to be inserted into a declassification machine. It will be appreciated that two or more discs may be loaded simultaneously, using multi-disk loading technology, including an auto-loader and unloader accessory.
[0132] When using a machine where the cutter is provided below the CD being declassified, it will be appreciated that the disk should be inserted data-side down into the machine, so that the data surface may be mechanically removed. The declassification machine (referring to FIG. 8( a )) may be switched on using the on/off switch 23 before, as or after a disk is inserted into the opening 6 .
[0133] The power requirements of a machine in which the cutter motor 3 , vacuum motor 15 and pinch roller motor 10 (in FIG. 4) as mentioned above are used is 100-130 vac 60 Hz, 3.7 amperes/445 watts, which provides relatively low power consumption. The declassification machine is pluggable into a wall outlet. Also, an emergency DC converter accessory may be provided to run on a 75 ampere-hour vehicle battery. In such a case, approximately 1900 disks may be declassified on a fully charged 75 ampere-hour, 30-lb. vehicle battery. A lighter-weight battery will provide destruction energy for a commensurate number of disks.
[0134] The motorized declassification machine and method are power-failure safe, in that in the event of loss of electrical power, the disk can be pulled out manually.
[0135] The declassification methods and machines according to the invention are simple to use for an unskilled operator, even under high stress conditions.
[0136] The sound level may be about 83 dB, A Scale, at 24 inches from the front disk slot (in a worst case position), which is comparable in sound level to a small vacuum cleaner. Such a sound level is quiet enough for an office environment.
[0137] The declassification methods and machines according to the invention are environmentally safe, in making a cool powder that is thought to be harmless, and is easily discarded or emptied. High temperatures are not used.
[0138] A declassification machine according to the invention is simple to use, like a CD player. Opening doors or drawers is not needed. Pushing buttons is not needed. Operating latches, catches, levers, hasps or the like is not needed. A machine according to the invention may be provided without exposed moving parts.
[0139] A declassification machine according to the invention is fully automatic and may be easily turned on for use, and the disk to be declassified inserted. The machine may be left on indefinitely or accidentally, and only the neon pilot light (using extremely low energy) remains on.
[0140] A machine according to the invention also advantageously may eject the disk and turn itself off.
[0141] In making a declassification machine according to the invention, in a preferred embodiment, the size and weight of the machine are minimized as much as possible. To accomplish such minimization, and to minimize the size and weight of a high-speed CD-disk declassification motorized machine to as small as about 8 inches by 10 inches by 12 inches and as light as about 17 pounds, while still providing a machine that outputs a verifiable center-ring-intact declassified CD, production may proceed as follows, with reference to FIGS. 4, 6, 8 ( a ).
[0142] As shown in FIG. 8( a ), a housing 31 of about 8 inches high, with a base of about 1 0 by 12 inches, may be provided. The housing 31 may be an NEMA 4X Fiberglass sculptured, gasketed enclosure. An opening 6 into which a CD or split DVD may be inserted is provided on a side of the housing.
[0143] Reference may be made to FIG. 4 for an example of how parts of the CD or split-DVD declassification machine may be disposed.
[0144] More particularly, in the housing interior, a system for capturing and positioning a CD or split-DVD is securely disposed, such that the capturing/positioning system is secured to the housing base.
[0145] To the capturing/positioning system is mechanically connected a system for disposing a patterned-surface cutter 2 of length about 1.52 inches, with the cutter parallel to and below where the CD or split-DVD will be held by the capturing/positioning system for cutting, with the cutter length aligned with the disk radius.
[0146] To the cutter 2 , a motor 3 is connected for rotating the cutter at 10,000-30,000 rpm. To the cutter motor 3 , a power cord 24 is connected for establishing connection to an external power source, such as for plugging into a wall outlet.
[0147] The disk capturing/positioning system may comprise a support platform 13 of about 6 inches wide by 5½ inches long for supporting the disk (such as a CD or split-DVD) during high-speeding cutting. The disk support platform 13 has a cut-out section (as seen with reference to FIG. 7) for the cutter 2 under the disk to contact the CD or split-DVD data surface. Preferably the size of the cut-out section in the support platform 13 is minimized to be no greater than needed for the rotating cutter 2 to contact the disk surface. The disk support platform 13 in FIG. 4 is secured to the housing using support frame 19 .
[0148] A microswitch system is included in the declassification machine shown in the figures, and comprises a microswitch 7 actuated by actuator arm 25 positioned (as in FIG. 6) with respect to the opening 6 into which the CD or split-DVD is inserted to detect entry of a CD or split-DVD into the housing.
[0149] The microswitch 7 is electrically connected to a timing circuit, and the timing circuitry is disposed in the housing interior.
[0150] In the inventive declassification machine shown, a motorized vacuum dust collection system is disposed in the housing interior. The motorized vacuum dust collection system comprises a vacuum motor 15 separate from the cutter motor 3 . The motorized vacuum dust collection system comprises a dust collection bag 4 (as shown in FIG. 5 when the machine is not operating and in FIG. 6 when the machine is operating) connected (with reference to FIG. 4) to a vacuum exhaust 17 . The vacuum exhaust is connected to a vacuuming device directed to vacuum dust from where the cutter 2 contacts the CD or split-DVD. The vacuum bag 4 in a preferred embodiment slips tightly onto a tapered rubber nipple 20 at the vacuum intake 17 .
[0151] The capturing/positioning system may be made using a motorized pinch roller system. The pinch roller 8 (with reference to FIG. 4) is positioned above and in close contact with the CD or split-DVD. A motor 10 separate from the cutter motor 3 and separate from the vacuum motor 15 is provided for operating the pinch roller.
[0152] For minimizing dust build-up on the pinch roller 8 , a brush 12 is disposed above the pinch roller 8 with the brushing end contacting the pinch roller 8 .
[0153] A flake-capturing screen 5 is shaped and positioned under the cutter 2 and close to the cutter without contacting the cutter and also under the disk support, and to completely block access by flakes to the vacuum intake.
[0154] For positioning the respective parts in a reduced-space configuration, two pressure springs 11 a and 11 b (as shown in FIG. 2) may be used in the disk positioning system.
[0155] In a preferred embodiment, all rotating components are disposed on permanently sealed, high-quality ball bearings.
[0156] In a preferred embodiment of a machine according to the invention, as shown in FIG., 12 , the vacuum system is driven from the main cutter motor, to provide a two-motor declassification machine. Advantageously, such a system reduces the number of separate motors needed.
[0157] In such an embodiment, the cutter motor drives the vacuum impeller 35 (referring to FIG. 12), which essentially is a centrifugal fan. The impeller 35 is in the impeller housing 36 . The vacuum system is mounted below the main support platform 13 , with the shaft axis vertical. A pulley (not shown in FIG. 12) is provided on the main cutter motor, a pulley 37 is provided on the vacuum impeller shaft 40 . Two additional pulleys 38 a and 38 b are mounted on the frame to allow the belt 39 to turn the corner and couple the motor pulley (not shown) to the vacuum impeller pulley 37 . Pulley diameters are sized to provide the vacuum impeller speed needed. Collected dust travels through a hose 41 and up to a bag (not shown in FIG. 12). Such a two-motor machine, by eliminating a third, separate vacuum motor, further reduces weight, cost, noise, power consumption and heat buildup within the housing. A two-motor machine according to this embodiment may be lighter than 17 pounds.
[0158] In another embodiment of a two-motor machine, the vacuum system is positioned close to the front disk slot, so that the impeller shaft pulley can be driven by a belt directly from the main motor shaft. A vacuum collection cup is provided, with a hose from the vacuum collection cup to the vacuum intake. The dust travels in the vacuum exhaust to a collection bag, as in the three-motor machine mentioned above.
[0159] An autoloader may be provided for feeding disks into the declassification machine.
[0160] Uncontrolled efforts to split a DVD may damage the DVD and result not in DVD half-disks but in DVD fragments that may be difficult or impossible to process with a rotating cutter (or any other acceptable means). Where DVDs are to be declassified by a data destruction machine, it will be appreciated that splitting of the DVDs to ready them for contact with a rotating cutter according to the invention preferably is accomplished in a controlled manner. Thus, where a rotating-cutter-containing data destruction machine is intended for use with DVDs, preferably a DVD splitter device is provided therewith, such as mechanically connected to the data destruction machine, most preferably detachably connected.
INVENTIVE EXAMPLE 1
[0161] A single-disk data declassification machine using a cylindrical herring bone cutter purchased from Manhattan Supply Corp. (part number 60469665) with shank slightly shortened was operated on 15 CD-ROM disks, 15 CD-WO disks and 15 CD-RWs at a time setting of no less than 8.5 seconds and a speed setting of approximately 20,000 rpm for each disk tested. After operation, declassified CDs remained, along with dust in the micron range.
INVENTIVE EXAMPLE 1-A
[0162] The inventive machine produced residue from the CD-ROM disks containing approximately 3.2% of the total weight in oversized particles with the remaining residue being consistent with security destruction standards. Evaluation of the oversized particles revealed that, due to heat created by friction of the initial cutting action or reduction in the secondary chamber, smaller particles were melting together, forming “remelt” particles. Further evaluation of these oversized particles revealed that no data could be retrieved. The machine therefore met the U.S. government standard for the secure routine destruction of classified and sensitive CD-ROM media.
INVENTIVE EXAMPLE 1-B
[0163] The machine produced residue from CD-WO (CD-R) disks containing approximately 8.6% of the total weight in oversized particles with the remaining residue consistent with the security destruction standard. Evaluation of these oversized particles revealed that they consisted of cc remelt” and metal foil. After further evaluation of both of the “remelt” and metal foil oversized particles, it was determined that no data could be retrieved. Therefore, the machine met U.S. government standards for the secure destruction of CD-WO media.
INVENTIVE EXAMPLE 1-C
[0164] The machine produced residue from CD-RW disks containing approximately 8.6% of the total weight in oversized particles with the remaining residue consistent with the security destruction standard. Evaluation of these oversized particles revealed that they consisted of “remelt” and metal foil. After further evaluation of both the “remelt” and metal foil oversized particles it was determined that no data could be retrieved. The machine therefore met U.S. government requirements for secure destruction of CD-RW media.
[0165] As a result of the testing, the machine may be characterized as “Meets DoD Standard for CD Destruction Devices”.
[0166] It will be appreciated that the above information is not intended to be limiting and that modifications may be made without departing from the spirit of the invention.
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The data destruction machine is a desk-top, portable unit with a short (under 10 second) cycle time, pluggable into a wall outlet. Upon insertion of a disk (such as a CD or split DVD) into the machine, which is fully automatic, data is removed. The machine converts the data-storage layer into residue consistent with security destruction standards from which no data is retrievable. A single machine may be used for declassifying CDs and split DVDs. Splitting DVDs in preparation for inserting them into the data destruction machine may be accomplished quickly and simply.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. Provisional Patent Application Ser. No. 60/489,664 filed Jul. 24, 2003.
TECHNICAL FIELD OF INVENTION
[0002] The present invention relates to amplifier design, and more particularly to a power amplifier for audio and other signals. Still more specifically, the present invention relates to design of an amplifier circuit capable of manipulating an unregulated AC signal to provide an amplified signal to a load device, so that fluctuations in the power supply to the amplifier circuit are compensated for, and noise or ripples present in the power supply are removed, eliminating the requirement for a regulated power supply.
BACKGROUND OF THE INVENTION
[0003] Power amplifiers are commonly used to amplify electrical signals supplying power to certain types of electronic devices, such as audio speakers. Most power amplifiers use, and depend upon, clean, regulated direct current (DC) power input. Unregulated DC power generated from unregulated alternating current (AC) is “noisy”, containing power fluctuations unsuitable for most power amplifying applications.
[0004] In typical applications, power amplifiers must convert an unregulated, noisy 120-volt AC power source into a regulated, clean DC power source. If the unregulated AC power input is simply rectified to a DC power input, any fluctuations, noise or ripple in the AC power signal may be transferred to the DC power signal. The noise inherent in DC power in this situation may be translated to the amplified output signal. In audio applications, such excessive variances in the power supply will result in undesirable hum, distortions, and noise at the speaker. As such, there is a need for regulated DC power supplies to power applications with a reduced noise factor.
[0005] Conventional power amplifiers rectify an AC signal to a regulated DC power source with transformers and other active inductive and capacitive circuits, which account for the majority of the weight, waste heat output, and cost of production associated with these prior-art amplifiers. As such, there is also a need for audio amplifiers that weigh less, produce less heat, and cost less.
[0006] A number of approaches have been tried to minimize or overcome the above-identified problems. U.S. Pat. No. 4,042,890 to Eckerie filters the DC power signal to reduce high-frequency noise. U.S. Pat. No. 4,605,910 to Covill produces a switch modulated signal for producing an output signal that is independent of the supply voltage, thereby eliminating noise caused by fluctuating AC voltage signals. U.S. Pat. No. 4,737,731 to Swanson senses variations in the DC power signal and adjusts the gain in the audio frequency signal according to the variances to reduce modulation distortion. In U.S. Pat. No. 5,132,637 also to Swanson, a plurality of actuable power amplifiers are controlled by a correction signal to produce a cleaner signal. U.S. Pat. No. 5,777,519 to Simopoulos uses a correction signal as an input to a variable switching power supply to eliminate some noise in the power signal.
[0007] However, each of these methods share the problems of high cost, high heat loss, high weight, and overall inefficiency. A different method for regulating the power output that eliminates the regulated DC power source would offer significant advantages in cost and efficiency as well as a significant reduction in weight and increase in output power.
SUMMARY OF THE INVENTION
[0008] The present invention eliminates the need to regulate a DC power supply by regulating the gain of an amplifier in response to fluctuations and ripple in the unregulated DC power supply so that those fluctuations and ripples do not appear at the output power signal. Unregulated AC power may be supplied from a conventional AC outlet or from an isolation or other transformer. Unregulated AC power is first rectified into unregulated DC power, and this unregulated DC power signal is monitored by a voltage divider to establish a power supply “variance” signal. This variance signal is then squared by an analog multiplier. A second multiplier processes the signal from the first multiplier with a triangular wave signal to produce an input signal to an internal comparator. The first and second voltage multipliers comprise a triangular wave modulator. The resulting output signal from the second multiplier is the modulated triangular wave signal.
[0009] An internal comparator accepts an input audio signal as well as the output signal from the second multiplier. This internal comparator monitors and processes the input audio signal with the modulated triangular wave signal to generate a Pulse Width Modulation (PWM) output signal. From the internal comparator, the PWM output signal is amplified by power device transistors, and the amplified PWM signal passes through filters to remove a high-frequency carrier component. The signal output from the filters is an amplified PWM power signal, which is then used to drive a load device.
[0010] The variances in the power supply voltage are demodulated or removed by this approach, thereby eliminating the need for a regulated DC power supply. The invention provides for dynamic adjustment for noise in the unregulated DC power supply, resulting in a simpler and more efficient power amplifier to derive a clean, regulated, amplified power drive signal. The present invention also provides audio improvements including compression and frequency equalization.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The objects and features of the invention will become more readily understood from the following detailed description and appended claims when read in conjunction with the accompanying drawings in which like numerals represent like elements.
[0012] FIG. 1 is a basic circuit block diagram illustrating a preferred embodiment of the functional components of the power amplifier of the present invention.
[0013] FIG. 2 is a circuit schematic of a preferred embodiment of the AC power circuit.
[0014] FIG. 3 is the circuit schematic of a preferred embodiment of the DC bridge rectifier and voltage divider.
[0015] FIG. 4 is a circuit schematic of a preferred embodiment of the triangular wave modulator (TWM) containing two voltage multipliers.
[0016] FIG. 5 is a circuit schematic of a preferred embodiment of the pulse width modulator (PWM) controller containing the triangular wave generator and pulse width modulation amplifier.
[0017] FIG. 6 is the circuit schematic of a preferred embodiment of the power device transistor and filter.
[0018] FIG. 7 is a circuit schematic of a preferred embodiment of the RMS-to-DC converter used to provide an additional signal for providing dynamic range compression, or Automatic Gain Control, to the amplifier circuit.
[0019] FIG. 8 is a composite circuit schematic of a preferred embodiment of the present invention for a modulated triangular wave audio power amplifier.
[0020] FIG. 9 illustrates the internal operative connectivity for the PWM controller illustrated schematically and described in detail in connection with FIG. 5 .
[0021] FIG. 10 is a block diagram of the modulated triangular wave audio power amplifier configured as a noise-canceling amplifier.
[0022] FIG. 11 is a block diagram of the modulated triangular wave audio power amplifier configured to compress or expand dynamic range or for signal equalization or cancellation.
[0023] FIG. 12 is a block diagram of the modulated triangular wave audio power amplifier configured to introduce an additional signal to output.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] In the following Detailed Description of the Preferred Embodiments, reference is made to the accompanying drawings which form a part hereof, and in which are shown by way of illustration specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention. For example, intervening electrical components may be located along electrical connections, and electrical components of different ratings may be used, without departing from the scope of the present invention. Moreover, persons of ordinary skill in the art will know that numerous minor alternatives to a specific circuit design are possible, without departing from the scope of the present invention. Thus understood, the details of the circuit provided, including the ratings of the electrical components in the specific preferred embodiments, are not intended to limit the scope of any claim, nor to be read into any claim, but merely to provide an example of a fully enabled and disclosed best mode of practicing a preferred embodiment of the invention.
[0025] FIG. 1 illustrates a preferred embodiment of the basic electrical components of the amplifier of the present invention. As seen in FIG. 1 , an AC power supply 5 is coupled to an optional AC power circuit (transformer) 7 by an electrical connection 50 . Optional AC power circuit 7 is coupled to a bridge rectifier 10 by an electrical connection 51 . Bridge rectifier 10 is coupled to a voltage divider 15 by an electrical connection 55 . Bridge rectifier 10 is also coupled to a power device transistor 30 by an electrical connection 60 .
[0026] Voltage divider 15 is coupled to a first input 21 of a first voltage multiplier 20 by an electrical connection 65 and to a second input 22 by an electrical connection 66 . The output of first voltage multiplier 20 is coupled to a first input 24 of a second voltage multiplier 23 by an electrical connection 67 . A triangular wave generator 27 is coupled to a second input 26 of second voltage multiplier 23 by electrical connection 68 . First voltage multiplier 20 and second voltage multiplier 23 comprise a triangular wave modulator (TWM) 91 .
[0027] The output of second voltage multiplier 23 is coupled to a first input 28 of an internal comparator 25 by an electrical connection 70 . In a preferred embodiment, an audio signal source 35 is coupled to a second input 29 of an internal comparator 25 by an electrical connection 80 . The output of internal comparator 25 is coupled to a power device transistor 30 by an electrical connection 75 . In the preferred embodiment, internal comparator 25 is internal of a pulse width modulation controller integrated circuit (PWM controller 93 ) that includes triangular wave generator 27 , as described in detail below. Power device transistor 30 is coupled to a filter 40 by an electrical connection 85 . Filter 40 is coupled to a load device 45 by an electrical connection 90 .
[0028] In operation, unregulated AC power supply 5 supplies an unregulated, AC power signal to the amplifier. The unregulated AC power signal passes through bridge rectifier 10 , which rectifies, or converts, the unregulated AC power signal into an unregulated DC power signal. This unregulated DC power signal is used to provide a reference voltage to triangle wave modulator 91 as well as being used by power device transistors 30 to power load device 45 .
[0029] From bridge rectifier 10 , the unregulated DC power signal passes through voltage divider 15 . Voltage divider 15 establishes a unity voltage level and provides two input power signals comprising the voltage variance of the power signal into first voltage multiplier 20 . First voltage multiplier 20 multiplies these two signals together, providing an unregulated DC power signal equal to the square of the voltage variance.
[0030] The output of first voltage multiplier 20 is coupled to first input 24 of second voltage multiplier 23 . Triangular wave generator 27 generates a triangular wave signal that is coupled to second input 26 of second voltage multiplier 23 . These two signals are multiplied together by second voltage multiplier 23 to generate a modulated triangular wave signal.
[0031] The modulated triangular wave signal, output from triangular wave modulator 91 , is the first input to PWM Amp 25 . The second input to PWM Amp 25 is the audio signal being amplified, from audio source 35 . PWM Amp 25 compares the modulated triangular wave signal and the audio signal to generate a pulse width modulation (PWM) power signal carrying the audio component. The PWM power signal then passes to power device transistors 30 , which amplify the PWM power signal. This amplified PWM power signal then passes through filter 40 (e.g., an inductance capacitor filter) which filters out the high-frequency carrier component of the PWM power signal. This filtered PWM power signal provides a clean, undistorted audio signal free of noise to load device 45 because the modulated triangle wave signal compensates for variances in AC power supply 5 , powering the load device 45 for the relevant application.
[0032] FIG. 2 illustrates a preferred embodiment for the AC power circuit ( 7 in FIG. 1 ) of the present invention. In this embodiment, the AC power circuit uses a triac 150 and optocoupler 140 to delay the onset of AC power in the amplifier. This time delay power-on circuit delays the onset of AC power to allow the control circuit to stabilize and avoid loud pops when switched on.
[0033] In the circuit, AC power from an outside AC power source (e.g., wall outlet, generator, etc.) is provided through an electrical pole 101 and an electrical pole 103 . Electrical poles 101 and 103 are coupled respectively by an electrical connection 102 and an electrical connection 104 in a parallel electrical circuit with a two-pole circuit breaker 105 . Electrical connection 102 is coupled from circuit breaker 105 to a transformer 110 (e.g., 12-volt transformer). Electrical connection 104 is also coupled from circuit breaker 105 to transformer 110 .
[0034] Transformer 110 steps down the supply voltage (e.g., from 120-volts AC to 12-volts AC). Current flows from transformer 110 through two electrical connections 111 and 113 to a bridge rectifier 112 . The output from bridge rectifier 112 passes through electrical connections 116 and 114 to a filter network 115 . In a specific preferred embodiment, filter network 115 comprises a 2200 μF capacitor 117 , a 100 μF capacitor 118 , and a 0.1 μF capacitor 119 coupled in parallel with bridge rectifier 112 by electrical connections 116 and 114 .
[0035] An electrical connection 121 couples a power supply regulator 120 to electrical connection 116 . In a specific preferred embodiment, power supply regulator 120 is of the type comparable to a Motorola 78L12. Power supply regulator 120 is coupled to an electrical ground 108 by an electrical connection 123 . A capacitor 124 and a capacitor 126 are coupled to power supply regulator 120 by an electrical connection 122 . The two capacitors 124 and 126 are also coupled together by electrical connection 114 .
[0036] An electrical connection 127 couples a resistor 128 to a terminal V 12 125 . Terminal V 12 125 represents a source of direct current (DC) power supplied for the circuit. In the preferred embodiment disclosed, the voltage supplied is for a 12-volt circuit. Also in the preferred embodiment disclosed, resistor 128 is a 68K-ohm resistor. A resistor 129 is coupled to electrical connection 127 by an electrical connection 130 in a parallel electric circuit configuration.
[0037] As stated, terminal V 12 125 is coupled to electrical connection 127 , and this electric terminal V 12 125 provides a DC power source (e.g., 12-volt). Resistor 128 and resistor 129 are both coupled to the DC power source. Resistor 128 is coupled in series with another resistor 131 by electrical connection 133 . In a specific preferred embodiment, resistor 131 is a 68K-ohm resistor. Resistor 129 is coupled in series with a capacitor 132 by an electrical connection 134 . Resistor 131 is coupled to an electrical ground 108 by an electrical connection 136 , and capacitor 132 is coupled to an electrical ground 108 by an electrical connection 137 .
[0038] A comparator 135 is coupled to electrical connections 133 and 134 . The non-inverting input to comparator 135 is coupled to electrical connection 134 by an electrical connection 139 . The inverting input of comparator 135 is coupled to electrical connection 133 by an electrical connection 141 . Comparator 135 compares the input voltages of the two electrical connections. If the voltage at electrical connection 139 is less than the voltage at electrical connection 141 , the output of comparator 135 will be low, with the voltage at the output at an electrical connection 142 at the lowest possible value (e.g., digital output=0). If the voltage at electrical connection 139 is greater than the voltage at electrical connection 141 , the output of comparator 135 will be high, with the voltage at the output at electrical connection 142 at its highest value (e.g., digital output=1).
[0039] An optocoupler 140 is comprised of a light emitting diode (LED) 171 and a phototransistor 172 inside a component case. Light emitting diode 171 emits light when the digital output value from comparator 135 equals 1 (e.g., the voltage at electrical connection 139 is greater than that at electrical connection 141 ). An electrical connection 143 couples a resistor 144 to the LED 171 . An electrical connection 146 couples resistor 144 to ground 108 . In a specific preferred embodiment, resistor 144 is a 560K-ohm resistor.
[0040] Phototransistor 172 has a light sensitive base region. When light strikes the photosensitive base of phototransistor 172 , the emitter-to-collector resistance falls, allowing current to flow through phototransistor 172 . When the digital output value from comparator 135 equals 1 (logic 1 state), LED 171 is illuminated. Light from LED 171 charges the base of phototransistor 172 , permitting current flow through phototransistor 172 . Thus, optocoupler 140 functions as a switch triggered by the output of comparator 135 .
[0041] An electrical connection 152 couples circuit breaker 105 and the AC power to a capacitor 157 , a triode alternating current switch (triac) 150 , and a resistor 145 . Resistor 145 is coupled to optocoupler 140 by an electrical connection 147 . An electrical connection 149 further couples electrical connection 147 to the gate of triac 150 . Triac 150 is coupled to a terminal L 2 165 and optocoupler 140 by an electrical connection 151 . Capacitor 157 is coupled to a resistor 155 by an electrical connection 156 , and resistor 155 is further coupled to terminal L 2 165 by an electrical connection 153 . Terminal L 1 160 is coupled to transformer 110 and breaker 105 by electrical connection 107 .
[0042] Optocoupler 140 isolates triac 150 from the control circuit. When phototransistor 172 is activated by LED 171 , voltage applied to the gate of triac 150 causes current to flow through triac 150 and energize terminal L 2 165 . Once the gate activates triac 150 , AC power will continue to terminal L 2 165 and L 1 160 as long as the circuit remains energized. The optocoupler 140 and triac 150 combination will delay circuit power-up until the control circuit stabilizes, avoiding pops and hiss from the audio output.
[0043] FIG. 3 illustrates a preferred embodiment of a bridge rectifier 205 ( 10 in FIG. 1 ) and a voltage divider (resistors 210 , 215 , and their electrical interconnection, 15 in FIG. 1 ) of the present invention. A pair of terminals L 1 160 and L 2 165 are coupled to bridge rectifier 205 by electrical connections 201 and 202 respectively. Two electrical output connections from bridge rectifier 205 couple to a resistor-capacitor (RC) filter and resistor voltage divider network arrangement. An electrical connection 208 couples bridge rectifier 205 to terminal V H 240 . Terminal V H 240 represents a high voltage terminal connection. An electrical connection 207 couples bridge rectifier 205 to an electrical connection 221 , and to an electrical connection 206 . Electrical connection 221 is coupled to ground 108 . An electrical connection 209 couples bridge rectifier 205 to a capacitor 230 . In a specific preferred embodiment, capacitor 230 is a 1000 μF capacitor. Electrical connection 206 couples capacitor 230 to electrical connection 207 . Electrical connection 209 is also coupled to electrical connection 208 .
[0044] A resistor 210 and a resistor 215 are connected in series to each other and to capacitor 230 in a parallel circuit. An electrical connection 212 couples resistor 210 to electrical connection 208 . An electrical connection 211 further couples resistor 210 to resistor 215 . Electrical connection 221 couples resistor 215 to ground 108 .
[0045] An electrical connection 213 couples resistors 210 and 215 to the non-inverting terminal of an operational amplifier 218 (op amp 218 ). An electrical connection 217 couples the output of op amp 218 to the inverting terminal input of op amp 218 . Thus configured op amp 218 performs as a voltage follower. An electrical connection 216 connects the output of op amp 218 (the voltage follower) to a terminal T 1 250 . The arrangement of the resistors 210 and 215 and the electrical connections 213 and 211 between resistors 210 and 215 comprises a resistor voltage divider network. One or both of resistors 210 and 215 may be variable, to accommodate adjustment of the power variance signal.
[0046] FIG. 4 illustrates a preferred embodiment of the circuit for the triangular wave modulator ( 91 in FIG. 1 ) of the present invention. Although the preferred embodiment shown in FIG. 4 discloses a design for an analog circuit, the equivalent functionality may be achieved through digital circuitry, such as, for example, by use of digital signal processors.
[0047] As seen in FIG. 4 , a terminal T 1 250 is coupled to a first resistor 382 by an electrical connection 301 . Resistor 382 is subsequently coupled to a first voltage multiplier 310 ( 20 in FIG. 1 ), an integrated circuit chip with a voltage multiplier circuit, by an electrical connection 383 to pin 1 . Terminal T 1 250 is coupled to a second resistor 381 by electrical connection 301 through an electrical connection 303 . Resistor 381 is subsequently coupled to first voltage multiplier 310 by an electrical connection 384 to pin 8 . Pin 7 of voltage multiplier 310 is coupled to a capacitor 305 (typically 0.1 μF) by an electrical connection 308 . Pin 2 of first voltage multiplier 310 is coupled to electrical connection 308 by an electrical connection 309 .
[0048] Capacitor 305 is coupled to ground 108 by an electrical connection 306 . Terminal V G 302 is coupled to electrical connection 308 by an electrical connection 304 . Terminal V G 302 represents a virtual ground for supplying a ground reference to single power supply electrical components. Pin 5 of first voltage multiplier 310 is coupled to a resistor 315 by an electrical connection 312 , and resistor 315 is coupled to a terminal V 12 125 by an electrical connection 314 . In a specific preferred embodiment, resistor 315 is 60K-ohm resistor. Pin 6 of first voltage multiplier 310 is coupled to terminal V G 302 by electrical connection 377 .
[0049] Pin 4 of first voltage multiplier 310 is coupled to the inverting input of an op amp 320 by an electrical connection 311 . A resistor 325 is coupled to the inverting input of op amp 320 by an electrical connection 317 , which is coupled to electrical connection 311 . An electrical connection 321 couples an RMS terminal 330 to the pin 8 input of a second voltage multiplier 340 ( 23 FIG. 1 ) through an electrical connection 336 . An electrical connection 324 couples resistor 325 to the output of op amp 320 through an electrical connection 327 . An electrical connection 326 couples a resistor 335 to electrical connection 324 .
[0050] Electrical connection 336 couples resistor 335 to pin 8 of second voltage multiplier 340 . This signal input is the square of the variance of the input voltage to first voltage multiplier 310 . The signal from RMS terminal 330 is added to this signal. The second input is from a triangular wave generator through pin 1 of second voltage multiplier 340 . Pin 7 of second voltage multiplier 340 is coupled to an electrical connection 351 by electrical connection 341 . Pin 2 of second voltage multiplier 340 is coupled to electrical connection 341 by an electrical connection 343 .
[0051] Pin 5 of second voltage multiplier 340 is coupled to a resistor 355 by an electrical connection 337 . Resistor 355 is further coupled to a terminal V 12 125 by an electrical connection 339 . In a specific preferred embodiment, resistor 355 is a 60K-ohm resistor. Pin 6 of second voltage multiplier 340 is connected to V G 302 by an electrical connection 379 which is coupled to electrical connection 351 .
[0052] Pin 4 of second voltage multiplier 340 is the output of the two voltage multipliers. This output is connected to an inverter amplifier circuit, comprising an op amp 350 and resistor 358 . Pin 4 of second voltage multiplier 340 is coupled to the inverting input of op amp 350 by an electrical connection 344 . Electrical connection 356 couples resistor 358 to electrical connection 344 . The output of op amp 350 is coupled to electrical connection 357 , which couples resistor 358 to capacitor 360 by connection 352 . Capacitor 360 is coupled to terminal T 3 375 by electrical connection 361 .
[0053] Pin 1 of second voltage multiplier 340 receives the input triangular wave signal. Terminal T 2 380 is coupled to a capacitor 365 by electrical connection 366 . In a specific preferred embodiment, capacitor 365 is a 0.047 μF capacitor. Capacitor 365 is coupled to the non-inverting input of a voltage follower op amp 370 by an electrical connection 371 . The output of op amp 370 is coupled to a resistor 345 by an electrical connection 346 . In a specific preferred embodiment, resistor 345 is a 10K-ohm resistor. Electrical connection 346 is coupled to the inverting input of voltage follower op amp 370 by an electrical connection 373 . Resistor 345 is coupled to pin 1 of second voltage multiplier 340 by an electrical connection 342 .
[0054] FIG. 5 illustrates a preferred embodiment of the present invention for the pulse width modulation controller ( 93 in FIG. 1 ) including its audio input circuitry, the triangular wave generator, and the pulse width modulation amplifier. The audio source signal input to the amplifier is through terminals T 4 401 and T 5 402 . Terminal T 4 401 is coupled to a capacitor 412 by an electrical connection 407 . In a specific preferred embodiment, capacitor 412 is a 22 μF capacitor. A resistor 405 is coupled to electrical connection 407 by an electrical connection 408 . In a specific preferred embodiment, resistor 405 is a 100K-ohm resistor. Resistor 405 is coupled to a terminal V G 302 by an electrical connection 409 , and terminal T 5 402 is coupled to electrical connection 409 by an electrical connection 404 .
[0055] Capacitor 412 is coupled to a resistor 415 by an electrical connection 406 . In a specific preferred embodiment, resistor 415 is an 11K-ohm resistor. A capacitor 410 is coupled to electrical connection 406 by an electrical connection 403 . In a specific preferred embodiment, capacitor 410 is a 0.1 μF capacitor 410 . Resistor 415 is coupled to the non-inverting terminal of an op amp 416 by an electrical connection 414 . Capacitor 410 is connected in a parallel circuit to resistor 415 by an electrical connection 411 connected to electrical connection 414 .
[0056] Op amp 416 is configured as a follower. Electrical connection 414 is coupled to the non-inverting input of op amp 416 . The output of the op amp 416 is coupled to a resistor 418 by an electrical connection 413 . In a specific preferred embodiment, resistor 418 is a 390-ohm resistor. An electrical connection 417 couples electrical connection 413 to the inverting input of op amp 416 , thus configuring op amp 416 as a voltage follower. Resistor 418 is coupled to a capacitor 420 by an electrical connection 419 . In a specific preferred embodiment, capacitor 420 is a 22 μF capacitor. Capacitor 420 is coupled to a pulse width modulation controller 430 ( 93 in FIG. 1 ).
[0057] In the preferred embodiment disclosed, PWM controller 430 is an integrated circuit chip, which provides the triangular wave generator and internal comparator circuit. An electrical connection 421 is connected to PIN 1 (AUDA) of PWM controller 430 . A terminal AA 425 is coupled to electrical connection 421 by an electrical connection 426 . Terminal AA 425 represents the audio input to the circuit. In the preferred embodiment, the audio input is buffered as shown by voltage follower 416 . A capacitor 423 is coupled to electrical connection 421 by an electrical connection 422 , and the capacitor 423 is coupled to ground 108 by an electrical connection 427 . In a specific preferred embodiment, capacitor 423 is a 6800-pF capacitor.
[0058] An electrical connection 451 couples the audio input signal to an inverting amplifier 450 . Electrical connection 451 is coupled to a resistor 452 . An electrical connection 449 couples resistor 452 to the inverting input of op amp 450 . An electrical connection 467 couples electrical connection 449 to another resistor 448 . In a specific preferred embodiment, resistor 452 and resistor 448 are 22K-ohm resistors.
[0059] A capacitor 456 is coupled to electrical connection 451 by an electrical connection 477 . Capacitor 456 is coupled to ground 108 by an electrical connection 457 . In a specific preferred embodiment, capacitor 456 is a 47-pF capacitor. A resistor 454 is coupled to electrical connection 477 by an electrical connection 453 , in a parallel circuit arrangement with capacitor 456 . An electrical connection 459 couples resistor 454 to connection 458 , thence to Terminal V G 302 .
[0060] Terminal V G 302 is coupled to electrical connection 459 by an electrical connection 458 . An electrical connection 461 couples electrical connection 459 to the non-inverting input of op amp 450 . A capacitor 462 is coupled to electrical connection 461 by an electrical connection 469 , and electrical connection 493 couples capacitor 462 to electrical connection 495 and ground 108 .
[0061] The output of the op amp 450 is coupled to a resistor 445 by an electrical connection 471 . In a specific preferred embodiment, resistor 445 is a 390-ohm resistor. Resistor 445 is coupled to a capacitor 443 by an electrical connection 444 . In a specific preferred embodiment, capacitor 443 is a 22-μF capacitor. An electrical connection 479 couples capacitor 443 to pin 8 , the Audio B (AUD B) input, on controller 430 . An electrical connection 481 couples electrical connection 479 to a capacitor 440 , and electrical connection 497 couples capacitor 440 to ground 108 . In a specific preferred embodiment, capacitor 440 is a 6800-pF capacitor 6800.
[0062] In a specific preferred embodiment, pulse width modulation controller 430 is a Zetex ZXCD 1000, the internal configuration of which is illustrated in FIG. 9 . In this embodiment, electrical connection 421 is coupled to pin 1 of PWM controller 430 . Pin 1 is the Audio A (AUD A) input, which is the non-inverting input to the first internal comparator on controller 430 . The Audio B (AUD B) input, pin 8 , is coupled to op amp 450 by electrical connection 479 . AUD B is the non-inverting input to the second internal comparator on controller 430 . A terminal T 3 375 , the output from second voltage multiplier 340 , is coupled to the Triangle B (TRI B) input, pin 7 , of PWM controller 430 by electrical connection 489 . Electrical connection 429 couples electrical connection 489 , and terminal T 3 375 , to Triangle A (TRI A) input, pin 2 of PWM controller 430 .
[0063] PWM controller 430 includes two internal comparators (see FIG. 9 ). The AUD A input, pin 1 of PWM controller 430 , is coupled to the non-inverting input of the first internal comparator, and the TRI A input, pin 2 of PWM controller 430 , is the inverting input of the first internal comparator. The Output A (OUT A), pin 15 of PWM controller 430 , is the output signal from the first internal comparator and is coupled to terminal T 6 498 by an electrical connection 463 . The AUD B input, pin 8 on PWM controller 430 , is the non-inverting input of the second internal comparator, and the TRI B input, pin 7 of PWM controller 430 , is the inverting input of the second internal comparator. The Output B (OUT B), pin 10 of PWM controller 430 , is the output signal from the second internal comparator and is coupled to terminal T 7 499 by an electrical connection 486 .
[0064] PWM controller 430 also generates the triangular wave signal input to second voltage multiplier 340 . OSC A generates a triangular wave signal. The OSC A output, pin 3 , is coupled to terminal T 2 380 by electrical connection 431 . Referring back to FIG. 4 , it is seen that the triangular wave signal at terminal T 2 380 subsequently passes through capacitor 365 , follower 370 , and resistor 345 , to the pin 1 input of second voltage multiplier 340 . Referring again to FIG. 5 , pin 5 of PWM controller 430 , COSC, is coupled to a capacitor 437 by electrical connection 432 , and capacitor 437 is coupled to ground 108 by electrical connection 439 . In a specific preferred embodiment, capacitor 437 is a 330-μF capacitor. Pin 9 of PWM controller 430 , GND, is coupled to ground 108 by electrical connection 479 . Pin 11 of PWM controller 430 , GND 2 , is coupled to electrical connection 479 and ground 108 by an electrical connection 496 .
[0065] Pin 12 of PWM controller 430 , 9 VB, is connected to an internal power supply of PWM controller 430 (typically 9-volt), and is coupled by an electrical connection 472 to three capacitors 470 , 474 , and 480 , which are individually connected in a bridge, or parallel arrangement to electrical connection 479 . Pin 14 of the PWM controller 430 , 9 VA, is connected to the internal power supply of PWM controller 430 (typically 9-volt), and is coupled by an electrical connection 469 to electrical connection 472 and the three capacitors 470 , 474 , and 480 . Pin 16 of the PWM controller 430 , 5 V 5 , is connected to an internal power supply of PWM controller 430 (typically 5.5-volt), and is coupled to a capacitor 435 by an electrical connection 461 . Capacitor 435 is coupled to ground 108 by an electrical connection 443 . An electrical connection 439 couples a capacitor 434 to electrical connection 461 and to 5 V 5 . An electrical connection 441 couples capacitor 434 to ground 108 .
[0066] Pin 13 , V CC , receives the external power supply to PWM controller 430 . Pin 13 , V CC is coupled to the power supply terminal V 12 125 (12-volt in the specific preferred embodiment), by electrical connection 468 , and is coupled by three capacitors 473 , 475 , and 478 in a bridge, or parallel circuit arrangement, to electrical connection 479 and ground 108 . The external power supply V CC supplies power to PWM controller 430 , and regulators on PWM controller 430 drop the power to the internal power sources (typically 9-volt and 5.5-volt) required by the internal circuitry of PWM controller 430 .
[0067] FIG. 6 illustrates a preferred embodiment for the power device transistor and filter ( 30 in FIG. 1 ) of the present invention. A terminal T 6 498 is coupled by an electrical connection 501 to an electrical connection 503 . Electrical connection 503 couples a capacitor 521 to a capacitor 505 in series. An electrical connection 527 couples capacitor 521 to the anode of diode 530 . An electrical connection 529 couples the cathode of diode 530 to a terminal V H 213 . An electrical connection 533 couples a resistor 534 to electrical connection 529 and to the cathode of diode 530 in a parallel circuit. An electrical connection 531 couples electrical connection 527 and an electrical connection 532 to resistor 536 . An electrical connection 535 couples electrical connection 531 to the anode of a diode 537 in a parallel circuit to a resistor 536 . Cathode of diode 537 is coupled to electrical connection 539 by an electrical connection 538 .
[0068] An electrical connection 545 couples a capacitor 546 to electrical connection 529 and terminal V H 213 and the cathode of diode 530 . In a specific preferred embodiment, capacitor 546 is a 0.47-μF capacitor. An electrical connection 548 couples capacitor 546 to ground 108 .
[0069] Electrical connection 539 couples resistor 536 and electrical connection 538 to the gate of a P-channel metal-oxide-semi-conductor field-effect transistor (MOSFET) 540 . The source of MOSFET 540 is coupled to electrical connection 529 by an electrical connection 541 . The drain of MOSFET 540 is connected to an electrical connection 520 by an electrical connection 542 .
[0070] Capacitor 505 is coupled to the cathode of a diode 510 by an electrical connection 504 . An electrical connection 508 couples electrical connection 504 to a resistor 513 . An electrical connection 502 couples electrical connection 508 to a resistor 511 in a parallel circuit to diode 510 . An electrical connection 509 couples resistor 511 to an electrical connection 507 . An electrical connection 512 couples the cathode of a diode 514 to electrical connection 502 in a parallel circuit to resistor 513 . An electrical connection 515 couples the anode of diode 514 to an electrical connection 516 , which is coupled to resistor 513 .
[0071] Electrical connection 516 couples resistor 513 and the anode of diode 514 to the gate of an N-channel MOSFET 517 . The source of MOSFET 517 is coupled to electrical connection 507 by electrical connection 519 , and electrical connection 519 is coupled to electrical connection 548 and ground 108 by electrical connection 507 . The drain of MOSFET 517 is coupled to electrical connection 520 by an electrical connection 518 . Electrical connection 520 is coupled to a inductor 543 . Inductor 543 is coupled to the first output terminal OUT 1 601 of the amplifier by an electrical connection 544 . In a specific preferred embodiment, inductor 543 is a 20-μH inductor. Electrical connection 528 couples a capacitor 547 to electrical connection 520 and inductor 543 . An electrical connection 549 couples capacitor 547 to ground 108 . In a specific preferred embodiment, capacitor 547 is a 1-μF capacitor. The combination of inductor 543 and capacitor 547 forms an LC filter configuration for the signal output at OUT 1 601 .
[0072] A terminal T 9 499 is coupled by an electrical connection 551 to an electrical connection 553 . Electrical connection 553 couples a capacitor 571 and a capacitor 555 together in series. An electrical connection 577 couples capacitor 571 to the anode of a diode 580 . An electrical connection 579 couples the cathode of diode 580 to a terminal V H 214 . An electrical connection 583 couples a resistor 584 to an electrical connection 579 and the cathode of diode 580 in a parallel circuit. An electrical connection 581 also couples electrical connection 577 and an electrical connection 582 to a resistor 586 . An electrical connection 585 couples electrical connection 581 to the anode of a diode 587 in a parallel circuit to resistor 586 . The cathode of diode 587 is coupled to an electrical connection 589 by an electrical connection 588 .
[0073] An electrical connection 595 couples a capacitor 596 to electrical connection 579 and terminal V H 214 and the cathode of diode 580 . In a specific preferred embodiment, capacitor 596 is a 0.47-μF capacitor. Electrical connection 598 couples capacitor 596 to ground 108 .
[0074] An electrical connection 589 couples resistor 586 and an electrical connection 588 to the gate of a P-channel MOSFET 590 . The source of MOSFET 590 is coupled to an electrical connection 579 by an electrical connection 591 . The drain of MOSFET 590 is connected to an electrical connection 570 by an electrical connection 592 .
[0075] Capacitor 555 is coupled to the cathode of a diode 560 by an electrical connection 554 . An electrical connection 558 couples electrical connection 554 to a resistor 563 . An electrical connection 552 couples electrical connection 558 to a resistor 561 in a parallel circuit to diode 560 . An electrical connection 559 couples resistor 561 to an electrical connection 557 . An electrical connection 562 couples the cathode of a diode 564 to electrical connection 552 in a parallel circuit to resistor 563 . An electrical connection 565 couples the anode of diode 564 to an electrical connection 566 , which is coupled to resistor 563 .
[0076] Electrical connection 566 couples resistor 563 and the anode of diode 514 to the gate of an N-channel MOSFET 567 . The source of MOSFET 567 is coupled to electrical connection 557 by an electrical connection 569 , and electrical connection 569 is coupled to an electrical connection 598 and ground 108 by electrical connection 557 . The drain of MOSFET 567 is coupled to electrical connection 570 by an electrical connection 568 . Electrical connection 570 is coupled to an inductor 593 . Inductor 593 is coupled to the second output terminal OUT 2 602 of the amplifier by an electrical connection 594 . In a specific preferred embodiment, inductor 593 is a 20-μH inductor. An electrical connection 578 couples a capacitor 597 to electrical connection 570 and inductor 593 . Electrical connection 599 couples capacitor 597 to ground 108 . In a specific preferred embodiment, capacitor 597 is a 1-μF capacitor. The combination of inductor 593 and capacitor 597 forms an LC filter configuration for the signal output at OUT 2 602 . A load device (not shown), typically a speaker in audio applications, is connected to each of the outputs OUT 1 601 and OUT 2 602 .
[0077] FIG. 7 illustrates an alternative preferred embodiment in which a dynamic range compression component is added to the circuit. In this embodiment, an RMS-to-DC converter integrated circuit 605 (RMS converter 605 ) provides modulation to compensate for volume changes in the input signal (e.g., dynamic range compression). The triangular wave, in addition to being modulated to compensate for power variances, is further modulated with the output of the RMS (root-mean-square) converter 605 . The RMS converter 605 generates a signal relative to the RMS value of the audio input at AA 425 to obtain variable compression of the audio level. In a specific preferred embodiment, RMS converter 605 is an Analog Devices AD 736 RMS-to-DC converter integrated circuit. Pin 1 of RMS converter 605 is coupled to a capacitor 610 by an electrical connection 609 . In a specific preferred embodiment, capacitor 610 is a 10-μF capacitor. Electrical connection 641 couples a terminal V G 302 to capacitor 610 . An electrical connection 608 couples pin 8 of RMS converter 605 to electrical connection 641 and terminal V G 302 . Pin 2 of RMS converter 605 is coupled to terminal AA 425 by an electrical connection 603 and is the input into RMS converter 605 .
[0078] Pin 3 of RMS converter 605 is coupled to a capacitor 625 by an electrical connection 604 . In a specific preferred embodiment, capacitor 625 is a 47-μF capacitor. The output of RMS converter 605 at pin 6 is coupled to a potentiometer 650 by electrical connection 616 . Potentiometer 650 permits selectable, adjustable compression of the triangular wave modulated circuit. The wiper leading from potentiometer 650 is coupled to a resistor 645 . Resistor 645 is coupled to an RMS terminal 330 by an electrical connection 647 . In a specific preferred embodiment, resistor 645 is a 10K-ohm resistor. An electrical connection 652 couples potentiometer 650 to a terminal V G 302 . Electrical connection 616 from the output pin 6 of converter 605 is coupled to capacitor 625 by electrical connection 617 .
[0079] Pin 4 of converter 605 is coupled to an electrical ground 108 by an electrical connection 607 . An electrical connection 613 couples a capacitor 615 to electrical connection 607 . In a specific preferred embodiment, capacitor 615 is a 0.1-μF capacitor. An electrical connection 616 couples capacitor 615 to a terminal V G 302 . An electrical connection 611 couples electrical connection 607 to a capacitor 620 , and electrical connection 612 couples capacitor 620 to pin 5 of the converter 605 . In a specific preferred embodiment, capacitor 620 is a 100-μF capacitor.
[0080] Pin 7 of converter 605 is coupled to a terminal V 12 125 by an electrical connection 618 . An electrical connection 639 couples electrical connection 641 , and terminal V G 302 , to a capacitor 640 . An electrical connection 634 couples capacitor 640 to electrical connection 618 and the terminal V 12 125 . In a specific preferred embodiment, capacitor 640 is a 0.1-μF capacitor.
[0081] FIG. 8 illustrates the connectivity between the various circuit components described in detail hereinabove, showing the relationship between the rectifier and divider circuit of FIG. 3 , the triangle wave modulator of FIG. 4 , the pulse width modulator of FIG. 5 , and the power device of FIG. 6 , as might be implemented in a production circuit board.
[0082] FIG. 9 illustrates the internal operative connectivity for pulse width modulation controller 430 described in the preferred embodiment in detail in connection with FIG. 5 .
OPERATION OF THE PREFERRED EMBODIMENTS
[0083] FIG. 10 illustrates in schematic, block diagram form, the modulated triangular wave amplifier as similarly illustrated in FIG. 1 , according to a preferred embodiment of the present invention. In FIG. 10 , the device is configured as a noise-canceling amplifier, which is capable of removing or canceling “ripple” from a power supply. Power is supplied to rectifier 10 . A signal (such as an audio signal) to be amplified may be provided to an optional pre-amplifier 1011 to boost the signal strength. The amplified signal is then input to PWM controller 93 , while rectified power (DC) is input to TWM 91 .
[0084] A triangle (Δ) wave generated by triangle wave generator 91 ( 27 in FIG. 1 , and described in detail in connection with FIG. 4 ) is coupled from PWM controller 93 and is modulated by TWM 91 and returned to PWM controller 93 . The output of PWM controller 93 is input to power device 30 , which also receives rectified power from rectifier 10 . Thus, the output of PWM controller 93 is employed to cancel noise present in the rectified power signal. The output of power device 30 is typically applied to a filter 40 and then to a load 45 , such as an audio speaker.
[0085] FIG. 11 illustrates in schematic, block diagram form the modulated triangular wave amplifier according to another preferred embodiment of the present invention. In this preferred embodiment, the device is configured to modify the dynamic range of an input signal (i.e., to limit or enhance bandwidth, equalize the signal, or to compensate for, or cancel, signal elements). In this embodiment, power is supplied to rectifier 10 , while a signal (such as an audio signal) to be modified may be provided to an optional pre-amplifier 1011 to boost the signal strength. Rectified power (DC) is input to TWM 91 . The amplified signal is input to a Signal Processor 1013 coupled between the output of pre-amplifier 1011 and TWM 91 . The amplified signal is also input, without signal processing, to PWM controller 93 .
[0086] The choice of signal processor 1013 “type” corresponds with the desired modification to the signal. Thus, the output of PWM controller 93 , with the addition of signal processing through TWM 91 , is used in power device 30 to accomplish the desired modification to the input signal, while power-supply noise-cancellation is also achieved. This configuration is most effectively adapted for audio input signals with an audio speaker load 45 .
[0087] FIG. 12 illustrates in schematic block diagram form, the triangular wave modulated amplifier, according to another preferred embodiment of the present invention. In this preferred embodiment, the device is configured to introduce an overlay or cancellation signal (pink noise, an advertisement, compensation for ambient noise, etc.) onto the output signal to load 45 .
[0088] The overall configuration is identical to that in FIG. 11 , with an additional signal source 1015 supplied to signal processor 1013 . The signal processor 1013 then supplies the processed signal to TWM 91 , which in turn affects the desired modification to the output signal of PWM controller 93 . By this configuration, an overlay or background noise compensation signal may be added while power supply noise-cancellation is also provided.
[0089] In each of the embodiments of the present invention disclosed in FIG. 10 , FIG. 11 , and FIG. 12 , it is understood that unregulated DC power may be supplied directly TWM 91 , if DC power, rather than AC power, is the available power source.
[0090] While the invention has been particularly shown and described with respect to preferred embodiments, it will be readily understood that minor changes in the details of the invention may be made without departing from the spirit of the invention.
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The invention is a power amplifier circuit for providing a signal acceptable for use in audio amplifiers or similar applications without requiring a stable power supply free from fluctuations. An alternating current power supply signal rectified to a direct current signal is processed by two voltage multipliers. A voltage divider establishes a unity gain level, and the variance from this voltage is squared by the first voltage multiplier. This squared voltage is then multiplied with a triangular wave signal to generate a modulated triangular wave signal. The modulated triangular wave signal and a signal to be amplified, typically an audio signal, are processed by an internal comparator to generate a pulse width modulated signal. This modulated signal is processed by a power transistor network and filter to provide an amplified signal to a load device. By modulating the triangle wave signal to compensate for fluctuations in the power supply to the amplifier circuit, noise or ripples present in the power supply are demodulated, eliminating the requirement for a regulated power supply.
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FIELD OF THE INVENTION
The present invention relates to an improved method and apparatus for inspecting the lead integrity of integrated circuit chips.
BACKGROUND
Very large scale integrated (VLSI) circuit semiconductor chips are used in a wide variety of applications (e.g., computers, appliances, automobiles, etc.) and are manufactured in extremely large quantities. One or more VLSI chips are often mounted on a circuit board. As indicated by the very name, VLSI chips are highly integrated and incorporate a multiplicity of electronic functions. The continuing trend of VLSI chip manufacturing is toward further integration and miniaturization. As a consequence of their small size, VLSI chips are often created in a configuration referred to as quad flat packs (QFP's) or quad packs with closely spaced leads (the term "lead" and "pin" being used interchangeably) emanating from each side of the quad pack.
The connecting leads on the outer edge of the chips often exceed 80 leads per side and have a lead period (the center to center distance of two adjacent leads) of the order of 200 to 300 microns. As mentioned above, the present trend is towards further miniaturization of the chips, which will require an increased number of leads per chip, and smaller lead periods. The delicate nature of the leads makes them vulnerable to various kinds of damage such as bending, twisting and breaking. Damage to the leads can occur during the production, packing and transportation of the chip and, more often, during the assembly process.
Surface Mount Technology (SMT) is presently the most common assembly process for mounting chips onto a circuit board. The connecting leads of a chip are placed on special contact pads on the top surface of the circuit board. After mounting, the leads are soldered. QFP's are particularly configured for surface mounting with special leads often referred to as gull wings. It is necessary that the QFP's are accurately placed by pick and place machines onto the surface of the circuit board with the gull wing leads making proper contact with the pads. Typically, a large number of chips are assembled onto a single board and then flow soldered. If a single lead on any one chip is damaged, the entire board is rejected. A damaged lead is a lead, that after soldering does not make correct contact with the pad on the circuit board (causing an open circuit or a higher than acceptable impedance), or a lead that touches an adjacent lead causing a short circuit (or come so close as to interfere with correct operation). Given the size of the leads and the distance between them, there is a significant possibility for lead damage to occur during the high speed placement process.
As mentioned above, chips are plucked from a spool by an automated machine and are placed onto a circuit board. Currently the fastest assembly machines move at a rate of approximately 2 meters/second. In order to prevent large scale rejection of finished circuit boards, it is optimal to perform inspection of the leads after the chip has been picked from the spool, and prior to placement on the circuit board.
Conventional vision systems, such as those used in component placement machines have been suggested as one solution. These systems utilize solid state television cameras to capture an image of the leads under examination, and include a means to compare the captured image with a reference image (a template of good leads). A deviation from the template indicates the presence of a defect. The use of a video camera in an automated inspection system for inspecting the rows of pins on integrated circuit packages of the DIP (Direct Inline Package) type is described in U.S. Pat. No. 4,696,047. It should be noted that the leads on the DIP packages are much thicker with far more spacing between them as compared to Quad packs. There are a number of problems associated with this technique. The size and spacing of leads on VLSI chip requires very high resolution cameras to capture a usable image. This increases the cost and complexity of the system. In addition, the camera has to be synchronized with the movement of each lead under inspection. Image processing and comparison requires large amounts of computing power and time. Thus, this system can be slow and expensive.
Another solution proposed is the use of a plane of light for producing reflected images of the leads as shown in U.S. Pat. No. 5,212,390. This system directs a plane of light onto the leads, and the reflected image is captured by an optical sensor, such as a camera, and then analyzed by a computer. This method allows the calculation of any displacement in the position of a lead within the plane formed by the plurality of leads. Thus, leads which are bent out of the common plane can be detected. However, this system suffers from the aforementioned problems. This system utilizes a very high resolution camera and a computer to process the image. In addition, this system requires interruption of the assembly process to allow for the image to be captured and processed.
Yet another solution proposed is an electro-optical system for detecting selected geometrical properties of the leads on SMT packages are disclosed in U.S. Pat. Nos. 4,875,778 and 4,875,779. The '778 patent discloses a horizontally arranged linear array of photosensitive elements which are moved in a direction perpendicular to a reference surface and operated to provide a series of one dimensional horizontal scans along the leads. The system disclosed in '779 employs a vertically arranged linear array of photosensitive elements which are carried horizontally parallel to a reference surface and operated to provide a series of one dimensional scans vertically along the leads. The chip is placed on a flat test surface and the illumination is provided from within the test surface so as to outline the leads. The linear array of photosensitive elements is moved to scan and detect the light escaping from between the spaces in the leads and any light which escapes from the space between the end of a lead and the flat reference test surface. The analog output signal from the array is converted to a digital signal and is then fed to a microcomputer. The microcomputer analyzes the signal to identify changes in the light intensity values along the linear array. This approach also has some drawbacks. Each chip under inspection has to be first placed on the test surface, and the signal has to be analyzed by the microcomputer.
Another inspection technique is described in U.S. Pat. No. 5,162,866. In this system, the chip under inspection is placed flat onto a IC setting table so that the leads can be irradiated and viewed from the top. A laser beam is used to irradiate both the leads and the surface of the IC setting table. This surface has reference marks present on it. The light source and a photodetector are moved over the IC table so as to scan the leads and the table surface. The reflected light from the leads and the reference marks is used to extract information about any pitch deviations of the leads. Deviation in the planar direction can be detected on the basis of a timing change in the output of the optical sensor. This system requires accurate timing and intensity measurements.
U.S. Pat. Nos. 5,309,223 and 5,331,406 describe a laser based semiconductor lead measurement system. A multi-beam laser system is used to sense the position and condition of each of the many leads used on integrated circuits prior to their placement on a surface mount circuit board. Each lead is passed nominally through the focal point of a laser beam. The position of each lead is determined when it blocks all or a portion of the light of the laser beam. A processor means is used to calculate the actual position of each lead. The position of each lead is then sorted to determine the greatest deviation of any lead from a best fit line or from the seating plane. The processor then generates a reject, pass or repositioning signal. This system is designed to basically assist the pick and place machine in properly aligning the integrated circuits on to the circuit board. Again, as with many of the techniques described above, a processor is needed to calculate the condition of the leads.
It is among the objects of the present invention to provide an improved lead inspection technique that addresses and solves these and other problems of prior art lead inspection techniques.
SUMMARY
Applicant's invention utilizes light diffraction through a periodic pattern (series of leads) to form an approximate uniform image. A deviation in the approximate uniform image of the periodic pattern indicates the presence of damaged leads.
The leads on VLSI chips form a natural periodic pattern. Coherent light passing through the spaces between leads will be diffracted into multiple orders at different angles. For a plane wave, the components of these orders along the direction of the wave will have differing wavelengths depending on the order angle. Because the leads form a natural periodic pattern in one dimension, the diffracted light orders will add coherently at periodic intervals to form images of the original periodic pattern. The effect, known as self imaging, was first observed by H. F. Talbot in 1836 and was explained by Lord Rayleigh in 1881. The latter showed that for a plane wave incident at right angles, the distance between self images of the periodic structure is 2d 2 /λ, where d is the grating period and λ is the wavelength of the light. If the light is not passing at normal incidence (right angles) through the periodic structure, but rather at an angle θ, the distance is 2(d cos θ) 2 /λ (θ is assumed to be in the plane which contains the normal and the line through the periodic structure). Applicant has observed that at one quarter of the self imaging distance, there is a uniform signal across the field when the periodic pattern is undamaged. Due to interferometric effects of the order of one micron, the wavelength of the light, there is a significant signal when there is even a very small deviation from a precise periodic structure.
A simplified explanation follows. Plane wave coherent light, after passing through a periodic structure, may be represented by a sum of sinusoids having different frequencies (or exponential terms) in a Fourier series:
f(x)=Σ.sub.n a.sub.n exp [i2πnx/d] (1)
where d is the period of the periodic structure, x is along the periodic structure, a n is the amplitude of the nth diffraction order, and i is the square root of -1. As the period of the structure is much greater than the wavelength of light, the diffracted energy remains close to the z axis taken to be the direction of propagation of the original light. However, because the components of the different diffraction orders along the z axis have different frequencies, the terms in the sum will interfere with each other as they propagate along the z axis. After diffraction through a distance z, the light field can be written (see equation 2.28 in K. Petorski, "Self imaging phenomena and its application" in Progress in Optics Volume XXVII, Ed E Wolfe, 1989): ##EQU1## Exponential forms independent of n are neglected because we are interested only in intensity. For self imaging, z=z s is selected so that the first exponential term in equation (2) is one for every diffraction order n. At this distance (or multiples of this distance) y(x, z s )=f(x), producing an exact image (equation (1)) of the input periodic structure. The diffraction orders are adding constructively to reconstruct the original periodic structure. The first exponential term in equation (2) becomes one for every diffraction order n when the exponent is 2πm, where m is an integer. Therefore self imaging occurs at periodic intervals of:
z.sub.s 2d.sup.2 /λ (3)
The periodic structure of VLSI leads may be represented by a square wave. Assuming equal width leads and spaces, this can be written (see W. Siebert, Circuits, Signals and Systems, McGraw-Hill, 1986, equation 12.3-8): ##EQU2## From equation (3), a quarter distance to the self image is defined by the following equation:
z.sub.q =z.sub.s /4=d.sup.2 /(2λ) (5)
The distance along the light beam from the lead plane to the detector plane is effectively reduced to (d cos θ) 2 /(2λ) if the light is not passing at normal incidence (right angles) through the periodic structure. As used herein the distance z q is the distance in terms of optical path and not necessarily physical distance. After diffraction, equation (4) is multiplied by the first exponential term of equation (2). Multiplicative phase forms independent of n are neglected because we are interested only in intensity. Using equation (5) to replace z we obtain: ##EQU3## As n is odd and the square of an odd number is also odd, the exponential term in equation (6) is always imaginary with amplitude one. Therefore, all the terms in the summation are imaginary and the summation becomes i times the square wave f(x) of equation (4) but with the DC component removed. The square of a unit amplitude square wave with zero DC component is constant at 0.25. As a result the intensity at the quarter self image distance y q y q *=.linevert split.y q .linevert split. 2 =(real part) 2 +(imaginary part) 2 =0.5 2 +0.25=0.5 and shows no variation in x and thus no sign of the periodic pattern. The phases from all diffraction orders must exactly match to achieve this uniform result.
Any deviation from the periodic structure of the leads results in a significant local change in uniformity due to a change in diffraction. The wavelength is approximately 0.6 microns so that a change of less than one millionth of a meter can cause an interference fringe to move from destructive to constructive interference, producing a noticeable signal. As the effect is local to the relative position of the damaged leads, only a few leads are needed to establish the periodic structure adequately for this process. Laboratory experiments and computer simulations described below illustrate this effect.
Applicant's invention allows lead inspection to be carried out while the component is in motion. Thus, there is no need to stop or interrupt the assembly process while the actual inspection is being carried out. In fact, inspection can be carried out after the chip is picked up by the placement arm. This is possible because an inspection is completed within 0.5 microseconds with inexpensive components. As mentioned above, parts on the fastest assembly machine move at approximately 2 meters per second. Therefore, during inspection, one part will move only 1 micron, a distance too small to have an adverse effect on applicant's inspection system. In fact, this invention can easily accept much higher assembly speeds by utilizing faster electronics.
It will be understood that the relative "movement" of the leads in the inspection system hereof can be implemented using an array for the source and/or detector. For example, a linear array of photodetectors along the direction of the leads can be placed in the detector plane and the laser source pulsed. In this case, the laser should be wide enough to cover all the leads at once. The array may be housed in a single chip so that it may be envisioned as one detector with elements rather than many detectors in a row. Computer simulation suggests that the number of detectors approximates the number of leads. This is at least an order of magnitude less than would be required in a vision system with similar performance because a vision system has to be able to observe the smallest defect to be detected, needing at least twenty elements per lead period. The outputs of the detectors can be processed by averaging to find the mean. Each detector is squared and the square of the mean subtracted. A level exceeding a threshold, set appropriately above the square mean, indicates a damaged lead. The anticipated level of noise and the acceptable level of lead distortion can be used to determine the amount the threshold is set above the average.
Alternatively, or in addition, instead of squaring values, a differential computation may be used for effectively detecting skewed leads. In this case each detector output is subtracted from that on either side. The resultant values are then thresholded with appropriate thresholds in a similar manner as described above (but with different threshold values).
A further consideration arises if a charge coupled device is used. These are widely available in 1-D and 2-D arrays (used in vision cameras). A 1-D device, as used in conjunction with applicant's invention, would be normally read out sequentially from one end. In this case the detector outputs are converted into a time sequence and the processing can be identical to that used for the case of moving leads relative to the light beam.
Different chips can be taken into account as previously described by having a detector size selected from the smallest lead period and the number of detectors (or elements in the array) determined by the largest period. In the case of large periods, neighboring detectors are summed to emulate larger width detectors.
Applicant's invention also eliminates the need for complicated computer processing by delivering results within the inspection interval of 0.5 microseconds. Since the inspection interval is only 0.5 microseconds, mechanical vibrations will not affect the inspection process since typical mechanical vibrations have time periods much larger than 0.5 microseconds. This invention detects deviation from a periodic structure as a means of inspection. The periodic structure is generated for each set of leads as they pass through the system and the inspection process detects defects if there are any deviations present in this periodic structure. Thus there is no need for a template representing good leads. Accurate alignment or lead positioning is not required. Leads on a tilted VLSI chip still act as a periodic structure. In some situations, a tilt of the light with respect to the periodic structure may be desirable to improve diagnosing certain defects such as lack of coplanarity.
Further features and advantages of the invention will become more readily apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an apparatus that can be used in practicing an embodiment of the invention.
FIG. 2 is a flow diagram of a technique in accordance with an embodiment of the invention.
FIG. 3a is a photograph of four undamaged leads.
FIG. 3b is a photograph taken at a quarter self image of the leads of the FIG. 3a.
FIG. 3c is a plot of an electronic output of the photodetector as the undamaged leads pass through the system.
FIG. 4a is a photograph of four leads with one damaged lead bent sideways.
FIG. 4b is a photograph taken at a quarter self image of the leads of the FIG. 4a.
FIG. 4c is a plot of an electronic output of the photodetector as the damaged lead of FIG. 4a passes through the system.
FIG. 5a is a photograph of four leads with one damaged lead bent downward.
FIG. 5b is a photograph taken at a quarter self image of the leads of the FIG. 5a.
FIG. 5c is a plot of an electronic output of the photodetector as the damaged lead of FIG. 5a passes through the system.
FIG. 6a shows an image of four leads used for computer simulation in which one lead is shifted by half its width.
FIG. 6b shows the computer simulated output of a detector that moves across the diffraction image resulting from the lead configuration of FIG. 6a.
FIG. 7a shows an image of four leads used for computer simulation in which one lead is missing.
FIG. 7b shows the computer simulated output of a detector that moves across the diffraction image resulting from the lead configuration of FIG. 7a.
FIG. 8a shows an image of four leads used for computer simulation in which one lead is shifted by 12.5% of its width.
FIG. 8b shows the computer simulated output of a detector that moves across the diffraction image resulting from the lead configuration of FIG. 8a.
FIG. 9 is a schematic of an apparatus for simultaneous inspection of leads in practicing an embodiment of the invention.
DETAILED DESCRIPTION
An embodiment of Applicant's invention is illustrated in conjunction with FIG. 1 for the inspection of leads 113 in VLSI chips 112. The flow diagram of FIG. 2 is also referenced when appropriate. In this particular embodiment, the components include: a laser diode 108 such as those mass produced for CD players, a collimating lens 105 attachment for the laser diode 108, so as to illuminate a sequence of four or so leads 113 with a plane wave, a laser diode driver (not shown) on a circuit board 103 that generates a short electronic pulse 202, a photodetector 102 to collect the signal light 119, electronic circuitry on circuit board 103 to perform: sampling, amplification and, squaring 204, thresholding 205 & 206, and latching 206, an LED control (not shown), a red LED 107 for indicating lead damage and a green LED 106 for indicating absence of lead damage, a light emitter 109 and photodetector 110 pair, a lead counter (not shown) on circuit board 103 for counting (202) leads 113 and activating the laser diode driver, electronic interface for a PC (not shown), control mirror 117, for setting distance between leads 113 (when intercepting light beam 119) and photodetector 102, manual mirror selection control 120 and a control mirror motor 116 for automatic adjustment of mirror 117..
The system unit 121 has a slot 115 like a credit card reader. As the leads 113 pass along the slot 115, in a direction represented by the arrow 122, a light emitter 109 photodetector 110 pair detects (201) leads 113. The output of the photodetector 110 is used to pulse (202) the laser diode 108, starting at a time such that beam 119 passes through the first four leads 113. A 0.5 microsecond pulse is used so that the chip 112, carried by spindle 111, does not have to stop moving and the system is robust against vibration. Collimated light 119, from the laser diode 108, passes through four or so leads 113 to the signal photodetector 102. The detector area should be adjusted between large and small lead periods for good performance. Computer simulations indicate that the detector width w, in the direction along the leads should be in the order of the size of the lead period d (i.e., w=d). A square detector can be used. Altering the detector size can be accomplished by the use of a mask 101 which covers a larger area of the detector from light when inspecting smaller lead periods. In such a case, the mask acts like a square aperture in a similar manner as a camera aperture. Alternatively, an array of detectors may be used. In this case, detectors are selected and summed in groups. For example, four small square detectors can be arranged to form a larger square. One detector is used for small lead periods. For lead periods of twice the size, we sum the four detectors to emulate a detector having twice the side length. The output of the photodetector 102 is electronically sampled, amplified, and squared 204. If this is then above a threshold 206, a latch 206 is activated and the red LED 107 is lit to indicate that a damaged lead 113, has been detected. If this threshold is not exceeded, the green LED 106 is lit indicating undamaged leads 113. For the case where four leads are covered by the laser beam 119 and the leads 113 are adequate to activate the emitter 109 detector 110 pair, every lead 113 can be observed by four different pulses 119. In a preferred embodiment the diode would additionally be pulsed at a high rate (greater than 5 MHz), and a corresponding frequency filter in the detector circuit can be used to make the detector insensitive to room light variations. A rotating mirror 117 may be adjusted manually to set the distance between the leads 113 and photodetector 102 according to equation (5). The adjustment is discretized so that each position allows one or more additional reflections between the two vertical mirrors 118. A motor 116 can allow this adjustment to be set by the computer for the case where the part type is known in the computer, as in an assembly machine. In this case the computer can be used to inform the electronics of the number of leads on this side of the part. A manual adjustment knob 104, can also serve this purpose. The maximum range of lead periods currently planned is 200 microns to 1,300 microns. Therefore the range of distance between leads 113 and photodetector 102 from equation (5) is from 3.2 cm to 1.3 m for a wavelength of 633 nm. The analysis is set forth for the case where the lead width equals the gap width between the leads, but can apply in different arrangements that result in a periodic structure.
FIGS. 3-5 are experimental results obtained in utilizing applicant's invention in inspecting damaged and undamaged leads. FIG. 3a is a photograph of four undamaged leads. FIG. 3b is a photograph showing uniform intensity across the diffraction image at a distance of a quarter of the self image for the leads shown in FIG. 3a. The white box shows the detector size used to scan the diffraction image as the leads move through the light beam. The arrow shows the relative direction of the detector with respect to the diffraction image as the leads move through the light beam. The output of a detector represented by the white box in FIG. 3b as the leads move through the beam is seen in FIG. 3c. The electronic output of the system is shown in the y axis, while the x axis represents the lead positions moving left to right in the path of the light. The detector output is proportional to the average of the intensities falling in the area of the white box times the area of the box. The output is seen to be approximately constant as the leads move over the detector. Small deviations from constant may be due to small deformities in the leads because the system is more sensitive than the human eye.
A photograph of four leads with one lead deformed by skew (or sideways bending) is seen in FIG. 4a. FIG. 4b is a photograph of the diffraction image at a distance of a quarter of that for self image for the leads of FIG. 4a. The image is seen to vary in intensity from left to right with variation going from light at the center to dark at the right of center. The measured output of a detector represented by the white box in FIG. 4b is seen in FIG. 4c as the leads move across the detector. The more than 50% variation of amplitude from average caused by the variation from light to dark in FIG. 4b, indicates the presence of a skewed lead.
FIG. 5a is a photograph of four leads in which one is bent down, used for laboratory experiments to verify detection of lack of coplanarity. FIG. 5b is a photograph of the diffraction image at a distance of a quarter of that for self image for the leads of FIG. 5a. The image is seen to have a bright part in the center when moving from left to right. The measured output of a detector represented by the white box in FIG. 5b as the leads move across the detector is shown in FIG. 5c. The greater than 100% peak relative to the average provides significant information for detecting short or bent down leads.
FIGS. 6-8 represent computer simulations representing three types of lead deformities. FIG. 6a shows an image of four leads used for computer simulation in which one lead is shifted by half its width. This also represents the case of the top half of a lead shifted as the detector can be set to view only the top halves of the leads.
FIG. 6b shows the computer simulated output of a detector that moves across the diffraction image resulting from the lead configuration of FIG. 6a. The diffraction image is at a distance of a quarter of that for self image of the leads. A differential (maximum minus minimum) variation of almost 50% indicates that a signal can be developed with a percentage change comparable to the percentage shift in lead deformation. The amplitude and shape of the response are consistent with the experimental results of FIG. 4c.
FIG. 7a shows an image of four leads used for computer simulation in which one lead is missing. This also represents the case of the top half of a lead missing as the detector can be set to view only the top halves of the leads.
FIG. 7b shows the computer simulated output of a detector that moves across the diffraction image resulting from the lead configuration of FIG. 7a. The diffraction image is at a distance of a quarter of that for self image of the leads. Variations of approximately 50% and the shape of the response are consistent with the experimental results of FIG. 5c.
FIG. 8a shows an image of four leads used for computer simulation in which one lead is shifted by 12.5% of its width. For a 100 micron wide lead this represents only 12.5 microns making the deformity invisible to the naked eye but close to the limits required for a lead inspection system.
FIG. 8b shows the computer simulated output of a detector that moves across the diffraction image resulting from the lead configuration of FIG. 8a. The diffraction image is at a distance of a quarter of that for self image of the leads. A differential (maximum minus minimum) variation of almost 12% indicates that a signal can be developed with a percentage change comparable to the percentage shift in lead deformation. This confirms the approximately linear relations observed in describing FIG. 6b.
FIG. 9 shows an apparatus for simultaneous inspection of all leads on one edge of a chip. Light from laser diode 108 passes through a short focus lens (not shown) in a housing 901 and a collimating lens 902. A laser diode can generate an oval shaped beam 903. A fan beam (not shown), with narrower waist, can be used to increase the percentage of light falling on the detector, but requires special optics. The beam 903 illuminates the top part of all leads 113 on one edge of the chip 112. A detector array 904 is placed at a quarter of the self image distance from the leads 113. The signal from each array element 905 of the detector array 904 may be passed to electronic circuit board 103, squared and the average computed. This average is then subtracted from each element squared signal. A threshold is set at some percentage above the average. Leads are considered damaged if the threshold is exceeded and undamaged if the threshold is not exceeded.
The invention has been described with reference to particular preferred embodiments, but variation within the spirit and the scope of the invention will occur to those skilled in the art.
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A technique for detecting damage of leads arranged in a generally parallel periodic pattern, includes the following steps: directing a coherent light beam at a plurality of adjacent leads; detecting an image at a distance from the leads at which the light beam would form a diffraction image having substantially uniform intensity when the leads form a substantially uniform pattern; moving the pattern of leads and the light beam with respect to each other; and detecting damage of leads from variation in intensity of the detected image.
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BACKGROUND OF THE INVENTION
Floral pollen is the male seed (sperm) of flowers which brings about the fertilization of the plant. This pollen consists of tiny corpuscles, 500/1000ths of a millimeter, and is produced in so-called "anthers" which form the upper part of the "stamens" of a plant. These stamens, which vary in number, according to the species of the plant, grow up from the base of the flower as delicate filaments which are broadened into small pads at their free ends. In these pads, the pollen is formed and from these anthers, the foraging bees collect their pollen.
The worker bees who collect pollen mold it into a solid mass with a little honey and then attach the resulting kernel to the outer part of their hind legs.
When a pollen collecting worker bee returns to its hive, it stores the pollen in a separate group of cells from the honey inside the honeycombs, to be taken out again when needed.
Since pollen is considered by many the perfect food, and by others, a diet supplement, it is collected from honeybees by means of pollen traps which are attached to their hives. In many of the prior art uses, a grid is placed over the hive entrance so that the bees have to push through it to get into the hive. In doing so, the pollen pellets are dislodged from their legs and fall into a trough.
DESCRIPTION OF THE PRIOR ART
Pollen traps have been placed over the hive entranceways to collect pollen with most of the pollen contaminated with large amounts of trash, including dead bees accumulated in a pile between the hive entrance and the pollen trap.
Prior art pollen traps that are attached to the entranceways to the hives agitate the bees when the traps are removed and interrupt the flight of the bees into the hives causing them to gather in front of the hive, often in clusters.
U.S. Pat. No. 4,337,541 discloses a pollen trap for use on honeybee colonies employing a pollen collecting drawer which may be removed from any side of the hive, provides a cluster space for the worker bees in the pollen trap, forms with the bottom board a hive entranceway, collects the pollen, and is removed from the hive to obtain the pollen.
U.S. Pat. application Ser. No. 354,882, filed Mar. 4, 1982 and entitled Pollen Trap for Beehives with Dual Entranceways, filed by the same applicant of this invention, is a further improvement of the prior art.
U.S. Pat. application Ser. No. 428,050, filed Sept. 29, 1982 and entitled Pollen Trap for Double Queen Colony with Queen Excluder, filed by the same applicant of this invention, is a still further improvement of the prior art.
Other patents of interest are U.S. Pat. Nos. 3,995,338; 4,007,504 and French Pat. No. 1,223,455; which disclose pollen traps of one form or another.
Manuel R. Chepote Malatesta, in his article published January, 1979 in the American Bee Journal, entitled "The Andes Pollen Trap", discloses the benefits of a double layer wire mesh for removing pollen from the legs of the bees.
No known prior art exists wherein a pollen trap is provided with a closable entranceway or free flight bee excluder.
SUMMARY OF THE INVENTION
In accordance with the invention claimed, a new and improved pollen trap is provided which forms an entranceway to the hive which may be opened or closed to control the flight or movement of the bees into the hive.
It is, therefore, one object of this invention to provide a new and improved pollen trap.
Another object of this invention is to provide a new and improved pollen trap which controls flight movement of the bees into the pollen trap.
A further object of this invention is to provide a pollen trap, the entranceway of which may be selectively opened or closed.
A still further object of this invention is to provide a new and improved pollen trap for a beehive employing a flight controlled entranceway for the worker bees and separate entranceway for drones and queen bees.
Further objects and advantages of the invention will become apparent as the following description proceeds and the features of novelty which characterize this invention will be pointed out with particularity in the claims annexed to and forming a part of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be more readily described by reference to the accompanying drawings in which:
FIG. 1 is a perspective exploded view of a modern beehive;
FIG. 2 is a side view of a modification of the beehive shown in FIG. 1 employing the new pollen trap at its base;
FIG. 3 is a view similar to FIG. 2 showing the novel pollen trap at the top of the beehive;
FIG. 4 is a view similar to FIGS. 2 and 3 showing the novel pollen trap in the center of the beehive;
FIG. 5 is a front view of the novel pollen trap disclosed and embodying the invention;
FIG. 6 is a top view, partially broken away, of the pollen trap shown in FIG. 5 with the drawer shown partially withdrawn;
FIG. 7 is a cross-sectional view of FIG. 6 taken along the line 7--7;
FIG. 8 is a cross-sectional view of FIG. 6 taken along the line 8--8;
FIG. 8B is an enlargement of the circled area labeled 8B in FIG. 6;
FIG. 8C is an enlargement of the circled area labeled 8C in FIG. 6;
FIG. 9 is a cross-sectional view of a modification of the pollen trap and drawer shown in FIG. 6 illustrating a further front entranceway for the bees;
FIG. 10 is a cross-sectional view of a further modification of the pollen trap and drawer shown in FIGS. 6 and 9 illustrating a bee entranceway below the drawer;
FIG. 11 is an end view of the pollen traps shown in FIGS. 6, 9 and 10 showing the drone and queen bee entranceway and the worker been entranceway at the back of the pollen drawer;
FIG. 12 is a modification of an existing pollen trap of the type shown in FIGS. 6, 9 and 10 embodying an entranceway barrier or bee excluder; and
FIG. 13 is a new pollen trap built to embody the bee excluder shown in FIG. 12.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawings by characters of reference, FIG. 1 discloses a modern beehive 10 comprising a pallet supported bottom board 11, a brood nest or box 12, a queen excluder 13 comprising a grate mesh formed of wire 0.163 to 0.167 inches apart, one or more honey storage supers 14, an inner cover 15 and a cover or roof 16.
The queen excluder 13 has spaces wide enough so that worker bees may pass through, but the queen and drone bees cannot. If the queen excluder is placed above the brood nest, the queen is confined in that area and cannot lay eggs in the honey storage area of the supers.
The brood nest 12 and super 14, comprising an open ended rectangular shell, contain a plurality of hanging combs or frames 17. Although ten frames are shown in the brood nest 12 in FIG. 1, many beekeepers use nine frames in the standard hive. The slightly wider spacing makes it easier to remove the combs and to inspect the brood nest.
In the super 14 (and honey storage area), beekeepers use nine frames evenly spaced. By using nine frames in a ten-frame beehive, the bees, due to the wider spacing in the super than in the brood nest, draw out the cells making them deeper, thereby easier to uncap by the beekeeper.
There are also eight to twelve-frame beehives with smaller or larger brood boxes, respectively. The disclosed pollen traps are built smaller or larger to fit these often called non-standard hives.
Each hanging frame 17 is rectangular in form and designed to leave a bee space all around. Lugs (not shown) may be formed as extensions of the top bar 19 so that the frames can be hung from rebates in the side walls of the brood nest and super or from the built-out portions of these parts of the hive as well known in the art. Sheets of wax foundation 20 complete the well-known frame construction.
An entranceway 21 into the beehive is generally formed between the bottom board 11 and the bottom of the brooder box 12, as shown in FIG. 1.
In accordance with the invention claimed, a new and improved pollen trap 22 is added to the modern beehive 10 in such a manner that the flight of bees coming into the hive may be controlled.
Although the pollen trap 22 is generally mounted on the bottom board 11 and between it and the brood box 12, as shown diagrammatically in FIG. 2, it may also be mounted at the top of the hive, as diagrammatically shown in FIG. 3, or in the middle of the hive, as diagrammatically shown in FIG. 4, and operate effectively. The parts of the hives, including the addition of the pollen trap 22, may be readily interconnected by suitable means such as a pin and socket arrangement, not shown.
FIGS. 5-8 disclose in more detail pollen trap 22 which may be positioned in any one of the three positions diagrammatically shown in FIGS. 2-4. This pollen trap comprises an open-ended, rectangular, box-like frame 23 having a rectangularly-shaped drawer 24 slidably mounted on a pair of rails 24A, one of which is shown in FIG. 8, fastened to the sides 25 of frame 23 and arranged to extend into frame 23 from end 26 thereof through an opening 27. An entranceway 28 is provided above the plate or handle 29 of the drawer for the worker bees 30 to enter the pollen trap, as shown in FIG. 8, and extends laterally across the longitudinal axis of drawer 24. It directs the bees upwardly through a passage 31 extending between a grating or offset screen 32 of predetermined size mesh and a lower screen 33. Screen 33 comprises a mesh smaller than the size of the worker bees and forms a barrier over the top of drawer 24.
It should be noted that a different diameter of screen 35 is used on the bottom of the pollen drawer and another screen 35' on the bottom of frame 23, as shown in FIG. 8.
When the humidity is dry and below 30-50%, relatively small mesh screens are used on the bottom of drawer 24 and frame 23, since air circulation is not necessary to dry out the pollen. When the humidity is above 80%, a wire mesh of a relatively larger size is used on the bottom of the pollen drawer to permit the maximum circulation of air and heat through the pollen to help remove the moisture and dry the pollen.
It is proposed that a screen having 7 squares to the inch formed from wire of a diameter 0.018 of an inch be used over the pollen drawer to allow the pollen to fall through into the pollen drawer and yet keep the bees out of the pollen drawer. The 8 squares to the inch screen heretofore used in such a small mesh that, in the times of pollen flows of large granules, they pile up on the corners of the wire and eventually create a solid mass of pollen up through the wire and theoretically could permit the colony to smother. Wire mesh of 6 squares to the inch is large enough so that bees penetrate the wire and enter the pollen drawer; yet the wire is small enough that the bees cannot then escape, but are left in the pollen drawer to eat the pollen and eventually die. Neither the 8 nor the 6 squares to the inch mesh is correct for the screens over the pollen drawer. Seven squares to the inch is ideal and serves and accomplishes both tasks of allowing the pollen to free flow into the pollen drawer, regardless of the size of the granules, and yet keeps all bees out of the pollen drawer.
This trap is unique in that screen 32 comprises a plate having a mesh employing 7 round holes of 3/16 inch diameter per square inch.
As indicated in FIG. 8, most of the bees enter the hive and the pollen trap through the entranceway 28 and move into and along a passageway 31 between grids or screens 32 and 34. At this point, the bees have to crawl through the opening in the grid or screen 32. The function of the pollen traps is to force the incoming foraging bees with pollen pellets on their hind legs to twist their bodies through the opening in screen or grid 32. In twisting through the grid, pollen pellets are scraped off their legs and fall down through screen 33 into the pollen drawer 24 above screen 35 positioned at the bottom of the drawer.
A further entranceway 36 and passageway 37 is provided between frame 23 of the pollen trap 22 and the top of bottom board 11, as shown in FIG. 8. This entranceway 36, which has an opening extending across the end of the pollen trap immediately below drawer 24, directs the bees 30 through passageway 37 to a space 38 behind drawer 24 and then over screen 33 into passageway 31. The bees then pass through screen or grid 32 in the same manner as the bees entering the pollen trap 22 through entranceway 28.
With the dual entranceway and passageway shown, the bees can enter the hive above and below the drawer 24 without clustering to get in and then are directed to pass through the screen 32 from both ends thereof. Thus, the bees are spread out over more of the grid structure than heretofore possible with a single entranceway.
FIGS. 8B and 8C show enlargements of the screen or grid configuration.
FIG. 11 illustrates that the entranceway 36 may be positioned to open from the back 26A of the beehive; i.e., from the side opposite to that provided for drawer 24, by merely reversing the bottom board 11. With this arrangement, the bees immediately enter space 38 from the entranceway 36 and do not have to travel the length of the other passageway 37, as is necessary with the structure shown in FIG. 8. Exits 39 shown in FIGS. 11, 12 and 13 provided at rear of the pollen trap are used by drones and the queen bee.
FIG. 9 illustrates a modification of the pollen trap 22 shown in FIGS. 1-8 wherein drawer 24 is covered by a barrier comprising offset parallel arranged parts 40 and 41 which form between their juxtapositioned ends an entranceway 42 into the hive at a position above drawer 24. This entranceway is covered by screen or grate 32.
FIG. 10 illustrates a further modification of the pollen trap 22 wherein the juxtapositioned ends of parts 40 and 41 are interconnected by grate 32 with the entranceway 36 being below drawer 24. Thus, bees 30 entering the hive through entranceway 36 pass through passageway 37, space 38 and through screen or grate 32 and into the beehive, as shown.
In accordance with the invention claimed, pollen trap 22 is modified to selectively block or open an entranceway into the beehive through the pollen trap. As shown in FIG. 12, the frame of the pollen trap is modified to include a bee excluder or part 43 pivotally mounted on frame 23 within entranceway 28 so as to selectively open or close the entranceway to admit or exclude bees from the hive.
When part 43 is pivoted to a position laterally of the longitudinal axis of drawer 24, it opens entranceway 28 and admits bees into the beehive. When part 43 is moved to a point where it is flush with the outside surface of frame 23, it closes entranceway 28 and keeps bees from entering the beehive.
FIG. 12 illustrates a presently known pollen trap modified to employ the bee excluder feature. This is accomplished by placing strips 45, 46 and 47 around the top edges of frame 23, as shown. These strips are of the same height as part 43 and serve merely to increase the height of the pollen trap a bit without changing its function.
FIG. 13 illustrates a pollen trap 22A built to accommodate the pivotally mounted bee excluder, or part 43, in the manner shown.
It should be noted that the bee excluder 43 is mounted in the entranceway, whether the entranceway is positioned in the beehive above or below the drawer 24.
An improved pollen trap for beehives is thus disclosed in accordance with the stated objects of the invention and although but a few embodiments of the invention have been illustrated and described, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims.
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A pollen trap for use on honeybee colonies employing a pollen collecting drawer and having an entranceway into the trap positioned either above or below the pollen collecting drawer and employing a pivotally movable barrier in the entranceway for selectively prohibiting the bees from entering the pollen trap.
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RELATED APPLICATIONS
[0001] This application claims priority to U.S. Patent Application Ser. No. 62/138,264 filed Mar. 25, 2015, entitled “Compost Filter Netting that is Linearly Stable During Filling” which is incorporated herein by reference.
BACKGROUND INFORMATION
[0002] 1. Field of the Invention
[0003] The present invention relates to compost filter socks, and more particularly to compost filter netting that is linearly stable during filling, method of using the same and the compost filter socks formed thereby.
[0004] 2. Background Information
[0005] The following is a detailed dissertation on compost filter socks in general leading to the specific problem addressed by the present invention, and should be helpful in understanding the specifics of the present invention.
[0006] A compost filter sock (also called a compost filter sleeve, or silt sleeve, or filter sock, compost filter tube, compost mesh sleeve, or similer terms) is a type of contained compost filter berm. A compost filter sock is a mesh tube or netting sleeve (referenced herein as compost filter netting) filled with mostly composted material and that is conventionally placed perpendicular to sheet-flow runoff to control erosion and retain sediment in disturbed areas.
[0007] The idea of an erosion control device formed as a mesh structure filled with compost material as the filler goes at least as far back as 1935 in a patent application by Mark S. Willing for a “means for preventing soil erosion.” At that time, the time of the “dust bowl” in the central United States, soil erosion was a big problem in the United States and wind and water erosion was destroying large swaths of cropland. Mr. Willing's early compost filter sock U.S. Pat. Nos. 2,079,779 and 2,201,279, which are incorporated herein by reference, disclosed the use of brush or bundled weeds as the compost filler for these early compost filter socks.
[0008] Over the years improvements have been developed giving further detail to the desired compost filler material, the desired netting opening size for the compost filter netting, the length and diameter size of compost filter socks, filling arrangements and installation instructions. See, for example U.S. Pat. No. 3,957,098, which is incorporated herein by reference, disclosing a 1972 development referred to as “an erosion control bag” having a porosity of 10 to 35 cubic feet per minute so that air and water may escape from the bag as water and a filler are pumped into the bag. U.S. Pat. No. 4,044,525, which is incorporated herein by reference, discloses a 1975 development wherein wood chips are blown from the discharge tube of the wood chipper straight into a tube-like structure which has perforated walls allowing the air carrying the wood chips to escape from the structure while the chips are retained inside.
[0009] The oil skimming/spill absorbing field, which uses absorbent material (including compostable material) in netting, has also yielded improvements relevant to compost filter socks as evidenced in U.S. Pat. Nos. 3,617,566, 3,739,913, 4,366,067, and 4,659,478, which are incorporated herein by reference.
[0010] Within the last 30 years, tubular compost filter socks filled with straw and hammered wood have been introduced. In the late 1990's filter berms where introduced. The filter berm was basically a triangular windrowed pile of decomposing organic material from land clearing, tree-trimming, or other sources. Some of the people doing work early in the evolution and proliferation and re-introduction of modern compost filter sock were John Engwer at FilterMitt, Kevin Lane at Lane ECS, Tom Truelsen at Soil Tek, Rod Tyler at Filtrexx, Keith and Kevin Weaver at Weaver Express, and Doug Cadwell at River Valley Organics. Soon a “modern day” tubular mesh fabric, or compost filter netting, holding in place the berm material was introduced and the term “Compost Filter Sock” began to be widely used. Today's compost filter sock is, however, a modern day version of the original Willing patents.
[0011] Maine was one of the first states to embrace compost filter socks and associated standards. In the past 10-15 years, other states have followed suit. As of mid-2014, at least one Standard Setting Organization (SSO) in every state has adopted a “Compost Filter Sock” standard. For a representative example that is incorporated herein by reference consider Pennsylvania's Department of Environmental Protection's standards for compost filter sock aspects including netting, compost and installations spelled out in “Erosion and Sediment Control Best Management Practices.”
[0012] The modern compost filter socks are typically oval in cross section, once formed, although the compost filter netting is often circular in cross section prior to filling. A compost filter sock, provides a three-dimensional filter that retains sediment and other pollutants (e.g., suspended solids, nutrients, and motor oil) while allowing the cleaned water to flow through. For reference see Faucette, et al. 2005. Evaluation of Stormwater from Compost and Conventional Erosion Control Practices in Construction Activities, Journal of Soil and Water Conservation, 60:6, 288-297; and Tyler, R. and B. Faucette 2005. Organic BMPs used for Stormwater Management—Filter Media Test Results from Private Certification Program Yield Predictable Performance, U.S. Composting Council 13 th Annual Conference and Trade Show, January 2005, San Antonio, Tex.
[0013] The compost filter socks are used in place of a traditional sediment and erosion control tools, such as a silt fence or straw bale barrier. Composts used in compost filter socks are conventionally made from a variety of feed-stocks, including municipal yard trimmings, food residuals, separated municipal solid waste, bio-solids, and manure. Compost filter socks are generally placed along the perimeter of a site, or at intervals along a slope, to capture and treat storm-water that runs off as sheet flow. Compost filter socks are flexible and can be filled in place or pre-filled and moved into position, making them especially useful on steep or rocky slopes where installation of other erosion control tools is not feasible. There is greater surface area contact with soil than typical sediment control devices, thereby reducing the potential for runoff to create rills under the device and/or create channels carrying unfiltered sediment. Additionally, compost filter socks can be laid adjacent to each other, perpendicular to storm-water flow, to reduce flow velocity and soil erosion. Compost filter socks can also be used on pavement as inlet protection for storm drains and to slow water flow in small ditches.
[0014] Compost filter socks used for erosion control are most commonly 12 inches in diameter, although 8 inch, 18 inch, 24 inch and even 36 inch diameter compost filter socks are used in some applications. The smaller 8 inch diameter filter socks are commonly used as storm-water inlet protection. The “diameter” of the compost filter sock is typically given as the diameter of the unfilled compost filter netting used to form the compost filter sock, because when the compost filter sock is in position, gravity will make the cross section take an oval or “D” shape in which the width of the compost filter sock exceeds the original diameter and the height of the compost filter sock is less than the original diameter.
[0015] Compost filter socks can be what are termed “vegetated” or “un-vegetated”. Vegetated compost filter socks can be left in place to provide long-term filtration of storm-water as a post-construction best management practice. The vegetation grows into the slope, further anchoring the compost filter sock. Un-vegetated compost filter socks are often cut open (cutting through the netting) when the project is completed, and the compost filling is spread around the site as soil amendment or mulch. The compost filter netting is then disposed of unless it is biodegradable.
[0016] According to the U.S. Environmental Protection Agency's National Pollutant Discharge Elimination System description of Construction Site Storm-water Runoff Control, three advantages the compost filter sock has over traditional sediment control tools, such as a silt fence, are: i) Installation does not require disturbing the soil surface (no trenching), which reduces erosion; ii) It is easily removed; and iii) The operator must dispose of only a relatively small volume of material, if any. These advantages lead to cost savings, either through reduced labor or disposal costs.
[0017] Further, the use of compost provides additional benefits. The compost retains a large volume of water, which helps prevent or reduce rill erosion and aids in establishing vegetation on the filter sock. The mix of particle sizes in the compost filter material retains as much, or more, sediment than traditional perimeter controls, such as silt fences or hay bale barriers, while allowing a larger volume of clear water to pass through. Silt fences often become clogged with sediment and form a dam that retains storm-water, rather than letting the filtered storm-water pass through. In addition to retaining sediment, compost can retain pollutants such as heavy metals, nitrogen, phosphorus, oil and grease, fuels, herbicides, pesticides, and other potentially hazardous substances—improving the downstream water quality. Nutrients and hydrocarbons adsorbed and/or trapped by the compost filter can be naturally cycled and decomposed through bioremediation by microorganisms commonly found in the compost matrix.
[0018] Compost filter socks are applicable to construction sites or other disturbed areas where storm-water runoff occurs as sheet flow. Common industry practice for compost filter devices is that drainage areas do not exceed 0.25 acre per 100 feet of device length and flow does not exceed one cubic foot per second. Compost filter socks can be used on steeper slopes with faster flows if they are spaced more closely, stacked beside and/or on top of each other, made in larger diameters, or used in combination with other storm-water controls, such as compost blankets. Once the compost filter sock is filled and put in place, it should be anchored to the slope. The preferred anchoring method is to drive stakes through the center of the sock at regular intervals; alternatively or in addition, stakes can be placed on the downstream side of the sock. The ends of the compost filter sock should be directed upslope, to prevent storm-water from running around the end of the sock. The compost filter sock may be vegetated by incorporating seed into the compost prior to placement in the filter sock. Since compost filter socks do not have to be trenched into the ground, they can be installed on frozen ground or even on cement or other “inhospitable” surfaces.
[0019] Compost filter socks offer a large degree of flexibility for various applications. A large number of qualitative studies have reported the effectiveness of compost filter socks in removing “settleable” solids and total suspended solids from storm-water. These studies have consistently shown that compost filter socks are generally more effective than traditional erosion and sediment control systems. Compost filter socks are often used in conjunction with compost blankets to form a storm-water management system. Together, these two systems retain a very high volume of storm-water, sediment, and other pollutants. For further background see, Alexander, R. 2003. Standard Specifications for Compost for Erosion/Sediment Control developed for the Recycled Materials Resource Center, University of New Hampshire, Durham, N.H.; Alexander, R. 2001. Compost Use on State Highway Applications, Composting Council Research and Education Fund and U.S. Composting Council, Harrisburg, Pennsylvania; AASHTO. 2003 Standard Specifications for Transportation Materials and Methods of Sampling and Testing, Designation MP-9, Compost for Erosion/Sediment Control (Filter Berms), Provisional, American Association of State Highway Officials, Washington, D.C.; Glanville et al. 2003. Impacts of Compost Blankets on Erosion Control, Revegetation, and Water Quality at Highway Construction Sites in Iowa, T. Glanville, T. Richard, and R. Persyn, Agricultural and Biosystems Engineering Department, Iowa State University of Science and Technology, Ames, Iowa; Juries, D. 2004. Environmental Protection and Enhancement with Compost, Oregon Department of Environmental Quality, Northwest Region; McCoy, S. 2005. Filter Sock Presentation provided at Erosion, Sediment Control and Stormwater Management with Compost BMPs Workshop, U.S. Composting Council 13th Annual Conference and Trade Show, January 2005, San Antonio, Tex.; MnDOT. 2005. Storm Drain Inlet Protection Provisions, S -5.5 Materials, B. Compost Log, Minnesota Department of Transportation, Engineering Services Division, Technical Memorandum No. 05-05-ENV-03, Jan. 18, 2005; ODEQ. 2004. Best Management Practices for Stormwater Discharges Associated with Construction Activity, Guidance for Eliminating or Reducing Pollutants in Stormwater Discharges, Oregon Department of Environmental Quality, Northwest Region; USCC. 2001. Compost Use on State Highway Applications, U.S. Composting Council, Washington, D.C; USEPA. 1998. An Analysis of Composting as an Environmental Remediation Technology. U.S. Environmental Protection Agency, Solid Waste and Emergency Response (5305W), EPA530-R-98-008, April 1998; and W&H Pacific. 1993. Demonstration Project Using Yard Debris Compost for Erosion Control, Final Report, presented to Metropolitan Service District, Portland, Oreg.
[0020] The details of making the conventional compost filter socks are also described in some detail in U.S. Pat. Nos. 7,226,240 and 7,452,165 which are incorporated herein by reference. Additionally advantageous packaging of compost filter sock netting is disclosed in U.S. Published Patent Application No. 2015-0047298 which is incorporated herein by reference.
[0021] Compost filter socks are often assembled by tying a knot in one end of the compost filter netting, filling the compost filter netting with the composted material, typically usually using a pneumatic blower then knotting the other end of the compost filter netting once the desired length is reached. Often this is done in-situ by having a pneumatic blower on site, which in this context is also called a blower truck as it is typically mounted on a vehicle. The appropriate compost is delivered to the site in bulk, or manufactured at the site (which minimizes waste removal from vegetation removal during site preparation), or a combination of these. The compost filter netting is also delivered to the site and typically comes in large rolls or coils. The operator of the pneumatic blower must unravel an entire length of the compost filter netting from the coil, and then load the entire desired compost filter netting length onto the nozzle of the blower to form what is referenced herein as a compression bundle. Once “loaded” the leading end is pulled from the nozzle and a knot is provided in the end before beginning filing. The trailing end is knotted after the compost filter sock of the desired length is formed.
[0022] The conventional plastic compost filter nettings, however, have a design that results an excessive amount of linear shrinking during filling, sometimes up to 40% and the amount of “shrinkage” is often quite variable. Conventional plastic compost filter nettings for compost filter socks will stretch out radially as they are being filled and will consequently and simultaneously shorten in length. This leads to the problem of having the site manager properly calculate the shrinkage rate when ordering sufficient length of compost filter netting. The high variability in shrinkage rates for even the same brand of compost filter netting has resulted in a large number of miscalculations and shortage of compost filter netting. The result of under calculation of shrinkage is schematically shown in FIG. 1 . A job is laid out, for example as generally shown in FIG. 3 , and the plastic compost filter netting is ordered, but excessive shrinkage has the in situ manufactured compost filter sock 10 come up short of the planned length as shown. For the site plan the missing portion of compost filter sock 10 is filled in with a supplemental filter sock 10 ′. The compost filter netting for the supplemental sock 10 ′ is typically overnighted or otherwise expressly delivered to the site at high shipping rates, but the true cost of the miscalculation is in the idle equipment (e.g., the blower truck) and work crew who must be maintained for a full extra day for a minor additional installation.
[0023] Those making an under-calculation on shrinkage that results in the substantial increase in labor and equipment rental costs (and minor increase in compost filter netting costs) will typically not make such a mistake again, but rather will build in excessive shrinkage factors in subsequent jobs, which results in excessive waste in compost filter netting purchased per future job. The UV degradation characteristics of compost filter netting may make it difficult for some contractors to easily reuse excess compost filter netting for a subsequent job, meaning the extra ordered compost filter netting due to overcompensation for shrinkage is merely lost.
[0024] The above discussion of miscalculation of shrinkage was assuming the user properly filled the compost filter netting. A separate issue of flattening during the functional longevity period should be mentioned. Flattening during the functional longevity period or undue flattening means that the installed compost filter sock does not satisfy the height requirements of the plan during the relevant use period, i.e. the sock has unduly “flattened” out. If it is below the minimum height requirements the filter sock will not function as designed. Further the installer may be subject to fines for such failures. Flattening has been found to be caused by under filling that may be caused by undersized cone and/or excessive linear tension (tugging) during filling. For this reason under filling is generally avoided and overfilling is more often a problem. Additionally, if the compost is more chip than shred and the compost filter sock goes through several freeze/thaw cycles, the sock may flatten and this can be exacerbated by weak radial support in the netting material.
[0025] As noted, in practice overfilling of the netting material is actually encountered more often in practice and the netting material will “balloon” out and waste filler material and overstress the netting material, and makes finished length even more unpredictable. A lack of radial stability results in a greater prevalence to overfilling.
[0026] There remains a need in the art for plastic compost filter netting that exhibits linear stability (e.g., minimizes shrinkage) and radial stability (i.e. minimize circumferential or diametrical changes) during filling to facilitate the construction of compost filter socks in situ.
SUMMARY OF THE INVENTION
[0027] This invention is directed to a compost filter netting comprises netting, generally of a man made synthetic material, formed in a tube having a diameter of 6″-36″ wherein the netting includes minimum netting openings of typically ⅛-⅝″, more preferably ⅛ to ⅜″, and configured to be filled with compost to form a compost filter sock, wherein the linear length of the compost filter sock is not less than 93%, and preferably not less than 95%, and generally at least 98% of the linear length of the originally manufactured empty compost filter netting. A method of forming a compost filter sock using the compost filter netting and the compost filter sock made thereby is disclosed. The compost filter netting substantially eliminates the problem of miscalculation of shrink rate that is problematic for in field applications.
[0028] The features that characterize the present invention are pointed out with particularity in the claims which are part of this disclosure. These and other features of the invention, its operating advantages and the specific objects obtained by its use will be more fully understood from the following detailed description in connection with the attached figures.
BRIEF DESCRIPTION OF THE FIGURES
[0029] FIG. 1 is a schematic top view of an installed compost filter sock of the prior art illustrating typical miscalculation of netting shrinkage;
[0030] FIG. 2 is a schematic section elevation view of an installed compost filter sock according to the present invention;
[0031] FIG. 3 is a schematic top view of an installed compost filter sock according to the present invention;
[0032] FIG. 4 is an enlarged schematic view of the compost filter netting according to the present invention;
[0033] FIGS. 5A and B are enlarged images of a segment of the compost filter netting of a compost filter sock according to the present invention;
[0034] FIG. 6 is a schematic illustration of expansion pleats in the compost filter netting of a compost filter sock according to the present invention;
[0035] FIG. 7 is a schematic illustration of visible stake placement indicia in the compost filter netting of a compost filter sock according to the present invention;
[0036] FIG. 8A is a schematic representation of the warp knitting technology used for forming the compost filter netting of the present invention; and
[0037] FIG. 8B is a schematic representation of circular knitting technology used to form the compost filter netting of the prior art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] FIGS. 2-8A illustrate a compost filter sock 10 according to the present invention. The sock 10 of the present invention is a warp knitted structure as described below and shown schematically in FIG. 8A , as opposed to a circular knitted structure of common prior art compost filter socks which is shown schematically in FIG. 8B . These views illustrate that the compost sock 10 according to the present invention can be utilized and placed in a conventional fashion and operate as substantially conventional compost filter socks after filling. Namely the compost filter sock 10 may be staked in position with stakes 20 driven through the compost filter netting 12 and compost 14 at spaced locations along the sock 10 to secure the sock 10 at a desired location between the disturbed area 22 and the undisturbed area 24 for proper runoff control. As described below the sock 10 of the present invention may have visible indicia 44 integrated into the sock to indicate the desired location of the stakes 20 , e.g., every 10 feet of sock 10 . The specifics for a given sock 10 will be spelled out by a site plan for a given job, a representative arrangement of which is shown in FIG. 3 and will be generally known to those of skill in the art.
[0039] The compost filter sock 10 comprising netting 12 formed in a tube having a diameter of 6″-36″ wherein the netting 12 includes minimum netting openings 38 of typically ⅛-⅝″, and preferably ⅛-⅜″, and compost filling 14 the compost filter netting 12 . The netting 12 is preferably formed from manmade synthetic yarns or materials, such as polyolefin or polyamide materials. Acceptable polyolefin materials include PP and PE materials.
[0040] The mesh opening 38 size is significant for a proper compost filter sock 10 as if the openings 38 are too small, the sock 10 “blinds”; and if the openings 38 are too big, the compost 14 washes or falls out. The openings 38 may be formed as a straight forward ⅛″-⅜″ inch square, ⅛″-⅜″ hex, or ⅛″-⅜″ round. The preferential warp knitted structure described below and shown in FIGS. 5A-B yields an elongated triangle for openings 38 that are about ⅜″ long, about 3/16″ wide at the fat end tapering to about ⅛″ at the narrow end, and quite effective openings 38 for compost filter netting 12 . For precision it is noted that for round openings 38 the linear measurement given is normally of the diameter, or largest diameter for an oval. Similarly the linear measurement is generally the diameter for hexagon shaped openings and anything higher order than a rectangle (octagon, heptagon, etc). For a rectangle or a triangle shaped opening the linear measurement is typically associated with a major or longest side.
[0041] A key aspect of the present invention is that the linear length of the compost filter sock 10 when fully filled is not less than 93% of the linear length of the empty or originally manufactured compost filter netting 12 . This aspect of the invention is referenced as linear stability, and a compost filter sock 10 that exhibits a linear length of the compost filter sock 10 which is not less than 93% of the linear length of the empty or originally manufactured compost filter netting 12 when filled to a full capacity will be considered to exhibit linear stability within the meaning of this application. FIG. 8A is a schematic representation of the warp knitting technology used for forming the compost filter netting 12 of the present invention and FIG. 8B is a schematic representation of circular knitting technology used to form the compost filter netting of the prior art. Warp knitting technology used in the present invention exhibits the radial and linear its stability because the warp thread 34 stitches are effectively independent of the adjacent warp thread 34 stitches resulting in stability in the warp and weft direction, whereas in circular knitting the rows of stitches in the weft direction are made of the same continuous yarn and exhibits less stability for forces applied in that direction. In the circular knitting as shown the weft direction is left to right and as force is applied in the weft direction the material elongates in the weft direction (radially unstable) and shortens in the warp direction (linearly unstable) thereby not exhibiting the desired stability.
[0042] The ends 16 of the netting 12 are sealed, such as by knotting, and the linear length of the compost filter sock 10 is defined as the length measured from one end 16 to the other end 16 along the axis 32 of the netting 12 . The length of the prefilled compost filter netting 12 , for calculation of linear stability, will be from the location of the one end 16 to the other end 16 along the axis 32 of the prefilled netting 12 . The compost filter sock 10 according to the invention preferably exhibits a linear length of the compost filter sock when the netting 12 is filled to a full capacity which is not less than 95% of the length of the empty or originally manufactured compost filter netting 12 . More preferably the sock 10 when filled to a full capacity exhibits a linear length of which is not less than 97% of the length of the empty or originally manufactured compost filter netting 12 . In testing a linear length of the compost filter sock 10 when filled to a full capacity was not less than 98% of the length of the empty or originally manufactured compost filter netting 12 .
[0043] FIG. 7 is a schematic illustration of integrated visible stake placement indicia 44 in the compost filter netting 12 of a compost filter sock 10 according to the present invention. As the sock 10 of the present invention is linearly stable as discussed above due to the use of warp knitted structure as shown and described, it can include integral stake indicia (e.g., every 10 feet), within the netting 12 . These are not meaningful or possible with the prior art sock structures because after filling any such preformed indicia would not be spaced at known locations (e.g. 10 ft indicia on an original prior art sock may end up being 6 ft apart after filling due to 40% shrinkage or any number between 6 ft and 10 ft). Specifically in FIG. 7 the integrated visible stake placement indicia 44 in the compost filter netting 12 of a compost filter sock 10 is formed by a distinctly colored thread 35 (e.g., an orange thread) that follows a warp thread 34 (not shown in FIG. 7 for clarity) and then inlays back and forth between two adjacent warp threads 34 at the appropriate intervals to form the indicia 44 . Warp knitting technology can easily and effectively add distinct visible threads at any location in the netting 12 as known in the art to form the indicia 44 , but it is the linear stability that allows these to be added in a meaningful manner. The indicia 44 also serve as a sock 10 length measurement tool for users and inspectors, separate from stake placement. It is anticipated that multiple threads 35 (e.g., 4-8) would be spaced circumferentially around the netting 12 to form rows of indicia 44 such that the indicia 44 would always be visible to users regardless of how a particular sock 10 is positioned on the ground.
[0044] The compost filter sock 10 according to the invention preferably exhibits a radial stability, wherein the circumference of the empty or originally manufactured compost filter netting 12 is at least 90% of the circumference of the compost filter sock 10 when filled to a full capacity, and preferably the circumference of the empty or originally manufactured compost filter netting 12 is at least 95% of the circumference of the compost filter sock 10 when filled to a full capacity. This measurement does not include the use or deployment of expansion pleats 42 as shown in FIG. 6 .
[0045] Damage to the netting 12 of the present invention, with this increased radial stability, due to overfilling is prevented with a pair (or more) of expansion pleats 42 . Each expansion pleat 42 is a ⅓″ pinched or doubled area of netting that may be stitched or otherwise closed. FIG. 6 shows an expansion pleat 42 on the right that remains intact and an expansion pleat 42 on the left that is opening (the stitching or other fastening mechanism is failing). The fastening of the expansion pleat 42 is configured to fail at less than the radial tension capacity of the netting 12 so the expansion pleats 42 thus yield some radial expansion to the sock 10 , if needed. The additional capacity of the netting 12 due to the pleats 42 is not considered in calculating the radial stability of the netting 12 which is a physical measurement or parameter of the netting 12 itself. Two ⅓″ pleats 42 are shown but more may be included if desired. However, two pleats 42 is particularly well suited for forming the netting 12 on a RASCHELL Warp Knitted Double Needle Bar Machine.
[0046] The compost filter netting material 12 of the sock 10 is preferably formed of manmade synthetic material, such as polyolefin materials or polyamide materials. Suitable polyolefin materials include polyester or polypropylene or combinations thereof. Polyester and polypropylene netting materials 12 are easily scalable and still allow the compost filter netting 12 to satisfy the requirements of compost filter netting set by every state requirement. For example the requirements of compost filter netting set by the Pennsylvania Department of Environmental Protection, as of 2015, includes minimum requirements of “5 mil HDPE” (high density polyethylene) netting to be photodegradable, to have 12″-32″ diameters, minimum mesh openings of ⅜″, minimum tensile strength of 26 PSI, exhibit Ultraviolet stability of at least 23% original strength at 1000 hours (ASTM g-155 test), and have a minimum functional longevity of at least nine months; minimum requirements of Multi-filament Polypropylene (MFPP) netting to be photodegradable, to have 12″-32″ diameters, minimum mesh openings of ⅜″ (effective diameter), minimum tensile strength of 44 PSI, exhibit Ultraviolet stability of 100% original strength at 1000 hours (ASTM g-155 test), and have a minimum functional longevity of at least twelve months; and minimum requirements of Heavy Duty Multi-filament Polypropylene (HDMFPP) netting to be photodegradable, to have 12″-32″ diameters, minimum mesh openings of ⅛″ (effective diameter), minimum tensile strength of 202 PSI, exhibit Ultraviolet stability of at least 100% original strength at 1000 hours (ASTM g-155 test), and have a minimum functional longevity of at least twenty-four months. For reference the functional longevity is a combination of strength (tensile strength is the typical test—26 psi is minimum using ASTM 5035 test) and degradation (photo, oxo, oxo-bio, degradation—minimum is photo-based—23% retained strength at 1000 hours—ASTM G-155).
[0047] One embodiment of the present invention shown in FIGS. 5A and B utilizes 5-mil HDPE (wherein the 5-mil is a pre-stretched fiber diameter average), which is photodegradable according to Pennsylvania Department of Environmental Protection standards, has mesh openings of ⅜″ according to Pennsylvania Department of Environmental Protection standards, has a tensile strength of 52 PSI according to ASTM 5034 procedures, exhibits a UV stability of 50% at 1000 hours, has a minimal functional longevity of 1 year.
[0048] One aspect of the present invention to achieve the linear stability of the netting 12 of the invention is wherein the compost filter netting 12 includes warp 34 and weft 36 threads wherein the warp threads 34 extend substantially longitudinally along the longitudinal axis 32 of the tube of netting 12 while the weft threads 36 extend generally perpendicular to the longitudinal axis 32 of the tube of netting 12 . The arrangement of the warp 34 and weft 36 threads is analogous to the arrangement found in the LENO™ brand onion bags manufactured by a co-developer of the present technology, and the range of variation of the warp threads 34 from being parallel with the axis 32 (substantially longitudinally) or of the weft threads 36 extend generally perpendicular to the longitudinal axis 32 of the tube of netting 12 within the meaning of the present invention are defined in this bag forming technology. As noted above the netting 12 may be effectively formed using warp knitting technology on a RASCHELL Warp Knitted Double Needle Bar Machine.
[0049] “Grab Test” results (See ASTM D 5034) were conducted on socks 10 formed according to the present invention and which are shown in FIGS. 5A and B. These results demonstrate some of the strength advantages of the netting 12 and sock 10 of the present invention. The tests results demonstrated an average horizontal breaking strength (horizontal relative to the sock 10 on the ground—also called the Warp direction in these tests) of 28 lbf and an average vertical direction breaking strength (also called filling or cross direction in this test) of 56 lbf for a blended breaking strength of 42 lbf. This demonstrates significant strength and stability advantages with the netting 12 of the present invention.
[0050] The compost filter netting 12 of the present invention allows for effective and efficient use of an infield blower truck with a pneumatic nozzle. The method of manufacturing a compost filter sock 10 using the compost filter netting 12 includes the initial step of providing the compost filter netting 12 to the site. This may effectively be done in a vacuum packed unit as described in U.S. Published Patent Application No. 2015-0047298 which is incorporated herein by reference. The compost filter netting 12 is loaded or placed onto the pneumatic nozzle. Following this loading, one open end and a leading length of the compost filter netting 12 is removed or pulled from from the pneumatic nozzle while maintaining the opposite end and the remainder of the compost filter netting 12 on the pneumatic nozzle. The next step for forming a compost filter sock 10 is sealing the leading open end 16 such as by simply tying a knot in the leading length. The compost filter sock 10 is formed in a conventional fashion by filling the compost filter netting 12 with compost 14 to a full capacity using the nozzle and a supply of compost from a hopper or storage area. After a compost filter sock 10 of a desired length has been formed the trailing end 16 of the netting material 12 is sealed, such as by another knot.
[0051] If there is a substantial length of unused compost filter netting 12 after formation of the compost filter sock 10 of a desired length then the material may be severed, generally near where the trailing knot 26 is to be formed and the remaining length of material 12 forming a reusable remnant. However, the present invention is designed to minimize substantial lengths of unused compost filter netting 12 due to miscalculations of shrinkage or intentional over calculations of shrinkage. More significantly, the present invention intends to minimize the likelihood of user running out of compost filter netting 12 prior to the required length of finished fully filled compost filter sock 10 .
[0052] While the invention has been shown in several particular embodiments it should be clear that various modifications may be made to the present invention without departing from the spirit and scope thereof. The scope of the present invention is defined by the appended claims and equivalents thereto.
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A compost filter netting comprises plastic netting formed in a tube having a diameter of 6″-36″ wherein the plastic netting includes netting openings of ⅛-⅜″ and configured to be filled with compost to form a compost filter sock, wherein the linear length of the compost filter sock is not less than 93% of the linear length of the originally manufactured empty compost filter netting. A method of forming a compost filter sock using the compost filter netting and the compost filter sock made thereby is disclosed. The compost filter netting substantially eliminates the problem of miscalculation of shrink rate that is problematic for in field applications.
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FIELD OF THE INVENTION
The present invention relates to a silver-based contact material for use in power engineering switchgear, particularly for contacts in low-voltage switches, in which, in addition to silver, there are present as active components at least iron oxide used main component and at least one further metal oxide as secondary component metal.
BACKGROUND OF THE INVENTION
For contact pieces in low-voltage power engineering switchgear, for instance in power switches as well as in direct-current, motor and auxiliary contactors, contact materials on the one hand of the silver-metal (AgMe) system and on the other hand of the silver-metal oxide (AgMeO) system are known. Representatives of the first system are, for instance, silver-nickel (AgNi) or silver-iron (AgFe); representatives of the second system are in particular silver-cadmium oxide (AgCdO) or silver-tin oxide (AgSnO2). In addition to this, there can be further metal oxides such as, in particular, bismuth oxide (Bi 2 O 3 ), copper oxide (CuO) and/or tantalum oxide (Ta 2 O 5 ).
The practical utility of a contact material having a base of silver-metal or silver-metal oxide is determined by the so-called electric contact properties spectrum. Controlling parameters are, in this connection, the lifetime number of switchings on the one hand, which is determined by the consumption of the switch piece, and the so-called excess temperature, i.e. the heating of the contact at the contact bridge which results essentially from the electrical resistance of the said contact structure. Sufficiently low tendency to welding-together of the contact pieces and resistance to corrosion are furthermore important since the switch properties can change with time due to long-time corrosion of the material in air-break switchgear.
From DE-A-1 608 211 there is already known an electric contact material of the silver-metal oxide system which can also contain iron oxide in addition to cadmium and/or tin oxide. Furthermore, in DE-C-38 16 895 the use of a silver-iron material with 3 to 30 wt. % iron and one or more of the additions manganese, copper, zinc, antimony, bismuth oxide, molybdenum oxide, tungsten oxide and chromium nitride in amounts of a total of 0.05 to 5% by weight, balance silver, are proposed for electric contacts. In addition, from DE-A-39 11 904 there is known a powder-metallurgy method for the production of a semifinished product for electric contacts from a composite material having a base of silver with iron, in which 5 to 50 wt. % iron is used as first secondary component and 0 to 5% by weight of a second secondary component consisting of one or more substances from the group containing the metals titanium, zirconium, niobium, tantalum, molybdenum, manganese, copper and zinc as well as their oxides and carbides. The iron in elementary form is obtained in this connection in particular by chemical precipitation. Finally, from JP-A-1/055345 a material of the aforementioned type is known which consists of a silver matrix in 0.5 to 20% by weight divided iron oxide particles, in which a part of the iron oxide is replaced by at least one of the oxides of nickel, cobalt, chromium, molybdenum, tungsten, cadmium, zinc, antimony, tin, bismuth, indium, lean, manganese, beryllium, calcium, magnesium or copper. The contact pieces produced therefrom are said to be excellent for use in switches due to good mechanical properties and high arc resistance.
The materials of the prior art in most cases do not satisfy at the same time all requirements of the spectrum of switch properties. In the final analysis, it is desired to achieve for the specific case of use an optimum of in each case the most important parameters which is adapted thereto.
SUMMARY OF THE INVENTION
Proceeding from the above requirements, the object of the invention is to provide further contact materials having a base of silver and iron oxide. These materials are to be characterized by low contact heating with stable heating behavior, little tendency towards welding together, and a long life with respect to the switch current intensities. Furthermore, good corrosion resistance is to be present. In accordance with the invention, this object is achieved by providing a material which, in addition to the iron oxide, also contains as a further active component rhenium oxide and/or bismuth zirconate and/or boron oxide and/or zirconium oxide, the iron oxide being present as a main component in a proportion of between 1 and 50% by weight and the further active (i.e., secondary) components being present in a proportion of between 0.01 and 5% by weight. In this connection, the iron oxide may have the constitution Fe 2 O 3 or Fe 3 O 4 , or possibly also be a mixed form.
DETAILED DESCRIPTION OF THE INVENTION
Within the scope of the present invention, it has been recognized that, in particular, iron oxide as main active component together with one or more of the metal oxides indicated above as a secondary component improves the spectrum of properties as contact material. The iron oxide is preferably present in amounts of less than 40% by weight and in particular less than 30%. As the further oxide, rhenium oxide, bismuth zirconate, boron oxide or else zirconium oxide may be used individually or in combination, in different weight proportions.
There is particularly advantageous a contact material of the aforementioned type in which the iron oxide is present in proportions of 2 to 20% by weight, with an addition of 0.5 to 2% rhenium oxide and/or 0.05 to 3% bismuth zirconate and/or 0.05 to 0.5% boron oxide and/or 0.05 to 2% zirconium oxide, balance silver. The boron oxide is preferably boric acid.
Further details and advantages of the invention will become evident from the following description of embodiments. In this connection, there is described on the one hand different methods of producing the material claimed and, on the other hand, the attached table containing individual examples of concrete compositions of material in accordance with the invention.
In the table, measured values are indicated for the excess temperature of the materials claimed, each of which was measured on the contact bridge of the switchgear. In the first column of the measured temperature values, there is set forth the maximum excess temperature and in the second column of the measured temperature values there is set forth the mean bridge temperature as they result in each case as difference in temperature from room temperature. The measured temperature values were obtained in switching tests in a 15 kW contactor up to a number of switchings of n s =50,000 switchings.
The table covers three embodiments with informative compositions of the contact material claimed. In this connection, the manufacture of the actual material and the fabrication of the corresponding contacts can be carried out in accordance, in part, with different methods. The measured value of the materials in accordance with the invention is compared with AgFe 2 O 3 6,4. Furthermore, an AgFe9 contact material is contained in the table. The results will be discussed in detail further below.
First Method of Manufacture:
For the manufacture of a contact material AgFe 2 O 3 5,7 ReO 2 1,1, corresponding proportions of powdered silver, powdered iron oxide and powdered rhenium oxide are mixed. For this, commercial powdered iron oxide or rhenium oxide is used.
By wet mixing of the powdered oxide a powder mixture is prepared. Strips or wires of the material are first of all produced from the powder mixture by so-called extrusion as semifinished product for the contact pieces. The process conditions with respect to temperature on the one hand and pressure on the other hand are so selected that an undesired evaporation of rhenium is taken into account. For a dependable bonding technique it is advantageous to produce strips with a solderable silver layer by the two-layer extrusion method. Contacts of directional structure can then be cut from the semifinished product thus produced.
In an identical manner of procedure, the proportions of silver, iron oxide and rhenium oxide can be varied. A material having the composition AgFe 2 O 3 5,7 ReO 2 2,2 was also examined.
Second Method of Manufacture:
In another method, the contacts were produced by molding. This is particularly advantageous when the further oxide as secondary active component is not rhenium oxide but, for instance, zirconium oxide. For this purpose again, corresponding proportions of powdered silver, powdered iron oxide and powdered zirconium oxide are mixed together. Specifically, a material having the composition AgFe 2 O 3 5,4ZrO 2 1,0 was examined.
It may furthermore be advantageous to use, in addition to powdered silver and powdered iron oxide, as further addition a powder consisting of a mixture of two or more components of rhenium oxide, bismuth zirconate, boron oxide and zirconium oxide. With suitable adaptation of the proportions of such a mixture, the specific advantages of the individual addition oxides can be combined with each other.
After wet mixing for a suitable period of time, moldings are compressed from the powdered mixture to form contacts with a pressure of about 200 MPa. For a dependable technique of bonding the contact to the contact support by brazing, it is furthermore advantageous, in this pressing process, to compress a second layer of pure silver jointly with the actual contact layer so as to form a two-layer contact.
The moldings are thereupon sintered at a temperature of about 850° C. for about one hour. In order to obtain the least possible porosity of the final contacts, the sintered bodies are then further pressed under a pressure of about 1000 MPa and again sintered for about one hour at about 800° C. The calibrating of the contacts produced in this manner is again effected with a pressure of about 1000 MPa.
For the production of suitable silver/metal oxide powder mixtures, it is also possible to use a long-time mixing of the silver and individual oxide powders in the manner of so-called mechanical alloying. In this way, the structural properties of the final material are advantageously influenced. The fabricating of the contacts can in each case again be effected optionally by extrusion or molding. Particularly upon the use of rhenium oxide as additional active component, possible evaporation of the rhenium must again be taken into account. This danger is not present in the case of zirconium oxide.
The table shows that in the first two examples of the material of the invention there is an average bridge temperature which lies above the value of AgFe9 and also AgFe 2 O 3 6,4. As compared with this, the corresponding value in the third example is below the comparative examples. It is to be noted that AgFe--and AgFe 2 O 3 materials show in this connection a similar temperature behavior. As a whole, all values for the mean bridge temperature lie within a range of 70 ±5K.
Aside from the mean bridge temperature it is however now found that the maximum excess temperature in the case of all the materials of the invention is significantly below the comparative examples. In particular, the statistically occurring maximum values of the excess temperature, which can lead to damage to the switchgear could, however, scarcely be controlled up to now.
From the measured values, it can thus be noted that an addition of either rhenium oxide or, in particular, zirconium oxide decisively stabilizes the temperature behavior of an AgFe 2 O 3 material. The latter is expressed in the clearly lower maximum excess temperature.
In accordance with the table, AgFe 2 O 3 ReO 2 and AgFe 2 O 3 ZrO 2 materials were examined in detail. The same positive influence as of rhenium oxide or zirconium oxide can be expected also on the part of other suitable oxide additions. For example, bismuth zirconate (2Bi 2 O 3 ×3ZrO 2 ) or boric acid (H 3 BO 4 ) can be used as suitable secondary components for the iron oxide. Mixtures of the individual components are also possible.
In the materials of the invention, the iron oxide can be present not only in the chemical constitution Fe 2 O 3 but also in the constitution Fe 3 O 4 , or in a mixed form. In detail, it is found that the iron oxide should be present, in particular, in proportions of 2 to 20% by weight, the addition of rhenium oxide should be between 0.5 and 5%, the addition of bismuth zirconate between 0.05 and 3%, the addition of boric acid between 0.05 and 0.5%, and the addition of zirconium oxide between 0.05 and 2%.
TABLE______________________________________ Mean BridgeMaterial T.sub.U(max) in K Temp. in K______________________________________AgFe.sub.2 O.sub.3 6,4 162 71AgFe.sub.2 O.sub.3 5,7ReO.sub.2 1,1 109 75AgFe.sub.2 O.sub.3 5,7ReO.sub.2 2,2 120 73AgFe.sub.2 O.sub.3 5,4ZrO.sub.2 1,0 89 66AgFe9 145 67______________________________________
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In particular for contacts in low-voltage switches, the contact material consists of silver and further active components. In accordance with the invention, there are present as active components, in combination, iron oxide (Fe 2 O 3 /Fe 3 O 4 ) in a proportion of between 1 and 50% by weight and at least one oxide of a further chemical element in a proportion of between 0.01 and 5% by weight. In particular, contact materials of the constitution AgFe 2 O 3 ReO 2 and AgFe 2 O 3 ZrO 2 have proven suitable in practice. The manufacture of the material and fabricating of the contacts can be effected by methods of powder metallurgy with the inclusion of molding or extrusion technique.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a divisional of U.S. Ser. No. 10/079,670, filed Feb. 20, 2002 which is a continuation-in-part of U.S. Ser. No. 09/779,861, filed Feb. 8, 2001 as well as U.S. Ser. No. 10/021,724 filed Dec. 12, 2001 (which claims priority to provisional patent applications Nos. 60/261,752 filed Jan. 16, 2001, 60/286,155 filed Apr. 24, 2001 and 60/296,042 filed Jun. 5, 2001). The following is also based upon and claims priority to U.S. provisional application Ser. No. 60/354,552, filed Feb. 6, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates to a well screen for use in a wellbore aspects relates to a well screen. More specifically, the present invention relates to a partial filter media used to advantage with side conduits (i.e., alternate flowpaths), control lines, and the like.
BACKGROUND OF THE INVENTION
[0003] It is common to place a sand screen in a well to filter solids from the production fluid (e.g., hydrocarbons, water). It is often desirable to route cables or side conduits adjacent the screens. For example, a side conduit, or shunt tube, may be used to improve a gravel pack in a well. As another example, a control line may be routed to bypass at least a portion of the sand screen. Likewise, it may be desirable to route other types of conduits, like chemical injection lines, to bypass at least a portion of the screen. It may also be desirable to mount other equipment (e.g., sensors) adjacent the screens. Many other such examples exist.
[0004] Typically, however, mounting a device (e.g., control line, side conduit, other equipment) adjacent the screen or inside the screen reduces the inside diameter of the screen. Mounting equipment inside the screen's base pipe may create other issues as well.
[0005] Accordingly, there exists a continuing need for a screen and related devices that maximizes the inner diameter of the screen while still allowing devices such as control lines, tubes, side conduits, and equipment to bypass the screen or mount adjacent the screen.
SUMMARY
[0006] In general, according to one embodiment, the present invention provides a partial filter media used to advantage with side conduits (i.e., alternate flowpaths), control lines, and the like. Other features and embodiments will become apparent from the following description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a illustrates a well having a screen with a partial screen wrapping and screen-adjacent devices placed therein.
[0008] FIGS. 2 through 5 illustrate various embodiments of the screen of the present invention.
[0009] FIGS. 6 through 17 are cross-sectional views of various embodiments of the screen of the present invention.
[0010] FIGS. 18 through 24 are cross-sectional views of various embodiments of the expandable screen of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0011] In the following description of the present invention, 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.
[0012] In this description, the terms “up” and “down”; “upward” and downward”; “upstream” and “downstream”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly described some embodiments of the invention. However, when applied to apparatus and methods for use in wells that are deviated or horizontal, such terms may refer to a left to right, right to left, or other relationship as appropriate.
[0013] FIG. 1 illustrates a typical gravel pack completion in which a wellbore 10 penetrates a subterranean zone 12 that includes a productive formation. The wellbore 10 has a casing 16 that has been cemented in place. The casing 16 has a plurality of perforations 18 which allow fluid communication between the wellbore 10 and the productive formation 14 . A well tool 20 is positioned within the casing 16 in a position adjacent productive formation 14 , which is to be gravel packed.
[0014] The well tool 20 comprises a tubular member 22 attached to a production packer 24 , a cross-over 26 , one or more screens 28 and optionally a lower packer 30 . Blank sections 32 of pipe may be used to properly space the relative positions of each of the components. An annulus area 34 is created between each of the components and the wellbore casing 16 .
[0015] In a typical gravel pack operation the packer elements 24 , 30 are set to ensure a seal between the tubular member 22 and the casing 16 . Gravel laden slurry is pumped down the tubular member 22 , exits the tubular member through ports in the cross-over 26 and enters the annulus area 34 . Slurry dehydration occurs when the carrier fluid leaves the slurry. One way the carrier fluid can leave the slurry is by way of the perforations 18 and entering into the formation 14 . The carrier fluid can also leave the slurry by way of the screen 28 and entering the tubular member 22 . The carrier fluid entering through the screen 28 flows up through the tubular member 22 until the cross-over 26 places it into the annulus area 36 above the production packer 24 , where it can be circulated to the surface. With proper slurry dehydration the gravel grains should be deposited within the annulus area 34 and pack tightly together. Note that there are many processes used to provide a gravel pack in a well and the above description is but one example.
[0016] As used herein, the term “screen” refers to wire wrapped screens, mechanical type screens and other filtering mechanisms typically employed with sand screens. Screens generally have a perforated base pipe with a filter media (e.g., wire wrapping, mesh material, pre-packs, multiple layers, woven mesh, sintered mesh, foil material, wrap-around slotted sheet, wrap-around perforated sheet, or a combination of any of these media to create a composite filter media and the like) disposed thereon to provide the necessary filtering. The filter media may be made in any known manner (e.g., laser cutting, water jet cutting and many other methods). Sand screens need to have openings small enough to restrict gravel flow, often having gaps in the 60-120 mesh range, but other sizes may be used. The screen element 28 can be referred to as a screen, sand screen, or a gravel pack screen. Many of the common screen types include a spacer that offsets the screen from a perforated base tubular that the screen surrounds. The spacer provides a fluid flow annulus between the screen and the base tubular. Screens of various types commonly known to those skilled in the art. Note that other types of screens will be discussed in the following description. Also, it is understood that the use of other types of base pipes, e.g. slotted pipe, remains within the scope of the present invention.
[0017] However, as shown in FIG. 1 , the sand screens of the present invention have a first portion 46 that has a filter media 42 thereon and a second portion 48 that does not have a filter media thereon. Thus, the filter media 42 is provided around a portion of the circumference of the base pipe 40 only as shown in the figures. Thus, in the embodiment of the present invention shown, the base tubular, or base pipe, 40 comprises apertures 44 located within a certain radial arc. A screen element, or filter media, 42 is attached to the exterior of the base tubular 40 and covers the apertures 44 ( FIG. 2 ). The portion of the base tubular containing apertures is referred to as the first portion, or radial aperture zone, 46 . The portion of the base tubular 40 not containing apertures is referred to as the second portion, or radial blank zone, 48 .
[0018] As shown in FIG. 1 , one or more adjacent-screen devices 50 are placed radially adjacent to the second portion of the screen 28 . Placing the adjacent-screen devices 50 radially adjacent to the second portion of the screen 28 increases the inner diameter of the screen 28 by reducing the overall outer profile of the screen 28 . Note that the outer diameter of the screen 28 is limited by the inner diameter of the casing 16 and other considerations.
[0019] As used herein, the general term adjacent-screen device 50 shall be used to refer generally to equipment placed in the well that is radially adjacent to a screen. For example, adjacent screen devices may comprise control lines and cables, side conduits (e.g., shunt tubes, chemical injection lines, fluid conduits, hydraulic control lines), intelligent completion devices, (e.g., sensors) and other equipment. Examples of control lines 52 are electrical, hydraulic, fiber optic lines and combinations of thereof. Note that the communication provided by the control lines 52 may be with downhole controllers rather than with the surface and the telemetry may include wireless devices and other telemetry devices such as inductive couplers and acoustic devices.
[0020] Examples of intelligent completions devices 54 are gauges, sensors, valves, sampling devices, a device used in intelligent or smart well completion, temperature sensors, pressure sensors, flow-control devices, flow rate measurement devices, oil/water/gas ratio measurement devices, scale detectors, actuators, equipment sensors (e.g., vibration sensors), sand detection sensors, water detection sensors, data recorders, viscosity sensors, density sensors, bubble point sensors, pH meters, multiphase flow meters, acoustic sand detectors, solid detectors, composition sensors, resistivity array devices and sensors, acoustic devices and sensors, other telemetry devices, near infrared sensors, gamma ray detectors, H 2 S detectors, CO 2 detectors, downhole memory units, downhole controllers, perforating devices, shape charges, locators, and other downhole devices. In addition, the control line itself may comprise an intelligent completions device as in the example of a fiber optic line that provides functionality, such as temperature measurement, pressure measurement, sand detection, phase measurement, oil-water content measurement, seismic measurement, and the like. In one example, the fiber optic line provides a distributed temperature functionality (or distributed temperature sensor) so that the temperature along the length of the fiber optic line may be determined.
[0021] FIG. 2 illustrates one embodiment of the present invention in which the filter media 42 comprises multiple layers. The figure shows a control line 52 extending through the second portion 48 of the screen 28 . In one embodiment, the screen 28 is made by cutting along the longitudinal wire to which the wrapped wire (for example) of the filter media 42 is welded. This cut is made on such that the longitudinal wire remains with the screen section to be used in the screen 28 . Two boss rings are then cut to provide the same gap as in the cut screen. The boss rings are then welded to each end of the screen with the cutaway section of ring oriented with that of the screen. A base pipe 40 is selectively perforated such that the portion of the base pipe 40 corresponding to the second portion 48 remains unperforated and the screen section is positioned on the base pipe 40 so that the cutaway section is aligned with the unperforated portion of the base pipe. The screen section and boss members are then welded to the base pipe 40 so that the unperforated section and the cutaway sections define the second portion 48 of the screen 28 .
[0022] FIG. 3 illustrates another embodiment in which the filter media 42 comprises an inner mesh layer and an outer wire wrap layer. The figure also shows a control line 52 extending through the second portion 48 of the screen 28 as well as an intelligent completions device (e.g., a sensor) 54 placed in the second portion 48 . The intelligent completions device 54 has a control line 52 extending therefrom that is also positioned in the second portion 48 . In one embodiment, the screen 28 is made in a manner similar to that of the screen of FIG. 2 . Note that the mesh material may be provided in a predetermined width so that the material does not require cutting to define a cut-away portion for the second portion 48 .
[0023] FIG. 4 illustrates another embodiment in which the filter media 42 is a mesh material. The second portion 48 extends along a helical path and has a control line 52 positioned therein. Accordingly, FIG. 4 illustrates that the second portion 48 may follow a path other than a linear path along the screen 28 . Thus, the path of the second portion 48 along the screen 28 may be arcuate. In one embodiment, the screen is manufactured by cutting the filter media 42 to define the helical (or arcuate) path and attaching the filter media to the base pipe 40 with the arcuate path aligned with an unperforated section of the base pipe 40 to define the second portion 48 .
[0024] In FIG. 5 , the second portion 48 does not extend the length of the screen 28 . Instead, the second portion 48 is in the form of a cut-out. An intelligent completions device 54 is placed in the cut-out second portion 48 . In the illustration, a control line 52 extends from the intelligent completions device 54 outside of the second portion 48 (adjacent the first portion 46 ).
[0025] Referring to FIG. 6 , an embodiment of the screen 28 is illustrated in cross-section. As in the previously described embodiments, the filter media 42 is provided around a portion of the circumference of the base pipe 40 . The screen material 42 extends about a portion of the circumference of the base pipe 40 to define the first portion 46 of the circumference that is covered by the screen material 42 and the second portion 48 of the circumference that is not covered by the screen material 42 . As shown in the figures there may be one or any number of second, unwrapped portions 48 (as well as first portions 46 ).
[0026] One or more side conduits, or shunt tubes, 56 (two shown) are affixed directly onto or adjacent the base pipe 40 in the second portion 48 and extend longitudinally along the length of the base pipe 40 (or at least a portion of the length thereof). The side conduits 56 are shown as having an elliptical cross-section, but other cross-sections (e.g. rectangular) may be used with the present invention.
[0027] An example of an embodiment of the screen 28 used with a control line 52 is shown in FIG. 7 . In the illustrated embodiment, both a side conduit 56 and two control lines 52 are affixed, or adjacent, to the base pipe 40 . In this embodiment, the control line 52 comprises an intelligent completions device 50 .
[0028] FIG. 8 shows another embodiment of the invention in which the screen 28 has a side conduit 56 mounted in the second portion 48 thereof. A shroud 70 surrounds the screen 28 providing protection for the screen 28 and side conduit 56 . In the embodiment shown, the shroud 70 is eccentrically mounted with respect to the screen 28 .
[0029] FIG. 9 shows another exemplary embodiment in which the one wall of the side conduits 56 is formed by the base pipe itself by welding a u-shaped member to the base pipe. In the embodiment of this figure, the screen material is then connected to the side conduit 56 (at its outer diameter as measured from the center of the base pipe). FIG. 9 illustrates two such side conduits 56 . FIG. 10 is similar to FIG. 9 , but shows four such side conduits. In one embodiment, the screen 28 is manufactured by selectively perforating a base pipe 40 and connecting the side conduits 56 to the unperforated portion thereof to form a first assembly. A filter media 42 is laser cut or water jet cut to the desired filtering specification and size and is connected to the first assembly.
[0030] FIG. 11 illustrates an alternative embodiment in which an outer member 60 is mounted to the base pipe 40 (as by attaching the outer member 60 to the side conduits 56 ). The outer member 60 and the base pipe 40 define a side passageway 62 therebetween which may be used to transport fluids, solids (e.g., sand), slurries and other materials. Note that the outer member 60 surrounds an unperforated portion of the base pipe 40 (a second portion 48 ).
[0031] FIG. 12 illustrates yet another embodiment similar to FIG. 9 . In this embodiment, the filter media 42 is connected to the side conduit 56 on one end and spacing members 64 on the other end. The spacing members 64 may also provide protection for the control line 40 and may have the associated and required strength to provide such protection. Note that the base pipe 40 in FIG. 12 is unperforated about its full circumference in the cross section shown. Thus, in this embodiment, the flow may be directed to another perforated area of the screen, to a valve, to pressure equalizing equipment (e.g., a tortuous path), or to other equipment through the annulus between the filter media 42 and the base pipe 40 as desired.
[0032] FIG. 13 discloses another embodiment similar to that shown in FIG. 12 , but further including a protective shroud 70 . In the embodiment shown, the shroud 70 has an optional side opening 72 that facilitates placement of the control line in the second portion 24 .
[0033] In FIG. 14 , the base pipe 40 includes a side pocket 82 and comprises a side pocket mandrel 80 . The side pocket mandrel 80 has a conventional design in that it has a main bore 84 and a side pocket 82 and is capable of receiving a device, such as an adjacent-screen device 50 in the side pocket 82 . A filter media 42 extends about a portion of the side pocket mandrel 80 . For example, the filter media 42 may extend about the portion of the side pocket mandrel 80 defining the main bore 84 and attach to the portion of the side pocket mandrel 80 surrounding the side bore 82 (as shown in the figure). The portion covered by the filter media 42 is perforated and represents the first portion 46 of the screen 28 .
[0034] FIGS. 15 shows another embodiments of the screen 28 having a protective shroud 70 . The figure illustrates a sand screen 28 in which the second portion 48 of the screen 28 covers a greater portion of the circumference (arc) than the first portion 46 . The figure shows a number of adjacent-screen devices 50 in the second portion 48 . The large arc of the second portion 48 facilitates the placement of numerous adjacent-screen devices 50 as well as alignment of control lines 52 and side conduits 56 with other equipment. The figure shows a number of control lines 52 , a side conduit 56 , and an intelligent completions device 54 in the second portion.
[0035] FIG. 16 shows a screen 28 having three first and second portions 46 , 48 with adjacent-screen devices 50 mounted in the second portions.
[0036] FIG. 17 illustrates an alternative embodiment of the present invention in which the adjacent-screen device 50 mounted in the second portion 48 is a shape charge 90 . A clip 92 holds the shape charge 90 to the base pipe 40 . Note that with a helical or other pattern of the second portion 48 along the length of the screen 28 a plurality of shaped charges can provide a spiral or other shot pattern. In this manner the shape charges are provided on the screen 28 and the well may be perforated and then gravel packed without moving the completion in a single trip into the well. Methods and devices for detonating the shape charges 90 are well known.
[0037] In another embodiment of the present invention, the screen 28 is of the expandable type. Expandable screens generally have an expandable base pipe 100 , an expandable shroud, or protective tube, 102 , and a filter media 104 of one or more layers interposed therebetween that can expand without losing its expanding characteristics. It should be noted that many types of expandable tubes are available. As examples, the expandable tubing may be a solid expandable tubing, a slotted expandable tubing (or other types wherein the structure is weakened by perforating the base pipe, as with holes), or any other type of expandable conduit. Examples of expandable tubing are the expandable slotted liner type disclosed in U.S. Pat. No. 5,366,012 issued Nov. 22, 1994 to Lohbeck, the folded tubing types of U.S. Pat. No. 3,489,220, issued Jan. 13, 1970 to Kinley, U.S. Pat. No. 5,337,823, issued Aug. 16, 1994 to Nobileau, U.S. Pat. No. 3,203,451, issued Aug. 31, 1965 to Vincent, the expandable sand screens disclosed in U.S. Pat. No. 5,901,789, issued May 11, 1999 to Donnelly et al., U.S. Pat. No. 6,263,966, issued Jul. 24, 2001 to Haut et al., PCT Application No. WO 01/20125 A1, published Mar. 22, 2001, U.S. Pat. No. 6,263,972, issued Jul. 24, 2001 to Richard et al., as well as the bi-stable cell type expandable tubing disclosed in U.S. patent application Ser. No. 09/973,442, filed Oct. 9, 2001. Each length of expandable tubing may be a single joint or multiple joints.
[0038] FIG. 18 discloses one embodiment of the present invention comprising an expandable base pipe 100 , an expandable shroud 102 and a filter media 104 . In the embodiment shown, the filter media 104 is a series of scaled filter sheets. The screen 28 has a first portion 46 that has a filter media 104 thereon and a second portion 48 that does not have a filter media thereon. A protective member 106 is provided on the second portion 48 and an adjacent screen device 50 (e.g., a control line 52 ) is placed therein. The protective member 106 may take the form, as an example, of a channel that extends the length of the screen 28 . In another embodiment, the protective member 106 extends only a portion of the full length of the screen 28 or comprises multiple devices spaced along the length of the screen 28 . The protective member may be attached to the expandable base pipe 100 , the expandable shroud 102 , or formed as an integral part of one or more of these elements.
[0039] In FIG. 19 , the protective member 106 is formed as part of the expandable shroud 102 . In the embodiment shown, the shroud 102 forms two protective members 106 . A first protective member 108 is in the form of a channel. Although not shown, the filter media 104 could pass beneath the shroud channel. A second protective member 110 forms an internal cavity 112 through which a control line 52 may pass or an intelligent completions device 54 may reside. In an alternative embodiment, the internal cavity 112 may itself comprise a side conduit 56 .
[0040] FIG. 20 shows another embodiment of the present invention illustrating two additional alternative protective members 106 . The first protective member 114 shown comprises a pair of parallel bars 116 mounted to the expandable base pipe 100 and the expandable shroud 102 on either side of the second portion 48 . The bars 116 extend longitudinally along the screen 28 . A clip 118 is then locked to the two bars 116 to secure the control line 52 in place.
[0041] The second protective member 120 shown in FIG. 20 is a channel. The channel 120 has a dovetail groove forming a mouth with a smaller width than the inner portion of the channel 120 . In this embodiment, the control line 52 is noncircular and capable of fitting through the mouth in one orientation after which it is reoriented so that it cannot pass through the mouth. Thereby the control line 52 is held in the channel 120 .
[0042] FIG. 21 illustrates one possible technique for manufacturing a screen 28 of the present invention. One or more protective members 106 are mounted to the base pipe 100 . In the illustration, one of the protective members 106 is a channel attached to the base pipe 100 . A control line 52 is placed in the channel. A clip (not shown) may be used to maintain the control line 52 in the channel. The other illustrated protective members 106 comprises a side conduit 56 mounted to the expandable base pipe 100 and a protruding member 122 spaced therefrom and also mounted to the base pipe 100 . A control line 52 may be placed in the space between the side conduit 56 and the protruding member 122 . The filter media 104 are attached to shroud sections 102 (although they may also be connected to the base pipe 100 ). The filter media 104 is provided in sheets that are arranged in an overlapping fashion so that the sheets slide over one another during expansion.
[0043] The side conduit 56 of the expanding embodiment of the screen 28 may be used, for example, to deliver chemicals to the well (chemical injection line), to deliver fluids to below the screen 28 , to gravel pack areas around the screen 28 that are not fully expanded or where there is an annulus, to deliver fracturing fluids, or for other purposes. Thus, the method would be to place the expandable screen 28 having a side conduit 56 attached thereto into the well, expand the expandable screen, and deliver a fluid through the side conduit 56 to complete the desired operation.
[0044] FIG. 22 illustrates another embodiment of the present invention expanded in a wellbore 10 . The screen 28 has an expandable base pipe 100 , an expandable shroud 102 , and a series of scaled filter sheets therebetween providing the filter media 104 . Some of the filter sheets are connected to the protective member 106 . The figure shows, for illustration purposes, a control line 52 , an intelligent completions device 54 , and a side conduit 56 positioned within the second portion 48 of the screen 28 .
[0045] FIG. 23 illustrates another embodiment of the present invention in which the expandable base pipe 100 has a relatively wider unexpanding portion (e.g., a relatively wider thick strut in a bistable cell) that defines the second portion 48 . The screen 28 does not have a shroud, although one may be included as previously discussed. One or more grooves 124 extend the length of the screen 28 . An adjacent-screen device 50 may be placed in the groove 124 or other area of the second portion 48 . Additionally, the base pipe 100 may form a longitudinal passageway 126 therethrough that may comprise or in which an adjacent-screen device 50 may be placed. FIG. 24 shows a groove 124 in the expandable base pipe 100 that has a dovetail design as previously described. Note that, although the grooves and passageways are described as formed in the expandable base pipe 100 , they may also be formed in a shroud 102 of the screen 28 .
[0046] Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function.
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The present invention provides a screen for a well that utilizes a partial screen wrapping used to advantage with side conduits (e.g., alternate flowpaths), control lines, intelligent completions devices, and the like. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] None
FEDERALLY SPONSORED RESEARCH
[0002] None
SEQUENCE LISTING
[0003] None
BACKGROUND OF THE INVENTION
Field of the Invention
[0004] This invention relates to a type of gun known as a two-stage light gas gun, which is designed to fire projectiles at very high speeds.
Background of the Invention
[0005] A light gas gun is designed to shoot projectiles at very high speeds by utilizing a high-pressure gas of low atomic number, typically either hydrogen or helium. Used extensively for research involving hypervelocity projectiles, the use of light gases as a propelling medium has produced projectile speeds up to several times greater than the highest speed attained by guns utilizing conventional propellants such as modern gunpowders.
[0006] In the prior art there exists various designs of light gas guns that can generally be categorized as being of one-stage, two-stage, or three-stage design. All three types of light gas gun designs are capable of firing projectiles at hypervelocity speeds. The object of this invention relates to the two-stage design. It should be mentioned that another type of hypervelocity gun appearing in the prior art is the shock wave gun, which in some embodiments takes the form of a special type of two-stage light gas gun.
[0007] In the two-stage light gas gun design, either hydrogen or helium gas is initially held within a so-called pump tube. Within the pump tube is a piston called the pump piston that is used to compress the light gas. Rigidly connected to one end of the pump tube is a so-called launch tube that holds a projectile to be launched. An explosive charge, such as gunpowder or a fuel/air mixture, lies on one side of the pump piston. On the other side of the piston is the light gas along with a diaphragm that initially prevents the light gas from flowing from the pump tube into the launch tube. The diaphragm, which is placed near the junction of the pump and launch tubes, is a type of one-use valve that is designed to burst open at a preset pressure. When the explosive charge is ignited it causes the piston to accelerate towards the diaphragm, an action that quickly compresses the hydrogen (or helium). When the piston has compressed the light gas to a predetermined pressure, the diaphragm bursts open. The high-pressure, hot hydrogen (or helium) pours through the burst diaphragm and into the launch tube, which in turn causes the projectile to be expelled from the launch tube's muzzle. The launch tube is typically several times smaller in diameter than the pump tube. The pump and launch tubes together form the overall length of a conventional two-stage light gas gun.
[0008] In the NACA technical note 4143 by Charters et al (1957) a two-stage light gas gun is described that contains a pump piston as well as a heavier secondary piston called a valve piston. After ignition of the powder charge, the pump piston and valve piston are driven in opposite directions along the length of the pump tube. The movement of the heavy valve piston allows the delayed release of hot propellant gases from the pump tube. The pump piston is designed to ‘bounce back’ after the diaphragm is ruptured, preventing it from ramming into the end of the pump tube, which could possibly damage the gun. In spite of its positive features, this design has several drawbacks. First, between firings the gun must be partially disassembled in order to return the pump and valve pistons to the firing position. Another drawback is the residue—such as a carbon buildup—that forms due to the repeated use of a solid propellant in the pump tube, which must periodically be cleaned out. Another disadvantage is that the pump tube must be lengthened in order to accommodate the rearward movement of the valve piston. A final drawback is that a danger exists that if too much propellant is used, or an insufficient quantity of light gas is present before firing, that the freely-moving pump piston will collide with the end of the pump tube, leading to damage of the piston, the pump tube, or both.
[0009] In U.S. Pat. No. 2,872,846 Crozier (1959) shows an alternative embodiment that is basically identical to the Charters (1957) design described above, except that Charters' valve piston, whose action allows leftover propellant to escape the pump tube, is absent. The simpler design, however, leads to its first drawback: there is no provision for the automatic and convenient venting of propellant gases once the gun has been fired. Other than that difference, Crozier's design has several distinct disadvantages in common with Charters' design. First, a danger exists that if too much propellant is used, or an insufficient quantity of light gas is present before firing, the pump piston will collide with the end of the pump tube, leading to damage of the piston, the pump tube, or both. Second, between firings the gun must be partially disassembled in order to return the pump piston to the firing position. Third, due to the repeated use of a solid propellant in the pump tube, residue forms that periodically must be cleaned out.
[0010] In contrast to the design of Charters et al (1957) summarized above in which the pump piston bounces back from the end of the pump tube, U.S. Pat. No. 2,882,796 to Clark et al (1959) describes a pump piston designed to purposely ram into the diaphragm-end of the pump tube. The pump piston is made of a material—such as nylon—that is readily deformable under high pressures. This design has the advantage that it eliminates the concern of damage to the pump tube by the pump piston, since the pump piston is specifically design to impact and then squeeze into the constriction of the pump tube that leads into the launch tube. However, there are distinct disadvantages of this design: 1) as in the Crozier (1959) design described previously, there is no mechanism provided to automatically vent the remaining propellant gases once the gun has been fired; 2) the pump tube must be opened up so that the tightly squeezed compression piston can be extricated, considerably slowing the process of preparing the gun for another firing; 3) after each firing, residue from the propellant can contaminate the interior of the pump tube; and 4) after each firing the old pump piston is severely distorted and must be discarded, while a new pump piston must be loaded into the pump tube. Discarding the pump piston after each shot increases costs as compared to a pump piston that can be reused repeatedly.
[0011] In U.S. Pat. No. 4,038,903 Wohlford (1977) describes a telescoped two-stage light gas gun. The telescoped gun was intended as an anti-aircraft weapon, its design permitting a higher rate of fire as compared with previous two-stage light gas gun designs. The gun is designed so that the pump piston and launch tube always move together as a single, ridged unit. One favorable feature of the gun is that the area of the pump piston that the propellant gas pushes against is greater than the area of the pump piston that compresses the light gas; unfortunately, the ratio of propellant area to compression area is not very high, being only fractionally higher than unity, i.e., much closer to a ratio of 1 than to a ratio approaching 2 or more. In spite of a few favorable features, the telescoped design suffers from a number of drawbacks: 1) in order for there to be a good seal between the outside of the gun barrel and the inside of the pump tube opening, not only must the inside of the gun barrel be machined to a high degree of precision (which is normally the case for most gun barrels), but also both the outside of the gun barrel and the inside of the pump tube opening must be machined very close to round as well. However, repeated firing of the weapon will heat its various parts. If the gun barrel is heated more or less than the pump tube, the expansion of the two parts will also vary, which could lead to either significant loss of gas at the pump tube/launch tube seal, or to increased friction at the same seal thereby slowing the motion of the pump piston; (2) this design allows propellant residue to form on both the inside of the pump tube and the outside of the launch tube, which can lead to increased wear of those parts, as well as the need for frequent cleanings of those same parts; (3) after a projectile is fired from the gun, the reloading of another projectile is overly complicated. First the rear of the pump tube must be opened, and then the rear of the launch tube must be opened as well. After the projectile (and possibly a diaphragm) is loaded, first the launch tube must be closed, followed by closure of the pump tube. Such a procedure takes an inordinate amount of time for a gun designed to be a weapon; (5) if too little light gas is introduced into the pump tube, then the pump tube piston might violently collide with the end of the pump tube housing, damaging or destroying the gun; and (6) in the telescoped gun design, the breach end of the launch tube is rigidly connected to the pump piston. That pump piston/launch tube connection is riddled with holes that allow the hot, compressed light gas to enter from the pump tube. Such a design is structurally much weaker than in other light gas gun designs, wherein there is a simple transition from the pump tube into the launch tube, and said transition of the two tubes is very strong because it is encased within a large block of metal.
[0012] In U.S. Pat. No. 4,658,699 Dahm (1987) describes a two-stage light gas gun referred to as a ‘wave gun’. The wave gun uses a light and flexible pump piston that—after the projectile has exited the launch tube—is forced through the pump tube/launch tube constriction, and then travels through and out the launch tube. Higher muzzle velocities of the projectile are claimed for this design, as compared to other two-stage light gas guns. The design, however, is beset by a variety of drawbacks: (1) expulsion of the light piston entirely from the gun means that propellant residue contaminates not only the pump tube, but the launch tube as well; (2) the mechanical integrity of the pump piston is questionable because it is designed to travel back and forth within the pump tube several times before finally being expelled from the gun. Such a ‘wave’ motion with the hot, high-pressure propellant gas on one side and the hot, high-pressure light gas on its other side would put enormous stresses on such a light and deformable piston, which could well lead to a blow-by of the propellant and/or light gases and subsequent contamination of the light gas with propellant, which in turn would degrade the interior ballistic performance of the projectile; (3) increased erosion of the launch tube interior. High velocity light gas guns have traditionally suffered from erosion of the launch tube after each firing of the gun. But the wave gun not only expels the projectile and associated light gas from the launch tube, but the pump piston and the propellant as well. The additional material ejected through the launch tube at high speeds would probably increase launch barrel erosion significantly as compared to more conventional designs; and (4) a final drawback of the wave gun design is that if all or part of the deformable pump piston does not completely leave the launch tube, its presence could impede a subsequent firing with potentially catastrophic damage to the gun.
[0013] In the article titled “World's Largest Light Gas Gun Nears Completion at Livermore” appearing in Aviation Week and Space Technology/Aug. 10, 1992/pp 57-59, a two-stage light gas gun designed by John Hunter uses a methane/air mixture as the propellant to accelerate a heavy steel piston down a long pump tube to compress the light gas. The pump tube is at a right angle to the launch tube. Shock absorbers negate the recoil transmitted through both the pump and launch tubes. The pump and launch tubes are connected in such a way that the launch tube can be swiveled to any angle from horizontal up to vertical. A positive feature of Hunter's design is that it uses a clean-burning and inexpensive propellant source. However, the design possesses a number of disadvantages: (1) the pump tube is excessively long compared to the launch tube length; indeed, the prototype that was constructed had a pump tube nearly twice as long as the launch tube. Such a long pump tube makes for an unwieldy design, and means a much more expensive gun; (2) a right angle between the pump and launch tubes leads to large torques on each tube that are eliminated with shock absorbers, which increases complexity and the total cost of the gun. Moreover, failure of a shock absorber could lead to severe damage of the gun, especially in the vicinity where the pump and launch tubes meet; (3) even though methane is typically very clean burning as compared to, say, gunpowder, if the combustion of methane is not complete, carbon deposits could still form in the pump tube; (4) after the gun is fired the freely-moving, heavy pump piston must be returned the length of the long pump tube before another firing can take place, slowing the time between firings; and (5) the swivel connection between the pump and launch tubes, which allows a projectile is to be fired at various angles, must be made of very strong materials and to very close tolerances so that no leakage of hot gases occurs, which all translates into a significant increase in the cost of the gun.
[0014] In NASA Contractor Report 4491 titled “Concept Definition Study for an Extremely Large Aerophysics Range Facility” by Hallock F. Swift, dated February 1993, a two-stage light gas gun is proposed that foregoes the use of a combustible propellant to propel the pump piston, using instead helium compressed to 15,000 pounds per square inch. The helium is held within high-pressure storage tanks until it is quickly released into the pump tube, at which time the highly compressed helium accelerates a large and heavy pump piston down the pump tube, compressing low-pressure helium on the opposite side of the pump piston, which in turn launches the projectile from the launch tube.
[0015] A prominent feature of the proposed light gas gun is that no propellant residue should form in the pump tube since the propelling gas—namely helium—is non-combustible. In spite of that advantageous characteristic, the design has a number of other features that are decidedly disadvantageous: first, the pump piston is partially deformed on each shot, and must be either discarded completely, or repaired for subsequent use, and either option translates into increased cost per shot from the gun; second, at the end of each firing the pump tube must be opened and a device inserted in order to retrieve the used pump piston, a procedure which considerably slows the process of readying the gun for another firing; third, helium used as the propelling gas of the pump piston is rather expensive; therefore, the design calls for reuse of the helium, which entails pumping it from the pump tube back into the original storage tanks; the reuse of the helium increases the complexity of the entire gun system, and greatly delays the possible time between firings; the author cites a ballpark figure of around an hour to recompress the helium; while higher-capacity pumps could certainly decrease the time needed to recompress the helium, the higher initial and ongoing costs associated with their use would also significantly increase the overall cost of the entire system.
[0016] As demonstrated above, there are many different designs of two-stage light gas guns known in the prior art. Each design possesses various strengths and weaknesses, some of which were outlined above; however, the designs known heretofore all suffer from a number of drawbacks:
(a) after the gun is fired, the pump piston cannot be quickly returned to its original start position for another firing of the gun; (b) the length of time to reload the gun with a projectile is excessive; (c) in the prior art a number of different types of gases have been used to propel a pump piston down the length of a pump tube, but under the right conditions any type of propelling gas is capable of leaving residues within the pump tube that build up over repeated firings of the gun; (d) after the gun is fired, the spent propellant gas is expelled either through the use of some type of valve integrated into the pump tube, which adds cost and complexity to the gun design, or by exiting through the launch tube, which can foul the launch tube with propellant residue and/or increase interior erosion; (e) the area of the pump piston the propelling gas pushes against versus the area of the pump piston that compresses the light gas is restricted in all previous designs known heretofore, and that restriction limits the utility of those designs; specifically, most designs in the prior art set the area of the pump piston that the propelling gas pushes against equal to the area of the pump piston compressing the light gas; but at least one design results in a ratio of propelling area to compression area slightly greater than 1; however, no known previous design allows a broad range of ratios. (f) no design known heretofore is easily adapted to a variety of roles; a design that is well-suited for laboratory research is unwieldy when applied to a military role or space launch applications, and vice versa;
BACKGROUND OF INVENTION
Objects and Advantages
[0023] Several objects and advantages of my invention are:
(a) to provide a two-stage light gas gun in which the pump piston can quickly be returned to its start position for another firing; (b) to provide a two-stage light gas gun that can be quickly reloaded with a projectile for a subsequent firing of the gun; (c) to provide a two-stage light gas gun that prevents any possible residue from the gas propelling the pump piston from contaminating either the pump or launch tubes; (d) to provide a two-stage light gas gun in which the gas propelling the pump piston is quickly and automatically vented without the need for valves; (e) to provide a variety of possible ratios, from less than one, to equal to one, to greater than one, of the area of the piston the propelling gas pushes against versus the area of the pump piston compressing the light gas; (f) to provide a two-stage light gas gun design that performs well in a variety of roles: laboratory research, anti-armor, very long-range artillery, and shots into outer space.
[0030] Further objects and advantages are to provide a two-stage light gas gun in which the pump piston can be halted reliably at a predetermined position within the pump tube, which can utilize inexpensive and clean-burning propellants—such as an alcohol/air mixture—without the need for an excessively long pump tube, which can use the spent propellant gas to counteract the recoil due to firing the gun, which does not deform the pump piston as part of the gun's firing cycle, which provides for a pump tube that is considerably shorter than the launch tube, and in which the projectile can be loaded into the gun via a conventional breech block. Still further objects and advantages of my invention will become apparent upon consideration of the drawings and ensuing description.
SUMMARY
[0031] In accordance with the present invention an improved two-stage light gas gun for launching projectiles at very high speeds, and consisting of three main parts: a launch tube from which a projectile is fired; a pump tube filled with pressurized hydrogen or helium; and an expansion tube containing a propellant charge. When the propellant charge is ignited a piston in the expansion tube is driven forward and pushes on a piston in the pump tube, compressing the hydrogen or helium, which in turn expels the projectile from the launch tube at high speed.
DRAWINGS
Figures
[0032] In the drawings, closely related figures are identified by the same number but with different alphabetic suffixes.
[0033] FIG. 1 shows a lateral cross-sectional view of the preferred embodiment of a two-stage light gas gun constructed in accordance with the present invention.
[0034] FIG. 2 shows a magnified view of a more-or-less central portion of FIG. 1 .
[0035] FIGS. 3A-3F depict the steps involved in firing the two-stage light gas gun of the preferred embodiment of the invention.
[0036] FIG. 4 shows a lateral cross-sectional view of an alternative embodiment of a two-stage light gas gun constructed in accordance with the present invention.
[0037] FIGS. 5A-5E depict the steps involved in firing the two-stage light gas gun of the alternative embodiment of the invention shown in FIG. 4 .
[0038] FIG. 6 shows a cross-sectional, muzzle-end view of the expansion tube and launch tube of the alternative embodiment of FIG. 4 .
[0039] FIG. 7 shows a cross-sectional, muzzle-end view of an expansion tube and launch tube; the expansion tube cross-section is an alternative to the embodiment of FIG. 4 .
[0040] FIG. 8 shows a lateral cross-sectional view of an alternative embodiment of the invention.
[0041] FIG. 9 shows a lateral cross-sectional view of an alternative embodiment of the invention.
[0042] FIG. 10 shows a lateral cross-sectional view of an alternative embodiment of the invention.
DETAILED DESCRIPTION
FIGS. 1 and 2 —Preferred Embodiment
[0043] A preferred embodiment of the two-stage light gas gun of the present invention is depicted in FIG. 1 , which is of a lateral, cross-sectional view. FIG. 2 shows a magnified portion of FIG. 1 . The gun can conveniently be divided into four segments: the expansion tube 10 , pump tube 11 , connecting block 12 , and launch tube 13 . The four main segments of the gun are made out of any suitable material typically employed in producing guns, such as high strength steel. Materials lighter than steel, such as titanium, or metal matrix composites, can also be employed if their tensile and compressive strengths are adequate for the role.
[0044] A shoulder 14 near the middle of expansion tube 10 defines combustion region 15 . A one-way valve 16 allows an oxidizing gas, such as air, nitrous oxide, or pure oxygen, to flow into combustion chamber 15 but prevents it from passing back out. The gas is supplied from a pump or pressurized tank 17 that is connected to one-way valve 16 .
[0045] Fuel injector 18 is connected to fuel tank 19 by fuel line 20 , which may be of either rigid or flexible construction. Spark plug 21 is connected to power supply 22 , which is grounded to expansion tube 10 by metallic bolt 23 . Pressure relief valve 24 opens automatically if the pressure inside combustion chamber 15 exceeds a predetermined safe value; valve 24 can also be opened manually.
[0046] Within expansion tube 10 is expansion piston 25 , which is connected to smaller pump piston 26 within pump tube 11 by connecting rod 27 . On the piston side of shoulder 14 is o-ring 28 . Expansion tube 10 has the four removable plugs 29 t (“t” stands for “top”), 29 b (“b” stands for “bottom”), 30 t , and 30 b . At one end of expansion tube 10 , at the end opposite combustion chamber 15 , are end-stops 31 t and 31 b , held in place by bolts 32 t and 32 b , respectively.
[0047] Situated between expansion tube 10 and pump tube 11 are return rollers 33 t and 33 b . At one end of pump tube 11 is end cap 34 , the inside face of which holds o-ring 35 . One-way valve 36 allows a light gas, either hydrogen or helium, to flow into cavity 39 defined by pump tube 11 , but prevents the light gas from flowing back out. Pressure tank 38 contains a light gas and is connected by high-pressure line 37 to one-way valve 36 . Connecting block 12 holds diaphragm 40 . Projectile 41 lies within launch tube 13 and adjacent to diaphragm 40 .
Operation—FIGS. 1 , 3 A- 3 F
[0048] Operation of the two-stage light gas gun that is the object of this invention begins with unscrewing launch tube 13 from connecting block 12 and loading diaphragm 40 and projectile 41 ( FIG. 1 ). Diaphragm 40 may be held in place by any convenient means, such as a slight taper of its outer surface, along with a corresponding taper of the inner portion of connecting block 12 where diaphragm 40 fits (said taper is not represented in FIG. 1 ). Plugs 30 t and 30 b have been removed as shown in FIGS. 3A through 3F in order to allow the venting of the spent propellant gas; plugs 29 t and 29 b remain in place, but could have been removed to allow venting of the propellant gas earlier in the firing sequence. With diaphragm 40 and projectile 41 loaded into the gun and launch tube 13 screwed back into connecting block 12 , the sequence of events leading to expulsion of the projectile from the gun appears in FIGS. 3A through 3F (in what follows, identifying numbers refer back to FIG. 1 and/or FIG. 2 ).
[0049] In FIG. 3A , either hydrogen or helium gas has been supplied under pressure from tank 38 , through high-pressure line 37 and one-way valve 36 into cavity 39 of pump tube 11 . The stippling within cavity 39 indicates the presence of the hydrogen or helium gas. The pressure of the gas within cavity 39 pushes upon pump piston 26 , forcing it against end cap 34 . O-ring 35 , being squeezed between pump piston 26 and end cap 34 , forms a tight seal that prevents the pressurized gas from leaking out of pump tube 11 . The pressure exerted upon pump piston 26 by the pressurized gas in cavity 39 is also partially exerted upon expansion piston 25 by way of connecting rod 27 . The resulting force acting upon expansion piston 25 squeezes o-ring 28 up against shoulder 14 , forming a tight seal. In order to ensure that adequate force is applied to both o-ring seals 28 and 35 , the distance between pump piston 26 and expansion piston 25 may be adjusted by screwing connecting rod 27 further into, or out of, either piston individually.
[0050] Continuing with FIG. 3A , combustion chamber 15 has been pressurized with air or other oxidizing gas via pressurized tank 17 and one-way valve 16 , immediately after which liquid fuel, such as alcohol, is supplied from fuel tank 19 , through fuel line 20 , and injected by fuel injector 18 into combustion chamber 15 . The stippling within combustion chamber 15 depicts the resulting fuel/air, or more broadly, the fuel/oxidizer, mixture. The pre-ignition pressure within combustion chamber 15 is held sufficiently lower than the pressure within pump tube 11 so that expansion piston 25 is held tightly against shoulder 14 and o-ring 28 . To illustrate this principle, suppose the pressure of the light gas within pump tube 11 is 1,000 pounds per square inch. If the area of expansion piston 25 that is exposed to the fuel/air mixture is equal to the area of pump piston 26 that is exposed to the high-pressure light gas within cavity 39 , then a pre-ignition fuel/air pressure of 250 pounds per square inch results in a force on the left face of expansion piston 25 that is one-fourth as large as the force pushing on the right face of pump piston 26 . As long as the larger force exerted through pump piston 26 is properly distributed by connecting rod 27 , both pistons will be firmly pressed up against their adjacent o-rings, i.e., o-rings 28 and 35 .
[0051] FIG. 3B depicts ignition of the fuel-air mixture by means of spark plug 21 . Combustion of the fuel/air mixture greatly increases the pressure within combustion chamber 15 so that the force pushing expansion piston 25 to the right is considerably greater than the force pushing pump piston 26 to the left. In FIG. 3C both pistons, along with connecting rod 27 joining them, have moved in unison to the right. After expansion piston 25 separated from shoulder 14 a much greater surface area of expansion piston 25 was exposed to the hot combustion gases, which in turn greatly increased the force pushing expansion piston 25 to the right. In FIG. 3C the light gas within cavity 39 of pump tube 11 has been considerably compressed from its initial volume.
[0052] In FIG. 3D expansion piston 25 has moved past the second set of plugs, 30 t and 30 b , but not yet met end-stops 31 t and 31 b . The force due to the combustion gas has fallen dramatically, partly because energy has been extracted from it, and partly because the gas is being vented through the open plugs. Also in FIG. 3D diaphragm 40 has been breached and the hot, high-pressure light gas is shown accelerating projectile 41 down launch tube 13 . Even though the light gas is now at a much higher pressure than the combustion gas in expansion tube 10 , the piston/connecting rod structure continues to move to the right due to its momentum. Only when expansion piston 25 has impacted end-stops 31 t and 31 b does the entire piston/connecting rod structure come to a halt, as shown in FIG. 3E . Note also in FIG. 3E that projectile 41 has completely exited launch tube 13 , and that the combustion gas and light gas have both been largely dissipated, as indicated in expansion tube 10 by the reduced amount of stippling within it, and in launch tube 13 by the complete absence of any stippling.
[0053] FIG. 3F shows the piston/connecting rod structure returning to its original start position depicted in FIG. 3A via the impetus supplied by return rollers 33 t and 33 b . Valve 24 has been manually opened to allow the venting of residual propellant gas trapped by the return of expansion piston 25 to its position adjacent to shoulder 14 . Valve 24 is then closed, and the process of readying the gun for launching another projectile is repeated as described at the beginning of this section.
FIG. 4 —First Alternative Embodiment
[0054] An alternative embodiment of the present invention is shown in FIG. 4 . Like the preferred embodiment, the two-stage light gas gun shown in FIG. 4 can be conveniently divided into the four sections of expansion tube 50 , pump tube 51 , connecting block 52 , and launch tube 53 . However, in the preferred embodiment shown in FIG. 1 those four components—the expansion tube 10 , pump tube 11 , and launch tube 13 , as well as the connecting block 12 —are laid out linearly (that is, they share a common axis); by contrast, in the alternative embodiment of FIG. 4 , the expansion tube 50 and pump tube 51 lie beneath launch tube 53 . It is noted that while pump tube 51 and launch tube 53 possess a cylindrical shape, expansion tube 50 has a rectangular shape, as depicted in the muzzle-end-view perspective of FIG. 6 (only launch tube 53 and expansion tube 50 appear in FIG. 6 ).
[0055] Shoulder 54 near the middle of expansion tube 50 helps define combustion chamber 55 . One-way valve 56 allows an oxidizing gas to flow into combustion chamber 55 but not back out. The oxidizing gas is supplied through high pressure line 57 .
[0056] Fuel injector 58 is supplied by fuel line 59 , which may be of either rigid or flexible construction. Spark plug 60 is connected to power supply 61 , which is grounded to expansion tube 50 by metallic bolt 62 . Valve 63 acts as a pressure relief valve opening automatically if the pressure inside combustion chamber 55 exceeds a predetermined safe value; valve 63 can also be opened by movement of linkage 64 .
[0057] Expansion tube 50 and launch tube 53 are rigidly attached to each other by connectors 65 l and 65 r (“l” stands for left, and “r” for right). Within expansion tube 50 is expansion piston 66 , which is connected to smaller pump piston 67 within pump tube 51 by connecting rod 68 . On the piston side of shoulder 54 is o-ring 69 . Situated between expansion tube 50 and pump tube 51 are return rollers 70 t and 70 b (“t” stands for top, and “b” for bottom). Idler sprocket 71 and rocker arm 72 are situated beneath return rollers 70 t and 70 b . At one end of expansion tube 50 , opposite combustion chamber 55 , is end-stop 73 . Between end-stop 73 and expansion piston 66 is exhaust port 76 , which is threaded.
[0058] At the one end of pump tube 51 is end cap 74 , the inside face of which holds o-ring 75 . One-way valve 77 allows a light gas to flow into cavity 78 that is defined by pump tube 51 and connecting block 52 . High pressure line 79 supplies a light gas to one-way valve 77 .
[0059] Screw-type breach block 80 is screwed into connecting block 52 . Connecting block 52 holds diaphragm 81 . Projectile 82 lies within launch tube 53 and adjacent to diaphragm 81 .
Operation of First Alternative Embodiment—FIGS. 4 , 5 A- 5 E
[0060] The description of the operation of the alternative embodiment will be more concise than for the preferred embodiment since the operation of the two is very similar. The sequence of events leading to expulsion of the projectile from the gun appears in FIGS. 5A through 5E ; reference numbers refer back to FIG. 4 .
[0061] Operation of the alternative embodiment begins with unscrewing breach block 80 from connecting block 52 , followed by loading projectile 82 into the breach-end of launch tube 53 , with diaphragm 81 then placed behind, and in contact with, projectile 82 . In FIG. 5A , either hydrogen or helium gas has been supplied under pressure into cavity 78 via one-way valve 77 . The pressure of the gas within cavity 78 pushes upon pump piston 67 , forcing it against end cap 74 . O-ring 75 , being squeezed between pump piston 67 and end cap 74 , forms a tight seal that prevents the pressurized gas from leaking out of cavity 78 . The pressure exerted upon pump piston 67 by the pressurized gas in cavity 78 is also exerted upon expansion piston 66 by way of connecting rod 68 . The resulting force upon expansion piston 66 squeezes o-ring 69 up against shoulder 54 , forming a tight seal.
[0062] Continuing with FIG. 5A , combustion chamber 55 has been pressurized with an oxidizing gas via one-way valve 56 , and injected with liquid fuel via fuel injector 58 . Ignition of the fuel/air mixture by means of spark plug 60 is depicted by the squiggly lines appearing in FIG. 5A .
[0063] In FIG. 5B both pistons, along with connecting rod 68 joining them, have moved in unison to the left in response to the combustion of the fuel/air mixture originally confined in combustion chamber 55 . Movement to the left of connecting rod 68 rotates return rollers 70 t clockwise and 70 b counterclockwise, winding torsion springs affixed to each. Idler sprocket 71 is engaged by return roller 70 b , which in turn rotates rocker arm 72 counterclockwise, thereby shifting linkage 64 to the right. Linkage 64 pushes a lever on valve 63 , but not to the point where valve 63 is yet open.
[0064] In FIG. 5C movement of expansion piston 66 has exposed port 76 , allowing hot combustion gases to vent from expansion tube 50 . Moreover, rocker arm 72 has rotated further counterclockwise, shifting linkage 64 further to the right which opens valve 63 , thereby venting additional hot combustion gases from expansion tube 50 . Also in FIG. 5C diaphragm 81 has been breached and the hot, high-pressure light gas has pushed projectile 82 partway down launch tube 53 . Even though the light gas is at a higher pressure than the combustion gas in expansion tube 50 , the piston/connecting rod structure continues to move to the left due to its momentum. Only when expansion piston 66 has impacted end-stop 73 does the entire piston/connecting rod structure come to a halt, as shown in FIG. 5D . Note also in FIG. 5D that projectile 82 has completely exited launch tube 53 .
[0065] FIG. 5E shows return of the piston/connecting rod structure mid-way towards its original start position of FIG. 5A by return rollers 70 t and 70 b via the force applied by their embedded torsion springs. As expansion piston 66 reaches shoulder 54 , valve 63 is closed; then the process of readying the gun for launching another projectile can be repeated as described at the beginning of this section, with the caveat that once breach block 80 is unscrewed from connecting block 52 , the spent diaphragm is removed before the loading of a new diaphragm 81 and projectile 82 can commence.
FIG. 8 —Second Alternative Embodiment
[0066] The second alternative embodiment of the invention, shown in FIG. 8 , is quite similar to the first alternative embodiment shown in FIG. 4 , so the description of its parts and its operation will be abbreviated. The principle difference between the first and second alternative embodiments is that expansion tube 50 shown in FIG. 4 has been eliminated. In place of an expansion tube, and the many ancillary components associated with it, there is electric motor 90 , small gear 91 , and large gear 92 .
[0067] In contact with large gear 92 is toothed rod 93 , near the middle of which is bar stop 94 . Attached to the threaded end of toothed rod 93 is pump piston 95 , which lies within pump tube 96 . One-way valve 97 , which is supplied through high-pressure line 98 , is attached to pump tube 96 , as are end stops 99 a and 99 b (“a” stands for “above”, while “b” stands for “below”). Affixed to pump piston 95 , and squeezed between pump tube 96 and pump piston 95 , is o-ring 100 . Both pump tube 96 and screw-type breach block 102 are threaded into connecting block 101 . Launch tube 103 contains projectile 104 and diaphragm 105 .
[0068] The operation of the two-stage light gas gun depicted in FIG. 8 is as follows: first, screw-type breach block 102 is unscrewed and projectile 104 is loaded into launch tube 103 , followed by diaphragm 105 . Screw-type breach block 102 is then replaced. Light gas is subsequently directed from high pressure line 98 , through one-way valve 97 , and into pump tube 96 until the gas pressure reaches a predetermined level. The light gas cannot escape past pump piston 95 due to the compression seal of o-ring 100 .
[0069] Electric motor 90 then spins smaller gear 91 clockwise, causing the counterclockwise rotation of larger gear 92 , which in turn engages the teeth of toothed rod 93 , pushing toothed rod 93 and attached pump piston 95 down pump tube 96 in the direction of screw-type breach block 102 . Movement of pump piston 95 down pump tube 96 compresses the light gas introduced through one-way valve 97 , until sufficient pressure is attained, rupturing diaphragm 105 , and propelling projectile 104 down and out of launch tube 103 .
[0070] After diaphragm 105 ruptures, power to electric motor 90 is shut off; however, pump piston 95 continues to compress the light gas for a short period of time due to its own momentum, along with the combined momentum of attached toothed rod 93 , and gears 91 and 92 , and electric motor 90 . Forward motion of pump piston 95 and toothed rod 93 is finally halted by pressure of the light gas pushing on pump piston 95 , as well as by the impact of bar stop 94 with end stops 99 a and 99 b.
[0071] The slow reversal of electric motor 90 reverses the rotation of gears 91 and 92 , which retracts toothed rod 93 and pump piston 95 until o-ring 100 is again compressed. A new firing cycle can then commence with opening of screw-type breach block 102 as described previously, with the single caveat that the previously-used diaphragm 105 is discarded before the loading of a new projectile 104 and new diaphragm 105 .
FIG. 9 —Third Alternative Embodiment
[0072] This embodiment of the invention, depicted in FIG. 9 , is very similar to the second alternative embodiment shown in FIG. 8 . What differentiates the two embodiments is that electric motor 90 , small gear 91 , large gear 92 , and toothed rod 93 have been replaced with a new set a parts; otherwise, the components of the two embodiments are identical. That new set of parts consists of electric motor 110 , pulley 111 , cable 112 , smooth rod 116 , compression springs 113 a and 113 b (“a” stands for “above” and “b” stands for “below”), brackets 114 a and 114 b , and connectors 115 r and 115 f (“r” stands for “rear” and “f” stands for “front”). For the parts of the two embodiments that are identical, their corresponding reference numbers are the same in FIGS. 8 and 9 .
[0073] Compression springs 113 a and 113 b are affixed at one end to brackets 114 a and 114 b , and at the other end to bar stop 94 . Brackets 114 a and 114 b are each connected at one end to pump tube 96 . Connectors 115 r and 115 f support launch tube 103 by rigidly connecting launch tube 103 to bracket 114 a.
[0074] The operation of the third alternative embodiment shown in FIG. 9 in terms of loading and firing the gun is exactly the same as the operation of the second alternative embodiment shown in FIG. 8 , with the exception of how pump piston 95 is propelled down pump tube 96 to compress the light gas.
[0075] In the third alternative embodiment shown in FIG. 9 , after projectile 104 and diaphragm 105 are loaded and the light gas is introduced into the gun, all in the manner described previously for the second alternative embodiment, the gun is ready to be fired. Initially, pulley 111 is prevented from rotating, which keeps sufficient tension on cable 112 such that compression springs 113 a and 113 b cannot expand and push upon bar stop 94 . The gun is fired when pulley 111 is released, allowing it to freely rotate and release cable 112 ; thereafter, compression springs 113 a and 113 b push upon bar stop 94 , which in turn pushes upon and accelerates both smooth rod 116 and pump piston 95 . Compression of the light gas by pump piston 95 bursts diaphragm 105 , propelling projectile 104 down launch tube 103 in exactly the same manner as described previously for the second alternative embodiment.
[0076] The movement of smooth rod 116 is halted by attached bar stop 94 when the later impacts end stops 99 a and 99 b . The gun is readied for another firing by first powering up electric motor 110 , which rotates pulley 111 and rolls up cable 112 onto pulley 111 . Winching cable 112 onto pulley 111 squeezes compression springs 113 a and 113 b until pump piston 95 meets the closed end of pump tube 96 , squeezing o-ring 100 . The spent diaphragm 105 is removed, and a new projectile 104 and diaphragm 105 are put into place; subsequently, a new charge of light gas is introduced into the gun, as per the description of operation for the second alternative embodiment given previously.
FIG. 10 —Fourth Alternative Embodiment
[0077] Yet another alternative embodiment of the present invention is depicted in FIG. 10 . While having several parts in common with the second and third alternative embodiments, the fourth alternative embodiment of the invention is unique in that the pump piston is actuated via a cable instead of a rigid rod.
[0078] The parts differentiating this fourth alternative embodiment, as depicted in FIG. 10 , from the third alternative embodiment consist of: cable 120 , which is affixed at one end to pump piston 121 , and which passes through cable sleeve 122 , over upper pulley 123 a and around lower pulley 123 b , past end stops 125 a and 125 b , and terminating at its other end on flywheel 127 . Electric motor 126 shares a common axle with flywheel 127 ; cable stop 124 is firmly affixed to cable 120 and lies between lower pulley 123 b and end stops 125 a and 125 b . One-way valve 128 , which is supplied through high-pressure line 129 , is affixed to connecting block 131 and is situated close to cable sleeve 122 . Pump tube 130 is threaded into connecting block 131 .
[0079] The operation of the fourth alternative embodiment, in terms of loading and firing the gun, follows much the same procedure as the operation of the second and third alternative embodiments shown in FIGS. 8 and 9 , respectively; however, pump piston 121 is propelled down pump tube 130 by the action of a cable, instead of a rod which is utilized in all previous embodiments of the invention.
[0080] For the fourth alternative embodiment, shown in FIG. 10 , after projectile 104 and diaphragm 105 are loaded and the light gas is introduced into the gun from high-pressure line 129 and through one-way valve 128 , all in the manner described previously for the second and third alternative embodiments, the gun is ready to be fired. Electric motor 126 first spins up flywheel 127 . When flywheel 127 attains a predetermined rpm it engages cable 120 . As flywheel 127 rotates, it wraps up cable 120 . Cable 120 is pulled over lower pulley 123 b and upper pulley 123 a , through cable sleeve 122 and through pump tube 130 , where it transmits a force to pump piston 121 to which cable 120 is affixed. Cable sleeve 122 forms a close fit with cable 120 and connecting block 101 such that the light gas is prevented from leaking past cable 120 as it slides through cable sleeve 122 . Pump piston 121 is accelerated by cable 120 down pump tube 130 , compressing the light gas to a pressure sufficient to burst diaphragm 105 . The movement of cable 120 is halted when affixed cable stop 124 meets end stops 125 a and 125 b.
[0081] The gun is readied for a subsequent firing by opening screw-type breach block 102 , removing the spent diaphragm 105 , and loading new projectile 104 and diaphragm 105 . After screw-type breach block 102 is replaced and tightened, a new charge of light gas is supplied through one-way valve 128 via high-pressure line 129 . The pressurized light gas pushes pump piston 121 back to the closed end of pump tube 130 where it seats against o-ring 100 .
Additional Embodiments
[0082] The screw-type breech block 80 shown in FIG. 4 can be replaced by a more conventional sliding-type breech block, thus significantly reducing the time required to reload the gun.
[0083] In FIGS. 4 and 8 the diaphragms 81 and 99 , respectively, are valves that can be used only once and then they must be replaced. Each diaphragm can be replaced with a quick-opening valve that can be used in repeated gun firings without the need to be replaced.
[0084] A further additional embodiment relates to the preferred embodiment of FIG. 1 , wherein the expansion tube is considered to be cylindrical. However, the expansion tube in the alternative embodiment of FIG. 4 has a transverse cross-section that is rectangular, as depicted in the end-view perspective of FIG. 6 , which shows the muzzle-end of the launch tube as well as the corresponding end of the expansion tube. Obviously, many other cross-sectional shapes are possible for the expansion tube; one alternative shape of an expansion tube is shown (along with the launch tube) in the end-view perspective of FIG. 7 .
[0085] An anti-recoil mechanism is described which acts to counteract recoil when the gun is fired. For the preferred embodiment of FIG. 1 , ports 30 t and 30 b can be fitted with tubes bent at right-angles so that spent propellant gas is vented in the opposite direction of the projectile motion. The same sort of anti-recoil tube can be fitted to port 76 in the alternative embodiment shown in FIG. 4 .
ADVANTAGES
[0086] From the description provided previously, a number of advantages of my two-stage light gas gun become evident:
(a) After the gun is fired, the pump piston can quickly be returned to its start position for another firing. (b) Any possible residue from the gas that propels the pump piston is prevented from contaminating either the pump tube or the launch tube. (c) Spent propellant gas is quickly and automatically vented. (d) The pump piston can be reliably halted at a predetermined position within the pump tube; hence the pump piston can be made of a non-deformable material, such as aluminum or steel, which facilitates long piston life, but without the danger that it could ram into the end of the pump tube and damage the gun. (e) The piston area that the propellant gas expands against can be greater than, equal to, or less than, the piston area compressing the light gas; the variety of possible ratios of propellant area to compression area means that the invention can be adapted to efficiently meet the requirements of a particular role. (f) Making the piston area that the propellant gas expands against several times greater than the piston area compressing the light gas allows for the use of much cheaper propellants, such as an alcohol/air mixture, in place of a more-conventional, and expensive, modern gunpowder, while still allowing the pump tube to be much shorter than the launch tube. (g) In an alternative embodiment of the invention, a projectile can be loaded into the gun via a conventional breech block, thus greatly reducing the time required to reload the gun as compared with two-stage light gas gun design seen in the prior art. (h) Propellant gases expelled from the expansion tube can be used to counteract the recoil due to firing the gun. (i) My design for a two-stage light gas gun can be effectively applied to a variety of roles:
laboratory research, anti-armor, artillery, high altitude intercept, and space launches.
CONCLUSION, RAMIFICATIONS, AND SCOPE OF THE INVENTION
[0097] It should thus be apparent to the reader that the improved two-stage light gas gun of the invention provides, as compared to previous designs appearing in the prior art, a reliable and compact gun that can sustain a high rate of fire, while also being capable of operating with an inexpensive propellant. In addition, the invention has the following distinct advantages in regards to previous embodiments of two-stage light gas guns:
the pump piston can quickly be returned to its start position for another firing; it can quickly be reloaded with a new projectile after it has been fired; it prevents any possible residue from the propellant contaminating the pump tube; the propellant is quickly and automatically vented without the need for valves; it provides a variety of possible ratios, from less than one, to equal to one, to greater than one, of the area of the piston the propellant pushes against versus the area of the pump piston compressing the light gas; it performs well in a variety of roles: laboratory research, anti-armor, very long-range artillery, and shots into outer space; the pump piston can be halted reliably at a predetermined position within the pump tube; the spent propellant gas can be used to counteract the recoil of the gun; the projectile can be loaded into the gun via a conventional breech block.
[0107] The invention has the additional positive features of providing for a pump tube that is considerably shorter than the launch tube, as well as preventing deformation of the pump piston as a normal part of the firing cycle.
[0108] Although several embodiments of the present invention, along with many of its advantages, have been described above in detail, it should be understood that various alterations, modifications, and alternate constructions can be made herein without departing from the spirit and scope of the invention as defined by and within the appended claims. Indeed, the scope of the present application is not intended to be limited to the particular embodiments of the machine, manufacture, composition of matter, means, methods, and steps described in the specification. Instead, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the scope of the present invention as defined in the appended claims.
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An improved two-stage light gas gun for launching projectiles at high speeds. The gun consists of three tubes: the expansion, pump, and launch tubes. The expansion tube contains a close-fitting expansion piston that is propelled by an explosive charge. The expansion piston in turn drives the pump piston housed within the pump tube by means of a rod connecting the two pistons. The action of the pump piston adiabatically compresses and heats a light gas of hydrogen or helium, bursting a diaphragm at a predetermined pressure and expelling the projectile from the launch tube at a very high speed.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This utility application is the Continuation-In-Part application of the nonprovisional utility U.S. patent application Ser. No. 10/764,793 filed on Jan. 26, 2004, which claims benefit from is the nonprovisional application of U.S. Provisional Application Nos. 60/477,591 filed on Jun. 12, 2003 and 60/517,069 filed on Nov. 5, 2003, each of which are herein incorporated by reference in their entirety.
BACKGROUND OF INVENTION
[0002] This invention relates to pneumatic guns, air rifles, pellet rifles, paintball guns and the like. Such pneumatic guns are typically driven by either hand cocked springs, compressed gas, or hand operated pumps. The disadvantages of these guns are outlined in more detail below.
[0003] Air rifles have been around for many years and have seen numerous evolutionary changes over the years. The most common methods for propelling the projectile use the energy from compressed gas or from a spring. There are four major techniques shown in the prior art for launching the projectile with many variations based upon such teachings. These techniques include: (i) the use of stored compressed gas in the form of carbon dioxide cylinders or other high pressure storage tanks; (ii) using a powerful spring to push a piston which compresses air which then pushes the projectile; (iii) using a hand pump to pressurize the air for subsequent release; and (iv) using a direct acting means such as a solenoid plunger or centrifugal force to push the projectile out of the barrel. All of these methods have distinct disadvantages when compared to the present invention.
[0004] The first technique requires a source of compressed air, such as a tank or canister. Filling, transporting and using such a canister represents a significant inconvenience and burden for the user. Often, additional equipment such as regulators, evaporation chambers, multistage regulators and complicated timing circuits are required to reduce and control the very high pressure in the cylinder to a level suitable for launching the projectile. This further increases the cost and complexity of such an air gun. Additionally, in the case of carbon dioxide driven air or paintball guns, there is a large variation in the velocity of the projectile with varying ambient temperatures. Furthermore, these tanks store an incredible amount of energy which, if released suddenly through a tank fault, could represent a significant safety factor. Disposable cartridges, which can be used in less costly air guns, significantly increase refuse issues. Additional teachings such as those contained in U.S. Pat. Nos. 6,516,791, 6,474,326, 5,727,538 and 6,532,949 teach of various ways of porting and controlling high pressure air supplies to improve the reliability of air guns (specifically paintball guns and the like) by differentiating between the airstream which is delivered to the bolt which facilitates chambering the projectile and the airstream which pushes the projectile out of the barrel. All of these patents still suffer from the major inconvenience and potential safety hazard of storing a large volume of highly compressed gas within the air gun. Additionally, as they combine electronic control with the propulsion method of stored compressed gas, the inherent complexity of the mechanism increases, thus, increasing cost and reliability issues. Further, U.S. Pat. No. 6,142,137 teaches about using electrical means to assist in the trigger control of a compressed air gun such as a paintball gun. In this patent, an electromotive device is used in conjunction with electronics to define various modes of fire control such as single shot, burst or automatic modes. While this addresses the ability of multiple modes of fire, it does not solve the fundamental propulsion problem associated with gas cylinders and, in addition, it is expensive and complicated.
[0005] The second technique is actually quite simple and has been used for quite a few years in many different types of pellet, “bb” or air rifles. The basic principle is to store energy in a spring which is later released to rapidly compress air. This air then pushes the projectile out of the barrel at high velocity. Problems with this method include the need to “cock” the spring between shots. Thus, it is only suitable for single shot devices and is limited to very slow rates of fire. Furthermore, the spring results in a double recoil effect when it is released. The first recoil is due to the unwinding of the spring and the second recoil is due to the spring slamming the piston into the end of the cylinder (i.e. forward recoil). Additionally, the spring air rifles require a significant amount of maintenance and, if dry-fired, the mechanism can be damaged. Finally, the effort required for such “cocking” is often substantial and can be difficult for many individuals. References to these style air guns can be found in U.S. Pat. Nos. 3,128,753, 3,212,490, 3,523,538, and 1,830,763. Additional variations on the above technique have been attempted through the years including using an electric motor to cock the spring that drives a piston. This variation is detailed in U.S. Pat. Nos. 4,899,717 and 5,129,383. While this innovation solves the problem of cocking effort, the resulting air rifle still suffers from a complicated mechanism, double recoil and maintenance issues associated with the spring piston system. Another mechanism which uses a motor to wind a spring is shown in U.S. Pat. No. 5,261,384. Again, the use of indirect means to store the electrical energy in a spring before release to the piston to push the projectile results in an inefficient and complicated assembly. Furthermore, the springs in such systems are highly stressed mechanical elements that are prone to breakage and which increase the weight of the air gun. A similar reference can be seen in U.S. Pat. No. 1,447,458 which shows a spring winding and then delivery to a piston to compress air and propel a projectile. In this case, the device is for non-portable operation.
[0006] The third technique, using a hand pump to pressurize the air, is often used on low end devices and suffers from the need to pump the air gun between 2 to 10 times to build up enough air supply for sufficient projectile velocity. This again limits the air rifle or paintball gun to slow rates of fire. Additionally, because of the delay between when the air is compressed and when the compressed air is released to the projectile, variations in the energy are quite common for a standard number of pumps. Further taught in U.S. Pat. Nos. 2,568,432 and 2,834,332 is a method to use a solenoid to directly move a piston which compresses air and forces the projectile out of the air rifle. While this solves the obvious problem of manually pumping a chamber up in order to fire a gun, these devices suffer from the inability to store sufficient energy in the air stream. Solenoids are inefficient devices and can only convert very limited amounts of energy due to their operation. Furthermore, since the air stream is coupled directly to the projectile in this technique, the projectile begins to move as the air is being compressed. This limits the ability of the solenoid to store energy in the air stream to a very short time period and further relegates its use to low energy air rifles. In order to improve the design, the piston must actuate in an extremely fast time frame in order to prevent significant projectile movement during the compression stroke. This results in a very energetic piston mass similar to that shown in spring piston designs and further results in the undesirable double recoil effect as the piston mass must come to a halt. Additionally, this technique suffers from dry-fire in that the air is compressed between the piston and the projectile. A missing projectile allows the air to communicate to the atmosphere through the barrel and can damage the mechanism in a dry-fire scenario. Another variant of this approach is disclosed in U.S. Pat. No. 1,375,653, which uses an internal combustion engine instead of a solenoid to act against the piston. Although this solves the issue of sufficient power, it is no longer considered an air rifle as it becomes a combustion driven gun. Moreover, it suffers from the aforementioned disadvantages including complexity and difficulty in controlling the firing sequence. Further taught in U.S. Pat. No. 4,137,893 is the use of an air compressor coupled to a storage tank which is then coupled to the air gun. Although this solves the issue of double recoil, it is not suitable to a portable system due to inefficiencies of compressing air and the large tank volume required. When air is used in this fashion, it compresses via adiabatic means, but the heat of compression is dissipated due to the large volume of air and the subsequent storage in a tank. In order to overcome the variation in air pressure, further expense and complexity in terms of valving and regulators must be added. A variation of the above is to use a direct air compressor as shown in U.S. Pat. No. 1,743,576. Again, due to the large volume of air between the compression means and the projectile, much of the heat of compression is lost leading to a very inefficient operation. Additionally, this patent teaches of a continuously operating device which suffers from a significant lock time (time between trigger pull and projectile leaving the barrel) as well as the inability to run in a semiautomatic or single shot mode. Further disadvantages of this device include the pulsating characteristics of the air stream which are caused by the release and reseating of the check valve during normal operation.
[0007] The fourth technique is to use direct mechanical action on the projectile itself. The teachings in U.S. Pat. Nos. 1,343,127 and 2,550,887 represent such mechanisms. Limitations of this approach include difficulty in achieving high projectile velocity since the transfer of energy must be done extremely rapidly between the impacting hammer and the projectile. Additionally, this method suffers from the need to absorb a significant impact as the solenoid plunger must stop and return for the next projectile. This can cause a double-recoil firing characteristic. Since the solenoid plunger represents a significant fraction of the moving mass (i.e. it often exceeds the projectile weight) this type of system is very inefficient and limited to low velocity, low energy air guns as may be found in toys and the like. Variations of this method include those disclosed in U.S. Pat. No. 4,694,815 in which a hammer driven by a spring contacts the projectile. The spring is “cocked” via an electric motor, but again, this does not overcome the prior mentioned limitations.
[0008] All of the currently available devices suffer from a number of disadvantages, some of which include:
1. Difficult operation. Cocking or pumping air rifles can be time consuming and a physical chore. 2. Inability to rapidly move between single fire, semiautomatic, burst or automatic modes. Inability to support rapid-fire operation required by the above. 3. Significant inconvenience in the refilling transport and use of high-pressure gas cylinders. 4. Non-portability. Traditional air rifles at carnivals and the like are tethered to a compressed air supply or due to inefficient compressor operation require a large power source such as a wall outlet. 5. Double recoil effects. 6. Complicated mechanisms and air porting schemes leading to potentially expensive production costs and reliability issues. 7. Inefficient usage and/or coupling of the compressed air to the projectile resulting in low energy projectiles and large energy input requirements.
BRIEF SUMMARY OF THE INVENTION
[0016] In accordance with the present invention, a piston is driven by a rack and pinion mechanism or other linear motion converter, to compress air within a cylinder. When the desired pressure or stroke is reached a valve is opened, or is allowed to open, releasing the high-pressure air toward a projectile and launching the projectile. An electric motor, which derives its power from a low impedance electrical source, such as rechargeable batteries, is coupled, to the rack via a pinion creating a very simple and robust design. The coupling mechanism includes provisions to decouple the motor from the rack at a point in the cycle. Additionally, the piston and rack assembly is coupled to a bolt in order to force the bolt to move in cooperation with the movement of the piston. This coupling includes springs and sliding members to reduce the travel of the bolt to fractional percentage of the overall piston movement. This increases the overall safety and reduces the wear of the mechanism.
[0017] Accordingly, besides the objects and advantages of the portable electric air gun as described, several objects and advantages of the present invention are:
1. To provide an electric motor driven gun in which the operating element has an added degree of safety in that the energy is on demand and not stored in high pressure cylinders. 2. To provide a means in which the operation is portable eliminating any tethering of hoses or cords. 3. To provide a means in which the operation uses relatively low pressure air thus reducing the sound profile and allowing for stealth operation. 4. To provide a means in which the control of the projectile is enabled by electronic means thus increasing the safety profile and speed control. 5. To provide an electric motor driven gun in which the source of energy is a rechargeable power supply thus eliminating the use of disposable or refillable gas pressure cylinders and decreasing overall operational cost. 6. To provide an electric motor driven gun which is mechanically simpler to construct and simpler to operate. 7. To provide a means for reducing the lock time in a fire on demand electric motor driven air gun. 8. To provide a means in which the feed mechanism for the projectiles is controlled by the electric motor thus allowing for a simple design which does not rob energy from the air stream. 9. To provide a means in which the compression is more efficiently utilized by reducing the delay between compression and firing, thus, accessing a large part of the heat energy of compression. 10. To provide a design which uses direct air compression and eliminates the spring piston and its associated double recoil. 11. To provide a design in which the energy to return the piston uses a spring or vacuum which is energized on the compression stroke of the piston.
[0029] Further objects and advantages will become more apparent from a consideration of the ensuing detailed description and drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0030] Reference numbers for the drawings are shown below.
[0031] FIG. 1 is a side assembly view of the electric powered air gun in the forward or firing position.
[0032] FIG. 2 is a side assembly view of the electric powered air gun in the retracted position.
[0033] FIG. 3 is a side assembly view of the rack and pinion piston drive assembly.
[0034] FIG. 4 is a side assembly view of the rack and pinion piston drive assembly used in combination with an elastic storage element and retaining mechanism.
[0035] FIG. 5 is a schematic of a control circuit
REFERENCE NUMBERS IN DRAWINGS
[0000]
1 Motor
2 Power Source
3 Control Circuit
4 Rack
5 Piston
6 Bolt
7 Valve
8 Barrel
9 Projectile
10 Start Switch
11 Magnet
12 Sensor Switch
13 Compressed Air Passageway
14 Cylinder
15 Bolt Link
16 Projectile Inlet Port
17 Bumper
18 Solenoid
19 Solenoid Detent
20 Bolt Return Spring
21 Forward Air Chamber
22 Projectile Feeder
23 Lost motion coupling
30 Actuation Limit Spring
31 Pinion Gear
32 Drive Train
33 Plunger
34 Bias Spring
35 Piston Return Spring
36 Elastic storage element
37 Retaining mechanism
38 Communication Link
39 Grip
40 Support Bearing
41 Rack Pinion
42 Trigger
43 Check Valve
44 Relief Valve
45 Rack and pinion assembly
46 Gear teeth
47 Section without gear teeth
DETAILED DESCRIPTION OF THE INVENTION
[0077] Although the following relates substantially to one embodiment of the design, it will be understood by those familiar with the art that changes to materials, part descriptions and activation methods can be made without departing from the spirit of the invention. Additional designs can be created by combining various described elements. These may have particular advantages depending on the design requirements of the particular electric air gun.
[0078] Referring to FIG. 1 , the user presses a start switch ( 10 ), or trigger that causes power to be directed from the power source ( 2 ), to the motor ( 1 ) by the control circuit ( 3 ). The control circuit is described later but can be as simple as any means for connecting and disconnecting power to the motor ( 1 ) to allow an air compression and projectile fire cycle. The motor ( 1 ) turns transferring energy through the rotating elements of the system into a linear motion converter and subsequently into the compression of air. The linear motion converter is any means of converting the rotating motion into a linear translation. Examples of linear motion converters include leadscrews with leadnuts, gearbelts with gearbelt pulleys and rack and pinions. The embodiment illustrated in FIG. 1 includes a motor ( 1 ), a gear reduction system ( 32 ), and a rack and pinion assembly ( 45 ) including rack ( 4 ) and rack pinion ( 41 ). The rack pinion ( 41 ) is coupled to the motor ( 1 ) through the gear reduction system ( 32 ), which comprises one or more stages of gear reduction. The rack ( 4 ) is attached to the piston ( 5 ), as shown in FIG. 1 . The purpose of the gear reduction system ( 32 ) is to allow sufficient energy to be transferred from the motor ( 1 ) to the air which is being compressed by the piston ( 5 ). Other reduction means including, but not limited to, pulleys, gear belts, planetary systems, could be used without departing from the spirit of the invention. In the present embodiment, the piston ( 5 ) and the cylinder ( 14 ) form the forward air chamber ( 21 ). At its initial state before the cycle starts, the forward air chamber ( 21 ) has a volume that is greater than 3 in 3 , with the most desirable starting volume being between 7 in 3 and 9 in 3 . The initial pressure of this starting air is between 0 and 2 atmospheres with the most desirable starting pressure being 1 atmosphere. The piston ( 5 ) begins to move forward in cooperation with the rack ( 4 ) compressing the air in the forward air chamber ( 21 ) while also energizing the piston return spring ( 35 ). The piston return spring ( 35 ) biases the piston ( 5 ) and rack ( 4 ) to the initial starting position. Although the return element is shown as a spring in the attached figures, alternative means such as vacuum on the back side of the cylinder ( 14 ) could be used as well. The important point is that the return element is energized by the motor ( 1 ) during the compression cycle.
[0079] Although the embodiment of FIG. 1 shows the initial position of the piston ( 5 ) at the rearward part of the stroke, it is possible to change the starting point such that it corresponds to a small amount of initial compression of the air. A retaining mechanism such as a sear pin to lock the gear and rack ( 4 ), could be used to maintain this semienergized state. The purpose of allowing some of the energy to be stored in the air stream would be to reduce the time between when trigger ( 42 ) is pulled and shot fired (lock time) on the first shot. This reduction would stem from the fact that some of the firing energy is already stored in the air stream and that the piston ( 5 ) would not need to travel as far to complete the stroke. The advantage in reducing the lock time on the first shot is that operator is most likely to notice a delay on the first shot of a sequence but less likely to notice on subsequent shots. The means for retaining the piston ( 5 ) in such position could additionally be electrical such as a solenoid detent in addition to mechanical means. Referring to FIG. 4 , a substantial lock time improvement of the present invention can be achieved by using an elastic storage means ( 36 ), such as a spring, to drive the piston. The energy is stored in the spring then cocked in the rearward position. The spring could be steel, rubber, etc. The motor ( 1 ) and linear motion converter drives the piston ( 5 ) rearward to store energy in the elastic storage element ( 36 ). When the trigger ( 42 ) is pulled, the retaining mechanism ( 37 ) releases the piston ( 5 ) allowing it to be driven forward to compress the air. This releasing of the spring energy and allowing it to compress the air happens quickly giving a more responsive trigger to the player for the first shot. By incorporating a valve ( 7 ) in conjunction with this elastic storage means, we can eliminate or greatly minimize the double recoil effect commonly seen in spring piston air guns. This technique of compressing the air against a valve allows us to substantially convert most of the stored energy into energy in the air stream while at the same time controlling the speed at which the piston ( 5 ) impacts the end of the cylinder ( 14 ). This allows a much gentler impact of the piston ( 5 ) on the end of the cylinder ( 14 ), thus greatly mitigating the double recoil and associated wear seen in spring piston air guns.
[0080] Continuing our discussion of the cycle, as the pinion ( 41 ) rotates it drives the rack ( 4 ) which moves the piston ( 5 ), down the cylinder ( 14 ) in the forward direction, storing energy in the air stream. This energy rapidly compresses the air in the forward air chamber ( 21 ) in such a way that the compression exponent is polytropic. At the appropriate forward point the compressed air in the forward air chamber ( 21 ) is channeled to the projectile ( 9 ) through the valve ( 7 ). In an efficient design, the time involved in the compression cycle is sufficiently short so as to yield a compression exponent of at least 1.10.
[0081] At the end of the compression stroke, the forward air chamber ( 21 ) contains high-pressure air that is released to the projectile ( 9 ) through the valve ( 7 ). The opening of the valve ( 7 ) can be by direct mechanical coupling and/or electrical techniques. As is shown in FIG. 1 , one embodiment incorporates an electronic solenoid ( 18 ) which is controlled in response to timing and/or a sensor such as air pressure, piston location or motor speed. Ideally, the electronics controls the motor such that the valve ( 7 ) releases when the motor ( 1 ) has slowed to such a point that most of the rotational kinetic energy has been converted to energy in the compressed air. At or near the end of the piston ( 5 ) stroke, the valve ( 7 ) is caused to shift open. This rapidly releases the compressed air into the compressed air passageway ( 13 ) and then into the barrel ( 8 ) of the air gun. In order to be effective in an electric marker, it is essential that valve ( 7 ) losses be held to a minimum. Two parameters that must be carefully controlled in the valve ( 7 ) are pressure drop through the valve ( 7 ) and valve opening time.
[0082] The projectile ( 9 ), which is located within the barrel ( 8 ), begins to accelerate under the force of the compressed air and is driven out of the barrel ( 8 ) at a high velocity. At this point, the motor ( 1 ) may be allowed to continue to rotate driving the rack pinion ( 41 ). The rack pinion ( 41 ) has a section ( 47 ) of the gear in which the teeth ( 46 ) have been cutaway. When this section ( 47 ) opposes the mating rack ( 4 ), there is nothing to retain the rack and pinion assembly ( 45 ) in its current position. The piston return spring ( 35 ) will then force the rack and piston assembly ( 45 ) back to its initial starting position. Decoupling the motor ( 1 ) and drive train ( 32 ) from the piston ( 5 ) and rack ( 4 ) allows a rapid return since the piston return spring ( 35 ) only needs to position the piston and rack assembly ( 45 ). This results in a more efficient system with higher rates of fire. A further advantage of this approach is that the motor ( 1 ) can drive in a single direction and crashing the piston ( 5 ) into the end of the cylinder ( 14 ) can be eliminated by controlling the number of gear teeth ( 46 ) in both the rack ( 4 ) and rack pinion ( 41 ).
[0083] Looking to FIGS. 1 and 2 , a sensor switch ( 12 ) recognizes when the piston ( 5 ) is in its approximate initial position and ready for cycle initiation. The sensor switch ( 12 ) may be a hall switch used in conjunction with a magnet ( 11 ), which is attached to the piston ( 5 ). It is understood that any sensing means which allows positional information of the piston ( 5 ) could be used for the sensor switch ( 12 ), including but not limited to: reed switches, optical sensors and mechanical limit switches. It is further desired to have a means of monitoring the rotation and or rotational velocity of the system. Such means could include voltage sensing on the motor ( 1 ) or a rotational sensor located preferably in a gear within the drive train ( 32 ). The sensor could allow the control circuit ( 3 ) to determine the piston ( 5 ) location by counting revolutions and processing the information as it relates to both speed and linear inch of travel per revolution of the motor ( 1 ). Additionally, the voltage sensing scheme could be used to monitor either the loaded or unloaded motor velocity and thus allow tuning the system for maximum energy extraction per cycle. A further use of such velocity information would be to limit the velocity of the motor ( 1 ) during the retraction of the piston ( 5 ), thus ensuring sufficient time for the rack ( 4 ) and piston ( 5 ) to return to the start position before engaging the rack pinion ( 41 ). Additional uses of such information could be to alter the speed of the piston ( 5 ) during the compression stroke or altering the timing of the release of the valve ( 7 ). After the air pressure has been released to the projectile ( 9 ) and the piston ( 5 ) has returned, a full cycle has been completed and the electric air gun is ready for initiation of another cycle. It should be noted while a rack and pinion assembly is described in this embodiment, substantially similar elements which convert rotational motion to linear motion (i.e. a linear motion converter) may be substituted. Such elements could include, but are not limited to, slider crank mechanisms, lead screw and nuts or gear and belt driven systems.
[0084] A bolt ( 6 ) is used in many air gun designs to chamber the projectile ( 9 ). It can be either manually operated or automatically operated. In the embodiment shown in FIGS. 1 and 2 , the bolt ( 6 ) is coupled to the rack ( 4 ) thru a system of linkages and springs. These linkages and springs include an actuation limit spring ( 30 ), a bolt link ( 15 ) and a bolt return spring ( 20 ). Additionally, the air compressed by the piston ( 5 ) may travel thru the bolt ( 6 ) allowing for a more efficient and compact design. In the present design, the bolt coupling mechanism is referred to as a lost motion device. The purpose of this is to limit the motion of the bolt to a fraction of the piston ( 5 ) movement with the desired ratio being less then 80%. The actuation limit spring ( 30 ) which is inserted between the bolt link ( 15 ) and the bolt ( 6 ) limits the bolt ( 6 ) forces improving the safety profile against possible pinch points. For example, if the user were to depress the mechanism and insert their finger in the projectile inlet port ( 16 ), the force of the bolt ( 6 ) if directly coupled to the piston ( 5 ) could injure the operator. The bolt return spring ( 20 ) maintains a normally open bolt design, increasing the time available for the projectile ( 9 ) to fall into position. Depending on the design requirements, the springs ( 20 , 30 ) could be biased in such a way as to result in open or closed bolt designs. Since many of these designs will employ gravity feeders, the open bolt design is useful as it allows extra time for the projectile ( 9 ) to fall into place during intermittent firing modes.
[0085] The present invention includes additional enhancements like end of stroke bumpers ( 17 ) shown in FIG. 1 . These elements absorb excess kinetic energy at the ends of stroke and help minimize reactionary forces or prevent damage in the event of a malfunction. These bumpers are may be made from elastomeric materials including but not limited to urethanes, rubbers and neoprenes. They are designed to absorb impacts of at least 10 inch-lbs without damage.
[0086] In accordance with the present invention, it is beneficial to combine feeders with the operational characteristics of the electric air gun as described in patent application Ser. No. 10/764,793, the contents of which are hereby incorporated and included by reference.
[0087] Circuit Operation:
[0088] A schematic of the control circuit ( 3 ) is shown in FIG. 5 . In the embodiment illustrated, the control circuit ( 3 ) includes a microprocessor, high power switching elements and at least one control circuit input. The control circuit input(s) can be internal or external timers or sensors. Looking additionally to FIG. 1 , the gun uses a start switch ( 10 ), at least one sensor to detect position of the compression piston ( 5 ), a method of determining motor speed and FETs or relays to control power to the motor ( 1 ). Although these elements are used in the present design, it is understood by those familiar with the art that considerable simplification is possible without departing from the spirit of the invention. The cycle begins with the pressing of the start switch ( 10 ). Although the power can be directed to the motor ( 1 ) through the start switch ( 10 ), it is desirable to use Mosfets or Relays.
[0089] In order to maintain responsiveness of an electric air gun, it is desirable that the overall resistance from the power source ( 2 ) to the motor ( 1 ) be kept very low. A key design parameter is that the overall circuit resistance from the power source ( 2 ) to the motor ( 1 ) must be less then 0.02 ohms per applied volt from the power source ( 2 ). For very high performance electric air guns, a brushless motor has advantages of lower maintenance, high power density and good heat dissipation. The issue of heat dissipation is important to intermittent on demand electric air guns. A separate cooling fan may be needed to cool the switching elements and/or the motor depending on the duty cycle requirements. The cooling fan may be controlled in response to either a heat sensor such as a thermister or thermocouple placed within the body of the electric air gun. Additionally, the heat sensor could be used to limit the cycling of the unit should excessive temperatures be reached. It is further possible to control the cooling fan in response to a predetermined program stored within the microprocessor.
[0090] Once power is applied to the motor ( 1 ), the piston ( 5 ) begins to advance via the rotation of the rack pinion ( 41 ) driving the rack ( 4 ). The feedback elements are used to determine the location of the piston ( 5 ). The control circuit ( 3 ) can make decisions in regards to releasing the high-pressure air in the case of a solenoid or other electromotive retention of the valve ( 7 ). Additionally, sensor input can be useful in recovery from various jam conditions. At the end of a cycle, a further control circuit input such as another sensor, pressure transducer or a timer may be used to shut the power off from the motor ( 1 ) and thus leave the electric air gun ready for the next cycle.
[0091] A further enhancement of the control circuit ( 3 ) includes monitoring the start switch ( 10 ) depressions during a cycle. This allows the gun to continue cycling in a seamless fashion in the event the start switch ( 10 ) is actuated faster than the electrical projectile ( 9 ) launches can occur. For example, one or more additional trigger ( 42 ) pulls could be stored thus allowing the user the ability to fire sequential shots in a semiautomatic fashion without having to coordinate the shots with the finish of a cycle in the electric air gun. A further embodiment includes the ability to have a shot counter or battery monitor to warn the user when the battery is low. For example, with a power source ( 2 ) which is good for 300 shots, a warning light could be illuminated when less then 25 shots remain. Additionally, the voltage of the battery or the voltage applied to the motor ( 1 ) during the compression cycle may be monitored. This allows the microprocessor to adjust the duty cycle of the motor ( 1 ) thru either pulsing the motor ( 1 ) or pulse width modulation of the motor power to create uniform compression cycles even as the battery voltage decays, thus extending the number of shots per charge.
[0092] The sensor locations may include at least one position of the piston ( 5 ). In order to determine motor ( 1 ) velocity, it is desirable to monitor the voltage on the motor ( 1 ) during an unloaded condition. The difference between these voltages multiplied by the motor Kv (rpm/volt) constant can be used to approximate the motor speed. It is understood by those skilled in the art that the sensors can be used in conjunction with circuit elements to allow location at different places and that sensors can be of many forms including but not limited to limit switches, hall effect sensors, photosensors and reed switches without departing from the spirit of the invention.
[0093] A further improvement in the electric air gun includes routing at least a portion of the power through the start switch ( 10 ) to allow cycling only if the start switch ( 10 ) is depressed. To reduce contact wear, the control circuit ( 3 ) may introduce a delay such that the high power is switched after the start switch ( 10 ) is fully closed thus eliminating arcing.
[0094] Additional enhancements to the control circuit include provision for or providing a communication port or a display which communicates status conditions. Safety provisions include the microprocessor locking out the unit operation on certain fault conditions, integration of a password required for operation or the inclusion of a keyswitch required for operation.
[0095] Thus, although there have been described particular embodiments of the present invention of a new and useful PORTABLE ELECTRIC-DRIVEN COMPRESSED AIR GUN, it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.
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A portable motor driven air gun powered by a power source includes a motor that is coupled to a pinion which drives a rack connected to a piston. The piston compresses air in a chamber producing high-pressure air. When sufficient energy is stored within the air stream by the piston, a valve opens which releases the compressed air to push a projectile through a barrel. The pinion rotates until it comes to an interrupted thread surface, at which point the rack and pinion are returned to the starting position via a spring. The piston may be coupled to a bolt thru a lost motion device to facilitate positioning of the projectile for firing. The direction speed and operative modes of the gun may be controlled with an electric circuit. The power source may be rechargeable, allowing the air gun to be operated independent from either a wall outlet or a compressed air supply.
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FIELD OF THE INVENTION
The present invention relates to a system and method for selectively creating an airflow sufficient to entrain an anticipated length of the thread and capturing the length of thread from the airflow to provide for selective removal of a captured thread length from the airflow.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 6,817,306 discloses a cut looper thread disposal means at a side location of the needle and orthogonal to the sewing direction. This disposal means includes a thread suction tube (thread suction device), a thread pick and pull cylinder, and a looper thread presser foot. The thread suction tube sucks and collects the part of the looper thread cut by the stationary blade, at a single location, that is, in the vicinity of a suction port. The thread pick and pull cylinder picks at a pick part of the looper thread and pulls it into the vicinity of the suction part of the suction tube.
However, this machine mounted, automated device is not applicable to individual users. Further, this device is integral with the sewing machine and is not compatible with any retrofit of the machine. That is, the device has limited applicability for individual users.
BRIEF SUMMARY OF THE INVENTION
The present disclosure provides a thread capturing apparatus including a housing having an inlet and an outlet, the inlet at least partially defined by a throat having a converging section; a grill removably connected relative to the housing, the grill located proximal to the throat; a motor within the housing; a fan connected to the motor and disposed within the housing, the fan selected to create an airflow through the housing from the inlet to the outlet; and a proximity sensor initiating rotation of the fan in response to a portion of the user being located within (i) a substantially predetermined distance from the housing or (ii) a detecting region/volume of the proximity sensor.
In a further configuration, the housing has a removable wall selectively providing access to the fan independent of the inlet and the outlet of the housing. Further, the housing, the motor, and the fan can be sized to entrain a thread within the created air flow through the throat.
A method is provided including the steps of initiating an airflow through a converging throat into a housing in response to locating a portion of the thread within a given distance or volume from the converging throat or a grill adjacent to the converging throat, at least a portion of the airflow passing through the grill; at least partially entraining the thread in the airflow through the grill to engage the thread on the grill; and automatically terminating airflow through the converging throat.
It is further contemplated, the airflow can be initiated in response to one of a portion of the user and the thread being disposed within a given distance from the throat or within a detecting volume of the proximity sensor.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
FIG. 1 is a perspective view of the thread capturing device, with a portion of the device removed for illustration purposes; and
FIG. 2 is an exploded perspective view of the thread capturing device.
FIG. 3 is a perspective view of an alternative configuration of the device.
DETAILED DESCRIPTION OF THE INVENTION
The thread capturing device 10 includes a housing 20 having an inlet 22 and an outlet 24 ; a fan assembly 40 and a removable grill 60 .
The housing 20 generally includes an enclosing body 30 such as having top 31 , bottom 32 , left 33 , right 34 , front 35 and back 36 walls. It is contemplated the top 31 , bottom 32 , left 33 , right 34 , front 35 and back 36 walls can be individually formed or as many as five of the walls can be integrally formed such as by casting or molding.
One of the walk includes the inlet 22 and another wall includes the outlet 24 . As seen in FIG. 1 , the top wall 31 or lid includes the inlet 22 and the back wall 36 includes the outlet 24 .
In one configuration of the housing 20 , as seen in FIG. 2 , the side walk 33 , 34 include opposing retaining channels 38 on an inside surface of the walls.
The housing 20 can be formed from a variety of materials including metals, plastics, composites, or laminates. A representative size of the housing 20 is approximately 4 inches wide, approximately 8 inches long, and approximately 8 inches tall.
The inlet 22 has an area of approximately 16 square inches and the outlet 24 has at least approximately 16 square inches.
As seen in FIG. 2 , the lid or top wall 31 can be removably attached to the remaining walls for accessing the interior of the housing 20 and the fan assembly 40 .
As seen in FIG. 2 , the fan assembly 40 includes a plurality of blades 42 , a motor 44 and an engaging collar 46 , wherein peripheral edges of the engaging collar are sized to be received within the retaining channels 38 of the side walls 33 , 34 , thereby locating the fan assembly relative to the housing 20 .
The fan blades 42 are selected to provide a relatively high flow at a given rotation rate. Satisfactory fan blades 42 have been found to have a dimension of approximately 2.5 inches. The fan blades 42 can number from 2 to 5 or more.
The motor 44 can be driven by an internal power source 48 , such as a battery or plurality of batteries retained within the housing 20 , or an external source by means of an electrical plug. A satisfactory motor 44 includes a dc motor of approximately 33 watts. However, as discussed below, the specific speed of the motor 44 is at least partly determined by the sizing of the housing 20 inlet and the configuration of the fan blades 42 .
In one configuration the fan assembly 40 , the housing inlet 22 and housing outlet 24 are selected to provide an air flow of about between 3 and 8 ounces thrust.
Referring to FIGS. 1 and 2 , the thread capturing device 10 includes a throat 50 proximal to the inlet 22 of the housing 20 , wherein the throat defines a converging section 52 extending from a wide end to a narrow end. The throat 50 can be fixedly or removably attached to the housing 20 . In one configuration the throat 50 converges by between 10% and 70%. That is, the area of narrow end can be approximately 90% to 30% of the area of the wide end.
The removable grill 60 is disposed within the throat 50 . The grill 60 is removably located relative to the housing 20 , such as by removably connecting the grill to the throat 50 which is affixed to the housing or affixing the grill relative to the throat, wherein the throat is removably attached to the housing. The grill 60 or throat 50 can be removably connected by gravity or a retaining mechanism such as magnets, detents, snap-fit, threads, or hook and loop fasteners. In FIG. 3 , the grill 60 is located at or proximal to the bottom of the throat 50 . Thus, the throat 50 and the grill 60 can be simultaneously removed, cleaned and replaced. However, it is also contemplated the grill 60 can be operably located nearer the inlet of the throat 50 such that the grill (and enmeshed threads) can be removed from the throat, the grill cleaned and replaced.
The grill 60 includes at least one and more preferably, a plurality of slats or bars 62 extending across the area of the throat. The slats 62 are selected to engage the threads entrained in a passing airflow. Therefore, the slats 62 can have a cross section configured to enhance engagement with the threads. The slats 62 can also have a relatively abrupt edge or leading edge to assist in retention of threads. In one configuration, the grill 60 has a mesh size between approximately 15 mm to 200 mm, such that the threads accumulate on the grill.
The grill 60 is operably retained within or connected to the throat 50 such that a portion of the grill and slats 62 occlude a portion of the inlet 22 .
The thread capturing device 10 can include a proximity sensor 70 known in the art, wherein the proximity sensor is configured to detect the presence of a user within a predetermined location of the housing 20 , such as the inlet 22 . The proximity sensor 70 can define a detecting region or volume, wherein the presence of a portion of the user within the zone is sensed and causes activation of the fan assembly 40 . In one configuration, the proximity sensor 70 is selected to detect a user's hand within approximately 6 inches of the inlet. That is, the detecting region has a six inch dimension. Depending on the proximity sensor 70 , the zone sensed by the proximity sensor can be substantially spherical or having generally planar edges. The proximity sensor 70 is operably connected to the fan assembly 40 or the power supply 48 for initiating rotation of the blades 42 .
It is also contemplated the thread capturing device 10 can include a control switch 74 for selectively disposing the device in an operative state or an inoperative state. The control switch 74 can be connected to at least one of the power source 48 , the motor 44 and the proximity sensor 70 .
A controller 80 or timer (which can be integral with the controller or separate component 82 , is operably connected to at least one of the fan assembly 40 , the proximity sensor 70 and the power source 48 . The controller 80 or timer 82 is configured to maintain operation of the fan assembly 40 for a fixed period of time from activation, or from the last activation. Satisfactory periods of operation include between approximately 1 to 8 seconds. Thus, the fan assembly 40 terminates operation independent of user intervention.
In operation, a user having a thread to be captured passes their hand within the detecting region of the proximity sensor 70 . Upon the proximity sensor 70 detecting passage or presence of the hand, the proximity sensor initiates rotation of the fan assembly 40 which creates an airflow across the grill 60 through the inlet 22 of the housing 20 and to the outlet 24 of the housing.
The airflow is sufficient to entrain an anticipated length of thread such as between approximately one quarter inch to 6 or 12 inches from within the detecting zone of the proximity sensor 70 . The thread is typical sewing thread for residential or even commercial weight, such as fixed length of one inch to 6 inches.
As the generated airflow passes by the hand of the user (the hand having the thread), the length of thread is entrained within the airflow and removed from the hand. The airflow than passes across the grill 60 and the thread engages portions of the slats 62 and is thus retained by the grill. The controller 80 or timer 82 then terminates operation of the fan assembly 40 after the predetermined time period has elapsed since the last actuation of the proximity sensor 70 or fan assembly.
Upon collection of a given number of threads on the grill 60 , the user can use a control button 84 to place the thread capturing device in an inoperative state. The control button 84 can be in the form of a shut off, disable or disconnect switch between the power source 48 and the fan assembly 40 . The user can then remove the grill 60 (or the grill and the throat 50 ) along with the captured threads. The captured threads from the removable grill 60 can then be readily disposed as a group into an appropriate disposal mechanism.
The removable grill 60 (or grill and throat 50 ) is then reengaged with the housing 20 and the control button 84 is actuated to render the capturing device in the operative state and the cycle can repeat.
Although the present invention has been described in terms of preferred embodiments, it will be understood that variations and modifications may be made without departing from the true spirit and scope thereof.
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A system and method for capturing thread from an entraining air flow is provided, wherein the entraining airflow is selectively created in response to a location of the user relative to the device. The entraining airflow is sufficient to entrain an anticipated length of the thread, wherein the entraining airflow then passes through a grill. The grill shape, the airflow rate and the airflow velocity are selected to retain the entrained thread on the grill. The airflow is then terminated without requiring user intervention. Upon retention of a number of threads on the grill, the grill is separated from the housing and the retained threads are simultaneously disposed of in a desired container.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of covering a substrate surface with a sintered layer, particularly to a method of covering the surface of a steel material with a sintered layer exhibiting a high corrosion resistance and a high abrasion resistance.
2. Description of the Related Art
FIGS. 9 and 10 show conventional methods of covering a substrate surface with a sintered body. In the art shown in FIG. 9, a sintered body 101 prepared by sintering a molded material is bonded to a substrate 102. On the other hand, the art shown in FIG. 10 utilizes a hot isostatic pressing (HIP) which comprises a hermetic welding step applied to a raw material powder loaded in a space defined by a vessel 110 and a substrate 111, and a deaeration step in preparation for the subsequent bonding step which is carried out by means of sintering under pressure so as to cover the substrate 111 with a sintered layer 112.
However, the art shown in FIG. 9 necessitates two heating steps, i.e., the sintering step and the bonding step, leading to a high manufacturing cost. In addition, a precision processing is required for improving the areal precision of the bonding portion between the sintered body 101 and the substrate 102. Thus, this prior art is not applicable to a substrate of a complex shape. The art shown in FIG. 10 also leaves room for further improvement. First of all, this art requires both a hermetic welding step and a deaeration step, leading to an increase in the required time of the manufacturing process, Also, deformation under high temperatures and high pressures is involved in this prior art, with the result that the hermetically welded portion tends to be broken. Further, this art necessitates a welding technique of a high level and a deformation estimating technique of a high level for the substrate during sintering. In practice, a preliminary test is conducted and the amount of deformation is empirically determined based on the result of the preliminary test. Particularly, where the thickness of the substrate is changed from portion to portion in a complex manner, the amount of deformation is large, with the result that the necessity of the preliminary test is enhanced. What should also be noted is that the prior art shown in FIG. 10 requires a very expensive HIP apparatus of high temperature and high pressure.
SUMMARY OF THE INVENTION
The present invention, which has been achieved in view of the situation described above, is intended to provide a method of covering a substrate surface with a sintered layer of an excellent performance by a simple process and with a low cost.
According to the present invention, there is provided a method of covering a substrate surface with a sintered layer, comprising the steps of:
loading a powdery raw material in a region of forming a sintered layer; and
sintering the loaded powdery raw material so as to form a sintered layer covering the substrate surface;
wherein the powdery raw material contains at least two elements and has a temperature region in which a solid phase and a liquid phase are present together, said liquid phase being wettable with the substrate, and said sintering step is performed within the temperature region in which the solid phase and the liquid phase are present together.
The present invention can be employed in various fields. Desirably, the method of the present invention can be employed in the manufacture of cylinders, nozzles and check valves for the injection molding machine, barrels and screws for the biaxial kneading extruder, and nozzles for the extruder.
FIG. 1 shows the principle of the present invention. Before the loading step of a powdery raw material, a substrate 1 and a tool 2 are defatted and washed. Since the stain of the substrate 1 causes reduction in the bonding strength with a sintered layer, the defatting and washing should be carried out carefully. Rust should also be removed in this step.
The loading space of the powdery raw material is formed in the region of forming a sintered layer on the substrate 1 by the welding to the tool 2 or by a mechanical assembling which does not use a tool. Since pressure is not applied to the powdery raw material in the sintering step, the assembling strength may be low. In order to prevent the tool forming the loading space from reacting with or being bonded to the melt of the powdery raw material in the sintering step, thermal spraying of a ceramic material or the like should be applied to the surface of the tool.
A powdery raw material 3 is loaded in the loading space. The raw material 3 should contain at least two elements and should have a temperature region in which a solid phase and a liquid phase are present together, said liquid phase being wettable with the substrate. The raw material 3 should exhibit the properties required for the sintered layer such as a corrosion resistance and an abrasion resistance. It is possible for the powdery raw material 3 to be an alloy consisting of at least two elements or a mixture of a plurality of powdery raw materials. As described above, the powdery raw material should have a temperature region in which a solid phase and a liquid phase are present together. This requirement denotes that, in the case of an alloy, the solidus of the alloy element differs in temperature from the liquidus. In the case of a mixture, at least two element of the mixture should have different melting points in order to enable the mixture to have a temperature region in which a solid phase and a liquid phase are present together.
At least one ceramic material may be contained in the powdery raw material as one of at least two elements or at least one ceramic material may be mixed with the powdery raw material used in the present invention. The mixing amount of the ceramic material, such as metal carbide, metal nitride, metal boride or metal silicide, is about 20% in the case of a hot isostatic pressurizing method. In the present invention, however, it is possible to add 40-50% of a ceramic material. Where a steel material is used as a substrate, it is possible to use, for example, a Ni alloy powder or a Co alloy powder as the powdery raw material in order to obtain a sintered layer exhibiting a corrosion resistance and an abrasion resistance.
The preferred Ni alloy powder has a chemical composition of 9.0 to 18.0% by weight of Cr, 1.7 to 3.9% by weight of B, 2.5 to 4.7% by weight of Si, 0.4 to 5.0% by weight of Fe, the balance of Ni, and unavoidable impurities. The preferred Co alloy powder has a chemical composition of 2.5 to 29.0% by weight of Ni, 17.0 to 22.0% by weight of Cr, 2.8 to 3.8% by weight of B, 1.7 to 4.0% by weight of Si, 1.0% or less by weight of Fe, 4.0 to 7.0% by weight of W, the balance of Co, and unavoidable impurities.
Vibration should be applied during the loading step of the powdery raw material so as to achieve a high loading density. It is desirable to set the loading density at 60% or more. If the loading density is 50% or less, cracking tends to be caused by the shrinkage of the sintered layer.
In the next step, a sintering treatment is applied at a temperature at which a solid phase and a liquid phase of the raw material are present together. Where an alloy is used as the powdery raw material, the sintering treatment should be carried out at a temperature falling between the solidus and the liquidus. In the case of using a mixture, the sintering treatment should be carried out at a temperature higher than the melting point of one element of the mixture and lower than the melting point of another element. If the sintering treatment is carried out at a temperature at which a solid phase alone is present, a sintered layer 4 contains many bores and has a low density. If the sintering treatment is carried out at a temperature at which a liquid phase alone is present, a shrinkage cavity is formed in the final solidifying portion as in the casting.
If the powdery raw material is heated to a temperature at which a solid phase 5 and a liquid phase 6 are present together, the liquid phase 6 exerts an attractive force between the solid particles 5. In this step, the attractive force is not generated between the tool 2 and the solid particles because a thermal spraying of a ceramic material, which is not wetted with the liquid phase, is applied to the surface of the tool 2. On the other hand, the liquid phase 6 is wettable with both the substrate 1 and the solid particles 5, with the result that the liquid phase and the solid particles are moved in the direction of achieving a bonding with the substrate. With progress in the sintering treatment, the liquid phase 6 is generated from within the solid particles 5. As a result, the raw material particles 3 are diminished and the clearance between adjacent particles 3 is filled with the liquid phase 6. Further, the substrate is covered with the resultant sintered layer 4. In the sintering step employed in the present invention, the liquid phase 6 need not be supplied from outside the system.
In the sintering cycle from the sintering cycle to the cooling process, it is desirable to employ a two-stage heating, i.e., a cycle including a heating process, a soaking process, a temperature elevating process, a sintering process and a cooling process, as shown in FIG. 11. In a preferred sintering cycle, the heating process is performed at a heating rate of 5° to 10° C./min. In the succeeding soaking process, the temperature is made uniform over the entire product and the sintering is performed. The temperature in the soaking process is set at 20° to 30° C. below the melting point of the powdery raw material. Then, the temperature is elevated at a rate of 0.1 to 5° C./min. in the temperature elevating process. It is necessary to decrease the temperature elevating rate if the product has a complex shape. The temperature in the subsequent sintering process should be determined in a manner to generate a liquid phase sufficient to fill the clearance formed among the powdery particles of the raw material. The sintering temperature depends on the components of the powdery raw material. The sintering process should be started when the entire product has been heated to a predetermined temperature and should be continued for about 20 minutes. Further, it is desirable to employ a furnace cooling in the cooling process.
In the sintering cycle from the heating process to the cooling process, it is desirable to use a sintering furnace free of an oxidizing atmosphere such as a hydrogen furnace or a vacuum furnace. In view of the properties of the sintered layer formed after the sintering process, it is desirable to use a vacuum furnace. In the case of using a vacuum furnace, degassing is performed and, thus, micro-pores are not formed in the resultant sintered layer.
Finally, the substrate covered with the sintered layer is processed into a desired size and shape.
In the present invention, the substrate surface can be covered with a sintered layer by a simple process of sintering the loaded powdery raw material. Pressurizing under high temperatures as in the hot isostatic pressurizing process need not be employed in the present invention, with the result that the substrate and the loading space are deformed little. Deformation takes place mainly in the loaded portion of the powdery raw material, i.e., the sintered layer, in the present invention. In addition, the deformation takes place in mainly the thickness direction of the sintered layer. Thus, the amount of deformation can be easily estimated by calculating the porosity in the loading step of the powdery raw material. It follows that it is possible to form a sintered layer of a uniform thickness with a high dimensional accuracy. Further, a hermetic welding is unnecessary in the present invention. Deaeration and hermetic treatment are also unnecessary. Thus, the welded portion is not broken. Still further, a relatively cheap furnace such as a hydrogen furnace or a vacuum furnace is used in the present invention. Since a hot isostatic pressurizing apparatus is not required, the facility cost is low in the present invention. It should also be noted that the sintering and coupling are performed simultaneously by the attractive force between the liquid phase (melt) generated from the powdery raw material and the remaining solid particles. What should also be noted is that it is possible for the powdery raw material to contain a relatively large amount of a ceramic material, making it possible to form a sintered layer exhibiting a high abrasion resistance.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
FIG. 1 shows the principle utilized in the method of the present invention;
FIG. 2A is a perspective view of an injection molding machine and a substrate having on a surface a raw material powder according to the invention;
FIG. 2B is a perspective view of a substrate having a sintered layer according to the invention;
FIG. 2C is a perspective view of a substrate having a sintered layer which was mechanical processed according to the invention;
FIG. 2D is a top view of the injection molding machine and substrate of FIG. 2A;
FIG. 3A is a perspective view of a barrel having on a surface a raw material powder according to the invention;
FIG. 3B is perspective view of a barrel having a sintered layer which was mechanical processed according to the invention;
FIG. 3C is a top view of the barrel shown in FIG. 3A;
FIG. 4A is a perspective view of a screw having on a surface a raw material powder according to the invention;
FIG. 4B is a screw having a sintered layer according to the invention;
FIG. 4C is a screw having a sintered layer which was mechanical processed according to the invention;
FIG. 4D is a top view of the screw shown in FIG. 4A;
FIG. 4E is a top view of the screw shown in 4C;
FIG. 5A is a nozzle having on a surface a raw material powder according to the invention;
FIG. 5B is a nozzle having a sintered layer which was mechanical processed according to the invention;
FIG. 5C is a top view of the screw shown in FIG. 5B;
FIG. 6A is a nozzle having on a surface a raw material powder according to the invention;
FIG. 6B is a nozzle having a sintered layer according to the invention;
FIG. 6C is a nozzle having a sintered layer which was mechanical processed according to the invention;
FIG. 6D is a top view of the nozzle shown in FIG. 6A;
FIG. 6E is a top view of the nozzle shown in FIG. 6C;
FIG. 7A is a check valve having on a surface a raw material powder according to the invention;
FIG. 7B is the check valve of FIG. 7A having on another surface a raw material powder according to the invention;
FIG. 7C is a check valve having a sintered layer according to the invention;
FIG. 7D is a check valve having a sintered layer which was mechanical processed according to the invention.
FIG. 8 is a graph showing the abrasion resistance of a sample obtained in Example 2 by using Okosi abrasion test machine and that of a sample manufactured by using a hot isostatic pressurizing apparatus;
FIGS. 9 and 10 show conventional methods; and
FIG. 11 is a graph showing the preferred sintering cycles of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described with reference to Examples which follow. Of course, the technical scope of the present invention is not restricted by the following Examples.
EXAMPLE 1
Application to a Cylinder for an Injection Molding Machine
In this Example, a sintered layer was formed on the inner surface of a substrate 11 used as a cylinder in an injection molding machine, as shown in FIGS. 2A-2C.
In the first step, the inner surface of the substrate 11, which was provided by an SCM pipe having an inner diameter of 20 mm and a length of 630 mm, was defatted. A steel material having a thermal expansion coefficient substantially equal to that of the sintering raw material was selected as the material of the substrate 11 in order to prevent the residual stress between the substrate and the sintered layer. As shown in FIG. 2A, a loading space was formed in contact with the inner surface of the substrate 11 by using a centering tool 12, which was formed of an S25C material having a thermal spraying of alumina applied to the contact region with the sintering raw material powder, a sintering tool 13 formed of an S25C rod (15 mm in diameter and 630 mm in length) having a thermal spraying of alumina applied to the surface, and a spacer 14 formed of an S25C material. The thermal spraying of alumina applied to the surfaces of the centering tool 12 and the sintering tool 13 was intended to cause the sintering material layer to be shrunk in the sintering step toward the substrate. Also, if the melt of the raw material powder is bonded to the tool, it is impossible to remove the tool after formation of the sintered layer. The thermal spraying was also intended to prevent the melt from being bonded to the centering tool and the sintering tool.
An alloy consisting of 10.3% by weight of Cr, 2.1% by weight of B, 2.9% by weight of Si, 0.4% by weight of Fe and the balance of Ni was loaded as a sintering raw material powder 15 in the loading space, as shown in Table 2. The alloy has a ternary eutectic temperature of 980° C., a binary eutectic temperature of 1055° C. and an initial crystallization temperature higher than 1055° C. In other words, both a solid phase and a liquid phase are present together under temperatures ranging between 980° C. and 1055° C. The alloy is suitable for use in the present invention because, if the sintering is performed under temperatures noted above, the sintered layer is not collapsed, leading to formation of a dense sintered layer. Also, the alloy of the particular composition is excellent in corrosion resistance and abrasion resistance, meeting the required performance of a cylinder for an injection molding machine.
A gas atomized powder of 150 μm or less was used as a raw material powder. The raw material powder was loaded into the loading space from the upper end of the assembly shown in FIG. 2A while striking the outer surface of the cylinder with a copper hammer. The loading density was found to be 61%. Then, a sintering treatment was performed under vacuum. In the sintering treatment, the raw material powder was kept at 950° C. for 40 minutes, followed by elevating the temperature to 1025° Cat a rate of 4° C./min. Further, the temperature was kept at 1025° C. for 40 minutes, followed by a furnace cooling so as to form a cylindrical sintered layer 16 as shown in FIG. 2B.
The inner diameter of the sintered layer 16 was found to be about 17 mm. Since the raw material powder was loaded to form a cylindrical powdery layer having a thickness of 2.5 mm, the reduction in the thickness of the layer caused by the shrinkage accompanying the sintering treatment was about 1 mm, which was about 40% of the thickness in the loading step, i.e., 2.5 min. A layer 17 resulting from solidification of the liquid phase was formed in the lower portion in a height of about 45 mm. Also, a peeling of a layer was found in the uppermost portion. These layer 17 and the peeling were small enough to be removed by a mechanical processing. Finally, a mechanical processing was applied so as to obtain a desired article, a shown in FIG. 2C.
EXAMPLE 2
Application to a Barrel in a Biaxial Kneading Extruder
As shown in FIG. 3, an annular loading space 5.0 mm thick was formed on the inner surface of a substrate 21, i.e., an SCM 440 pipe having an inner diameter of 50 mm, by using a sintering tool 22 having a diameter of 40 mm, which was formed of an S25C material having a thermal spraying of alumina applied to the surface.
A raw material powder 23 of the composition shown in Table 2 was loaded in the loading space, with a loading density of about 60%, as shown in FIG. 3A. Then, the raw material powder was sintered so as to obtain a sintered layer 24 having a thickness of 3 mm and free of pores. The shrinkage in the thickness of the sintered layer was about 40%. Also, a well region corresponding to the liquid phase was found in the lower portion. Finally, a mechanical processing was applied so as to obtain a barrel for a biaxial kneading extruder, said barrel having an inner diameter of 45 mm and a length of 420 mm, as shown in FIG. 3B. The sintered layer formed on the inner surface of the barrel was found to be 2.5 mm thick.
An abrasion resistance test (Okosi method) was applied to the resultant sample so as to examine the relationship between the friction rate and the specific abrasion amount. FIG. 8 shows the results together with the results for a sample manufactured by utilizing the hot isostatic pressurizing apparatus. The mating member used in this test was SKD11, HRC58; the final load was 18.9 kg, and the friction distance was 600 m. FIG. 8 clearly shows that the sample manufactured by the method of the present invention exhibits an excellent abrasion resistance.
EXAMPLE 3
Application to a Screw for a Biaxial Kneader
A loading space was formed between a substrate 31, i.e., an S35C rod having an outer diameter of 37 mm, and a sintering tool 32, i.e., an S25C cylinder having an inner diameter of 46 mm, provided with a draft, and having a thermal spraying of alumina applied to the surface. A raw material powder 33 of the composition shown in Table 2 was loaded in the loading space, as shown in FIG. 4A. Then, the raw material powder was sintered so as to obtain a sintered layer 34, as shown in FIG. 4B. Finally, a mechanical processing was applied to the sintered layer so as to obtain a screw for a biaxial kneader, said screw having an outer diameter of 44 mm, an inner diameter of 25 mm, and a length of 40 mm, as shown in FIG. 4C.
EXAMPLE 4
Application to a Nozzle for an Injection Molding Machine
A loading space was formed by using a substrate 41 formed of an SCM440 material, a first sintering tool 42 formed of an S25C material having a thermal spraying of alumina applied to the surface, and a second sintering tool 43, i.e., an alumina pin. A raw material powder 44 shown in Table 2 was loaded in the loading space, as shown in FIG. 5A. Then, the raw material powder was sintered to form a sintered layer 45, followed by applying a mechanical processing so as to obtain a nozzle for an injection molding machine, said nozzle having an outer diameter of 110 mm, and a length of 185 ram, as shown in FIG. 5B.
EXAMPLE 5
Application to a Nozzle for an Extruder
A raw material powder 52 shown in Table 2 was loaded in a loading space formed in a substrate 51 consisting of an SCM440 material, as shown in FIG. 6A. Then, the raw material powder was sintered to form a sintered layer 53, as shown in FIG. 6B, followed by applying a mechanical processing so as to obtain an extruder nozzle having a diameter of 420 mm, as shown in FIG. 6C.
EXAMPLE 6
Application to a Check Valve for an Injection Molding Machine
A raw material powder 64 shown in Table 2 was loaded in a first loading space defined between a first sintering tool 62 formed of an S25C material having a thermal spraying of alumina applied to the surface and a second sintering tool 63 formed of an S25C material having a thermal spraying of alumina applied to the inner surface, as shown in FIG. 7A. Then, a substrate 61 formed of an S25C material was put on the loaded raw material powder, and a second loading space was formed around the substrate 61, followed by loading the raw material powder 64 in the second loading space, as shown in FIG. 7B. Further, the raw material powder was sintered to obtain a sintered layer 65, as shown in FIG. 7C, followed by applying a mechanical processing so as to obtain a check valve having an inner diameter of 25 ram, an outer diameter of 37 mm and a length of 41 mm for an injection molding machine, as shown in FIG. 7D.
The conditions employed in Examples 1 to 6 are shown in Table 1. Also, the compositions of the raw material powders employed in these Examples are shown in Table 2.
SCM440 S25C, SKD11, and S35C described in the above examples correspond 4140, 1025, D2, and 1035 of AISI, and also correspond 42CrMo4, C25, X210Cr12, C35 of DIN, respectively.
As apparent from the Examples described above, the method of the present invention makes it possible to cover the surface of a substrate having a complex shape as in Examples 2, 4 and 6 with a sintered layer performing desired functions, though it was impossible to form such a sintered layer on the substrate surface of a complex shape in the conventional method. In the conventional hot isostatic pressurizing method, it was impossible to form a sintered layer of a high accuracy. In the present invention, however, pressure is not applied during the heating step, making it possible to form such a sintered layer. As a matter of fact, the dimensional accuracy of the inner diameter was ±0.1 and the pitch accuracy was ±0.2 or less even in a large sintered layer as in Example 2, though the liquid phase solidified portion was smaller in diameter by 3.2 mm than the sintered layer because the inner diameter tool was 110 mm in diameter. Since it was possible to apply cutting to the liquid phase solidified portion, a cutting treatment was applied to the entire inner surface of the sintered layer in the final stage.
In the conventional hot isostatic pressurizing method, the loading space of the powdery raw material is hermetically closed, and pressure is applied during the heating step. However, the hermetic closing and pressurizing need not be employed in the present invention. As a result, the excess liquid phase flows downward and can be removed in the mechanical treatment after the sintered layer formation. Also, a large amount of the solid phase in the sintering step remains in the sintered layer covering the substrate surface. The solid phase is superior to the liquid phase solidified portion in both the corrosion resistance and the abrasion resistance. It follows that the sintered layer formed by the method of the present invention is superior in performance to that formed by the conventional hot isostatic pressuring method.
The flow of the liquid phase noted above permits increasing the mixing ratio of the ceramic material in the resultant sintered layer in the case where it is intended to form a sintered layer containing ceramic materials such as carbides as in Examples 5 and 6. The increase in the mixing ratio of the ceramic material permits further improving the abrasion resistance and the corrosion resistance of the sintered layer covering the substrate surface.
What should also be noted is that the method of the present invention is simple in process, does not require a costly equipment, and permits lowering the manufacturing cost of an article including a substrate whose surface is covered with a sintered layer.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, and illustrated examples shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
TABLE 1______________________________________ Powdery Load- Thick-Ex- raw ing nessam- material thick- afterple (see ness sinteringNo. Article Substrate table 2) (mm) (mm)______________________________________1 Cylinder for SCM440 Ni alloy 2.5 1.5 ± 0.2injection molding 150 μm ormachine less2 Barrel for SCM440 Ni alloy 5.0 3.0 ± 0.2biaxial kneader 60 μm or less3 Screw for biaxial S35C Co ally 12.0 7.3 ± 0.3kneader 60 μm or less4 Nozzle for in- SCM440 Co ally 3.2 1.9 ± 0.2jection molding 60 μm ormachine less5 Extruder nozzle SCM440 Ni alloy 2.5 1.5 ± 0.3 60 μm or less plus 40% 10 μm WC powder6 Check valve for SCM440 Ni alloy 2.5 1.5 ± 0.2injection molding 60 μm ormachine less plus 40% 10 μm WC powder______________________________________
TABLE 1-1______________________________________ Temperature elevatingExample Soaking proces Sintering SinteringNo. process (°C./min) process atmosphere______________________________________1 950° C. 4.0 1025° C. vacuum 40 minutes 40 minutes2 950° C. 1.0 1025° C. " 80 minute 60 minutes3 1020° C. 2.0 1100° C. " 30 minutes 35 minutes4 1020° C. 2.0 1100° C. " 30 minutes 35 minutes5 950° C. 0.5 1025° C. hydrogen 90 minutes 75 minutes (hydrogen furnace)6 950° C. 0.2 1025° C. hydrogen 20 minutes 30 minutes (hydrogen furnace)______________________________________
TABLE 2______________________________________(Composition of Powdery Raw Material, % by weight)ExampleNo. Ni Cr B Si Fe W Co______________________________________1 balance 10.3 2.1 2.9 0.4 -- --2 balance 10.0 2.2 3.2 0.5 -- --3 9.8 24.2 2.9 3.2 1.0 7.0 balance4 9.8 24.2 2.9 3.2 1.0 7.0 balance5 balance 9.9 2.3 3.2 0.7 -- --6 balance 9.9 2.3 3.2 0.7 -- --______________________________________
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A method of covering a substrate surface with a sintered layer comprises the step of loading a powdery raw material in a region of forming a sintered layer on the surface of a substrate, and the step of sintering the loaded powdery raw material so as to form a sintered layer on the surface of the substrate. The powdery raw material contains at least two elements and has a temperature region in which a solid phase and a liquid phase are present together. The liquid phase is wettable with the substrate. The sintering step is performed within a temperature region in which the solid phase and the liquid phase of the powdery raw material are present together.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/807,732, filed Jul. 19, 2006, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] It has been reported that individuals in the USA spend up to about 90% of their time indoors. Because poor indoor air quality has been linked to respiratory illnesses, allergies, asthma and sick building syndrome, adequate ventilation and indoor air quality are important for the health, well-being, productivity and thermal comfort of building occupants. However, heat gains and losses through infiltration and ventilation are believed to account for a significant amount of the energy required to maintain comfortable conditions within buildings. Consequently, in an effort to save energy by reducing shell heat gains and losses, the construction of the building envelope has become increasingly tighter. Increased airtightness of buildings results in less ventilation, with the result that the benefits of lower energy requirements are generally obtained at the expense of adequate indoor air quality.
[0003] For commercial buildings, indoor air quality can be regulated by air systems that supply air to the indoor space by mixing fresh outdoor air with return air from the indoor space. In residential buildings, however, outdoor air typically enters the space through doors, operable windows, and infiltration. During the heating and cooling seasons, ventilation is usually limited to infiltration because residential air systems typically use only recirculated air and residential hydronic systems heat air through convection with no direct air exchange. The low ventilation associated with these systems can increase indoor pollutant levels because and indoor air pollutants (for example, emissions from indoor sources) are not able to escape the home, and insufficient outdoor air is available to dilute indoor air pollutants.
[0004] In view of the above, measures for providing adequate fresh air to residential buildings are being explored, with particular emphasis on achieving improvements in indoor air quality with minimal energy usage. In recent years, integrated sustainable design concepts have been adapted that can improve indoor air quality in buildings while conserving energy. For instance, ventilated building facades are currently being integrated into commercial buildings. However, this technology has not been utilized as frequently in residential buildings because of expense and because multistory facades may not be applicable to residential designs. Another approach is windows having a ventilation capability. An example is an airflow window, which as the name implies differs from a conventional window by the existence of internal airflow, in the form of free or forced convection through an airflow cavity between two layers of glass (glazing). The potential for using airflow windows in residential construction has been explored because they are not as complicated as ventilated facades and have the potential for improving indoor air quality and conserving energy for heating and cooling while also allowing daylight to enter a room.
[0005] The airflow cavity of an airflow window is usually combined with a double-glazed insulated unit (two layers of glass spaced apart and hermetically sealed with an air space therebetween), resulting in a triple-paned construction. However, various combinations of single panes or double-glazed insulated units can be used to form an airflow window. Four main modes of operation have been reported for airflow windows: supply, exhaust, indoor air curtain, and outdoor air curtain. These modes are respectively represented in FIGS. 1 through 4 , which depict outside air being to the left of each window 100 , 200 , 300 , and 400 , respectively, and the inside air being to the right of each window. Typically used during the heating season, the supply air window 100 ( FIG. 1 ) draws air from the outdoor space (e.g., outside) 102 to the indoor space (e.g. a room) 104 through an airflow cavity 106 between an outside glass pane 108 (represented as a single pane) and an inside glass pane 110 (represented as a double-glazed insulated unit). Conversely, during the cooling season, the exhaust air window 200 shown in FIG. 2 exhausts air from the indoor space 204 to the outdoor space 202 through an airflow cavity 206 between an outside glass pane 208 110 (represented as a double-glazed insulated unit) and an inside glass pane 210 (represented as a single pane). FIGS. 3 and 4 show the indoor and outdoor air curtain windows 300 and 400 , respectively, as having airflow cavities 306 and 406 that define airflow paths from inside to inside and outside to outside, respectively. In all cases, airflow is typically from bottom to top as a result of the configurations making use of the thermal buoyancy effects as air increases in temperature. It has been reported that the exhaust air window 200 may also be used during the heating season with airflow from top to bottom.
[0006] In general, the working principle of an airflow window is to entrain the solar heat that has been captured by the airflow window and direct the solar energy indoors or outdoors, depending on the operating mode of the window. Captured solar energy is used to preheat outdoor air in the supply mode of FIG. 1 , and reheat indoor air in the indoor air curtain mode of FIG. 3 . This working principle is ideal for use during the heating season. For the exhaust and outdoor air curtain modes of FIGS. 2 and 4 , airflow is used to remove solar energy by convecting away the excess heat during the cooling season and decreasing conductive heat losses during the heating season. The supply air window 100 can also be used for night cooling.
[0007] Airflow through the supply airwindow 100 is mainly driven by buoyant effects. Solar energy absorbed by the window 100 heats the air inside the airflow cavity 106 . The heated air rises, causing the air in the cavity 106 to stratify and move in an upward direction. The strength of the buoyant forces is governed by the vertical temperature differences in the airflow cavity 106 , which is influenced by the height of the window 100 . In general, the taller the window 100 and/or the greater the temperature difference, the greater the buoyant force. To ensure airflow into the room when buoyant forces are weak, the supply air mode requires that the room 104 in which the window 100 is located be kept at a slightly negative pressure. Airtight construction in the rest of the room 104 is also essential for achieving airflow only through the window 100 .
[0008] As compared to a conventional window, the exhaust air window 200 can improve thermal comfort conditions by tempering and then exhausting room air between the two glass panes 208 and 210 . This is beneficial during both the heating and cooling seasons because the airflow cavity 206 is respectively warmer or cooler. The decrease in temperature difference between an occupant of the room 204 and the surface of the inside glass pane 210 decreases the radiation exchange and improves thermal comfort. The temperature of the airflow cavity 206 also helps to reduce conduction losses through the window 200 . Air can be exhausted by natural effects or mechanical effects by positively pressurizing the room 204 .
[0009] Although the air curtain modes cannot be used to improve indoor air quality or meet ventilation requirements, they offer benefits related to energy consumption and thermal comfort. The outdoor air curtain 400 of FIG. 4 is most beneficial on a sunny day during the cooling season. Warmer outdoor air is driven upward through the airflow cavity 406 because of buoyancy effects. As the air is heated in the cavity 406 , it is drawn to and exhausted from the top of the window 400 , which in turn causes air to be drawn from the outdoor space 402 into the airflow cavity 406 through an opening at the bottom of the cavity 406 . In this way, the daylighting benefits from solar radiation can be enjoyed without overheating the window 400 and subsequently increasing the temperature of the room 404 . By helping to prevent overheating in the airflow cavity 406 , the temperature difference between the outdoor space 402 and indoor room 404 is minimized, which reduces heat transfer through the window 400 into the room 404 and consequently decreases the amount of energy needed to cool the room 404 .
[0010] The indoor air curtain window 300 of FIG. 3 works in a similar fashion during the heating season. Solar energy is absorbed by the air within the airflow cavity 306 , causing the air to become heated and rise through the cavity 306 , and finally convected to the indoor space/room 304 through an opening at the top of the window 300 . The rising air within the cavity 306 causes cooler air to be drawn from the room 304 into the airflow cavity 306 through an opening at the bottom of the cavity 306 .
[0011] Airflow windows are most effective when installed on the south facade of a building because the increased incident solar radiation on the west and east facades can promote overheating of the window. On the other hand, an airflow window installed on the north facade may not receive enough incident solar radiation during the winter months to effectively temper air supplied to the building. Therefore, for most climates, airflow windows are limited to installation on the south facade.
[0012] The airflow window designs described above have several limitations. For instance, only the supply air mode offers the potential for improving indoor air quality by drawing fresh air from an outdoor space 102 into the room 104 . Several limitations to the implementation of these airflow windows also arise from the design of their airflow cavities 106 , 206 , 306 , and 406 , which are open and as a result raise issues concerning security, acoustics, air quality, cleaning and maintenance, thermal comfort and/or condensation. For some building locations, conventional windows are useful to attenuate outdoor noise, whereas the airflow cavities 106 , 206 , 306 , and 406 of the airflow windows 100 , 200 , 300 , and 400 may provide a channel for outdoor noises to enter the indoor space 104 , 204 , 304 , and 404 , potentially causing acoustic problems. The ability to filter outdoor air before it enters a building in the supply air window 100 is important when considering indoor air quality. However, filters can hinder the effectiveness of natural ventilation. Airflow in the airflow cavities 106 , 206 , 306 , and 406 of all airflow window modes can also promote the collection of dirt and dust on the interior surfaces of the window. Though offering the benefit of preheating air that enters a building during the day during the heating season, the supply air window 100 can contribute to heat losses during the night when the temperature of the inner pane 110 can drop, affecting the thermal comfort of the building occupants. Finally, condensation in an airflow window may occur if the surface temperature of a glazing layer falls below the dew point temperature of the air it contacts. Moisture can accumulate at the base of the window, which can lead to damage of the materials used to construct the window. Additionally, high outdoor humidity levels can increase the humidity indoors and decrease thermal comfort.
[0013] Other shortcomings of airflow windows are due to their added complexity as compared to a conventional window. The initial cost of purchasing an airflow window is likely higher, though strongly dependent on the type of airflow window and exact construction, as well as the availability of the product in relation to the building location. However, the use of airflow windows may reduce the size of the HVAC system required to heat and cool and building, providing a significant trade-off for the increased cost of an airflow window.
[0014] In view of the foregoing, though airflow window technology offers significant potential benefits including improved indoor air quality and reduced heating/cooling loads, current airflow windows have a number of limitations and as such further improvements in their construction and effectiveness would be desirable.
BRIEF SUMMARY OF THE INVENTION
[0015] The present invention provides airflow window systems capable of drawing fresh outdoor air into an indoor space to improve air quality within the indoor space, and also tempering the incoming outdoor air with outgoing indoor air, thus reducing the heating/cooling demands associated with introducing the outdoor air to the indoor space.
[0016] The airflow window system generally includes at least three glazing layers positioned roughly parallel to each other to define at least two internal airflow cavities within the airflow window system. A first of the glazing layers is adjacent a first of the two internal airflow cavities, a second of the glazing layers is adjacent a second of the two internal airflow cavities, and a center glazing layer is between the first and second glazing layers and separates the first and second internal airflow cavities. Airflow cavity openings are located adjacent the uppermost and lowermost extents of each airflow cavity, and airflow is enabled through the first internal airflow cavity between the openings thereof and enabled through the second internal airflow cavity between the openings thereof.
[0017] A significant advantage of this invention is the ability to employ the center glazing layer as a heat transfer medium between two air flows, one drawn from an outdoor space and supplied to an indoor space and the second drawn from the indoor space and exhausted to the outdoor space. In this manner, the window system operates as a crossflow heat exchanger capable of supplying fresh outdoor air to an enclosed indoor space, while reducing the thermal load resulting from the import of fresh air by thermally tempering the incoming fresh air with the outgoing indoor air.
[0018] Other objects and advantages of this invention will be better appreciated from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIGS. 1 through 4 are schematic cross-sectional representations showing four modes of operation for prior art airflow windows: supply, exhaust, indoor air curtain, and outdoor air curtain, respectively.
[0020] FIGS. 5 and 6 are schematic cross-sectional representations showing two modes of operation, supply and exhaust, respectively, for airflow windows in accordance with two embodiments of this invention.
[0021] FIG. 7 schematically represents a frontal view of the airflow window of FIG. 5 .
[0022] FIGS. 8 and 9 are schematic cross-sectional representations of the airflow windows of FIGS. 5 and 6 with optional features in accordance with additional embodiments of the invention.
[0023] FIGS. 10 and 11 are overviews of the convection and radiation effects, respectively, on the airflow window of FIG. 5 .
[0024] FIGS. 12 and 13 are graphs plotting data obtained from simulations to assess the performance of airflow windows with the supply and exhaust operating modes represented in FIGS. 5 and 6 , respectively.
[0025] FIGS. 14 and 15 are graphs plotting data obtained from simulations to assess the winter and summer performance of the supply-mode airflow window of FIG. 5 under varying solar radiation conditions.
[0026] FIGS. 16 and 17 are graphs plotting data obtained from simulations to assess the winter and summer performance of the supply-mode airflow window of FIG. 5 under varying combinations of solar radiation and wind conditions.
[0027] FIGS. 18 and 19 are graphs plotting data obtained from simulations to assess the winter and summer performance of the supply-mode airflow window of FIG. 5 at different airflow rates.
[0028] FIGS. 20 and 21 are graphs plotting data obtained from simulations to assess the winter and summer performance of the supply-mode airflow window of FIG. 5 for different airflow cavity widths.
[0029] FIGS. 22 and 23 schematically represent perspective views of the airflow windows of FIGS. 5 and 6 with optional features in accordance with additional embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The present invention provides embodiments for an airflow window system that defines two separate airflow paths in an arrangement that has the potential for providing energy savings and improving indoor air quality within a building in which the window system is installed. Two embodiments are schematically represented in FIGS. 5 and 6 . In each embodiment, the dual airflow path configuration is believed capable of offering benefits over the conventional airflow windows of FIGS. 1 through 4 . In particular, the dual airflow path configuration has the advantage over the supply air window 100 ( FIG. 1 ) of tempering incoming outdoor air with outgoing indoor air, thus reducing the heating/cooling demands associated with introducing outdoor air to an indoor space, and has the advantage over the exhaust air window 200 ( FIG. 2 ) and air curtain windows 300 and 400 ( FIGS. 3 and 4 ) by drawing fresh outdoor air into an indoor space, thus improving air quality of the indoor space.
[0031] The airflow window systems 10 and 50 of FIGS. 5 and 6 are shown as being a triple glazed unit, i.e., three glass layers or panes 18 , 19 , and 20 , that define two parallel airflow cavities 16 a and 16 b through which air is allowed or forced to flow (because of the similar construction and sharing of basic components, identical reference numbers are used to identify the individual components of the window systems 10 and 50 in the Figures). The window systems 10 and 50 provide two different modes of operation, referred to as supply and exhaust, respectively. In the supply mode embodiment depicted in FIG. 5 , outdoor air (OA) from an outdoor space 12 enters an opening 22 at the lower end of an outer airflow cavity 16 a defined between the outer pane 18 and the center pane 19 , flows upward through the cavity 16 a , and is discharged as tempered fresh air (TFA) into an indoor space 14 by passing through an opening 24 at the upper end of the cavity 16 a . Simultaneously, indoor air (IA) enters an opening 26 at the upper end of an inner airflow cavity 16 b defined between the center pane 19 and the inner pane 20 , flows downward through the cavity 16 b , and is discharged as exhaust air (EA) into the outdoor space 12 by passing through an opening 28 at the lower end of the cavity 16 b . In the exhaust mode embodiment depicted in FIG. 6 , airflow directions through the airflow cavities 16 a and 16 b are reversed. Outdoor air (OA) from the outdoor space 12 enters through the opening 24 , flows downward through the outer airflow cavity 16 a , and is discharged through the opening 22 as tempered fresh air (TFA) into the indoor space 14 , and indoor air (IA) simultaneously enters the opening 28 , flows upward through the inner airflow cavity 16 b , and is discharged through the opening 26 as exhaust air (EA) into the outdoor space 12 .
[0032] In each embodiment, exhausted indoor air is used to temper incoming outdoor air, thus reducing hearing/cooling demands of the indoor space 12 while providing fresh air to the indoor space 12 . The exhausted indoor air flows through the inner airflow cavity 16 b of each window system 10 and 50 , so that the temperature of the inner pane 20 stabilizes relatively close to the air temperature within the indoor space 12 to promote the thermal comfort of occupants of the indoor space 12 . Other operational aspects and efficiencies associated with these different modes will become apparent in the following discussion.
[0033] As can be seen from the airflow schematics in FIGS. 5 and 6 , the openings through which air enters the window systems 10 and 50 ( 22 and 26 in FIG. 5 ; 24 and 28 in FIG. 6 ) are positioned adjacent the openings through which air exits the window systems 10 and 50 ( 24 and 28 in FIG. 5 ; 22 and 26 in FIG. 6 ). To reduce short-circuiting tempered fresh air (TFA) into the indoor air (IA) stream, the window systems 10 and 50 can be configured so that the width of the upper and lower extent of each window system 10 and 50 is divided (perhaps equally) between the openings serving as inlet and outlet, as represented in FIG. 7 for the supply mode embodiment of FIG. 5 . Due to this positioning of the inlets/outlets in the supply mode of FIG. 5 , airflow 40 through the outer airflow cavity 16 a is generally diagonally upward from the opening 22 to the opening 24 , and airflow 42 through the inner airflow cavity 16 b is generally diagonally downward from the opening 26 to the opening 28 (flow directions are reversed for the exhaust mode of FIG. 6 ). With this configuration, each of the window systems 10 and 50 performs as a crossflow heat exchanger with solar energy recovery.
[0034] The performance of the window systems 10 and 50 were investigated both using computational methods (computational fluid dynamics, or CFD) and experiments to confirm the computational methods. The CFD simulations employed FLUENT®, a commercial CFD software program, to model convection, conduction, and radiation within the window systems 10 and 50 . Because the window systems 10 and 50 are intended for use in residential buildings, the computational and experimental investigations were based on a window height of about 1.22 meters (about four feet) and a window width of about 0.92 meter (about three feet), which are within common ranges for residential window dimensions. The thickness of each pane 18 , 19 , and 20 was set at 3 mm. Because mixed-mode heat transfer is present in the window systems 10 and 50 , the effects from conduction, convection and radiation must be considered when developing a window model. The following is an overview of the three main modes of heat transfer as they relate to the window systems 10 and 50 .
[0035] Due to a temperature difference on either side of each glass pane 18 , 19 , and 20 , conduction occurs through each pane 18 , 19 , and 20 . Because conduction through the glass panes 18 , 19 , 20 is intended, a double-glazed insulated unit is not believed to be necessary or preferred for any of the panes 18 , 19 , and 20 , particularly the center pane 19 . To the contrary, conduction across the center pane 19 is desirable because of the intended heat exchanger effect between the air flows in the two airflow cavities 16 a and 16 b . As such, heat transfer between the two air flows can be improved to some extent by manufacturing the center pane 19 from a material having a relatively high thermal conductivity coefficient, for example, greater than the materials of the inner and outer panes 18 and 20 . Notable highly conductive materials include metals such as aluminum alloy, pure copper, and pure silver with conductivities of about 170, 401 and 429 W/m 2 , respectively. Disadvantages of metallic materials include poor transmittance of light and susceptibility to corrosion. Transparent/translucent materials such as polymers tend to be less conductive than glass, for example, acrylic, polycarbonate, and polyethylene have conductivities that range from about 0.13 to 0.30 W/m·K. Therefore, glass is believed to be preferred for the center pane 19 , though it is within the scope of this invention that other materials could be used, especially transparent/translucent materials that are more thermally conductive than glass.
[0036] The linear temperature profile across each pane 18 , 19 , and 20 is small when compared to the more parabolic temperature profile due to convection. The resistance to conduction (R cond ) is defined as:
R cond =L/kA
where L is the thickness of the pane 18 , 19 , or 20 , k is the thermal conductivity of the pane material, and A is the surface area of the pane 18 , 19 , or 20 perpendicular to heat transfer. For a 3 mm thick glass pane with a conductivity of about 1.4 W/m·K, the resulting resistance to heat transfer is small. As a result, the temperature difference across each glass pane 18 , 19 , and 20 is relatively small. It was therefore assumed that the surface temperatures of each pane 18 , 19 , and 20 are the same across the thickness of the pane 18 , 19 , and 20 at each position for the computational simulations and experiments.
[0037] Convective heat transfer effects are present within and around the window systems 10 and 50 due to the airflow over the glass panes 18 , 19 , and 20 , as represented in FIG. 10 . Convection can be due to natural or forced effects. On the outer surface of the outer pane 18 , wind is the main driving force. Therefore, windy and calm conditions should be considered. Per design conditions listed in the ASHRAE Fundamentals Handbook (2001), a windy condition indicates an outside air velocity of about 6.7 m/s, whereas calm conditions are similar to indoor airflows far from a diffuser, or about 0.2 to about 0.3 m/s. On the interior surfaces of the panes 18 , 19 , and 20 , i.e., those defining the airflow cavities 16 a and 16 b , convective heat transfer effects are present as a result of natural convection as the air within the cavities 16 a and 16 b becomes more or less buoyant as a result of an increase or decrease in temperature, as the case may be. Natural convection within the cavities 16 a and 16 b has different influences on the performance of each window system 10 and 50 because of their different operating modes: supply and exhaust ( FIGS. 5 and 6 ). Depending on the season, each configuration would align the airflow paths between the indoors/outdoors with the direction of dominant buoyancy forces. The supply mode ( FIG. 5 ) would appear to be most effective during the heating season, when exhausted indoor air cools and sinks in the inner airflow cavity 16 b , driving the air to the outdoor space 12 , while cold outdoor air is heated and rises within the outer airflow cavity 16 a , driving the air to the indoor space 14 . Conversely, the exhaust mode ( FIG. 6 ) would appear to be most useful during the cooling season, again because the airflow patterns within the window system 50 work with the naturally prevailing buoyancy forces.
[0038] FIGS. 8 and 9 depict modified versions of the embodiments of FIGS. 5 and 6 , in which the airflow through the cavities 16 a and 16 b is supplemented with fans 30 , whose size and efficiencies can be selected to ensure that the indoor space 12 can be supplied with sufficient outdoor air to improve indoor air quality. For the following investigations, forced convection using fans was studied in detail. In part, the concern was that the experiments on test prototypes were to be conducted in an indoor test facility, and without exposure to solar radiation or a radiation source of the same intensity, buoyancy forces would be too small to accurately measure and airflow may be flowing in several directions at the inlets/outlets of the window system. Therefore, it was concluded that the validation of a CFD model by experimental measurements would only be possible if a mechanically ventilated (forced convection) window was evaluated. ASHRAE Standard 62.2-2004 specifies a minimum 10 L/s (20 cfm) per person of outdoor air in residential areas. For the investigations discussed below, flow rates of about 10 to about 20 L/s (about 20 to about 40 cfm) per window were evaluated, based on the premise of two occupants in a room with two windows.
[0039] Three radiation interactions are present in the window systems 10 and 50 : radiation to the indoor space 14 , radiation between each pane 18 , 19 , and 20 , and solar radiation as represented in FIG. 11 . Each type of radiation plays a role in the performance of the window. The energy from solar radiation was estimated for each pane 18 , 19 , and 20 based on a survey of typical meteorological (TMY2) solar data and calculations from the FLUENT® solar load calculator was conducted for several locations in the United States. This data suggested about 1000 W/m 2 as a suitable approximation for the average solar radiation flux during a sunny day, with about 800 W/m 2 as direct radiation and about 200 W/m 2 from atmospheric diffusive radiation and ground reflection. Likewise, a cloudy day was estimated to provide no direct radiation, but 200 W/m 2 diffusive radiation. The absorptivity of each pane 18 , 19 , and 20 was estimated using data from the ASHRAE Fundamentals Handbook (2001) for a clear-clear-clear triple glazing unit. In general, about 12% of solar radiation was estimated as being absorbed by the outer pane 18 , about 8% by the middle pane 19 , and about 5% by the inner pane. 20 . At solar noon on a vertical south facade, the actual incident solar radiation is dependent on the angle of the sun. For winter computations, the sun angle was presumed to be about 350 from horizontal, and for summer computations this angle was presumed to be about 75° from horizontal. From these angles, the solar radiation flux values were adjusted accordingly. During sunny days in the winter and summer, incident radiation was estimated to be about 820 and about 260 W/m 2 , respectively.
[0040] FIGS. 8 and 9 further show the window systems 10 and 50 equipped with optional louvers 34 located in their outer airflow cavities 16 a . The louvers 34 can promote the absorption of solar radiation, and are therefore of interest to the invention. If configured to be rotated, the louvers 34 can also be used to effectively obstruct the flow of airflow through the airflow cavity 16 a . While within the scope of the present invention, the presence and possible effect of the louvers 34 was not included in the simulations and experimental investigations.
[0041] Taking into consideration the above factors, CFD simulations were performed based on the configurations of the window systems 10 and 50 described above. The summer indoor and outdoor temperatures used for the simulations were 24° C. and 37° C., respectively, and the winter indoor and outdoor temperatures used for the simulations were 22° C. and 2° C., respectively. Due to their complexity, the CFD simulations will not be described in any detail here, other than to report that the results provided numerous temperature data for each panel 18 , 19 , and 20 and for each opening 22 , 24 , 26 , and 28 under steady-state conditions, and that these results suggested that significant benefits could be obtained with the window systems of FIGS. 5 and 6 . Therefore, validation of the simulation data was pursued with experimental testing of actual hardware.
[0042] The experimental investigations obtained flow and temperature data with a full-scale airflow window installed in an environmental chamber facility. A preliminary investigation was performed for the forced convection supply mode ( FIG. 8 ) underwinter and summer conditions with no solar radiation. As with the CFD simulations, the glazing area was about 1.22 meters high and about 0.92 meter wide. The multiple layer construction of the window system was formed using double strength, clear glass panes with a thickness of about 3 mm. Nine thermocouples were glued on one surface of each pane for a total of twenty-seven surface temperature readings. Each of the two airflow inlets and two airflow outlets of the window system (corresponding to openings 22 and 26 and openings 24 and 28 , respectively, in FIGS. 5, 7 , and 8 ) was monitored with three thermocouples for inlet/outlet airflow temperature measurements, for a total of twelve airflow temperature readings.
[0043] The preliminary investigation was conducted for four different scenarios: winter and summer conditions with forced airflow through the airflow cavities of about 10 or about 15 L/s. Results from these experiments were found to be in good agreement with the data from the CFD simulation of the supply-mode window system. Therefore, it was concluded that the CFD simulations were of sufficient accuracy to conduct parametric studies to identify optimal values for several parameters of the window systems 10 and 50 . The parameters considered were the mode of operation (supply and exhaust), solar radiation, wind, airflow rate, and cavity width over winter and summer conditions.
[0044] An optimal airflow window configuration would be expected to depend on the mode of operation and weather conditions. For example, it was conjectured that the supply mode ( FIGS. 5, 7 , and 8 ) may be most effective during winter months, while the exhaust mode ( FIGS. 6 and 9 ) may be most effective during summer months. Such configurations may make use of natural buoyancy effects to drive airflow in the window cavities, allowing for fan energy consumption to be reduced. However, for reasons previously discussed, the investigation focused on using a fan to drive the airflows through the airflow cavities. Other than where noted, the same parameters used in the original CFD simulations were used in the parametric studies.
[0045] FIGS. 12 and 13 are graphs generated from a CFD simulation showing the effect that the particular mode (supply and exhaust) has on the exit temperature of the tempered fresh air supplied by the window system 10 / 50 to the indoor space. Results are presented for each window system 10 and 50 under summer and winter conditions and sunny and cloudy sky conditions, using a forced airflow rate of 10 L/s and a cavity width of 12 mm. The most desirable mode of operation would provide the highest exit temperature to the indoors during the winter and the lowest exit temperature to the indoors during the summer. For a flowrate of 10 L/s, the supply mode was slightly better during the winter and the exhaust mode slightly better during the summer. However, this difference was only about 1° C. or less, indicating that the mode of operation is not likely critical under the evaluated conditions using fan-driven airflow.
[0046] A subsequent simulation with the airflow rate increased from 10 L/s to 20 L/s indicated that the performance from the supply and exhaust modes would be nearly identical. An increase in forced airflow rate is indicative of a decreased ratio of natural convection to forced convection. Because the mode of operation appeared to become less important with increasing airflow rates, it was decided that only the supply mode (the window system 10 of FIGS. 5, 7 , and 8 ) would be evaluated with subsequent simulations.
[0047] Next, the effects of solar radiation and wind were investigated with CFD simulations. FIGS. 14 and 15 show exit temperatures to the indoor space for four combinations of solar radiation and wind under winter and summer conditions, respectively, and FIGS. 16 and 17 show exit temperatures to the indoor space for three solar radiation conditions in winter and summer, respectively. As before, the simulation used an airflow rate of 10 L/s and a cavity width of 12 mm. During winter conditions, the exit temperature to the indoors was the highest under sunny and calm conditions. On the other hand, during summer conditions, the exit temperature to the indoors was the lowest under cloudy and calm conditions. Given the desired effect on exit temperature, these conditions provided the best performance for each season. Results indicated that solar radiation is desirable during the winter (heating) season and less desirable during the summer (cooling). Calm wind conditions were favorable for promoting less convective heat losses during the winter and less convective heat gains during the summer.
[0048] CFD simulations were then conducted to evaluate the effect of airflow rate within the airflow cavities 16 a and 16 b . FIGS. 18 and 19 show the simulated results of airflow rate on the exit temperature during winter conditions and summer conditions, respectively. Note that the most and least desirable solar radiation and wind combinations are highlighted for each season. Again, the simulation used a cavity width of 12 mm, while the evaluated airflow rates were 10, 15, and 20 L/s. The effect of airflow rate on exit temperature can be seen to vary significantly between winter and summer conditions. During sunny, winter conditions, the largest increase in exit temperature to the indoors was achieved with the lowest flow rate. The trends also seem to indicate that the decrease in window performance with an increase in flow rate is not linear, and that window performance is most sensitive to changes at lower flow rates. However, under summer and cloudy winter conditions, flow rate appears to have little if any effect on exit temperature to the indoor space. This may have been due to the relatively small incident solar radiation simulated for sunny summer days and cloudy or sunny winter days.
[0049] Finally, FIGS. 20 and 21 represent the data obtained from CFD simulations conducted to evaluate the effect of the width of the airflow cavities 16 a and 16 b . Airflow rates for the simulation were again 10 L/s. Overall, it was found that smaller cavity widths improved window performance. Unlike airflow rate, cavity width appeared to have a small impact on exit temperature under winter conditions. The impact of cavity width on exit temperature for both winter and summer was about 1° C. for cavity widths over a range of 9 to 15 mm. The efficiency of the heat exchange between the two cavities 16 a and 16 b of the window system 10 and energy reclamation was used to measure the window performance for each of the parameters studied.
[0050] Heat recovery efficiency values were assessed for the combination of parameters suggested as being optimal under the simulated conditions discussed above. As set forth in the equation below, heat recovery efficiency (ε) can be calculated by taking the absolute value of the ratio between the actual temperature change of the air in the inner cavity to the maximum temperature difference between the outdoor and indoor air temperatures.
ε=|( T out −T o,i )/( T out −T in )|
[0051] In the equation, T out is the outdoor temperature, T in is the indoor temperature, and T o,i is the average exit temperature to the indoors.
[0052] Heat recovery efficiency was found to be greatest when the flow rate and cavity width are the smallest values evaluated, 10 L/s and 9 mm, respectively. During winter conditions, performance was maximized under sunny and calm weather conditions with an efficiency of 80.5%. During summer conditions, performance was maximized under cloudy and calm weather conditions with an efficiency of 23.7%. Using the same flow rate and cavity width values, the lowest heat recovery efficiencies were also calculated. During winter conditions, the lowest efficiency calculated was 34.1%, and occurred under cloudy and windy conditions. Under summer conditions, the lowest calculated efficiency was 14.7%, which occurred during sunny and windy conditions.
[0053] From the above it was concluded that each of the airflow window systems 10 and 50 represented in FIGS. 5 through 9 offer great potential for conserving energy and improving indoor air quality. Forced or natural convention airflow can be used to temper outdoor air with exhausted indoor air, thus reducing heating/cooling demands associated with providing fresh air to an indoor space year round. The window systems 10 and 50 conserve energy by operating as a cross-counterflow heat exchanger utilizing solar energy trapped by the panes 18 , 19 , and 20 of the window systems 10 and 50 . Supply air temperatures and inner pane temperatures were closer to the indoor space temperature under all weather conditions studied, thus promoting the thermal comfort of occupants of the indoor space.
[0054] Two implementations for the window system 10 of FIGS. 5, 7 , and 8 are shown in perspective in FIGS. 22 and 23 (the same implementations are also applicable to the window system 50 of FIGS. 6 and 9 ). In FIGS. 22 and 23 , the openings 22 , 24 , 26 , and 28 are in the form of plenums located and fluidically connected to the appropriate airflow cavity 16 a or 16 b . FIG. 22 shows fans 30 within the openings 28 and 24 to the airflow cavities 16 a and 16 b , respectively, for the purpose of providing mechanical (forced) ventilation through the airflow cavities 16 a and 16 b . Due to the symmetry of the supply and exhaust air window configurations (for example, compare FIGS. 5 and 6 ), the supply and exhaust modes of operation can be interchanged by rotating the window system 10 about its central vertical axis 36 , as represented in FIG. 23 . FIG. 23 also shows the openings 22 , 24 , 26 , and 28 equipped with doors 38 that can be opened and closed, depending on the rotational orientation of the window system 10 and its operating mode (supply or exhaust). When open, the doors 38 can also serve as deflectors to promote natural ventilation and separation of air entering and leaving the window system 10 .
[0055] While the invention has been described in terms of specific embodiments, it is apparent that other forms could be adopted by one skilled in the art. For example, the physical configuration of the window systems 10 and 50 could differ from that shown, materials and processes other than those noted could be use, and more than two airflow cavities 16 a and 16 b could be provided. Therefore, the scope of the invention is to be limited only by the following claims.
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An airflow window system that includes at least three glazing layers positioned roughly parallel to each other to define at least two internal airflow cavities within the window system. A first of the glazing layers is adjacent a first of the airflow cavities, a second of the glazing layers is adjacent a second of the airflow cavities, and a center glazing layer is between the first and second glazing layers and separates the first and second airflow cavities. Airflow cavity openings are located adjacent the uppermost and lowermost extents of each airflow cavity, and airflow is enabled through the first airflow cavity between the openings thereof and enabled through the second airflow cavity between the openings thereof. The window system operates as a crossflow heat exchanger capable of supplying fresh outdoor air to an enclosed indoor space, while thermally tempering the incoming fresh air with outgoing indoor air.
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[0001] This invention was made with Government support under Contract Number N00019-02-C-3002 of the Joint Strike Fighter Program. The Government has certain rights in this invention
TECHNICAL FIELD
[0002] The present invention generally relates to check valves with flapper closure elements, and more particularly relates to methods and apparatus for retaining the hinge shaft on which the closure elements of check valves are pivotally mounted.
BACKGROUND
[0003] Check valves with flapper (or “wafer”) type closure elements are utilized in many industries. The check valves are typically mounted in pipes or other such conduits enable fluid flow in one direction and prevent fluid flow in the opposite direction. The closure elements of the check valve are pivotally mounted on a hinge shaft and can be biased closed by a resilient element such as a hinge spring. The hinge shaft is typically mounted by press fitting the ends of the hinge shaft in through holes formed in a valve body. The valve body is then mounted in a pipe or conduit, for example, to enable air intake for an engine of an aircraft.
[0004] Conventional check valves can encounter problems because the hinge shaft may loosen and migrate out of the valve body. This issue is exacerbated by the high temperature and vibration environments of many types of check valves, particularly where there is a clearance between the valve body and the walls of the conduit in which it is mounted.
[0005] Accordingly, it is desirable to provide methods and apparatus for satisfactory retaining hinge shafts in check valves. In addition, it is desirable to provide check valves that securely retain their hinge shafts in high temperature and vibration environments. Furthermore, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description of the invention and the appended claims, taken in conjunction with the accompanying drawings and this background of the invention.
BRIEF SUMMARY
[0006] In accordance with one exemplary embodiment, a check valve includes a valve body defining a flow passage therethrough; a hinge shaft; a bushing coupling the hinge shaft to the valve body; a pin secured to the valve body and engaging the bushing; and a closure element pivotally mounted on the hinge shaft for opening and closing the flow passage.
[0007] In accordance with another exemplary embodiment, a method of retaining a hinge shaft in a check valve is provided. The method includes the steps of mounting a bushing on the hinge shaft to couple the hinge shaft to a valve body of the check valve; inserting a pin in a groove of the bushing; and securing the pin to a valve body of the check valve to prevent movement of the bushing and the hinge shaft in a longitudinal direction.
[0008] In accordance with yet another exemplary embodiment, a check valve includes a valve body comprising a flow passage and a bore; a hinge shaft; a bushing having a circumferential surface and coupling the hinge shaft to the valve body; a pin at least partially housed in the valve body and engaging the bushing at the circumferential surface to prevent movement of the bushing and the hinge shaft in a longitudinal direction; and a closure element pivotally mounted on the hinge shaft for opening and closing the flow passage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:
[0010] FIG. 1 is an isometric view of a check valve in accordance with an exemplary embodiment;
[0011] FIG. 2 is a cross-sectional view of the check valve of FIG. 1 through line 2 - 2 ;
[0012] FIG. 3 is a cross-sectional view of the check valve of FIG. 1 through line 3 - 3 ;
[0013] FIG. 4 is a more detailed view of a portion of FIG. 3 ; and
[0014] FIG. 5 is a more detailed view of another portion of FIG. 3 .
DETAILED DESCRIPTION
[0015] The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.
[0016] FIG. 1 is an isometric view of a check valve 100 in accordance with an exemplary embodiment. The check valve 100 includes a valve body 102 having an annular configuration defining a central flow passage 104 . The valve body 102 can be coupled to or within a pipe or conduit (not shown) to enable fluid flow into the pipe or conduit through the flow passage 104 in direction 105 . As will be discussed in further detail below, the check valve 100 is urged open by fluid flowing in the direction 105 while preventing fluid from flowing out of the check valve 100 in an opposite direction.
[0017] The valve body 102 has an annular flange 106 that defines the flow passage 104 and that includes an upstream surface 108 and a downstream surface 110 . In one embodiment, the flow passage 104 is about 7 inches in diameter, although other sizes may be utilized depending on the specific application. The valve body 102 further includes a transverse post 112 that extends diametrically across the flow passage 104 . Generally, the transverse post 112 has an upstream surface 114 that is coplanar with the upstream surface 108 of the annular flange 106 . The valve body 102 also includes first and second flanges 116 and 118 , respectively, that extend perpendicularly to the plane of the annular flange 106 .
[0018] As best shown in FIG. 2 , which is a cross-sectional view of the check valve 100 of FIG. 1 through line 2 - 2 , two generally flat valve closure elements 120 and 122 (also referred to as “flappers” or “wafers”), each shaped generally like one-half of a circular disc, are pivotally mounted on a hinge assembly 126 . The closure elements 120 and 122 are preferably identical, having flat and smooth upstream surfaces 128 and 130 and downstream surfaces 136 and 138 . In alternate embodiments, the closure elements 120 and 122 can be replaced by a greater or fewer number of closure elements, and/or the closure elements can have different shapes other than the semicircular shape in the depicted embodiment.
[0019] As described in further detail below, the closure elements 120 and 122 resiliently biased into a closed position in which the upstream surfaces 128 and 130 of the closure elements 120 and 122 come to a fluid-tight rest against the downstream surface 110 of the annular flange 106 , thus completely shutting off flow through the check valve 100 . When the closure elements 120 and 122 are in their fully open position, as illustrated by the dashed image 170 of FIG. 2 , the closure elements 120 and 122 rest against a stop 172 mounted in between the first and second flanges 116 and 118 generally parallel and downstream to the transverse post 112 and the hinge assembly 126 .
[0020] As best shown in FIG. 3 , which is a cross-sectional view of the check valve 100 of FIG. 1 through line 3 - 3 , the hinge assembly 126 includes a hinge shaft 127 having end portions 150 and 151 mounted and secured in holes 148 and 149 formed in the first and second flanges 116 and 118 . The hinge shaft 127 is generally cylindrical and has a circumferential surface 162 , although other configurations and cross-sectional shapes, such as square or hexagonal, can be provided. Generally, both holes 148 and 149 are through holes, although one or more of the holes 148 and 149 can be blind holes. The hinge shaft 127 extends across the flow passage 104 , generally parallel to the transverse post 112 . The mechanism for retaining the hinge shaft 127 in holes 148 and 149 of the flanges 116 and 118 is discussed in further detail below.
[0021] The hinge assembly 126 may include a helical spring 140 surrounding the hinge shaft 127 . The helical spring 140 includes two ends 132 and 134 that bear against the downstream surfaces 136 and 138 (not shown in FIG. 3 ) of the closure elements 120 and 122 (not shown in FIG. 3 ), respectively, to bias them into their closed position (such as shown in FIG. 2 ). The force exerted by the helical spring 140 against the closure elements 120 and 122 is sufficient to hold them generally in the closed position, and to facilitate their automatic closure when fluid is not flowing through the valve, thereby preventing undesired reversed flow through the valve in the upstream direction. In an alternate embodiment, the helical spring 140 can be replaced by another resilient element, or omitted such that the valve is biased closed by gravity or air pressure.
[0022] FIG. 4 illustrates circled portion 142 ( FIG. 3 ) of the check valve 100 in greater detail. Particularly, FIG. 4 illustrates how the hinge shaft 127 is mounted and secured in the first flange 116 . The hinge assembly 126 further includes a bushing 190 that couples the hinge shaft 127 to the first flange 116 in hole 150 . The bushing 190 serves as a cylindrical lining for hole 150 and can be manufactured from the same or different material as the hinge shaft.
[0023] The bushing 190 is configured as a blind hole with a bottom wall 191 that prevents the hinge shaft 127 from migrating out of the bushing 190 . The bushing 190 includes a groove 152 formed in its circumferential surface. The groove 152 is configured to receive a locking pin 154 inserted through a bore 156 in the valve body 102 that is aligned with the groove 152 . The locking pin 154 is generally inserted at approximately 90° to a longitudinal axis 160 of the hinge shaft 127 and the bushing 190 , although any angle between 45° and 135°, and preferably 80° and 100°, can be provided. The locking pin 154 prevents the bushing 190 (and thus, the hinge shaft 127 ) from moving along the longitudinal axis 160 , thus preventing the hinge assembly 126 locking pin from migrating out of the hole 148 and out of the valve body 102 . The locking pin 154 is securely retained in the bore 156 by threads formed on the locking pin 154 that cooperate with thread formed within the bore, i.e., a threaded screw attachment between the locking pin 154 and the bore 156 .
[0024] FIG. 5 illustrates circled portion 143 ( FIG. 3 ) of the check valve 100 in greater detail. Portion 143 is similar to portion 142 in that a bushing 192 couples the hinge shaft 127 to the second flange 118 in hole 149 . The bushing 192 is configured as a blind hole with a bottom wall 193 that prevents the hinge shaft 127 from migrating out of the bushing 192 . The bushing 192 includes a groove 153 formed in its circumferential surface. The groove 153 is configured to receive a second locking pin 155 inserted through a bore 157 in the valve body 102 that is aligned with the groove 153 . The locking pin 155 is generally inserted at approximately 90° to a longitudinal axis 160 of the hinge shaft 127 and the bushing 191 , although any angle between 45° and 135°, and preferably 80° and 100°, can be provided. The locking pin 155 prevents the bushing 191 (and thus, the hinge shaft 127 ) from moving along the longitudinal axis 160 , thus preventing the hinge assembly 126 from migrating out of the hole 148 and out of the valve body 102 . The locking pin 155 is securely retained in the bore 157 by threads formed on the locking pin 155 that cooperate with thread formed within the bore 157 .
[0025] In an alternate embodiment, the grooves 152 and 153 on the bushings 190 and 192 replaced by a slot or hole. In another embodiment, locking pin 155 can be omitted and the hinge assembly 126 can be retained by the single locking pin 154 . Moreover, in yet another alternate embodiment, one or more of the bushings 190 and 192 can be welded to the hinge shaft 127 .
[0026] The locking pins 154 and 155 and the bushings 190 and 192 enable the hinge shaft 127 to be retained without a substantial change to the weight and/or space requirements of the check valve 100 . Moreover, the locking pins 154 and 155 and the bushings 190 and 192 retain the hinge shaft 127 in high temperature and/or vibration environments. The check valve 100 can be manufactured from any suitable metallic or non-metallic material, including plastics and ceramics. In one embodiment, the valve body 102 , the closure elements 120 and 122 , bushings 190 and 192 , and the hinge shaft 127 can be manufactured from aluminum, and the locking pins 154 and 155 can be manufactured from stainless steel. Generally, the check valve 100 is manufactured to withstand temperatures from about −40° F. to about 330° F. Although embodiments have been discussed in connection with check valves, the locking pins 154 and 155 and the bushings 190 and 192 can retain a hinge shaft 127 in other types of valves.
[0027] While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims.
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Methods and apparatus are provided for retaining a hinge shaft of a check valve with a bushing. The check valve includes a valve body defining a flow passage therethrough; a hinge shaft; a bushing coupling the hinge shaft to the valve body; a pin secured to the valve body and engaging the bushing; and a closure element pivotally mounted on the hinge shaft for opening and closing the flow passage.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application 61/040,562, filed Mar. 28, 2008, which is hereby incorporated by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
This invention was made with United States government support awarded by the following agencies: National Science Foundation Grant CHE-0449959. The United States government has certain rights in the invention.
BACKGROUND OF INVENTION
The emergence of resistant bacterial strains without the increased development of new antibiotic structure classes constitutes a serious medical crisis. Brown, E. D.; Wright, G. D. Chem. Rev. 2005, 105, 759-774; Coates, A.; Hu, Y.; Bax, R.; Page, C. Nat. Rev. Drug Discovery 2002, 1, 895-910. Infection with the common pathogen Staphylococcus aureus has been estimated to double the cost, length of stay, and the even death rate in New York City hospitals. Rubin, R. J.; Harrington, C. A.; Poon, A.; Dietrich, K.; Greene, J. A.; Moiduddin, A. Emerging Infectious Diseases 1999, 5, 9-17. Designing antibiotics that treat bacterial infections is a constant struggle for synthetic chemists and biologists because bacteria have an extraordinary ability to adapt and develop resistance to new antibacterial agents. For example, the most recent antibiotic, Linezolid, was released on the market in 2000, only to have cases of Linezolid-resistant bacteria reported the following year. This was alarming news, because Linezolid is a member of the oxazolidinone family, a structure class that had never previously been used as a scaffold for antibacterial agents. This development underscores the need for the discovery of new structural scaffolds with antibacterial activity.
Combinatorial chemistry continues to play an important role in advancing the chemical biology and drug discovery fields. Navre, M., Application of combinatorial chemistry to antimicrobial drug discovery. Expert Opin. Invest. Drugs 1998, 7, 1257-1269; Seneci, P.; Miertus, S., Combinatorial chemistry and high-throughput screening in drug discovery: Different strategies and formats. Mol. Diversity. 2000, 5, 75-89. One of the main advantages of combinatorial chemistry is the ability to generate a large, diverse library of compounds using a minimum amount of reagents in a relatively short amount of time. Because a combinatorial approach can generate a large number of compounds, this makes it ideal for probing and studying biological targets.
Solid-phase chemistry has taken on a major role in advancing combinatorial chemistry. Ganesan, A., Recent developments in combinatorial organic synthesis. Drug Discovery Today 2002, 7, 47-55; Balasubramanian, S., Solid phase chemical technologies for combinatorial chemistry. J. Cell. Biochem. 2001, 28-33; Bannwarth, W., Solid phase chemistry. Linkers for solid-phase organic synthesis (SPOS) and combinatorial approaches on solid support. Methods Princ. Med. Chem. 2000, 9, 47-98. Traditional solid phase techniques employ hydrophobic polymeric supports, such as polystyrene beads. Yu, Z. R.; Bradley, M., Solid supports for combinatorial chemistry. Curr. Opin. Chem. Biol. 2002, 6, 347-352. Although these solid supports offer advantages, including rapid and easy compound purification, there are some disadvantages. The hydrophobic nature of polystyrene beads is not compatible with many reactions that require the use of aqueous or certain polar solvents. Recently, the implementation of small molecule macroarrays in combinatorial chemistry has lead to an improved ability to perform both on- and off-support biological assays. Blackwell, H. E., Hitting the SPOT: small-molecule macroarrays advance combinatorial synthesis. Curr. Opin. Chem. Biol. 2006, 10, 203-212; Bowman, M. D.; Jacobson, M. M.; Blackwell, H. E., Discovery of fluorescent cyanopyridine and deazalumazine dyes using small molecule macroarrays. Org. Lett. 2006, 8, 1645-1648; Bowman, M. D.; Jacobson, M. M.; Pujanauski, B. G.; Blackwell, H. E., Efficient synthesis of small molecule macroarrays: optimization of the macroarray synthesis platform and examination of microwave and conventional heating methods. Tetrahedron 2006, 62, 4715-4727; Lin, Q.; Blackwell, H. E., Rapid synthesis of diketopiperazine macroarrays via Ugi four-component reactions on planar solid supports. Chem. Commun. 2006, 2884-2886.
Solid phase synthesis requires a linker to attach or “link” a synthesized substrate to an insoluble support. A variety of linkers have been used in solid phase synthesis, with two of the most widely used being the Wang and Rink linkers. James, I. W., Linkers for solid phase organic synthesis. Tetrahedron 1999, 55, 4855-4946. These two acid labile linkers are advantageous for synthesis because they can be cleaved with relatively mild acids in a short period of time.
Small molecule macroarrays can be traced back to the origins of the SPOT-synthesis technique. Frank, R., Spot-Synthesis—an Easy Technique for the Positionally Addressable, Parallel Chemical Synthesis on a Membrane Support. Tetrahedron 1992, 48, 9217-9232. Frank originally designed the SPOT-synthesis technique for the construction of peptide libraries as an alternative to standard solid phase peptide synthesis approaches (i.e. the use of polystyrene beads). Using the SPOT technique individual polypeptides can be synthesized in a spatially addressed format, and the resulting polypeptide arrays can be used in a variety of on support biological assays.
The generation of small molecule macroarrays involves the use of a planar cellulose support for library construction. This cellulose support is readily accessible laboratory filter paper, an inexpensive alternative to other solid-phase supports. A variety of organic compounds can be used as building blocks for constructing arrays of small molecules. Recently, Blackwell et al. has constructed small molecule macroarrays utilizing multi-component reactions, and microwave irradiation to construct libraries of heterocylces, chalcones, diketopiperazines, and fluorescent cyanopyridine and deazalumazine dyes. Bowman, M. D.; Jeske, R. C.; Blackwell, H. E., Microwave-accelerated SPOT-synthesis on cellulose supports. Org. Lett. 2004, 6, 2019-2022; Lin, Q.; O'Neill, J. C.; Blackwell, H. E., Small molecule macroarray construction via Ugi four-component reactions. Org. Lett. 2005, 7, 4455-4458; Bowman, M. D.; Jacobson, M. M.; Blackwell, H. E., Discovery of fluorescent cyanopyridine and deazalumazine dyes using small molecule macroarrays. Org. Lett. 2006, 8, 1645-1648; Bowman, M. D.; Jacobson, M. M.; Pujanauski, B. G.; Blackwell, H. E., Efficient synthesis of small molecule macroarrays: optimization of the macroarray synthesis platform and examination of microwave and conventional heating methods. Tetrahedron 2006, 62, 4715-4727. Small molecule macroarrays have advantages over traditional solution-phase synthesis, as several hundred compounds can be synthesized in high purity and screened for biological activity in a few days using a minimal amount of reagents, for example as illustrated in FIG. 1 .
Application of a combinatorial approach to the identification of antibacterial agents permits the generation of diverse arrays of compounds that can be screened for antibacterial activity. Several new antibacterial agents have been identified in combinatorial libraries using a variety of screening techniques, including pyrrolidine bis-cyclic guanidines, hydrazinyl urea-based compounds, benzopyrans, thymidinyl derivatives, and natural product derivatives, and certain 1,3-diphenyl-2-propen-1-ones (chalcones). Hensler, M. E.; Bernstein, G.; Nizet, V.; Nefzi, A., Pyrrolidine bis-cyclic guanidines with antimicrobial activity against drug-resistant Gram-positive pathogens identified from a mixture-based combinatorial library. Bioorg. Med. Chem. Lett. 2006, 16, 5073-5079; Nicolaou, K. C.; Roecker, A. J.; Barluenga, S.; Pfefferkorn, J. A.; Cao, G. Q., Discovery of novel antibacterial agents active against methicillin-resistant Staphylococcus aureus from combinatorial benzopyran libraries. Chembiochem 2001, 2, 460-465; Sun, D.; Lee, R. E., Solid-phase synthesis development of a thymidinyl and 2′-deoxyuridinyl Ugi library for anti-bacterial agent screening. Tetrahedron Lett. 2005, 46, 8497-8501; Shi, S.; Zhu, S.; Gerritz, S. W.; Esposito, K.; Padmanabha, R.; Li, W.; Herbst, J. J.; Wong, H.; Shu, Y. Z.; Lam, K. S.; Sofia, M. J., Solid-phase synthesis and anti-infective activity of a combinatorial library based on the natural product anisomycin. Bioorg. Med. Chem. Lett. 2005, 15, 4151-4154; Ansari, F. L.; Nazir, S.; Noureen, H.; Mirza, B., Combinatorial synthesis and antibacterial evaluation of an indexed chalcone library. Chem. Biodiv. 2005, 2, 1656-1664.
Chalcones are small molecule natural products found in a variety of plants that exhibit a wide range of biological activities. Kromann, H.; Larsen, M.; Boesen, T.; Schonning, K.; Nielsen, S. F., Synthesis of prenylated benzaldehydes and their use in the synthesis of analogues of licochalcone A. Eur. J. Med. Chem. 2004, 39, 993-1000; Jun, N.; Hong, G.; Jun, K., Synthesis and evaluation of 2′,4′,6′-trihydroxychalcones as a new class of tyrosinase inhibitors. Bioorg. Med. Chem. 2007, 15, 2396-2402; Lawrence, N. J.; Patterson, R. P.; Ooi, L.-L.; Cook, D.; Ducki, S., Effects of a-substitutions on structure and biological activity of anticancer chalcones. Bioorg. Med. Chem. Lett. 2006, 16, 5844-5848; Modzelewska, A.; Pettit, C.; Achanta, G.; Davidson, N. E.; Huang, P.; Khan, S. R., Anticancer activities of novel chalcone and bis-chalcone derivatives. Bioorg. Med. Chem. 2006, 14, 3491-3495.
Certain chalcones exhibit antimicrobial activity. Sivakumar, P. M.; Seenivasan, S. P.; Kumar, V.; Doble, M., Synthesis, antimycobacterial activity evaluation, and QSAR studies of chalcone derivatives. Bioorg. Med. Chem. Lett. 2007, 17, 1695-1700; Gafner, S.; Wolfender, J.-L.; Mavi, S.; Hostettmann, K., Antifungal and antibacterial chalcones from Myrica serratia. Planta Med. 1996, 62, 67-9. Naturally-occurring chalcones (shown below) are generally lipophilic and have moderate antibacterial activity. There have been solution-phase synthetic efforts directed at improving the antibacterial activity of naturally-occurring chalcones by increasing their water solubility. Nielsen, S. F.; Boesen, T.; Larsen, M.; Schonning, K.; Kromann, H., Antibacterial chalcones-bioisosteric replacement of the 4′-hydroxy group. Bioorg. Med. Chem. 2004, 12, 3047-3054; Nielsen, S. F.; Larsen, M.; Boesen, T.; Schonning, K.; Kromann, H., Cationic chalcone antibiotics. design, synthesis, and mechanism of action. J. Med. Chem. 2005, 48, 2667-2677.
Chalcones should thus be a useful scaffold for making and assessing small molecules for antimicrobial activity. Furthermore, chalcones are adaptable to macroarray methods due to their relatively straightforward synthesis. The key feature of combinatorial chemistry—the speed at which a large number of diverse compounds can be generated—can be applied to the rapid discovery of new lead structures for use as antibacterial agents. The generation of small molecule macroarrays can streamline the process for generating diverse small molecule libraries with potential antibacterial activities, and can be used to identify novel antimicrobial agents, including antibacterial agents.
Backwell et al. WO 2008/016738 (published Feb. 7, 2008) have reported making chalcone-based small molecule macroarrays including chalcones, and cyanopyridine and methylpyrimidine derivatives of chalcones and the screening of the compound libraries made for antibacterial activity. These macroarrays employed planar cellulose membranes derivatized with a Wang-type linker. See: Bowman, et al. Tetrahedron 2006.
Bacterial cellular membranes have been identified as a possible target of antibacterial agents. Bacterial membranes are composed mostly of negatively charged phospholipid, phosphatidylglycerol. In contrast, eukaryotic cellular membranes comprise two different phospholipids, phosphatidylcholine and sphingomyelin. Zasloff, M., Antimicrobial peptides of multicellular organisms. Nature 2002, 415, 389-395. The differences in the composition of bacterial and eukaryotic membranes represent a unique structural difference that may be exploited as an antibacterial target. This is shown in the effectiveness of certain antimicrobial peptides, which are inherently present in humans, termed host-defense peptides. Host-defense peptides are short peptides (12-50 amino acids) that are found in a variety of living organisms including humans, and there have been synthetic examples of mimicking host-defense peptides for use as a potential antibacterial therapeutic. Schmitt, M. A.; Weisblum, B.; Gellman, S. H., Unexpected relationships between structure and function in alpha-, beta-peptides: antimicrobial foldamers with heterogeneous backbones. J. Am. Chem. Soc. 2004, 126, 6848-6849; Epand, R. F.; Raguse, T. L.; Gellman, S. H.; Epand, R. M., Antimicrobial 14-Helical beta-Peptides: Potent Bilayer Disrupting Agents. Biochemistry 2004, 43, 9527-9535; Schmitt, M. A.; Weisblum, B.; Gellman, S. H., Interplay among Folding, Sequence, and Lipophilicity in the Antibacterial and Hemolytic Activities of alpha/beta-Peptides. J. Am. Chem. Soc. 2007, 129, 417-428. Most of these amphipathic peptides contain structural features that are believed to contribute to their antibacterial activity, including regions of positively charged amino acid residues (for attraction to negatively charged bacterial membranes), and regions of hydrophobic amino acid residues (for insertion and subsequent disruption of the membrane).
Peptoids, or N-substituted glycine oligomers, are possible alternatives to antimicrobial peptides because they are resistant to proteolytic degradation and diverse libraries with a variety of sidechains can be generated using commercially available amines.
The present invention relates to additional methods for synthesis of small molecule macroarrays of chalcones and derivatives thereof and screening of such arrays for useful biological activities, including therapeutic activities and particularly antimicrobial activities. The invention relates in a second aspect to methods for covalently linking amino acids, peptides and/or peptoids to the chalcones and chalcone derivatives of such macroarrays to expand the potential for new antimicrobial compounds. The invention additionally relates to novel chalcones and chalcone derivatives exhibiting antimicrobial, particularly antibacterial activity.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 illustrates a graphical representation of small molecule macroarray construction.
FIG. 2 provides a synthetic scheme showing Rink and Wang linking routes.
FIG. 3 provides a synthetic scheme showing the pathway for synthesis of library members.
FIG. 4 provides a list of materials used in the synthetic scheme of FIG. 3 for synthesis of library members.
FIG. 5 provides a synthetic scheme showing a pathway for chalcone/peptide synthesis.
FIG. 6 provides a synthetic scheme showing a pathway for peptoid/chalcone synthesis.
FIG. 7 provides a synthetic scheme showing an alternative pathway for peptide synthesis.
FIG. 8 shows an image of a TTC-stained agar-overlay assay showing active chalcones F17 and B19.
FIGS. 9A through 9O provide data showing the activity of chalcone library members.
FIGS. 10A through 10F provide data showing the activity of cyanopyridine library members.
FIGS. 11A and 11B provide data showing the activity of certain amino-pyrimidine library members.
FIGS. 12A and 12B provide data showing the activity of certain methyl-pyrimidine library members.
FIGS. 13A through 13E provide data showing dose responses for a number of library members.
FIGS. 14A through 14C provide data showing hemolytic activity of a number of library members.
FIG. 15 provides data showing membrane permeability for a number of compounds.
FIG. 16 illustrates the structures of a number of library members.
SUMMARY OF THE INVENTION
In one aspect, the invention relates to methods for generating small molecule macroarrays useful for screening of the molecules therein for antimicrobial activity. The methods employ a solid-support platform, preferably a planar cellulose support, which involves the use of a Rink amide linker (See FIG. 2 ) to attach small molecules of the library to the support. The use of this linker results in the formation of an amide group on small molecules released from the support (See FIG. 3 ). This group is polar and generally enhances the water-solubility of the small molecule which in turn can enhance the biological activity of the small molecule. The use of the Rink linker in synthesis of macroarrays and or microarrays allows additional chemical moieties to be covalently attached to the small molecules to enhance the diversity of molecules which can be synthesized and screened using the macroarray methods. In particular, the invention provides methods for making such small molecules linked to amino acids, peptides, N-substituted glycines, or peptoids (oligomers of N-substituted glycines). The attachment of such species can enhance and/or expand the biological activity of the small molecules to which they are attached and allow for targeting of the small molecules to specific sites in a cell or in an organism.
The use of the Rink linker for attachment of library compounds to the solid platform provides better mechanical properties for the on-support screening of the small molecule macroarrays.
The present invention provides versatile methods for screening compounds for antimicrobial activity, including antibacterial activity. The present methods are based on using combinatorial synthetic methods to generate arrays (e.g., macroarrays) comprising a large number of candidate molecules, identifying compounds of the array exhibiting antimicrobial activity and quantifying MICs of select compounds in the array. Structurally distinct candidate molecules are synthesized and bonded to distinct known locations (e.g., spots or regions) on a surface of a unitary substrate via linkers (i.e., linking groups attaching the candidates to the substrate). Candidate molecules are subsequently liberated from the substrate by cleaving the linkers and assayed for antibacterial activity by bringing the array into contact with a microbial culture, such as a bacterial culture or fungal culture. An advantage provided by the macroarray platform of the present screening methods is that qualitative and/or quantitative characterization of the antibacterial properties of large numbers of candidate compounds can be achieved on a relatively short time scale (i.e. days) using a single overlay visualization and/or quantification assay step.
In specific embodiments, the methods of this invention are applied to the synthesis of small molecule chalcones and derivatives thereof, particularly, cyanopyridine derivatives, alkyl pyrimidine derivatives and aminopyrimidine derivatives thereof.
In specific embodiments, the methods of this invention are applied to the synthesis of macroarrays for screening for antimicrobial activity. In more specific embodiments, the methods of this invention are applied to the synthesis of macroarrays for screening for antibacterial activity. In additional specific embodiments, the methods of this invention are used for screening macroarrays for activity against strains of the genus Staphylococcus and more particularly against strains of S. aureus and even more particularly against strains of Staphylococcus and S. aureus which exhibit methicillin-resistance (e.g., MRSA). The methods herein can be employed for the synthesis and identification of antibacterial compounds.
In another aspect, the present invention relates generally to compounds providing antibacterial therapeutic agents and preparations, and related methods of using and making antibacterial compounds. Antibacterial compounds of the present invention include chalcone, and alkylpyrimidine, aminopyrimidine and cyanopyridine derivatives of chalcones exhibiting antibacterial activity. In particular, certain antibacterial compounds of the invention exhibit minimum inhibitory concentrations (MIC) against a given bacterium similar to or less than conventional antibacterial compounds in wide use.
In an aspect, the present invention provides a composition of matter comprising a chalcone or chalcone derivative having Formula I:
and salts, esters and solvates thereof,
where:
M is
where R 11 is a an optionally substituted C1-C6 alkyl or NRR′, R 12 is an optionally substituted C1-C6 alkyl and R and R′ are independently selected from the group consisting of hydrogen, an optionally substituted C1-C6 alkyl, particularly a C1-C6 alkyl substituted with a C6-C13 aryl group, or an optionally substituted C3-C8 cycloalkyl, an optionally substituted C3 to C10 heterocycloalkyl or an optionally substituted C3 to C10 heterocycloalkene, each of which heterocycles contain 1, 2 or 3 heteroatoms (e.g., O, N or S), or an optionally substituted C6-C13 aryl group which includes an C1-C6 alkyl-substituted aryl group,
at least one of R 1 -R 5 is a —O—(CH 2 ) n —CO—NH 2 group, where n is an integer ranging from 1-6 (inclusive) and the remaining R 1 -R 5 are selected from hydrogen, halogen, hydroxyl, an amino group (—NH 2 , —NRR′), a —CN group, an azide group, a —NO 2 group, an optionally substituted C1-C12 alkyl, alkenyl or alkynyl group, an optionally substituted C6-C13 aryl group, an optionally substituted heterocycloalkyl C3-C8 (where the heteroatom(s) are N, O or S) and optionally substituted C1-C12 alkoxy or C6-C13 aryloxy groups;
at least one of R 6 -R 10 is a non-hydrogen substituent, where R 6 -R 10 are independently selected from the group consisting of hydrogen, halogen, hydroxyl, an amine group, a —CN group, an azide group, a —NO 2 group, an optionally substituted C1-C12 alkyl, C2-C12 alkenyl or C2-C12 alkynyl group, an optionally substituted C6-C13 aryl group, an optionally substituted C1-C12 alkoxy or C6-C13 aryloxy group, or a —O—(CH 2 ) m —CO—NH 2 group, where m is an integer ranging from 1-6 (inclusive).
In the above definitions, R and R′ are selected from hydrogen, C1-C6 alkyl (preferably C1-C3 alkyl), C3-C8 cycloalkyl, including cyclohexyl, C4-C8 heterocycloalkyl (heteroatom=N, O or S), and C6-C13 aryl.
Optional substitution, includes substitution with one or more halogens, —OH, —OR, —SH, —SR, —COOH, —COO − , —NRR′, —NRR′R″, —CONRR′, —NR—C(NRR′)═NR, —NR—C(NRR′)═NRR′ + , or C1-C3-alkyl groups, which in turn are optionally substituted with one or more halogens, —OH, —SH, —COOH, —COO − , C1-C3 alkoxy, —NRR′, —NRR′R″, —CONRR′, —NR—C(NRR′)═NR, or —NR—C(NRR′)═NRR′, where R, R′ and R″ are in particular hydrogen, or C1-C3 alkyl groups or C6-C13 aryl groups, which in turn can be substituted with one or more halogens, —OH, —SH, —COOH, —COO − , or C1-C3 alkoxy.
In another aspect, the invention provides, chalcones, alkyl-substituted cyanopyridines and alkyl-substituted alkyl or animopyrimidines of Formula X:
and salts, esters and solvates thereof
where:
M is
R 11 is a C1-C6 alkyl or NRR′ and R 12 is C 1 -C 6 alkyl and R and R′ are independently selected from the group consisting of hydrogen, C1-C6 alkyl which can be substituted with one or more of halogen, C6-C13 aryl group, a C3-C8 cycloalkyl, a C3 to C10 heterocycloalkyl, (where the heteroatom(s) are N, O or S) which contains 1 or 2 heteroatoms (e.g., O, N or S), or a C6-C13 aryl group which includes an C1-C6 alkyl-substituted aryl group;
at least one of R 1 -R 5 is selected from
where:
each p, independently, is an integer from 1 to 6, inclusive, and r and s, independently are integers ranging from 1 to 100, inclusive, and more preferably r and s range from 2-10, 6-20, or 10-50 inclusive, R aa is selected from hydrogen, C1-C8 alkyl, C1-C8 alkenyl, C1-C8 alkynyl, C6-C13 aryl, C6-C13 aralkyl, C1-C8 ether, C1-C8 thioether, C3-C8 cycloalkyl or cycloalkenyl, C3-C10 heterocylic which contains 1, 2 or 3 heteroatoms (e.g., N, O or S), or a C3-C13 heteroaromatic group having 1, 2 or 3 heteroatoms (N, O or S) all of which groups are optionally substituted, particularly with one or more halogens, OH, OR, SH, SR, C1-C3-alkyl, —COOH, —COO − , —NRR′, —NRR′R″, —CONRR′, —NR—C(NRR′)═NR, and —NR—C(NRR′)═NRR′ + , where R, R′ and R″ are in particular hydrogen, and C1-C3 alkyl groups; and R b is hydrogen, C1-C3 alkyl or R aa and R b together form an optionally substituted C3-C8 cycloalkyl or cycloalkenyl which optionally contains one or two heteroatoms (e.g., N, O or S), or R b is
R p is selected from hydrogen, C1-C8 alkyl, C1-C8 alkenyl, C1-C8 alkynyl, C6-C13 aryl, C1-C8 ether, C1-C8 thioether, C3-C8 cycloalkyl or cycloalkenyl group, which optionally contains one or two heteroatoms (e.g., N, O or S), and a C3-C13 heteroaromatic group having 1, 2 or 3 heteroatoms (N, O or S), all of which are optionally substituted, particularly with one or more halogens, OH, OR, SH, SR, C1-C3-alkyl, —COOH, —COO − , —NRR′, —NRR′R″, —CONRR′, —NR—C(NRR′)═NR, and —NR—C(NRR′)═NRR′ + , where R, R′ and R″ are in particular hydrogen, and optionally substituted C1-C3 alkyl groups; and one of R 13 or R 14 together with R aa form an optionally substituted C3-C8 cycloalkyl or cycloalkenyl group which optionally contains one or two heteroatoms (e.g., N, O or S);
each R 13 and R 14 are independently selected from hydrogen, C1-C6 alkyl which may be substituted with one or more halogens and benzyl or phenyl optionally substituted with one or more halogens, hydroxyl or C1-C3 alkyl groups;
remaining R 1 -R 10 are independently selected from the group consisting of hydrogen, hydroxy, halogen, nitro, alkyl, alkenyl, alkynyl, cycloalkyl, alkoxy, aryl, aralkyl, aryloxy, arylthio, heteroaryl, heteroarylalkyl, heterocyclic, amino, aminoalkyl, aminoarylalkyl, hydroxyaminoalkyl, cycloalkylaminoalkyl, heteroarylaminoalkyl, heterocyclicaminoalkyl, hydroxyl, hydroxyalkyl, alditol, carbohydrate, polyol alkyl, —(O(CH 2 ) 2 ( 1-3 )O—C1-C3 alkyl, polyoxyalkylene, cycloalkyloxy, cycloalkylalkoxy, haloalkoxy, arylalkoxy, heteroarylalkoxy, heterocyclicoxy, heterocyclicalkoxy, —O(C(R) 2 ) 1-6 C(O)OR, —O(C(R) 2 ) 1-6 C(O)NRR′, amino, alkylamino, acylamino, dialkylamino, cycloalkylamino, arylamino, aralkylamino, heteroarylamino, heteroaralkylamino, heterocyclicamino, heterocyclicalkylamino, —NRR′, —NH(C(R) 2 ) 1-6 C(O)OR′, —NRC(O)R′, —NRC(O)OR′, —NRC(O)SR′, —NRSO 2 NRR′, —NHSO 2 R′, —NRSO2NRR′, —N(C(O)NRR′) 2 , —NRSO 2 R, —NRC(O)NRR′, thiol, alkylthio, haloalkylthio, arylthio, aralkylthio, heteroarylthio, heteroaralkylthio, heterocyclicthio, heterocyclicalkylthio, alkylsulfonyl, arylsulfonyl, haloalkylsulfonyl, —S(CRR′) 1-6 COOR, —S(CF 2 ) 1-6 COOR, —SO 2 NRR′, —SO 2 NROR, —SO 2 NR(O)NRR′, sulfonic acid, sulfonate, sulfate, sulfinic acid, sulfenic acid, cyano, tetrazol-5-yl, carboxy, —C(O)OR, —CONRR′, —C(O)NR(O)R, —CONRSO 2 R, —CONRSO 2 NRR′, —(CRR′) 1-6 (O)OH, —PO 2 H 2 , —PO 3 H 2 , —P(R)O 2 H, and phosphate, all of which can be optionally substituted by one or more selected from the group consisting of halo, alkyl, lower alkyl, alkenyl, cycloalkyl, acyl, hydroxy, hydroxyalkyl, heterocyclic, amino, aminoalkyl, alkoxy, oxo, cyano, carboxy, carboxyalkyl, alkoxycarbonyl, and groups formed by replacing one (preferably) or more non-adjacent CH 2 groups of an alkyl group with an —O-(ether)-S-(thioether), —NR—, —CO—, —SO—, SO 2 —, —NR—CO—, —NR—CO—NR—, —NR—CO—O—, —CO—O—, —CO—S—, —CO—, -aryl-, -aryl-O—, -aryl-S—, -heteroaryl-, or a -heterocyclic-moiety; and
optionally two R 1 -R 5 on adjacent ring carbons and/or two R 6 -R 10 on adjacent ring carbons taken together form a 3-8 member cycloalkyl, a 3-8 member heterocyclic group having 1-3 heteroatoms (e.g., N, O and/or S), a C6-C12 aryl, a 3-8 member heteroaryl group (having 1-3 heteroatoms (e.g., N, O and/or S) optionally substituted by one or more C1-C3 alky, acyl, alkoxycarbonylalkyl, carboxyalkyl, hydroxyalkyl, aminoalkyl, aminohydroxylalkyl, hydroxy, alkyl, carboxy, hydroxyalkyl, carboxyalkyl, amino, cyano, alkoxy, alkoxycarbonyl, acyl, oxo, —NRR′, cyano, carboxy, and halo.
In specific embodiments, R aa , R 13 or R 14 , independently of each other, are selected from one or more of hydrogen, methyl, isopropyl, isobutyl, sec-butyl, methylthioethyl, phenylmethyl, 4-OH-phenylmethyl, mercaptomethyl, hydroxylmethyl, 2-hydroxy-ethyl, 4-aminobutyl, carbamoylmethyl, 2-carbamoylethyl, carboxymethyl, 2-carboxyethyl, 1H-imidazol-4-yl-methyl, 3-guanidopropyl, or -(1H-indol-3-yl)methyl groups.
The present invention provides compounds exhibiting useful in vitro antibacterial activities against a variety of bacteria strains, including drug resistant bacterial strains, thereby providing antibacterial therapeutic agents and preparations useful for a range of important clinical applications.
In another aspect, the present invention provides combinatorial libraries of compounds, including candidate compounds for screening microbial activity including antibacterial activity. In an embodiment of this aspect of the present invention, the present invention provides one or more combinatorial libraries of chalcone compounds and/or derivative thereof having any one of the formulas herein.
In another aspect, the present invention provides pharmaceutical and therapeutic preparations comprising a therapeutically effective amount of one or more compounds of the present invention of Formula I and X above optionally in combination with a pharmaceutically acceptable carrier. In particular, pharmaceutical and therapeutic preparations of this invention comprise an amount or combined amount of one or more compounds of this invention effective for inhibiting the growth of a selected bacterium, particularly a bacterial pathogen and more particularly a bacterial human or veterinary pathogen. Compounds useful in the methods of this invention include pharmaceutically-acceptable salts and esters of the compounds of formulas herein. Compounds useful in the methods of this invention include pharmaceutically-acceptable prodrugs of the compounds of formulas herein.
Salts include any salts derived from the acids of the formulas herein which are acceptable for use in human or veterinary applications. The term esters refer to hydrolyzable esters of chalcone compounds, or chalcone derivatives of the present invention. The term ester includes, among others, esters of the compounds of the formulas herein (e.g., Formulas I and X), in which hydroxy groups have been converted to the corresponding esters with inorganic or organic acids such as nitric acid, sulphuric acid, phosphoric acid, citric acid, formic acid, maleic acid, acetic acid, succinic acid, tartaric acid, methanesulphonic acid, p-toluenesulphonic acid and the like, which are non toxic to living organisms. Salts and esters of this invention are prepared by methods that are well known in the art. Salts and esters of the compounds of the formulas herein are those which have the same or similar pharmaceutical or therapeutic (human or veterinary) properties as the chalcone compounds and/or chalcone derivatives of the present invention. Therapeutic and pharmaceutical preparations of the present invention comprise one or more of the compounds of the present invention in an amount or in a combined amount effective for obtaining the desired therapeutic benefit. Therapeutic and pharmaceutical preparations of the invention optionally further comprise a pharmaceutically acceptable carrier as known in the art.
In another aspect, the present invention provides a method of treating an infectious disease comprising administering to a patient in need of treatment, a composition comprising a compound of the present invention. In an embodiment, the infectious disease relates to that associated with an infectious agent comprising a bacterium. In an embodiment, the bacteria are Gram-positive bacteria. In a specific embodiment, the bacteria include one or more of Bacillus, Listeria, Staphylococcus, Streptococcus, Enterococcus, Corynebacterium, Propionibacterium and Clostridium . In a specific embodiment, the bacteria are one or more selected from the group consisting of S. aureus, S. epidermidis and B. subtilis . In a specific embodiment, the bacteria are one or more drug resistant bacteria.
In another aspect, the present invention provides methods of inhibiting growth of bacteria. In a specific embodiment of this aspect, a method of the present invention comprises the step of contacting the bacteria with an effective amount of one or more chalcone or chalcone derivative compounds of this invention which exhibit antibacterial activity. In an embodiment, the bacteria are Gram-positive bacteria. In a specific embodiment, the bacteria include one or more of Bacillus, Listeria, Staphylococcus, Streptococcus, Enterococcus, Corynebacterium, Propionibacterium and Clostridium . In a specific embodiment, the bacteria are one or more selected from the group consisting of S. aureus, S. epidermidis and B. subtilis . In a specific embodiment, the bacteria are one or more drug resistant bacteria. Methods of inhibiting bacteria of the present invention include methods useful for treatment of a subject (human or veterinary) and also include methods useful for inhibiting bacteria outside of a subject, such as use for sterilization and disinfection.
In another embodiment, the invention provides a medicament for treatment of a an infectious disease, particularly one associated with or caused by a bacterium. The medicament comprises a therapeutically effective amount of one or more compounds of this invention as illustrated in one or more formulas herein which compounds exhibit antimicrobial and/or antibacterial activity. The invention also provides a method for making this medicament which comprises combining a therapeutically effective amount of one or more compounds of this invention having antimicrobial and/or antibacterial activity with a selected pharmaceutical carrier appropriate for a given method of administration. The medicament may be an oral dosage form, an intravenous dosage form or any other art-recognized dosage form.
In another aspect, the present invention provides methods of synthesizing the compounds of the present invention, including methods of synthesizing chalcones, cyanopyridine derivatives of chalcones, alkylpyrimidine derivatives of chalcones, and aminopyrimidine derivatives of chalcones. In an embodiment, for example, the present invention includes methods of synthesizing compounds employing a Rink linker as illustrated in FIG. 3 herein.
In another aspect, the present invention provides methods of screening compounds, classes of compounds and combinatorial libraries of compounds for antimicrobial activity, including antibacterial activity. In an embodiment of this aspect, a method for screening a plurality of candidate compounds for antimicrobial activity of the present invention comprises the steps of: (i) providing a spatially-addressed array of the candidate compounds supported by a first unitary substrate, wherein the candidate compounds are individually addressed to selected positions of the substrate via linkers; (ii) contacting a microbial culture with the array or with a portion of the array transferred to a second unitary substrate in a manner retaining the relative positions of candidate compounds in the array, whereby candidate compounds having antimicrobial activity exhibit a zone of inhibition in the microbial culture; and (iii) identifying one or more positions in the array or transferred portion of the array corresponding to one or more candidate compounds exhibiting zones of inhibition. In the methods herein, the candidate compounds of the spatially addressed array are linked to that array employing a Rink linker as illustrated in FIG. 3 herein. Optionally, methods of this aspect of the present invention further comprise the step of transferring the portion of the array to a second unitary substrate in a manner retaining the relative positions of candidate compounds in the array. In some embodiments, this transfer step is carried out multiple times so as to generate a plurality of array samples for screening. In a specific embodiment, the invention provides a method of screening the plurality of candidate compounds for antibacterial activity wherein the microbial culture is a bacterial culture. Alternatively, the invention provides a method of screening the plurality of candidate compounds for antifungal activity wherein the microbial culture is a fungal culture. Useful arrays in the present methods include macroarrays and microarrays of candidate compounds.
The present invention includes methods using overlay assaying techniques wherein a microbial culture is provided in contact with the entire array or a portion thereof to provide effective, nearly simultaneous readout of the activities of a large number of candidate compounds. Overlay assaying techniques useful in these methods include, but are not limited to, techniques wherein an agar medium inoculated with bacteria is provided in contact with the array to provide screening of the antibacterial activities of candidate compounds of the array.
In some embodiments, the methods of the present invention further comprise the step of cleaving the linkers prior to the step of contacting the bacterial culture with the array or transferred portion of the array. This additional step facilitates achieving effective and biologically significant contact between compounds of the array and the microbial culture. Preferably, the step of cleaving the linkers connecting compounds of the array and the substrate is carried out in a way that does not substantially disrupt the position of individual compounds of the array on the substrate. In some embodiments, the screening methods further comprises the step of transferring the portion of the array to a second unitary substrate in a manner retaining the relative positions of candidate compounds in the array. Exemplary means of transferring a portion of the array in these embodiments include, but are not limited to, overlay transfer methods, such as positioning cleaved arrays between a solvent saturated surface and one or more dry cellulose sheets. An advantage of this embodiment of the present invention is that a single array may be used to generate a plurality of “copies” (i.e., transferred portions of the array which retain the spatially address nature of the compounds in the array) that can be screened to provide replicated assays.
Screening methods of the present invention may further comprise a number of optional steps. In an embodiment, for example, the method further comprises incubating the microbial culture, such as a bacteria culture, in contact with the array or transferred portion of the array. In an embodiment, for example, the method further comprises the step of measuring a zone of inhibition parameter exhibited by one or more candidate compounds of the array. Useful zone of inhibition parameters for the present methods include, but are not limited to, a diameter of inhibition, a radius of inhibition, and an area of inhibition. In an embodiment, for example, the method further comprises the step of contacting the bacterial culture with a visualization agent, whereby the visualization agent is capable of differentiating between zones of inhibition and zones of no activity. Useful visualization agents include, but are not limited to, redox indicators such as triphenyl tetrazolium chloride capable of providing clear and reproducible visualization of areas of live and dead bacteria for the measuring one or more zone of inhibition parameters.
Preferably for many applications, candidate compounds are linked to the substrate in a manner such that they can be non-destructively cleaved from the first unitary substrate. The choice of linker and mechanism of cleavage from the substrate may affect the composition of candidate compounds released from the substrate via cleavage reactions. When the Rink linker is used, for example, cleavage of linkers results in candidate compounds having an —CO—NH 2 group introduced through the linking chemistry.
Substrates useful in the present methods include planar (2D) substrates and three-dimensional substrates. Three-dimensional substrates include beaded materials, such as beaded cellulose, and other useful materials such as tissue engineering scaffolds. A range of substrate compositions are useful in the present invention including, but not limited to, cellulose substrate, nylon substrate, polypropylene substrate, polycarbonate substrate, glass substrate, gold substrate, silicone substrate or amorphous carbon substrate. In some embodiments, the unitary substrate supporting the arrays of this invention is a planar substrate.
In some methods candidate compounds are synthesized in an array bound to a surface. The candidate compounds are typically linked to the surface by a linker group, preferably for many screening applications a cleavable linker group. In the methods described herein a Rink Linker is employed. The methods of this invention are particularly useful when practiced with macroarrays. However, the methods can be practiced employing microarrays.
DETAILED DESCRIPTION OF THE INVENTION
All technical and scientific terms used herein have the broadest meanings as commonly understood by one of ordinary skill in the art to which this invention pertains.
The present invention relates in part to libraries of compounds prepared in array form for testing for biological activity. The array format of the methods herein is particularly suited to assessing activity of library compounds for antimicrobial activity, including anti-fungal, anti-yeast, anti-protozoan, and antibacterial activity. Compounds of libraries herein exhibit antimicrobial activity including antibacterial activity.
For example, the present invention provides in one aspect a composition of matter comprising a chalcone or chalcone derivative having Formula I:
and salts, esters and solvates thereof,
where:
M is
where R 11 is a C1-C6 alkyl or NRR′ and R 12 is C 1 -C 6 alkyl and R and R′ are independently selected from the group consisting of hydrogen, C1-C6 alkyl which can be substituted with a C6-C13 aryl group, a C1-C8 cycloalkyl, a heterocycloalkyl C3-C8 (where the heteroatom(s) are N, O or S) which optionally contains 1 or 2 heteroatoms (e.g., O, N or S), or a C6-C13 aryl group which includes an C1-C6 alkyl-substituted aryl group,
one of R 1 -R 5 is a —O—(CH 2 ) n —CO—NH 2 group, where n is 1-6 and the remaining R 1 -R 5 are selected from hydrogen, halogen, hydroxyl, an amino group (—NH 2 , —NRR′), a —CN group, an azide group, a —NO 2 group, an optionally substituted C1-C12 alkyl, alkenyl or alkynyl group, an optionally substituted C6-C13 aryl group, an optionally substituted heterocycloalkyl C3-C8 (where the heteroatom(s) are N, O or S) and optionally substituted C1-C12 alkoxy or C6-C13 aryloxy groups;
wherein at least one of R 6 -R 10 is a non-hydrogen substituent and where R 6 -R 10 are independently selected from the group consisting of hydrogen, halogen, hydroxyl, an amine group, a —CN group, an azide group, a —NO 2 group, an optionally substituted C1-C12 alkyl, alkenyl or alkynyl group, an optionally substituted C6-C13 aryl group, an optionally substituted C1-C12 alkoxy or C6-C13 aryloxy group, and a —O—(CH 2 ) m —CO—NH 2 group, where m is 1-6.
More specifically the invention provides a chalcone compound of Formula II:
and salts, esters and solvates thereof
wherein one of R 1 -R 5 is a —O—(CH 2 ) n —CO—NH 2 group where n is 1-6 and the remaining R 1 -R 5 are selected from hydrogen, halogen, hydroxyl, an amine group (—NH 2 , —NRR′), a —CN group, an azide group, a —NO 2 group, optionally substituted C1-C12 alkyl, alkenyl or alkynyl groups, optionally substituted C6-C13 aryl groups, optionally substituted heterocycloalkyl C3-C8 (where the heteroatom(s) are N, O or S) and optionally substituted C1-C12 alkoxy or C6-C13 aryloxy groups, wherein at least one of R 6 -R 10 is a non-hydrogen substituent and where R 6 to R 10 are selected from the group consisting of from hydrogen, halogen, hydroxyl, an amine group, a —CN group, an azide group, a —NO 2 group, optionally substituted C1-C12 alkyl, alkenyl or alkynyl groups, optionally substituted C6-C13 aryl groups, optionally substituted C1-C12 alkoxy or C6-C13 aryloxy groups, and a —O—(CH 2 ) m —CO—NH 2 group, where m is 1-6.
Additionally the invention provides compounds of Formulas III and IV:
where variables are as defined above, and where R 11 is more preferably an optionally substituted C1-C3 alkyl or an —NH 2 group and R 12 is more preferably a C1-C3 alkyl or hydrogen.
In specific embodiments of the compounds of Formulas I-IV, X and XI (below), one, two or three of R 6 -R 10 are halogens, including one, two or three bromines, one, two or three chlorines or one, two or three fluorines. In a specific embodiment the remaining R 6 -R 10 are hydrogens.
In specific embodiments of the compounds of Formulas I-IV, X and XI, one, two or three of R 6 -R 10 are C1-C6 haloalkyl groups, including one, two or three C1-C6 perfluoralkyl groups, one, two or three C1-C3 perfluoralkyl groups or one, two or three trifluoromethyl groups and the remaining R 6 -R 10 are hydrogens.
In specific embodiments of the compounds of Formulas I-IV, X and XI, R 6 , R 7 and R 9 or R 10 are halogens or haloalkyl groups, particularly bromines, chlorines or fluorines and particularly trifluoromethyl groups. In a specific embodiment the remaining R 8 and R 9 or R 10 are hydrogens.
In specific embodiments of the compounds of Formulas I-IV, X and XI, R 6 , R 7 and R 9 or R 10 are halogens, particularly bromines, chlorines or fluorines. In a specific embodiment the remaining R 8 and R 9 or R 10 are hydrogens.
In specific embodiments of the compounds of Formulas I-IV, X and XI, R 6 , R 7 and R 9 or R 10 are C1-C6 fluoroalkyl groups, more specifically perfluoroalkyl group, and even more specifically trifluoromethyl groups. In a specific embodiment the remaining R 8 and R 9 or R 10 are hydrogens.
In specific embodiments of the compounds of Formulas I-IV, X and XI, R 11 and R 12 are C1-C3 alkyl or hydrogen.
In specific embodiments of the compounds of Formulas I-IV, X and XI, R 6 or R 7 or R 8 is a halogen or a C1-C3 perfluoralkyl group. In a specific embodiment the remaining R 6 -R 10 groups are hydrogens.
In specific embodiments of the compounds of Formulas I-IV, X and XI, one of R 1 -R 5 is an OH, C1-C3 alkoxy, a phenoxy, a benzyloxy, —COC1-C3 alkyl, C1-C6 haloalkyl, or halo. In another specific embodiment of the compounds of Formulas I-IV, X and XI, one of R 1 -R 5 is an OH, methoxy, trifluoromethyl, bromo, fluoro or chloro group.
In specific embodiments of the compounds of Formulas I-IV, one of R 1 , R 2 or R 3 is —O—(CH 2 ) n —CO—NH 2 , where n is 1-6. In other embodiments, R 1 is —O—(CH 2 ) n —CO—NH 2 , where n is 1-6. In other embodiments, R 2 is —O—(CH 2 ) n —CO—NH 2 , where n is 1-6. In other embodiments one of R 1 , R 2 or R 3 is —O—CH 2 CO—NH 2 . In other embodiments, R 1 is —O—CH 2 —CO—NH 2 . In other embodiments, R 2 is —O—CH 2 —CO—NH 2 . In other embodiments, all other R 1 -R 5 are hydrogens.
In specific embodiments of the compounds of Formulas I-IV, R 1 is —O—(CH 2 ) n —CO—NH 2 , where n is 1-6 and R 4 is a halogen. In specific embodiments, all of R 2 , R 3 and R 5 are hydrogens.
In specific embodiments of the compounds of Formulas I-IV, R 1 is —O—(CH 2 ) n —CO—NH 2 , where n is 1-6 and all of R 2 , R 3 , R 4 and R 5 are hydrogens.
In specific embodiments of the compounds of Formulas I-IV, R 3 is —O—(CH 2 ) n —CO—NH 2 , where n is 1-6 and R 4 is a C1-C3 alkyl or perfluoralkyl. In specific embodiments, all of R 1 , R 2 and R 5 are hydrogens.
In specific embodiments of the compounds of Formulas I-IV and X, none of R 1 -R 10 is an OH group. In specific embodiments of the compounds of Formulas I-IV and X, none of R 1 -R 5 is an OH group. In specific embodiments of the compounds of Formulas I-IV and X, none of R 6 -R 10 is an OH group.
The invention provides antimicrobial, particularly antibacterial, compounds including F17, F19, F11, F12, F13, F6, B17, B19, or B14 (see FIGS. 3 , 4 and 16 for naming convention).
The invention provides antimicrobial, particularly antibacterial, compounds including F5, F7, F9, F18. F26 and D27.
The invention provides antimicrobial, particularly antibacterial, compounds including F8. F10, F22, F25, E6 and B27.
In another aspect the invention provides compounds of Formula X:
and salts, esters and solvates thereof
where:
M is
R 11 is a C1-C6 alkyl or NRR′ and R 12 is C 1 -C 6 alkyl and R and R′ are independently selected from the group consisting of hydrogen, C1-C6 alkyl which can be substituted with one or more of halogen, C6-C13 aryl group, a C3-C8 cycloalkyl, a C3 to C10 heterocycloalkyl, (where the heteroatom(s) are N, O or S) which contains 1 or 2 heteroatoms (e.g., O, N or S), or a C6-C13 aryl group which includes an C1-C6 alkyl-substituted aryl group;
at least one of R 1 -R 5 is selected from
wherein p is an integer 1-6;
(including NH 2 -peptide-CO—(CH 2 )p-O—), where p is an integer from 1 to 6, r is an integer ranging from 1 to 100 and more preferably from 10 to 50,
R aa is selected from hydrogen, C1-C8 alkyl, C1-C8 alkenyl, C1-C8 alkynyl, C6-C13 aryl, C6-C13 aralkyl, C1-C8 ether, C1-C8 thioether, C3-C8 cycloalkyl or cycloalkenyl which optionally contains one or two heteroatoms (e.g., N, O or S), and a C3-C13 heteroaromatic group having 1, 2 or 3 heteroatoms (N, O or S) all of which are optionally substituted, particularly with one or more halogens, OH, OR, SH, SR, C1-C3-alkyl, —COOH, —COO − , —NRR′, —NRR′R″, —CONRR′, —NR—C(NRR′)═NR, and —NR—C(NRR′)═NRR′ + , where R, R′ and R″ are in particular hydrogen, and C1-C3 alkyl groups; R b is hydrogen, C1-C3 alkyl or R aa and R b together form an optionally substituted C3-C8 cycloalkyl or cycloalkenyl which optionally contains one or two heteroatoms (e.g., N, O or S),
where p is 1-6, s is an integer ranging from 1 to 100 and more preferably from 10 to 50;
R p is selected from hydrogen, C1-C8 alkyl, C1-C8 alkenyl, C1-C8 alkynyl, C6-C13 aryl, C1-C8 ether, C1-C8 thioether, C3-C8 cycloalkyl or cycloalkenyl group which optionally contains one or two heteroatoms (e.g., N, O or S), and a C3-C13 heteroaromatic group having 1, 2 or 3 heteroatoms (N, O or S), all of which are optionally substituted, particularly with one or more halogens, OH, OR, SH, SR, C1-C3 alkyl, —COOH, —COO − , —NRR′, —NRR′R″, —CONRR′, —NR—C(NRR′)═NR, and —NR—C(NRR′)═NRR′ + , where R, R′ and R″ are in particular hydrogen, and C1-C3 alkyl groups; and one of R 13 or R 14 together with R aa form an optionally substituted C3-C8 cycloalkyl or cycloalkenyl group which optionally contains one or two heteroatoms (e.g., N, O or S); R 13 and R 14 are independently selected from hydrogen, C1-C6 alkyl which may be substituted with one or more halogens and benzyl or phenyl optionally substituted with one or more halogens, hydroxyl or C1-C3 alkyl groups; R 1 -R 10 are independently selected from the group consisting of hydrogen, hydroxy, halogen, nitro, alkyl, alkenyl, alkynyl, cycloalkyl, alkoxy, aryl, aralkyl, aryloxy, arylthio, heteroaryl, heteroarylalkyl, heterocyclic, amino, aminoalkyl, aminoarylalkyl, hydroxyaminoalkyl, cycloalkylaminoalkyl, heteroarylaminoalkyl, heterocyclicaminoalkyl, hydroxyl, hydroxyalkyl, alditol, carbohydrate, polyol alkyl, —(O(CH 2 ) 2 ( 1-3 )O—C1-C3 alkyl, polyoxyalkylene, cycloalkyloxy, cycloalkylalkoxy, haloalkoxy, arylalkoxy, heteroarylalkoxy, heterocyclicoxy, heterocyclicalkoxy, —O(C(R) 2 ) 1-6 C(O)OR, —(C(R) 2 ) 1-6 C(O)NRR′, amino, alkylamino, acylamino, dialkylamino, cycloalkylamino, arylamino, aralkylamino, heteroarylamino, heteroaralkylamino, heterocyclicamino, heterocyclicalkylamino, —NRR′, —NH(C(R) 2 ) 1-6 C(O)OR′, —NRC(O)R′, —NRC(O)OR′, —NRC(O)SR, —NRSO 2 NRR′, —NHSO 2 R′, —NRSO2NRR′, —N(C(O)NRR′) 2 , —NRSO 2 R, —NRC(O)NRR′, thiol, alkylthio, haloalkylthio, arylthio, aralkylthio, heteroarylthio, heteroaralkylthio, heterocyclicthio, heterocyclicalkylthio, alkylsulfonyl, arylsulfonyl, haloalkylsulfonyl, —S(CRR′) 1-6 COOR, —S(CF 2 ) 1-6 COOR, —SO 2 NRR′, —SO 2 NROR, —SO 2 NR(O)NRR′, sulfonic acid, sulfonate, sulfate, sulfinic acid, sulfenic acid, cyano, tetrazol-5-yl, carboxy, —C(O)OR, —CONRR′, —C(O)NR(O)R, —CONRSO 2 R, —ONRSO 2 NRR′, —(CRR′) 1-6 (O)OH, —PO 2 H 2 , —PO 3 H 2 , —P(R)O 2 H, and phosphate, all of which can be optionally substituted by one or more selected from the group consisting of halo, alkyl, lower alkyl, alkenyl, cycloalkyl, acyl, hydroxy, hydroxyalkyl, heterocyclic, amino, aminoalkyl, alkoxy, oxo, cyano, carboxy, carboxyalkyl, alkoxycarbonyl, and groups formed by replacing one (preferably) or more non-adjacent CH 2 groups of an alkyl group with an —O-(ether)-S-(thioether), —NR—, —CO—, —SO—, SO 2 —, —NR—CO—, —NR—CO—R—, —NR—CO—O—, —CO—O—, —CO—S—, —CO—, -aryl-, -aryl-O—, -aryl-S—, -heteroaryl-, or a -heterocyclic-moiety; two R 1 -R 5 on adjacent ring carbons and/or two R 6 -R 10 on adjacent ring carbons taken together form a 3-8 member cycloalkyl, a 3-8 member heterocyclic group having 1-3 heteroatoms (e.g., N, O and/or S), a C6-C12 aryl, a 3-8 member heteroaryl group (having 1-3 heteroatoms (e.g., N, O and/or S) optionally substituted by one or more C1-C3 alky, acyl, alkoxycarbonylalkyl, carboxyalkyl, hydroxyalkyl, aminoalkyl, aminohydroxylalkyl, hydroxy, alkyl, carboxy, hydroxyalkyl, carboxyalkyl, amino, cyano, alkoxy, alkoxycarbonyl, acyl, oxo, —NRR′, cyano, carboxy, and halo.
The invention provides compounds of Formula XI:
where R 1 -R 10 are as defined for Formula X.
In a specific embodiment of Formulas X and XI, R 1 -R 10 groups other than those which comprise amino acid, peptide, N-substituted glycines or peptoids, are selected from halogens, hydroxyl, C1-C3 alkyl, C1-C6 haloalkyl, —COC1-C3 alkyl, phenoxy, and phenyl.
In specific embodiments of Formulas X and XI, R 1 , R 2 , R 3 or R 6 is selected from:
wherein p 1, 2 or 3;
(including NH 2 -peptide-CO—(CH 2 )p-O—), where p is 1, 2 or 3, and r is an integer ranging from 1 to 100 and more preferably from 10 to 50, and each R b is hydrogen or linked to R aa and each R aa alone or in combination with R b are amino acids side groups of amino acids found in proteins and in particular the 20 common amino acids (Ala, Arg, Asn, Asp, Cys, Gln, Glu, Gly, His, Ile, Leu, Lys, Met, Phe, Ser, Thr, Trp, Tyr, and Val);
where p is 1, 2 or 3; s is an integer ranging from 1 to 100 and more preferably from 10 to 50; R p is selected from hydrogen, C1-C8 alkyl, alkenyl, or alkynyl, C6-C13 aryl, C3-C8 cycloalkyl which optionally contains one or two heteroatoms (e.g., N, O or S), an C1-C8 alkyl amino group, a C1-C8 alkylamide, —(CH 2 ) m NRR′, —(CH 2 ) m CONRR′, —(CH 2 ) m —NR—C(NRR′)═NR, where m is an integer ranging from 1-6, and R, R′ are in particular hydrogen, and C1-C3 alkyl groups; and R 13 or R 14 are hydrogen except that one of R 13 or R 14 together with R p can form an optionally substituted C3-C8 cycloalkyl or cycloalkenyl group which optionally contains one or two heteroatoms (e.g., N, O or S);
where Raa is as defined above; or
where r is an integer ranging from 1-100 (also 10-50) and Raa is as defined above.
In a specific embodiment of Formulas X and XI which contains
the selected R aa and R b form a peptide that is amphipathic, In another embodiment, the peptide formed by the combined R aa and R b is a host defense peptide as is known in the art. Peptides in this group may contain 1-10, 20-30, 25-40, or 50-100 amino acids,
In a specific embodiment of Formulas X and XI which contains
and is 10 to 50, the combined R aa and R b form a peptide that is amphipathic. In another embodiment, the peptide formed by the combined R aa and R b is a host defense peptide as is known in the art. Peptides in this group may contain 1-10, 20-30, or 25-40 amino acids.
In additional specific embodiments of Formulas X and XI which contains
the independently selected Raa and Rb groups together form a peptide that is cationic, e.g, that is rich in Lys, Arg and/or His amino acid groups. More specifically, in an embodiment, the peptide is one wherein 50% of more of the R aa and Rb groups are those of cationic amino acids, for example Lys, Arg and/or His. More specifically, in an embodiment, the peptide is one wherein 75% of more of the R aa and Rb groups are those of cationic amino acids, for example Lys, Arg and/or His In more specific embodiments, the peptide formed has only Lys and/or Arg groups. In more specific embodiments, the peptide formed has only Lys and/or Arg groups and r is 1-10, 2-10, 3-10, 6-10 or 6-20. In more specific embodiments, the peptide formed has only His groups. In more specific embodiments, the peptide formed has only His groups and r is 1-10, 2-10, 3-10, 6-10 or 6-20. In specific embodiments, the peptides are formed from L-amino acids. In other embodiments, the peptides are formed from D-amino acids.
In additional specific embodiments of Formulas X and XI which contains
the independently selected Raa and Rb groups together form a peptide that is cationic but which has hydrophobic and/or aromatic peptide regions flanking the cationic regions. For example, the peptide can contains a poly Arg, poly Lys or poly His portion, ranging in size from 6-20 amino acids, with one or two flanking region having 2 or more, including 2-10 or 2-20, hydrophobic or aromatic amino acids. In specific embodiments, the peptides are formed from L-amino acids. In other embodiments, the peptides are formed from D-amino acids.
In any of the formulas herein where appropriate any of the variable groups can comprise a protecting group.
As used herein optional substitution means substitution with one or more non-hydrogen substituents selected from the group consisting of hydroxyl group, halide, —CN group, —NO 2 group, a-NH 2 , an amine group (—NRR′), an amide group (—NR—CO—R′ or —CO—NR′R), an acyl group (—CO—R), thiol, substituted or unsubstituted C1-C6 alkyl, akenyl or alkynyl groups, substituted or unsubstituted C6-C13 aryl groups, substituted or unsubstituted C1-C6 alkoxy groups, substituted or unsubstituted C6-C13 aryloxy groups, substituted or unsubstituted C3-C12 heterocyclic groups where the heteroatoms are N, O or S. Non-hydrogen substitution for substituents mean substitution with one or more non-hydrogen groups selected from hydroxyl, halogen, —CN, —NO 2 , —NR″R′″, unsubstituted C1-C3 alkyl, unsubstituted phenyl or benzyl groups.
In the above definitions, R and R′ are selected from hydrogen, C1-C6 alkyl (preferably C1-C3 alkyl), C3-C8 cycloalkyl, C4-C8 heterocycloalkyl (heteroatom=N, O or S), and C6-C13 aryl; and R″ and R′″ are selected from hydrogen, C1-C6 alkyl (preferably C1-C3 alkyl), C3-C8 cycloalkyl, C4-C8 heterocycloalkyl (heteroatom=N, O or S), and C6-C13 aryl.
In addition, hereinafter, the following definitions apply:
As used herein, the term “array” refers to an ordered arrangement of structural elements, such as an ordered arrangement of individually addressed and spatially localized elements. Arrays useful in the present invention include arrays of containment structures and/or containment regions, such as fluid containment structures or regions, provided in a preselected, spatially organized manner. In some embodiments, for example, different containment structures and/or regions in an array are physically separated from each other and hold preselected materials, such as the reactants and/or products of chemical reactions, for example candidate compounds for screening of antimicrobial activity.
Arrays of the present invention include “microarrays” and “macroarrays” which comprise an ordered arrangement of containment structures and/or containment regions capable of providing, confining and/or holding reactants, products, solvent and/or catalysts corresponding to one or more chemical reactions, reaction conditions and/or screening conditions. In some embodiments, a portion of the reactants and/or products confined in a containment structure/region of a microarray or macroarray are immobilized, for example by spatially localized conjugation to a selected region of containment structure or region. Microarrays and macroarrays of the present invention, for example, are capable of providing an organized arrangement of containment structures and/or regions, wherein different containment structures and/or regions are useful for providing, confining and/or holding preselected combinations of reactants, products and/or candidate compounds having well defined and selected compositions, concentrations and phases. Containment structures and/or regions of microarrays and macroarrays are also useful for providing, confining and/or holding the products of chemical reactions. In some embodiments, for example, each containment structure and/or region of the microarrays and macroarrays is physically separated and contains the product of a different chemical reaction or a chemical reaction carried out under different reaction conditions.
The terms “microarray” and “macroarray” are used herein in a manner consist with the art. In some embodiments, a microarray comprises a plurality of containment structures or regions having at least one microsized (e.g., 1 to 1000s of microns) or sub-microsized (e.g., less than 1 micron) physical dimension. In some contexts, containment structures/regions of a microarray are smaller than containment structures/regions of a macroarray. In some contexts, containment structures/regions of a microarray are provided in a higher density than containment structures/regions of a macroarray. In some contexts, the number of containment structures/regions of a microarray is larger than the number of containment structures/regions of a macroarray. In specific embodiments, the invention provides macroarrays produced by SPOT synthesis are described herein and as known in the art. Macroarrays in the context of the present invention which are arrays of candidate compound for screening are prepared such that each compound member of the array (each spatially-localized compound) is present in an amount sufficient to allow its removal form the array for further analysis, for example, to measure spectral properties or to obtain confirmatory structural analysis (e.g., by mass spectroscopic analysis or NMR analysis). As will be understood by one having ordinary skill in the art may different microarray and macroarray formats are useable in the present invention including, but not limited to, standard 96, 384 or 1536 microarray configurations.
As defined herein, “contacting” means that a compound used in the present invention is provided such that is capable of making physical contact with another element, such as a microorganism, a microbial culture or a substrate. In another embodiment, the term “contacting” means that the compound used in the present invention is introduced into a subject receiving treatment, and the compound is allowed to come in contact in vivo.
Alkyl groups include straight-chain, branched and cyclic alkyl groups. Alkyl groups include those having from 1 to 30 carbon atoms. Alkyl groups include small alkyl groups having 1 to 3 carbon atoms. Alkyl groups include medium length alkyl groups having from 4-10 carbon atoms. Alkyl groups include long alkyl groups having more than 10 carbon atoms, particularly those having 10-30 carbon atoms. Cyclic alkyl groups include those having one or more rings. Cyclic alkyl groups include those having a 3-, 4-, 5-, 6-, 7-, 8-, 9- or 10-member carbon ring and particularly those having a 3-, 4-, 5-, 6-, or 7-member ring. The carbon rings in cyclic alkyl groups can also carry alkyl groups. Cyclic alkyl groups can include bicyclic and tricyclic alkyl groups. Alkyl groups are optionally substituted. Substituted alkyl groups include among others those which are substituted with aryl groups, which in turn can be optionally substituted. Specific alkyl groups include methyl, ethyl, n-propyl, iso-propyl, cyclopropyl, n-butyl, s-butyl, t-butyl, cyclobutyl, n-pentyl, branched-pentyl, cyclopentyl, n-hexyl, branched hexyl, and cyclohexyl groups, all of which are optionally substituted. Substituted alkyl groups include fully halogenated or semihalogenated alkyl groups, such as alkyl groups having one or more hydrogens replaced with one or more fluorine atoms, chlorine atoms, bromine atoms and/or iodine atoms. Substituted alkyl groups include fully fluorinated or semifluorinated alkyl groups, such as alkyl groups having one or more hydrogens replaced with one or more fluorine atoms. An alkoxyl group is an alkyl group linked to oxygen and can be represented by the formula R—O.
Alkenyl groups include straight-chain, branched and cyclic alkenyl groups. Alkenyl groups include those having 1, 2 or more double bonds and those in which two or more of the double bonds are conjugated double bonds. Alkenyl groups include those having from 2 to 20 carbon atoms. Alkenyl groups include small alkenyl groups having 2 to 3 carbon atoms. Alkenyl groups include medium length alkenyl groups having from 4-10 carbon atoms. Alkenyl groups include long alkenyl groups having more than 10 carbon atoms, particularly those having 10-20 carbon atoms. Cyclic alkenyl groups include those having one or more rings. Cyclic alkenyl groups include those in which a double bond is in the ring or in an alkenyl group attached to a ring. Cyclic alkenyl groups include those having a 3-, 4-, 5-, 6-, 7-, 8-, 9- or 10-member carbon ring and particularly those having a 3-, 4-, 5-, 6- or 7-member ring. The carbon rings in cyclic alkenyl groups can also carry alkyl groups. Cyclic alkenyl groups can include bicyclic and tricyclic alkyl groups. Alkenyl groups are optionally substituted. Substituted alkenyl groups include among others those which are substituted with alkyl or aryl groups, which groups in turn can be optionally substituted. Specific alkenyl groups include ethenyl, prop-1-enyl, prop-2-enyl, cycloprop-1-enyl, but-1-enyl, but-2-enyl, cyclobut-1-enyl, cyclobut-2-enyl, pent-1-enyl, pent-2-enyl, branched pentenyl, cyclopent-1-enyl, hex-1-enyl, branched hexenyl, cyclohexenyl, all of which are optionally substituted. Substituted alkenyl groups include fully halogenated or semihalogenated alkenyl groups, such as alkenyl groups having one or more hydrogens replaced with one or more fluorine atoms, chlorine atoms, bromine atoms and/or iodine atoms. Substituted alkenyl groups include fully fluorinated or semifluorinated alkenyl groups, such as alkenyl groups having one or more hydrogens replaced with one or more fluorine atoms.
Aryl groups include groups having one or more 5- or 6-member aromatic or heteroaromatic rings. Aryl groups can contain one or more fused aromatic rings. Heteroaromatic rings can include one or more N, O, or S atoms in the ring. Heteroaromatic rings can include those with one, two or three N, those with one or two O, and those with one or two S, or combinations of one or two or three N, O or S. Aryl groups are optionally substituted. Substituted aryl groups include among others those which are substituted with alkyl or alkenyl groups, which groups in turn can be optionally substituted. Specific aryl groups include phenyl groups, biphenyl groups, pyridinyl groups, and naphthyl groups, all of which are optionally substituted. Substituted aryl groups include fully halogenated or semihalogenated aryl groups, such as aryl groups having one or more hydrogens replaced with one or more fluorine atoms, chlorine atoms, bromine atoms and/or iodine atoms. Substituted aryl groups include fully fluorinated or semifluorinated aryl groups, such as aryl groups having one or more hydrogens replaced with one or more fluorine atoms.
Arylalkyl groups are alkyl groups substituted with one or more aryl groups wherein the alkyl groups optionally carry additional substituents and the aryl groups are optionally substituted. Specific alkylaryl groups are phenyl-substituted alkyl groups, e.g., phenylmethyl groups. Alkylaryl groups are alternatively described as aryl groups substituted with one or more alkyl groups wherein the alkyl groups optionally carry additional substituents and the aryl groups are optionally substituted. Specific alkylaryl groups are alkyl-substituted phenyl groups such as methylphenyl. Substituted arylalkyl groups include fully halogenated or semihalogenated arylalkyl groups, such as arylalkyl groups having one or more alkyl and/or aryl having one or more hydrogens replaced with one or more fluorine atoms, chlorine atoms, bromine atoms and/or iodine atoms.
Optional substitution of any alkyl, alkenyl and aryl groups includes substitution with one or more of the following substituents: halogens, —CN, —COOR, —OR, —COR, —OCOOR, —CON(R) 2 , —OCON(R) 2 , —N(R) 2 , —NO 2 , —SR, —SO 2 R, —SO 2 N(R) 2 or —SOR groups. Optional substitution of alkyl groups includes substitution with one or more alkenyl groups, aryl groups or both, wherein the alkenyl groups or aryl groups are optionally substituted. Optional substitution of alkenyl groups includes substitution with one or more alkyl groups, aryl groups, or both, wherein the alkyl groups or aryl groups are optionally substituted. Optional substitution of aryl groups includes substitution of the aryl ring with one or more alkyl groups, alkenyl groups, or both, wherein the alkyl groups or alkenyl groups are optionally substituted.
Optional substituents for alkyl, alkenyl and aryl groups include among others:
—COOR where R is a hydrogen or an alkyl group or an aryl group and more specifically where R is methyl, ethyl, propyl, butyl, or phenyl groups all of which are optionally substituted; —COR where R is a hydrogen, or an alkyl group or an aryl groups and more specifically where R is methyl, ethyl, propyl, butyl, or phenyl groups all of which groups are optionally substituted; —CON(R) 2 where each R, independently of each other R, is a hydrogen or an alkyl group or an aryl group and more specifically where R is methyl, ethyl, propyl, butyl, or phenyl groups all of which groups are optionally substituted; R and R can form a ring which may contain one or more double bonds; —OCON(R) 2 where each R, independently of each other R, is a hydrogen or an alkyl group or an aryl group and more specifically where R is methyl, ethyl, propyl, butyl, or phenyl groups all of which groups are optionally substituted; R and R can form a ring which may contain one or more double bonds; —N(R) 2 where each R, independently of each other R, is a hydrogen, or an alkyl group, acyl group or an aryl group and more specifically where R is methyl, ethyl, propyl, butyl, or phenyl or acetyl groups all of which are optionally substituted; or R and R can form a ring which may contain one or more double bonds; —SR, —SO 2 R, or —SOR where R is an alkyl group or an aryl groups and more specifically where R is methyl, ethyl, propyl, butyl, phenyl groups all of which are optionally substituted; for —SR, R can be hydrogen; —OCOOR where R is an alkyl group or an aryl groups; —SO 2 N(R) 2 where R is a hydrogen, an alkyl group, or an aryl group and R and R can form a ring; —OR where R=H, alkyl, aryl, or acyl; for example, R can be an acyl yielding —OCOR* where R* is a hydrogen or an alkyl group or an aryl group and more specifically where R* is methyl, ethyl, propyl, butyl, or phenyl groups all of which groups are optionally substituted;
Specific substituted alkyl groups include haloalkyl groups, particularly trihalomethyl groups and specifically trifluoromethyl groups. Specific substituted aryl groups include mono-, di-, tri, tetra- and pentahalo-substituted phenyl groups; mono-, di-, tri-, tetra-, penta-, hexa-, and hepta-halo-substituted naphthalene groups; 3- or 4-halo-substituted phenyl groups, 3- or 4-alkyl-substituted phenyl groups, 3- or 4-alkoxy-substituted phenyl groups, 3- or 4-RCO-substituted phenyl, 5- or 6-halo-substituted naphthalene groups. More specifically, substituted aryl groups include acetylphenyl groups, particularly 4-acetylphenyl groups; fluorophenyl groups, particularly 3-fluorophenyl and 4-fluorophenyl groups; chlorophenyl groups, particularly 3-chlorophenyl and 4-chlorophenyl groups; methylphenyl groups, particularly 4-methylphenyl groups, and methoxyphenyl groups, particularly 4-methoxyphenyl groups.
As to any of the above groups which contain one or more substituents, it is understood, that such groups do not contain any substitution or substitution patterns which are sterically impractical and/or synthetically non-feasible. In addition, the compounds of this invention include all stereochemical isomers arising from the substitution of these compounds.
Pharmaceutically acceptable salts comprise pharmaceutically-acceptable anions and/or cations. Pharmaceutically-acceptable cations include among others, alkali metal cations (e.g., Li + , Na + , K + ), alkaline earth metal cations (e.g., Ca 2+ , Mg 2+ ), non-toxic heavy metal cations and ammonium (NH 4 + ) and substituted ammonium (N(R′) 4 + , where R′ is hydrogen, alkyl, or substituted alkyl, i.e., including, methyl, ethyl, or hydroxyethyl, specifically, trimethyl ammonium, triethyl ammonium, and triethanol ammonium cations). Pharmaceutically-acceptable anions include among other halides (e.g., Cl − , Br − ), sulfate, acetates (e.g., acetate, trifluoroacetate), ascorbates, aspartates, benzoates, citrates, and lactate.
Compounds of the invention can have prodrug forms. Prodrugs of the compounds of the invention are useful in the methods of this invention. Any compound that will be converted in vivo to provide a biologically, pharmaceutically or therapeutically active form of a compound of the invention is a prodrug. Various examples and forms of prodrugs are well known in the art. Examples of prodrugs are found, inter alia, in Design of Prodrugs, edited by H. Bundgaard, (Elsevier, 1985), Methods in Enzymology, Vol. 42, at pp. 309-396, edited by K. Widder, et. al. (Academic Press, 1985); A Textbook of Drug Design and Development, edited by Krosgaard-Larsen and H. Bundgaard, Chapter 5, “Design and Application of Prodrugs,” by H. Bundgaard, at pp. 113-191, 1991); H. Bundgaard, Advanced Drug Delivery Reviews, Vol. 8, p. 1-38 (1992); H. Bundgaard, et al., Journal of Pharmaceutical Sciences, Vol. 77, p. 285 (1988); and Nogrady (1985) Medicinal Chemistry A Biochemical Approach, Oxford University Press, New York, pages 388-392).
The compounds of this invention may contain one or more chiral centers. Accordingly, this invention is intended to include racemic mixtures, diasteromers, enantiomers and mixture enriched in one or more steroisomer. The scope of the invention as described and claimed encompasses the racemic forms of the compounds as well as the individual enantiomers and non-racemic mixtures thereof.
Before the present methods are described, it is understood that this invention is not limited to the particular methodology, protocols, cell lines, and reagents described, as these 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 limit the scope of the present invention which will be limited only by the appended claims.
It must be noted that as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural reference unless the context clearly dictates otherwise. Thus, for example, reference to “a cell” includes a plurality of such cells and equivalents thereof known to those skilled in the art, and so forth. As well, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably.
As used herein, the term “treating” includes preventative as well as disorder remittent treatment. As used herein, the terms “reducing”, “suppressing” and “inhibiting” have their commonly understood meaning of lessening or decreasing.
In certain embodiments, the present invention encompasses administering the compounds useful in the present invention to a patient or subject. A “patient” or “subject”, used equivalently herein, refers to an animal. In particular, an animal refers to a mammal, preferably a human. The subject either: (1) has a condition remediable or treatable by administration of a compound of the invention; or (2) is susceptible to a condition that is preventable by administering a compound of this invention.
Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are now described. All publications mentioned herein are incorporated herein by reference for the purpose of describing and disclosing the chemicals, cell lines, vectors, animals, instruments, statistical analysis and methodologies which are reported in the publications which might be used in connection with the invention. Nothing herein is to be construed as an admission that the invention is not entitled to antedate such disclosure by virtue of prior invention.
The inventors have a developed an expedient approach to synthesize and screen focused parallel libraries prepared in a macroarray format for antibacterial behavior. Using this format, the inventors have discovered several new antibacterial agents, some of which are comparable to linezolid with respect to antibacterial activity. The inventors have discovered a new structure class for antibacterial compounds that displays excellent activity against S. aureus.
Cellulose paper is a robust, easy-to-manipulate support for the synthesis of macroarrays of chalcones and chalcone derived heterocycles ( FIG. 2 ). Bowman, M. D.; Jacobson, M. M.; Pujanauski, B. G.; Blackwell, H. E. Tetrahedron 2006, 62, 4715-4727.
To further expand the utility of this platform, the synthesis of the macroarrays was coupled with high throughput screening techniques. Antimicrobial cationic peptides had been previously prepared by the SPOT-synthesis technique and subsequently screened to find inhibitors at the μg/mL range. Hilpert, K.; Volkmer-Engert, R.; Walter, T.; Hancock, R. E. W. Nature Biotechnology 2005, 23, 1008-1012. Encouraged by this work and previously published accounts of the antibacterial activity of chalcones, the inventors looked at the synthesis and the screening of small molecules by both on-support and solution-based assays. Nielsen, S. F.; Larsen, M.; Boesen, T.; Schønning, K.; Kromann, H. J. Med. Chem. 2005, 48, 2667-2677; Nielsen, S. F; Boesen, T.; Larsen, M.; Schønning, K.; Kromann, H. Biorganic Medicinal Chemistry 2004, 12, 3047-3054; Bowden, K. Dal Pozzo, A.; Duah, C. K. J. Chem. Res . ( S ) 1990, 12, 2801-2830.
The invention may be further understood by the following non-limiting examples:
EXAMPLE 1
Synthesis of Libraries Employing Rink Linkers
FIG. 1 illustrates a general schematic of small molecule macroarray library construction and screening. In order to improve coupling efficiency of the initial building blocks and expand the set of possible building blocks used in library construction, we chose to explore the use of the well-characterized Rink-amide linker system. Bernatowicz, M. S.; Kearney, T.; Neves, R. S.; Koster, H., An Efficient Method for Racemization Free Attachment of 9-Fluorenylmethyloxycarbonyl-Amino Acids to Peptide-Synthesis Supports. Tetrahedron Lett. 1989, 30, 4341-4344; Rink, H., Solid-phase synthesis of protected peptide fragments using a trialkoxy-diphenyl-methyl ester resin. Tetrahedron Lett. 1987, 28, 3787-90. FIG. 2 illustrates the generation of the Rink linker on planar cellulose substrate (e.g., chromatography paper). The figure shows a comparison to the Wang linker used in previous work (WO08/016,738).
It was reasoned that the use of this system would circumvent some of the problems that are associated with using the Wang linker system to construct small molecule macroarrays. One main advantage of using the Rink linker system is the relatively mild conditions required (standard diisopropylcarbodiimide (DIC) coupling conditions) for coupling the Rink linker to the amino-cellulose support. These conditions are beneficial as they permit the support to stay robust throughout the entire macroarray construction, making it easier to perform syntheses and on-support biological assays post cleavage. Furthermore, we found the Rink linker support to be highly stable, as the support could be prepared and used after sitting on the bench-top for several weeks. This Rink linker strategy also reduces the number of synthetic steps needed to generate a linker suitable for substrate attachment, as an Fmoc-Rink-amide linker can be attached and deprotected in three high-yielding steps. Also, the Rink linker is acid labile, so similar cleavage conditions (TFA vapor) can be used as previously described for the Wang linker system.
Blackwell et al. has previously had success attaching initial building blocks to Rink linker-derivatized cellulose support using standard peptide coupling reagents. Lin, Q.; O'Neill, J. C.; Blackwell, H. E., Small molecule macroarray construction via Ugi four-component reactions. Org. Lett. 2005, 7, 4455-4458. Using Fmoc-Rink-amide linker and amino-cellulose support, Rink support was prepared with a coupling efficiency of ˜75%. All coupling efficiencies were quantified using standard UV-Fmoc analysis. Carpino, L. A.; Han, G. Y., 9-Fluorenylmethoxycarbonyl Amino-Protecting Group. J. Org. Chem. 1972, 37, 3404. Because of the relative expense of the Fmoc-Rink-amide linker, it was “spotted” (along with coupling reagents) onto the amino-cellulose support, in contrast to the blanket functionalization used with the Wang linker system. Bowman, M. D.; Jacobson, M. M.; Blackwell, H. E., Discovery of fluorescent cyanopyridine and deazalumazine dyes using small molecule macroarrays. Org. Lett. 2006, 8, 1645-1648. We observed a dramatic improvement in the coupling efficiency of the Rink linker compared to previous results with the Wang linker system (75% vs. 15%), especially since the spotting approach employed relied on the use of significantly less linker material.
In order to attach the acetophenones to the Rink linker, bromoacetic acid (BrAcOH) could be attached using standard DIC coupling conditions, followed by displacement of the bromide by an amino acetophenone. Hydroxyacetophenones however, would still need to be subjected to a KOtBu/DMF solution, in which we found certain hydroxyacetophenones to be insoluble. In order to overcome these solubility problems, the hydroxyacetophenones could first be converted into acetyl-phenoxyacetic acids via S N 2 reaction with methyl bromoacetate and subsequent saponification. These acetyl-phenoxyacetic acids could be directly attached to the Rink-amide linker via a DIC coupling reaction at room temperature to produce support-bound acetophenones, which were then available for further derivatization reactions. Coupling of the acetyl-phenoxyacetic acids to the Rink support proceeded with excellent purity (>95% as determined by HPLC analysis) and modest conversion (60-90% as determined by HPLC analysis). We found that this reaction step could be performed at lower temperatures (43° C.) relative to the Wang linker support (80° C.), which was advantageous as we had observed that multiple reactions at high temperatures “wrinkled” the cellulose support, making it incompatible with on-support biological assays.
With the acetophenones attached to the Rink linker support, we needed to determine if the same reaction conditions used for the Claisen-Schmidt condensation (benzaldehyde spotted 3× in 1.5 M KOH in 50% EtOH/H 2 O, 80° C., 10 min) would be compatible with the Rink linker system. Before it would be practical to construct larger macroarrays, it was beneficial to optimize the Claisen-Schmidt condensation reaction on the planar array. Initial results from small test libraries had indicated low purities (<60% as determined by HPLC analysis) for the corresponding “Rink” chalcones after TFA cleavage. After several optimization attempts, we found that performing the reaction at a lower temperature (43° C.) resulted in the best reaction conversion and purity of the corresponding Rink support bound chalcones (>85% as determined by HPLC analysis) after TFA cleavage. Again, the low reaction temperatures also helped to preserve the robustness of the cellulose support.
With the optimized reaction conditions in hand, we proceeded to construct a small molecule macroarray of chalcone derivatives. This library was designed to validate the utility of the Rink system as an improved platform for small molecule macroarray construction, compared to the previous Wang linker system. Acetophenone and benzaldehyde building blocks as shown in FIG. 4 where chosen for preparing a library of chalcones as shown in FIG. 3 . Pyrimidine and pyridine heterocycle derivatives of chalcones were synthesized using previously reported reaction conditions (see FIG. 3 ). Bowman, M. D.; O'Neill, J. C.; Stringer, J. R.; Blackwell, H. E., Rapid Identification of Antibacterial Agents Effective against Staphylococcus aureus Using Small-Molecule Macroarrays. Chem. Biol. 2007, 14, 351-357; see also WO 2008/016738.
Libraries containing 174 chalcones, 174 cyanopyridines, and 24 pyrimidines were synthesized on a planar cellulose support system ( FIG. 3 ). LC-MS analyses of a subset of the total compounds (20%) cleaved from the macroarray showed good to excellent purities (80-99%).
FIGS. 5-7 illustrate one advantage of the use of the Rink linker for array synthesis in that it can be used to attach amino acids, peptides, N-substituted glycines or peptoids (oligomers of N-substituted glycines) to the chalcone backbone. FIG. 5 illustrates addition of a N-protected amino acid to the Rink linker followed by reaction with an acetophenone (as described above, exemplary acetophenones listed in FIG. 4 ). Thereafter the benzaldehyde (as described above, exemplary benzaldehydes listed in FIG. 4 ) is reacted with the attached acetophenone to form the chalcone. As illustrated the chalcone derivatized with the amino acid can be released from the substrate. Also as illustrated in FIG. 5 multiple amino acids can be added at point “#” in the synthesis using standard solid-phase peptide synthesis. The R group of the amino acid can in general be any group that does not interfere with the chemistry illustrated in FIG. 5 . As is known in the art certain R groups that might be sensitive or interfere with the chemistry shown may be provided with protective groups. A wide variety of protective groups is known in the art and one of ordinary skill in the art understands how to chose a protective group useful for a given set of reaction conditions.
FIG. 6 illustrates attachment of an N-substituted glycine to a chalcone backbone. The Rink linker is first reacted as illustrated in FIG. 6 with bromoacetic acid to form a solid attached bromoacetamide which in turn is reacted with a primary amine (most generally NH 2 —R p , see formulas above for exemplary definition of R b ) forming an N-substituted glycine on the solid. The primary amine may be a diamine (as illustrated) a triaminer or a polyamine, in each case the additional amine groups in the R b group must be protected during synthesis). Steps 1 and 2 of FIG. 6 can be repeated to form a peptoid on the solid, e.g.:
The unprotect amine group attached to the solid is then reacted with the acetophenone as described above and thereafter reacted with the benzaldehyde to form the chalcone. FIG. 7 illustrates an alternative peptide synthesis combined with chalcone formation on a solid. In this case an O-protected amino acid (e.g., using OtBu protecting group) is reacted with bromo acetamide on the solid. The unprotected NH of the attached amino acid is then reacted with the acetophenone followed by reaction with the benzaldehyde to form the chalcone. Peptide synthesis can be continued after deprotection of the O-tBu group (other appropriate protecting groups can be used) either before or after chalcone formation. In all of FIGS. 5-7 , the chalcone formed can be further reacted as illustrated in FIG. 3 to form cyanopyridines and pyrimidines.
EXAMPLE 2
Solution Phase Synthesis of Rink Acetophenones and Rink Chalcones
As previously discussed, the acetophenones used in macroarray construction required a carboxylic acid functionality for attachment to the Rink amide linker. To efficiently install this moiety, a general synthetic scheme was designed to derivatize a variety of acetophenones (Scheme 1). An acetophenone was reacted with methyl bromo acetate in the presence of potassium carbonate (K 2 CO 3 ), and the product was isolated by precipitation from water. Hydrolysis of the ester with NaOH in H 2 O/THF afforded the acetyl-phenoxyacetic acid carboxylic acid in excellent purity.
In order to estimate the loadings of individual macroarray members, the corresponding acetophenones were cleaved from the macroarray and analyzed by HPLC analysis. An accurate calibration curve was needed for each acetophenone building block to estimate the loading of each macroarray member. Initial attempts at solid phase synthesis of the desired control compounds resulted in low purities and low yields (data not shown), therefore a solution-phase method was pursued.
An acetophenone was reacted with commercially available 2-bromoacetamide in the presence of K 2 CO 3 , with the product precipitating out after addition of the reaction mixture to water. This solution-phase reaction produced the desired “Rink” acetophenone acid in high yield (70-90%) and excellent purity; allowing for calibration curve generation.
EXAMPLE 3
Lead Compound Re-synthesis
Once active compounds had been identified in the biological assays (as described under Aim 2), they were synthesized in solution to obtain an authentic sample for characterization and further biological evaluation. As some of the active chalcones were similar in structure to our previously reported active chalcones synthesized with the Wang linker 43 , our initial synthetic route was aimed at generating the chalcone first, followed by an S N 2 reaction with 2-bromoacetamide. Although this short synthesis allowed us to obtain the desired chalcone in sufficient quantities after several re-crystallizations, an alternate synthesis was devised to increase reaction yields and decrease purification time.
We found that our solution-phase synthesis of Rink acetophenones could be modified to yield our target chalcones in moderate yields and high purities (Scheme 2). The high purities were attributed to the careful choice of solvent used in the Claisen-Schmidt condensation between the Rink acetophenone and an aldehyde. After dissolving the Rink acetophenone and benzaldehyde in a 1:1 H 2 O:MeOH mixture, 100 uL of a 1:1 (w:v) NaOH:H 2 O solution was added with the chalcone product precipitating out of solution. Purification was thus greatly simplified (no re-crystallization or column chromatography required), as the precipitate was simply filtered and washed several times with a 1:1 H 2 O:MeOH solution to afford the desired Rink chalcone product in excellent purity.
In order to verify that solution phase synthesis affords only the trans chalcone product, a 1 H NMR spectrum was analyzed by measuring the coupling constants of the two vinylic protons present in the α,β-unsaturated enone moiety. Only one set of vinylic proton peaks were observed and these had coupling constants ranging from 16-17 Hz, indicating a trans double bond. In order to rule out the possibility of the vinylic proton peaks of the cis isomer being obscured or overlapping with other aromatic peaks in the 1 H NMR spectrum, the solution phase Rink chalcones were subjected to LC-MS analysis, which indicated the presence of only 1 peak at 254 nm, thus confirming our initial hypothesis that the trans chalcone is formed when solution phase synthesis is employed.
It was important to determine which isomers (trans or cis) were produced in the our solution phase Rink chalcone synthesis because it had been previously reported that the trans chalcone isomer is responsible for the antimicrobial activity, while the cis isomer was virtually inactive. Larsen, M.; Kromann, H.; Kharazmi, A.; Nielsen, S. F., Conformationally restricted anti-plasmodial chalcones. Bioorg. Med. Chem. Lett. 2005, 15, 4858-4861.
Although the double bond of the chalcone is prone to photoisomerization under certain conditions, it is difficult to predict the rate and extent of isomerization for individual chalcones because it is highly dependent on a variety of factors including solvent and type of substitution on aromatic rings. Larsen et al. 2005. The activity results observed for the chalcones may be affected by some level of isomerization of the chalcones.
EXAMPLE 4
Antibacterial Screening
After preparation of the small molecule macroarray, we examined several methods for analyzing the antibacterial activity of individual compounds on the macroarray. Our first plan was to analyze each compound using a standard Kirby-Bauer disk diffusion assay. However, this assay gave only a qualitative assessment of antibacterial activity and furthermore, all of the compound was consumed in the assay.
Next examined was a solution-based assay that consisted of “punching out” individual spots from the macroarray with a standard desktop hole-punch, cleaving the compound in the presence of TFA vapor, and eluting with acetonitrile, and generating stock solutions in DMSO to test antibacterial activity. This procedure allowed for evaluation of antibacterial activity using a minimal amount of compound in a solution-based antibacterial assay, while the remaining compound could be used in HPLC analysis. This allowed direct assessment of the purity of compounds that were used in the solution-based antibacterial assay.
The third method evaluated was to determine antibacterial activity was an agar-overlay technique (as illustrated in FIG. 8 ), in which a macroarray was cleaved, overlaid with agar inoculated with S. aureus , and incubated for 18 h at 37° C. Macroarrays were cleaved for 1 h in a sealed desiccator saturated with TFA vapor. After the incubation period, triphenyl tetrazolium chloride (TTC) was added to the macroarray, allowing a clear determination of active antibacterial compounds. TTC is a redox indicator commonly used to show the presence or absence of live bacteria. Areas that appeared white indicated dead bacteria (i.e. antibacterial compound), whereas red areas indicated live bacteria (i.e. compound without antibacterial activity).
One drawback to the agar-overlay technique was that the entire compound was consumed during the assay. Therefore, it was impossible to determine the purities of the compounds that were being screened in the agar-overlay format, which could lead to mis-identification of inactive compounds that merely had low purities. To address this issue it was considered that creating “copies” of the macroarray would allow use of the agar-overlay assay and still have enough of the compound to either test against other bacterial strains or analyze purity by HPLC. A method was used in which the cleaved macroarray could be transferred to multiple cellulose sheets simultaneously. See WO 2008/016738 for more details of this method particularly as applied to macroarrays having Wang linkers. The copies are made by sandwiching a cleaved macroarray between solvent-soaked cellulose sheets and dry cellulose sheets. Pressure is applied, and the solvent is wicked upwards, transferring compound to the previously dry cellulose sheets in a spatially addressed manner. With each new macroarray copy, it is possible to simultaneously screen antibacterial activity of a compound against a number of important human pathogenic bacteria including, methicillin-resistant S. aureus (MRSA), Staphylococcus epidermidis, Bacillus subtilis , and Klebsiella pneumoniae.
Cleaved macroarrays are neutralized with ammonia vapor before being placed in a suitably sized agar dish. Freshly prepared agar inoculated with bacteria is poured over the entire macroarray, and the array was incubated for 18 h at 37° C. After 18 h, a solution of TTC is added and hits are identified as described above. Agar-overlay assays can also be used to screen antibacterial activity against S. epidermidis, B. subtillis , and K. pneumoniae . Estimated MICs were determined by cleaving the parent acetophenone building block from the macroarray and determining the approximate loading by HPLC analysis.
Prior to the agar-overlay assay, copies are made of the cleaved macroarray. In order to validate the agar-overlay screen, we use one copy for the agar-overlay method and another copy for a solution-phase MIC assay. In the solution phase assay, individual spots are punched out, placed in separate 4 mL glass vials, and eluted with acetonitrile. After solvent removal, loadings are estimated by analyzing an HPLC trace of the parent macroarray-cleaved acetophenone. Within a given series of acetophenones the corresponding Claisen-Schmidt condensation, as well as the other heterocycle generating reactions, proceeded with nearly 100% conversion. Therefore, we used the amount of cleaved acetophenone from one spot to estimate the amount of chalcone, pyrimidine, or cyanopyridine derivative on other spots. In general, compound amount (post-cleavage) ranged from 100-200 nmoles per spot, which was enough material to perform solution-phase antibacterial assays as well as HPLC or LC-MS analyses.
Macroarray compounds are dissolved in DMSO and pipetted into a 96-well multititer plate containing Luria-Bertani (LB) broth inoculated with MRSA. The final concentrations of the compounds selected, e.g., 50 μM, 25 μM, 12.5 μM, 6.3 μM, and 3.1 μM, with a final DMSO concentration of 2.5% for each compound in a given well. The plate is incubated with shaking at 37° C. for 18 h, and the absorbance is measured at 595 nm using a plate-reader. The approximate MIC can be determined by the complete absence of bacterial growth relative to our negative control (LB broth with no bacteria added). FIGS. 9A-9O , 10 A- 10 F, 11 A- 11 B and 12 A- 12 B illustrate results of such assays with certain compounds of Formula I.
It was found that the agar-overlay assay provided a good primary screen for the macroarrays, as the compounds that showed activity in the agar-overlay assay (white spots) also showed good to strong antibacterial activity in the solution-phase assay. The screening methods can be used for a variety of microorganism, including bacteria and fungus. In particular, the screening methods can be employed to assess antibacterial activity against Gram-Negative and Gram-Positive bacteria.
FIGS. 13A-13E provide exemplary MIC data for several compounds of Formula I.
Compounds useful for therapeutic application preferably have low hemolytic activity. The hemolytic activity of several compounds of Formula I was assessed using standard methods as illustrated in FIGS. 14A-14C .
Compounds useful for therapeutic application as antimicrobial activity preferably affect bacterial cell membrane permeability. FIG. 15 illustrates the affect of several compounds of Formula I on the permeability of bacterial cells.
Support Solution Support MIC MIC Compound Purity (%) a (μM) b (μM) c F19 82 <3.125 3.1 ± 0.2 F17 87 <3.125 3.5 ± 0.5 B19 80 <3.125 4.0 ± 0.5 F5 97 12.5-25 17 ± 1.0 B18 87 25-50 54 ± 1.0 linezolid — — 5.0 ± 1.0 ciprofloxacin — — 0.6 ± 0.2
Table 1. Antibacterial activity of lead compounds from Rink support. (a) determined by HPLC trace at 254 nm. (b) solution-phase assay from cleaved macroarray. (c) authentic solution-phase sample.
Chalcones B19, F17, and F19 had antibacterial activity with MICs of 4.0±0.5 μM, 3.5±0.5 μM, and 3.1±0.2 μM, respectively (Table 1). (Note that compound names are based on the letter and number code of FIG. 4 which identifies the acetophenone and benzaldehyde used to form the base chalcone.) Several active chalcones, (B19, F17, F19, F5 and B18), were synthesized in solution to obtain more precise MIC values using our previously described solution phase assay. Notably, we identified chalcones that have antibacterial activities against MRSA in the low micromolar range and comparable to commercial therapeutics (ciprofloxican and linezolid).
In particular Compounds F19, F17 and B19 exhibited low solution MIC's (5 microliter or less) against MRSA and also exhibited low levels of hemolysis at 4× their MIC.
Materials and Methods
Bacteriological Assays
Bacteriological work was performed with strains obtained from ATCC. Luria-Bertani (LB) medium was used, as directed, for all bacterial work and was solidified with agar as needed. Overnight cultures were grown at 37° C. with shaking ( B. subtilis was grown at 30° C.).
Disk Diffusion Assay
Compound spots were cleaved with TFA and neutralized with NH 3 as described herein. A 200-μL portion of diluted S. aureus 10390 (10 6 CFU/mL) was spread homogeneously across an agar plate. Compound spots were placed onto the agar, the plate was incubated at 37° C. for 18 h, and the diameters of the zones of inhibition were measured.
Agar Overlay TTC Assay
Macroarray copies were generated using the array transfer protocol described herein. Warm agar (15 mL) containing 10 6 CFU/mL bacteria was poured into a Petri dish (9 cm diameter). The dish was swirled to eliminate air bubbles, and a macroarray copy (6×6 cm) was fully submerged in the agar. Following an 18 h incubation at 37° C., the plates were flooded with 0.1% (w/v) TTC in LB and allowed to develop for 1 h to visualize the zones of inhibition. Red zones indicated healthy bacteria, while white zones indicated that a compound on the macroarray inhibits growth of the bacterial strain.
MIC Determination
For estimated MIC determination, DMSO was added to the dried compound residue obtained from a single spot to afford ca. 100 μL of a 2 mM stock solution. Aliquots (5 μL) of these solutions were added to a 96-well plate, followed by 195 μL of diluted S. aureus 10390 (10 6 CFUs/mL) to yield ca. 50 μM final concentrations. The plates were swirled for 1 h to ensure compound dissolution, incubated for 12 h at 37° C., and the absorbance at 595 nm was recorded using a plate reader. Compounds that showed a selected level of growth inhibition at ca. 50 μM were subjected to further testing at C1-C3 concentrations (ca. 25 and 12.5 μM). Actual MIC values were determined for lead compounds resynthesized in solution using an analogous procedure with solutions of known concentration.
Analytical and Synthetic Instrumentation.
1 H NMR and 13 C NMR spectra were recorded on a Bruker AC-300 spectrometer in deuterated solvents at 300 MHz and 75 MHz, respectively. Chemical shifts are reported in parts per million (ppm, δ) using tetramethyl silane (TMS) as a reference (0.0 ppm). Couplings are reported in hertz. LC-MS analyses were performed using a Shimadzu LCMS-2010a (Columbia, Md.) equipped with two pumps (LC-10ADvp), controller (SCL-10Avp), autoinjector (SIL-10Advp), UV diode array detector (SPD-M10Avp), and single quadrupole analyzer (by electrospray ionization, ESI). The LC-MS is interfaced with a PC running the Shimadzu LCSolutions software package (Version 2.04 Su2-H2). A Supelco (Bellefonte, Pa.) 15 cm×2.1 mm C-18 wide-pore reverse-phase column was used for all LC-MS work. Standard reverse-phase HPLC conditions for LC-MS analyses were as follows: flow rate=200 μL/min; mobile phase A=0.4% formic acid in H 2 O; mobile phase B=0.2% formic acid in acetonitrile. HPLC analyses were performed using a Shimadzu HPLC equipped with a single pump (LC-10Atvp), solvent mixer (FCV-10Alvp), controller (SCL-10Avp), autoinjector (SIL-10AF), and UV diode array detector (SPD-M10Avp). A Shimadzu Premier 25 cm×4.6 mm C-18 reverse-phase column was used for all HPLC work. Standard reverse-phase HPLC conditions were as follows: flow rate=1.0 mL/min; mobile phase A=0.1% trifluoroacetic acid (TFA) in water; mobile phase B=0.1% TFA in acetonitrile. UV detection at 254 nm was used for all HPLC analyses. Compound purities were determined by integration of the peaks in HPLC traces measured at this wavelength.
Attenuated total reflectance (ATR)-IR spectra were recorded with a Bruker Tensor 27 spectrometer, outfitted with a single reflection MIRacle Horizontal ATR by Pike Technologies. A ZnSe crystal with spectral range 20,000 to 650 cm −1 was used. UV spectra were recorded using a Cary 50 Scan UV-Vis spectrometer running Cary WinUV 3.00 software. Thin layer chromatography (TLC) was performed on silica gel 60 F 254 plates (E-5715-7, Merck). Sonication of reactions was performed in a laboratory ultrasound bath (Branson model #1510R-MT). All reported melting points are uncorrected.
Macroarray reactions subjected to oven heating were performed on a pre-heated bed of sand in a standard drying oven (VWR model #13OOU). Temperature measurements of planar surfaces were acquired using a non-contact IR thermometer (Craftsman model #82327) with an error of ±2.5%. An Eppendorf pipetteman with a calibrated range between 0.5 μL and 10.0 μL was used to “spot” or apply reagents onto planar membranes in a spatially addressed manner using disposable plastic tips. Washing steps were 5 min each. After each washing sequence, the macroarray was dried under a stream of N 2 for 20 min.
Solution-phase, microwave-assisted reactions were performed in a Milestone MicroSYNTH Labstation multimode microwave (MW) synthesis reactor. i This instrument is equipped with a continuous power source (1000 W max) and interfaced with an Ethos MicroSYNTH Lab Terminal PC running EasyWave reaction monitoring software. Using this reactor system, MW irradiation can be applied to reactions using either power (wattage) control or temperature control. Specialized, 70 mL Teflon/polyetheretherketone (PEEK) vessels, designed to withstand temperatures up to 200° C. and pressures up to 280 psi, were used for all MW-assisted reactions. The internal temperature of the reaction vessel was monitored using a fiber-optic temperature sensor enclosed in a protective ceramic sheath. At pressures above the 280-psi limit, the vessels are designed to release excess pressure by venting and then resealing themselves. No evidence of venting was observed during the course of the reactions described herein.
All chemical reagents were purchased from commercial sources (Alfa-Aesar, Aldrich, and Acros) and used without further purification. Solvents were purchased from commercial sources (Aldrich and J. T. Baker) and used as obtained, with the exception of dichloromethane (CH 2 Cl 2 ), which was distilled over calcium hydride immediately prior to use. Planar cellulose membranes (Whatman 1Chr and 3MM chromatography paper, 20×20 cm squares) were purchased from Fisher Scientific and stored in a dessicator at room temperature until ready for use. All reaction on planar supports were performed under air.
TFA vapor compound cleavage procedure. Cleavage was performed either on compound spots (for the Kirby-Bauer disk diffusion assay and the solution-phase MIC assay) or the intact macroarray (for the TTC agar overlay assay). Compound spots were punched out of macroarrays using a standard desktop hole punch (spot diameter=6 mm) and placed in individual 4 mL vials. A 10 mL portion of TFA was added to the bottom of a glass vacuum dessicator (interior diameter 21 cm, interior height 20 cm). Up to 240 vials containing the spots (or one 12 cm×18 cm, intact macroarray) were placed on a perforated ceramic platform in the dessicator that was situated 7 cm above the TFA. The dessicator was evacuated to 60 mm Hg over a 10 min period. The dessicator was disconnected from the vacuum, sealed, and allowed to stand for an additional 50 min at room temperature. The vials (or intact macroarray) were removed from the dessicator and allowed to vent in a fume hood for 15 min. For routine LC-MS characterization or the solution-phase MIC assays, the compounds were eluted from the spots by adding acetonitrile (1.0 mL) to each vial. The vials were sealed and shaken for 15 min, after which the paper disks were removed, and the acetonitrile was evaporated under reduced pressure. For the Kirby-Bauer disk diffusion assay or the TTC agar overlay assay, the cleaved spots or macroarrays were subjected to an ammonia (NH3) neutralization step instead of elution (see biological assay section below). This cleavage method gave quantitative release of products (as determined by quantification of cleaved hydroxyacetophenone).
Full Bacteriological Assay Protocols
Kirby-Bauer Disk Diffusion Assay.
Preparation of Spots. Compound Spots were Subjected to the TFA cleavage conditions described above. The spots were next subjected to NH3 vapor to neutralize any remaining TFA. A 100 mL portion of concentrated NH4OH solution was poured into a 2.6 L Pyrex dish. Vials containing the spots (or intact macroarrays) were placed inside a small evaporating dish, and this was placed into the NH4OH solution. The Pyrex dish was covered, and NH3 vapor was allowed to slowly diffuse into the vials. After 1 h, the vials were removed from the NH3 chamber, and the spots were allowed to stand open in a fume hood for at least 15 min to vent prior to analysis in the following assays. This afforded dry, paper disks containing adsorbed compound. Vancomycin susceptibility test disks (30 μg per disk) and methicillin susceptibility disks (10 μg per disk) were used as controls as received.
Representative assay procedure. A 400 μL portion of S. aureus overnight culture was diluted with 100 mL of sterile LB broth to give ca. 1.0×106 colony forming units (CFUs) per mL. A 200 μL portion of this suspension was added to Petri dishes containing non-selective agar, and spread homogeneously across the agar with a sterile cotton swab.
Up to four compound disks (prepared as described above) were placed gently onto the bed of agar equidistant from each other. (Note: either face of the disk could be placed on top of the agar, as the compound was distributed uniformly throughout the disk.) The Petri dishes were incubated at 37° C. for 18 h. The plates were removed, and the diameters of the zones of inhibition were measured in mm using a ruler.
Macroarray Transfer Protocol.
A chalcone macroarray (12 cm×18 cm) was subjected to the TFA cleavage and NH 3 neutralization conditions described above, except that the spots were not punched out of the array. The intact, cleaved, and dried macroarray was cut into six square sections (12 spots each), and a concentrated fluorescent dye solutions in EtOAc was spotted (ca. 10 nL, using a glass capillary) in-between the compounds for later verification of macroarray transfer.
Untreated Whatman 3MM filter paper was cut into 6 cm×6 cm squares and arranged into a 2 cm high stack (30 squares). This stack was placed into a glass Petri dish (diameter=15 cm) containing 50 mL EtOH and allowed to soak up the solvent until saturated. A macroarray section was placed facedown on the stack, followed by four additional dry squares of Whatman 3MM. A flat aluminum block was placed on top of the stack and pressure (3 kg) was applied for 90 sec. The four sheets were then removed from the stack, separated with tweezers, allowed to dry, and visualized with a UV lamp (Centela Mineralight Lamp UVGL-58 at 366 nm) to confirm compound transfer. The fluorescent spots were marked with a #2 lead pencil and connected to form a grid. These macroarray copies were subjected to the TTC assay described in detail below. To prevent contamination in subsequent copies, the top two soaked sheets of the filter paper stack were removed after each transfer and replaced with fresh squares of EtOH-soaked filter paper.
This method gave a gradient of compound concentrations, with the last copy containing the most compound. The gradient was consistent across all locations on the array and for all compounds in the same structure class. Other solvents (CH 2 Cl 2 , MeOH) and longer transfer times were examined; the methods described here were found to be optimal.
Agar Overlay TTC Screening Protocol.
Test tubes were filled with 15 mL of 0.8% (w/v) agar in LB, autoclaved, and stored in a 55° C. water bath until needed. For bacterial overlay, an appropriate volume of overnight culture was added to each test tube. The tube was gently vortexed, and the contents (15 mL) were quickly poured into a sterile, polystyrene Petri dish (diameter=9 cm). The dish was swirled to eliminate lingering air bubbles, and a 12-spot macroarray copy (described above) was gently slid into the solution. The dish was swirled to completely immerse the membrane in agar, and the agar was allowed to cool. The dish was incubated for 18 h at 37° C. Following incubation, the plates were “flooded” by the addition of 8 mL of 0.1% (w/v) TTC solution in LB and allowed to develop for ca. 1 h to visualize the zones of inhibition. Red zones above the macroarray copy indicated healthy cells, while white zones indicated that a compound on the macroarray copy had growth inhibitory activity against the strain of interest.
Initially, we performed our overlays according to the procedures published by Silen et al (Silen, J. L.; Lu, A. T.; Solas, D. W.; Gore, M. A.; Maclean, D.; Shah, N. H.; Coffin, J. M.; Bhinderwala, N. S.; Wang, Y.; Tsutsui, K. T.; Look, G. C.; Campbell D. A.; Hale, R. L.; Navre, M.; DeLuca-Flaherty, C. R. Antimicrob. Agents Chem. 1998, 42, 1447-1453.) However, we found that all of the compounds “hit” using this method, and we were unable to determine our best hits. To better resolve the relative activities of our compounds, the agar volume was increased from eight to 15 mL .
Methicillin susceptibility test. We examined the susceptibility of our two S. aureus strains to methicillin using the agar overlay TTC assay. A susceptibility disk containing 10 μg of methicillin was placed in a Petri dish. Warm agar (0.8% in 15 mL LB) containing 106 CFU/mL of either S. aureus 10390 (SA) or methicillin-resistant S. aureus 33591 (MRSA) was poured over the disk. The dishes were incubated at 37° C. for 18 h and visualized with TTC.
Macroarray Overlay Data.
Estimated MIC Determination Protocol for Macroarray Compounds.
Preparation of spot samples and controls. An aliquot of DMSO (ca. 100 μL depending on the loading of the parent hydroxyacetophenone) was added to the dried compound residue obtained after TFA cleavage and elution from a single spot. This afforded a 2.0 mM “spot stock” solution for each spot. A small aliquot of each “spot stock” solution was saved for subsequent LC-MS analysis.
For the linezolid standard, 1.0 mL of acetonitrile was added to a single linezolid susceptibility test disk (30 μg per disk) in a 4 mL vial and vortexed for 15 min. The disk was removed, and the solution was concentrated under reduced pressure. The resulting residue was dissolved in 44 μL of DMSO to afford a 2.0 mM “spot stock” solution of linezolid.
Control “support” spots were punched from planar supports that had undergone all macroarray synthesis steps except for the loading of the initial hydroxyacetophenone building blocks. These samples allowed us to study the effects of the support background composition on bacterial growth. In addition, hydroxyacetophenone derived spots that had undergone all macroarray synthesis steps except for the Claisen-Schmidt condensation were used as “parent” controls. These samples allowed us to determine the effects of minor impurities resulting from unreacted acetophenone reacting in subsequent steps. “Spot stock” solutions were generated from each of these spots as described above. In all cases studied, neither the support nor the parent control spots affected S. aureus growth.
For estimated MIC screens, 5.0 μL portions of the “spot stock” solutions were added to the appropriate wells in a sterile, polystyrene 96-well plate to yield ca. 50 μM solutions (dependent on the initial loading of hydroxyacetopheneone and compound purity). To the positive and negative control wells, 5.0 μL of DMSO were added (positive controls contained bacteria but no compound, while negative controls had neither compound, nor bacteria). All estimated MIC assays were performed in quadruplicate. Note: the MIC value is defined as the lowest concentration where no bacterial growth occurs.
Representative estimated MIC assay procedure. This assay procedure is based in part on the method reported by Strøm et al. (Strøm, M. B.; Haug, E. B.; Skar, M. L.; Stensen, W.; Stiberg, T.; Svendsen, J. S. J. Med. Chem. 2003, 46, 1567-1570.) A 400 μL portion of overnight S. aureus 10390 culture was diluted with 100 mL of sterile LB broth to give ca. 10 6 CFUs per mL. Aliquots (195 μL) of this solution were added to all of the wells in a sterile 96-well plate (except for the negative control wells; 195 μL of sterile LB broth were added to these wells). The plates were placed on an orbital shaker table and gently swirled for 1 h to ensure compound dissolution, and then incubated (without shaking) for 12 h at 37° C. The absorbance at 595 nm was recorded using a plate reader. Compounds that demonstrated complete growth inhibition had an absorbance equal to that of the negative control. Compounds exhibiting no growth inhibition had an absorbance equal to that of the positive control.
Compounds that showed a selected complete growth inhibition at ca. 50 μM were subjected to further testing. The original “spot stock” solutions of these compounds were diluted with DMSO to give ca. 25 and 13 μM final concentrations and tested for inhibitory activities using the procedure described above.
All references throughout this application, for example patent documents including issued or granted patents or equivalents; patent application publications; and non-patent literature documents or other source material; are hereby incorporated by reference herein in their entireties, as though individually incorporated by reference, to the extent each reference is at least partially not inconsistent with the disclosure in this application (for example, a reference that is partially inconsistent is incorporated by reference except for the partially inconsistent portion of the reference).
When a group of substituents is disclosed herein, it is understood that all individual members of those groups and all subgroups, including any isomers and enantiomers of the group members, and classes of compounds that can be formed using the substituents are disclosed separately. When a Markush group or other grouping is used herein, all individual members of the group and all combinations and subcombinations possible of the group are intended to be individually included in the disclosure. When a compound is described herein such that a particular isomer or enantiomer of the compound is not specified, for example, in a formula or in a chemical name, that description is intended to include each isomer and enantiomer of the compound described individually or in any combination. When an atom is described herein, including in a composition, any isotope of such atom is intended to be included. Specific names of compounds are intended to be exemplary, as it is known that one of ordinary skill in the art can name the same compounds differently. Every formulation or combination of components described or exemplified herein can be used to practice the invention, unless otherwise stated. Whenever a range is given in the specification, for example, a temperature range, a time range, or a composition range, all intermediate ranges and subranges, as well as all individual values included in the ranges given are intended to be included in the disclosure.
All patents and publications mentioned in the specification are indicative of the levels of skill of those skilled in the art to which the invention pertains. References cited herein are incorporated by reference herein in their entirety to indicate the state of the art, in some cases as of their filing date, and it is intended that this information can be employed herein, if needed, to exclude (for example, to disclaim) specific embodiments that are in the prior art. For example, when a compound is claimed, it should be understood that compounds known in the prior art, including certain compounds disclosed in the references disclosed herein (particularly in referenced patent documents), are not intended to be included in the claim.
The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention. It will be apparent to one of ordinary skill in the art that methods, devices, device elements, materials, procedures and techniques other than those specifically described herein can be applied to the practice of the invention as broadly disclosed herein without resort to undue experimentation. All art-known functional equivalents of methods, devices, device elements, materials, procedures and techniques described herein are intended to be encompassed by this invention. Whenever a range is disclosed, all subranges and individual values are intended to be encompassed. This invention is not to be limited by the embodiments disclosed, including any shown in the drawings or exemplified in the specification, which are given by way of example or illustration and not of limitation.
The terms and expressions which have been employed herein are used as terms of description and not of limitation, and 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, but it is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments, exemplary embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims. The specific embodiments provided herein are examples of useful embodiments of the present invention and it will be apparent to one skilled in the art that the present invention may be carried out using a large number of variations of the devices, device components, methods steps set forth in the present description. As will be obvious to one of skill in the art, methods and devices useful for the present methods can include a large number of optional composition and processing elements and steps.
Many of the molecules disclosed herein contain one or more ionizable groups [groups from which a proton can be removed (e.g., —COOH) or added (e.g., amines) or which can be quaternized (e.g., amines)]. All possible ionic forms of such molecules and salts thereof are intended to be included individually in the disclosure herein. With regard to salts of the compounds herein, one of ordinary skill in the art can select from among a wide variety of available counterions those that are appropriate for preparation of salts of this invention for a given application. In specific applications, the selection of a given anion or cation for preparation of a salt may result in increased or decreased solubility of that salt.
Every formulation or combination of components described or exemplified herein can be used to practice the invention, unless otherwise stated.
Whenever a range is given in the specification, for example, a temperature range, a time range, or a composition or concentration range, all intermediate ranges and subranges, as well as all individual values included in the ranges given are intended to be included in the disclosure. It will be understood that any subranges or individual values in a range or subrange that are included in the description herein can be excluded from the claims herein.
All patents and publications mentioned in the specification are indicative of the levels of skill of those skilled in the art to which the invention pertains. References cited herein are incorporated by reference herein in their entirety to indicate the state of the art as of their publication or filing date and it is intended that this information can be employed herein, if needed, to exclude specific embodiments that are in the prior art. For example, when composition of matter are claimed, it should be understood that compounds known and available in the art prior to Applicant's invention, including compounds for which an enabling disclosure is provided in the references cited herein, are not intended to be included in the composition of matter claims herein.
As used herein, “comprising” is synonymous with “including,” “containing,” or “characterized by,” and is inclusive or open-ended and does not exclude additional, unrecited elements or method steps. As used herein, “consisting of” excludes any element, step, or ingredient not specified in the claim element. As used herein, “consisting essentially of” does not exclude materials or steps that do not materially affect the basic and novel characteristics of the claim. In each instance herein any of the terms “comprising”, “consisting essentially of” and “consisting of” may be replaced with either of the other terms. The invention illustratively described herein suitably may be practiced in the absence of any element or elements, limitation or limitations which is not specifically disclosed herein.
One of ordinary skill in the art will appreciate that starting materials, biological materials, reagents, synthetic methods, purification methods, analytical methods, assay methods, and biological methods other than those specifically exemplified can be employed in the practice of the invention without resort to undue experimentation. All art-known functional equivalents, of any such materials and methods are intended to be included in this invention. The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention that in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims.
Methods of this invention comprise the step of administering a “therapeutically effective amount” of the present therapeutic formulations containing the present compounds, to treat, reduce or regulate a disease state in a patient, including a disease state involving one or more infectious agents such as bacteria. The term “therapeutically effective amount,” as used herein, refers to the amount of the therapeutic formulation, that, when administered to the individual is effective to treat, reduce or regulate a disease state in a patient, including a disease state involving one or more infectious agents such as bacteria. As is understood in the art, the therapeutically effective amount of a given compound or formulation will depend at least in part upon, the mode of administration (e.g. intravenous, oral, topical administration), any carrier or vehicle employed, and the specific individual to whom the formulation is to be administered (age, weight, condition, sex, etc.). The dosage requirements need to achieve the “therapeutically effective amount” vary with the particular formulations employed, the route of administration, and clinical objectives. Based on the results obtained in standard pharmacological test procedures, projected daily dosages of active compound can be determined as is understood in the art.
Any suitable form of administration can be employed in connection with the therapeutic formulations of the present invention. The therapeutic formulations of this invention can be administered intravenously, in oral dosage forms, intraperitoneally, subcutaneously, or intramuscularly, all using dosage forms well known to those of ordinary skill in the pharmaceutical arts.
The therapeutic formulations of this invention can be administered alone, but may be administered with a pharmaceutical carrier selected upon the basis of the chosen route of administration and standard pharmaceutical practice.
The therapeutic formulations of this invention and medicaments of this invention may further comprise one or more pharmaceutically acceptable carrier, excipient, or diluent. Such compositions and medicaments are prepared in accordance with acceptable pharmaceutical procedures, such as, for example, those described in Remingtons Pharmaceutical Sciences, 17th edition, ed. Alfonoso R. Gennaro, Mack Publishing Company, Easton, Pa. (1985), which is incorporated herein by reference in its entirety.
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The present invention relates generally to compounds providing antibacterial therapeutic agents and preparations, and related methods of using and making antibacterial compounds. Antibacterial compounds of the present invention include chalcone, alkylpyrimidine, aminopyrimidine and cyanopyridine compounds and derivatives thereof exhibiting minimum inhibitory concentrations (MIC) similar to or less than conventional antibacterial compounds in wide use.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a helmet which a driver wears when he rides on various kinds of vessels and vehicles such as a motorcycle, and a automobile, a motorboat or a bicycle, and more particularly to a helmet which has a ventilation structure in the helmet and a straightening structure for channeling off a traveling wind from a surface of the helmet.
[0003] 2. Description of the Related Art
[0004] As related art literature information relevant to the present invention, we note Japanese Patent Laid-Open No. 2000-328343 [Patent Document 1] and WO2002-100204 [Patent Document 2].
[0005] The constitution described in the above-mentioned Patent Document 1 is characterized in that a portion which performs the channeling-off of a traveling wind (a rear straightening member) and a portion which performs the ventilation (a passage forming member) are mounted on a surface of a helmet body as an integral structure.
[0006] Further, the constitution described in the above-mentioned Patent Document 2 is also characterized in that a portion which performs the channeling-off of a traveling wind (an air flow deflection surface) and a portion which performs the ventilation (a ventilation port) are mounted on a surface of a helmet body as an integral structure.
[0007] That is, the inventions disclosed in the above-mentioned Patent Document 1 and Patent Document 2 are useful from a viewpoint of enhancing a ventilation action and a straightening action by channeling-off the above-mentioned traveling wind.
[0008] Here, with respect to the inventions described in the above-mentioned Patent Document 1 and Patent Document 2, the portion which performs the channeling-off of the traveling wind and the portion which performs the ventilation are integrally formed and, at the same time, these portions are mounted on fixed positions on the surface of the helmet body in an immobile state. Accordingly, there may be a case that a targeted channeling function cannot be sufficiently obtained depending on the difference in intrinsic driving postures of helmet wearers, speeds of vehicles and the like.
[0009] Accordingly, it is a task of the present invention to obtain a targeted traveling-wind channel-off function irrespective of the difference in intrinsic driving postures of helmet wearers, speeds of vehicles.
SUMMARY OF THE INVENTION
[0010] To achieve the above-mentioned object, the present invention adopts following technical means.
[0011] The technical means is directed to a helmet which mounts a straightening member relating to holding of stability of the helmet against flow of air during traveling on a surface of a helmet body, wherein the straightening member is formed so as to allow a helmet wearer to adjust a position of the straightening member in a fore-and-aft direction corresponding to various intrinsic driving postures of the helmet wearer and a speed of vehicles (first invention).
[0012] Further, another technical means is directed to a helmet which mounts a straightening member relating to holding of stability of the helmet against flow of air during traveling on a surface of a helmet body, wherein the straightening member is formed so as to allow a helmet wearer to adjust an angle of a straightening surface which faces a traveling wind corresponding to various intrinsic driving postures of the helmet wearer and a speed of vehicles (second invention).
[0013] Further, still another technical means is directed to a helmet which mounts a straightening member relating to holding of stability of the helmet against flow of air during traveling on a surface of a helmet body, wherein the straightening member is formed so as to allow a helmet wearer to adjust a position of the straightening member in a fore-and-aft direction and, at the same time, to adjust an angle of a straightening surface which faces a traveling wind corresponding to various intrinsic driving postures of the helmet wearer and a speed of vehicles (third invention).
[0014] Further, when the helmet includes an air ventilation port on the surface of the helmet body, from a viewpoint of enhancing the discharge efficiency from a discharge port, it is preferable that the straightening body is capable of adjusting a relative position thereof within a range that the straightening member is capable of straightening the flow of air in the vicinity of the ventilation port (fourth invention).
[0015] When the helmet includes a ventilation cover which covers the ventilation port, from a viewpoint of the enhancement of the discharge efficiency from the ventilation cover, the enhancement of the manipulation performance and the assurance of favorable design, it is preferable that the straightening member forms an integral structure with the ventilation cover (fifth invention).
[0016] As the structure which changes the position of the straightening member, it is possible, for example, the structure which is a combination of an elongated hole which is formed along the fore-and-aft direction in one side of the straightening member or a support portion which supports the straightening member and a fitting member which is formed on another side and is fitted in the elongated hole and in which the fitting member holds the position of the straightening member and releases such holding, and the structure which forms ratchets on the straightening member and a support surface which supports the straightening member and in which the position of the straightening member is changed by moving the straightening member in the fore-and-aft direction against the fitting resistance of the ratchet.
[0017] Further, as the structure which changes the angle of the straightening member, it is possible, for example, the structure which includes an adjustment means which rotatably supports the front side of the straightening member so as to move the rear end of the straightening member vertically and holds the straightening member at predetermined position, and the structure which pivotally supports the front side of the straightening member and forms ratchets over the straightening member and a support surface which support the straightening member behind the pivotally supporting portion and moves the straightening member vertically against the fitting resistance of the ratchets so as to change the position of the straightening member.
[0018] The present invention can expect following excellent effects due to the above-mentioned constitutions.
[0019] According to the first invention, by allowing the helmet wearer to change the position of the straightening member to a position which corresponds to the various intrinsic driving postures of the helmet wearer and the speed of vehicles, it is helps to obtain the targeted traveling-wind channel-off function.
[0020] Further, according to the second invention, by allowing the helmet wearer to change the angle of the straightening member to an angle which corresponds to the various intrinsic driving postures of the helmet wearer and the speed of vehicles, it is possible to obtain the targeted traveling-wind channel-off function.
[0021] Further, according to the third invention, in addition to the acquisition of the effects of the claims 1 and 2 , the adjustment corresponding to the various intrinsic driving postures of the helmet wearer and the speed of a vehicles is enabled and hence, it helps to enhance the targeted traveling-wind channel-off function.
[0022] Further, according to the fourth invention, in addition to the acquisition of the effects of the above-mentioned first and second inventions, the straightening is conducted in the vicinity of the ventilation port for ventilation and hence, it helps to efficiently perform the discharge from the discharge port. Due to this efficient discharge, it helps to allow the traveling wind to efficiently enter the inside of the helmet through an intake port and hence, it helps to expect the efficient ventilation in the helmet.
[0023] Further, according to the fifth invention, it helps to expect the discharge efficiency from the ventilation cover, the enhancement of the manipulation performance and the favorable design.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a perspective view of a helmet according to the present invention;
[0025] FIG. 2 is a cross-sectional view taken along a line (II)-(II) in FIG. 1 ;
[0026] FIG. 3 is an enlarged view with a part broken away of an essential part showing another embodiment;
[0027] FIG. 4 is a perspective view taken along a line (IV)-(IV) in FIG. 3 ;
[0028] FIG. 5 is an enlarged view of an essential part showing another example;
[0029] FIG. 6 is a cross-sectional view taken along a line (VI)-(VI) in FIG. 5 ;
[0030] FIG. 7 is an enlarged view of an essential part showing another example;
[0031] FIG. 8 is a cross-sectional view taken along a line (VIII)-(VIII) in FIG. 7 ;
[0032] FIG. 9 is a cross-sectional view taken along a line (IX)-(IX) in FIG. 7 ;
[0033] FIG. 10 is a cross-sectional view of an essential part showing another example;
[0034] FIG. 11 is a cross-sectional view taken along a line (XI)-(XI) in FIG. 10 ;
[0035] FIG. 12 is a perspective view of an essential part showing another example;
[0036] FIG. 13 is a perspective view of an essential part showing another example; and
[0037] FIG. 14 is a perspective view of an essential part showing another example.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] Best modes for carrying out a helmet of the present invention are explained hereinafter in conjunction with drawings.
[0039] FIG. 1 to FIG. 4 show the first embodiment (helmet A) of the present invention, FIG. 5 to FIG. 11 show the second embodiment (helmet B) of the present invention, and FIG. 12 and FIG. 13 show the third embodiment (helmet C) of the present invention.
[0040] The basic constitution of the helmets A to C illustrated in the respective modes is configured as follows. That is, in the inside of a helmet body 1 which is formed in a given shape using a fiber reinforced resin material, an impact absorbing liner which is formed of foamed styrene or a material having an impact absorbing function equivalent to an impact absorbing function of the foamed styrene, a head interior member which is arranged inside the impact absorbing liner and is made of a urethane material or the like, and cheek pads are interiorly formed. A shield 2 is mounted on a front opening portion of the helmet body 1 in a state that the shield 2 can be opened and closed, wherein the shield 2 is provided with two ventilation ports, that is, left and right ventilation ports 2 L, 2 R which discharge hot air inside the helmets A to C.
[0041] Here, although the helmet illustrated in this mode for carrying out the invention is a full-face type helmet, the present invention is not limited to the full-face type helmet and is also applicable to a jet type helmet and a half type helmet.
[0042] First of all, the first mode of the present invention is explained.
[0043] The helmet A of this mode is characterized in that ventilation covers 3 L, 3 R which cover and conceal the above-mentioned ventilation ports 2 L, 2 R are mounted on a surface of the helmet body 1 , and a position of a straightening member 4 can be changed due to the slide structure which allows the straightening member 4 to slide in the fore-and-aft direction along the ventilation covers 3 L, 3 R.
[0044] The ventilation covers 3 L, 3 R of this mode are approximately tunnel-like covers which are formed to guide a traveling wind from a front side to a rear side of the helmet body 1 . Each of the respective ventilation covers 3 L, 3 R forms an intake port 31 in a front end thereof and an discharge port 32 in a rear end thereof. By making use of a negative pressure which is generated when the traveling wind eriters the helmet A from the intake port 31 and is discharged from the discharge port 32 , hot air in the inside of the helmet A is sucked from the ventilation ports 2 L, 2 R which are positioned inside the ventilation covers 3 L, 3 R.
[0045] Hereinafter, the slide structure of the above-mentioned straightening member 4 in the helmet A of this mode is explained (see FIG. 1 , FIG. 2 ).
[0046] The above-mentioned straightening member 4 is configured such that the straightening member 4 includes an elongated hole 42 for slide guiding on a front side and a straightening surface 41 on a rear side and, further, includes slide surfaces 43 L, 43 R which slide while being guided by the ventilation covers 3 L, 3 R. The straightening member 4 is mounted on the helmet body 1 by allowing a small screw 12 which fixes the position of the straightening member 4 or releases such fixing to be threadedly engaged with a screw hole 11 formed in the surface of the helmet body 1 between the above-mentioned ventilation covers 3 L, 3 R through the elongated hole 42 .
[0047] That is, according to the slide structure having the above-mentioned constitution, the straightening member 4 is allowed to be slidable in the fore-and-aft direction along the ventilation covers 3 L, 3 R by loosening or slackening the above-mentioned small bolt 12 and is held at the position by fastening the small bolt 12 .
[0048] Here, the slide distance of the above-mentioned straightening member is ensured by an amount corresponding to a length of the elongated hole. The change of the slide distance can be realized by preparing the straightening members having elongated holes of different lengths and by exchanging one straightening member with another straightening member which has the targeted elongated hole (not shown in the drawing).
[0049] Hereinafter, another slide structure of the straightening member 4 which slides in the fore-and-aft direction is explained (see FIG. 3 and FIG. 4 ).
[0050] The slide structure of this mode is characterized in that the sliding and the fixing of the straightening member 4 are controlled by ratchets. The explanation of parts which overlap the above-mentioned parts is omitted by giving the same symbols to the parts.
[0051] The straightening member 4 is mounted on the helmet body 1 in a state that the straightening member 4 is mounted on a fixed plate 44 which is fixedly secured to the surface of the helmet body 1 between the above-mentioned ventilation covers 3 L, 3 R by way of a ratchet 5 and a slide guide portion 6 which are formed over the fixed plate 44 and the straightening member 4 .
[0052] The ratchet 5 is configured such that fitting recessed portions 51 L, 51 R in two rows which form a large number of indentations 51 therein in the fore-and-aft direction of the above-mentioned ventilation covers 3 L, 3 R are mounted on the fixed plate 44 and, at the same time, resilient fitting members 52 L, 52 R which are engaged with or disengaged from the indentations 51 formed in either one of the above-mentioned fitting recessed portions 51 L, 51 R are mounted on the above-mentioned straightening member 4 .
[0053] The slide guide portion 6 is configured such that latch projections 53 L, 53 R are mounted on the above-mentioned fixed plate 44 along the fitting recessed portions 51 L, 5 1 R in a state that the latch projections 53 L, 53 R are arranged outside the above-mentioned fitting recessed portions 51 L, 51 R, while slide projections 54 L, 54 R which are slidably engaged with the above-mentioned latch projections 53 L, 53 R are mounted on the straightening member 4 .
[0054] That is, according to the slide structure having the above-mentioned constitution, the position of the straightening member 4 is held by the engagement of the resilient fitting members 52 L, 52 R with the fitting recessed portions 51 L, 51 R formed in the ratchet 5 , while the engagement of the resilient fitting members 52 L, 52 R with the fitting recessed portions 51 L, 51 R is released by sidably moving the straightening member 4 with a force larger than a resilient force of the ratchet 5 and the straightening member 4 is slidably moved in the fore-and-aft direction due to the slide movement of the slide projections 54 L, 54 R along the latch projections 53 L, 53 R.
[0055] Here, the slide distance of the above-mentioned straightening member is ensured by an amount corresponding to a length of the above-mentioned fitting recessed portions and latch projections. The change of the slide distance can be realized by preparing the fitting recessed portions and latch projections having different lengths and by exchanging one straightening member with another straightening member which has the targeted fitting recessed portion and latch projection (not shown in the drawing).
[0056] Further, the mode of arrangement of the constitutional members of the above-mentioned ratchet and the slide guide portion may adopt a mode which is opposite to the illustrated mode.
[0057] Further, one of constitutional members consisting of the above-mentioned ratchet and slide guide portion may be directly formed on the ventilation cover.
[0058] The second mode of the present invention is explained hereinafter.
[0059] The helmet B of this mode includes ventilation covers 3 L, 3 R in the same manner as the above-illustrated helmet A and also includes a straightening member 7 between the ventilation covers 3 L, 3 R.
[0060] Further, the straightening member 7 of this mode is configured to be capable of changing an angle of a straightening surface 71 against a traveling wind by changing an angle of the straightening member 7 by rotatably supporting the straightening member 7 using the pivotally supporting portion P as an axis.
[0061] Here, the explanation of parts which overlap the parts of the above-mentioned helmet A is omitted by giving the same symbols.
[0062] The angle changing structure of the above-mentioned straightening member 4 in the helmet B of this mode is explained hereinafter (see FIG. 5 and FIG. 6 ).
[0063] The straightening member 7 of this mode is rotatably supported on a pivotally supporting plate 45 which is fixedly secured to the surface of the helmet body 1 between the above-mentioned ventilation covers 3 L, 3 R.
[0064] In the above-mentioned pivotally supporting plate 45 , a space S which has a size to allow the snug fitting of the straightening member 7 is formed. The straightening member 7 is fitted in the space S and front-end-side side surfaces of the straightening member 7 are pivotally supported on front-end-side side surfaces of the space S.
[0065] Further, the above-mentioned straightening member 7 is supported on a bolt 72 which is mounted between a rear-end-side bottom surface of the straightening member 7 and a bottom surface 451 of the pivotally supporting plate 45 .
[0066] The above-mentioned bolt 72 has an upper end thereof fitted in an elongated groove 73 formed in the rear-end-side bottom surface of the straightening member 7 in a state that the bolt 72 is slidable in the elongated groove 73 and is prevented from being removed from the elongated groove 73 . The above-mentioned bolt 72 has a lower end thereof threaded into a pedestal portion 74 mounted on the above-mentioned helmet body 1 .
[0067] The above-mentioned elongated groove 73 is provided for absorbing the displacement of the fitting position of the bolt 72 at the time of changing the angle of the straightening member 7 described later.
[0068] A dial 75 is fixedly mounted on and is disposed around the above-mentioned bolt 72 . When the dial 75 is rotated, the bolt 72 is rotated and a projecting length of the bolt 72 with respect to the pedestal portion 74 is adjusted to a short length as well as to a long length.
[0069] That is, according to the angle changing structure of this mode, by elongating the projecting length of the above-mentioned bolt 72 with the rotation of the above-mentioned dial 75 , a rear end portion of the straightening member 7 is lifted upwardly and the position is held.
[0070] Here, the above-mentioned straightening member 7 is rotated using the above-mentioned pivotally supporting portion P as the center of rotation so that an angle thereof is changed upwardly.
[0071] Further, by shortening the projecting length of the above-mentioned bolt 72 with the reverse rotation of the above-mentioned dial 75 , the bolt 72 pulls down the rear end portion of the straightening member 7 and the position is held.
[0072] Here, the above-mentioned straightening member 7 is rotated using the above-mentioned pivotally supporting portion P as the center of rotation so that an angle thereof is changed downwardly.
[0073] Due to the above-mentioned operations, the angle of the straightening member 7 is changed and hence, it is possible to change the angle of the straightening surface 71 against the traveling wind.
[0074] Here, an angle variable range of the above-mentioned straightening member is increased or decreased corresponding to the vertical movable distance of the bolt. The change of this angle variable range can be realized by exchanging bolts which have different lengths (not shown in the drawing).
[0075] Further, the straightening member may be directly pivotally supported on the ventilation cover.
[0076] Another angle changing structure of the straightening member 7 whose angle is changed is explained hereinafter (see FIG. 7 to FIG. 9 ).
[0077] The angle changing structure of this mode is characterized by gradually changing the angle of the straightening member 7 by a left-and-right rotational manipulation of a lever 76 and the explanation of parts which overlap the above-mentioned parts is omitted by giving the same symbols.
[0078] On a rear-end-side bottom surface of the above-mentioned straightening member 7 , a recessed plate 78 is formed in a projecting manner, wherein a large number of indentation portions 77 are formed in the left-and-right direction in parallel in a state that heights of the indentation portions 77 are gradually changed in the longitudinal direction. Further, a projecting portion 79 of the above-mentioned lever 76 is configured to be fitted in any selected one of the indentation portions 77 formed on the recessed plate 78 .
[0079] The above-mentioned indentation portions 77 are formed in an arcuate shape, while the projecting portion 79 is formed in an arcuate shape which conforms to the arcuate shape of the above-mentioned indentation portions 77 .
[0080] The above-mentioned lever 76 is pivotally supported on a bottom surface 452 of the pivotally supporting plate 45 in a state that the lever 76 is rotatable in the left-and-right direction, wherein with the left-and-right rotating manipulation of the lever 76 , the fitting position of the projecting portion 79 with respect to the above-mentioned indentation portions 77 is changed.
[0081] Symbols 80 L, 80 R indicate leaf springs which are fixedly secured to the straightening member 7 , while symbols 81 L, 81 R indicate latch portions which are formed on the above-mentioned bottom surface 452 to latch the above-mentioned leaf springs 80 L, 80 R. By applying a biasing force of the leaf springs 80 L, 80 R which are latched to the latch portions 81 L, 81 R to the downward rotation of the straightening member 7 , the fitting state of the projecting portion 79 with respect to the indentation portions 77 is held.
[0082] That is, according to the angle changing structure of this mode, the fitting position of the projecting portion with respect to the above-mentioned indentation portions 77 is changed with the left-and-right rotary manipulation of the above-mentioned lever 76 , and the rear end portion of the straightening member 7 is moved vertically due to the change of the fitting position and the fitted state is held by the biasing force of the above-mentioned leaf springs 80 L, 80 R.
[0083] Here, the angle of the above-mentioned straightening member 7 is changed due to the rotation thereof using the above-mentioned pivotally supporting portion P as the center of rotation.
[0084] Due to the above-mentioned operations, the angle of the straightening member 7 is changed thus capable of changing the angle of the straightening surface 71 with respect to the traveling wind.
[0085] Here, although the biasing force is applied to the straightening member using leaf springs in this mode, the present invention is not limited to this mode and the present invention can be exercised also using a biasing means which possesses a substantially equal biasing force as represented by a tensile spring or rubber.
[0086] Further, an angle variable range of the above-mentioned straightening member can be widened or narrowed by adjusting a height of the above-mentioned recessed plate 78 . The change of this angle variable range can be achieved by, for example, preparing straightening members having recessed plates which differ in height and by exchanging one straightening member with another straightening member which has the targeted recessed plate.
[0087] Further, the straightening member may be directly pivotally mounted on the ventilation cover.
[0088] Hereinafter, another angle changing structure of the straightening member 7 whose angle is changed is explained (see FIG. 10 and FIG. 11 ).
[0089] The angle changing structure of this mode is characterized by controlling the change of the angle and the fixing of the straightening member 7 using ratchets 8 . The explanation of parts which overlap the above-mentioned parts is omitted by giving the same symbols.
[0090] Further, since the ratchets 8 have the substantially same constitution as the previously-illustrated ratchets 5 , the detailed explanation of the ratchets 8 is omitted. The ratchets 8 are constituted of resilient fitting members 82 L, 82 R which are mounted on left and right side surfaces of the above-mentioned straightening member 7 and fitting recessed portions 83 L, 83 R which are formed on left and right side surfaces of the pivotally supporting plate 45 in a vertically extending manner.
[0091] That is, according to the angle changing structure of this mode, by vertically moving the rear end portion of the straightening member 8 with a force larger than a resilient force of the ratchets 8 , the straightening member 8 is rotated in the fore-and-aft direction and hence, the angle of the straightening member 8 can be changed.
[0092] Here, the angle variable range of the above-mentioned straightening member in this embodiment can be widened or narrowed corresponding to the number of indentations formed in the fitting recessed portion. That is, the change of the angel variable range can be achieved by, for example, preparing straightening members having fitting recessed portions which differ in the number of indentations and by exchanging one straightening member with another straightening member having the targeted fitting recessed portion.
[0093] Further, the straightening member may be directly pivotally supported on the ventilation cover.
[0094] Hereinafter, the slide structure and the angle changing structure of the straightening member in the helmet C of this mode are explained ( FIG. 12 , FIG. 13 ).
[0095] In the above-mentioned helmets A, B, the straightening members 4 , 7 are formed in an associated manner with the above-mentioned ventilation covers 3 L, 3 R. However, this mode is directed to the helmet C in which the straightening member 9 is provided independently from the above-mentioned ventilation covers 3 L, 3 R.
[0096] The straightening member 9 shown in FIG. 12 is constituted of a slide straightening member 91 which is provided slidably in the fore-and-aft direction with respect to the helmet body 1 and an angle changing straightening member 92 which is provided to a center portion of the slide straightening member 91 in a state that an angle of the angle changing straightening member 92 can be changed.
[0097] An elongated hole portion 93 is formed on a front side of the above-mentioned slide straightening member 91 to ensure a slide distance and a small bolt 12 is threaded into the helmet body 1 through the elongated hole portion 93 . Accordingly, by loosening or slacking the small bolt 12 , the slide straightening member 91 becomes slidable in the fore and aft direction.
[0098] Further, the above-mentioned angle changing straightening member 92 is configured to be rotated with respect to the slide straightening member 1 so as to change the angle of the straightening surface 94 . Accordingly, with respect to the angle changing structure, the angle changing structure in the above-mentioned helmet B is applicable and hence, the illustration and the explanation of the angle changing structure are omitted.
[0099] That is, the straightening member 9 shown in FIG. 12 is characterized in that the slide straightening member 91 slides in the fore-and-aft direction with respect to the helmet body 1 so as to change the position of the straightening surface 94 and, at the same time, the angle changing straightening plate 92 is rotated to change the angle of the straightening surface 94 .
[0100] The straightening member 9 shown in FIG. 13 is constituted of a fixed straightening member 95 which is fixed with respect to the helmet body 1 and an angle changing straightening member 96 which is mounted on a center portion of the fixed straightening member 95 in a state that an angle thereof can be changed.
[0101] The above-mentioned angle changing straightening member 96 is rotated with respect to the fixed straightening member 95 so as to change an angle of the straightening surface 94 . Accordingly, with respect to the angle changing structure, the angle changing structure in the above-mentioned helmet B is applicable and hence, the illustration and the explanation thereof are omitted.
[0102] That is, the straightening member 9 shown in FIG. 12 is characterized in that the angle changing straightening plate 96 is rotated to change the angle of the straightening surface 94 .
[0103] The straightening member 10 shown in FIG. 14 is characterized in that the straightening member 10 is mounted on the ventilation cover 3 in a state that the straightening member 10 is slidable in the fore-and-aft direction or an angle of the straightening member 10 is changeable.
[0104] The ventilation cover 3 of this mode is formed of an integral body which is formed by connecting left and right cover portions 30 L, 30 R by way of a connecting portion 30 arranged in front of a portion where the straightening member 10 is mounted.
[0105] In the drawing, numeral 300 indicates intake ports which are opened in distal ends of the cover portions 30 L, 30 R, numeral 301 indicates switch mechanism mounting holes which are opened in upper surfaces of the cover portions 30 L, 30 R to adjust an amount of air taken from the intake ports 300 , and numeral 302 indicates ventilation ports which are opened in rear ends of the cover portions 30 L, 30 R.
[0106] According to the ventilation cover 3 of this mode, the ventilation cover 3 and the straightening member 10 are formed into a unit and hence, the efficiency of the mounting operation can be enhanced.
[0107] Further, it is possible to provide the straightening member which can adjust the angle thereof with a minimum weight without damaging a function of a conventional ventilation cover and, at the same time, it is possible to provide a sophisticated ventilation cover in terms of design.
[0108] The present invention is not limited to the illustrated modes and the present invention can be exercised with constitutions which do not depart from contents described in respective claims in the Patent Claims.
[0109] Having described specific preferred embodiments of the invention with reference to the accompanying drawings, it will be appreciated that the present invention is not limited to those precise embodiments, and that various changes and modifications can be effected therein by one of ordinary skill in the art without departing from the scope of the invention as defined by the appended claims.
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This invention is to obtain a targeted traveling-window channeling-off function irrelevant to respective intrinsic driving postures of a helmet wearer, a speed of vehicles and the like. Helmets A, B, C include straightening members which relate to the holding of the stability of the helmets during traveling. The straightening members are provided in a state that a position of the straightening members is adjustable in a fore-and-aft direction or an angle of straightening surfaces which face a traveling window in an opposed manner is adjustable corresponding to various intrinsic driving postures of a helmet wearer and a speed of vehicles.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The instant invention is directed toward a portable carrier that permits rapid access to a carried item (e.g., keys, Mace™, pepper spray, a light, tools, a knife, whistles, electronic devices, alarms, and door openers). More specifically, it relates to a carrier that attaches to a user or something being worn by a user and permits that person to easily and rapidly access a desired item for convenience or safety reasons.
[0003] 2. Background Art
[0004] Having rapid and easy access to a selected item has been a problem in the past. For example, for safety reasons it may be desirable to have rapid and easy access to a self-defense product like Mace™ or pepper spray. Such access would allow a person to be able to have the defensive spray in hand to use immediately when needed to deter an attacker while being carried in such a manner as not to interfere with other activities, such as jogging or walking. In the past, consumers have tried to solve the problem of ready availability by attaching such personal defense spray canisters to key chains or carrying the canisters in purses, in hand, in pockets, and in fanny packs. The disadvantages of these prior methods is that the canister is not quickly accessible when needed or the hands are not free to carry other objects.
BRIEF SUMMARY OF THE INVENTION
[0005] A flexible strap of either elastic or non-elastic material is adapted to be formed into a closed loop and passed around a human body part for securing an auxiliary item thereto. The auxiliary item might be keys, pepper spray, a light, tools, a knife, whistles or the like. The strap, in the preferred embodiments, includes releasable fasteners so that it can be independently formed into a loop of a desired size for the body part on which it is to be mounted, with those releasable fasteners possibly being in the form of hook and loop type fasteners.
[0006] The means for attaching auxiliary items to the strap are disclosed in several embodiments including a closed loop cord, a hook or loop type fastener material for securement to the complimentary hook or loop type material on the strap, a pocket formed on the strap with a separate strip of material that is secured to the base strap so as to define an open space between the strip and base strap, or a cylindrical sleeve in which an auxiliary item can be releasably retained.
[0007] Other aspects, features and details of the present invention can be more completely understood by reference to the following detailed description of the preferred embodiments, taken in conjunction with the drawings and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is an isometric view of a first embodiment of a carrier according to the present invention;
[0009] [0009]FIG. 2 is an isometric view of an item to be carried on the carrier depicted, for example, in FIG. 1;
[0010] [0010]FIG. 3 is an isometric view of an alternative embodiment of the present invention similar to that depicted in FIG. 1;
[0011] [0011]FIG. 4 is an isometric view of a second alternative embodiment of a portable carrier according to the instant invention;
[0012] [0012]FIG. 5 is an isometric view of an optional pouch strip for use in combination with the embodiments depicted in FIGS. 1, 3, and 4 ;
[0013] [0013]FIG. 6 is an isometric view of a third alternative embodiment of a carrier according to the instant invention;
[0014] [0014]FIG. 7 is an isometric view of a fourth alternative embodiment of a carrier according to the present invention depicting an optional means for attaching the carrier, and
[0015] [0015]FIG. 8 is an isometric view of an optional pouch strip for use in combination with the embodiments depicted in FIGS. 6 and 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Referring first to FIG. 1, a first preferred embodiment 10 of the portable carrier of the present invention is described. The first embodiment comprises a strap 12 of flexible, elastic or non-elastic material having a longitudinal dimension L 1 and a lateral dimension W 1 . The strap also includes a first end 14 and a second end 16 . A first part of a fastening system such as a hook and loop material 18 (e.g., Velcro™) having a longitudinal dimension L 2 and a lateral dimension W 2 is attached to the strap of material 12 , as shown in FIG. 1. The first part of the hook and loop material 18 may be attached to the strap 12 with glue, stitching, or any other means. In this first preferred embodiment the longitudinal dimension L 2 of the first part of the hook and loop material 18 is less than the longitudinal dimension L 1 of the strap 12 . Further, the lateral dimension W 2 of the first part of the hook and loop material 18 is less than the lateral dimension W 1 of the strap 12 . Adjacent the second end 16 of the strap 12 is a margin 20 . A second part of the hook and loop material 22 is attached to the strap 12 in this margin 20 on the opposite side of the strap 12 from the side on which the first part of the hook and loop material 18 is attached. In this manner, when the first end 14 of the strap is placed in overlapping configuration with the second end 16 of the strap so as to form the strap into a ring or loop (not shown), the second part of the hook and loop material 22 may be mated to the first part of the hook and loop material 18 at a position which holds the carrier as desired. This first preferred embodiment 10 also includes an attachment loop 24 of a cord or the like. The attachment loop 24 is a cord of material that is stitched adjacent one end of the first part of the hook and loop material 18 . An item to be carried (e.g., a key, whistle, electronic device, alarm, door opener, or personal defense spray) maybe attached to this attachment loop 24 . Although this attachment loop 24 is not depicted in the remaining figures, it could be used in conjunction with any of the embodiments of the invention described herein. The longitudinal dimension L 1 of the strap 12 is defined by the intended use of the portable carrier. For example, the portable carrier could be designed to be worn around a person's waist, arm, leg, or finger. Alternatively, the personal carrier could form the belt of a “fanny pack.” If, for example, the user desires to wear the portable carrier around his or her waist, the resulting longitudinal dimension L 1 of the strap will be greater than if the user desires to wear the portable carrier around his or her arm.
[0017] Referring next to FIG. 2, an example of how an item to be carried could be attached to the carrier shown in FIG. 1. Shown in FIG. 2 is a container 26 of defense spray, in this case pepper spray. A piece 28 of the second part of the hook and loop material is associated with the pepper spray. As depicted in FIG. 2, this piece 28 of the second part of the hook and loop material is actually attached to a band of elastic 30 , which is then slid over the pepper spray canister. Alternatively, the piece 28 of the second part of the hook and loop material could be affixed directly to the side of the pepper spray canister 26 . Subsequently, since the piece 28 of the second part of the hook and loop material is now combined with the pepper spray canister 26 , that canister 26 may be subsequently mated to the first part of the hook and loop material 18 attached to the strap 12 at any desired location along the longitudinal dimension L 2 of the first part of the hook and loop material 18 .
[0018] Referring now to FIG. 3, a first alternative embodiment 32 of the portable carrier is shown. In this embodiment, a flexible, elastic or non-elastic strap 34 has a longitudinal dimension L 3 and a width dimension W 3 . Similar to what is shown and described with reference to FIG. 1, in FIG. 3 the strap 34 has a second end 36 with a margin 38 adjacent thereto. A piece of a second part of hook and loop material 40 of approximately the same width W 3 is attached in the margin 38 adjacent the second end 36 of the strap 34 . On the opposite face of the strap 34 is a piece of the first part of hook and loop material 42 which also has a width W 3 and a length L 4 that is preferably slightly greater than one half of L 3 . The embodiment 32 provides a more secure means for attaching the portable carrier to a user since the amount of hook and loop material being mated is correspondingly larger.
[0019] Referring now to FIG. 4, a second alternative embodiment 44 of the portable carrier of the present invention is described. This embodiment is most similar to the embodiment depicted in FIG. 3 with a piece of the first part of the hook and loop material 46 secured on a first face to the strap 48 . In this case, however, the strap 48 is attached to the user in a slightly different manner. In particular, a draw loop 50 is attached to the strap adjacent a first end 52 of the strap 48 . This draw loop 50 may be attached, for example, by sewing or hemming a portion of the strap 48 over a portion of the draw loop 50 . As was the case with the previous embodiments, a margin 53 is located adjacent to a second end 54 of the strap 48 . In this second alternative embodiment, however, a piece of the second part of the hook and loop material 56 is attached to each side of the strap material in the margin 53 . In this manner, the strap 48 maybe removably attached to the user in at least two different ways. First, the second end 54 of the strap 48 may be inserted through the draw loop 50 and doubled back onto itself entrapping a portion of the draw loop 50 before the second part of the hook and loop material 56 is mated with the first part of the hook and loop material 46 . Second, using the portion of the second part of the hook and loop material 56 on the opposite side of the strap, the second end 54 of the strap may be inserted through the draw loop and mated to the first part of the hook and loop material 46 without doubling back the second end of the strap material onto itself to entrap a portion of the draw loop 50 .
[0020] Referring now to FIG. 5, an optional pouch 58 is illustrated that may be combined with the previously described portable carriers of FIGS. 1, 3, and 4 . For illustrative purposes only, the pouch 58 will be described in connection with the second alternative embodiment 44 shown in FIG. 4. FIG. 5 is the back side of the portable carrier shown in FIG. 4. As shown in FIG. 5, a small strip 60 of material may be attached to the strap 48 (FIG. 4), on the opposite side of the strap 48 from the side having the first part of the hook and loop material 46 attached to it, in a manner to create an open space between this small strip of material 60 and the strap 48 . The pouch 58 is created by affixing the small strip of material 60 to the strap 48 at locations along opposite sides 59 and 59 a of the strip 60 thereby creating an open space between the strip 60 and the strap 48 . A third side 62 of the strip 60 can also be secured to the strap 48 thereby creating a pocket with the fourth side 64 of the pouch 58 being unsecured to the strap 48 . This fourth side 64 may then be removably attached to the strap using Velcro™, snaps, zippers, or any other closures (e.g., those used in purses). The sides 59 , 59 a , 62 of the strip 60 may be affixed to the strap 48 by, for example, stitching.
[0021] Referring next to FIG. 6, a third embodiment 66 of a portable carrier according to the present invention is described. This embodiment is most similar to the embodiment depicted in FIG. 3 with like parts having the same reference numerals. In this embodiment, however, a cylindrical pocket or sleeve 68 has been attached to the strap 34 . There are at least two possible methods for creating the cylindrical pocket 68 . First, a separate strip of material may be formed into a cylindrical shape and then attached to the strap 34 in any secure manner. Second, a portion of the strap material may itself be gathered into a loop and then stitched or glued to itself so that the cylindrical pocket 68 takes shape. The cylindrical pocket 68 is preferably formed from an elastic-type material so that it grips and holds an item placed therein. For example, if the cylindrical pocket 68 depicted in FIG. 6 were used in combination with the pepper spray canister 26 shown in FIG. 2, the cylindrical pocket would be dimensioned such that it would be slightly smaller in cross-sectional diameter than the cross-sectional diameter of the pepper spray canister 26 . Thus, the pepper spray canister 26 would be snugly held within the cylindrical pocket 68 , but a user could quickly draw the pepper spray canister 26 from the cylindrical pocket 68 in case of an emergency.
[0022] [0022]FIG. 7 depicts an embodiment 69 similar to the second alternative embodiment 44 with like parts having been given like reference numerals. In FIG. 7, however, a cylindrical pocket 70 such as the pocket 68 described with reference to FIG. 6 is secured to or formed on the strap 48 .
[0023] [0023]FIG. 8 illustrates a strap similar to FIG. 5 with like parts having been given like reference numerals and wherein a cylindrical pocket 72 has been secured to or formed thereon as described in connection with FIGS. 6 and 7.
[0024] Although several embodiments of this invention have been described above, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this invention. For example, the preferred materials for the strap is either nylon or elastic. One could, however, make the strap from cloth, plastic, rubber, or any other flexible material that may be shaped or formed to encircle the wrist, arm, leg, finger, or waist, for example, of the user. Similarly, a single pouch is depicted in each of FIGS. 5 and 8 even though multiple pouches could be used, and these pouches could be located on either side or both sides of the strap. Also, additional attachment loops (see FIG. 1) may be used to suit the desires of various users. It may also be desirable to use alternative means of attaching items to the carrier. For example, one half of a snap could be attached to the strap and the mating opposite half of the snap could be affixed to the item to be carried. The item could then be “snapped” to the strap, providing hands-free carrying of the item in combination with ready and convenient accessibility. An important feature of the instant invention is the ability to have an item readily accessible without having to hold the item in one's hand. A benefit of wearing the portable carrier of the present invention includes a deterrent effect. More particularly, if a stalker or potential attacker is watching someone, that stalker or potential attacker is less likely to select for a victim someone who clearly has defensive means (e.g., pepper spray or Mace™) readily available to them. It is, therefore, intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting.
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A portable carrier adapted for releasable connection to the human body and adapted to carry an auxiliary item such as keys, Mace™, pepper spray, or the like, includes a base strap having first and second parts of a hook and loop type fastener secured thereto. The strap is adapted to be wrapped around a part of the human body and secured to itself to releasably secure the strap to the human body at a desired location. The strap includes means in the form of an attachment loop, a cylindrical pocket, or a pouch adapted to releasably retain the auxiliary item in a manner for rapid-access by the user of the carrier. Alternatively, the auxiliary item may be adapted to directly attach to the base strap itself.
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BACKGROUND OF THE INVENTION
The invention relates to a glass conduit, particularly to be used as a feeder, a working tank and/or as a distributing conduit of a glass melting furnace. The glass conduit includes, successively from the interior toward the exterior, a trough chanelling the glass melt and a trough cover, each made of a fire-proof material, an insulation which includes several individual form bodies, an external casing which at least partially surrounds this insulation arrangement and a beam configuration which supports the glass conduit at least at its bottom and longitudinally.
So far, glass conduits of this kind have been erected as one piece and at the location of use, i.e. in the glassworks. Typically, the conduits have a length of approximately 10 to 15 m; also considering the heavy weight, it is impossible to transport the glass conduit. The beam configuration which supports the weight is generally erected as a so-called "steel boat" in which the insulating parts as well as the trough and the trough covering are manually incorporated. Depending on the size and length of the glass conduit the building time required amounts to approximately two weeks. When the glass conduit is defective or requires overhauling or repairing, the entire furnace must be shut down over a longer period of time. This involves loss of production which negatively affects the yield of the furnace operator. Another disadvantage with conventional glass melting conduits is that during tempering and operation of the conduit the joints of the trough can become leaky such that the melt flows into the insulation arrangement thus rendering the latter ineffective. This adversely affects the production since the molten glass is of a poorer quality and leads to faulty products. Since the glass conduit is configured as one piece, this leakage can often be detected only very late. It is very laborious and requires a time and labor intensive partial disassembling of the conduit to detect the leaking joint to be sealed again.
From U.S. Pat. No. 2,494,974 a glass furnace is known which includes two or more segments which are successively disposed in longitudinal direction. The individual segments differ from each other with respect to their insulating properties. This is accomplished for the individual parts of the furnace, the trough, through cover and external thermal insulation by employing different materials. With regard to the remaining properties, particularly in the mechanical-constructional design, this glass furnace corresponds to conventional constructions; hence, in this case, too, the entire furnace must be manually erected at the site of operation. Therefore, this known furnace also has the above stated disadvantages.
It is therefore an object of the invention to provide a glass conduit of the aforesaid kind which does not have these disadvantages and, in particular, can be repaired, assembled and disassembled more efficiently and also can be operated more safely.
SUMMARY OF THE INVENTION
The inventive glass conduit includes several conduit segments which basically join each other along planes of separation which run vertically and transversely to the longitudinal direction of the glass conduit, and can be braced against one another via coupling agents.
This segment design provides the possibility to prefabricate the conduit away from the site of operation in several units each of which can be transported. The prefabricated conduit segments must then only be transported to and assembled at the site of operation, e.g. a glassworks. The standstill times of glass melting furnaces, e.g. when the feeders must be replaced, are thus reduced to 1/10 of the original nonproductive time. The loss of production is reduced correspondingly and the operating results are improved. Moreover, in case repairing is required, the individual conduit segments can be replaced quickly and simply which also saves time and costs. An additional advantage is the improved compensation of expanding movements and the so caused mechanical strains in the glass conduit when the latter is tempered before charged with the glass melt. This improved compensation is achieved by the possibility to finally join and brace the conduit segments, which are relatively short as compared to the total length of the conduit, after completion of the tempering. Finally, it is an advantage of the new glass conduit that parts of the conduit segments can be reused since the segment design in accordance with the invention permits an at least partial standardization. The costs for parts and initial material are thus reduced.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side view of a glass conduit including several conduit segments,
FIG. 2 is an enlarged and detailed representation of a conduit segment of FIG. 1, also a side view,
FIG. 3 shows a cross section through the conduit segment taken along line III--III in FIG. 2 and
FIG. 4 shows is a longitudinal cross section through the rear of the glass conduit of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the glass conduit 1 includes a total of three conduit segments 2, 3 and 4 which are successively disposed on a common support beam configuration 5. The first conduit segment 2, i.e. the one on the left in FIG. 1, is configured as a connecting conduit segment to the glass discharge end of a glass melting furnace 10 which is indicated in the drawing only in outlines. The last conduit segment 4, i.e. the one on the right in FIG. 1, is at its free front side connected to or provided with a glass melt discharge 11 which is indicated by broken lines and connected to a glass working machine for manufacturing bottles or other glass objects.
In the vicinity of the separating planes 6, 6' which basically run vertically and transversely to the longitudinal direction of the glass conduit 1, the conduit segments 2 and 3, 3 and 4 are connected to one another at their front sides and braced by means of coupling agents, studs 36 and 46 in this case. Additional coupling agents 26, in this case also studs, serve to join the first conduit segment to the glass melting furnace 10.
All conduit segments 2, 3, and 4 have their own supporting frame construction 24, 34, and 44. The respective frames 24, 34 and 44 are each preferably made of a corner-, T-, U- or a double T-iron. The frames 24, 34, 44 contain the appertaining conduit segment 2, 3, 4, respectively, on the bottom, the top and longitudinally. In the interior of each segment a hollow space is configured for guiding the glass melt. On the bottom side, this space is formed by a trough and on the top side by a trough cover each of which are made of a fire-proof material. These parts are not visible in FIG. 1. Following this toward the exterior is an insulation which is not visible either. Inside the individual segments 2, 3, 4 these parts are supported in their position relatively to one another and with respect to the frame 24, 34, 44 by means of thrust bolts 27, 37, 47 and clamping bolts 27', 37', 47'. This ensures that even while transporting individual segments 2, 3, 4 that all parts of the segments 2, 3 ,4 remain in their given position even when relatively strong accelerating and shaking forces occur, as for example when transporting with a truck. The thrust bolts 27, 37 and 47 extend from the side in horizontal direction through the parts of the frames 24, 34, and 44 and, from the longitudinal sides of the segments 2, 3, 4 they press the intermediate parts against each other. The clamping bolts 27', 37' and 47', however, extend downwardly through the upper part of the frame 24, 34 and 44 and into the upper part of the insulation inside the respective segment 2, 3, 4. They serve particularly to protect the upper parts of the respective segment 2, 3, 4 against transportation damage. During operation of the glass conduit 1 these clamping bolts 27', 37' and 47' can be loosened or even totally removed.
Furthermore, FIG. 1 shows for each segment 2, 3, 4 at the upper end of the appertaining frame 24, 34, 44 several stopper ears 29, 39, 49, respectively. The latter serve to attach chains or ropes by means of which the respective segment 2, 3 or 4 can be lifted and moved using a crane.
The bottom of each of the segments 2, 3, 4 is provided with rollers 29', 39' and 49' which are disposed in pairs at the longitudinal sides of the segment 2, 3, 4 and rest on the support beam configuration 5. For this purpose, the support beam configuration is, on its top side, provided with a top rolling surface 50 on which the rollers 29', 39', 49' can move. On the one hand, this facilitates setting up the glass conduit since the individual segments 2, 3, 4 can be easily moved into the desired position and, on the other hand, this includes the possibility of a friction-free expanding when the glass conduit is tempered.
As already mentioned, the individual segments 2, 3 and 3, 4 contact one another in the vicinity of the front separating planes 6 and 6'. In this area, it is advantageous to first omit insulation and external cover during assembly in order to provide improved monitoring possibilities when the glass conduit is tempered. It is only after the tempering is completed that the segments 2 and 3, 3 and 4 are mechanically braced with respect to each other by means of the coupling agents 36 and 46 using the necessary tensile strength and insulated in the vicinity of the separating planes 6 and 6' by means of an insulating mass which is preferably tamped in. Cracks or enlargement of joints can hence hardly occur. For protection, the tamped-in insulating mass which annularly surrounds the area of the separating planes 6 and 6' is on its external side, in turn, enclosed by pressure plates 60. For inspection purposes of the joints in the area of the separating planes 6 and 6', the insulating material or the tamped-in insulating mass can relatively easily be removed again after removal of the trough plate 60 . Once the inspection and any necessary repairing, have been carried out, the insulating material can be applied and tamped in again.
Since the trough is also composed of several individual sections over the length of a segment 2, 3, 4, there are also trough joints within each of the segments 2, 3 ,4. In order to later have easy access to these joints, the external cover 33 is also in section as it can be seen from FIG. 1, and interrupted in the vicinity of the joints which are in each conduit segments 2, 3, 4. The insulation is also interrupted in the same way and later, particularly following the tempering of the glass conduit 1, it is filled to completion with tamped in insulating mass. This insulating mass is also covered with pressure plates 60' and secured in its position. Hence, all joints in the trough inside the glass conduit 1 remain easily accessible for later inspections and repair.
In order to permit a desired cooling of the glass melt flowing through the glass conduit 1, the segments 2, 3, 4 are provided on top with cooling apertures covered with a lid 28', 38' and 48' which can be moved or horizontally swung. Furthermore, in the transitional area between the bottom and the top, the individual segments 2, 3, 4 are provided with a number of lead-in openings 28", 38", 48" which serve to introduce burners, thermoelements or the like. The openings 28", 38" and 48" run in a basically horizontal direction and end in the inside of the glass conduit, preferably just above the level of the glass melt contained therein.
Due to its frame construction 24, 34 and 44, each of the segments 2, 3, 4 is self-supporting. The entire arrangement of the glass conduit 1, in this case including three conduit segments 2, 3, 4, however, is not self-supporting but is supported by the support beam arrangement 5 disposed below. The support beam arrangement 5 includes in the present case a pair of parallel longitudinal beams 51 of which only the front beam is visible in FIG. 1 due to the lateral point of view. There are spaced-apart stabilizing transverse beams 52 running between the two longitudinal beams 51. The support beam arrangement 5, in turn, rests on several posts 53 the bottom ends of which are supported, for example, in concrete and the top ends of which are provided with means to adjust the height of the support beam arrangement 5.
FIG. 2 of the drawing is an enlarged and detailed representation showing the structure of intermediate conduit segment 3, which includes a lower part 3' and an upper part 3" which are enclosed and supported by the common frame 34. The lower frame part 35 holds the trough which is in the interior of the segment 3 including the appertaining insulation and external casing 33 whereas the upper frame part 35' surrounds, longitudinally and on the top, the also non-visible trough cover including the appertaining insulation and external casing 33'. There are thrust bolts 37 at the longitudinal sides of the conduit segment 3 which are passed through the vertically running parts of the upper part 35' of the frame 34. The clamping bolts 37' are passed through a horizontally running beam of the upper part 35' of the frame and the bottom ends of these bolts extend into the insulation of the upper part 3" of the conduit segment 3.
The lower part 3' shows how the external casing 33 is divided into individual segments between each of which is disposed a pressure plate 60' for the tamped in and underlying insulating mass of the appertaining trough joint.
The lids 38' for the cooling apertures can be seen at the top of the upper part 3" of the conduit segment 3. The passages 38" in the center area of the longitudinal side of the conduit segment 3 in the transitional area between the upper part 3' and the upper part 3" are here visible again.
The stopper ears 39 are visible at the top end of the respective vertically running parts of the frame 34. The rollers 39' are visible at the bottom of the conduit segment 3 and partially covered by parts of the lower part 35 of the frame 34.
As FIG. 2 further clearly shows the front surfaces of the conduit segment 3 are not continuous but are configured to have a small projection and recess. An improved distribution and holding of the load is thus achieved in segments connected to each other. The support beam configuration is again visible below the conduit segment 3, in particular the longitudinal beam 51 thereof including the top rolling surface 50 and the transverse beams 52.
FIG. 3 is a cross section through the conduit segment 3 taken along the line III--III in FIG. 2 showing the structure of the conduit segments 3 concerned. It must be noted here that the internal structure of the other conduit segments 2 and 4 are mostly identical unless the immediate connecting area of the glass melt furnace 10 and the glass discharge 11 are concerned.
In the center of the conduit segment 3 a flat hollow space 30 is visible which is formed by a trough 31 and serves to channel the glass melt. The trough, which is made of a fire-proof material, is covered on top by a lid 31'. On the edges between the trough 31 and the trough lid 31', there are small form bodies disposed which are also made of a fire-proof material. Underneath and on the sides of the trough 31 as well as on the sides of the trough lid 31', there are insulations 32 and 32' which are composed of individual form bodies, e.g. a chamotte. Toward the exterior, the insulations 32 and 32' are covered by an external casing 33 and 33', respectively, made of sheet steel. The external casing 33 of the lower part 3' of the conduit segment 3 is dimensioned so as to be relatively stable and included in the lower part 35 of the supporting steel frame 34. In the area of the upper part 3" of the conduit segment 3 there is a free space between the top external casing 33' and the upper part 35' of the frame surrounding this casing. Beams which run longitudinally along the external casing 33' are disposed in the lateral parts of this free space. These beams can be pressed from the exterior toward the interior by means of thrust bolts 37 which are passed through the frame 34. For this purpose, the frame 34 is advantageously provided with threaded boreholes or threaded sleeves which extend in horizontal direction from the exterior toward the interior. The trough cover 31 and the appertaining form body of the insulation 32' are braced with respect to each other by means of the thrust bolts 37 such that they function practically as one piece without any further coupling means.
The clamping bolts 37' which pass downward into the upper part 3" serve to press the trough cover 31' downward toward the trough 31 and to rigidly hold it there between the inserted form bodies. This prevents particularly the individual parts of the upper part 3" and the lower part 3' from sliding or coming loose during transportation of the conduit segment 3, e.g. on a truck.
In order to adjust the compressive force of the thrust bolts 37' the latter can also be attached in threaded boreholes or sleeves in the upper part 35' of the frame 34. At the external end, each thrust and clamping bolt 37 and 37' has a hexagon head for setting a wrench.
One of the cooling apertures the course of which is indicated by a broken line extends through the upper part 3" of the conduit segment 3 from the hollow space 30 for the glass melt to the upper side of the conduit segment 3. As already mentioned, at its upper end the cooling aperture 38 is covered by means of the lid 38' which can be removed whenever necessary.
Lead-in openings 38" for passing through burners, thermoelements and the like are provided in the transitional area between the trough 31 and the trough cover 31', in particular in the smaller form bodies between the latter.
In the bottom part of the longitudinal sides and in the area of the lower part of the conduit segment 3, the front parts of the frame 34, particularly the lower parts 35 thereof, are configured like flanges and provided with regularly spaced-apart boreholes for passing through the coupling agents 36, threaded bolts in this case, which serve to join the segment 3 to the adjacent segment.
Further stopper ears 39 are attached to the upper end of the upper part 35' of the frame 34; at the opposing lower end of the conduit segments 3 there are further rollers 39' attached.
These rollers 39' can move on the rolling surface 50 of the longitudinal beams 51 of the support beam arrangement 5. The transverse beam 52 connects the two longitudinal beams 51 of the support beam arrangement 5 in transverse direction.
FIG. 4, finally, is a longitudinal partial section in a vertical plane through the glass conduit 1; the section is taken through the conduit segment 4 and through a part of the conduit segment 3. In order to avoid a confusing representation, FIG. 4 does not show frame and casing of the glass conduit 1. As already described, the conduit segments 3 and 4 contact one another along a basically vertical separating plane 6'. The one part of the trough 31 which is located in the conduit segment 3 and the one part of the trough 41 for the glass melt which is located in the conduit segment 4 also contact one another in alignment in plane 6'. The joint resulting in this area following the course of trough is covered toward the bottom by a tamped in insulating mass 61. In the upper part, the joint in the area of the separating plane 6' is also covered by a tamped in insulating mass 62 above the trough covers 31' and 41' which also contact each other. The insulating masses 61 and 62 form a circumferential ring around the trough 31 and 41 and the trough cover 31', 41'. The insulating masses 61 and 62 are supported by the pressure plates 60 (FIG. 1).
The trough in each conduit segment is divided into longitudinal sections which meet at joints 6". In the vicinity of these joints the insulation is formed toward the bottom by a tamped in insulating mass 63. Between the areas where the insulating mass 61, 62, 63 is tamped in, there are the aforesaid insulations 32 and 32' and 42 and 42' which are made of rigid form bodies. The insulating masses 61, 62, and 63 are tamped in preferably after the tempering of the glass conduit 1 such that expansions in the area of vicinity of the joints 6' and 6" cannot affect the tightness and the functioning cf the insulating in general. The tamped in joint masses 61, 62, 63 can be easily removed after removal of the corresponding covers and pressure plates in order to carry out inspection and repair work in the area of the separating plane 6' and 6".
Further, FIG. 4 shows parts of the glass conduit 1 described hereinbefore. Both parts of the trough 31 and 41 thus form a continuous hollow space 30, 40 through which flows the glass melt to the glass discharge 11 shown in the right portion of FIG. 4. Above the hollow space 30, 40 there are apertures 38" and 48" for the aforementioned elements such as heating elements and the like. Toward the top the trough 31, 41 is defined by the trough cover 31', 41'. Toward the exterior or the top the latter is followed by the appertaining insulation 32' and 42'. Following the course of the glass conduit 1 there are several additional cooling apertures 38, 48 each of which is covered by a lid 38' and 48'.
For reasons of clarity, the present embodiment of the glass conduit 1 comprises only three conduit segments 2, 3, 4. In practice, of course, larger numbers of conduit segments, e.g. four to eight, are possible.
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A plurality of conduit segments contact on another which run vertically and transversely to the direction in which molten glass is channelled. Each segment includes at least one trough section and at least one cover section, an insulation of individual formed bodies, and an external casing. The segments are coupled together on support beams and may have removable insulation at joints to facilitate inspection.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application No. P 44 28 802.6 filed Aug. 13, 1994, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to an apparatus for monitoring the winding of sliver (wrap formation) on a roll of a sliver guiding roll pair in a fiber processing machine, particularly a drawing frame. The apparatus includes a pressure roll and a driving roll as well as a pressing mechanism for pressing the pressure roll against the driving roll. Further, switching means are provided for deenergizing the drive of the driving roll when wrap formation occurs about either roll. There is further provided a device which accommodates the pressing mechanism and the pressure roll and which also serves for lifting the pressure roll off the driving roll.
In a known apparatus of the above-outlined type a pressure-roll holder is mounted by a bolt on a pivotal yoke. For exerting a pressure on the pressure-roll bearing, a pressure piston is provided in a guide bearing in the pressure-roll holder. A pressing lever exerts a pressure on the guide bearing by means of a compression spring situated between the pressing lever and the piston. The piston has an adjustable shifting element which may be immobilized by a setscrew and which is provided with a shifting cam. The shifting element carries an adjustable contact ring which may be immobilized by a setscrew. To the pivotal yoke a guide bar is secured by means of a carrier element made of an insulating material. The guide bar serves for receiving a contact sleeve which is slidably arranged on the guide bar such that the friction between the guide bar and the contact sleeve does not allow the latter to slide by virtue of its own weight. On the contact sleeve a contact cam is provided which is situated between the shifting cam and the contact ring. The contact sleeve and the contact ring are connected to opposite electric poles of an electric control. If sliver begins to be wound on a pressure roll or driving roll, the pressure roll is displaced against the resistance of the piston by the cooperating driving roll so that the piston is shifted upwardly until the switching element contacts the switching sleeve. In this manner, a switching function is initiated, resulting in an immediate stoppage of the operation of the drawing frame. The distance between the switching element and the contact edge corresponds to the switching stroke of the piston. This distance also corresponds to the thickness of the sliver winding on the roll. It is therefore apparent that the distance is chosen to be as small as possible to ensure that the drawing frame is brought to a standstill as rapidly as possible when wrap formation starts. It follows that the switching voltage must not be high to securely avoid arc generation between the switching element and the switching sleeve even in case of very small distances. If, because of an operational reason, the cylindrical working face of the pressure roll has to be re-ground, the diameter of the roll will necessarily be reduced. The pivotal yoke, however, is fixed in the same operational position independently from such a diameter decrease so that the piston, when pressure is exerted against the bearing, automatically executes a follow-up shift one-half the diametrical difference of the re-ground pressure roll. In such a follow-up adjustment the switching sleeve is also automatically adjusted to the same extent by means of the lid-like closure member. In this manner the distance is automatically shifted to the desired value upon each follow-up grinding of the pressure roll. Before the pivotal yoke is lifted off its abutment, the operating person, by means of a handle, releases the pressing lever so that the spring is relaxed. If the friction between the piston and the guide bearing is selected such that the piston, after lifting the pivot yoke, is not moved downwardly by its own weight, then the shifting cam, together with the contact sleeve, again attains its operational position upon re-positioning the pressing lever. If, however, the pressure roll has to be re-ground, resulting in a reduced roll diameter, the shifting cam displaces the contact sleeve downwardly into its operational position upon positioning the pressing lever until the pressure roll lies on the driving roll. In this manner, the distance between the contact cam and the contact ring is maintained in its original magnitude.
The above-outlined conventional apparatus requires substantial technical and constructional outlay for several reasons. For each roll pair a separate monitoring device is provided, that is, for the drawing frame a plurality of monitoring devices are necessary. It is an additional disadvantage that each individual monitoring device requires a substantial structural and installational outlay. It is a further drawback that in each instance a plurality of distances between the switching element and the switching sleeve have to be accurately set in order to prevent electric arcing even in case of very small distances.
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, is simple to construct and install and which makes possible to reliably monitor sliver wrapping in a fiber processing machine, particularly a drawing frame.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the sliver processing machine includes a plurality of roll pairs between which a running sliver passes. Each roll pair is composed of a driving roll and a pressure roll. A separate pressing device is connected with each pressure roll for urging each pressure roll against its driving roll. Each pressing device has a shiftable element displaced by the pressure roll upon radial displacement of the pressure roll in response to winding of sliver on either the pressure roll or the associated driving roll. A common actuating element is connected to each shiftable element of each pressing device for displacing the common actuating element upon displacement of any one of the shiftable elements. A switching device is connected to the common actuating element. The switching device has an idle state and a signal-generating state. The switching device is placed into the signal-generating state by the common actuating element upon displacement of the common actuating element by any one of the shiftable elements, whereby the switching device generates a signal in response to winding of sliver on any roll of any of the roll pairs.
By virtue of the fact that the pressing device is coupled with a common, displaceable actuating element, a single monitoring device for a plurality of sliver treating roll pairs is provided in a simple manner. According to the invention, the switching device is actuated by one of the individual shiftable elements via the common actuating element, so that each roll pair needs to affect only a single shiftable element, whereby a significant structural and installational simplification is achieved. Therefore it suffices to use a single switching device to respond to displacements of the common actuating element which too, result in advantages as far structure and installation are concerned. Also, the monitoring device according to the invention is significantly simpler than any known individual monitoring device.
The invention has the following additional advantageous features:
The switching device has a predetermined switching path which remains constant independently from the position of the pressing device.
The switching path may be set such that it remains constant, independently from the diameter of the pressure roll or the driving roll.
The pressing piston is constituted by a spring-biased pressing bar which may be actuated hydraulically, pneumatically or by a spring.
The actuating element may be shifted radially relative to the rolls.
The actuating element is longitudinally displaceable.
The actuating element is an elastic tension element.
The actuating element is a cable, a strap or the like.
The actuating element is biased, for example, by a spring.
The actuating element is fixedly held at one end thereof.
The cable is trained about a cable deflecting pulley.
The actuating element is deflected by deflecting rollers, deflecting cylinders or deflecting pins or the like.
Each piston may displace an associated shiftable deflecting element.
The excursion of the shiftable deflecting roller corresponds to the thickness of the wrapped (wound) sliver.
The actuating element is constituted by a bar, a bow, or the like.
With each shiftable deflecting roller at least one non-shiftable (that is axially fixed) deflecting roller is associated.
With each holding device for receiving the pressing mechanism two non-shiftable deflecting rollers are associated.
The shiftable deflecting roller is facing that side of the non-shiftable deflecting rollers which is oriented away from the pressure roll.
The actuating element is connected with a movable switching device.
The movable switching device has a metal surface.
The movable switching device cooperates with a stationary switching device.
The stationary switching device comprises a measuring device which is an inductive proximity switch.
On both sides of the drawing unit (that is, at opposite axial ends of the rolls of the drawing unit) a monitoring apparatus according to the invention is provided.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevational view of a drawing unit of a drawing frame, incorporating a preferred embodiment of the invention.
FIG. 1a is a top plan view of a detail of the preferred embodiment of FIG. 1.
FIG. 1b is a side elevational view of a detail of the preferred embodiment of FIG. 1.
FIG. 2a is a sectional view taken along line IIa--IIa of FIG. 1.
FIG. 2b is an illustration similar to FIG. 2a, showing a different operational position.
FIG. 3a is a side elevational detail of another preferred embodiment.
FIG. 3b is as view similar to FIG. 3a, showing a different operational position.
FIG. 4 is a view similar to FIG. 1, incorporating still another preferred embodiment.
FIG. 4a is a view similar to FIG. 2a, showing the modification according to FIG. 4.
FIG. 5 is a perspective view of a drawing frame, including a drawing unit incorporating the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning to FIG. 1, a 4-over-3 drawing unit DU of an otherwise not illustrated drawing frame is shown. The drawing unit is composed of three lower rolls I, II and III and four upper rolls 1, 2, 3 and 4. The roll I is the lower outlet roll, the roll II is the lower middle roll and the roll III is the lower input roll. The drawing unit DU processes the sliver 38. The draft is composed of a pre-draft and a principal draft. The roll pairs 4/III and 3/II form the pre-drafting field whereas the roll pairs 3/II and 1, 2/I form the principal drafting field.
The lower output roll I is driven by the principal motor 59 which thus sets the delivery speed for the drawing unit DU. The lower input and middle rolls III and II, respectively, are driven by a motor 60 and a pre-draft transmission gear. The lower rolls I, II and III can thus be designated as driving rolls. The upper rolls 1-4 are pressed against the respective lower rolls I, II, III by pressing devices 5, 6, 7 and 8 mounted in a yoke 13 which is pivotally secured to the machine frame 12 at 13a. The upper rolls 1-4 are thus driven by the lower rolls I-III by frictional engagement. The direction of rotation of the rolls I, II, III as well as 1, 2, 3 and 4 is shown by the arcuate arrows drawn into the respective roll. The sliver 38 which is composed of a plurality of slivers 53a, 53b and 53c as shown in FIG. 4, runs in the direction G. The lower rolls I, II and III are supported in bearing sleeves 11 (FIGS. 2a and 2b) mounted on the machine frame 12.
As shown in FIGS. 2a and 2b, a pressure roll holder 14 is provided which radially displaceably (floatably) supports the pressure roll 4. It is noted that separate such pressure roll holders 14 are associated with the other pressure rolls 1-3.
With particular reference to FIGS. 1b and 2a, the pressure roll holder 14 for the pressure roll 4 carries two non-shiftable deflecting rollers 37a and 37b whose rotary axis is at a distance a from one another. Similar non-shiftable deflecting rollers 34a, 34b; 35a, 35b; and 36a, 36b are associated with respective pressure rolls 1, 2 and 3.
As seen in FIGS. 1 and 2a, the pressure roll 4 is associated with a vertically-oriented pressing bar 23 which carries a shiftable deflecting roller 32. Similarly, the pressure rolls 1, 2 and 3 are associated with respective pressing bars 23 which, in turn, carry respective shiftable deflecting rollers 29, 30 and 31. In each instance, the distance between the line connecting the rotary axes of the two non-shiftable deflecting rollers and the rotary axis of the respective shiftable deflecting roller is designated at b.
A single cable 39 is trained consecutively about the outwardly-oriented surface of all shiftable and non-shiftable deflecting rollers in each pressure roll holder 14. The cable 39 is stationarily held at one of its ends by a securing pin 47 affixed to the pivotal yoke 13. Upstream of the roll pair III/4 as viewed in the direction of sliver run G the cable 39 is trained about a deflecting roller 48a. As shown in FIG. 1a, the other end of the cable 39 is attached to an end of a tension spring 49 whose other end is secured to a stationary support 50. Particularly referring to FIGS. 1 and 1b, the four displaceable pressing bars 23 are thus coupled with only a single actuating element (that is, the cable 39) which operates a switching device including a leaf spring 41 and an inductive proximity switch 42. Upon occurrence of sliver wrapping, the switching device 41 and 42 is actuated even if only a single shiftable deflecting roll undergoes excursion.
As shown in FIG. 1a, on each side of the drawing unit (that is, at each axial end of the rolls of the drawing unit) a monitoring device is arranged for detecting wrap formation. The cables 39a and 39b are trained about respective deflecting rollers 48a and 48b. One end of the cables 39a and 39b is secured to a respective tension spring 49a and 49b which are hooked at their other end into stationary posts 50a and 50b, respectively.
Turning to FIGS. 2a and 2b, the pressure roll holder 14 is composed of upper and lower parts 15 and 16. The upper part 15 constitutes a cylinder unit including a cylinder 17 slidably receiving a piston 18. The piston 18 is secured to the pressing bar 23 which, in turn, slides in a guide sleeve 24 provided in a sleeve body 27 situated in the lower part 16 of the pressure roll holder 14.
A bearing 25 supporting an end of the pressure roll 4 extends in an opening 26 of the pressure roll holder 14. The pressing bar 23 presses with its other end against the bearing 25 to maintain the pressure between the pressure roll and the lower driving roll III.
As shown in FIGS. 2a and 2b, a diaphragm 65 secured to the upper part 15 of the pressure roll holder 14 divides the cylinder 17 into an upper and a lower cylinder chamber 17a and 17b, respectively. To generate pressure in the upper cylinder chamber 17a, a nipple 17' is provided to which a non-illustrated pneumatic pressure hose is connected. The lower cylinder chamber 17b may be depressurized by means of a non-illustrated vent. A pin 28 extends through the sleeve body 27 and is, at one end, secured to the pressing bar 23. At its other end the pin 28 carries the shiftable deflecting roller 32. Two further pins 33a (only one is visible in FIGS. 2a and 2b) are secured to the sleeve body 27 and pass bilaterally therethrough. The two pins 33a carry, at one of their ends, the non-shiftable deflecting rollers 37a, 37b (only the roller 37a is visible in FIG. 2a, both are visible in FIG. 1). The pins 28 and 33a extend parallel to the axes of rolls 4, III. The distance between a line connecting the axes of the non-shiftable deflecting rollers 37a and 37b and the axis of the shiftable deflecting roller is designated at b in FIGS. 1b and 2a.
In operation, after the sliver is guided over the lower rolls I, II and III, the pivotal yoke 13 is swung into its working position illustrated in FIG. 1 and fixed in this position so that the pressure rolls 1, 2, 3 and 4 may press the sliver 38 against the respective lower rolls I, II and III. The pressure is obtained by the pressing bars 23 which lie on the respective bearing 25a-25d and are urged downwardly by pressurizing the respective upper cylinder chamber 17a.
With particular reference to FIG. 2b, if on the pressure roll 4 or the lower roll III a sliver winding 38a appears, the pressure roll 4 is, by its associated lower roll III pushed away in the direction A against the resistance of the pressing bar 23 into the position 4' so that the bearing 25 too, and therefore also the pressing bar 23 are displaced in the direction A. As a result, at the same time, the shiftable deflecting roller 32 carried by the pin 28 is displaced in the direction A. The distance b (FIG. 2a) is increased to the distance c (FIG. 2b). It is to be understood that this sequence of events also takes place in the respective other pressure roll holders 14 in case sliver winding on any other pressure roll or lower roll takes place. As shown in FIG. 1b, the distance increase from to causes the cable 39 and the carrier 40 secured to the cable 39 to be pulled in the direction C. This causes the leaf spring 1 which, at one of its ends is affixed to the carrier 40, to be shifted in the direction E. As a result, the metallic surface of the leaf spring 41 approaches the inductive proximity switch 42 so that a switching action takes place whereby a control unit 43 causes an immediate interruption of the drive (drive motors 59, 60) of the drawing frame. The difference between the distances c and b corresponds to the thickness d of the winding 38a generated on the roll.
If for operational reasons the cylindrical working face of some or all of the pressure rolls 1-4 has to be ground, the diameter of such pressure roll is reduced. Thus, the piston 18 and therefore also the pressing bar 23 are shifted upon pressure against the bearing 25 automatically by an amount which equals half the diametrical difference. Upon such a follow-up shift automatically the position of the shiftable deflecting roll 31 is displaced by the same amount.
FIGS. 3a and 3b illustrate a mechanical solution by means of which essentially the same functions as those described in connection with FIGS. 2a and 2b may be performed. In order to exert pressure on the pressure roll bearing 25 a pressing bar 23 is provided in a bearing sleeve 24 of the pressure roll holder 14. Between a fixed end plate 44 and a movable plate 46 a compression spring 45 is disposed which, via the plate 46 exerts pressure on the upper end of the pressing bar 23. The plate (intermediate member) 46 prevents direct contact of the compression spring 45 with the pressing bar 23.
In the embodiment according to FIGS. 4 and 4a, the single actuating element is constituted by a substantially rigid actuating component, referred to as an actuating bar 63 which is, at its one end, pivotally secured to a machine frame component at 64. The bar 63, similarly to the cable 39 of the earlier-described embodiment, is displaced upon movement of any one of the pressing bars 23. For this purpose the actuating bar 63 extends in the vicinity of each pressing bar 23 associated with a respective pressure roll 2, 3 or 4. A stop 66 situated preferably close to the free end of the bar 63, remote from the pivot 64, is carried by a machine component and determines the position of rest (non-actuated position) of the bar 63.
As a part of the pressing bars 23, respective extensions such as lugs or pins 67, 68 and 69 are affixed to the pressing bar body and are so positioned that their path of movement is traversed by the actuating bar 63. In FIG. 4, a substantial length portion of the pressing bar 23 associated with the pressure roll 4 is shown in dotted lines to illustrate that it carries the pin 69. Stated differently, the pins 67, 68 and 69 replace the shiftable deflecting rollers 29, 30 and 31 of the embodiment described in connection with FIG. 1 and thus the pins 67, 68 and 69 are affixed to the respective pressing bars 23 similarly to the roller shaft (pin) 28 illustrated in FIG. 2a. FIG. 4a shows such an arrangement for the pressure roll holder 14 associated with the pressure roll 4. The free end of the bar 63 remote from its pivotal end cooperates with a proximity switch 42 which responds to a change in distance from the bar 63, just as the proximity switch 42 of FIGS. 1 and 1b responds to a change in distance from the component 41.
As any one of the pressing bars 23 is lifted by the respective pressure roll 2, 3 or 4 because winding of the sliver about a roll occurs, the respective pins 67, 68 or 69 will displace the bar 63, whereupon the proximity switch 42 will respond.
It is to be added that apart from the different actuating element (bar 63 instead of flexible belt 39) and its displacement mechanism (pins 67, 68 and 69 instead of shiftable rollers 30, 31 and 32) the operating mechanisms, for example, the pressure generator for the pressing bars 23 is the same as in the embodiment described in connection with FIG. 1.
It is well known that during normal, proper operation of the drawing frame, thickness variations in the running sliver may occur and such variations may cause radial excursions of the pressure rolls 1-4 and thus longitudinal, upward displacements of the pressing bars 23. It is apparent that such displacements should not give rise to a signal which is to represent the undesired sliver winding. Such an operation may be ensured, for example, by an appropriate setting of the sensitivity of the respective pressure sensor 42 which then would ignore displacements of the respective pressing bars 23 caused by thickness fluctuations of the running sliver. Or, particularly in the FIG. 4 embodiment, the position of the stop 66 which determines a position of rest of the non-actuated bar 63 may be made adjustable so that a positional change of the bar 63 does not occur during those displacements of the pins 67, 68, 69 which are part of the normal sliver treating operation.
FIG. 5 illustrates a drawing frame DF which may incorporate the invention. The drawing frame DF may be an HS Model high production machine manufactured by Trutzschler GmbH & Co. KG, Monchengladbach, Germany. Underneath the sliver inlet 52 of the drawing frame DF a plurality of cylindrical coiler cans 51 are arranged and the input sliver 53a, 53b and 53c is drawn therefrom by rollers and introduced into the drawing unit DU. After passing the drawing unit DU, the drafted sliver 55 is deposited into a coiler can 57 by means of a rotary coiler head 56. The drawing unit DU and the coiler head 56 are protected by a drawing unit cover 61 provided with a window 58 for observing the sliver drafting and sliver depositing processes.
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.
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A sliver processing machine includes a plurality of roll pairs between which a running sliver passes. Each roll pair is composed of a driving roll and a pressure roll. A separate pressing device is connected with each pressure roll for urging each pressure roll against its driving roll. Each pressing device has a shiftable element displaced by the pressure roll upon radial displacement of the pressure roll in response to winding of sliver on either the pressure roll or the associated driving roll. A common actuating element is connected to each shiftable element of each pressing device for displacing the common actuating element upon displacement of any one of the shiftable elements. A switching device is connected to the common actuating element. The switching device has an idle state and a signal-generating state. The switching device is placed into the signal-generating state by the common actuating element upon displacement of the common actuating element by any one of the shiftable elements, whereby the switching device generates a signal in response to winding of sliver on any roll of any of the roll pairs.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Subject matter disclosed herein may be disclosed and claimed in the following application filed concurrently herewith, assigned to the assignee of the present invention:
[0002] “Fiber Spinning Process Using a Weakly Interacting Polymer”, Ser. No. 61/191,103 (Docket No. TK4955 US PRV), filed in the names of Dee, Hovanec, and VanMeerveld.
FIELD OF THE INVENTION
[0003] The present invention relates to a process for forming a fibrous web from a high throughput electroblowing process.
BACKGROUND
[0004] Solution spinning processes are frequently used to manufacture fibers and nonwoven fabrics, and in some cases have the advantage of high throughputs, such that the fibers or fabrics can be made in large, commercially viable quantities. These processes can be used to make fibrous webs that are useful in medical garments, filters and other end uses that require a selective barrier. The performance of these types of fibrous webs can be enhanced with the utilization of fibers with small diameters.
[0005] A type of solution spinning called electroblowing produces very fine fibers by spinning a polymer solution through a spinning nozzle in combination with a blowing gas and in the presence of an electric field.
[0006] However, it would be desirable to increase the throughput of this process to increase process efficiencies and lower the cost of manufacturing, without sacrificing fiber uniformity and product quality.
SUMMARY OF THE INVENTION
[0007] The present invention is a fiber spinning process comprising the steps of providing a polymer solution, which comprises at least one polymer dissolved in at least one solvent with a vapor pressure of at least about 6 kPa at 25° C., to a spinneret, issuing the polymer solution in combination with a blowing gas in a direction away from at least one spinning nozzle in the spinneret and in the presence of an electric field wherein the polymer solution is discharged through the spinning nozzle at a discharge rate between about 6 to about 100 ml/min/hole, forming fibers, and collecting the fibers on a collector.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The accompanying drawing, which is incorporated in and constitutes a part of this specification, and together with the description, serves to explain the principles of the invention.
[0009] FIG. 1 is a schematic of a prior art electroblowing apparatus useful for preparing a fibrous web according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0010] The present invention relates to solvent-spun webs and fabrics for a variety of customer end-use applications, such as filtration media, energy storage separators, protective apparel and the like.
[0011] The present invention uses an electroblowing process to spin a polymer dissolved in a high vapor pressure solvent at a high rate of throughput into fibers and webs.
[0012] The process for making a fiber layer(s) is disclosed in International Publication Number WO2003/080905 (U.S. Ser. No. 10/822,325), which is hereby incorporated by reference. FIG. 1 is a schematic diagram of an electroblowing apparatus useful for carrying out the process of the present invention using electroblowing (or “electro-blown spinning”) as described in International Publication Number WO2003/080905. This prior art electroblowing method comprises feeding a solution of a polymer in a solvent from a storage tank 100 , through a spinneret 102 , to a spinning nozzle 104 to which a high voltage is applied, while compressed gas or blowing gas is directed toward the polymer solution through a blowing gas nozzle 106 as the polymer solution exits the spinning nozzle 104 to form fibers, and collecting the fibers into a web on a grounded collector 110 under vacuum created by vacuum chamber 114 and blower 112 .
[0013] The collection apparatus is preferably a moving collection belt positioned within the electrostatic field between the spinneret 102 and the collector 110 . After being collected, the fiber layer is directed to and wound onto a wind-up roll on the downstream side of the collector 110 . Optionally, the fibrous web can be deposited onto any of a variety of porous scrim materials arranged on the moving collection belt, such as spunbonded nonwovens, meltblown nonwovens, needle punched nonwovens, woven fabrics, knit fabrics, apertured films, paper and combinations thereof.
[0014] Optionally, a secondary gas can contact the fibers downstream from the spinneret to help drive off solvent from the fiber. When electroblowing fibers with a high throughput rate, large quantities of solvent must be removed from the fiber forming polymer solution. The secondary gas can be positioned to impinge the fibers or can be used as a sweeping gas to help remove solvent from the general spinning area.
[0015] In order to spin fibers at high throughput or discharge rate, solvents with high vapor pressure can be used. According to the invention, solvents with vapor pressures of at least 6 kPa at 25° C. are preferred, of at least 10 kPa at 25° C. are more preferred and of at least 20 kPa at 25° C. are still more preferred. Suitable solvents with high vapor pressure include methanol (16.9), ethanol (7.9), acetone (30.8), butanone (12.1), dichloromethane (58.1), 1,2-dichloroethane (10.6), trifluoroacetic acid (14.7), ethyl acetate (12.4), tetrahydrofuran (21.6), chloroform (26), carbon tetrachloride (15.4), and hydrocarbons including pentane (68.3), hexane (20.2), heptane (6.1), cyclohexane (13), methylcyclohexane (6.1), and benzene (12.3), where the numbers in parentheses are the vapor pressures of these solvents at 25° C. in units of kPa. The vapor pressure data was obtained from “Organic Solvents”. Volume 2, fourth edition, by John Riddick, William Bunger, and Theodore Sakano, John Wiley & Sons, 1986 or from the DIPPR® database of physical properties of solvents.
[0016] According to the invention, solvents with vapor pressures of at least 6 kPa at 25° C. are preferred, of at least 10 kPa at 25° C. are more preferred and of at least 20 kPa at 25° C. are still more preferred.
[0017] The polymer solution can be spun at a temperature of about 0° C. to the boiling point of the solvent.
[0018] These solvents can be used to prepare polymer solutions that can be spun at a discharge rate between about 6 to about 100 ml/min/hole, more advantageously between about 10 to about 100 ml/min/hole, and most advantageously between about 20 to about 100 ml/min/hole.
[0019] The polymer(s) that can be used in making fiber layers in accordance with the process of the present invention are not particularly limited, provided that they are substantially soluble in the selected solvent at the desired concentration and can be spun into fibers by the process described herein. Examples of these polymers generally include hydrocarbon polymers. Examples of hydrocarbon polymers suitable for the present invention include polyolefins, polydienes, polystyrene and blends thereof. Examples polyolefins include polyethylene, polypropylene, poly(1-butene), poly(4-methyl-1-pentene), and blends, mixtures and copolymers thereof.
[0020] In addition to the forgoing polymers, other examples include polysulfones, polycarbonates, poly(meth)acrylates, cellulose esters, polyvinylchlorides, and blends thereof. Examples of poly(meth)acrylates include polymethylacrylate and polymethylmethacrylate. Examples of cellulose esters include cellulose triacetate. Examples of polyesters include polyethylene therephthalate, polypropylene therephthalate, polybutylene therephthalate, poly(epsilon-caprolactone), poly(DL-lactic acid) and poly(L-lactide).
[0021] The blowing gas can be selected from the group of air, nitrogen, argon, helium, carbon dioxide, hydrocarbons, halocarbons, halohydrocarbons and mixtures thereof. The blowing gas is injected at a flow velocity of about 50 to about 340 m/sec and a temperature from about ambient to about 300° C.
[0022] The fibers produced have a number average fiber diameter preferably less than 1,000 nanometers, more preferably less than 800 nanometers and most preferably less than 500 nanometers. The fibers can be continuous or discontinuous. The fibers can have an essentially round cross section shape.
[0023] The electric field can have a voltage potential of about 10 to about 100 kV. The electric field can be used to create a corona charge.
[0024] The fibers can be collected into a fibrous web comprising round cross section, weakly interacting polymer fibers having a number average fiber diameter less than about 1,000 nanometers.
[0025] The secondary gas can be selected from the group of air, nitrogen, argon, helium, carbon dioxide, hydrocarbons, halocarbons, halohydrocarbons and mixtures thereof. The secondary gas is injected at a flow velocity of about 50 to about 340 m/sec and a temperature from about ambient to about 300° C.
Test Methods
[0026] Fiber Diameter was determined as follows. Two to three scanning electron microscope (SEM) images were taken of each fine fiber layer sample. The diameter of clearly distinguishable fine fibers were measured from the photographs and recorded. Defects were not included (i.e., lumps of fine fibers, polymer drops, intersections of fine fibers). The number average fiber diameter from about 50 to 300 counts for each sample was calculated.
EXAMPLES
[0027] The fiber examples below were prepared using the general process and apparatus described above with the specific changes as noted below.
Example 1
[0028] A 9 wt % solution of polymethylmethacrylate (PMMA) was dissolved in acetone (vapor pressure of 24.2 kPa at 25° C.) at room temperature. A magnetic stirrer was used to agitate the solution. The homogeneous solution was transferred to a sealed glass container and transported to the spin chamber. The solution was transferred into the reservoir of the spin chamber and sealed. A spinneret with a 0.254 mm inside diameter single spinning nozzle was used. A drum collector was used to collect the sample. The spinneret was placed at a negative potential of 100 kV. The collector was grounded. The distance from the spinning nozzle exit to the collector surface was 51 cm. Air was used for the blowing gas. Nitrogen was used for the secondary gas to control the relative humidity and the temperature in the spin chamber. The flow of nitrogen was sufficient to avoid the concentration of the solvent vapor in the spin chamber exceeding the lower explosion limit. The relative humidity was controlled to be less than 11%. The spin chamber temperature was close to 23° C. for the duration of the experiment. A nitrogen pressure of 0.2044 MPa was used to maintain a solution flow rate of 6.7 ml/min/hole. The blowing gas was controlled to maintain an exit velocity on the order of 67 m/sec. The blowing gas temperature was close to 23° C. Fiber was visible in the plume soon after the solution flow was initiated. Fiber was deposited in a swath on the drum. The number average fiber diameter of the fibers was measured to be 393 nanometers.
Example 2
[0029] A 9 wt % solution of polystyrene was dissolved in dichloromethane (vapor pressure of 58.1 kPa at 25° C.) at room temperature. A magnetic stirrer was used to agitate the solution. The homogeneous solution was transferred to a sealed glass container and transported to the spin chamber. The solution was transferred into the reservoir of the spin chamber and sealed. A spinneret with a 0.406 mm inside diameter single spinning nozzle was used. A drum collector was used to collect the sample. The spinneret was placed at a negative potential of 100 kV. The collector was grounded. The distance from the spinning nozzle exit to the collector surface was 95 cm. Air was used for the blowing gas. Air was used for the secondary gas to control the relative humidity and the temperature in the spin chamber. The flow of air was sufficient to avoid the concentration of the solvent vapor in the spin chamber exceeding the lower explosion limit. The relative humidity was controlled to be less than 11%. The spin chamber temperature was close to 32° C. for the duration of the experiment. A nitrogen pressure of 0.515 MPa was used to maintain a solution flow rate of 34.3 ml/min/hole. The blowing gas was controlled to maintain an exit velocity on the order of 150 m/sec. The blowing gas temperature was close to 24° C. Fiber was visible in the plume soon after the solution flow was initiated. Fiber was deposited in a swath on the drum. The number average fiber diameter of the fibers was measured to be 335 nanometers.
Example 3
[0030] A 9 wt % solution of polystyrene was dissolved in dichloromethane (vapor pressure of 58.1 kPa at 25° C.) at room temperature. A magnetic stirrer was used to agitate the solution. The homogeneous solution was transferred to a sealed glass container and transported to the spin chamber. The solution was transferred into the reservoir of the spin chamber and sealed. A spinneret with a 0.406 mm inside diameter single spinning nozzle was used. A drum collector was used to collect the sample. The spinneret was placed at a negative potential of 100 kV. The collector was grounded. The distance from the spinning nozzle exit to the collector surface was 114 cm. Air was used for the blowing gas. Air was used for the secondary gas to control the relative humidity and the temperature in the spin chamber. The flow of air was sufficient to avoid the concentration of the solvent vapor in the spin chamber exceeding the lower explosion limit. The relative humidity was controlled to be less than 11%. The spin chamber temperature was close to 37° C. for the duration of the experiment. A nitrogen pressure of 0.77 MPa was used to maintain a solution flow rate of 57.1 ml/min/hole. The blowing gas was controlled to maintain an exit velocity on the order of 150 m/sec. The blowing gas temperature was close to 24° C. Fiber was visible in the plume soon after the solution flow was initiated. Fiber was deposited in a swath on the drum. The number average fiber diameter of the fibers was measured to be 630 nanometers.
Example 4
[0031] An 11 wt % solution of Engage 8400 (an ethylene octene copolymer), available from DuPont, was dissolved in methylcyclohexane (vapor pressure of 6.1 kPa at 25° C.) using a reflux condenser. A magnetic stirrer was used to agitate the hot solution. The homogeneous solution was transferred to a sealed glass container and transported to the spin chamber. The solution was transferred into the reservoir of the spin chamber and sealed. A spinneret with a 0.4064 mm inside diameter single spinning nozzle was used. A drum collector was used to collect the sample. The spinneret was placed at a negative potential of 100 kV. The collector was grounded. The distance from the spinning nozzle exit to the collector surface was 30 cm. Air was used for the blowing gas. Nitrogen was used for the secondary gas to control the relative humidity and the temperature in the spin chamber. The flow of nitrogen was sufficient to avoid the concentration of the solvent vapor in the spin chamber exceeding the lower explosion limit. The relative humidity was controlled to be less than 9%. The spin chamber temperature was close to 29° C. for the duration of the experiment. A nitrogen pressure of 0.308 MPa was used to maintain a solution flow rate of 12.6 ml/min/hole. The blowing gas was controlled to maintain an exit velocity on the order of 156 m/sec. The blowing gas temperature was close to 28° C. Once the solution flow was initiated, fiber was visible in the plume. Fiber was deposited in a swath on the drum. The number average fiber diameter of the fibers was measured to be 502 nanometers.
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The present invention is a fiber spinning process comprising the steps of providing a polymer solution, which comprises at least one polymer dissolved in at least one solvent with a vapor pressure of at least about 6 kPa at 25° C., to a spinneret, issuing the polymer solution in combination with a blowing gas in a direction away from at least one spinning nozzle in the spinneret and in the presence of an electric field wherein the polymer solution is discharged through the spinning nozzle at a discharge rate between about 6 to about 100 ml/min/hole, forming fibers, and collecting the fibers on a collector.
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BACKGROUND AND SUMMARY OF THE INVENTION
[0001] The present invention relates to a braking system for vehicles equipped with an ABS system or an antiskid protection system.
[0002] An antilock system for a motorcycle is known from German Patent Document 39 31 313 A1, in the case of which a total of only two rotational wheel speed sensors are provided, one sensor being assigned to the front wheel and the other being assigned to the rear wheel. For determining the wheel slip, a reference quantity is determined which is approximated to the course of the vehicle speed and in which case two channels are provided. The two reference speeds are determined on the basis of the assigned wheel speed and a multiplier dependent on the driving condition.
[0003] U.S. Pat. No. 5,791,744 A describes an electropneumatic braking system for rail vehicles, in which a ”universal unit” is assigned to each car and controls the brakes of the respective car. Such a universal unit consists of an electronic portion, a pneumatic portion and an electropneumatic portion. The electronic portion has, among other things, an interface for rotational wheel speed sensors.
[0004] German Patent Document DE 198 26 131 A1 describes an electric braking system for a motor vehicle in which two electronic arithmetic channels are provided. In the case of this braking system, among other values, slip values are computed individually for the each wheel. The rotational wheel speed of the respective wheel and a centrally computed estimated value for the vehicle speed are entered into the computation of the slip, the vehicle speed being computed in a single-channel manner, that is, not redandantly.
[0005] Modern road and rail vehicles are normally equipped with an antilock system which, in the case of road vehicles, is called an “ABS system” and, in the case of rail vehicles, is called an “antiskid protection system”. ABS systems and antiskid protection systems control the brake pressures at individual wheels or axles of the vehicle such that a locking of the wheels or wheel sets is prevented and the length of the braking is minimized. For such a brake pressure control, the slip values which exist at the individual wheels or axles are required and are determined from the respective wheel speeds and the actual vehicle speed. For this purpose, rotational wheel speed sensors are normally provided. In which case, an approximate value for the actual vehicle speed, that is, a “refernce speed”, is determined from the individual rotational wheel speeds. When the measured rotational wheel speed signals are faulty, for example, as a result of electromagnetic interference fields and/or system-caused measuring errors, which result in “peaks” in the speed course or acceleration course of the measuring signals, errors may then also occur when computing the reference speed.
[0006] A “false” reference speed may result in errors in controlling the braking force of the entire vehicle. This is problematic particularly in the case of those vehicles which only have an independent system for the braking force control.
[0007] The reason is that ABS systems or antiskid protection systems normally have a single-channel construction; that is, the rotational wheel speeds are detected in a single-channel manner. If one rotational wheel speed sensor fails, the assigned wheels can no longer be controlled corresponding to the existing rotational wheel speed.
[0008] To prevent faulty rotational wheel speed signals from falsifying the refernce speed value, conventional algorithms for computing the reference speed have a “detection” of faulty signals, but a reliable detection of all posible faults required very high expenditures. In addition, faults may have an effect on the calculation of the reference speed already during the fault disclosure time such that the braking force is affected.
[0009] It is an object of the invention to provide a braking system which is optimized with respect to the determination of the actual vehicle speed required for an ABS or antiskid protection control. This object is achieved by the present invention.
[0010] The basic principle of the invention consists of a braking system with an arithmetic unit which has at least two separate “channels”, in which, independently of one another, a “reference speed” is determined which is approximated to the actual vehicle speed. The at least two reference speeds are in each case used only for controlling a portion of the brakes in the vehicle.
[0011] The separate computation of the reference speeds can take place in a brake control unit or in an arithmetic unit. Only a part of the rotational wheel speed sensors in the vehicle, as well as a portion of the brakes in the vehicle, are assigned to each of the channels. On each channel, rotational wheel speed signals of different sensors are used for computing one reference speed respectively. Consequently, in the case of two channels, maximally half the brakes in the vehicle are controlled on the basis of one of the two reference speeds. Even when only one arithmetic unit, that is, one brake control unit, is provided, an error occurring in the detection of the rotational wheel speed may have an effect on maximally half of the brakes. An individual fault in the speed detection can therefore not influence the entire braking force of the vehicle.
[0012] In the “redundant” detection of the rotational wheel speed, at least two rotational wheel speed signals of a wheel or of a wheel group are always included in the control. The wheel or the wheel group can therefore also still be controlled when one of the two rotational wheel speed signals fails or has interference. This significantly improves the driving safety.
[0013] According to a further development of the invention, for a vehicle or in the case of several vehicle units coupled to one another, including at least one front axle and one rear axle, at least one front axle signal and one rear axle signal is analyzed on each channel. Thus, at least one rotational wheel speed sensor of a front axle and one rotational wheel speed sensor of a rear axle is connected to each channel. The first channel can therefore be used, for example, for the braking force control of the front axle or front axle group, and the second channel can be used for the braking pressure control of the rear axle or the rear axle group.
[0014] According to a further development of the invention, a control unit is provided for the plausibility check of the rotational wheel speed signals supplied by the rotational wheel speed sensors. The rotational wheel speed signals are checked particularly with respect to “signal peaks” which are based on interference. In the control unit, an analyzing algorithm is implemented which recognizes “faulty” rotational wheel speed signals and optionally excludes them for calculating the reference speed. All detected rotational wheel speed signals can be analyzed in a common arithmetic unit, can be compared with one another and can be checked with respect to plausibility. This permits the detection of “implausible” or “disturbed” rotational wheel speed signals and therefore increases the safety of the entire braking system.
[0015] The invention can be implemented at very reasonable cost because only one arithmetic unit or only one brake control unit is required. It can be used in the case of passenger cars, trucks, bikes as well as in the case of rail vehicles or trains.
[0016] These an other aspects of the present invention will become apparent from the following detailed description of the invention, when considered in conjunction with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a schematic view of a first embodiment for explaining the basic principle of the invention.
[0018] [0018]FIG. 2 is a schematic view of an embodiment of a use in the case of a motor bike.
[0019] [0019]FIG. 3 is a schematic view of an embodiment similar to that of FIG. 1.
[0020] [0020]FIG. 4 is a schematic view of an embodiment of a four-axle vehicle with kinematically uncoupled axles.
[0021] [0021]FIG. 5 is a schematic view of a first embodiment of a six-axle vehicle system.
[0022] [0022]FIG. 6 is a schematic view of a second embodiment of a six-axle vehicle system.
[0023] [0023]FIG. 7 is a schematic view of a third embodiment of a six-axle vehicle system.
[0024] [0024]FIG. 8 is a schematic view of a fourth embodiment of a six-axle vehicle system.
[0025] [0025]FIG. 9 is a schematic view of an embodiment of an eight-axle vehicle system.
[0026] [0026]FIG. 10 is a schematic view of an embodiment of a traction vehicle with kinematically coupled axles.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] [0027]FIG. 1 illustrates a vehicle 1 with a first wheel group 2 and a second wheel group 3 . The two wheel groups 2 , 3 may, for example, be bogies of a rail vehicle and each has a first axle 4 , 5 and a second axle 6 , 7 respectively. One rotational wheel speed sensor 8 - 11 respectively is assigned to the axles 4 - 7 .
[0028] The rotational wheel speed sensors 8 - 11 are connected with a brake control unit 12 which is shown here only schematically. In the brake control unit 12 , a plausibility check 13 is implemented which is to detect faulty or “disturbed” rotational wheel speed signals and optionally separate them.
[0029] The brake control unit 12 also has two channels for the separate or independent calculation of one reference speed respectively approximated to the actual vehicle speed. Brakes (not shown) provided in the vehicle are assigned to a first or to a second group. Here, the first group is formed by the brakes of the first wheel group 2 , and the second group is formed by the brakes of the second wheel group 3 . The brakes of the first wheel group 2 are controlled by a first channel of the brake control unit 12 , and the brakes of the second wheel group 3 are controlled by a second channel of the brake control unit 12 .
[0030] On the first channel, the rotational wheel speed signals are analyzed which are supplied by the rotational wheel speed sensors 8 , 9 . If the plausibility check 13 indicates that the signal supplied by the rotational wheel speed sensors 8 , 9 are plausible, both signals are entered into the reference speed calculation 14 of the first channel.
[0031] In the reference speed calculation 14 , for example, both signals supplied by the rotational wheel speed sensors 8 , 9 can be linked with one another to form a first reference speed V ref1 . However, during a braking operation, it may also make sense to consider the greater of the speeds measured by the rotational wheel speed sensors 8 , 9 as the V ref1 . If the vehicle 1 is a traction vehicle and is just being accelerated, it may, in contrast, make sense to accept the lower of the two speeds measured by the rotational wheel speed sensors 8 , 9 as the reference speed V ref1 .
[0032] The reference speed V ref1 determined by calculation 14 on the basis of rotational wheel speed signals of the first wheel group 2 and of the second wheel group 3 is used for the braking force control 15 of the first wheel group 2 . The rotational wheel speed signals supplied by the rotational wheel speed sensors 8 , 10 of the first wheel group 2 are entered into the “braking force control” 15 . Furthermore, the results of the plausibility check 13 are taken into account during the braking force control 15 . If the signals supplied by the rotational wheel speed sensors 8 , 10 are considered plausible, they can both be taking into account. Otherwise, a possibly faulty signal does not have to be considered.
[0033] The second channel is provided for the braking force control of the second wheel group 3 . On channel 2 , a reference speed calculation 16 is carried out using the signals supplied by the rotational wheel speed sensors 10 , 11 , analogous to channel 1 . The results of the plausibility check 13 are also taken into account. On the basis of the determined reference speed V ref2 by calculation 16 , control signals are generated for a braking force control 17 . During the braking force control 17 , the signals supplied by the rotational wheel speed sensors 9 , 11 as well as the results of the plausibility check 13 are analyzed.
[0034] An important advantage of the invention consists of the fact that a fault or an interference on one of the two channels can affect maximally half of the brakes in the vehicle 1 . If, for example, one of the two channels fails completely, the brakes of the other channel continue to be controllable. As an alternative to the embodiment illustrated here, more than two channels may also be provided, which further improves the fail-safe characteristic.
[0035] [0035]FIG. 2 shows an embodiment in relation to a motor bike 17 having a rear wheel 18 and a front wheel 19 . At the rear wheel 18 , the two rotational wheel speed sensors 8 , 10 are provided and, at the front wheel 19 , the two rotational wheel speed sensors 9 , 11 are provided to measure the speed of the front wheel or of the rear wheel. The rotational wheel speed sensors 8 - 11 are connected to the brake control unit 12 which is constructed analogous to FIG. 1. Analogous to FIG. 1, here also, two separate channels are provided, in which case a rotational wheel speed sensor 8 , 9 and 10 , 11 respectively is assigned to each channel. In the embodiment illustrated here, the rear wheel brake (not shown) is controlled by channel 1 and the front wheel brake is controlled by channel 2 . The rotational wheel speed sensors 8 , 10 and 9 , 11 respectively may be integrated in a “double pulse generator” which is more cost-effective than two individual sensors. rotational wheel speed signals supplied by the rotational wheel speed sensors 8 , 10 of the first wheel group 2 are entered into the "braking force control" 15 . Furthermore, the results of the plausibility chech 13 are taken into account during the braking force control 15 . If the signals supplied by the rotaitonal wheel speed sensors 8 , 10 are considered plausible, they can both be taken into account. Otherwise, a possibly faulty signal does not have to be considered.
[0036] The second channel is provided for the braking force control of the second wheel group 3 . On channel 2 , a reference speed calculation 16 is carried out using the signals supplied by the rotational wheel speed sensors 10 , 11 analogous to channel 1 . The results of the plausibility check 13 are also taken into account. On the basis of the detemined reference speed V ref2 by caluculation 16 , control signals are generated for a braking force control 17 . During the braking force control 17 , the signals supplied by the rotational wheel speed sensors 9 , 11 as well as the results of the plausubility check 13 are analyzed.
[0037] An important advantage of the invention consists of the fact that a fault or an interference on one of the two channels can effect maximally half of the brakes in the vehicle 1 . If, for example, one of the two channels fails completely, the brakes of the other channel continue to be controllable. As an alternative to the embodiment illustrated here, more than two channels may also be provided, which further improves the fail-safe characteristic.
[0038] [0038]FIG. 2 shows an embodiment in relation to a motor bike 17 having a rear wheel 18 anf a from wheel 19 . At the rear wheel 18 , the two rotational wheel speed sensors 8 , 10 are provided and, at the front wheel 19 , the two rotational wheel speed sensors 9 , 11 are provided to measure the speed of the from wheel or of the rear wheel. The rotational wheel speed sensors 8 - 11 are connected to the brake control unit 12 which is constucted analogous to FIG. 1. Analogous to FIG. 1, here also, two separate channels are provided, in which case a rotational wheel speed sensor 8 , 9 and 10 , 11 respectively is assigned to each channel. In the embodiment illustrated here, the rear wheel brake (not shown) is controlled by channel 1 and the from wheel brake is controlled by channel 2 . The rotational wheel speed sensors 8 , 10 and 9 , 11 respectively may be intergrated in a "double pulse generator" which is more cost-effective than two individual sensors.
[0039] [0039]FIG. 3 shows an embodiment similar to that of FIG. 1, in which the axles 4 , 6 of the first wheel group 2 and the axles 5 , 7 of the second wheel group 3 are each kinematically coupled, for example, by way of a connecting rod or a gearing. The rotational wheel speed sensors 8 - 11 are in each case assigned to the axles 4 , 6 and 5 , 7 respectively. Analogus to the embodiment of FIG. 1, the rotational wheel speed sensors 8 , 9 are assigned to a first channel 20 which is provided for controlling a first—here only schematically shown—group of brakes 21 . Analogously thereto, the rotational wheel speed sensors 10 , 11 are assigned to a second channel 22 which is provided for controlling a second brake group 23 . Although the two channels 20 , 22 are shown as separate “units”, they may, as illustrated in FIGS. 1 and 2, be formed by a common arithmetic unit.
[0040] [0040]FIG. 4 shows another embodiment of a four-axle vehicle. In contrast to the embodiment of FIG. 3, here, the axles 4 and 6 of the first wheel group or the axles 5 and 7 of the second wheel group are kinematically uncoupled from one another. One rotational wheel speed sensor 8 , 9 respectively is provided on the axles 4 and 7 . Two rotational wheel speed sensors 10 , 11 and 24 , 25 respectively are provided on the axles 5 and 6 . The rotational wheel speed sensors 8 , 11 , 24 are assigned to the first channel 20 , and the rotational wheel speed sensors 9 , 10 , 25 are assigned to the second channel 22 , channel 20 taking over the brake control, for example, at the axles 4 and 6 , and channel 22 taking over the brake control at the axles 5 and 7 .
[0041] [0041]FIG. 5 shows a embodiment for a six-axle vehicle which consists of two mutually coupled vehicle units 26 , 27 . A first wheel group 2 is assigned to vehicle unit 26 , and a second wheel group 3 is assigned to vehicle unit 27 . Furthermore, a “center” wheel group 28 is provided which is assigned to both vehicle units 26 , 27 . Wheel groups 2 , 3 , 28 are, for example, bogies of a rail vehicle to which one brake group 29 - 31 respectively is assigned. The brake groups 29 , 30 each having one brake unit 32 , 33 , and the brake group 31 having two brake units 34 , 35 . Here, the term “brake unit” indicates an individual brake or a group of brakes which are controlled by means of a common brake pressure.
[0042] The brake units 32 , 34 are controlled by the first channel 20 , and the brake units 33 , 35 are controlled by the second channel 22 . Here, one rotational wheel speed sensor 38 , 39 respectively of the axles 4 , 6 as well as one rotational wheel speed sensor 40 of an axle 36 of the center wheel group 28 are assigned to the first channel 20 . Rotational wheel speed sensors 41 , 42 of the axles 5 , 7 as well as a rotational wheel speed sensor 43 of an axle 37 of the center wheel group 28 are assigned to the second channel 22 .
[0043] In the case of the embodiment illustrated in FIG. 5, the six axles 4 - 7 , 36 , 37 are not coupled kinematically. The brakes of the axles 36 , 37 may be acted upon by different pressures. The brake control of the brake unit 34 takes place by way of the first channel, and the brake control of the brake unit 35 takes place by way of the second channel 22 . The brake unit 32 is also controlled by the first channel 20 , and the brake unit 33 is controlled by the second channel 22 .
[0044] [0044]FIG. 6 shows an embodiment of a six-axle vehicle, in which the individual axles of the wheel groups 2 , 3 , 28 are kinematically coupled, for example, by a transmission or a connecting rod. Two rotational wheel speed sensors 38 - 44 respectively are provided here on the axle 6 of wheel group 2 , the axle 37 of wheel group 28 and on the axle 5 of wheel group 3 . Furthermore, one additional rotational wheel speed sensor 45 - 47 respectively may be provided on the axles 4 , 7 , 36 , which sensors 45 - 47 are indicated here by a broken line.
[0045] In contrast to the above-explained embodiments, three channels 48 - 50 are provided here in FIG. 6. The rotational wheel speed sensors 39 , 43 and 46 are assigned to the first channel 48 ; the rotational wheel speed sensors 38 , 42 and 47 are assigned to the second channel 49 ; and the rotational wheel speed sensors 40 , 44 and 45 are assigned to the third channel 50 . Since the individual axles of the wheel group 2 , 3 , 28 are kinematically coupled, only three brake units 30 - 37 exist here. Brake unit 32 is controlled by the first channel 48 ; brake unit 34 is controlled by the second channel 49 ; and brake unit 33 is controlled by the third channel 50 . In contrast to the embodiment of FIG. 5, here the individual brakes of the wheel groups 2 , 3 , 38 are each controlled by means of the same brake pressure.
[0046] [0046]FIG. 7 shows another embodiment for a six-axle vehicle, in which the axles of the wheel groups 2 , 3 and 28 are kinematically coupled. In contrast to FIG. 6, only two channels 20 , 22 are provided here. Channel 20 controls the brake units 32 and 34 of wheel groups 2 and 28 respectively; and channel 22 controls the brake units 33 and 35 respectively of the wheel groups 3 and 28 respectively. The rotational wheel speed sensors 38 , 39 of axles 6 and 36 respectively are assigned to the first channel 20 . In addition, a rotational wheel speed sensor 40 of the axle 7 may be assigned to channel 20 . Two rotational wheel speed sensors of vehicle unit 26 and one rotational wheel speed sensor of vehicle unit 27 are then assigned to channel 20 .
[0047] Analogously thereto, the rotational wheel speed sensor 41 of axle 37 , the rotational wheel speed sensor 42 of axle 5 , and optionally the rotational wheel speedsensor 43 of axle 4 are assigned to the second channel 22 . The channel 22 therefore analyzes two rotational wheel speed signals of vehicle unit 27 and one rotational wheel speed signal of vehicle unit 26 .
[0048] [0048]FIG. 8 shows another embodiment for a six-axle vehicle. In this embodiment, the two axles 4 , 6 of wheel group 2 and the axles 5 , 7 of wheel group 3 are each kinematically coupled with one another. In contrast, the axles 36 , 37 of the center wheel group 28 are not coupled kinematically. Correspondingly, the assigned brake units 34 , 35 of the axles 36 , 37 can be controlled by different brake pressures. The brake unit 34 is controlled together with the brake unit 32 of the wheel group 2 by means of the first channel 20 ; and the brake units 33 , 35 are controlled by the second channel 22 . Here, a rotational wheel speed sensor 38 of the wheel group 2 and the rotational wheel speed sensor 39 of the axle 36 are assigned to channel 20 . Optionally, the rotational wheel speed sensor 43 of the axle 37 may be assigned to channel 20 . Analogously thereto, a rotational wheel speed sensor 40 of the wheel group 3 , a rotational wheel speed sensor 41 of the axle 37 , and optionally, a rotational wheel speed sensor 42 of the axle 36 are assigned to the second channel 22 .
[0049] In the embodiment illustrated in FIG. 8, two kinematically uncoupled axles and four axles which are in each case kinematically coupled in pairs are therefore provided, in which case the brakes of the center wheel group 28 can be acted upon by different brake pressures.
[0050] [0050]FIG. 9 shows an eight-axle vehicle which consists of three vehicle units 51 - 53 and has four wheel groups 54 - 57 . Each of the wheel groups consists of two axles which are each kinematically coupled with one another. Furthermore, at least one rotational wheel speed sensor 38 - 41 respectively is assigned to each wheel group 54 - 57 . At wheel groups 55 , 56 , optionally a second rotational wheel speed sensor 42 , 43 may in each case be provided. Here, the rotational wheel speed sensors 38 , 39 , 43 are assigned to the first channel 20 , and the rotational wheel speed sensors 40 , 41 and 42 are assigned to the second channel 22 . The brakes of the wheel groups 54 - 57 form one brake unit 58 - 61 respectively. The brake units 58 , 59 are controlled by the first channel 20 , and the brake units 60 , 61 are controlled by the second channel 22 .
[0051] [0051]FIG. 10 shows an embodiment of a traction vehicle 62 which has four axles 4 - 7 which are kinematically coupled by way of a connecting rod 63 . A rotational wheel speed sensor 8 of a first channel 20 is assigned to the two axles 4 , 5 , and a rotational wheel speed sensor 9 of a second channel 22 is assigned to the axles 6 , 7 . Channel 20 controls the brakes of axles 4 , 5 , and channel 22 correspondingly controls the brakes of axles 6 , 7 .
[0052] Although the present invention has been described and illustrated in detail, it is to be clearly understood that this is done by way of illustration and example only and is not to be taken by way of limitation. The scope of the present invention is to be limited only by the terms of the appended claims.
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The general principle underlying the invention is a braking system that is provided with an arithmetic unit with at least two independent channels for determining the reference speeds approximated to the actual vehicle speed. The at least two determined reference speeds are used only for regulating a part of the brakes installed in the vehicle.
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BACKGROUND OF THE INVENTION
This invention relates to vacuum breakers.
Vacuum breakers have been used in various water and plumbing systems to prevent a back flow or back siphoning of water from the outlet end of a hose or other water outlet. This can occur when a lowered pressure from the water source is encountered and an elevated pressure is encountered at the discharge or outlet of the water system.
Under such a condition, reverse flow can occur from the discharge end of the water system into the water supply. This can under certain conditions, result in contamination being introduced to the water supply system.
In order to prevent this back flow situation, hydrants or other fluid couplings are sometimes provided with vacuum breakers and back flow preventers. These devices sense a reverse pressure in the system and relieve the pressure so that fluid does not flow backwards into the water supply system through the hydrant.
Therefore, a primary object of the present invention is the provision of an improved vacuum breaker.
A further object of the present invention is the provision of an improved vacuum breaker which utilizes a single elastomeric sealing member for accomplishing both the vacuum breaking function and the back flow preventing function.
A further object of the present invention is the provision of a device which is reliable throughout extensive operation.
A further object of the present invention is the provision of a device which is sensitive to small differentials in pressure, and responds to small differentials in pressure so as to move from its normal to its back flow preventing positions.
A further object of the present invention is the provision of a device which is economical to manufacture, durable in use and efficient in operation.
SUMMARY OF THE INVENTION
The present invention utilizes an outer cylindrical housing having a bore extending through the length of the housing. The bore includes an inlet portion, an outlet portion and an intermediate portion therebetween. A pressure relief opening is provided in the intermediate portion.
Fitted within the outer housing is a cylindrical insert which is attached within the inlet end of the housing bore and which includes one end extending within the intermediate portion of the housing bore. The second end of the insert is spaced radially inwardly from the intermediate portion of the bore so as to define a pressure relief chamber therebetween. The insert includes a cavity having a plurality of pressure outlet openings extending radially outwardly therefrom so as to provide communication from the cavity within the insert to the pressure release chamber surrounding the insert.
A cylindrical rubber seal is fitted around the insert so as to be in covering relation over the radially extending pressure outlet openings therein. The sealing member is responsive to fluid pressure from within the insert so as to expand radially outwardly and form a sealing engagement over the pressure relief opening within the intermediate portion of the housing.
In operation, fluid is introduced into the cavity within the insert member. The fluid pressure causes the rubber sealing member to expand radially outwardly so that it covers up and seals the pressure relief opening within the intermediate portion of the outer housing. This permits fluid to flow from the insert outwardly through the pressure outlet openings thereof into the pressure relief chamber and thence outwardly through the outlet portion of the housing.
When fluid pressure is shut off from the insert member, the sealing member moves by virtue of its own resiliency back into sealing engagement over the pressure outlet openings of the insert member. However, in moving to this position, the rubber seal opens the pressure relief opening in the outer housing. Thus, fluid is free to flow in a reverse direction from the outlet opening of the housing into the pressure relief chamber and thence outwardly through the pressure relief opening. Thus, the pressure relief opening provides a vacuum breaking function, and the rubber seal provides a back flow preventing function because it is in covering relation over the pressure outlet openings of the insert member.
The device is simple in construction, and requires only a single rubber seal, whereas most vacuum breakers presently known require two or more seals to provide all of the functions accomplished with the present invention.
DETAILED DESCRIPTION OF THE FIGURES OF THE DRAWINGS
FIG. 1 is a perspective view of the present invention.
FIG. 2 is an end view as seen from the right end of the device shown in FIG. 1.
FIG. 3 is an exploded perspective view showing the outer housing in seciton and showing the insert and rubber seal in solid lines.
FIG. 4 is a sectional view taken along line 4--4 of FIG. 1.
FIG. 5 is a sectional view similar to FIG. 4, but showing the seal in its intermediate position.
FIG. 6 is a view similar to FIGS. 4 and 5, but showing the seal in its totally expanded position.
FIG. 7 is a sectional view of a modified form of housing without the insert in place.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, the numeral 10 generally designates the vacuum breaker of the present invention. Vacuum breaker 10 includes an outer housing 12 having an elongated bore 14 extending longitudinally therethrough. Housing 12 includes a cylindrical inlet portion 16, an intermediate portion 18, and an outlet portion 20. Within inlet portion 16, the interior walls of bore 14 are provided with threads 21. Within intermediate portion 18, a second set of threads 23 are provided.
Intermediate portion 18 includes an annular pressure relief groove 22 which extends around the circumference thereof. Groove 22 includes annular flanges 24, 26 on the opposite edges of groove 22 and these flanges 24, 26 protrude radially inwardly into the intermediate portion of bore 14.
Intermediate portion 18 also includes an enlarged diameter portion 28 which tapers radially inwardly toward outlet portion 20. Outlet portion 20 is provided with a plurality of threads 30 on its outer cylindrical surface.
The numeral 32 generally designates an insert member which is adapted to be inserted within bore 14. Insert member 32 includes a rear threaded end 34 which is adapted to threadably engage the threads 23 within intermediate portion 18 of bore 14.
Insert member 22 also includes an annular groove 36 which is positioned in registered alignment within the annular pressure relief groove 22 as shown in FIGS. 4-6 whenever the insert member is threaded within bore 14. At the bottom of groove 36 are a plurality of radially extending pressure outlet holes 38 which provide communication into a cavity 40 which is located within insert member 32. The rear end of insert member 32 includes an open end 42 which is shaped in a hexagonal shape as shown in FIG. 2 so as to receive a wrench for rotating the insert member as it is threaded into position. The forward end of insert member 32 is solid and this solid portion is designated by the numeral 44. Attached to the forward end 46 of insert member 32 are a plurality of vanes 48. As can be seen in FIGS. 4-6, vanes 48 engage the housing of outlet portion 20 of outer housing 10 when the threaded insert 32 is threaded within bore 14.
An annular shoulder 50 extends around the outside of insert member 32 adjacent groove 36.
Fitted around the outside of insert 32 is a rubber seal member 52. Seal member 52 includes a cylindrical portion 54, a rear axial end 56 and a forward axial end 58. Rear axial end 56 includes an annular ridge 60. Sealing member 52 surrounds annular member 32 in the position shown in FIGS. 4-6 with the rear end 56 of sealing member 32 being on the rearward side of annular groove 36 and holes 38 and with the forward end 58 resting in engagement with annular shoulder 50. When the insert member 32 is threaded within bore 14, annular ridge 60 fits within an annular groove within bore 14 so that the rear end 56 of sealing member 32 is tightly held against insert 32.
The forward end 58 of seal member 52, however, is free to expand radially outwardly away from shoulder 50.
In operation, the insert 52 is fitted within bore 14 to the position shown in FIG. 4. In this position, the sealing member 52 spans annular groove 36 and provides a sealing of the openings 38 therein. It should be noted that the insert member is spaced radially inwardly from the intermediate portion 18 of housing 12 so as to define a pressure relief chamber 62 therebetween. When the sealing member is in its normal position as shown in FIG. 4, fluid communication is provided from the outlet portion 20 of housing 12, into the pressure relief chamber 62 and also into the annular pressure relief groove 22. Pressure relief groove 22 is provided with a pressure relief opening 64 which permits the fluid to flow outwardly in the path indicated by arrow 66. This permits water within a hose attached to the outlet opening 20 to flow in a reverse direction into the outlet portion 20 and into the pressure relief chamber 62 and outwardly through the pressure relief opening 64. The seal 52 prevents fluid from flowing backward into the holes 38 and hence into the inlet portion 16 of bore 14. Furthermore, as the back flow pressure increases, the tightness of the seal member around holes 38 is increased so as to insure that a back flow condition will not occur.
FIG. 5 shows the position of the seal as fluid pressure is introduced to the inlet portion 16 of bore 14. As the pressure is initialy increased within cavity 40 of insert 32, it causes pressure to be exerted radially outwardly on the sealing member 32. Consequently, a bulge occurs in the central cylindrical portion 54 of seal 32. This bulge engages the annular flanges 24, 26 of pressure relief groove 22, thereby closing communication from pressure relief chamber 62 to the pressure relief opening 64 as shown in FIG. 5.
Continued increase in pressure within cavity 40 causes the seal member to move to the position shown in FIG. 6. A comparison of FIGS. 5 and 6 shows that the forward end 58 of sealing member 32 remains in sealed engagement with annular shoulder 50 in the position shown in FIG. 5. However, a continued increase in the pressure within cavity 40 causes the end 58 of sealing member 32 to expand radially outwardly so as to permit fluid to flow from the holes 38 around shoulder 50 and into outlet portion 20 of bore 14, as indicated by the arrows 58 in FIG. 6.
When the fluid pressure source is shut off from inlet portion 16 of housing 12, the natural resiliency of sealing member 32 causes it to return to its original normal position shown in FIG. 4. This permits any back pressure or back flow of fluid to escape outwardly through pressure relief opening 64.
Sometimes during the operation of a valve such as shown in FIGS. 4-6, a condition can develop wherein the pressure is greater in the outlet portion 20 of bore 14 than it is in the inlet portion 16 of bore 14. When this occurs in devices which do not have a vacuum breaker, the fluid within the outlet portion 20 can siphon in a reverse direction back into the water supply system.
However, the present invention prevents this. With the present invention, when a lower pressure is encountered within the inlet portion 16 than is encountered within the outlet portion 20 of bore 14, the rubber seal 32 is permitted by virtue of its resiliency to return to its normal position shown in FIG. 4. This is true regardless of whether or not the fluid pressure within inlet opening 14 is shut off. Thus, with the rubber seal 33 in its normal position as shown in FIG. 4, the pressure is relieved by virtue of pressure relief opening 64.
The device is simple in construction and requires only one rubber seal for operation. Furthermore, wear and leakage around the sealing member is minimal by virtue of this specific construction described above.
Referring to FIG. 7, a modified form of the outer housing is shown and is designated by the numeral 70. The housing 70 shown in FIG. 7 is identical to the housing 12 shown in FIG. 1 with the exception that a plurality of pressure outlet openings 72 are provided around the circumference of annular groove 22. The other identical parts are marked with numerals which correspond to the numerals used in the device of FIG. 1.
Thus, it can be seen that the device accomplishes at least all of its stated objectives.
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The present invention comprises an outer housing and an inner housing having a pressure relief chamber defined therebetween. The inner housing receives fluid and directs it through a pressure outlet opening into the pressure relief chamber. The outer housing includes an outlet opening and a pressure relief opening. A flexible cylindrical seal surrounds the pressure outlet opening of the inner housing and is yieldably movable radially outwardly to a pressure flow position wherein it closes the pressure relief opening of the outer housing and opens the pressure outlet opening of the inner housing.
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CROSS-REFERENCE INFORMATION
The present invention is a continuation-in-part of patent application Ser. No. 10/083,726, entitled “An Online Marketplace For Moving and Relocation Services,” filed on Oct. 19, 2001, and now issued as U.S. Pat. No. 7,487,111 B2, the contents of which is fully incorporated by reference herein.
FIELD OF THE INVENTION
The present invention relates generally to a payment and review system for an online marketplace in a computer network environment, and more particularly, to a system for payment retrieval by vendors for rendered services and review of customers who received the services.
BACKGROUND OF THE INVENTION
Typically, a customer pays for service after the service is rendered. For example, a service provider such as a mover, a handyman, a plumber or an electrician will provide service for a customer at the customer's location. At the completion of the service, or job, the customer will pay the service provider, also referred to herein as a vendor. The basic service and payment transaction is straightforward. However, as the transaction is completed as soon as the customer pays the vendor, there should be further incentive for either party to engage in further communications. Typically, unless a customer has received either extremely good or extremely poor service from the vendor, that customer has little motivation to provide feedback about the services the customer received from the vendor.
Although feedback from customers is important for vendors, who use it to improve their services, having customer feedback is especially important in online marketplaces, where customers can select from a variety of vendors. The online marketplace is typically operated by a third party (i.e., an entity other than the vendor or customer), who receives a fee for each transaction between a customer and a vendor. The more transactions that occur in the marketplace, the more fees the third party receives. In order to continue to build goodwill with customers, the operator of the online marketplace would like to provide a system through which any customer that uses the marketplace can help to ensure himself/herself to have a good experience in that the vendor chosen by the customer provides an expected level of service.
One method for matching customer expectation with vendor capabilities is to implement a feedback system on the online marketplace where a customer can evaluate a particular vendor by reviewing feedback from the previous customers of the vendor. For example, in the case of emove.com, which is website operated by eMove, Inc. that provides an online marketplace for moving services, a vendor can be evaluated by the feedback provided by its previous customers. The feedback occurs after the vendor has provided the services.
As the customer who is moving is typically more concerned about the actual move, where a multitude of tasks need to be completed, than filling out reviews, providing a mechanism to facilitate feedback submission is a challenge. Most likely, if the customer has a computer, it is inaccessible as it is being moved itself, dramatically reducing the likelihood of the customer providing feedback for a vendor that has provided services as it requires the customer to seek out Internet access. Moreover, requiring a customer to “login” by remembering usernames or passwords assigned before the move when returning to the online marketplace to respond to a review after the move adds an additional layer of complication that makes the review process inconvenient to complete.
Conversely, vendors are interested in being paid for their services as soon as they have provided them, in addition to receiving feedback from customers. Vendors also want to ensure that any reviews provided for their services are based on actual work they have performed and completed, with an emphasis on receiving feedback as soon as the work is completed.
Accordingly, there is a need for a system that can provide payment to vendors and obtain feedback from customers with a minimal amount of effort by all parties involved.
SUMMARY OF THE PREFERRED EMBODIMENTS
In one preferred embodiment of the present invention, a method is provided that allows a vendor to retrieve payment for services rendered while simultaneously transmitting an e-mail message to the customer with a link to a review. In one embodiment, the method includes detecting a payment request from a vendor; generating a review based on the payment request; and, transmitting a reference to the review to a customer, wherein the reference provides a link to retrieve the review.
In another embodiment of the present invention, a computer readable medium having a computer readable program code contained therein for conducting a review includes computer readable program code for detecting a payment request from a vendor. The computer readable medium also includes computer readable program code for generating a review based on the payment request; and, computer readable program code for transmitting a reference to the review to a customer, wherein the reference provides a link to retrieve the review.
In another embodiment, the present invention is implemented in a review system having a processor and a memory coupled to the processor. The memory includes a vendor application and a customer application, wherein the vendor application is configured to receive a payment request from a vendor, and the customer application is configured to generate a review based on the payment request and transmit a reference to the review to a customer
Other features and advantages of the present invention will become apparent to those skilled in the art from the following detailed description. It is to be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the present invention, are given by way of illustration and not limitation. Many changes and modifications within the scope of the present invention may be made without departing from the spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be more readily understood by referring to the accompanying drawings in which:
FIG. 1 is a flow diagram illustrating the process of a customer ordering services using an online marketplace in accordance with one embodiment of the present invention.
FIG. 2 is a flow diagram illustrating the process of a vendor accessing and retrieving job information using the online marketplace in accordance with one embodiment of the present invention.
FIG. 3 is a flow diagram illustrating the process of the vendor retrieving payment using the online marketplace after providing services to the customer in accordance with one embodiment of the present invention.
FIG. 4 is a flow diagram illustrating the process of the online marketplace effecting a payment to the vendor in accordance with one embodiment of the present invention.
FIG. 5 is a flow diagram illustrating the process of the online marketplace sending out a message to the customer with a link to a review in accordance with one embodiment of the present invention.
FIG. 6 is a flow diagram illustrating the process of the customer using the online marketplace to retrieve the review referenced in the link sent in the process illustrated by FIG. 5 .
FIGS. 7 a - 7 g are screen shots of a user interface for the customer to place service requests.
FIGS. 8 a - 8 d are screen shots of a user interface for the vendor to access the vendor's account.
FIGS. 9 a - 9 b are screen shots of a user interface for the vendor retrieving payment for the vendor's services.
FIGS. 10 a - 10 b are screen shots of a user interface for the customer retrieving the review.
FIG. 11 shows a block diagram of an online marketplace application in accordance with one embodiment of the present invention.
Like numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a mechanism in a online marketplace for a service provider (“vendor”), who has provided service to a customer that has pre-paid for those services, to retrieve those funds from an “escrow” account. The vendor retrieves the funds based on a payment code that the customer gives to the vendor upon completion of the provision of the services. Once the payment code is entered, the vendor is paid and, simultaneously, the customer is e-mailed a link to a review form to provide feedback for the vendor. In one embodiment of the present invention, the link is a Universal Resource Locator (URL) to a web page on a website such as emove.com. When the customer clicks on the web page link in the review form, the customer will be taken to the website where the customer can provide feedback about the vendor (without having to first login to the website). Once the customer has submitted feedback, the customer will be credited with a refund of transaction fees charged by the online marketplace.
FIG. 1 is a flow chart illustrating the process for a customer to request service be provided by a vendor, in accordance with one embodiment of the present invention. The provision of the service is referred to as a “job” generally. In the presented example, the customer desires to contract for moving services to move furniture and boxes at a location in Grafton, N. Dak. As will be apparent from the description contained herein, the system in the example applies to other types of services, whether or not they are related to moving services. For example, services including, but not limited to, plumbing services, painting services, cleaning services, and gardening services, may be contracted for using the system.
In step 102 , the customer enters the general geographical area(s) where the service, or job, is to be performed. The system uses this information to select from a list of vendors that provide services in the entered geographical area(s) to be displayed, as discussed below. FIG. 7 a is a window displaying that the customer has entered “Grafton” in the “City:” field, and “ND” in the “State:” field, in the “Moving From:” section, indicating that the customer is requesting moving services only within the Grafton, N. Dak. region. The customer proceeds to the next step by clicking on the “LET'S GET STARTED” button, and operation continues with step 104 .
In step 104 , the customer enters the date on which the service is to be provided, and the type(s) of service desired. FIG. 7 b illustrates two services typically associated with moving help: loading/unloading help and driving help. In one embodiment, the services listed are based on previously defined categories of services. In another embodiment, the services listed include all the services offered by the vendors in the general geographical area previously entered by the customer. The customer can then proceed to the next step of the process as shown in FIG. 7 b and subsequent figures by clicking on the “NEXT STEP” button.
In step 106 , the system displays the vendors matched by the system that provide loading/unloading service in the Grafton, N. Dak. area. FIG. 7 c illustrates a window that lists two service providers: “Jane's Help” and “One Helpful Guy”, with rating information based on evaluations that have been previously submitted by other customers. The customer may receive more information by selecting the “more info . . . ” link, and read the received reviews for each vendor by selecting the “reviews . . . ” link for the appropriate vendor. In the example shown in FIG. 7 c , the customer has selected “Jane's Help” as the vendor to which the customer wishes to submit a request for moving help.
In step 108 , the customer is presented with a legal agreement outlining the terms and conditions under which access to the system is being provided for the customer to engage the services of the vendor. In another embodiment, the terms and conditions may also include the terms and condition for the selected vendor. FIG. 7 d illustrates a window with a summary of the terms and condition for emove.com, with a “user agreement” link for the customer to retrieve a detailed version of the terms and conditions. Operation continues with step 110 when the customer clicks on the “I AGREE” button.
In step 110 , the customer enters detailed job information, including the specific address where the service is to be provided, including the zip code; a phone number; the number of hours of service desired; and an elaboration of the service being requested. The customer may also provide other details, including but not limited to a preferred time of day for the provision of the service; major cross-street of the location; and other special needs or information. FIG. 7 e illustrates an exemplary window where the customer has entered the address of “123 N. Nowhere Ave.”; a zip code of “12345”; a phone number of “555-555-1234”; a description of “Moving furniture and boxes”; and a desired time period of “3” hours.
In step 112 , the customer is presented with a summary of the order to verify the details of the job and also requested to enter billing information. FIG. 7 f illustrates a window where the customer has entered his name (“John Doe”); address (“123 N. Nowhere Ave., Grafton, N. Dak., 12345”; e-mail address (“jdoe@mail.com”); payment (“Visa”); card number (“1111-1111-1111-1111”); and expiration date of the credit card (“January 2004”). The customer places the order by clicking on the “PLACE ORDER” button. The sequence contained in steps 102 to 112 illustrates one way for the system to receive a job request from a customer. For example, more or less information may be requested by the system depending on whether more or less screens, respectively, is presented to the customer.
In step 114 , the system presents the customer with a confirmation of the job request and other pertinent information, including instructions to provide the vendor with a payment code that will allow the vendor to retrieve remuneration, as described below, once the job has been completed. In addition, the vendor is contacted with notification that a new job request has been received for the vendor's services. For example, an e-mail informing the vendor that a new job request for the vendor's services has been received may be sent to the vendor. FIG. 7 g illustrates a sample confirmation window, displaying the payment code and the payment mechanism with which the customer will be charged when the vendor accepts the job request. In another embodiment, the customer is not presented with a payment code nor is the customer charged any fees until the vendor has accepted the job request. In yet another embodiment, the customer may be charged a fee as a deposit before the job request is presented to the selected vendor.
The contents of an exemplary e-mail that may be sent to a vendor notifying the vendor of a job request is as follows:
To: jane@jmh.com
From: serviceprovider@emove.com
Subject: You have an eMove job. Respond within 24
hours.
Body:
A customer has requested service from you.
Job # 47690
Load or Unload Help
2-man crew - we can do the whole load/unload for you!
Where & When:
Grafton, ND 12345
3 hour on Wednesday, December 25, 2002
Customer notes:
Move furniture and boxes.
Accept this job:
http://serviceprovider.emove.com/acceptjob?id=47690&vi
d=232&email=jane@jmh.com
Reject this job:
http://serviceprovider.emove.com/rejectjob?id=47690&vi
d=232&email=jane@jmh.com
... or go to http://www.emove.com/serviceprovider and
choose to either accept or reject this job. If you
accept this job, it will be scheduled and you will be
given more details. If you do not accept it within 24
hours, it will be counted as a rejection. Rejecting
too many jobs will result in bad karma!
Regards,
eMove Moving Help
End
As shown in the text above, the e-mail is sent to the vendor from emove.com, with links for the vendor to accept (“http://serviceprovider.emove.com/acceptjob?id=47690&vid=232&email=jane@jmh.com”) or reject (“http://serviceprovider.emove.com/rejectjob?id=47690&vid=232&email=jane@jmh.com”) the job request without having to login to the emove.com website. As suggested in the text of the e-mail, and as described below, the vendor may also view and accept the job on the website once the vendor accesses the vendor's account.
FIG. 2 is a flow chart illustrating the process for the vendor to access the vendor's account and retrieve job information, including accepting or denying new job requests, viewing currently scheduled jobs, viewing the vendor's ratings, or requesting payment for completed jobs, according to one embodiment of the present invention.
In step 202 , the vendor logs onto the website. FIG. 8 a illustrates a window where the vender provides his login information, including a user identifier (“Email address”) and a password (“Password”), and submits that information for validation to enter the site by clicking on the “SIGN IN” button. If a vendor has not previously signed-up as a service provider for emove.com, then the vendor can select the “Sign up for an account” link to create a new account.
In step 204 , the vendor has successfully logged onto the website and is presented with the vendor's account information. FIG. 8 b illustrates the window that is displayed to the vendor after the vendor has logged in. The display includes any new job requests the vendor has received (“New work requests”), which in this case is job #47690; any scheduled jobs to which the vendor has agreed to provide service (e.g., job #47587), and a link to a list of jobs that the vendor has completed (“Completed jobs”). The display also provides a summary of each of the jobs.
The display shown in FIG. 8 b also includes a summary of the vendor's current rating based on comments and feedback received from customers for which the vendor has previously provided services, including a graphic that displays the numerical summary rating using stars. In the example, as part of a customer's feedback, the customer may award a vendor a numerical rating ranging from “1” to “5,” with a rating of 1 being the worst rating and the rating of 5 being the best rating. The system will use an average of the numerical ratings of all customer responses to produce the number shown in the display. A link to the list of comments is also shown (“View comments . . . ”).
Continuing to refer to FIG. 8 b , and specifically the “New work requests” section listing a new job #47690 that was previously entered by the customer, the vendor can choose to accept or deny the new job request by clicking on the “Accept” or “Reject” buttons, respectively. If the vendor accepts the job request, the customer is sent an e-mail. If the vendor rejects the job request, the customer will receive an e-mail with a message that the vendor has rejected the service request. The customer may then be provided with a link in the e-mail to go directly to the service provider selection page—i.e., FIG. 7 c , to choose a new vendor to whom the customer will submit a service request.
The contents of an exemplary e-mail sent to the customer when the vendor accepts the job request is as follows:
To: jdoe@mail.com
From: movinghelp@emove.com
Subject: Load or Unload Help for 12/25/02 has been
accepted
Body:
******************************************************
Please do not reply directly to this message - use the
contact information below.
******************************************************
Dear John,
Jane's Help is happy to accept your request for
Load or Unload Help on Wednesday, December 25, 2002.
Please note that you have now pre-paid for 3
hours of our service and eMove has charged $110.00 on
your card for this job. We look forward to discussing
your needs in more detail. If you do not hear from us
within 24 hours, please call us at the phone number
below.
After the service is completed to your
satisfaction, we will need the Payment Code that
appears below from you to make sure we are paid for
this work.
----------------------------
*** Payment Code: 818826 ***
----------------------------
Critical Information:
- Do not give the Payment Code out until after
the job is completed.
- There will be no need to pay with cash or
check, unless you exceed the amount of pre-paid
service.
- If you have further questions about the Moving
Help process, please go to
http://www.emove.com/mh/faq.html
- Questions that we can't answer should be
directed to customersupport@emove.com (include the job
number, which is #47690)
Thanks for choosing us as your service provider.
We look forward to serving you.
Regards,
Jane Juniper
Jane's Moving Help
Contact info:
Phone: 555-555-4321
Email: jane@jmh.com
*** This email has been sent to you from eMove Moving
Help on behalf of Jane's Help. ***
End
As shown in the text above, the e-mail is sent to the customer from emove.com on behalf of the vendor, with contact information for the vendor listed at the end of the e-mail, which allows vendors that do not have electronic mail capabilities to provide services as the system sends the e-mails for coordinating the transaction. In this case, however, the vendor is contactable by e-mail.
The e-mail also notifies the customer that the customer has now pre-paid for the services as a vendor has accepted the job request. The funds are held in escrow pending completion of the scheduled job, and will be retrieved by the vendor using the payment code as described herein. Thus, practically, the customer has prepaid for the services, with the funds provided by the customer being held by emove.com until proof of the being completed is received.
Returning to FIG. 2 , in step 206 , the vendor accepts the new job request for job #47690 and is presented with a confirmation of the job being scheduled for performance by the vendor. FIG. 8 c illustrates an exemplary window displayed to the vendor listing the details of job #47690, which contains information previously entered by the customer—i.e., FIGS. 7 a - 7 g . As further discussed herein, this display is also where the vendor will enter the payment code provided by the customer once the vendor has performed the services for which the vendor is contracted.
In optional step 208 , the vendor is presented with an updated account display with the now accepted job request for job #47690 being listed under the “Scheduled jobs” section. FIG. 8 d illustrates the updated account display for the vendor. Listed along each job is a link to the detailed information for the job (“View”), which the vendor can access to retrieved detailed information—such as the one shown in FIG. 8 c.
Upon the scheduled day(s) of the service, the vendor performs the contracted for service and, upon completion of the job, the customer provides the vendor with the payment code. In this example, as contained in the above e-mail, the payment code is “818826.” Once the vendor receives the payment code from the customer, remuneration may be retrieved by the vendor by going to the emove.com website. As described below, the present invention provides for “simultaneous” payment retrieval by the vendor and transmittal of a review request to the customer.
FIG. 3 is a flow chart illustrating the process for payment retrieval by the vendor and transmission of the link to the review being sent to the customer in accordance with one embodiment of the present invention. As described, this process occurs when the vendor has completed the job for the user and the user has provided the vendor with a payment code. The vendor is then ready to retrieve the funds associated with the payment code.
In step 302 , the vendor logs onto the website and selects the job for which the vendor desires to receive remuneration by selecting on the “View” link for the appropriate job (e.g., job #47690) in FIG. 8 d . The login process is described above in relation to FIG. 8 a and the display of the (scheduled) jobs for which the vendor may enter payment is described above in relation to FIGS. 8 b and 8 c.
Once the vendor has navigated to the job detail screen as shown in FIG. 8 c , the vendor may enter the payment code and then clicks on the “GET PAID” button to submit the code. In FIG. 9 a , the vendor has entered the payment code (“818826”).
In step 306 , once the payment code is verified, the system transfers the funds to the vendor. As shown in FIG. 9 b , the vendor has previously indicated that the preferred payment method for the vendor is an electronic payment system provided by PayPal, Inc. In addition, as further detailed below, the system transmits a link to a review request for the job to the customer in an e-mail.
FIG. 4 illustrates the process under which the vendor is sent payment in accordance with one embodiment of the present invention, where, in step 402 , the system detects that the vendor is requesting payment based on the submission of the payment code. In step 404 , the system determines the preferred payment method as previously selected by the vendor, which may include, but is not limited to, electronic payment systems such as PayPal, Inc.; electronic fund transfers to the vendor's bank account; or a payment to a credit card account of the vendor. It is to be noted that the payment may be made in a variety of mechanisms. Once the payment mechanism has been determined, the system effects payment in step 406 .
FIG. 5 is a flow chart illustrating the process of the system sending an e-mail to the customer once the vendor has requested payment in accordance with one embodiment of the present invention, where, starting in step 502 , it is detected that the vendor has retrieved payment using the payment code for the job. In step 504 , it is determined whether the job has been completed, and operation proceeds with step 506 if the job has been completed. In step 506 , it is determined whether the job is unreviewed, and operation proceeds with step 508 if the job has not been reviewed. If it is determined that the job is not completed (step 504 ) or if it is determined that a review has already been submitted for the job associated with the payment code (step 506 ), operation will end and no message will be sent to the customer.
In step 508 , if the job is completed and no review has been submitted for the job, then, in the preferred embodiment, the system will construct and transmit an e-mail to the customer with a link to a review for reviewing the vendor with respect to the particular job. The system checks for these conditions to prevent a customer from completing a review if the customer has already submitted a review for the job; or if the job has not been “completed,” with the definition of a job being completed being equated to the vendor retrieving payment. In another embodiment, the review may be sent to the customer in the body of the e-mail, in which case the e-mail contains code that allow an e-mail reader program to retrieve and display the review automatically. For example, the e-mail may contain hypertext markup language (HTML) code that references and displays the review. As defined by the present invention, there is no distinction made between code that “references” the review and code that displays the review. Thus, the code for the link to the review could include the code to display the review itself, such that there would be no need to retrieve any further data from the system to display the review.
The contents of an exemplary e-mail message sent to the customer from emove.com is shown below:
To: jdoe@mail.com
From: movinghelp@emove.com
Subject: Get an eMove automatic refund - your comments
wanted!
Body:
Thank you for using eMove Moving Help. Your
Service Provider has been paid.
Moving families want to hear about your Load or
Unload Help experience with Jane's Help. The
transaction fee of $3.95 will automatically be
refunded to your credit card upon your rating. It
takes only 30 seconds!
To rate Jane's Help, click on the link below or
cut and paste it into your Web browser:
http://movinghelp.emove.com/ratejob?cid=90542-
12345&email=jdoe@mail.com&id=47690
To view a receipt of your Moving Help order, go
to:
http://movinghelp.emove.com/receipt?cid=90542-
12345&email=jdoe@mail.com&id=90542
Regards,
eMove Moving Help
www.emove.com
End
In the e-mail message shown above, the link to access the review (“http://movinghelp.emove.com/ratejob?cid=90456-12345&email=gct@jmbm.com&id=47690”) includes the customer identifier (“cid=90456-12345”), which includes the order number (“90456”) and zip code of the customer (“12345”); the e-mail address of the customer (“e-mail=jdoe@mail.com”); and the identifier of the job for which the review that is to be retrieved is associated (“id=47690”). The e-mail message also include the link to view a receipt of the job (“http://movinghelp.emove.com/receipt?cid=90542-12345&email=jdoe@mail.com&id=90542”) includes the same information as the link to access the review, with the difference that the identifier relates to the order number versus the job number. A sample receipt is shown in FIG. 7 g , which is discussed above. It should be noted that the link to the review may be of various forms, and is not limited to the specific format or type of the uniform resource locator (URL) shown above.
The present invention, by immediately contacting the customer as soon as the vendor retrieves payment for the vendor's services, provides for the maximum likelihood that the customer will submit a review for the service provided by the vendor. The inclusion of a direct link to the review form, without the need for the customer to login (i.e., enter a username and password), locate, and then retrieve the review for the particular job that was performed, reduces the number of operations that the user must engage in to provide feedback down to a single click on the link to the review. Also, as discussed herein, there is a financial incentive for the user to provide feedback. Other incentives, financial or otherwise, may be presented to the customer and the particular form of compensation should be not limited to the ones described herein.
FIG. 6 is a flow chart illustrating the process where the customer is retrieving the review using the link provided in the e-mail. In step 602 , the system detects a request by the customer to retrieve the review. Based on this request, a series of conditions are tested before the review is transmitted. In the embodiment where the e-mail sent to the customer contains the actual review, the conditions are tested before the customer's response to the review is accepted. These checks are necessary as a review should only be sent to the customer (or the response to the review accepted) if a job has been completed by the vendor (based on detection of the payment request), and if no evaluation has been previously completed by the customer.
It is first determined in step 604 whether the job associated with the review requested by the customer has been cancelled, thereby making any results of the review inapplicable. If the job has not been cancelled, operation continues with step 606 , where it is determined if the job is actually pending and not a “completed” job. If the job is determined to not be still pending, operation continues with step 608 , where it is determined if payment has been retrieved by the vendor. If the payment has been retrieved, then operation continues with step 610 , where it is determined if a review has already been submitted for the job associated with the review. If the job has been paid, operation continues with step 612 , where the review is presented to the customer. In the embodiment where the review has been previously transmitted, the response to the review is accepted at this point.
If at anytime none of the conditions described above are met such that sending the review (or receiving the response to the review) is valid (e.g., sending a review or receiving the response for a job that was never completed), the system will proceed with step 614 , where the request to retrieve the review (or to send the response) is denied. The system may display an error message with the reason the review is not being transmitted (or the response is not being accepted).
FIG. 10 a illustrates a window displaying a review configured in one embodiment of the present invention, where a customer may provide feedback by assigning a numerical rating to the vendor as well as provide written comments. The review also inquires as to how many hours out of the total of the contracted order was actually performed. When the customer has completed the review, the customer may click on the “submit” button to submit the feedback. In the example that is provided, the customer may assign a rating between 1 (lowest rating) and 5 (highest rating).
Once the response to the review is received from the customer, the vendor's rating information is updated. In addition, the refundable order handling fee is refunded to the customer, preferably using the same payment mechanism with which the customer originally paid for the services. For example, if the customer paid for the services with a credit card, the refund would be applied to the same credit card. FIG. 10 b illustrates the window displaying a “Thank You” message to the customer once the review has been submitted by the customer.
Other actions may be generated by the system based on the ratings received in the review from the customer. For example, if there is an unusually low rating given by the customer, an e-mail may be sent to the customer service department of the company operating the marketplace (i.e., e-move.com) to follow-up with the customer, as well as an e-mail to the vendor notifying them of the low rating and encouraging the vendor to follow-up with the customer as well. Conversely, a high rating would warrant a congratulatory e-mail to the vendor from the company operating the marketplace.
FIG. 11 is a block diagram of an online marketplace application in accordance with one embodiment of the present invention, which is software executing on an emove.com computer server. An online marketplace application 1102 contains four primary software components: a customer application 1104 , a vendor application 1106 , an administrative application 1108 , and an underlying layer 1110 . Customer application 1104 allows the customer to navigate through the marketplace with the functionality of the processes described in FIGS. 1 , 5 and 6 and provides the customer interface as described above in FIGS. 7 a - 7 g , and 10 a - 10 b . Thus, customer application 1104 provides the functionality of selecting and paying for a service from a particular vendor; and after the service is completed, customer application 1104 provides the functionality for accepting feedback and comments from the customer regarding the vendor. It also allows a customer to review the transactions that have been paid for before and after a job is completed.
Vendor application 1106 provides functionality for vendors to complete necessary tasks such as those described in FIGS. 2-4 for the online marketplace. Initially, vendor application 1106 processes vendors being added to the lists maintained by the host. Vendor application 1106 handles the login process for vendors entering the marketplace and processes payment codes entered by a vendor to transfer money from an escrow account to the vendor's account. Vendor application 1106 also processes scheduling services for the vendors and provides schedules to vendors. Vendor application 1106 provides the user interfaces describe in FIGS. 8 a - 8 c and 9 a - 9 b.
Administrative application 1108 allows an administrator of the online marketplace to oversee the entire application and perform basic administrative functions. A few examples of this include assigning a particular city to a service area or adding a new category of services to the services offered in the marketplace. It also allows an administrator to access data for analysis and creating statistics on customer behavior. Underlying layer 1110 provides the groundwork or foundation for the applications to function. For example, it maps the database containing vendor and customer information, needed by the applications to operate, and determines the overall look and feel of the online marketplace system.
Although the description of the invention is directed to vendors primarily as “service” providers, the mechanisms described above apply to vendors providing “goods” in addition to or instead of services. Thus, the “job” number would be related to a particular purchase of goods and the time would be related to the time of delivery.
Moreover, it is to be noted that although the description contained herein describes an exemplary series of steps executed in a particular order in accordance with one embodiment of the present invention, the sequence of operations may be altered or certain steps may be combined or cancelled in other embodiments of the present invention. Further, certain steps may be further divided in these other embodiments.
The system may also be implemented using a variety of technologies other than the client-server web system described herein. For example, the system may be implemented using a telephone system, where vendors may review job requests; respond to job requests; request payments; retrieve their customer provided ratings and feedback; and otherwise perform the same types of vendor operations using a telephone system as would be performed using the emove.com website. In addition, customers may receive a listing of vendors; review and select vendors for job requests; provide payment information; revise/review job requests; provide feedback and review for a completed job; and otherwise perform the same types of customer operations using a telephone system as would be performed using the emove.com website.
The embodiments described above are exemplary embodiments of the present invention. Those skilled in the art may now make numerous uses of, and departures from, the above-described embodiments without departing from the inventive concepts disclosed herein. Accordingly, the present invention is to be defined solely by the scope of the following claims.
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A method for conducting a review including the step of detecting a payment request from a vendor; generating a review based on the payment request; and, transmitting a reference to the review to a customer, wherein the reference provides a link to retrieve the review. A system for performing the method is also described.
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REFERENCE TO RELATED APPLICATIONS
[0001] The present patent application is a continuation-in-part of, and hereby claims priority to, U.S. Non-Provisional application Ser. No. 12/660,694, filed Mar. 2, 2010 entitled “Three Dimensional Connection System For Bed Frame”, which in turn, claims priority from U.S. Provisional Application Ser. No. 61/165,493 filed Mar. 31, 2009. The present application also hereby claims priority to U.S. Provisional Application Ser. No. 61/339,226, filed Mar. 2, 2010 entitled “Bed Frame Having Protective Plastic Coating”. Applicants claim the benefits of 35 U.S.C. §120 as to said Non-Provisional Application, and the benefits of 35 U.S.C. §119 as to said Provisional Applications, and the entire disclosures of all applications are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates to a bed frame for supporting a mattress or mattress set and, more particularly, to a bed frame that has a protective plastic casing that covers the structural components of the bed frame.
BACKGROUND OF THE INVENTION
[0003] There are currently in use conventional bed frame assemblies that are used for supporting a mattress or mattress set and such bed frame assemblies are normally made up of two side rails and at least one cross member. The bed frame supports the load of a mattress set by means of multiple support legs.
[0004] With many bed frames, the side rails and cross members are made of a metal, generally iron or steel, and the overall frame therefore has multiple sharp edges for the metal components. Further, the use of metal makes the bed frame a difficult platform on which the box spring and mattress are slid in assembling a bed. The metal material for bed frames is not particularly lubricious and therefore hampers the sliding of a box spring over the assembled frame and there is the possibility that one of the sharp edges of the bed frame will cause a tear in the box spring or mattress material.
[0005] Accordingly, it would be advantageous to provide a covering for a bed frame that is both protective of sharp edges as well as facilitate the sliding of a box spring over the bed frame in the assembly of a completed bed.
SUMMARY OF THE INVENTION
[0006] A feature of the present bed frame is that the metal frame is encased in plastic, thereby allowing the box spring and mattress to easily slide in place on top of the frame without contact with the metal, that is, along some portion or all of the length of a side rail or cross rail, the rail is totally surrounded by a plastic shield. The side rails and the cross rails are encased in a plastic shield and there are plastic injection molded end caps. With the present invention, therefore, the side and/or cross rail for a bed frame can be encased with plastic shields at the point of manufacture such that the rails are shipped with the plastic shields assembled thereto. As such, each step of the assembly of the bed frame using a plastic shielded component can have the advantage of the present invention since that assembly does not need to deal with hard steel components.
[0007] In an exemplary embodiment, the side rails are made from one or more rail steel angle iron pieces, however any structural metal beam can be used with the present invention including rolled tubing and folded strips. The plastic is a more lubricious surface than the steel and therefore the task is made simpler requiring less exertion and stress. Secondly, the plastic is not abrasive to the fabric of the bedding and so the material is protected from damage or wear. Thirdly, the plastic serves to make the frame quiet by inhibiting any metal on metal squeaking. The staples or tacks in the box spring can make sound on a metal bed frame. The plastic forms an entirely flat platform for supporting the bedding. In an exemplary embodiment, there may be grooves formed on the surface of the plastic that serve to further deaden any sounds and inhibit vibration.
[0008] In an exemplary embodiment, the bed frame has a double angle iron side rail encased in a plastic extrusion. This side rail is more rigid because it has a tall vertical proportion. The plastic serves to dress the frame and make it more like traditional finished furniture as well as to make the steel more comfortable and safer to handle because it is softer and has few edges.
[0009] The cross rails are preferred to also be made of two piece of angle iron covered by a plastic extrusion. This allows the cross rail to also present the appearance of a finished part. The ends of the cross rails are capped with an injection molded end caps. All metal rails, both assembled and unassembled, are encased by plastic. The plastic shield could be manufacture in many ways including injection molding, insert injection mold, and coating. A preferred method of manufacture is to extrude the shield. Ribs are utilized on the inside of the extrusion to support the shaping and hold the internal metal structure in place. These ribs can take a number of different configurations. The preferred rib configuration is to have two ribs hanging straight down from the curved surface to contact the metal structure. These would be positioned only about a 0.25 inch inboard of the outer edges of the metal. In this way, the ribs will not fall off the edge but are also as short as possible. This will help with the thickness and consistency during manufacture.
[0010] In a further embodiment, the side rail of the bed frame is constructed of a single L shaped angle iron completely encased in plastic. The vertical flange of the angle iron extends upwardly to form a ridge to retain the bedding from side to side movement. The plastic extends downward below the horizontal portion of the angle. In this way, the side rail has a larger visual impact on the appearance of the bedding. Also this serves the function of covering the cut end of the cross rails at the point they connect to the side rails.
[0011] In addition the plastic overhang allows for the addition of lighting where the wiring and the fixtures are shielded from view. This light serves as a safety feature but also makes the bed more visually exciting. The plastic shield could be manufactured in many ways including injection molding, insert injection mold, and coating. A preferred method of manufacture is to extrude the encasement. Ribs are required on the inside of the extrusion to support this shaping and hold the internal metal structure in place. These ribs can be provided in a number of different configurations.
[0012] In a further embodiment, the side rail of the bed frame is constructed of a single L shaped angle iron completely encased in plastic with the vertical flange of the angle iron extending downwardly such that the leg of the angle perpendicular to the floor is positioned below the bottom surface of the bedding. In this case, the plastic is extended above the vertical member of the angle iron to form a ridge that retains the bedding against side to side movement. In this way, the side rail has a larger visual impact on the appearance of the bedding.
[0013] Also the rail downward turned flange of the angle iron serves the function of covering the cut end of the cross rails at the point they connect to the side rails. In addition the plastic overhang allows for the addition of lighting where the wiring and the fixtures are shielded from view. As such, the geometry of the rail that allow for the rails rigidity is all below the bedding.
[0014] The upstanding rigid portion can be much abbreviated in height because it is only a retainer. This is critical when the box spring has pull out storage drawers that can be blocked by tall side rails. The plastic shield could be manufactured in many ways including injection molding, insert injection mold, and coating. A preferred method of manufacture is to extrude the encasement. The upstanding ridge of plastic could take many forms. The preferred embodiment would be a hollow loop within extending from the main body of the plastic shield. Within the upstanding loop there is a ribbed reinforcement to provide strength to the otherwise unsupported member.
[0015] As a still further exemplary embodiment, since the plastic shields are affixed to the bed frame component at the manufacturers location, the manufacturer can provide the bed shields in a variety of standard or custom colors so that the ultimate user may have a bed frame components that are of a particular color to match the room or to identify the component as applicable for a particular size or type of bed frame. Thus, the manufacturer can use a customer-selected color of plastic shield and that specific color bed frame components can be boxed up and shipped to the customer with the desired color.
[0016] These and other features and advantages of the present invention will become more readily apparent during the following detailed description taken in conjunction with the drawings herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is an exploded view illustrating a cross rail bed frame member having a protective plastic end cap;
[0018] FIG. 2 is an exploded view illustrating a side rail bed frame member having a protective plastic end cap;
[0019] FIG. 3 is a cross sectional view of a side rail encased in plastic made with two angle irons;
[0020] FIG. 4 is a cross sectional view of a cross rail encased in plastic made with two angle irons;
[0021] FIGS. 5 and 5A are a cross sectional view and an enlarged cross sectional view of a side rail having a plastic shield with surface grooves;
[0022] FIGS. 6 and 6A are a cross sectional view and an enlarged cross sectional view of a cross rail having a plastic shield with surface grooves;
[0023] FIG. 7 is a schematic view illustrating a mattress/foundation sliding on an entirely plastic encased bed frame;
[0024] FIG. 8 is a cross sectional view of a side rail made with an angle iron encased in plastic having one upturned flange with a plastic shield blocking the end of a cross rail;
[0025] FIG. 9 is a perspective view illustrating the visual difference between a raw angle iron and the plastic encasement covering the angle iron;
[0026] FIG. 10 is a cross sectional view of a side rail of FIG. 8 with a lighting strip concealed behind the plastic shield;
[0027] FIG. 11 is a perspective view illustrating bed frame and mattress with the concealed light of FIG. 10 ;
[0028] FIG. 12 is a cross sectional view of a side rail made with an angle iron encased in plastic having one downturned flange with a plastic shield blocking the end of a cross rail with a plastic lip for retaining the bedding;
[0029] FIG. 13 is a cross sectional view of a side rail of FIG. 12 with a lighting strip concealed behind the downturned flange of the angle iron;
[0030] FIG. 14 is a cross sectional view of a side rail of FIG. 12 having standing ribs to support the outer portion of the plastic shield; and
[0031] FIG. 15 is a cross sectional view of a side rail of FIG. 12 having a different configuration of outer portion of the plastic shield than the embodiment of FIG. 14 .
DETAILED DESCRIPTION OF THE INVENTION
[0032] Turning to FIG. 1 , there is shown an exploded view illustrating a bed frame cross rail 10 having a protective plastic end cap 12 that fits over the end of the cross rail 10 to cover the sharp edges that are present at the ends of the cross rail 10 . As can be seen, the cross rail 10 is comprised of two angle irons 14 , 16 secured together by means such a rivets 18 to form a T-shape. As is well known, the ends of such cross rails result in sharp edges of the angle irons 14 , 16 that can be hazardous to a person striking a sharp edge. The end cap 12 is also therefore a T-shape and fits over the ends of the cross rails 10 and may include an enlarged pocket 20 to enable the end cap 12 to slip over a rivet where necessary. Although only one end cap 12 is illustrated, both ends of the cross rails 10 may be protected by an end cap 12 .
[0033] Next, in FIG. 2 , there is an exploded view of a side rail 22 and a plastic end cap 24 that fits over the end of the side rail 22 . In this embodiment, again, there are two angle irons 26 , 28 that are secured together forming a combined vertical flange 30 and an overlapping inwardly directed horizontal flange 32 . There is also a plastic shield 34 that covers the external surface of the vertical flange 30 and abuts against the end cap 24 when the end cap 24 is slid onto the end of the side rail 22 , thereby fully covering the exterior surface of the vertical flange 30 . A fastener 36 can be used to secure the end cap 24 to the side rail 22 by passing though the end cap 24 and a hole 38 in the side rail 22 . The exterior surface 40 of the end cap 24 can be designed to be of the same curvature as the exterior surface 42 of the plastic shield 34 so that the two components meet in a smooth junction.
[0034] Turning next to FIG. 3 , there is shown a cross sectional view of a side rail 44 that, again, is constructed of two angle irons 46 , 48 secured together. As can be seen, the combined angle irons 46 , 48 forms an overlapping horizontal flange 50 and a combined adding vertical flange 52 that is twice the length of a vertical flange of the angle irons 46 , 48 . A plastic shield 54 fully surrounds the cross section of the side rail 44 such that the metal side rail 44 is completely covered and thus the cold steel or other metal is easier to handle and is more esthetically pleasing.
[0035] In the orientation of FIG. 3 , the plastic shield 54 has an exterior portion 56 that is held away or displaced from the vertical flange 52 by means of ribs 58 , 60 and which can be molded into the plastic shield 54 . Since the plastic shield 54 is, in the embodiment of FIG. 3 , unbroken, it can be slid along the longitudinal length of the side rail 44 in order to install the plastic shield 54 to the side rail 44 .
[0036] Turning next to FIG. 4 , there is a cross sectional view of a cross rail 62 that is, again, made up of two angle irons 64 , 66 that are secured together. In this embodiment, since the bed frame component is a cross rail, the cross rail 62 is oriented such that the upper, horizontal flange 68 is twice the length of a single flange of either of the angle irons 64 , 66 and the vertical flange 70 overlaps the flanges of the angle irons 64 , 66 . Again, however, there is a plastic shield 72 that surrounds the entire cross section of the cross rail 62 so as to fully cover the metal angle irons 64 , 66 .
[0037] It should be noted, that while the description of a cross rail or side rail component making up a bed frame may be described as being comprised of two angle irons secured together, the present invention is equally applicable to a side rail or cross rail being provided as a single, unitary construction.
[0038] In FIGS. 5 and 5A , there is cross sectional view of a side rail and an enlarged cross section of a side rail 44 with the plastic shield 54 as shown in the embodiment of FIG. 3 , however, the external surface 74 of the exterior portion 56 is curved outwardly and has surface grooves 76 formed thereon. The surface grooves 76 serve to further deaden any sounds and inhibit vibration. In addition, since the plastic shields may be extruded and have a shiny exterior finish, the use of the surface grooves 76 creates a finish that is less susceptible to marring or surface damage.
[0039] In FIGS. 6 and 6A , there is cross sectional view of the cross rail 62 and an enlarged cross section of the cross rail 62 with the plastic shield 72 as shown in the embodiment of FIG. 4 , however, the external surface 78 of the upper portion 80 of the plastic shield has surface grooves 82 formed thereon.
[0040] Next in FIG. 7 , there is a schematic view of a box spring 84 being slid onto a bed frame 86 . As can be seen, the box spring 84 slides in the direction of the arrow A along the side rails 88 . In accordance with the present invention, the side rails 88 are fully covered by a plastic shield 90 , including end caps 92 such that the box spring 84 can slide easily and in a more lubricious manner than if the box spring 84 were sliding along raw steel side rails. The protective plastic end caps 92 prevent the otherwise sharp edges of the side rails 88 from cutting into the box spring and the smooth sliding action along the plastic shields 90 of the side rails 88 also minimizes damage to the box spring.
[0041] Turning to FIG. 8 , there is shown a cross sectional view of a side rail 94 that is an L-shaped configuration, such as an angle iron, with a horizontal flange 96 positioned to underlie a box spring (not shown) and a vertical flange 98 extending upwardly from the horizontal flange 96 and adapted to be positioned proximate to, and run along, the outside edge of a box spring. Again, there is a plastic shield 100 that fully encases the side rail 94 so as to enclose the side rail 94 entirely. FIG. 8 also shows a cross rail 102 of a bed frame and, as can be seen, there is a downwardly directed portion 104 of the plastic shield 100 that extends below the horizontal flange 96 and which covers the outer end 106 of the cross rail 102 to provide protection again a person inadvertently encountering that outer end 106 and being injured.
[0042] As such, the plastic shield 100 not only encases the side rail 94 for protection to make the side rail 94 easier to handle and maneuver, but when the side rail 94 is assembled in constructing a bed frame, the same plastic shield 100 affords protection for persons by covering the outer end 106 of a cross rail 102 .
[0043] In the embodiment of FIG. 8 , there can also be seen a rib 108 that contacts the vertical flange 98 to position the exterior portion 110 of the plastic shield 100 outwardly from the vertical flange 98 and also a reinforcing rib 112 that adds strength and rigidity to the downwardly directed portion 104 .
[0044] Turning then to FIG. 9 , then is shown a perspective view of the side rail 94 of FIG. 8 with a portion of the plastic shield 100 removed so that a distinction can be seen between the easily handled and protected portion of the side rail 94 protected by the plastic shield 100 and the bare portion of the side rail 94 where there is no such protection.
[0045] Turning to FIG. 10 , there is a cross sectional view of a further exemplary embodiment of the side rail 94 of FIG. 8 . In FIG. 10 , a light 114 , such as a fluorescent light, is located underneath the horizontal flange 96 and thus is underneath the box spring and mattress and is located interior of the downwardly directed portion 104 and is therefore in a protective location where the light 114 cannot be easily kicked or otherwise struck by a person or objects nearing the bed frame.
[0046] In FIG. 11 , taken along with FIG. 10 , there is a perspective view of a box spring 116 and showing the side rail 94 having a plastic shield 100 and illustrating the effect of the indirect lighting where the light rays 118 are directed downwardly and inwardly by the downwardly directed portion 104 of the plastic shield 100 thereby creating a desirable lighting effect.
[0047] Turning next to FIG. 12 , there is shown a cross sectional view of an alternative embodiment of a side rail 120 that is an L-shaped configuration, such as an angle iron, with a horizontal flange 122 positioned to underlie a box spring 124 and a vertical flange 126 extending downwardly from the horizontal flange 122 , that is, the vertical flange 126 extends beneath the box spring 124 and is adapted to be positioned proximate to, and run along, the outside edge of the box spring 124 .
[0048] Again, there is a plastic shield 128 that fully encases the side rail 120 so as to enclose the side rail 120 entirely. FIG. 12 also shows a cross rail 130 of a bed frame and, as can be seen, there is a upwardly directed portion 132 of the plastic shield 128 that extends above the horizontal flange 122 and which is located proximate to the box spring 124 and prevents the box spring 124 from movement in a lateral direction.
[0049] As such, the plastic shield 128 not only encases the side rail 120 for protection to make the side rail 120 easier to handle and maneuver, but when the side rail 120 is assembled in constructing a bed frame, the same plastic shield 128 affords stability against lateral movement of the box spring 124 as well as protection against persons contacting the sharp outer end 134 of the cross rail 130 .
[0050] In the embodiment of FIG. 12 , there can also be seen a rib 136 that contacts the vertical flange 126 to position the exterior portion 138 of the plastic shield 128 outwardly of the vertical flange 126 and also a reinforcing rib 140 that adds strength and rigidity to the upwardly directed portion 132 .
[0051] Turning then to FIG. 13 , there is shown a cross sectional view of the side rail 120 of FIG. 12 further including a light 142 that can be positioned beneath the horizontal flange 122 and behind the vertical flange 126 so as to protect the light 142 from damage by persons or objects striking the light 142 .
[0052] In FIG. 14 , there is a side rail 120 that is constructed the same as in the FIG. 12 embodiment, that is, the side rail 120 is an L-shaped configuration, such as an angle iron, with the horizontal flange 122 positioned to underlie a box spring and the vertical flange 126 extending downwardly from the horizontal flange 122 .
[0053] With the FIG. 14 embodiment, however the plastic shield 144 is of a slightly different configuration, that is, the upwardly directed portion 146 is more circular in appearance and the exterior portion 148 of the plastic shield 144 is concave inwardly in design and there are two ribs 148 that extend inwardly from the exterior portion 148 and contact the vertical flange 126 to add strength and rigidity to the plastic shield 144 .
[0054] Finally, in FIG. 15 , there is a further embodiment wherein the plastic shield 152 has an outer portion 154 with a lower section 156 that is generally parallel to the vertical flange 126 with an upper section 158 that curves inwardly toward the vertical flange 126 , such that an upper rib 160 is shorter that a lower rib 162 .
[0055] While the present invention has been set forth in terms of a specific embodiment of embodiments, it will be understood that the present plastic shielding system for a bed frame herein disclosed may be modified or altered by those skilled in the art to other configurations. Accordingly, the invention is to be broadly construed and limited only by the scope and spirit of the claims appended hereto.
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A bed frame wherein the side rail and/or cross rails are fully encased in plastic shields. A plastic shield or shields cover the entire cross sectional area of the side and cross rails so that the side rail and cross rails are easy to handle and esthetically pleasing. The system avoids the need for a person to handle cold, sometimes dirty, steel and the cross and side rails may be T-shaped or L-shaped angle irons, or other configurations and covered with plastic shields. With the plastic shields, the steel members need not be finished since the outer appearance of the steel is encased by the plastic shields and not seen by persons.
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FIELD OF THE INVENTION
The present invention relates to digital circuits and, more particularly, to test circuits. Still more particularly, the present invention relates to boundary-scan circuits for use with linearized impedance control type output buffers.
BACKGROUND
Many complex circuits use boundary scan testing techniques to test the output buffers of the circuit. For circuits using conventional two-state or three-state CMOS output buffers, designers commonly use the boundary scan implementation defined in the IEEE Standard Test Access Port and Boundary-Scan Architecture IEEE Std 1149.1-1990 and IEEE Std 1149.1a-1993 (referred to herein as the IEEE 1149.1 Specification or Standard), which is incorporated herein by reference. As is well known, a boundary scan implementation allows for testing of interconnects in a board environment by loading or "scanning in" test patterns into a series of interconnected boundary scan registers (BSRs). Each test pattern loaded in the BSRs provides a different set of control and data signals to the output drivers. The responses of the output drivers to the test patterns can be captured by an adjacent circuit on the board and scanned out. To run a functional test vector, an input test pattern is scanned in through the BSRs. After one or more clock cycles, the response of the circuit can then be captured in the BSRs and either scanned out or monitored at the output pads.
FIG. 1 is a circuit diagram of a portion of a circuit 100 using a conventional boundary scan implementation for I/O drivers that have three-state drivers (TSDs). The circuit 100 includes a conventional TSD 102 serving as an output driver, having an output lead connected to an I/O pad 104. The I/O pad 104 is also connected to an input lead of an input driver 105, which drives any signal received from the I/O pad 104 to other portions (not shown) of the circuit 100 in the conventional manner. The circuit 100 also includes conventional BSRs 106 and 107, which are interconnected to form part of a "scan chain" for loading test patterns and scanning out capture data. The BSR 106 includes a capture, shift and update stage (CSUS) 108 that has an output lead connected to an input lead 111 of a two-input multiplexer 112. The other input lead 113 of the multiplexer 112 is connected to receive a fcn -- oe signal provided by another portion (not shown) of the circuit 100. The multiplexer 112 has an output lead 114 connected to the output enable lead of the TSD 102.
Similarly, the CSUS 110 has an output lead connected to an input lead 115 of another two-input multiplexer 116. The other input lead 117 of the multiplexer 116 is connected to receive a fcn -- data signal provided by another portion (not shown) of the circuit 100. The multiplexer 116 has an output lead 118 connected to an input lead of the TSD 102.
In operation during the boundary scan mode, the CSUSs 108 and 110 are loaded with a test pattern in the conventional manner (see the aforementioned 1149.1 specification). The test pattern is predetermined so that the CSUS 108 is loaded with a value for enabling or disabling the TSD 102, as desired. Thus, the CSUS 108 provides a bsr -- oe signal to the multiplexer 112. Similarly, the CSUS 110 is loaded with a desired value for the data signal to be provided to the input lead of the TSD 102. Thus, the CSUS 110 provides a bsr -- data signal to the multiplexer 116. The multiplexers 112 and 116 receive a mode signal via a line 120 that causes the multiplexers 112 and 116 to select the bsr -- oe and bsr -- data signals. A test access port (TAP) controller according to the 1149.1 specification typically provides this mode signal. Accordingly, the TSD 102 is controlled as desired by the test pattern loaded into the BSRs to test one of the various functions of the I/O driver. The output signal provided by the TSD 102 could then be monitored at the I/O pad 104 and compared to the expected result. Other test patterns may then be loaded to test other functions of the I/O drivers.
To test the input portion of the I/O driver, a test signal can be externally provided to the I/O pad 104. The driver 106 then drives the test signal to the rest of the circuit 100 (not shown). The response of the circuit 100 can then be captured in the BSRs. The capture data can then be scanned out from the BSRs and compared to the expected response. In this example, the CSUS 108 and 110 receive capture data through input leads 122 and 124, respectively.
During the functional mode, the mode signal is configured to cause the multiplexers 112 and 116 to select the fcn -- oe signal and the fcn -- data signal instead of the bsr -- oe and bsr -- data signals. Of course, the fcn -- oe and fcn -- data signals are generated by the circuit 100 during normal functional operation. Consequently, the multiplexers 112 and 116 provide the fcn -- oe and fcn -- data signals to serve as the data and oe signals received by the TSD 102.
However, some high performance circuits such as, for example, microprocessors, have to use other types of drivers for improved performance. One type that can be used is a linearized impedance control type (LIC) driver. FIG. 2 is a circuit diagram of an example of a portion of a circuit 200 including a LIC driver 202. Note, like reference numbers are used throughout the drawings for elements that has substantially similar structure and function. The LIC driver 202 includes a pull-up unit 204 and a pull-down unit 206. The pull-up unit 204 is connected to receive a q -- up signal via an input lead 208. Similarly, the pull-down unit 206 is connected to receive a q -- dn signal via an input lead 210. The LIC 200 can provide the functionality (i.e., a logic zero, logic one and high impedance state) of a conventional CMOS TSD through appropriate control of the logic levels of the q -- up and q -- dn signals, as summarized in Table 1 below.
TABLE 1______________________________________q.sub.-- up q.sub.-- dn LIC out______________________________________0 0 00 1 Z1 0 Illegal1 1 1______________________________________
The "Z" in Table 1 indicates a high impedance state. As is well known in the art of LIC drivers, the q -- up and q -- dn signals must be generated so that the q -- up signal is not at a logic one level at the same time the q -- dn signal is at a logic zero level.
It is appreciated that the q -- up and q -- dn signals of the LIC driver are not equivalent to the data and oe signals of a conventional CMOS TSD. That is, the oe and data signals cannot simply be replaced by the q -- up (or q -- dn) signals in an I/O driver using a LIC driver. Thus, circuits using boundary scan implementations according to the IEEE 1149.1 specification cannot be used with circuits having LIC drivers. However, because the IEEE 1149.1 standard is widely used in the industry, there is a need for a system that allows LIC drivers to be used with boundary scan implementations according to the IEEE 1149.1 specification.
SUMMARY
In accordance with the present invention, a circuit is provided for coupling a LIC driver to a boundary scan implementation. In one embodiment adapted for the IEEE 1149.1 boundary scan standard, the circuit includes a logic circuit that converts the data and oe signals of the IEEE 1149.1 specification to q -- up and q -- dn signals meeting the requirements of the LIC driver. In a further refinement, the logic circuit also converts functional q -- up and q -- dn signals provided by the circuit under test to the data and oe signals of the IEEE 1149.1 specification. This feature is advantageously used to capture data into the BSRs of the IEEE 1149.1 boundary scan implementation. As a result, the logic circuit allows the widely used IEEE 1149.1 boundary scan standard to be used with LIC drivers. The resulting compatibility simplifies the testing and use of the LIC drivers, and develops a new boundary scan standard for use only with LIC drivers that is compliant with the IEEE 1149.1 standard.
In a particular implementation of the above embodiment, the logic circuit includes a first logic circuit for converting the data and oe signals from the CSUSs to q -- up and q -- dn signals. The logic circuit also includes a second logic circuit for converting the functional q -- up and q -- dn signals (i.e., generated by the circuit under test) into "response" oe and data signals to be captured in the BSRs. The first and second logic circuits of the logic circuit thereby allow the IEEE 1149.1 boundary scan standard to be used with LIC drivers in a manner that is transparent to boundary scan tester.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a circuit diagram of a portion of a circuit with a conventional boundary-scan implementation;
FIG. 2 is a circuit diagram of a portion of a circuit with a conventional linearized impedance control type output driver;
FIG. 3 is a block diagram of an electronic system having a logic circuit for use with a linearized impedance control type output driver, in accordance with one embodiment of the present invention;
FIG. 4 is a circuit diagram of a portion of a circuit with a logic circuit for use with a linearized impedance control type output driver, in accordance with one embodiment of the present invention;
FIGS. 5A and 5B are flow diagrams illustrative of the operation of the logic circuit of FIG. 4;
FIG. 6 is a circuit diagram of an LIC-to-boundary scan logic circuit, in accordance with one embodiment of the present invention;
FIG. 7 is a circuit diagram of the LIC-to-boundary scan logic circuit of FIG. 6, according to one embodiment of the present invention;
FIG. 8 is a circuit diagram of a boundary scan-to-LIC logic circuit, in accordance with one embodiment of the present invention;
FIG. 9 is a circuit diagram of one embodiment of the boundary scan-to-LIC logic circuit of FIG. 8, in accordance with the present invention; and
FIG. 10 is a circuit diagram of another embodiment of the boundary scan-to-LIC logic circuit of FIG. 8, in accordance with the present invention.
DETAILED DESCRIPTION
FIG. 3 is a block diagram of an electronic system 300 according to one embodiment of the present invention. The electronic system 300 includes an integrated circuit 301 with a logic circuit for interfacing boundary scan circuitry with a linearized impedance control type output driver, a memory 303, interfaces 305 and peripherals 307 1 -307 N .
The electronic system 300 can be any type of electronic system. In this embodiment, the electronic system 300 is a computer system in which the integrated circuit 301 is a processor connected to the memory 303 and to interfaces 305. The processor can be any type of processor such as, for example, Pentium®, X86, Sparc®, Alpha®, MIPS®, HP®, and PowerPC® processors. The interfaces 205 are connected to peripherals 307 1 -307 N , thereby allowing the processor to interact with these peripherals. The memory 303 and the interfaces 305 can be any type of memory or interface for use in computer systems. Likewise, the peripherals can be any type of peripheral such as, for example, displays, mass storage devices, keyboards or any other type of input or input-output device. In accordance with the present invention, the logic circuit used in the integrated circuit 301 allows IEEE 1149.1 boundary scan circuitry to be used with a linearized impedance control type of output driver.
FIG. 4 is a circuit diagram of a portion of a logic circuit 400 that includes a logic circuit 402 for coupling LIC drivers to IEEE 1149.1 standard BSRs, in accordance with one embodiment of the present invention. The logic circuit 402 is connected to receive the bsr -- oe and bsr -- data signals from the CSUSs 108 and 110 of the BSRs 106 and 107. The logic circuit 402 is also connected to receive the "functional" (i.e., generated by the circuit 400 during normal functional operation) q -- up and q -- dn signals. The logic circuit 402 outputs a signal bsr -- q -- up, a signal bsr -- q -- dn, a signal rsp -- oe and a signal rsp -- data.
FIGS. 5A and 5B are flow diagrams illustrative of the operation of the logic circuit 402 (FIG. 4). Referring to FIGS. 4-5B, the logic circuit 402 operates as follows. In a step 501 (FIG. 5A), the logic circuit 402 enters a boundary scan "shift" mode in which a test pattern is shifted into the BSRs in the conventional manner. As previously described, the test pattern includes values stored in the CSUSs 108 and 110 for "setting" the output enable and data signals to predetermined logic levels to test the functionality of the LIC driver 202 (FIG. 2).
In a step 503 (FIG. 5A), the logic circuit 402 receives the output enable (i.e., bsr -- oe) signal and the data (i.e., bsr data) signal from the CSUSs 108 and 110. In a next step 505 (FIG. 5A), the logic circuit 402 converts the signals bsr -- oe and bsr -- data from the CSUSs 108 and 110 into q -- up and q -- dn signals (i.e., the bsr -- q -- up and bsr -- q -- dn signals), respectively. More specifically, for this "boundary scan-to-LIC" feature, the logic circuit 402 implements the truth table shown below in Table 2.
TABLE 2______________________________________bsr.sub.-- data bsr.sub.-- oe bsr.sub.-- q.sub.-- up bsr.sub.-- q.sub.-- dn LIC out______________________________________0 1 0 0 0X 0 0 1 Z1 1 1 1 1______________________________________
The X and Z in Table 2 respectively indicate a "don't care" and a high impedance condition. The logic circuit 402 provides the bsr -- q -- up and bsr -- q -- dn signals on output leads that are respectively connected to the input leads 111 and 115 of the multiplexers 112 and 116 (FIG. 1). As summarized in Table 2, the mapping of the bsr -- data and bsr -- oe signals into the bsr -- q -- up and bsr -- q -- dn signals omits the illegal condition of the bsr -- q -- up signal being at a logic one level at the same time that the bsr -- q -- dn signal is at a logic zero level. Particular embodiments of circuitry implementing the functionality of Table 2 are described below in conjunction with FIGS. 8-10. Of course, in light of the present disclosure, those skilled in the art of digital circuits can design many other circuits that implement the functionality of Table 2 without undue experimentation.
Conversely, during boundary scan testing of the function of the circuit 400, the logic circuit 402 enters a boundary scan capture mode during a step 507 (FIG. 5B). In a next step 509 FIG. 5B), the logic circuit 402 receives the functional LIC control signals (i.e., fcn -- q -- up and fcn -- q -- dn) resulting from the test pattern. Then in a step 511 (FIG. 5B), the logic circuit 402 converts the fcn -- q -- up and fcn -- q -- dn signals into "response" oe and data signals (i.e., the rsp -- oe and rsp -- data signals) to be captured in the CSUS 108 and 110 in the conventional manner. More specifically, for this "LIC-to-boundary scan" feature, the logic circuit 402 implements the truth table shown below in Table 3.
TABLE 3______________________________________fcn.sub.-- q.sub.-- up fcn.sub.-- q.sub.-- dn rsp.sub.-- data rsp.sub.-- oe______________________________________0 0 0 10 1 X 01 1 1 1______________________________________
The X in Table 3 indicates a "don't care" condition. The logic circuit 402 provides the signals rsp -- oe and rsp -- data on output leads that are respectively connected to the input leads 122 and 124 of the CSUS 108 and 110. As summarized in Table 3, the mapping of the fcn -- q -- up and fcn -- q -- dn signals into the rsp -- data and rsp -- oe signals does not include the illegal condition of the fcn -- q -- up signal being at a logic one level at the same time that the fcn -- q -- dn signal is at a logic zero level. Particular embodiments of circuitry implementing the functionality of Table 3 are described below in conjunction with FIGS. 6 and 7. Of course, in light of the present disclosure, those skilled in the art of digital circuits can design many other circuits that implement the functionality of Table 3 without undue experimentation. Then in a next step 513, the response signals rsp -- oe and rsp -- data are shifted out of the BSRs in the conventional manner. Alternatively, the step 505 may be performed so that the captured values are used to generate LIC control signals, which causes LIC drivers to output the response.
FIG. 6 is a circuit diagram of an LIC-to-boundary scan (LIC-BSR) logic circuit 602, in accordance with one embodiment of the present invention. In this embodiment, the LIC-BSR logic circuit 602 forms part of the logic circuit 402 (FIG. 4) to implement the aforementioned "LIC-to-boundary scan" feature. The LIC-BSR logic circuit 602 has input leads 604 and 606 and output leads 608 and 610. The input leads 604 and 606 are respectively connected to receive the signals fcn -- q -- up and fcn -- q -- dn generated by the circuit 800 during normal functional operation. The output leads 608 and 610 are respectively connected to the input leads 122 and 124 of the CSUS 108 and 110. The LIC-BSR logic circuit 602 operates during the boundary scan mode to convert the signals fcn -- q -- up and fcn -- q -- dn into the signals rsp -- oe and rsp -- data (conforming to the IEEE 1149.1 specification) to be captured in the CSUS 108 and 110. More specifically, the LIC-BSR logic circuit 602 implements the truth table shown below in Table 5. In this way, the LIC-BSR logic circuit 602 serves to make the IEEE 1149.1 boundary scan standard interoperable with the LIC driver 202.
TABLE 5______________________________________fcn.sub.-- q.sub.-- up fcn.sub.-- q.sub.-- dn rsp.sub.-- data rsp.sub.-- oe______________________________________0 0 0 10 1 X 11 1 1 1______________________________________
The X indicates a "don't care" condition. As summarized in Table 5, the mapping of the signals fcn -- q -- up and fcn -- q -- dn into the signals rsp -- data and rsp -- oe omits the illegal condition of the fcn -- q -- up signal being at a logic one level at the same time that the fcn -- q -- dn signal is at a logic zero level. A particular embodiment of a circuit implementing the functionality of Table 5 is described below in conjunction with FIG. 7. Of course, in light of the present disclosure, those skilled in the art of digital circuits can design many other circuits that implement the functionality of Table 5 without undue experimentation.
FIG. 7 is a circuit diagram of the LIC-BSR logic circuit 602 (FIG. 6), according to one embodiment of the present invention. In this embodiment, the LIC-BSR logic circuit 602 includes a non-inverting buffer 702 and a two-input OR gate 704. The buffer 702 has an input lead connected to receive the signal fcn -- q -- up and has an output that serves as the output lead 610 FIG. 6) of the LIC-BSR logic circuit 602. The OR gate 704 has one input lead connected to receive the signal fcn -- q -- up and has another input lead connected to receive the signal fcn -- q -- dn. The output lead of the OR gate 704 serves as the output lead 608 (FIG. 6) of the LIC-BSR logic circuit 602.
This embodiment of the LIC-BSR logic circuit 602 operates as follows. When the signals fcn -- q -- up and fcn -- q -- dn are both at logic zero levels, (i) the buffer 702 outputs the signal rsp -- data with a logic zero level to be captured in the CSUS 110 (FIG. 6), and (ii) the OR gate 704 outputs the signal rsp -- oe with a logic one level to be captured in the CSUSS 108 (FIG. 6). Thus, in this case, this embodiment of the LIC-BSR logic circuit 602 conforms to the first row of Table 5.
When the signal fcn -- q -- up is at a logic zero level and the signal fcn -- q -- dn is at a logic one level, the buffer 702 outputs the signal rsp -- data with a logic zero level while the OR gate 704 outputs the signal rsp -- oe with a logic one level. Thus, in this case, this embodiment of the LIC-BSR logic circuit 602 conforms to the second row of Table 5.
Then, when the signal fcn -- q -- up is at a logic one level and the signal fcn -- q -- dn is at a logic one level, the buffer 702 and the OR gate 704 output the signals rsp -- data and rsp -- oe with logic one levels. Thus, in this case, this embodiment of the LIC-BSR logic circuit 602 conforms to the third row of Table 5.
FIG. 8 is a circuit diagram of a portion of a circuit 800 having a boundary scan-to-LIC (also referred to herein as "BSR-LIC") logic circuit 802, in accordance with one embodiment of the present invention. In this embodiment, the BSR-LIC logic circuit 802 forms part of the logic circuit 402 (FIG. 4) to implement the aforementioned "boundary scan-to-LIC" feature. The boundary scan implementation used in the circuit 800 is substantially similar to the boundary scan implementation used in the circuit 400 (FIG. 4), except that in the circuit 800, the boundary scan implementation also supports a high impedance signal hiz. More specifically, the boundary scan implementation in the circuit 800 also supports the optional high impedance signal of the IEEE 1149.1 standard. The signal hiz is a global signal that can be used to configure several LIC drivers into the high impedance state using a single signal (i.e., without having to set several pairs of q -- up and q -- dn signals).
In particular, the BSR-LIC logic circuit 802 is connected to receive the signal bsr -- oe from the CSUS 108, the signal bsr -- data from the CSUS 110 and a signal bsr -- hiz -- n. The signal bsr -- hiz -- n is used during boundary scan testing and corresponds to the complement of a signal hiz typically provided by a TAP controller (not shown) compliant with the IEEE 1149.1 standard. The CSUSs 108 and 110 form part of a "scan chain" in the boundary scan implementation. Although in this embodiment the signals bsr -- oe and bsr -- data are provided from adjoining BSRs, it will be appreciated that these signals can be provided from non-adjoining BSRs as well. Further, in other embodiments, the bsr -- hiz -- n signal may be replaced with a bsr -- hiz signal, with the inversion performed in the BSR-LIC logic circuit 802.
The BSR-LIC logic circuit 802 has an output lead connected to the input lead 111 of the multiplexer 112, through which the BSR-LIC logic circuit 802 outputs the signal bsr -- q -- up. The other input lead 113 of the multiplexer 112 is connected to receive the "functional" q -- up signal (i.e., signal fcn -- q -- up) generated by the circuit 800 during normal functional operation. In addition, the BSR-LIC logic circuit 802 has another output lead connected to the input lead 115 of the multiplexer 116 through which the BSR-LIC logic circuit 802 outputs the signal bsr -- q -- dn. The other input lead 117 of the multiplexer 116 is connected to receive the "functional" q -- dn signal (i.e., signal fcn -- q -- dn) generated by the circuit 800 during normal functional operation.
This portion of the circuit 800 operates as follows. During the boundary scan mode, the BSR-LIC logic circuit 802 receives the signals bsr -- oe and bsr -- data from the CSUSs 108 and 110 and the signal bsr -- hiz -- n from the TAP controller (not shown). The BSR-LIC logic circuit then converts the signals bsr -- oe, bsr -- data and bsr -- hiz -- n into the signals bsr -- q -- up and bsr -- q -- dn that are used by the LIC driver 202. This conversion is performed so that the LIC driver 202 responds to the signals bsr -- oe, bsr -- data and bsr -- hiz -- n in the same way that a conventional CMOS TSD would respond. For example, when the signal bsr -- oe is deasserted during boundary scan testing, the BSR-LIC circuit 802 causes the signals bsr -- q -- up and bsr -- q -- dn to be at logic zero and logic one levels, respectively. Consequently, the LIC driver 202 enters a high impedance output state. Also, when the signal bsr -- hiz -- n is at a logic one level, the BSR-LIC logic circuit functions in response to the signals bsr -- oe and bsr -- data as described above in conjunction with Table 2. However, when the signal bsr -- hiz -- n is at a logic zero level during boundary scan testing, the BSR-LIC logic circuit 802 causes the signals bsr -- q -- up and bsr -- q -- dn to be at logic zero and logic one levels, respectively, which causes the LIC driver 202 to enter a high impedance output state. More specifically, the BSR-LIC logic circuit 802 implements the truth table shown below in Table 4.
TABLE 4______________________________________bsr.sub.-- data bsr.sub.-- oe bsr.sub.-- hiz.sub.-- n bsr.sub.-- q.sub.-- up bsr.sub.-- q.sub.-- dn LIC out______________________________________0 1 1 0 0 0X 0 1 0 1 Z1 1 1 1 1 1X X 0 0 1 Z______________________________________
The Xs indicate "don't care" conditions whereas the Zs indicate a high impedance state. As summarized in Table 4, the mapping of the signals bsr -- hiz -- n, bsr -- data and bsr -- oe into the signals bsr -- q -- up and bsr -- q -- dn omits the illegal condition of the bsr -- q -- up signal being at a logic one level at the same time that the bsr -- q -- dn signal is at a logic zero level. Particular embodiments of circuitry implementing the functionality of Table 4 are described below in conjunction with FIGS. 9-10. Of course, in light of the present disclosure, those skilled in the art of digital circuits can design many other circuits that implement the functionality of Table 4 without undue experimentation.
FIG. 9 is a circuit diagram of one embodiment of the BSR-LIC logic circuit 802 (FIG. 8), in accordance with the present invention. In this implementation, the BSR-LIC logic circuit 802 includes two-input multiplexers 902 and 904 and a two-input AND gate 906. The AND gate 906 is connected to receive from the CSUS 108 and 804 (FIG. 8) the signal bsr -- oe and the inverse of the high impedance control signal hiz (i.e., bsr -- hiz -- n). The output lead of the AND gate 906 is connected to the select input leads of the multiplexers 902 and 904. Accordingly, the output signal generated by the AND gate 906 serves as the select signal for the multiplexers 902 and 904.
In addition, the multiplexer 902 is connected to receive a logic zero signal on one input lead. In this embodiment, the logic zero signal is hardwired. The multiplexer 902 is also connected to receive at its other input lead the signal bsr -- data from the CSUS 110 (FIG. 8). The output signal of the multiplexer 902 serves as the signal bsr -- q -- up. Similarly, the multiplexer 904 is connected to receive a hardwired logic one signal at one input lead and the bsr -- data signal at the other input lead. The output signal of the multiplexer 904 serves as the signal bsr -- q -- dn. Both multiplexers are configured to select the signal bsr -- data when the select signal from the AND gate 906 is at a logic one level. Consequently, the multiplexers select the hardwired signal when the AND gate 906 outputs a logic high level signal.
This embodiment of the BSR-LIC logic circuit 802 operates as follows. When both the signal bsr -- hiz -- n and the signal bsr -- oe are at logic one levels (i.e., the driver is enabled and the "global" high impedance state is not selected), the AND gate 906 will output the select signal with a logic one level to the multiplexers 902 and 904. As a result, the multiplexers select the signal bsr -- data. Conversely, when either signal bsr -- oe or signal bsr -- hiz is at a logic zero level (i.e., the driver is disabled or the "global" high impedance state is selected), the AND gate 906 will generate the select signal with a logic zero level. Thus, the BSR-LIC logic circuit 802 outputs the signals bsr -- q -- up and bsr -- q -- dn with logic zero and logic one levels, respectively. Consequently, the LIC driver 202 will enter the high impedance state. Accordingly, this embodiment of the BSR-LIC logic circuit 802 implements the truth table of Table 8.
FIG. 10 is a circuit diagram of another embodiment of the BSR-LIC logic circuit 802 (FIG. 8), in accordance with the present invention. This embodiment includes a three-input AND gate 1001 and a three-input NAND gate 1003. The AND gate 1001 is connected to receive the signals bsr -- data, bsr -- oe and bsr -- hiz -- n. The output signal generated by the AND gate 1001 serves as the signal bsr -- q -- up received by the multiplexer 112 (FIG. 8).
The NAND gate 1003 is connected to receive the signals bsr -- data -- n (i.e., the complement of the signal bsr -- data), bsr -- oe and bsr -- hiz -- n. Of course, in other embodiments, an inverter may be included to generate the signal bsr -- data -- n from the signal bsr -- data. The output signal generated by the NAND gate 1003 serves as the signal bsr -- q -- dn received by the multiplexer 116 (FIG. 8).
This embodiment of the BSR-LIC logic circuit 802 operates as follows. When either the signal bsr -- oe or the signal bsr -- hiz -- n is at a logic low level, (i) the AND gate 1001 will output the signal bsr -- q -- up at a logic zero level, and (ii) the NAND gate 1003 will output the signal bsr -- q -- dn at a logic one level. As a result of the signals bsr -- q -- up and bsr -- q -- dn being at logic zero and logic one levels, respectively, the LIC driver 202 (FIG. 8) will enter a high impedance state.
In contrast, when the signals bsr -- oe and bsr -- hiz -- n are both at logic one levels, the AND gate 1001 is, in effect, equivalent to a non-inverting buffer receiving the signal bsr -- data. Thus, in this situation, the signal bsr -- q -- up is equivalent to the signal bsr -- data. Likewise, the NAND gate 1003 is, in effect, equivalent to an inverter receiving the signal bsr -- data -- n. Because of the two inversions, the NAND gate 1003 outputs the signal bsr -- q -- dn having the same logic level as the signal bsr -- data. Accordingly, this embodiment of the BSR-LIC logic circuit 802 implements the truth table of Table 8.
The embodiments of the circuit described above are illustrative of the principles of this invention and are not intended to limit the invention to the particular embodiments described. For example, in light of the present disclosure, those skilled in the art of boundary scan circuits can implement other embodiments adapted for use with other boundary scan standards without undue experimentation. In addition, switching devices other than the multiplexers described may be used in other embodiments. Accordingly, while the preferred embodiment of the invention has been illustrated and described, it will be appreciated that in view of the present disclosure, various changes can be made therein without departing from the spirit and scope of the invention.
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A method for coupling a linear impedance control (LIC) type output driver to IEEE 1149.1 boundary scan circuitry includes entering a boundary scan load mode to load a test pattern into a chain of boundary scan registers (BSRs). The test pattern includes values corresponding to output enable and data signals according to the IEEE 1149.1 standard. Then these data and output enable signals from the BSRs are converted into test "q -- up" and "q -- dn" signals meeting the requirements of the LIC driver. These test "q -- up" and "q -- dn" signals are selectively provided to the LIC driver during boundary scan testing of the LIC driver. In a further refinement, the method enters a boundary scan capture mode to capture the response (i.e., the functional q -- up and q -- dn signals) of the circuit under test to input test patterns shifted into the BSRs. The functional q -- up and q -- dn signals are converted into response data and oe signals complying with the IEEE 1149.1 specification, which are then captured in the BSRs. Thus, this method allows the widely used IEEE 1149.1 boundary scan standard to be used with LIC drivers. The resulting compatibility simplifies the testing and use of the LIC drivers, and provides a boundary scan standard for use with LIC drivers that is compliant with the IEEE 1149.1 standard.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a high-frequency apparatus that is suitably used in, for example, a digital broadcasting receiving tuner for a CATV.
[0003] 2. Description of the Related Art
[0004] FIGS. 7 and 8 are a side view and a bottom view, respectively, showing the configuration of a high-frequency apparatus disclosed in Japanese Patent No. 2908967. In the high-frequency apparatus, a frame 51 is formed of a metal plate and is shaped like an open square. Two covers 52 are attached to the frame 51 so as to respectively cover two opposing open faces of the frame 51 .
[0005] Although not shown, a circuit board having electronic components is placed in the frame 51 . A plurality of terminals 53 are arranged in line on the circuit board. The terminals 53 protrude downward from a bottom wall 51 a of the frame 51 . Two legs 51 b also protrude from the frame 51 in the same direction as that of the terminals 53 .
[0006] As shown in FIG. 7 , the high-frequency apparatus having this configuration is mounted on the motherboard 54 by fitting the legs 51 b and the terminals 53 in a hole (not shown) of a motherboard 54 , and soldering the legs 51 b and the terminals 53 to a conductive pattern (not shown) of the motherboard 54 while there is a space between the motherboard 54 and the bottom wall 51 a through which the terminals 53 extend.
[0007] However, when the above-described high-frequency apparatus is mounted on the motherboard 54 , the terminals 53 are exposed from the space between the motherboard 54 and the bottom wall 51 a , and an interfering wave enters the terminals 53 through the open space. In particular, an interfering wave enters an antenna terminal serving as one of the terminals 53 , and this reduces the performance of the apparatus.
SUMMARY OF THE INVENTION
[0008] The present invention has been made in view of these circumstances of the related art, and an object of the invention is to provide a high-frequency apparatus having high performance and capable of preventing the entry of an interfering wave into terminals.
[0009] In order to achieve the above object, a high-frequency apparatus according to an aspect of the present invention includes a frame formed of a metal plate; a circuit board mounted in the frame and having an electronic component to form a desired electric circuit; a plurality of terminals attached to the circuit board and protruding from the frame; and a shielding plate disposed outside the frame, the shielding plate electrically shielding at least one of the terminals and being electrically connected to the frame. The frame is mounted on a motherboard so that an exposed portion of the terminal disposed between the frame and the motherboard is shielded by the shielding plate.
[0010] In this case, the shielding plate for electrically shielding any of the terminals protruding from the frame shields the exposed portion of the terminal disposed between the frame and the motherboard. Therefore, it is possible to electrically shield a terminal which is adversely affected by an external wave, to prevent the entry of an interfering wave into the terminal, and to thereby achieve high performance.
[0011] Preferably, the at least one of the terminals is an antenna terminal. In particular, a digital broadcasting receiving tuner has a band of 800 MHz, which is equivalent to that of a mobile telephone. Therefore, it is possible to prevent the entry of an interfering wave from the mobile telephone to the antenna terminal, and to enhance the performance of the apparatus.
[0012] Preferably, the at least one of the terminals includes an antenna terminal and a ground terminal adjacent to the antenna terminal, and the ground terminal is soldered to the shielding plate. In this case, the antenna terminal is surrounded by the shielding plate that is grounded by being connected to the ground terminal. This reliably prevents the entry of an interfering wave, and ensures high performance.
[0013] Preferably, the shielding plate is formed of a resilient metal plate, and includes a flat portion and an elastic wall projecting from the flat portion toward the motherboard. Exposed portions of the antenna terminal and the ground terminal extend through the flat portion, and are surrounded by the elastic wall. The ground terminal is soldered to the flat portion. The elastic wall is in elastic contact with the motherboard when the frame is mounted on the motherboard. In this case, the exposed portions can be reliably shielded between the shielding plate and the motherboard, the entry of an interfering wave can be reliably prevented, and high performance can be achieved. In addition, since the ground terminal is soldered to the flat portion of the shielding plate, soldering to the shielding plate can be performed easily, and allows the shielding plate to be attached easily.
[0014] Preferably, the shielding plate is formed of a resilient metal plate, and includes flat portion and an elastic wall projecting from the flat portion toward the frame. Exposed portions of the antenna terminal and the ground terminal are surrounded by the flat portion and the elastic wall. The ground terminal is soldered to the flat portion. The flat portion is in elastic contact with the motherboard when the frame is mounted on the motherboard. In this case, the exposed portions can be reliably shielded between the shielding plate and the frame, the entry of an interfering wave can be reliably prevented, and high performance can be achieved. In addition, since the ground terminal is soldered to the flat portion of the shielding plate, soldering to the shielding plate can be performed easily, and allows the shielding plate to be attached easily.
[0015] Preferably, the shielding plate is in contact with a ground pattern provided on the motherboard. This makes grounding of the shielding plate more reliable.
[0016] Preferably, the frame includes a bottom wall, a hole provided in the bottom wall so that the terminals extend therethrough, and a pair of legs protruding downward from the bottom wall so as to be attached to the motherboard. The shielding plate includes a projection projecting from the flat portion toward the legs, and an elastic tongue bent from the flat portion toward the bottom wall. The elastic tongue of the shielding plate is in elastic contact with the bottom wall near the hole while the projection is retained by the legs. In this case, the shielding plate can be properly positioned and held relative to the frame, and can be attached stably.
[0017] According to the present invention, the shielding plate is provided to electrically shield any of a plurality of terminals protruding outside the frame, and the exposed portion of the terminal between the frame and the motherboard is shielded by the shielding plate. Therefore, especially, the exposed portion of a terminal that is likely to be adversely affected by an external wave can be electrically shielded by the shielding plate, the entry of an interfering wave into the terminal can be prevented, and high performance can be achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is an exploded perspective view showing the principal part of a high-frequency apparatus according to a first embodiment of the present invention;
[0019] FIG. 2 is a side view of the principal part of the first embodiment;
[0020] FIG. 3 is a sectional side view of the principal part;
[0021] FIG. 4 is a sectional front view of the principal part;
[0022] FIG. 5 is an exploded perspective view showing the principal part of a high-frequency apparatus according to a second embodiment of the present invention;
[0023] FIG. 6 is a sectional side view of the principal part of the second embodiment;
[0024] FIG. 7 is a side view of a known high-frequency apparatus; and
[0025] FIG. 8 is a bottom view of the known high-frequency apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Embodiments of the present invention will be described below with reference to the attached drawings.
[0027] FIGS. 1 to 4 show the configuration of a high-frequency apparatus according to a first embodiment of the present invention. The high-frequency apparatus includes a frame 1 formed of a metal plate. The frame 1 is shaped like an open square having opposing openings, and is constituted by a bottom wall 1 b having a plurality of holes 1 a, a pair of side walls 1 c bent upward from two opposing sides of the bottom wall 1 b, a pair of legs 1 d projecting downward from the side walls 1 c below the bottom wall 1 b, and a top wall (not shown) provided between the side walls 1 c.
[0028] The high-frequency apparatus also includes two covers 2 each formed of a metal plate. Each cover 2 includes a flat covering portion 2 a , and a resilient clamping portion 2 b bent on the periphery of the covering portion 2 a so as to clamp the frame 1 . The two covers 2 are attached to the frame 1 to form a housing and to electrically shield the interior of the frame 1 . In this state, the opposing openings of the frame 1 are closed by the covering portions 2 a , and the bottom wall 1 b, the side walls 1 c, and the top wall of the frame 1 are clamped by the clamping portions 2 b.
[0029] A circuit board 3 has a wiring pattern 4 . Various electronic components 5 are mounted on the wiring pattern 4 to form a desired electric circuit. A plurality of terminals 6 arranged in line are attached to the circuit board 1 such as to be connected to the wiring pattern 4 and to protrude from one side (bottom face) of the circuit board 1 . Among the terminals 6 , an antenna terminal 6 a and a ground terminal 6 b are adjacent to each other.
[0030] The circuit board 3 having this structure is mounted in the frame 1 by an appropriate means. The terminals 6 attached to the circuit board 3 protrude outside through the holes 1 a of the bottom wall 1 b. The antenna terminal 6 a and the ground terminal 6 b protrude through the same one opening 1 a.
[0031] A shielding plate 7 formed of a resilient metal plate includes a rectangular flat portion 7 a , a pair of first elastic walls 7 b bent and inclined downward from opposing long sides of the flat portion 7 a , a projection 7 c projecting from the center of one short side of the flat portion 7 a , an elastic tongue 7 d inclined upward and projecting from the center of the other short side of the flat portion 7 a , a pair of second elastic walls 7 e bent and inclined downward from the other short side of the flat portion 7 a , and large and small holes 7 f and 7 g provided in the flat portion 7 a.
[0032] When the shielding plate 7 is mounted in position, the flat portion 7 a faces the bottom wall 1 b, an exposed portion of the antenna terminal 6 a protrudes downward from the frame 1 through the large hole 7 f without contact with the flat portion 7 a , an exposed portion of the ground terminal 6 b protrudes downward from the frame 1 through the small hole 7 g , the projection 7 c is retained between the legs 1 d, and the elastic tongue 7 d is in elastic contact with the bottom wall 1 b near the hole 1 a.
[0033] In this case, as shown in FIGS. 2 to 4 , the first elastic walls 7 b are in elastic contact with the roots of the clamping portions 2 b of the covers 2 , the projection 7 c is in elastic contact with the roots of the legs 1 d, and portions of the antenna terminal 6 a and the ground terminal 6 b other than the exposed leading ends are surrounded by the shielding plate 7 . The ground terminal 6 b is joined to the flat portion 7 a of the shielding plate 7 by solder 8 . In this way, the high-frequency apparatus of the first embodiment is constructed.
[0034] The high-frequency apparatus having this configuration is applied, for example, to a digital broadcasting receiving tuner for a CATV. As shown in FIGS. 2 to 4 , the terminals 6 are fitted in holes (not shown) provided in a motherboard 9 , and are soldered to a wiring pattern (not shown) provided on the motherboard 9 .
[0035] In this case, the shielding plate 7 surrounds the antenna terminal 6 a and the ground terminal 6 b , and the first and second elastic walls 7 b and 7 e are in elastic contact with the motherboard 9 , so that there is no space between the shielding plate 7 and the motherboard 9 . The ground terminal 6 b and the shielding plate 7 are grounded by being connected to a ground pattern 10 provided on the motherboard 9 .
[0036] FIGS. 5 and 6 show a high-frequency apparatus according to a second embodiment of the present invention. In the second embodiment, first and second elastic walls 7 b and 7 e of a shielding plate 7 are bent toward a bottom wall 1 b of a frame 1 , and are in elastic contact with the frame 1 . Exposed portions of an antenna terminal 6 a and a ground terminal 6 b disposed between the bottom wall 1 b and a flat portion 7 a of the shielding plate 7 are surrounded by the flat portion 7 a and the first and second elastic walls 7 b and 7 e . The flat portion 7 a is pressed by a motherboard 9 .
[0037] Other structures are similar to those in the first embodiment. Like components are denoted by like reference numerals, and descriptions thereof are omitted.
[0038] It should be noted that the shielding plate 7 can have various structures other than the structures in the above-described embodiments.
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A high-frequency apparatus includes a shielding plate that electrically shields any of a plurality of terminals protruding from a frame. An exposed portion of the terminal disposed between the frame and a motherboard is shielded by the shielding plate. Therefore, especially, a terminal that is likely to be adversely affected by an external wave can be electrically shielded by the shielding plate, the entry of an interfering wave into the terminal can be prevented, and high performance can be achieved.
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BACKGROUND OF THE INVENTION
The present invention relates to sewing apparatus and, more particularly, to sewing machines of the type adapted to quilting.
The first practical sewing machine was independently invented by three different inventors in the United States in the period from the mid 1830's to 1850. The basic invention consisted of a reciprocating needle having an eye near its point and a reciprocating shuttle containing a bobbin of thread. As the threaded needle passed through to the opposite side of the cloth being sewn carrying the thread with it, the shuttle passes through a loop of thread formed on the underside of the cloth to loop the thread from its bobbin about the thread from the needle. Thereupon, the needle is withdrawn and the excess thread is drawn upward through the cloth to form a lock stitch.
The above basic invention appears to have been invented about 1830 by a Walter Hunt who, concerned about the possiblity that seamstresses would be thrown out of work, suppressed the invention and never applied for a patent. Elias Howe appears to have been the next rediscoverer of the invention about 1843 and received a patent on his invention in 1846. Isaac M. Singer was the third discoverer of the basic invention and received a patent on it in 1851.
Through the remainder of the 1800's and the first half of the 1900's, the basic sewing machine remained essentially unchanged with millions of units being produced for home and factory use worldwide.
More recently, the reciprocating shuttle has been virtually replaced in conventional sewing machines by a round bobbin. The round bobbin is much superior in efficiency, reliability and cost to the conventional shuttle.
A class of sewing machine to which the round bobbin has not been applied is the class of quilting machines. Quilting machines conventionally have two or more rows of needles which are reciprocated up and down together while the fabric is moved to form decorative patterns. A conventional quilting machine has a spacing between adjacent needles in a row of about one inch and a spacing between rows of about three inches. Quilting machines have employed pairs of shuttles to service one corresponding needle in each of the rows. In a quilting machine having, for example, 100 needles in a row, 100 pairs of shuttles have been reciprocated in correct phase with the operation of the needles.
From the above description of quilting machines, one can sense the extreme crowding of apparatus below the needle plate in order to form as many as 200 stitches at the same time. Due to the large number of simultaneous operations, the added smoothness, reliability and reduced cost of round bobbins would be desirable. However, due to the restricted space available in quilting machines, the use of round bobbins has not been successfully applied. Thus, present quilting machines require a large number of parts such as, for example, 1,040 parts not counting screws in a 72" wide standard quilting machine. A significant portion of these parts are special complicated expensive castings. With so many parts operating in a typical start-and-stop fashion of reciprocating shuttles, high complexity leading to high manufacturing and maintenance cost results.
From the standpoint of production, an uninterrupted run of a quilting machine is limited largely by the capacity of the bobbins in the shuttles. If a relatively small bobbin is employed, a relatively short run time of two or three hours is possible before the bobbins in all of the shuttles must be replenished. Although it is possible to use larger bobbins in the shuttles, when this is done, the machine must be slowed down due to the increased inertia of the many larger shuttles and bobbins.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a sewing apparatus which overcomes the drawbacks of the prior art.
It is a further object of the invention to provide a quilting machine which reduces the number of parts and permits increasing the speed of sewing.
It is a further object of the invention to provide a quilting machine having a plurality of rows of needles which eliminates the need for a conventional shuttle attending each needle.
It is a further object of the invention to provide a quilting machine which permits the use of larger bobbins to thereby enable longer uninterrupted quilting runs.
It is a further object of the invention to provide a quilting machine that is cheaper and simpler to build and maintain but which provides increased throughput with higher reliability. In a preferred embodiment, a 76-inch quilting machine employ only about 624 parts without requiring any special castings.
According to an aspect of the present invention, there is provided a sewing machine, comprising a needle plate having at least one needle hole therein, at least one needle having an eye proximate its point, means for entering the point through the needle hole whereby a thread loop is formed below the needle plate, at least one bobbin adapted for holding a supply of thread and for feeding out the thread under a controlled tension, at least one bobbin basket adapted to freely support the bobbin, means for preventing withdrawal of the bobbin from the bobbin basket, means for drawing the thread loop over an end of the bobbin, means for disengaging the hook from the thread loop, and means for withdrawing excess thread in the thread loop whereby one of a descending strand and an ascending strand passes between the bobbin and the bobbin basket to form a lock stitch with thread from the bobbin.
According to a feature of the present invention, there is provided a method for forming a stitch, comprising forming a thread loop with a needle below a needle plate, freely supporting a bobbin containing a thread in a bobbin basket below the needle plate, engaging the loop with a hook, holding open and pulling down the loop with the hook, drawing the thread loop over an end of the bobbin, disengaging the hook, and withdrawing excess thread in the loop to form a lock stitch with thread from the bobbin.
According to a further feature of the present invention, there is provided a quilting machine, comprising a needle plate, a plurality of spaced-apart needle holes in the needle plate, a plurality of needles aligned with the needle holes, means for controlling a supply of thread to an eye proximate a point of each of the plurality of needles, means for concertedly penetrating the plurality of needles through the needle holes whereby a plurality of thread loops is formed below the needle plate, a plurality of bobbins below the needle plate, each of the bobbins being associated with one of the plurality of needles, each of the bobbins containing a supply of thread and including means for feeding the thread out at a predetermined tension, a plurality of bobbin baskets freely supporting the bobbins, the bobbin baskets surrounding at most a portion of a surface of the bobbins, an enlarged diameter portion on each of the bobbins engaging its associated bobbin basket to support the bobbin in its bobbin basket by gravity, a conical lower end ending in a point on each of the bobbins, the point being free of the bobbin basket, the bobbin baskets being disposed to position the point of each of the bobbins below its associated thread loop, a plurality of hooks, one hook associated with each of the needles, means for concertedly entering each of the hooks into the thread loop formed by its associated needle and for enlarging the thread loop and for drawing the thread loop over the point on the bobbin, means for disengaging the hooks from the thread loops, means for withdrawing excess thread in the thread loops through the needle holes, one of a descending and an ascending strand of each of the thread loops passing between its associated bobbin and bobbin basket whereby a lock stitch is formed, and means for preventing removal of the bobbins from the bobbin baskets during withdrawal of excess thread.
The above, and other objects, 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
FIG. 1 is a schematic diagram of a quilting machine according to an embodiment of the invention wherein elements not necessary to the description of the function of the apparatus are omitted for clarity.
FIG. 2 is a closeup perspective view of a portion of the quilting machine of FIG. 1.
FIG. 3 is a side view of a bobbin used in the apparatus of FIGS. 1 and 2.
FIG. 4 is a view of the bobbin of FIG. 3 opened for further description.
FIG. 5 is a side view of a quilting machine according to the present invention.
FIGS. 6-9 are schematic diagrams to which reference will be made in explaining the operation of the apparatus of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention may be applicable to sewing machines employing a single needle. However, for purposes of illustration, a quilting machine is shown and described. One skilled in the art, with the instruction of the present specifcation, would readily understand the application to sewing apparatus having one or more needles in different patterns.
Referring now to FIG. 1, there is shown, generally at 10, a quilting machine having a needle plate 12 which includes a plurality of needle holes 14 therein. A presser foot 16 having a plurality of needle holes 18 therein aligned with needle holes 14 is arranged for up and down reciprocation as will be explained.
First and second needle bars 20 and 22 have disposed therein a plurality of needles 24 each of which is aligned with one of needle holes 18 in presser foot 16 and needle holes 14 in needle plate 12.
Needle bars 20 and 22 are maintained a fixed predetermined distance apart by a pair of bridges 26 and 28 which support vertical guide bars 30 and 32 respectively. A pair of guides 34 and 36 permit vertical reciprocation of vertical guide bar 30. Similarly, a pair of guides 38 and 40 permit vertical reciprocation of vertical guide bar 32. Thus, needle bars 20 and 22 may be moved vertically in a fashion which maintains needles 24 aligned with needle holes 14 and 18.
A reduction gear assembly 42 reduces the speed of an input shaft 44 from the typical motor speed of about 3,600 rpm to a speed on its output shaft 46 of from about 250 to about 1,000 rpm depending on the sewing speed desired or obtainable. Typically faster sewing speeds require higher horsepower from the drive motor (not shown). Quilting machines of the prior art driving 200 needles with corresponding shuttles have employed motors of about 2.5 horsepower. It is believed that the present invention, having lower inertia in its moving parts and capable of smoother operation, may be operated at the same speed as the prior art with less horsepower or may be operated at higher speeds than the prior art with the same horsepower. Although extensive use is made in the preferred embodiment of flexible timing belts and grooved pulleys, other power transmission techniques such as, for example, shafts and gears or sprockets and timing chains may be employed without departing from the spirit of the present invention.
A pulley 48, affixed to output shaft 46, drives a timing belt 50 which, in turn, drives a pulley 52 and an upper transmission shaft 54. Upper transmission shaft 54 is employed to drive the motion of presser foot 16, needle bars 20 and 22 and a thread take-up bar 56 in fixed phase relationships to form stitches.
Upper transmission shaft 54 rotates a pulley 58 which transmits power on a timing belt 60 and a pulley 62 to an upper subshaft 64. Due to the use of timing belts 50 and 60, a predetermined phase relationship is maintained between output shaft 46, upper transmission shaft 54 and upper subshaft 64. This phase relationship ensures that the several operations that are driven by these shafts are all accomplished with a predetermined phase relationship.
First and second eccentric wheels 66 and 68 include pivots 70 and 72 which are journalled to tie rods 74 and 76. A lower ends of tie rods 74 and 76 are journalled to pivots 78 and 80 which are rigidly attached to cross bars 82 and 84 of needle bars 20 and 22.
As eccentric wheels 66 and 68 are rotated by upper subshaft 64, needle bars 20 and 22, along with needles 24 are correspondingly raised and lowered.
Vertical actuating rods 86 and 88 are affixed at their lower ends to presser foot 16 and provide for time phased vertical reciprocation of presser foot 16 in order to hold the material to be sewn during entry and withdrawal of needles 24 and to release the material to be sewn between stitches so that it may be advanced. The advancing mechanism itself, being conventional, is not illustrated in order to avoid unnecessarily cluttering the drawing.
Vertical actuating rod 86 is guided in stationary guides 90 and 92. Similarly, vertical actuating rod 88 is guided in stationary guides 94 and 96. A compression spring 98 on vertical actuating rod 86 is biased between stationary guide 92 and a stop 100 which may be, for example, a pin as shown or any other device operative to receive spring force from compression spring 98. It would be clear that, as shown, spring force from compression spring 98 tends to urge vertical actuating rod 86 in the downward direction to urge presser foot 16 toward needle plate 12. Similarly, a compression spring 102 biased between guide 34 and a stop 104 tends to urge vertical actuating rod 88 and presser foot 16 in the downward direction.
A pair of cams 106 and 108 rotating with upper subshaft 64 engage cam followers 110 and 112 respectively rigidly coupled by connecting bars 114 and 116 to vertical actuating rods 86 and 88 respectively. As upper subshaft 64 performs a revolution, cams 106 and 108, rotating with it, concertedly elevate vertical actuating rods 86 and 88 and thereby elevate presser foot 16 at an appropriate point in the stitch cycle. Compression springs 98 and 102 ensure that cam followers 110 and 112 maintain contact with cams 106 and 108 and maintain spring pressure on presser foot 16 during an appropriate period in the stitch cycle.
The ends of thread take-up bar 56 are attached to levers 118 and 120 which are pivoted at their distal ends on pivots 122 and 124. A pair of kidney-shaped cams 126 and 128, rotating with upper transmission shaft 54, engage cam followers 130 and 132 pivoted on levers 118 and 120 respectively. Compression springs 134 and 136 maintain cam followers 130 and 132 in contact with cams 126 and 128.
A plurality of thread holes 138, one thread hole 138 per needle 24, are disposed along thread take-up bar 56.
A stationary thread guide bar 139 having a plurality of thread holes 141, one thread hole per needle 24, is disposed below thread take-up bar 56.
A thread creel 140, which is conventional and thus not shown in detail, contains a plurality of spools of thread, represented by spool 142, with one spool being provided for each needle 24. Thread 144 paid out from spool 142 passes through a thread tensioner 146 which may be, for example, a conventional spring-loaded plate-type tensioner, and thence through a thread hole 141 in thread guide bar 139, through a thread hole 138 in thread takeup bar 56 and then through the eye of a needle 24.
A pulley 148 on output shaft 46 is coupled to a pulley 150 on a lower transmission shaft 152 by a timing belt 154. A pulley 156 is coupled to a pulley 158 on a lower subshaft 160 by a timing belt 162.
Eccentric wheels 163 and 164 are journalled to tie rods 166 and 168 whose distal ends are pivoted to a hook base 170. Guide rods 172 and 174, affixed to the underside of hook base 170, are constrained to vertical motion by guides 176, 178, 180 and 182. Thus, as lower subshaft 160 rotates, hook base 170 is concertedly raised and lowered in phase with the remainder of the operating elements of quilting machine 10.
A bevel gear 184 on lower transmission shaft 152 meshes with and drives a bevel gear 186 which, in turn, rotates a shaft 188 and a cam plate 190. Cam plate 190 includes a cam groove 192.
A lever 194 is pivoted at a pivot 196 and includes a cam follower 198 engaged in cam groove 192. As cam plate 190 rotates, lever 194 is rotated about pivot 196 according to the shape of cam groove 192. The distal end of lever 194 is pivoted to an end of an actuating rod 200 which is constrained to linear fore and aft motion by guides 202 and 204. A yoke 206 on actuating rod 200 embraces, and is pivoted to, a guide 208 which encircles a tilt bar 210 which is, in turn, pivoted at a pivot 212 to hook base 170. An upward-extending portion 214 of tilt bar 210 is pivoted at a pivot 216 to a hook bar 218. A tilt arm 220 is pivoted at an upper pivot 222 to bar 218 and at a lower pivot 224 to hook base 170. The lengths of upward-extending portion 214 and tilt arm 220 are equal so that hook bar 218 always remains parallel to hook base 170. A plurality of hooks 226, equal in number to the number of needles 24 on needle bar 20 are disposed on hook bar 218.
A second hook bar 228 including hooks 230 equal in number to needles 24 on needle bar 22 is supported on tilt arms 232 and 234.
A rigid connection between tilt bar 210 and a lower pivot (not shown) on tilt arm 232 and/or a rigid connection between lower pivot 224 on tilt arm 220 and a corresponding pivot (not shown) at the bottom of tilt arm 234 maintains hook bars 218 and 228 concertedly parallel and at the same height. One method of maintaining parallelism employs a shaft (not shown) passing through hook base 170 and welded to tilt bar 210 at pivot 212 as well as to the corresponding lower pivot (not shown) on tilt arm 232.
From the preceding description, it will be clear that hook bars 218 and 228 are concertedly raised and lowered with hook base 170 at the same time that they are moved from side to side by tilt bar 210. The vertical and horizontal motions are sized and phased with respect to other motions in quilting machine 10 to produce a lock stitch.
Referring now to FIG. 2, a different perspective is shown to reveal elements below needle plate 12. A front bobbin bar 236 supports a plurality of bobbin baskets 238 with one bobbin basket 238 being associated with each needle hole 14 in needle plate 12. Similarly, a rear bobbin bar 240 supports a plurality of bobbin baskets 238, one for each needle hole 14 in the rear row. A bobbin 242 rests loosely in each bobbin basket with a thread 244 being withdrawn therefrom during the sewing operation as will be explained. A bobbin hold-down plate 246 is disposed a short distance above bobbins 242 to prevent bobbins 242 from being pulled completely out of bobbin baskets 238 during operation. A similar bobbin hold-down plate (not shown) is associated with bobbins 242 in the rear row.
Referring now to FIGS. 3 and 4, bobbins 242 are each seen to consist of a lower body 248 which is preferably of smooth metal or plastic and most preferably of aluminum or Teflon. Lower body 248 includes a cylindrical upper portion 250 and a gradually tapering conical portion 252 which smoothly joins upper portion 250 and ends in a point 254. A slit 256 at the top of upper portion 250 provides for exit of thread 244. A diagonally expanded transition portion 265 is increased in diameter compared to cylindrical upper portion 250. Expanded transition portion 265 bears against the upper rim of its bobbin basket 238 to hold bobbin 242 in its operational position.
A cap 258 includes a lower cylindrical portion 260 which is sized for a press fit into a top opening 262 in lower body 248. A central portion 264, having a diameter smaller than the maximum diameter of transition portion 265, abuts cylindrical portion 260. An annular groove 266 in central portion 264 receives a loosely fitted C-shaped loop of wire 268. A slanted hole 270 terminates at a lower opening 272 and an upper opening 274.
A skein of thread 276, fittable into the interior of lower body 248, provides the supply of thread 244.
Referring again to FIG. 3, it will be noted that thread 244 emerges from slit 256, passes under loop 268 in annular groove 266, enters lower opening 272 and exits upper opening 274. This path applies a controlled friction to thread 244 which permits only the required amount to be withdrawn from bobbin 242 as sewing proceeds. The friction is preferably sufficient to permit supporting the weight of bobbin 242 on thread 244 but light enough to permit additional thread 244 to be withdrawn upon the application of slightly more tension. Other thread friction devices are equally within the scope of the invention.
Referring now to FIG. 5, a side view of the apparatus is shown slightly out of phase for purposes of illustration. That is, needles 24 are shown just after they have been withdrawn slightly following their maximum penetration. Normally at this time, hooks 226 would be near the top of their travel preparatory to engagement with a loop 278 of thread 144 existing at this time. Instead, for purposes of illustration, FIG. 5 shows hooks 226 at their lower positions.
It will be noted that front and rear bobbin bars 236 and 240 are tilted so that points 254 of bobbins 242 are disposed forward of a vertical projection of needles 24. A stirrup 280 attached to each bobbin basket 238 has a rod 282 affixed thereto passing through a hole 284 in bobbin bar 236 or 240. A spring 286 on rod 282 is biased between front or rear bobbin bar 236 or 240 and a stop member such as a washer 288 and a pin 290. A lip 292 at the lower end of stirrup 280 passes over the bottom edge 294 of front bobbin bar 236. Lip 292 maintains bobbin basket 238 in its proper rotational orientation. With bobbin basket 238 in its operational position as shown, bobbin hold-down plate 246 prevents bobbin 242 from being withdrawn from bobbin basket 238. In order to change thread in bobbin 242, bobbin basket 238 is moved forward by compressing spring 286.
Other ways of freeing bobbin 242 from its entrapment by bobbin hold-down plate 246 would be clear to one skilled in the art. For example, bobbin hold-down plate 246 may be hinged, preferably spring loaded so that it can be swung away out of interference with removal of bobbin 242. Alternatively, a hinge may be provided on stirrup 280 to permit bobbin basket 238 to be tilted forward.
The path of hook 226 is represented by a dashed line 296. It will be noted that path 296 is an oval which, at its upper extremity, passes through loop 278 and at its lower extremity passes under point 254. Referring momentarily to FIG. 2, it will be seen that path 296 fairly closely follows the perimeter of bobbin basket 238 so that hooks 226 can operate in conjunction with their own bobbin baskets 238 without interference from adjacent elements.
Referring now to FIGS. 6-9, the sequence of the sewing operation is shown for a pair of adjacent bobbins 242 in highly schematized fashion. In order to avoid clutter in the drawing, extraneous elements have been omitted including cloth being sewn, presser foot 16 and the actuating elements.
In FIG. 6, needles 24 are descending and hooks 226 are ascending. In FIG. 7, needles 24 have reached their lowest point deeply penetrating needle holes 14 and inserting thread 144 well below needle plate 12. Hooks 226 are near the top of their trajectory and closely adjacent to needles 24. Just after the positions shown in FIG. 7, needles 24 begin to withdraw, however, a loop of thread is formed below needle plate 12 just as a hook portion 298 arrives to enter it. Hook portion 298 thereupon engages the loop and, as shown in FIG. 8, begins enlarging loop 278 by pulling thread 144 through needle 24 as indicated by an arrow 300.
For purposes of description, loop 278 consists of a descending strand 278a from needle 24 and an ascending strand 278b from hook portion 298 to needle hole 14. Hook portion 298 has a sufficient dimension in a plane at right angles to the page to keep a bottom of loop 278 relatively wide open.
Referring now to FIG. 9, as hook 226 passes beyond point 254 of bobbin 242, descending strand 278a remains in front of conical portion 252 whereas ascending strand 278b passes behind point 254. Loop 278 disengages from hook portion 298 and hook 226 continues on its trajectory preparatory to a next cycle. At this time, thread take-up bar 56 is actuated to withdraw excess thread 144 as indicated by an arrow 302. This process continues and loop 278 is drawn up behind bobbin 242 due to the loose fit of bobbin 242 in bobbin basket 238. Loop 278 is finally pulled completely out of bobbin basket 238 past bobbin 242. The movement of thread 144 past cap 258 is aided by the smooth transition provided by diagonally expanding transition portion 265 at the upper end of lower body 248. When all of the excess thread 144 in loop 278 is withdrawn through needle hole 14, a loop is formed around thread 244 from bobbin 242 as is required to produce a lock stitch.
The present invention should be considered equally applicable to single needle sewing machines, quilting machines having a single row of needles, quilting machines having two or more rows of needles and any variations thereon.
The present invention is also applicable to trapunto quilting wherein sets of closely spaced twin needles are employed with the loops formed by each of the needles of a twin being pulled down and looped in the same fashion as the single loop previously described.
Although the present invention shows all bobbin baskets 238 in a row attached to a single bobbin bar 236 or 240, this should not be considered to limit the invention. For example, each bobbin basket 238 may be separately removably attached below needle plate 12 so that the thread in the associated bobbin 142 may be replaced without disturbing any other bobbin 142. Alternatively, pairs of corresponding bobbin baskets 238 in the front and rear rows may be attached to a removable clip-in bar (not shown) or other structure so that the pair may be removed together for thread replenishment or maintenance without disturbing adjacent bobbins 142.
Having described specific preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications 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.
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A quilting machine employs bobbin holders which support bobbins each having a conical lower portion ending in a point. A plurality of hooks are driven in an eliptical path to engage and pull down a loop of thread formed by insertion of a needle through a needle plate and the partial withdrawal thereof. The hooks keep the loop open and pull it down so that it passes over the pointed lower end of the bobbin. In order to facilitate engagement of the loop over the bobbin, the bobbins are maintained in sloped fashion. A thread take-up mechanism pulls up the loop of thread with one of the strands of the loop passing behind the bobbin between the bobbin and the bobbin holder to form a lock stitch.
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DESCRIPTION
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a division of Ser. No. 025,878, filed Apr. 2, 1979, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to novel prostaglandin analogs. Particularly, these compounds are analogs of the prostaglandins wherein the C-19 position is substituted by hydroxy, i.e., 19-hydroxy-19-methyl-PG compounds. Most particularly, the present invention relates to novel 2-decarboxy-2-tetrazolyl-19-hydroxy-19-methyl-PG compounds, a disclosure of the preparation and use of which is incorporated here by reference from U.S. Pat. No. 4,228,104.
PRIOR ART
Prostaglandin analogs exhibiting hydroxylation in the 19-position are known in the art. See, for example, U.S. Pat. No. 4,127,612, Sih, J. C., Prostaglandins 13:831 (1977) and U.S. Pat. Nos. 3,657,316, 3,878,046, and 3,922,297. See also the additional references cited in U.S. Ser. No. 025,878.
SUMMARY OF THE INVENTION
The present invention particularly provides
a compound of the formula ##STR1## wherein D is (1) cis--CH═CH--CH 2 --(CH 2 ) g --CH 2 --,
(2) cis--CH═CH--CH 2 --(CH 2 ) g --CF 2 --,
(3) cis-CH 2 --CH═CH--CH 2 --CH 2 --,
(4) trans-(CH 2 ) 3 --CH═CH--,
(5) --(CH 2 ) 3 --(CH 2 ) g --CH 2 --,
(6) --(CH 2 ) 3 --CH 2 --CF 2 --,
(7) --(CH 2 ) 3 --O--CH 2 --,
(8) --(CH 2 ) 2 --O--(CH 2 ) 2 ,
(9) --CH 2 --O--(CH 2 ) 3 --,
(10) --(m-Ph)--(CH 2 ) 2 --, or
(11) --(m-Ph)--O--CH 2 --,
wherein --(m-Ph)-- is inter-meta-phenylene, and
wherein g is zero, one, two, or three;
wherein Q is α-OH:β-R 5 or α-R 5 :β-OH, wherein R 5 is hydrogen or methyl;
wherein R 7 and R 8 are hydrogen, alkyl of one to 12 carbon atoms, inclusive, benzyl, or phenyl, being the same or different;
wherein R 2 is hydrogen, hydroxyl, or hydroxymethyl;
wherein R 3 and R 4 are hydrogen, methyl, or fluoro, being the same or different, with the proviso that one of R 3 and R 4 is fluoro only when the other is hydrogen or fluoro;
wherein W is oxo, methylene, α-OH:β-H, or α-H:β-OH; and
wherein X is cis- or trans-CH═CH--, --C.tbd.C--, or --CH 2 CH 2 --.
With regard to the divalent the substituents described above (e.g., Q) these divalent radicals are defined as α-R i :β-R j , wherein R i represents the substituent of the divalent moiety in the alpha configuration with respect to the ring and R j represents the substituent of the divalent moiety in the beta configuration with respect to the plane of the ring. Accordingly, when Q is defined as a-OH:β-R 5 , the hydroxy of the Q moiety is in the alpha configuration, i.e., as in the natural prostaglandin, and the R 5 substituent is in the beta configuration.
Specific embodiments of the present invention include:
2-Decarboxy-2-tetrazolyl-19-hydroxy-19-methyl-PGF 2 α,
2-Decarboxy-2-tetrazolyl-11-deoxy-19-hydroxy-19-methyl-PGF 2 α,
2-Decarboxy-2-tetrazolyl-11-deoxy-11α-hydroxymethyl-19-hydroxy-19-methyl-PGF 2 α,
2-Decarboxy-2-tetrazolyl-19-hydroxy-19-methyl-PGF 2 β,
2-Decarboxy-2-tetrazolyl-11-deoxy-19-hydroxy-19-methyl-PGF 2 β,
2-Decarboxy-2-tetrazolyl-11-deoxy-11α-hydroxymethyl-19-hydroxy-19-methyl-PGF 2 β,
2-Decarboxy-2-tetrazolyl-19-hydroxy-19-methyl-PGE 2 ,
2-Decarboxy-2-tetrazolyl-11-deoxy-19-hydroxy-19-methyl-PGE 2 ,
2-Decarboxy-2-tetrazolyl-11-deoxy-11α-hydroxymethyl-19-hydroxy-19-methyl-PGE 2 ,
2-Decarboxy-2-tetrazolyl-9-deoxo-9-methylene-19-hydroxy-19-methyl-PGE 2
2-Decarboxy-2-tetrazolyl-9-deoxo-9-methylene-11-deoxy-19-hydroxy-19-methyl-PGE 2 ,
2-Decarboxy-2-tetrazolyl-9-deoxo-9-methylene-11-deoxy-11α-hydroxymethyl-19-hydroxy-19-methyl-PGE 2 ,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-15(S)-15-methyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-PGF.sub.1 α,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-16,16-difluoro-PGF 1 α,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-11-deoxy-PGF.sub.1 α,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-11-deoxy-15(S)-15-methyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-11-deoxy-PGF 1 α,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-11-deoxy-16,16-difluoro-PGF 1 α,
2-Decarboxy-2-tetrazolyl-4,5-dideoxy-19-hydroxy-19-methyl-11-deoxy-11.alpha.-hydroxymethyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-4,5-dideoxy-19-hydroxy-19-methyl-11-deoxy-11.alpha.-hydroxymethyl-15(S)-15-methyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-11-deoxy-11α-hydroxymethyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-11-deoxy-11α-hydroxymethyl-16,16-difluoro-PGF 1 α,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-15(S)-15-methyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-PGF.sub.1 β,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-16,16-difluoro-PGF 1 β,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-11-deoxy-PGF.sub.1 β,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-11-deoxy-15(S)-15-methyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-11-deoxy-PGF 1 β,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-11-deoxy-16,16-difluoro-PGF 1 β,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-11-deoxy-11.alpha.-hydroxymethyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-11-deoxy-11.alpha.-hydroxymethyl-15(S)-15-methyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-11-deoxy-11α-hydroxymethyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-11-deoxy-11α-hydroxymethyl-16,16-difluoro-PGF 1 β,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-15(S)-15-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-PGE.sub.1,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-16,16-difluoro-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-11-deoxy-PGE.sub.1,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-11-deoxy-15(S)-15-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-11-deoxy-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-11-deoxy-16,16-difluoro-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-11-deoxy-11.alpha.-hydroxymethyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-11-deoxy-11.alpha.-hydroxymethyl-15(S)-15-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-11-deoxy-11α-hydroxymethyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-11-deoxy-11α-hydroxymethyl-16,16-difluoro-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-15(S)-15-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-16,16-difluoro-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-11-deoxy-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-11-deoxy-15(S)-15-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-11-deoxy-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-11-deoxy-16,16-difluoro-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-11-deoxy-11α-hydroxymethyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5-didehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-11-deoxy-11α-hydroxymethyl-15(S)-15-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-11-deoxy-11α-hydroxymethyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-4,5,13,14-tetradehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-11-deoxy-11α-hydroxymethyl-16,16-defluoro-PGE 1 ,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-16,16-difluoro-PGF 1 α,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-15(S)-15-methyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-PGF.sub.1 α,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-16,16-difluoro-PGF 1 α,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-15(S)-15-methyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-11.alpha.-hydroxymethyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-11.alpha.-hydroxymethyl-16,16-difluoro-PGF 1 α,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-11.alpha.-hydroxymethyl-15(S)-15-methyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-16,16-difluoro-PGF 1 β,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-15(S)-15-methyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-PGF.sub.1 β,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-16,16-difluoro-PGF 1 β,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-15(S)-15-methyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-11.alpha.-hydroxymethyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-11.alpha.-hydroxymethyl-16,16-difluoro-PGF 1 β,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-11.alpha.-hydroxymethyl-15(S)-15-methyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-16,16-difluoro-PGE 1 ,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-15(S)-15-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-PGE.sub.1,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-16,16-difluoro-PGE 1 ,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-15(S)-15-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-11.alpha.-hydroxymethyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-11.alpha.-hydroxymethyl-16,16-difluoro-PGE 1 ,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-11-deoxy-11.alpha.-hydroxymethyl-15(S)-15-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-PGE 1 ,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-16,16-difluoro-PGE 1 ,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-15(S)-15-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-11-deoxy-PGE 1 ,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-11-deoxy-16,16-difluoro-PGE 1 ,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-11-deoxy-15(S)-15-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-11-deoxy-11α-hydroxymethyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-11-deoxy-11α-hydroxymethyl-16,16-difluoro-PGE 1 ,
2-Decarboxy-2-tetrazolyl-2,3-didehydro-19-hydroxy-19-methyl-9-deoxo-9-methylene-11-deoxy-11α-hydroxymethyl-15(S)-15-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-19-hydroxy-19-methyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-16,16-dimethyl-19-hydroxy-19-methyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-16,16-difluro-19-hydroxy-19-methyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-13,14-dihydro-19-hydroxy-19-methyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-11-deoxy-19-hydroxy-19-methyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-11-deoxy-16,16-dimethyl-19-hydroxy-19-methyl-PGF.sub.1 α,
2-Decarboxy-2-tetrazolyl-11-deoxy-16,16-difluoro-19-hydroxy-19-methyl-PGF.sub.1 α,
2-Decarboxy-2-tetrazolyl-11-deoxy-13,14-dihydro-19-hydroxy-19-methyl-PGF.sub.1 α,
2-Decarboxy-2-tetrazolyl-11-deoxy-11α-hydroxymethyl-19-hydroxy-19-methyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-11-deoxy-11α-hydroxymethyl-16,16-dimethyl-19-hydroxy-19-methyl-PFG 1 α,
2-Decarboxy-2-tetrazolyl-11-deoxy-11α-hydroxymethyl-16,16-difluoro-19-hydroxy-19-methyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-11-deoxy-11α-hydroxymethyl-13,14-dihydro-19-hydroxy-19-methyl-PGF 1 α,
2-Decarboxy-2-tetrazolyl-19-hydroxy-19-methyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-16,16-dimethyl-19-hydroxy-19-methyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-16,16-difluoro-19-hydroxy-19-methyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-13,14-dihydro-19-hydroxy-19-methyl-PGF 2 β,
2-Decarboxy-2-tetrazolyl-11-deoxy-19-hydroxy-19-methyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-11-deoxy-16,16-dimethyl-19-hydroxy-19-methyl-PGF.sub.1 β,
2-Decarboxy-2-tetrazolyl-11-deoxy-16,16-difluoro-19-hydroxy-19-methyl-PGF.sub.1 β,
2-Decarboxy-2-tetrazolyl-11-deoxy-13,14-dihydro-19-hydroxy-19-methyl-PGF.sub.1 β,
2-Decarboxy-2-tetrazolyl-11-deoxy-11α-hydroxymethyl-19-hydroxy-19-methyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-11-deoxy-11α-hydroxymethyl-16,16-dimethyl-19-hydroxy-19-methyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-11-deoxy-11α-hydroxymethyl-16,16-difluoro-19-hydroxy-19-methyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-11-deoxy-11α-hydroxymethyl-13,14-dihydro-19-hydroxy-19-methyl-PGF 1 β,
2-Decarboxy-2-tetrazolyl-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-16,16-dimethyl-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-16,16-difluoro-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-13,14-dihydro-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-11-deoxy-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-11-deoxy-16,16-dimethyl-19-hydroxy-19-methyl-PGE.sub.1,
2-Decarboxy-2-tetrazolyl-11-deoxy-16,16-difluoro-19-hydroxy-19-methyl-PGE.sub.1,
2-Decarboxy-2-tetrazolyl-11-deoxy-13,14-dihydro-19-hydroxy-19-methyl-PGE.sub.1,
2-Decarboxy-2-tetrazolyl-11-deoxy-11α-hydroxymethyl-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-11-deoxy-11α-hydroxymethyl-16,16-dimethyl-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-11-deoxy-11α-hydroxymethyl-16,16-difluoro-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-11-deoxy-11α-hydroxymethyl-13,14-dihydro-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-9-deoxo-9-methylene-19-hydroxy-19-methyl-PGE 1
2-Decarboxy-2-tetrazolyl-9-deoxo-9-methylene-16,16-dimethyl-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-9-deoxo-9-methylene-16,16-difluoro-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-9-deoxo-9-methylene-13,14-dihydro-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-9-deoxo-9-methylene-11-deoxy-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-9-deoxo-9-methylene-11-deoxy-16,16-dimethyl-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-9-deoxo-9-methylene-11-deoxy-16,16-difluoro-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-9-deoxo-9-methylene-11-deoxy-13,14-dihydro-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-9-deoxo-9-methylene-11-deoxy-11α-hydroxymethyl-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-9-deoxo-9-methylene-11-deoxy-11α-hydroxymethyl-16,16-dimethyl-19-hydroxy-19-methyl-PGE 1 ,
2-Decarboxy-2-tetrazolyl-9-deoxo-9-methylene-11-deoxy-11α-hydroxymethyl-16,16-difluoro-19-hydroxy-19-methyl-PGE 1 , and
2-Decarboxy-2-tetrazolyl-9-deoxo-9-methylene-11-deoxy-11α-hydroxymethyl-13,14-dihydro-19-hydroxy-19-methyl-PGE 1 .
The compounds of the present invention are particularly useful for inducing prostaglandin-like biological effects, as is described in U.S. Ser. No. 025,878. Uses of compounds in accordance with the present invention include, therefore, anti-asthmatic indications.
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The present invention provides novel 2-decarboxy-2-tetrazolyl-19-hydroxy-19-methyl-PG compounds and methods for their preparation and pharmacological uses for the induction of prostaglandin-like effects.
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FIELD OF INVENTION
[0001] The present invention relates to a method for producing male sterile plants. In particular this invention relates to transformation of a plant with said genetic construct comprising plant BECLIN 1 gene and expression of this gene in anther tapetum yields a male sterile transgenic plant. Male sterile plants are useful for the production of hybrid plants by sexual hybridization. The development of hybrid cultivars is highly desired because of their generally increased productivity due to increased hybrid vigor or heterosis.
BACKGROUND OF THE INVENTION AND PRIOR ART
[0002] Hybrid plants have become increasingly important in various commercial food crops around the world. Hybrid plants have the advantages of higher yield, better quality and stress resistance than their parents, because of heterosis or hybrid vigor. Crop uniformity is another advantage of hybrid plants when the parents are homozygous; this leads to improved crop management. Hybrid seed is therefore commercially important and sells at a premium price. In crops such as maize, sunflower, sorghum, sugar beet, cotton, and many vegetables, hybrids account for a large share of the seed market. Not only the USA and Europe, but also many developing countries rely on their food production to a large extent on hybrids. Sale of hybrids in various crops account for nearly 40 percent of the global commercial seed business of about US $ 15 billion. This share is likely to increase as the importance of hybrid vigor is yet to be realized fully, especially in developing countries.
[0003] The production of hybrid varieties of maize (from the thirties in the US), cotton (since 1970 in India) and of rice (since 1976 in China) represents the most significant and successful breeding efforts of the twentieth century. A 6-fold increase was observed between 1930 and 1990 for US corn yield after the introduction of hybrid breeding, compared to uniform performances for selected open pollinated populations during the previous 60 years (Stuber, 1994).
[0004] The concept of hybrid vigor ((Zirkle, 1952)) emerged since the early observations in the eighteenth century by J. G. Koelreuter of interspecific crosses in Nicotiana, Dianthus, Verbascum, Mirabilis, Datura , confirmed by Darwin (Darwin, 1876) in vegetables, and W. J. Beal in maize (Beal, 1880). Subsequently, this effect was exploited in plant breeding (Shull, 1952) when the tools to produce the necessary amount of seeds became available in hermaphrodite species: the first male sterility system was developed in onion in 1943 (Jones, 1943) and others were developed in a wide range of species such as sugar beet, maize, sorghum, sunflower, rice, rapeseed, carrot (Frankel, 1977).
[0005] The key to the successful commercial production of hybrid seeds is sufficient control of the pollination process that is male sterility. Male sterility is defined as the failure of plants to produce functional anthers, pollen, or male gametes. First documentation of male sterility came in 1763 when Kolreuter observed anther abortion within species and specific hybrids. Maize has distinctly separate male and female flowers which makes the plant well suited to manual or mechanical emasculation. The tassels are removed from the seed plants before they are able to shed pollen. Even though detasseling is currently used in hybrid seed production for plants such as maize, the process is labor-intensive and costly, both in terms of the actual detasseling cost and yield loss as a result of detasseling the female parent.
[0006] Most major crop plants of interest have both functional male and female organs within the same flower, therefore, emasculation is not a simple procedure. While it is possible to remove by hand the pollen forming organs before pollen is shed, this form of hybrid production is extremely labor intensive and expensive. Seed is produced in this manner only if the value and amount of seed recovered warrants the effort.
[0007] Another general means of producing hybrid seed is to use chemicals that kill or block viable pollen formation. These chemicals, termed gametocides, are used to impart a transitory male-sterility. Commercial production of hybrid seed by use of gametocides is limited by the expense and availability of the chemicals and the reliability and length of action of the applications. A serious limitation of gametocides is that they have phytotoxic effects, the severity of which is dependent on genotype. Other limitations include that these chemicals may not efficiently reach the mall reproductive parts or may not be effective for crops with an extended flowering period because new flowers produced may not be affected. Consequently, repeated application of chemicals is required.
[0008] Many current commercial hybrid seed production systems for field crops rely on a genetic means of pollination control. Plants that are used as females either fail to make pollen, fail to shed pollen, or produce pollen that is biochemically unable to affect self-fertilization. Of more widespread interest for commercial seed production are systems of pollen-control-based genetic mechanisms causing male sterility. There are three main types of male sterility observed in nature. All three types of male sterility are used in commercial breeding programs to ensure cross-pollination to produce hybrid seeds in different crops.
[0009] One type of male sterility is nuclear encoded called as genetic male sterility. It is ordinarily governed by a single recessive gene, ins but dominant genes governing male sterility are also known e.g. in sunflower. Thus nuclear male sterility can be either dominant or recessive. Many different nuclear male sterile (ms) genes have been isolated in maize. In rice 25 ms are known. In a plant homozygous recessive for such a gene, the pollen fails to develop to maturity. For breeding purposes, a recessive male-sterile parent plant is maintained by crossing it with a heterozygous male-fertile plant that also includes the recessive male-sterility allele, so that the offspring are 50% recessive male-sterile plants. The other 50% are male-fertile plants that have to be rogued out in outcrossing programs which can only be done efficiently if the recessive male-sterility allele is segregated together with a selectable or screenable marker. In U.S. Pat. No. 4,727,219, a procedure is described for the use of recessive male sterility for the production of, hybrid maize. Dominant nuclear male sterile plants, as compared to recessive male sterile plants, can be maintained through crossing with a male-fertile plant, to produce offspring that are 50% dominant male-sterile plants. The usefulness of dominant nuclear male-sterile plant is, however, limited because its dominant male-sterility allele is in most cases not tightly linked (i.e., within the same genetic locus) to a selectable or screenable marker. Dominant sterility can only be used for hybrid seed formation if propagation of the female line is possible (for example, via in vitro clonal propagation). Dominant nuclear male-sterile lines were developed with a blue seed marker in durum and common wheat (Tian and Liu, 2001). This genetic male sterility is of wide occurrence in plants but commercial utility of this sterility system is limited by the expense of clonal propagation and roguing the female rows of self-fertile plants.
[0010] Genetic male sterility may be subdivided into two broad groups: (1) environment insensitive i.e. ins gene expression is much less affected by environment and (2) environment sensitive i.e. ins gene expression occurs within specific range of temperature and/or photoperiod regimes; this type of sterility is known in rice, tomato, wheat etc. The environment sensitive male sterility is further divided into two groups (1) temperature sensitive genetic male sterility e.g. rice TGMS line Pei-Ai645 and (2) photoperiod sensitive genetic male sterility e.g. rice 5047S. In addition approaches in genetic engineering have been used to produce transgenic male sterility, for which a novel approach is discussed in this document.
[0011] The second type of male sterility is conditioned by hereditary particles in the cytoplasm. Cytoplasmic male sterility is caused by the extranuclear genome (mitochondria or chloroplast) and shows maternal inheritance. Manifestation of male sterility in these may be either entirely controlled by cytoplasmic factors or by the interaction between cytoplasmic and nuclear factors. They show non-Mendelian inheritance. This is not a very common type of male sterile system in the plant kingdom. Cytoplasmic male sterility (CMS) of the seed line can be achieved through crossing with naturally occurring CMS germplasm as female parent. Here the sterility is transmitted only through the female and all progeny will be sterile. This is not a problem for crops such as onions or carrots where the commodity harvested from the F1 generation is produced during vegetative growth. But in other cases where clonal propagation is not possible CMS lines must be maintained by repeated crossing to a sister line (known as the maintainer line) that is genetically identical except that it possesses normal cytoplasm and is therefore male fertile. This approach of induction of male sterility in the seed line on the basis of sterilizing cytoplasm was employed in rice, sorghum, sunflower and millet. But the offspring of plants of this type are only of commercial value if the economic product of the offspring is not for use as seed but rather for plants such as ornamentals and sugarbeet.
[0012] When nuclear genes for fertility restoration (Rf) are available for CMS system in any crop, it is called as cytoplasmic genetic male sterility (CGMS). The restorers of fertility (Rf) genes are distinct from genetic male sterility genes. This third type male sterility system is the result of a combination of both nuclear encoded male sterility and cytoplasmatically encoded male sterility. Here sterility is manifested by the influence of both nuclear and cytoplasmic genes. The cases of cytoplasmic male sterility would be included in the cytoplasmic-genic system as and when restorer genes for them would be discovered. It is likely that a restorer gene would be found for all the cases of cytoplasmic male sterility if thorough search were made. There are commonly two types of cytoplasms, N (normal) and S (sterile). The Rf genes do not have any expression of their own unless the sterile cytoplasm is present. Rf genes are required to restore fertility in S cytoplasm which causes sterility. Thus a combination of N cytoplasm with rfrf and S cytoplasm with Rf-produces fertiles; while S cytoplasm with Of produces only male steriles. N cytoplasm with Rfrf is best for stable fertility. U.S. Pat. No. 6,320,098 described a method of producing cytoplasmic-genetic male sterile soybean and method for producing hybrid soybean. U.S. Pat. No. 5,773,680 utilized cytoplasmic-genetic male sterility system in the production of hybrid wild rice.
[0013] Generally, the use of CMS for commercial seed production involves maintenance of three breeding lines: a male-sterile line (female parent), a maintainer line which is isogenic to the male-sterile line but contains fully functional mitochondria and a restorer line which has nuclear genes (Rf genes) for fertility restoration.
[0014] Discovery of dominant negative genes which would alter plant development would be particularly useful in developing genetic methods to induce male sterility because other available methods, including cytoplasmic male sterility and nuclear male sterility have shortcomings. A dominant negative gene is one that, when expressed, effects a dominant phenotype in the plant. Herskowitz (1987), used the term “dominant negative” to denote a gene that encodes a mutant polypeptide which, when over-expressed, disrupts the activity of the wild-type gene. A wild type gene is one from which the mutant derived. In the present description the dominant negative gene is applied to a gene coding for a product that disrupts an endogenous genetic process of a host cell which receives the gene, and that is effective in a single copy or may produce an effect due to overexpression of the gene either by increased production of the gene product. Exemplary of the class of dominant negative genes are cytotoxic genes, methylase genes, and growth-inhibiting genes. Dominant negative genes include diphtheria toxin A-chain gene (Czako and An, 1991), cell cycle division mutants such as CDC in maize (Colasanti, et al., 1991) the WT gene (Farmer, et al., 1994) and P68 (Chen, et al., 1991). Biotechnology has enabled the development of several new pollination control systems that could be useful for hybrid seed production. Since the first transgenic male sterility system was described (Mariani, 1990), many strategies to produce male-sterile plants have been reported. There has been significant interest in using an ablation system for controlling reproductive development in plants. Reproductive control has been achieved in several plant species by genetic ablation, which entails linking a reproductive-preferred promoter with a dominant negative gene to ablate reproductive cells. Prior art regarding the proposed invention are as follows:
Patents EP344029, EP1135982 and WO89/10396 described a system for producing a male sterile plant by transforming a plant with a DNA encoding barnase under the control of a tapetum-specific promoter. Barnase is an RNase originating in Bacillus amyloliquefaciens . This enzyme has 110 amino acid residues and hydrolyzes RNA. When expressed in cells, this enzyme degrades RNA in cells and thus inhibits the functions of the cells and finally causes cell death in many cases. By using this characteristic, it is therefore expected that the function of the specific site can be selectively controlled by expressing the barnase gene in a specific site of a plant. Transformation of tobacco and oilseed rape plants with such a promoter-gene construct prevented the plants from producing fertile pollen (Mariani et al., 1990). Similarly collapse of tapetum was also observed when A9 and A6 promoters were used to drive expression of the barnase gene in transgenic plants (Hird et. al., 1993; Paul et. al., 1992). When the barnase gene was employed as a male sterility gene, however, it was frequently observed that resulting male sterile transgenic plants exhibit unfavorable characteristics. PCT International Publication WO96/26283 refers to this problem in rice. It is also reported that similar phenomena are observed not only in rice but in lettuce (Reymaerts et. al., 1993). Patent Application 20020166140 reported mutated barnase gene at least in part and then the thus obtained mutant barnase gene, having a weakened effect was anther-specifically expressed in a plant so as to make the plant substantially male sterile without any substantially disadvantageous effect on the tissues other than anthers. In this patent production of male sterile plants, free from any unfavorable characteristic at a high efficiency was claimed. U.S. Pat. No. 5,763,243, U.S. Pat. No. 6,072,102, U.S. Pat. No. 5,792,853, U.S. Pat. No. 5,837,851 and U.S. Pat. No. 5,795,753 have used a DNA adenine methylase (DAM) gene, isolated from E. coli as a dominant negative gene. Changes in the DNA methylation pattern of specific genes or promoters have accounted for changes in gene expression. Methylation of DNA is a factor in regulation of genes during development of both plants and animals. Methylation patterns are established by methods such as the use of methyl-sensitive CpG-containing promoters (genes). In general, actively transcribed sequences are under methylated. In animals, sites of methylation are modified at CpG sites (residues). Genetic control of methylation of adenine (A) and cytosine (C) (nucleotides present in DNA) is affected by genes in bacterial and mammalian species. In plants, however, methyl moieties exist in the sequence CXG, where X can be A, C or T, where C is the methylated residue. Inactivation due to methylation of A is not known in plants, particularly within GATC sites known to be methylated in other systems. E. coli DNA adenine methylase (DAM) for which GATC is a target inactivates a genetic region critical for pollen formation or function thereby causing a male sterile plant to form. Patent E P0942965, U.S. Pat. No. 6,177,616 and U.S. Pat. No. 6,384,304 used DNA molecules which code for deacetylases or proteins having the biological activity of a deacetylase. These molecules can be used to produce plants having parts which can be deliberately destroyed i.e. plants which have male sterility, by the specific expression of a deacetylase gene (Kriete et. al. 1996, Bartsch 2001). The deacetylase genes from Streptomyces viridochromogenes [N-acetyl-L-phosphinothricylalanylalanine (N-acetyl-PTT) deacetylase, dea] and argE from Escherichia coli (N-acetyl-L-ornithine deacetylase) encode proteins having specificity for N-acetyl-L-PPT. For both genes, it was possible in the case of tapetum-specific expression in plants to show the occurrence of male-sterile flowers after treatment of individual buds with N-acetyl-L-PPT. For successful use of this system, in particular in the treatment of whole plants with N-acetyl-PPT under practically relevant conditions, it is advantageous to be able to employ deacetylases having high substrate affinity. Therefore further deacetylases having high affinity for N-acetyl-PPT were sought. In U.S. Pat. No. 6,177,616 and U.S. Pat. No. 6,384,304 N-acetyl-PPT deactylase gene from Stenotrophomonas sp. was used for the production of male sterile plants. Patent E P0455690, reported a method of inhibiting respiration of a plant cell by use of a gene, which is expressible in anthers of plants, to inhibit mitochondrial function leading to cell death and failure to produce viable pollen, thus imparting male sterility. The disrupter gene was selected from the mammalian uncoupling protein (UCP) cloned from mammalian (usually rat) brown adipose tissue. The proposed disrupter protein, UCP, is instrumental in the thermogenesis of mammalian brown adipose tissue and exists as a dimer in the mitochondrial inner membrane forming a proton channel and thus uncoupling oxidative phosphorylation by dissipation of the proton electrochemical potential differences across the membrane. U.S. Pat. No. 5,254,801, reported a phosphonate monoesterase gene (pehA), found suitable for purpose such as inducing male sterility for hybrid seed production in plants. A bacterial phosphonate monoester hydrolase was evaluated in plants as a conditional lethal gene useful for cell ablation and negative selection. A phosphonate monoesterase gene (pehA) encoding an enzyme that hydrolyzes phosphonate esters including glyceryl glyphosate to glyphosate and glycerol was cloned from the glyphosate metabolizing bacterium, Burkholderia caryophilli PG2982. As an example of tissue-specific cell ablation, floral sterility without vegetative toxicity was demonstrated by expressing the pehA gene using a tapetum specific promoter and treating the mature plants with glyceryl glyphosate. (Dotson et. al. 1996). WO 99/04023 proposed a method of controlling fertility of plants by the use of DNA molecule that encodes avidin, a glycoprotein. High level expression of avidin gene in anthers can induce male sterility. Avidin, a glycoprotein has a very strong affinity for biotin (vitamin H) with a K D (dissociation constant) of approximately 10 −15 M −1[1] , the highest known affinity between any protein and its ligand. This binding is essentially irreversible. Fertility can be restored by spraying the plant with a solution of biotin. U.S. Pat. No. 5,955,653 discovered a tapetum-specific callase (beta.-1,3-glucanase) gene, designated A6, from Brassica napus and other members of the family Brassicaceae including A. thaliana . The A6 gene encodes a 53 kDa callase enzyme of Brassica napus and equivalent proteins in other Brassicaceae family members. Coding sequence from the gene can be driven by an appropriate promoter to induce male sterility in plants. Microspore release is the process by which the immature microspores are liberated from a protective coat of .beta.(1,3) poly-glucan (callose) laid down by the microsporogenous cells before meiosis (Rowley, (1959); Heslop-Harrison (1968)). The anther-expressed glucanase responsible for the dissolution of this callose coat is known as callase. Callase is synthesised by the cells of the tapetum and secreted into the locule. The appearance of the enzyme activity is developmentally regulated to coincide precisely with a specific stage of microspore development. The basis of the use of a glucanase as a sterility DNA lies in the fact that mis-timing of the appearance of callase activity is associated with certain types of male-sterility (Warmke and Overman, 1972). One important attraction of glucanase as a potential sterility DNA is that it already occurs in a natural system. But the timing of the appearance of callase activity is critical. U.S. Pat. No. 7,230,168 described transformation of a plant cell with a nucleic acid construct encoding cytokinin oxidase where expression of the cytokinin oxidase inhibits pollen formation or male organ development in the transgenic plant. Fertility restoration in the plant may be achieved after restoration of normal cytokinin levels by application of cytokinins or cytokinin oxidase inhibitor such as a cytokinin oxidase 1 inhibitor. Hear ability of the particular cytokinin oxidase to oxidatively remove cytokinin side chains to give adenine and the corresponding isopentenyl aldehyde was utilized to create male sterility. In animal systems, studies of apoptosis have revealed pathways where proteins of the Bcl-2 family play key roles. The Bcl-2 family includes pro-apoptotic (e.g. Bax, Bak and Bid) and anti-apoptotic (e.g. Bcl-2, Bcl-xl and Ced-9) members that appear to control the initiation of apoptosis through mitochondria (Gross et al. 1999). A Bax gene has been shown to induce PCD in plant cells (Lacomme and Cruz 1999, Kawai-Yamada et al. 2001). A mouse Bax gene was connected to the tapetum-specific promoter, expression of the Bax gene caused cell death resulting pollen abortion (Tsuchiya et al. 1994, Ariizumi et al. 2002). A suppressor of Bax-induced cell death has been identified in plants. Expression of AtBI-1, a homolog of mammalian Bax inhibitor, in the tapetum at the tetrad stage inhibits tapetum degeneration and subsequently results in pollen abortion, while activation of AtBI-1 at the later stage does not (Patent JP2006345742-A, Kawanabe et. al. 2006). Diphtheria toxin A chain (DTA) gene was expressed in tapetum which resulted in dominant male sterility due to the specific cell ablation (Koltunow et. al., 1990). Similarly, when the S-locus glycoprotein gene promoter of Brassica was fused to the DTA gene and transferred into tobacco (Thorness et al., 1991) and A. thaliana (Thorness et al 1993) it resulted in self-sterile plants due to expression of gene in both pistil and anthers. APETALA3 (AP3) promoter-DTA fusion resulted in the complete ablation of petals and stamen in transgenic tobacco (Day et. al., 1995). Temperature sensitive diphtheria toxin A chain (DTA) gene was also used to confer conditional male sterility in Arabidopsis thaliana (Guerineau F et. al., 2003). O'Kefee et al (1994) described R7402/P450sU1 system in which P450SU1 ( Streptomyces griseolus gene encoding herbicide-metabolizing cytochrome) expression and R7402 treatment can be used as a negative selection system in plants. In tobacco expressing P450SU1 from a tapetum-specific promoter, treatment of immature flower buds with R7402 caused dramatically lowered pollen viability. Such treatment could be the basis for a chemical hybridizing agent. This may provide a strategy for development of a chemical male sterilant for hybrid seed production. A ribosome inactivating protein (RIP) from D. sinensis was used as a cytotoxic gene to induce male sterility in tobacco plants (Cho H J et. al. 2001). Ribosome inactivating protein inactivates eukaryotic ribosomes and inhibits general protein synthesis. Actually it inhibits its own protein synthesis (Boness et. al. 1994). Due to its suicidal action it was proposed to use in genetic cell ablation and genetic improvement by Cho H J. Hofig et. al. (2006) expressed a stilbene synthase gene (STS) in anthers of transgenic Nicotiana tabacum plants, resulting in complete male sterility in 70% of transformed plants. The grapevine stilbene synthase (STS) has been shown to compete with the enzyme chalcone synthase (CHS) for the substrates malonyl-CoAand coumaroyl-CoA. STS-induced sterility in tobacco is believed to result from a reduced or abolished flavonol biosynthesis. This has been confirmed by experiments where STS-sterile tobacco plants were regularly sprayed with flavonols and where fertility was partially restored. STS, when expressed in non-tapetal cells, is not expected to haye a toxic impact since there is no competing CHS present.
[0029] Autophagy is a ubiquitious process in eukaryotic cells, in which portions of the cytoplasm are sequestered in double-memberane vescicles for delivery to a degradative organelle, vacuole or lysosome (Reggiori et. al. 2002). Autophagy is known to be active at basal levels under normal physiological conditions; it can be stimulated by a plethora of stresses including cellular damage, nutrient starvation and pathogen infection (Levine and Klionsky, 2004). It is well established that autophagy promotes cell survival during nutrient starvation by degrading and recycling nutrients (Seay M. et. al. 2006). AuTophaGy-related (ATG) genes are essential for autophagosome formation. In the last decade, with the identification of approximately 30 ATG genes in Saccharomyces cerevisiae and other fungi (Klionsky et. al. 2003), the molecular mechanisms of autophagy have gradually been elucidated ((Klionsky et. al. 2005). Autophagy is conserved across all eukaryotes and homologs of many yeast ATG genes have recently been identified in various eukaryotic systems, and the molecular mechanisms of autophagy are also conserved (Yang Cao et. al. 2007). Autophagosome formation is a complex process and each Atg protein has been shown to function at specific stage during autophagosome formation in the yeast (Tsukada et. al. 1993). A number of Atg proteins accumulate to a perivacuolar structure termed the pre-autophagosomal structure (PAS) (Kim et. al. 2002). Among the ATG genes, ATG6 is relatively unique in its not being autophagy-specific (Yang Cao et. al. 2007). For example, the S. cerevisiae ATG6/VPS30 gene product is the only protein required for both autophagy and sorting of the vacuole resident hydrolase carboxypeptidase Y through the Vps pathway (Kametaka et. al. 1998). Yeast Atg6/Vps30 is a subunit of two distinct class III phosphotidylinositol (PtdIns) 3-kinase complexes pathways (Kihara et. al. 2001). Complex I functions in autophagy, whereas complex II is involved in Vps, which explains why Atg6/Vps30 participates in both, otherwise separate, pathways.
[0030] BECLIN 1, the mammalian homologue of yeast ATG6 was the first identified mammalian gene with a role in mediating autophagy (Liang et. al., 1999). BECLIN 1 was originally discovered during the course of a yeast two-hybrid screen of a mouse brain cDNA library using human Bc1-2 as the bait (Liang et. al. 1998). Overexpression of Human BECLIN 1 prompts autophagic cell death in human MCF7 breast carcinoma cells (Liang et. al., 1999). Recently BECLIN 1 was found to participate in apoptosis signaling through caspase-9 thus BECLIN 1 may be the critical ‘molecular switch’ and play an important role to fine tune autophagy and apoptosis (Wang et. al. 2007). BECLIN 1 is conserved in higher eukaryotes. Human Beclin 1 protein shares 36% identity and 52% similarity with Nicotiana Beclin 1 (Liang et. al., 1999).
[0031] If a plant is to survive an infection, hypersensitive response (HR) cell death (PCD) must be carefully controlled so that it does not spread throughout the plant and kill it. The plant ortholog of BECLIN 1 was first studied in Nicotiana benthamiana plants (Liu Y. et. al. 2005) and it was found essential for restriction of HR PCD during disease resistance (Seay M. et. al. 2006, Liu Y. et. al. 2005, Patel S. et. al. 2006). Plants deficient in the plant BECLIN 1 exhibit unrestricted HR PCD in response to pathogen infection (Liu Y. et. al. 2005). Autophagosomes were rarely observed in the cells of plant BECLIN 1 silenced plants after infection with TMV (Liu Y. et. al. 2005). Autophagosomes are induced at the site of TMV infection during HR PCD and plant BECLIN 1/ATG6 is required for induction of autophagy in both pathogen infected cells and uninfected adjacent cells to restrict HR PCD at infected site (Liu Y. et. al. 2005). Thus there is a prodeath signal(s) moving out of the pathogen-infected area into adjacent tissues and distal sites that is negatively regulated by autophagy. These findings provide the genetic evidence that ATG genes can function in vivo as a negative regulator of HR PCD. These results contrast with findings from mammalian studies in which ATG genes are required to promote PCD in cells lacking intact apoptotic machinery (Liu Y. et. al. 2005).
[0032] Recently, it was reported that AtBECLIN 1/ATG6 in plants has distinct function in addition to autophagy: vesicle trafficking and pollen germination (Fujiki Y. et. al. 2007, Qin G. et. al. 2007). They reported that deletions of AtBECLIN 1/ATG6 specifically influenced male gametophytes but not the female reproductive structures. Pollens lacking AtBECLIN 1/ATG6 failed to germinate. During pollen germination and pollen tube growth, cellular trafficking is critical for cell wall deposition and cell shape remodeling (Parton R M et. al. 2003, Parton R M et. al. 2001, and Helper P K et. al. 2001). It is possible that ATG6 deletions alter the cellular trafficking system which results failure of pollen germination (Qin G. et. al. 2007). AtBECLIN 1/ATG6 deficient plants displayed retarted growth, dwarfism and early senescence this suggests that AtBECLIN 1/ATG6 is required for normal plant development (Qin G. et. al. 2007).
[0033] Tapetum is the innermost sporophytic layer of anther wall and surrounds the microspores. The tapetum is known to provide nutrition to developing microspores especially exine of pollen grains, the main structural components of the pollen wall. The tapetum degenerates during the later stages of pollen development. It has been speculated that tapetum degeneration is a programmed cell death (PCD) event (Wu and Cheun 2000). [Nuclei of tapetum cells and the tissues of anther wall were found TUNEL (terminal deoxynucleotidyl transferase mediated dUTP nick end labeling) positive by Wang et. al. (1999).] The proper timing of cell death in the tapetum is essential for normal microsporogenesis. Kawanabe et. al. (2006) had shown that expression of mouse Bax gene in tapetum at early stage of pollen development can cause early degeneration of tapetum resulting into pollen abortion.
[0034] In the present invention, AtBECLIN 1/ATG6 gene is being expressed in tapetum in stage 2 and 3 of pollen development (which has not been previously reported). This causes disruption of normal cell death programme of tapetum and there is a delay in the induction of tapetal programmed cell death (PCD). Hence, pollen formed are abnormal having an intact tapetum, resulting in male sterility.
OBJECTS OF THE INVENTION
[0035] The main object of the present invention is to provide a method for producing male sterile plants by expressing plant BECLIN 1 gene in the tapetum layer of anthers during early stages of pollen development.
[0036] Another object of the present invention is to provide a method, wherein the expression of BECLIN 1 gene in the tapetum disrupts the normal cell death programme of tapetum, resulting in abnormal pollen having intact tapetum.
[0037] Another object of the present invention is to provide an expression vector comprising the expression cassette TA 29 BECLIN 1 which is a useful tool for generating male sterile lines of various crop plants.
[0038] Another object of the present invention is to provide an expression vector capable of introducing said expression cassette TA 29 BECLIN 1 into a plant cell genome when placed in Agrobacterium infected plant cells.
[0039] Yet another object of the present invention is to induce male sterility by causing transformation in plants selected from a group consisting of tobacco, cotton, rice, wheat, corn, potato, tomato, oilseed rape, alfalfa, sunflower, onion, clover, soyabean, pea.
[0040] Yet another object of the present invention is to obtain seeds of male sterile crop plants.
[0041] Yet another object of the present invention is to use a gene product of plant origin for induction of male sterility in plants, which circumvents the biosafety problems associated with expressing other bacterial, viral, mammalian proteins for the same purpose.
[0042] Still another object of the present invention is to express BECLIN 1 gene which codes for a non-cytotoxic polypeptide, hence does not pose any problems if leakage into other cells occurs.
SUMMARY OF THE INVENTION
[0043] Accordingly, the present invention provides a method for producing male sterile plants by expressing plant BECLIN 1 gene in the tapetum layer of anthers during early stages of pollen development.
[0044] In an embodiment of the present invention, the method comprises the steps of:
a) Detaching the third and fourth rosette leaves of about 3 week old Arabidopsis thaliana plants and floating them on deionized water in Petri dishes, adaxial side up; b) incubating the rosette leaves obtained in step (a) at 22±1° C. in the dark for about 48 hours to artificially induce autophagy; c) extracting total RNA from autophagy induced leaves obtained in step (b) as herein described; d) preparing cDNA from total RNA extracted in step (c) by known methods; e) amplifying plant BECLIN 1/ATG6 gene from cDNA prepared in step (d) using gene specific primers by PCR; f) cloning the amplified plant BECLIN 1/ATG6 gene obtained in step (e) in a vector as herein described; g) constructing an expression cassette by gene fusion between tapetum specific promoter having Seq ID no. 3 and plant Beclin 1/ATG6 gene having Seq ID no. 1 obtained from step (f) and Nos terminator sequence in a cloning vector; h) sub-cloning the expression cassette as constructed in step (g) into a binary vector as herein described; i) introducing the resultant binary vector of step (h), carrying the said expression cassette, into Agrobacterium tumefaciens; j) transforming the plant in which male sterility is to be induced with recombinant Agrobacterium tumefaciens obtained in step (i); k) developing independent transgenic lines.
[0056] In an another embodiment of the invention wherein transformation is carried out in plants selected from a group consisting of tobacco, cotton, rice, wheat, corn, potato, tomato, oilseed rape, alfalfa, sunflower, onion, clover, soyabean, pea.
[0057] In yet another embodiment of the invention wherein plant, cell, tissue are obtained by the above mentioned process.
[0058] In yet another embodiment of the invention a recombinant vector useful for inducing male sterility in plants by transformation comprising of:
i. an anther specific promoter; ii. a plant BECLIN 1 gene; iii. a Nos terminator sequence;
[0062] In yet another embodiment of the invention the anther specific promoter used is a tapetum specific promoter, represented by SEQ ID NO: 3.
[0063] In yet another embodiment of the invention the plant BECLIN 1 gene having SEQ ID NO: 1 and codes for a polypeptide having SEQ ID NO: 2 or its homologue.
[0064] In yet another embodiment of the invention the expression cassette comprises a chimeric gene fusion between tapetum specific promoter and plant Beclin ATG6 gene is having the polynucleotide sequence represented by SEQ ID NO: 4.
[0065] In yet another embodiment of the invention a plant, cell, tissue is transformed with the recombinant vector as mentioned above.
[0066] In yet another embodiment of the invention it provides a transgenic plant expressing/overexpressing plant BECLIN 1 gene in its anther.
[0067] In yet another embodiment of the invention the method is used for inducing male sterility in plants listed above.
[0068] In yet another embodiment of the invention use of the recombinant vector for inducing male sterility in plants listed above.
[0069] In yet another embodiment of the invention it provides a kit for inducing male sterility in plants comprising of
a. A vector having an anther specific promoter and a plant BECLIN 1 gene; b. Suitable reagents; c. Instruction manual.
DETAILED DESCRIPTION OF THE INVENTION
[0073] The present invention relates to a method for producing male sterile plants by expressing plant BECLIN 1 gene in the tapetum layer of anthers during early stages of pollen development.
[0074] It also relates to the use of AtBECLIN 1/ATG6 gene in the induction of male sterility in plants. In the present invention, AtBECLIN 1/ATG6 gene is being expressed in tapetum in stage 2 and 3 of pollen development. This causes disruption of normal cell death programme of tapetum and there is a delay in the induction of tapetal programmed cell death (PCD). Hence, pollen formed are abnormal, having an intact tapetum, resulting in male sterility. Most of the transgenic lines showed severely reduced pollen production as compared to the wild type tobacco plants. The pollens produced were deformed and most of them were empty. Even in in vitro pollen germination assay, pollen grains of these transgenic lines failed to germinate and those which germinated showed short pollen tubes.
[0075] This is for the first time it has been demonstrated that expression of plant autophagy related gene (ATG6 gene) in anther cells can cause the male sterility. We report that the expression of plant BECLIN 1/ATG6 gene, driven by a suitable promoter expressed in tapetum at an appropriate stage results in male sterility in transgenic tobacco.
[0076] The present invention provides a recombinant construct for transforming plants to confer male sterility, wherein the expression cassette comprises regulatory sequence operably linked to a polynucleotide sequence, plant BECLIN 1/ATG6 as shown in SEQ ID NO: 1 or a functional variant thereof. The invention also relates to a method of producing transgenic plants having plant parts which can be destroyed specifically after expressing said gene. Further, the invention provides a method for producing male sterile transgenic plants by expressing said gene product in tapetum.
[0077] In the present invention the term of male sterility in plants indicates about 90-100% sterility with 0-10% viable pollen production in anthers.
[0078] A “cloning vector” is a DNA molecule, such as a plasmid, cosmid, or bacteriophage that has the capability of replicating autonomously in a host cell. Cloning vectors typically contain one or a small number of restriction endonuclease recognition sites at which foreign DNA sequences can be inserted in a determinable fashion without loss of an essential biological function of the vector, as well as a marker gene that is suitable for use in the identification and selection of cells transformed with the cloning vector. Marker genes typically include genes that provide antibiotic or herbicide resistance.
[0079] An “expression cassette” is a DNA molecule comprising a gene that is expressed in a host cell and a promoter, driving its expression. Typically, gene expression is placed under the control of certain tissue-specific regulatory elements.
[0080] The term “expression” refers to the biosynthesis of a gene product. For example, in the case of a structural gene, expression involves transcription of the structural gene into mRNA and the translation of mRNA into one or more polypeptides.
[0081] A “recombinant vector” is a vector in which a foreign DNA has been inserted.
[0082] An “expression vector” is a vector in which an expression cassette has been genetically engineered.
[0083] A “binary vector” is able to replicate in both E. coli and Agrobacterium tumefaciens . It typically contains a foreign DNA in place of T-DNA, the left and right T-DNA borders, marker for selection and maintenance in both E. coli and Agrobacterium tumefaciens , a selectable marker for plants. This plasmid is said to be disarmed since its tumor-inducing genes located in the T-DNA have been removed.
[0084] A “suitable promoter” includes a tissue-specific or cell-specific promoter that controls gene expression in those particular cells of a particular tissue. An “anther-specific promoter” is a DNA sequence that directs a higher level of transcription of an associated gene in anther tissue than in some or all other tissues of a plant. In present invention suitable promoter directs expression only in cells that are critical for the formation or function of pollen, including tapetum cells, pollen mother cells, and early microspores.
[0085] A “functional variant of plant BECLIN 1/ATG6” is a variant which retains the autophagy inducing property and have 80% similarity of nucleotide sequence as shown in SEQ ID NO: 1 and amino acid sequence as shown in SEQ ID NO: 2.
[0086] The following examples are set forth as representative of specific and preferred embodiments of the present invention, and should not be construed so as to limit the scope of the invention.
Example 1
Isolation of a cDNA Encoding BECLIN 1/ATG6 Gene from Arabidopsis
[0087] Plant material: The ecotype Columbia (Col-0) of Arabidopsis thaliana was used throughout the experiments described here. Plants were grown on a compound soil mixture of vermiculite/peat moss/perlite (1:1:1) in a growth chamber with a light cycle of 16 h light/8 h dark and a temperature cycle of 23° C. day/18° C. night.
[0088] Artificial induction of autophagy: The third and fourth rosette leaves of 3 week old plants were detached and floated on deionized water in Petri dishes, adaxial side up. Leaves were incubated at 22±1° C. in the dark for 48 hours.
[0089] Cloning of plant BECLIN 1/ATG6 gene: Total RNA was extracted from autophagy induced leaves of Arabidopsis by TRI Reagent (Sigma). The amount of total RNA was measured by NanoDrop® ND-1000 UV-Vis Spectrophotometer. The quality of RNA was checked by visualizing the rRNA in ethedium bromide-coloured agarose gel under UV light. Ten micrograms of total RNA was used in cDNA preparation. cDNA was generated using SuperScript™ Reverse Transcriptase kit (Invitrogen) following the manufacturer's instructions. The cDNA was used as template to amplify plant BECLIN 1/ATG6 gene by using one set of primers, 5′-cta gtc tag aat gag gaa aga gga gat tcc aga-3′ and 5′-cgt cga gct cct aag ttt ttt tac atg aag gct ta-3′. The PCR reaction consisted of 30 cycles 94° C. for 30 sec, 58° C. for 30 sec and 72° C. for 90 sec. The PCR product of 1.5 kb was cloned in pBluescript SK+ vector (Stratagene, La Jolla, Calif.). Nucleotide sequence of the cloned PCR product was determined by using Big Dye Terminator v3.1 Cycle Sequencing Kit (Applied Biosystems). Sequence homology was analyzed using BLAST program.
Example 2
Construction of Chimeric Gene Fusion Between Tapetum Specific Promoter and Plant BECLIN 1/ATG6
[0090] An early stage, tapetum specific 1 kb BamH1/Xba1 promoter was fused with 1.5 kb Xba1/Sac1 plant BECLIN 1 gene and 250 bp Sac1/EcoR1 Nos terminator in BamH1/EcoR1 Sk+Cloning vector.
[0091] The entire expression cassette containing fragments BamH1/EcoR1 was further sub-cloned into binary vector pBI101. The resultant pBI101 carrying the expression cassette was into Agrobacterium tumefaciens strain LBA4404 following the modified protocol (Cangelosi et al., 1991).
Example 3
Transformation of Tobacco Plants
[0092] As described in Example 2, recombinant Agrobacterium tumefaciens carrying the expression cassette was used for transformation of Nicotina tabacum cv. Petit Havana by protocol as described by Horsch et al., in 1985.
[0093] In short a single isolated colony of A. tumefaciens LBA 4404 harboring binary vector with above described expression cassettes was inoculated in YEP medium containing antibiotics streptomycin (250 μg/ml) rifampicin (50 μg/ml) and kanamycin (100 μg/ml) and grown (200 rpm, overnight, 28° C.). Fifty micro liters of the overnight culture was diluted to 100 ml in YEP medium and grown till OD 600 reached to 0.8. Cells were recovered by centrifugation in SS34 rotor (5,000 rpm, 10 min, 4° C.). The pellet was suspended in co-cultivation medium (MS salts, 2% glucose, 10 mM MES and 100 mM acetosyrengone, pH 5.6) to OD 600 0.6. Tobacco leaf discs were co-cultivated with A. tumefaciens for two days in dark. After co-cultivation, the leaf discs were transferred to regeneration medium supplemented with cefotaxime (250 μg/ml) and kanamycin (100 μg/ml). The culture was incubated at 25 with 16 hrs light and 8 hrs dark cycle for a period of four weeks. After this, the transgenic shoots were harvested and transferred to rooting medium containing kanamycin (50 μg/ml). After incubation for 2-4 weeks, the putative transgenic plantlets were transferred to Hoagland solution for acclimatization and then transferred to vermiculite for hardening for three weeks. The plants were transferred from vermiculite to soil in glasshouse. Independent transgenic lines were developed for the expression cassette (chimeric gene fusion).
Example 4
Analysis of Transgenic Lines for Transgene Integration
[0094] Genomic DNA of the transgenic lines and control plant was isolated by CTAB method of DNA extraction. The genomic DNA was used as template to amplify a fragment of 2.5 kb comprising TA29 promoter and plant BECLIN 1 gene by using one set of primers, 5′ cgc gga tcc aga tct tcc aac att tact cc aag gg 3′ and 5′ cgt cga gct cct aag ttt ttt tac atg aag gct to 3′. The PCR reaction consisted of 94° C. for 4 min, 94° C. for 1 min, 60° C. for 1 min and 72° C. for 2 min, Go to 2 for 30 cycles 72° C. for 5 min. The desired band of 2.5 kb was obtained in the PCR of transgenic lines and positive control but not in control plants and negative control (without template). This experiment was repeated for three times for conformation.
Example 5
Analysis of Transgenic Lines for Male Sterility
[0095] The transgenic plants grew well to visible maturity and showed normal flowering. Expression of the autophagy gene in anthers did not lead to any morphological abnormalities except nonviable pollens and very poor or no seed setting. Thus the transgenic plants were male sterile. Pollen viability was evaluated by fluorescein diacetate staining (Heslop-Harrison, 1970). Pollen samples were collected at blooming time and their quality was tested by the fluorocromatic procedure (FCR), which principally tests the integrity of the plasmalema of the vegetative cell. This integrity seems to be closely correlated with viability. Most of the pollens of the transgenic plants were not viable. As shown in Table 1, plants of three transgenic lines had 5 to 14% viable pollen, rest of the pollens of the plants were not showing fluorescence ( FIG. 1 ). On the other hand control plants (Independent transgenic lines for an expression cassette comprising GUS reporter gene driven by tapetum specific promoter), showed 80 to 92% pollen viability (Table 2, FIG. 1 )
[0096] Invitro pollen germination test was performed using artificial liquid media proposed by Kwack (1964). Extensive pollen germination was observed in the cultured pollens of one anther of control plants (Independent transgenic lines for an expression cassette comprising GUS reporter gene driven by tapetum specific promoter) however pollens of transgenic lines either failed to germinate or if germinated showed severely retarded pollen tube growth. In the transgenic plants (Independent transgenic lines for the expression cassette comprising plant BECLIN 1/ATG6 gene driven by tapetum specific promoter) of four different lines 0-1% pollen germination was observed in comparison to 62-75% in control plants (Table 1 & Table 2).
[0097] Further, pollen grains were observed under scanning electron microscopy. The pollen grains of transgenic lines showed difference in sculpturing pattern of exine and lack of germ pores ( FIG. 3 ).
[0098] Fruit set was normal in the transgenic plants of all the six lines but the bulbs were of smaller size. Seed setting was severely affected in bulbs of the transgenic plants. Seed weight per pod of the transgenic plants of twelve different lines was nil to 32.07 mg whereas in control plants it was 36.6 mg to 113.34 mg (Table 3 & Table 4).
[0000]
TABLE 1
Evaluation of pollen viability and pollen germination
Transgenic Lines*
Pollen Viability %
Pollen Germination %
1354 (1)
2~6
0~0.03
1354 (2)
2~7
0~0.09
1354 (3)
9~14
0~1
1354 (4)
5~8
0~0.06
1354 (5)
7~10
0~0.08
1354 (6)
7~12
0~0.18
*Independent transgenic lines for the expression cassette comprising plant BECLIN 1/ATG6 gene driven by tapetum specific promoter as claimed in claim 6.
[0000]
TABLE 2
Evaluation of pollen viability and pollen germination
Transgenic Lines*
Pollen Viability %
Pollen Germination %
1351 (1)
85~90
65~75
1351 (2)
80~90
65~70
1351 (3)
80~92
62~71
1351 (4)
84~96
72~77
1351 (5)
80~92
74~79
1351 (6)
81~96
73~77
*Independent transgenic lines for an expression cassette comprising GUS reporter gene driven by tapetum specific promoter.
[0000]
TABLE 3
seed setting
Transgenic
Seed Weight
Total Number
Seed Weight
Line*
(gm)
of Pods
Per Pod (mg)
1354 (1)
Nil
9
Nil
1354 (2)
0.0522
37
1.41
1354 (3)
0.7102
42
13.9
1354 (4)
Nil
23
Nil
1354 (5)
0.210
18
11.6
1354 (6)
0.822
49
16.7
1354 (7)
0.102
9
11.3
1354 (8)
0.091
23
3.95
1354 (9)
0.370
28
13.21
11354 (10)
0.834
26
32.07
1354 (11)
0.228
10
22.8
1354 (12)
0.658
68
9.67
*Independent transgenic lines for the expression cassette comprising plant BECLIN 1/ATG6 gene driven by tapetum specific promoter.
[0000]
TABLE 4
Seed setting
Seed Weight
Total Number
Seed Weight
Control*
(gm)
of Pods
Per Pod (mg)
1351 (1)
1.7382
45
38.62
1351 (2)
0.3815
6
63.58
1351 (3)
1.7134
29
59.08
1351 (4)
1.9002
29
65.08
1351 (5)
0.440
12
36.6
1351 (6)
0.336
7
48.07
1351 (7)
1.064
12
88.67
1351 (8)
1.182
17
69.52
1351 (9)
0.680
6
113.34
1351 (10)
2.085
22
94.77
1351 (11)
1.21
11
110.36
1351 (12)
0.5
7
71.42
*Independent transgenic lines for an expression cassette comprising GUS reporter gene driven by tapetum specific promoter.
ADVANTAGES OF THE INVENTION
[0000]
1. The expression vector claimed in this invention is a good tool for generating male sterile lines of various crop plants.
2. It is advantageous to use plant BECLIN1/ATG6 as male sterility gene because it has no product which is cytotoxic outside the target cell.
3. The plant BECLIN1/ATG6, as a male sterility DNA mimics natural systems and is inherently less destructive than for example ribonuclease, diphtheria toxin and so does not present such a problem if ‘leakage’ occurs into other cells.
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The present invention relates to a method for producing male sterile plants. It involves selective killing of reproductive cells in plants by using an autophagy related gene plant BECLIN I/ATG6. An expression cassette comprising plant BECLIN I/ATG6, regulated by a tapetum specific promoter can induce killing of tapetum cells. A particular area of interest is transforming a plant with said genetic construct and expression of the plant BECLIN I/ATG6 gene in tapetum at early stage of anther development to cause early collapse of tapetum to produce nonviable pollen, thus imparting male sterility in plants.
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BACKGROUND OF THE INVENTION
The present invention relates to DNA sequences encoding for rat kynurenine aminotransferase.
The enzyme kynurenine aminotransferase (known in the art as KAT) catalyzes the biosynthesis of kynurenic acid (KYNA) from kynurenine (KYN) and is singularly responsible for the regulation of extracellular KYNA concentrations in the brain (J. Neurochem., 57, 533-540, 1991).
KYNA is an effective excitatory amino acid (EAA) receptor antagonist with a particularly high affinity to the glycine modulatory site of the N-methyl-D-aspartate (NMDA) receptor complex (J. Neurochem., 52, 1319-1328, 1989). As a naturally occurring brain metabolite (J. Neurochem., 51, 177-180, 1988 and Brain Res., 454, 164-169, 1988), KYNA probably serves as a negative endogenous modulator of cerebral glutamatergic function (Ann. N.Y. Acad. Sci., vol. 648, p. 140-153, 1992).
EAA receptors and in particular NMDA receptors are known to play a central role in the function of the mammalian brain (J. C. Watkins and G. L. Collingridge --eds.--, In: The NMDA receptor, Oxford University press, Oxford, p. 242, 1989). For example, NMDA receptor activation is essential for cognitive processes, such as, for example, learning and memory (J. C. Watkins and G. L. Collingridge --eds.--, In: The NMDA receptor, Oxford University press, Oxford, p. 137-151, 1989) and for brain development (Trends Pharmacol. Sci., 11, 290-296, 1990).
It follows that a reduction in NMDA receptor function will have detrimental consequences for brain physiology and, consequently, for the entire organism. For example, the decline in the number of NMDA receptors which occurs in the aged brain (Synapse, 6, 343-388, 1990) is likely associated with age-related disorders of cognitive functions.
In the brain, KYNA concentrations and the activity of KYNA's biosynthetic enzyme KAT show a remarkable increase with age (Brain Res. 558, 1-5, 1992 and Neurosci. Lett., 94, 145-150, 1988). KAT inhibitors, by providing an increase of the glutamatergic tone at the NMDA receptor, could therefore be particularly useful in situations where NMDA receptor function is insufficient and/or KAT activity and KYNA levels are abnormally enhanced. Hence they could be particularly useful in the treatment of the pathological consequences associated with the aging processes in the brain which are, for example, cognitive disorders including, e.g., attentional and memory deficits and vigilance impairments in the elderly.
KAT inhibitors may also be useful in the treatment of perinatal brain disorders which may be related to irregularities in the characteristic region specific pattern of postnatal KAT development (H. Baran and R. Schwarcz: Regional differences in the ontogenic pattern of KAT in the brain, Dev. Brain Res., 74, 283-286, 1993).
In subcellular fractionation studies KAT activity was recovered either in the cytosol and in mitochondria (J. Neurochem., 57, 533-540, 1991).
Most nuclear-encoded precursors of mitochondrial proteins contain amino-terminal presequences (Pfanner and Neupert, In: Current Topics in Bioenergetics, Vol. 15, Lee ed., New York Academic Press, p. 177-219, 1987 and Nicholson and Neupert, In: Protein Transfer and Organelle Biogenesis, R. C. Das and P. W. Robins, eds. New York Academic Press, 1988). These presequences are required for the precursor to enter the mitochondrial matrix, where they are proteolytically removed (Hurt et al., FEBS Lett. 178, 306, 1984, Horwich et al., EMBO J. 4, 1129, 1985). This cleavage is not essential for completing import but is necessary for further assembly of the newly imported polypeptides into functional complexes (Zwizinski and Neupert, J. Biol. Chem., 258, 13340, 1983; Lewin and Norman, J. Biol. Chem., 258, 6750, 1983; Ou et al. J. Biochem., 100, 1287, 1986). Precursor targeting sequences differ considerably in their structures. One of the few common themes is the high content of positively charged amino acids and of hydroxylated amino acids. Presequences may form an amphipathic structure in the form of either α-helices or β-sheets (von Heijne, EMBO J., 5, 1335, 1986; Roise et al., EMBO J., 5, 1327, 1986; Vassarotti et al., EMBO J., 6, 705, 1987). Despite the large variability of the sequences of mitochondrial leader peptides, relatively minor alterations of the presequence can prevent cleavage by the processing peptidase (Hurt et al., J. Biol. Chem. 262, 1420, 1987). This suggests that distinct, but up to now undefined, structural elements are required for cleavage. Similarly, the cleavage sites show wide variation among different precursors of a single organism and among precursors of different organisms.
Interestingly, using the protein algoritm described by Gavel and von Heijne (Protein Engineering, 4, 33-37, 1990), a potential mitochondrial transit peptide is predicted in position 1 to 24 of the deduced protein of only cDNA-2 disclosed in the present invention (see FIG. 3 and Example 3).
Recently Perry et al. (Mol. Pharm., 43:660-665, 1993) reported the cloning of a cDNA coding for rat kidney cytosolic cysteine conjugate β-lyase. When the cDNA was inserted into the expression vector pVS1000 and transfected into COS-1 tissue culture cells, a 7-10 fold increase in cytosolic β-lyase and glutamine transaminase K activities were detected.
The deduced amino acid sequence of rat β-lyase is identical to the deduced amino acid sequence of cDNA-1 (rat KAT) except for two residues (see SEQ ID NO:5). Moreover the existence of cDNA-2 was not reported by Perry et al. (Mol. Pharm., 43:660-665, 1993).
Whereas the identity with cysteine conjugate β-lyase and glutamine transaminase K is well documented (Abraham, D. G. and Cooper, A. J. L.; Analytical Biochem., 197:421-427, 1991), there are no reports indicating identity of kynurenine transaminase K neither with β-lyase nor with glutamine transaminase K.
SUMMARY OF THE INVENTION
We now report the cloning of rat kynurenine aminotransferases.
A first aspect of the present invention are isolated DNA sequences encoding KAT enzyme selected from the group consisting of:(a) isolated DNA sequence which encodes rat KAT; (b) isolated DNA sequence which hybridizes to isolated DNA sequence of (a) above and which encodes a KAT enzyme; and (c) isolated DNA sequence differing from the isolated DNA sequences of (a) and (b) above in codon sequence due to the degeneracy of the genetic code, and which encodes a KAT enzyme.
A second aspect of the present invention are vectors comprising a cloned DNA sequence as given above.
A third aspect of the present invention are host cells transformed with a vector as given above.
A fourth aspect of the present invention is an oligonucleotide probe capable of selectively hybridizing to a DNA comprising a portion of a gene coding for a KAT enzyme.
A fifth aspect of the present invention is isolated and purified KAT enzyme which is coded for by a DNA sequence selected from the group consisting of:(a) isolated DNA sequence which encodes rat KAT; (b) isolated DNA sequence which hybridizes to isolated DNA sequence of (a) above and which encodes a KAT enzyme; and (c) isolated DNA sequence differing from the isolated DNA sequences of (a) and (b) above in codon sequence due to the degeneracy of the genetic code, and which encodes a KAT enzyme.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 cytosolic enzyme activities in transfected COS-1 cells: A, glutamine transaminase K activity; B, kynurenine transaminase activity. Sense: PSVL-KAT transfected COS-1 cells where cDNA-1 is in the sense orientation. Antisense: pSVL-KAT transfected COS-1 cells where cDNA-1 is in reverse orientation. Each value is the mean of three separate experiments.
DETAILED DESCRIPTION OF THE INVENTION
Amino acid sequences disclosed herein are presented in the amino to carboxy direction, from left to right. The amino and carboxy groups are not presented in the sequence. Nucleotide sequences are presented herein by single strand only, in the 5' to 3' direction, from left to right. Nucleotides and amino acids are represented herein in the manner recommended by the IUPAC-IUB Biochemical Nomenclature Commission, or (for amino acids) by three letter code.
The rat kynurenine aminotransferase enzyme of the present invention includes proteins homologous to, and having essentially the same biological properties as, the protein coded for by the nucleotide sequences herein disclosed. This definition is intended to encompass natural allelic variants of KAT sequence.
Cloned genes of the present invention may code for KAT of any species of origin, but preferably code for enzymes of mammalian origin. Thus, DNA sequences which hybridize to the sequences given in (SEQ ID NO:5) and (SEQ ID NO:6) and which code for expression of KAT are also an aspect of this invention. Conditions which will permit other DNA sequences which code for expression of KAT to hybridize to the sequences given in (SEQ ID NO:5) and (SEQ ID NO:6) can be determined in a routine manner. Further, DNA sequences which code for polypeptides coded for by the sequences given in (SEQ ID NO:5) and (SEQ ID NO:6) or sequences which hybridize thereto and code for a KAT enzyme, but which differ in codon sequence from these due to degenerancy of the genetic code, are also an aspect of this invention. The degenerancy of the genetic code, which allows different nucleic acid sequences to code for the same protein or peptide, is well known in the literature. See e.g. U.S. Pat. No. 4,757,006 to Toole et al. at Col. 2, Table 1.
DNA which encodes the KAT enzyme may be obtained by a variety of means well known to the expert in the art and disclosed by, for example, Maniatis et al., Molecular cloning: a laboratory manual, Second Edition, Cold Spring Harbor Press, Cold Spring Harbor, N.Y. (1989).
For example, DNA which encodes the KAT enzyme may be obtained by screening of mRNA or genomic DNA with oligonucleotide probes generated from the KAT enzyme gene sequence information provided herein. Probes may be labeled with a detectable group such as a fluorescent group, a radioactive atom or a chemiluminescent group in accordance with known procedures and used in conventional hybridization assays, as described by, for example, Maniatis et al., Molecular cloning: a laboratory manual, Second Edition, Cold Spring Harbor Press, Cold Spring Harbor, N.Y. (1989).
KAT gene sequences may alternatively be recovered by use of the polymerase chain reaction (PCR) procedure, with the PCR oligonucleotide primers described herein or with oligonucleotide primers being produced from the KAT enzyme sequences provided herein. See U.S. Pat. Nos. 4,683,195 to Mullis et al. and U.S. Pat. No. 4,683,202 to Mullis. The PCR reaction provides a method for selectively increasing the concentration of a particular nucleic acid sequence even when that sequence has not been previously purified and is present only in a single copy in a particular sample. The method can be used to amplify either single- or double-stranded DNA. The essence of the method involves the use of two oligonucleotide probes to serve as primers for the template-dependent, polymerase mediated replication of a desired nucleic acid molecule.
The recombinant DNA molecules of the present invention can be produced through any of a variety of means well known to the expert in the art and disclosed by, for example, Maniatis et al., Molecular cloning: a laboratory manual, Second Edition, Cold Spring Harbor Press, Cold Spring Harbor, N.Y. (1989). In order to replicate the KAT enzyme DNA sequences, these must be cloned in an appropriate vector. A vector is a replicable DNA construct. Vectors are used herein either to amplify DNA encoding the KAT enzyme and/or to express DNA which encodes the KAT enzyme. An expression vector is a replicable DNA construct in which a DNA sequence encoding the KAT enzyme is operably linked to suitable control sequences capable of effecting the expression of the KAT enzyme in a suitable host. DNA regions are operably linked when they are functionally related to each other. For example: a promoter is operably linked to a coding sequence if it controls the transcription of the sequence. Amplification vectors do not require expression control domains. All that is needed is the ability to replicate in a host, usually conferred by an origin of replication, and a selection gene to facilitate recognition of transformants.
DNA sequences encoding KAT enzyme may be recombined with vector DNA in accordance with conventional techniques, including blunt-ended or staggered-ended termini for ligation, restriction enzyme digestion to provide appropriate termini, filling in of cohesive ends as appropriate, alkaline phosphatase treatment to avoid undesiderable joining, and ligation with appropriate ligases. Techniques for such manipulation are disclosed by Maniatis et al., Molecular cloning: a laboratory manual, Second Edition, Cold Spring Harbor Press, Cold Spring Harbor, N.Y. (1989) and are well known in the art.
Expression of the cloned sequence occurs when the expression vector is introduced into an appropriate host cell. If a prokaryotic expression vector is employed, then the appropriate host cell would be any prokaryotic cell capable of expressing the cloned sequences, for example E. coli. Similarly, if an eukaryotic expression vector is employed, then the appropriate host cell would be any eukaryotic cell capable of expressing the cloned sequence. A yeast host may be employed, for example S. cerevisiae. Alternatively, insect cells may be used, in which case a baculovirus vector system may be appropriate. Another alternative host is a mammalian cell line, for example cos-1 cells.
The need for control sequences into the expression vector will vary depending upon the host selected and the transformation method chosen. Generally, control sequences include a transcriptional promoter, an optional operator sequence to control transcription, a sequence encoding suitable mRNA ribosomal binding sites, and sequences which control the termination of transcription and translation. Vectors useful for practicing the present invention include plasmids, viruses (including phages), retroviruses, and integrable DNA fragments (i.e. fragments integrable into the host genome by homologous recombinantion). The vectors replicate and function independently of the host genome, or may, in some instances, integrate into the genome itself. Expression vectors should contain a promoter which is recognized by the host organism. The promoter sequences of the present invention may be either prokaryotic, eukaryotic or viral. Example of suitable prokaryotic sequences include the P R and P L promoters of bacteriophage lambda (The Bacteriophage Lambda, Hershey, A. D., Ed., Cold Spring Harbor Press, Cold Spring Harbor, N.Y. (1973); Lambda II, Hendrix, R. W., Ed., Cold Spring Harbor Press, Cold Spring Harbor, N.Y. (1980)); the trp, recA, heat shock, and lacZ promoters of E. coli and the SV40 early promoter (Benoist, C. et al. Nature 290: 304-310 (1981)).
As far as the Shine-Dalgarno sequence is concerned, preferred examples of suitable regulatory sequences are represented by the Shine-Dalgarno of the replicase gene of the phage MS-2 and of the gene cII of bacteriophage lambda. The Shine-Dalgarno sequence may be directly followed by the DNA encoding KAT and result in the expression of the mature KAT protein.
Alternatively, the DNA encoding KAT may be preceded by a DNA sequence encoding a carrier peptide sequence. In this case, a fusion protein is produced in which the N-terminus of KAT is fused to a carrier peptide, which may help to increase the protein expression levels and intracellular stability, and provide simple means of purification. A preferred carrier peptide includes one or more of the IgG binding domains of Staphylococcus protein A. Fusion proteins comprising IgG binding domains of protein A are easily purified to homogeneity by affinity chromatography e.g. on IgG-coupled Sepharose. A DNA sequence encoding a recognition site for a proteolytic enzyme such as enterokinase, factor X or procollagenase may immediately precede the sequence for KAT to permit cleavage of the fusion protein to obtain the mature KAT protein.
Moreover, a suitable expression vector includes an appropriate marker which allows the screening of the transformed host cells. The transformation of the selected host is carried out using any one of the various techniques well known to the expert in the art and described in Maniatis et al., Molecular cloning: a laboratory manual, Second Edition, Cold Spring Harbor Press, Cold Spring Harbor, N.Y. (1989).
One further embodiment of the invention is a prokaryotic host cell transformed with the said expression vector and able to produce, under appropriate culture conditions, the KAT of the invention.
Cultures of cells derived from multicellular organisms are a desiderable host for recombinant KAT synthesis. In principal, any eukaryotic cell culture is workable, whether from vertebrate or invertebrate culture, including insect cells. Propagation of such cells in cell culture has become a routine procedure. See Tissue Culture, Academic Press, Kruse and Patterson, eds. (1973). Examples of useful host cell lines are HeLa cells, CHO and COS cell lines. The transcriptional and translational control sequences in expression vectors to be used in transforming vertebrate and invertebrate cells are often provided by viral sources. For example, commonly used promoters are derived from Adenovirus 2, polyoma and SV40. See, e. g. U.S. Pat. No. 4,599,308.
An origin of replication may be provided either by construction of the vector to include an exogenous origin or may be provided by the host cell chromosomal replication mechanism. If the vector is integrated into the host cell chromosome, the latter may be sufficient.
Rather than using vectors which contain viral origins of replication, one can transform mammalian cells by the method of cotransformation with a selectable marker and the KAT DNA. An example of a suitable marker is dihydrofolate reductase (DHFR) or thymidine kinase. See U.S. Pat. No. 4,399,216.
Cloned genes and vectors of the present invention are useful to transform cells which do not ordinarly express KAT to thereafter express this enzyme. Such cells are useful as intermediates for making recombinant KAT preparations useful for drug screening.
Moreover, genes and vectors of the present invention are useful in gene therapy. For such purposes, adenovirus vectors as well as retroviral vectors as described in U.S. Pat. No. 4,650,764 to Temin and Watanabe or U.S. Pat. No. 4,861,719 to Miller may be employed.
Cloned genes of the present invention, and oligonucleotides derived therefrom, are useful for screening for restriction fragment length polymorphism (RFLP) associated with certain disorders.
Oligonucleotides of the present invention are useful as diagnostic tools for probing KAT gene expression in various tissues. For example, tissue can be probed in situ with oligonucleotide probes carrying detectable groups by conventional autoradiography techniques to investigate native expression of this enzyme or pathological conditions relating thereto.
Genetically modified (transfected) cells have been successfully used for cerebral implantation. Cells transfected with the KAT gene can be useful for delivering kynurenic acid (or any other KAT product; see below) to the brain. This may prove to be an attractive means to circumvent the blood-brain barrier for kynurenic acid through peripheral administration of kynurenine (or any appropriate substrate of KAT; see below).
Transfected cells expressing large quantities of KAT are also useful for the production of neuroactive kynurenic analogs. For example, KAT is capable of forming the potent NMDA receptor antagonist and neuroprotectant 7- chlorokynurenic acid from its bioprecursor L-4-chlorokynurenine (J. Med. Chem., 37, 334-336, 1994).
The present invention is explained in greater detail in the following examples. These examples are intended to be illustrative of the present invention, and should not be constructed as limiting thereof.
EXAMPLE 1
Amino Acid Sequence of Tryptic Fragments of the Rat KAT
Protein Purification
Rat KAT was prepared essentialy as described by Okuno et al. Brain Res., 534, 37-44, 1990. The enzyme eluted from a Sephacryl S-200 column was separated by HPLC on a reverse-phase column (SC18, 250×4.6 mm, Japan Spectro. Co. Ltd). Elution was performed with a gradient of solvent A (70% (vol/vol) acetonitrile in 0.1% trifluoroacetic acid (TFA)) and solvent B (0.1% TFA) applied for 40 min at a flow rate of 1 ml/min.
Trypsin and CNBr Digestion and Fragment Purification
500 pmoles of HPLC-purified rat KAT sample were digested by trypsin as described (T. E. Hughi --eds.-- In: Techniques in protein chemistry, ACADEMIC PRESS, INC., p. 377-391, 1989) and by CNBr. These samples were subjected to reverse-phase HPLC after digestion and the resulting peaks collected.
Amino Acid Sequence Analysis
Sequence analysis was performed essentialy as described (Fabbrini et al. FEBS Lett., 286, 91-94, 1991). SEQ ID NO:1 shows the partial amino acid sequence of rat KAT: N-terminus of mature KAT SEQ ID NO:1, a CNBr fragment SEQ ID NO2, tryptic fragment 112 of KAT (SEQ ID NO3), and tryptic fragment 130 of KAT (SEQ ID NO:4).
EXAMPLE 2
Polymerase Chain Reaction (PCR) Cloning
RNA Extraction
Total RNA from rat kidney was extracted from small quantities of tissue according to the instruction of RNAzol™ method (RNAzol-Cinna/Biotex Lab, Tex., USA).
First Strand cDNA Synthesis
First strand cDNA was synthesized from 3 mg of total RNA using 2 mg oligo polydT (18 pb), 4 ml of dNTP (2.5 mM), 8 ml of AMV buffer (TrisHCl pH8.8 250 mM/KCl 200 mM/MgCl 2 50 mM/DTT 20 mM) in a final volume of 38.75 ml. The solution was boiled for 3 minutes at 65° C. and throw in ice for 10 minutes; 0.75 ml of RNAsin (40 u/ml Promega) and 0.5 ml of AMV Reverse trascriptase (25 u/ml Boehringer Mannheim,GmbH, Germany) were added to the cold solution. The reaction was carried on at 42° C. for 2 h.
Design and Synthesis of Degenerated Oligionucleotides
Since the relative position of tryptic fragments 112 and 130, along the rat KAT primary structure, was unknown four degenerated oligonucleotides 26 bp long were designed and synthesized using a DNA/RNA synthesizer 380B Applied Biosystems. The product of the reaction was purified on Sephadex G50 (Nap 25 Column, Pharmacia).
The sense orientation oligonucleotide, OligoA: (AAYYTNTGYCARCARC AYGAYGTNGT) (SEQ ID NO:7) and the anti-sense orientation oligonucleotide, OligoC: (ACNACRTCRTGYTGYTGRCANARRTT) (SEQ ID NO:8) based on the peptide sequence Asn-Leu-Cys-Gln-Gln-His-Asp-Val-Val (residues 7-15 of fragment 130 (SEQ ID NO:4)) while the sense orientation oligonucleotide, OligoB: (ACNGANARRTTYTGRTCX ATNCCRTC) (SEQ ID NO:9) and the corresponding anti-sense oligonucleotide, OligoD: (GAYGGNATZGAYCARAAYYTNTCNGT) (SEQ ID NO:10) based on the peptide sequence Asp-Gly-Ile-Asp-Gln-Asn-Leu-Ser-Val (residues 3-11 of fragment 112) (SEQ ID NO:3) (N=T/C/A/G; Z=T/C/A; R=A/G; Y=T/C; X=T/G/A) were synthesized.
Polymerase Chain Reaction Condition
The first strand cDNA was divided in two aliquotes and amplified by PCR as described below. The two oligonucleotide, mixture PCR1: oligoA and oligoD and PCR2 oligo B and oligoC were used as primer in the PCR reaction. 70 ng of template CDNA were combined with 10 mg of each set of primers, 10 ml of 10× Taq polymerase buffer (500 mM KCl/100 mM Tris-HC1, pH 8.3), 8 ml of 25 mM MgCl 2 , 18 ml of a dNTP solution (2.5 mM dNTP) and 0.5 ml (2.5 units) of Taq DNA polymerase (Perkin Elmer Cetus). The volume was brought to 100 ml with H 2 O and the mixture was overlayed with mineral oil to prevent evaporation. The tube was heated to 94° C. for 3 minutes, denaturation was carried out for 3 minutes at 94° C., annealing for 2 min at 60° C. and polymerization for 2 minutes and 30 seconds at 72° C. The cycle was repeated 30 times.
A specific amplification product was observed only with PCR1. The product of the amplification was a DNA molecule of about 550 bp. The PCR1-amplification product was re-amplified using a new set of oligos, basically with the same sequence of oligoA and oligoC with SalI linkers and 5'-extra nucleotides. OligoE: (GCTAGTCGACACNACRTCRTGYTGYTGRCANARRTT) (SEQ ID NO:11) complementary to nucleotides coding for peptide 130 (SEQ ID NO:4) and oligoF: (GATCGTCGACGAYGGNATZGAYCARAAYYTNTCNGT) (SEQ ID NO:12) corresponding to nucleotides coding for peptide 112, (SEQ ID NO:3).
After PCR amplification the resulting DNA fragment was digested overnight with the restriction enzyme Sal1 and ligated to the Sal1 site of the cloning plasmid pUC 18 (Yanisch-Perron, C. et al.; Gene, 33:103-119, 1985). The recombinant plasmid was extracted according to the instruction of the Qiagen Plasmid Maxi Protocol; precipitated with PEG and denaturated with NaOH 2N.
Sequencing was carried out with universal and forward primer and subsequently with a series of synthetic oligonucleotide primers according to the dideoxy chain termination method (F. Sanger et al. Proc. Natl. Acad. Sci. USA 74, 5463-5467 (1977) using Sequenase (United States Biochemicals Corp., Cleveland, Ohio).
Both strands of the insert were sequenced revealing an open reading frame of 196 amino acids. Part of the two rat KAT peptides that were sequenced are coded for the corresponding 588 bp open reading frame. This open reading frame is used as probe in the cDNA library screening described in Example 3.
EXAMPLE 3
cDNA Library Screening
About 500,000 recombinant phages of λgt11 rat kidney cDNA library (Clontec Laboratories, USA) were plated on a lawn of E. coli Y1090 cells. After an overnight growth at 37° C. the recombinant phages were transferred in duplicate nitrocellulose filters, their DNA was denatured, neutralized and baked under vacuum at 80° C. for 2 h. Prehybridization was carried out at 60° C. for 4 h in 6xSSC (1X SSC: ), 5x Denhardt's (1X Denhardt: ), 1% SDS, 200 ug/ml salmon sperm DNA. The filters were then hybridized overnight at 60° C. in the same mixture with the addition of about 1.5×10 6 cpm/ml of labeled probe (see Example 2). The probe was labeled with ( 32 p) dCTP by Multiprime DNA labelling system (Amersham), purified on Nick Column (Pharmacia) and added to the hybridizing solution. The filters were washed at 60° C. twice in 2xSSC, 0.1% SDS and ones in 1xSSC, 1%SDS. Filters were exposed to Kodak X-AR film (Eastman Kodak Company, Rochester, N.Y., USA) with intensifying screen at -80° C.
Positive phage plaques were isolated and screened again twice in order to isolate single clones.
Recombinant Phage DNA Extraction and Sequencing Methods
About 50,000 phages of each positive clone were plated on a lawn of E. coli Y1090 cells. After an overnight growth at 37° C. phages were resuspended in SM buffer (100 mM NaCl/8 mM MgSO 4 /50 mM Tris-HCl, pH 7.5 /gelatin 0.001%) and chloroform 0.3%; the suspension was treated with 1 mg of RNAse and 1 mg of DNAse. Phage DNA was precipitated with PEG 10%/1M NaCl, extracted with phenol and phenol:chloroform:iso-amyl alcohol and precipitated with PEG again.
The phage DNA was digested with EcoRI and the insert was ligated to the EcoRI site of pUC18.
The recombinant plasmid was extracted according to the instruction of Qiagen Plasmid Maxi Protocol; precipitated with PEG and denaturated with 2N NaOH .
Sequencing was carried out with universal and forward primer and subsequently with a series of synthetic oligonucleotide primers according to the dideoxy chain termination method (F. Sanger et al. Proc. Natl. Acad. Sci. USA 74, 5463-5467 (1977)) using Sequenase (United States Biochemicals Corp., Cleveland, Ohio).
Two positive clones were isolated, cDNA-1 and CDNA-2. Both strands of the two CDNAs were sequenced. (see SEQ ID NO:5 and 6).
CDNA-1 encodes a deduced protein of 423 amino acid residues whereas cDNA-2 encodes a deduced protein of 437 amino acid residues.
The two deduced proteins differ only in their N-terminus Moreover, the cDNA-2 clone is not homogeneous, since an alternative 5' sequence introduces an upstream ATG starting codon. The two alternative protein sequences predicted by the cDNA-2 clone are both illustrated in SEQ ID NO:6.
As already said, the 437 amino acids long protein deduced from the cDNA-2 clone presents a putative mitochondrial transit peptide in position 1 to 24 which is only partially present in the 423 amino acid long protein.
EXAMPLE 4
Expression in Mammalian Cells
The expression plasmid encoding rat KAT was constructed as follows. a) To remove the 5' and the 3' untranslated sequences, as well as the putative mitochondrial targeting peptide, PCR amplification was performed using two specific oligonucleotides with XhoI linkers. The sense orientation oligonucleotide
(5'-TGTCCTCGAGACCATGACCAAACGGCTGCAGGCTCGGA-3') (SEQ ID NO:13) begins at +241 of cDNA-1, whereas the antisense-orientation oligonucleotide(5'-GTACCTCGAGTCAGGGTTGGAGCTCTTTCCACTTG-3') (SEQ ID NO:14) complements the sequence starting from the end of the coding sequence. The XhoI-digested fragment, after being controlled by sequencing, was cloned into the XhoI site of pSVL expression vector (Pharmacia Biotechnology). COS-1 cells were transfected with 10 ug of PSVL-KAT plasmid by calcium phosphate method (Maniatis et al., Molecular cloning: a laboratory manual, Second Edition, Cold Spring Harbor Press, Cold Spring Harbor, N.Y. (1989)). 72 hours after transfection, cells were disrupted by freezing and thawing and after centrifugation the supernatant was used for KAT and glutamine transaminase K activities.
EXAMPLE 5
Kynurenine Amino Transferase and Glutamine Amino Transferase K Activities
Kynurenine Transaminase Assay
The reaction mixture (100 ul) contained 70 uM pyridoxal phosphate, 5 mM pyruvate, 3 mM kynurenine, and KAT sample in 0.17 M potassium phosphate buffer, pH 8.1, and was incubated at 37° C. for 30 min and 1 h. Reaction was stopped by adding 20 ul TCA 50% and the precipitate was removed by centrifugation. The supernatant was analyzed by HPLC with a C18 column (Vydac 201TP54, 25×4.6 cmxmm) at 1 ml/min, equilibrated with 5 mM acetic acid, 5% methanol, 0.1% heptane sulfonic acid, pH 3.0, and kynurenic acid was eluted with 50 mM acetic acid, 5% methanol, 0.5% heptane sulfonic acid, pH 4.5. Absorbance at 243 nm was measured.
Glutamine Transaminase K Assay
Glutamine transaminase K activity was measured as described by Cooper and Meister (Methods Enzymol., 113, 344-349, 1985).
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 14(2) INFORMATION FOR SEQ ID NO:1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 23 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:LeuGlnAlaXaaXaaLeuAspGlyIleAspGlnAsn1510LeuXaaValGluPheGlyLysThrXaaGluTyr1520(2) INFORMATION FOR SEQ ID NO:2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 16 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:XaaXaaLeuProGlyAlaGluAspGlyProTyr1510AspArgArgXaaAla15(2) INFORMATION FOR SEQ ID NO:3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 14 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:3:ArgLeuAspGlyIleAspGlnAsnLeu15SerValGluPheGly10(2) INFORMATION FOR SEQ ID NO:4:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 31 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:4:XaaGluLeuGluLeuValAlaAsnLeuCysGlnGln1510HisAspValCysIleSerAspGluValTyrGlnGln1520ValTyrAspLeuGlyHisGln2530(2) INFORMATION FOR SEQ ID NO:5:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 1893 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: DNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:5:AAACTGACCAAGGAGTATGATCAATCCCGTCCAGCCTCCGAGCCTGCAGC50CGTTTGGTCATGGTGAGCTGCTTCAGCTAACAATTGCACTGACAGTGCTC100TTGAGCCAAGTTGCTTCTGGGCGGAAGTAGTCCATCTAGGGCTCGGCCTC150TTTAAAGAAACAGACTTCTGCAACCTTGGGACTACGTTTGGGGTCGCCGG200CTATTGGACGGAGCAGCGCAATTGTTAGCTGAAGCAGCTCACCATGACC249MetThrAAACGGCTGCAGGCTCGGAGGCTGGACGGGATTGATCAAAAC291LysArgLeuGlnAlaArgArgLeuAspGlyIleAspGlnAsn51015CTCTGGGTGGAGTTTGGCAAACTGACCAAGGAGTATGACGTC333LeuTrpValGluPheGlyLysLeuThrLysGluTyrAspVal202530GTGAACTTGGGTCAGGGCTTCCCTGACTTCTCGCCTCCGGAC375ValAsnLeuGlyGlnGlyPheProAspPheSerProProAsp3540TTTGCAACGCAAGCTTTTCAGCAGGCTACCAGTGGGAACTTC417PheAlaThrGlnAlaPheGlnGlnAlaThrSerGlyAsnPhe455055ATGCTCAACCAGTACACCAGGGCATTTGGTTACCCACCACTG459MetLeuAsnGlnTyrThrArgAlaPheGlyTyrProProLeu606570ACAAACGTCCTGGCAAGTTTCTTTGGCAAGCTGCTGGGACAG501ThrAsnValLeuAlaSerPhePheGlyLysLeuLeuGlyGln758085GAGATGGACCCACTCACGAATGTGCTGGTGACAGTGGGTGCC543GluMetAspProLeuThrAsnValLeuValThrValGlyAla9095100TATGGGGCCTTGTTCACAGCCTTTCAGGCCCTGGTGGATGAA585TyrGlyAlaLeuPheThrAlaPheGlnAlaLeuValAspGlu105110GGAGATGAGGTCATCATCATGGAACCTGCTTTTGACTGTTAT627GlyAspGluValIleIleMetGluProAlaPheAspCysTyr115120125GAACCCATGACAATGATGGCTGGAGGTTGCCCTGTGTTCGTG669GluProMetThrMetMetAlaGlyGlyCysProValPheVal130135140ACTCTGAAGCCGAGCCCTGCTCCTAAGGGGAAACTGGGAGCC711ThrLeuLysProSerProAlaProLysGlyLysLeuGlyAla145150155AGCAATGATTGGCAACTGGATCCTGCAGAACTGGCCAGCAAG753SerAsnAspTrpGlnLeuAspProAlaGluLeuAlaSerLys160165170TTCACACCTCGCACCAAGGTCCTGGTCCTCAACACACCCAAC795PheThrProArgThrLysValLeuValLeuAsnThrProAsn175180AACCCTTTAGGAAAGGTATTCTCTAGGATGGAGCTGGAGCTG837AsnProLeuGlyLysValPheSerArgMetGluLeuGluLeu185190195GTGGCTAATCTGTGCCAGCAGCACGATGTCGTGTGCATCTCT879ValAlaAsnLeuCysGlnGlnHisAspValValCysIleSer200205210GATGAGGTCTACCAGTGGCTGGTCTATGACGGGCACCAGCAC921AspGluValTyrGlnTrpLeuValTyrAspGlyHisGlnHis215220225GTCAGCATCGCCAGCCTCCCTGGCATGTGGGATCGGACCCTG963ValSerIleAlaSerLeuProGlyMetTrpAspArgThrLeu230235240ACCATCGGCAGTGCAGGCAAAAGCTTCAGTGCCACTGGCTGG1005ThrIleGlySerAlaGlyLysSerPheSerAlaThrGlyTrp245250AAGGTGGGCTGGGTCATGGGTCCAGATAACATCATGAAGCAC1047LysValGlyTrpValMetGlyProAspAsnIleMetLysHis255260265CTGAGGACAGTGCACCAGAATTCTATCTTCCACTGCCCCACC1089LeuArgThrValHisGlnAsnSerIlePheHisCysProThr270275280CAGGCCCAGGCTGCAGTAGCCCAGTGCTTTGAGCGGGAGCAG1131GlnAlaGlnAlaAlaValAlaGlnCysPheGluArgGluGln285290295CAACACTTTGGACAACCCAGCAGCTACTTTTTGCAGCTGCCA1173GlnHisPheGlyGlnProSerSerTyrPheLeuGlnLeuPro300305310CAGGCCATGGAGCTGAACCGAGACCACATGATCCGTAGCCTG1215GlnAlaMetGluLeuAsnArgAspHisMetIleArgSerLeu315320CAGTCAGTGGGCCTCAAGCTCTGGATCTCCCAGGGGAGCTAC1257GlnSerValGlyLeuLysLeuTrpIleSerGlnGlySerTyr325330335TTCCTCATTGCAGACATCTCAGACTTCAAGAGCAAGATGCCT1299PheLeuIleAlaAspIleSerAspPheLysSerLysMetPro340345350GACCTGCCCGGAGCTGAGGATGAGCCTTATGACAGACGCTTT1341AspLeuProGlyAlaGluAspGluProTyrAspArgArgPhe355360365GCCAAGTGGATGATCAAAAACATGGGCTTGGTGGGCATCCCT1383AlaLysTrpMetIleLysAsnMetGlyLeuValGlyIlePro370375380GTCTCCACATTCTTCAGTCGGCCCCATCAGAAGGACTTTGAC1425ValSerThrPhePheSerArgProHisGlnLysAspPheAsp385390CACTACATCCGATTCTGTTTTGTCAAGGACAAGGCCACACTC1467HisTyrIleArgPheCysPheValLysAspLysAlaThrLeu395400405CAGGCCATGGATGAGAGACTGCGCAAGTGGAAAGAGCTCCAA1509GlnAlaMetAspGluArgLeuArgLysTrpLysGluLeuGln410415420CCCTGAGGAGGCTGCCCTCAGCCCCACCTCGAACACAGGCCTCAGCTATGCCT1562ProTAGCACAGGGATGGCACTGGAGGGCCCAGCTGTGTGACTGCGCATGTTTC1612CAGAAAAGAGGCCATGTCTTGGGGGTTGAAGCCATCCTTTCCCAGTGTCC1662ATCTGGACTATTGGGTTGGGGGCCAGTTCTGGGTCTCAGCCTACTCCTCT1712GTAGGTTGCCTGTAGGGTTTTGATTGTTTCTGGCCTCTCTGCCTGGGGCA1762GGAAAGGGTGGAATATCAGGCCCGGTACCACCTTAGCCCTGCCGAGGCTC1812TGTGGCTTCTCTACATCTTCTCCTGTGACCTCAGGATGTTGCTACTGTTC1862CTAATAAAGTTTTAAGTTATTAGGACCCTCA1893(2) INFORMATION FOR SEQ ID NO:6:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 2304 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: DNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:6:GGGCGACTCTAGATTTTTTTTTTTTTTTACCTTCTACCTTTTATTGTCAC50GTGAACCATGGTCCTACAGGCTGCTGACAAGCTTGGCTGAGCAGGGATCC100CAGGGGCGTCGGCAGGAGATGAGGAAGGGTTGCTGGGAGGGCTTGGCCTC150TTCCTTGAGAAGACAGCAAATGTATCCAGCCTAGATTAAGGGTAGGGCAT200CCCCTATCCCTGTCAGTGGGCCTAGATCTCAGAGCCCCACATTAAAGACT250GCTAATGGGTCAGAAATGGGGGTCCCTTAGATGGGGGTAGGCAGCAAGGC300CCTCCCTCCAGTGTTCTCATTCTGTTCCGGTTTCATTTGTTGTGTCCAGG350GACGGTGAAGCAGATACCAGTCTCAAGCCCCAGGGTGCAGGAAGACGGGA400AATGGGAAAATGGAAACATTCTTCAAGTGACCAGAGCACTCTGCCGGGGA450CAAAAGACTTTGCCTTGAACGCGTAGTGGAGAAGCTACAAACCCCAGGTC500CCAGTGGCCTGATTGACTTAGGGTCTCAGCTGGCCCAAAACTCAGTGTGT550AGATCAGACTGATCTCAAACTCACAGAGATCTCCCTGCCTTTGCCTGCTG600AGTCCTGGGATTAAAGGCATGAATCACAGTACCTGGTGCCTTTTC645MetAsnHisSerThrTrpCysLeuPhe15TTTAAAAAGCTCACCATGACCAAACGGCTGCAGGCTCGGAGG687PheLysLysLeuThrMetThrLysArgLeuGlnAlaArgArg101520MetThrLysArgLeuGlnAlaArgArg110CTGGACGGGATTGATCAAAACCTCTGGGTGGAGTTTGGCAAA729LeuAspGlyIleAspGlnAsnLeuTrpValGluPheGlyLys253040LeuAspGlyIleAspGlnAsnLeuTrpValGluPheGlyLys152025CTGACCAAGGAGTATGACGTCGTGAACTTGGGTCAGGGCTTC771LeuThrLysGluTyrAspValValAsnLeuGlyGlnGlyPhe455055LeuThrLysGluTyrAspValValAsnLeuGlyGlnGlyPhe303540CCTGACTTCTCGCCTCCGGACTTTGCAACGCAAGCTTTTCAG813ProAspPheSerProProAspPheAlaThrGlnAlaPheGln606570ProAspPheSerProProAspPheAlaThrGlnAlaPheGln455055CAGGCTACCAGTGGGAACTTCATGCTCAACCAGTACACCAGG855GlnAlaThrSerGlyAsnPheMetLeuAsnGlnTyrThrArg7580GlnAlaThrSerGlyAsnPheMetLeuAsnGlnTyrThrArg6065GCATTTGGTTACCCACCACTGACAAACGTCCTGGCAAGTTTC897AlaPheGlyTyrProProLeuThrAsnValLeuAlaSerPhe809095AlaPheGlyTyrProProLeuThrAsnValLeuAlaSerPhe707580TTTGGCAAGCTGCTGGGACAGGAGATGGACCCACTCACGAAT939PheGlyLysLeuLeuGlyGlnGluMetAspProLeuThrAsn100105110PheGlyLysLeuLeuGlyGlnGluMetAspProLeuThrAsn859095GTGCTGGTGACAGTGGGTGCCTATGGGGCCTTGTTCACAGCC981ValLeuValThrValGlyAlaTyrGlyAlaLeuPheThrAla115120125ValLeuValThrValGlyAlaTyrGlyAlaLeuPheThrAla100105110TTTCAGGCCCTGGTGGATGAAGGAGATGAGGTCATCATCATG1023PheGlnAlaLeuValAspGluGlyAspGluValIleIleMet130135140PheGlnAlaLeuValAspGluGlyAspGluValIleIleMet115120125GAACCTGCTTTTGACTGTTATGAACCCATGACAATGATGGCT1065GluProAlaPheAspCysTyrGluProMetThrMetMetAla145150GluProAlaPheAspCysTyrGluProMetThrMetMetAla130135GGAGGTTGCCCTGTGTTCGTGACTCTGAAGCCGAGCCCTGCT1107GlyGlyCysProValPheValThrLeuLysProSerProAla155160165GlyGlyCysProValPheValThrLeuLysProSerProAla140145150CCTAAGGGGAAACTGGGAGCCAGCAATGATTGGCAACTGGAT1149ProLysGlyLysLeuGlyAlaSerAsnAspTrpGlnLeuAsp170175180ProLysGlyLysLeuGlyAlaSerAsnAspTrpGlnLeuAsp155160165CCTGCAGAACTGGCCAGCAAGTTCACACCTCGCACCAAGGTC1191ProAlaGluLeuAlaSerLysPheThrProArgThrLysVal185190195ProAlaGluLeuAlaSerLysPheThrProArgThrLysVal170175180CTGGTCCTCAACACACCCAACAACCCTTTAGGAAAGGTATTC1233LeuValLeuAsnThrProAsnAsnProLeuGlyLysValPhe200205210LeuValLeuAsnThrProAsnAsnProLeuGlyLysValPhe185190195TCTAGGATGGAGCTGGAGCTGGTGGCTAATCTGTGCCAGCAG1275SerArgMetGluLeuGluLeuValAlaAsnLeuCysGlnGln215220SerArgMetGluLeuGluLeuValAlaAsnLeuCysGlnGln200205CACGATGTCGTGTGCATCTCTGATGAGGTCTACCAGTGGCTG1317HisAspValValCysIleSerAspGluValTyrGlnTrpLeu225230235HisAspValValCysIleSerAspGluValTyrGlnTrpLeu210215220GTCTATGACGGGCACCAGCACGTCAGCATCGCCAGCCTCCCT1359ValTryAspGlyHisGlnHisValSerIleAlaSerLeuPro240245250ValTryAspGlyHisGlnHisValSerIleAlaSerLeuPro225230235GGCATGTGGGATCGGACCCTGACCATCGGCAGTGCAGGCAAA1401GlyMetTrpAspArgThrLeuThrIleGlySerAlaGlyLys255260265GlyMetTrpAspArgThrLeuThrIleGlySerAlaGlyLys240245250AGCTTCAGTGCCACTGGCTGGAAGGTGGGCTGGGTCATGGGT1443SerPheSerAlaThrGlyTrpLysValGlyTrpValMetGly270275280SerPheSerAlaThrGlyTrpLysValGlyTrpValMetGly255260265CCAGATAACATCATGAAGCACCTGAGGACAGTGCACCAGAAT1485ProAspAsnIleMetLysHisLeuArgThrValHisGlnAsn285290ProAspAsnIleMetLysHisLeuArgThrValHisGlnAsn270275TCTATCTTCCACTGCCCCACCCAGGCCCAGGCTGCAGTAGCC1527SerIlePheHisCysProThrGlnAlaGlnAlaAlaValAla295300305SerIlePheHisCysProThrGlnAlaGlnAlaAlaValAla280285290CAGTGCTTTGAGCGGGAGCAGCAACACTTTGGACAACCCAGC1569GlnCysPheGluArgGluGlnGlnHisPheGlyGlnProSer310315320GlnCysPheGluArgGluGlnGlnHisPheGlyGlnProSer295300305AGCTACTTTTTGCAGCTGCCACAGGCCATGGAGCTGAACCGA1611SerTyrPheLeuGlnLeuProGlnAlaMetGluLeuAsnArg325330335SerTyrPheLeuGlnLeuProGlnAlaMetGluLeuAsnArg310315320GACCACATGATCCGTAGCCTGCAGTCAGTGGGCCTCAAGCTC1653AspHisMetIleArgSerLeuGlnSerValGlyLeuLysLeu340345350AspHisMetIleArgSerLeuGlnSerValGlyLeuLysLeu325330335TGGATCTCCCAGGGGAGCTACTTCCTCATTGCAGACATCTCA1695TrpIleSerGlnGlySerTyrPheLeuIleAlaAspIleSer355360TrpIleSerGlnGlySerTyrPheLeuIleAlaAspIleSer340345GACTTCAAGAGCAAGATGCCTGACCTGCCCGGAGCTGAGGAT1737AspPheLysSerLysMetProAspLeuProGlyAlaGluAsp365370375AspPheLysSerLysMetProAspLeuProGlyAlaGluAsp350355360GAGCCTTATGACAGACGCTTTGCCAAGTGGATGATCAAAAAC1779GluProTyrAspArgArgPheAlaLysTrpMetIleLysAsn380385390GluProTyrAspArgArgPheAlaLysTrpMetIleLysAsn365370375ATGGGCTTGGTGGGCATCCCTGTCTCCACATTCTTCAGTCGG1821MetGlyLeuValGlyIleProValSerThrPhePheSerArg395400405MetGlyLeuValGlyIleProValSerThrPhePheSerArg380385390CCCCATCAGAAGGACTTTGACCACTACATCCGATTCTGTTTT1863ProHisGlnLysAspPheAspHisTyrIleArgPheCysPhe410415420ProHisGlnLysAspPheAspHisTyrIleArgPheCysPhe395400405GTCAAGGACAAGGCCACACTCCAGGCCATGGATGAGAGACTG1905ValLysAspLysAlaThrLeuGlnAlaMetAspGluArgLeu425430ValLysAspLysAlaThrLeuGlnAlaMetAspGluArgLeu410415CGCAAGTGGAAAGAGCTCCAACCCTGAGGAGGCTGCCCTCAGCC1949ArgLysTrpLysGluLeuGlnPro435440ArgLysTrpLysGluLeuGlnPro420425CCACCTCGAACACAGGCCTCAGCTATGCCTTAGCACAGGGATGGCACTGG1999AGGGCCCAGCTGTGTGACTGCGCATGTTTCCAGAAAAGAGGCCATGTCTT2049GGGGGTTGAAGCCATCCTTTCCCAGTGTCCATCTGGACTATTGGGTTGGG2099GGCCAGTTCTGGGTCTCAGCCTACTCCTCTGTAGGTTGCCTGTAGGGTTT2149TGATTGTTTCTGGCCTCTCTGCCTGGGGCAGGAAAGGGTGGAATATCAGG2199CCCGGTACCACCTTAGCCCTGCCGAGGCTCTGTGGCTTCTCTACATCTTC2249TCCTGTGACCTCAGGATGTTGCTACTGTTCCTAATAAAGTTTTAAGTTAT2299TAGGA2304(2) INFORMATION FOR SEQ ID NO:7:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 26 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: DNA (synthetic)(xi) SEQUENCE DESCRIPTION: SEQ ID NO:7:AAYYTNTGYCARCARCAYGAYGTNGT26(2) INFORMATION FOR SEQ ID NO:8:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 26 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: DNA (synthetic)(xi) SEQUENCE DESCRIPTION: SEQ ID NO:8:ACNACRTCRTGYTGYTGRCANARRTT26(2) INFORMATION FOR SEQ ID NO:9:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 26 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: DNA (synthetic)(xi) SEQUENCE DESCRIPTION: SEQ ID NO:9:ACNGANARRTTYTGRTCDATNCCRTC26(2) INFORMATION FOR SEQ ID NO:10:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 26 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: DNA (synthetic)(xi) SEQUENCE DESCRIPTION: SEQ ID NO:10:GAYGGNATHGAYCARAAYYTNTCNGT26(2) INFORMATION FOR SEQ ID NO:11:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 36 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: DNA (synthetic)(xi) SEQUENCE DESCRIPTION: SEQ ID NO:11:GCTAGTCGACACNACRTCRTGYTGYTGRCANARRTT36(2) INFORMATION FOR SEQ ID NO:12:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 36 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: DNA (synthetic)(xi) SEQUENCE DESCRIPTION: SEQ ID NO:12:GATCGTCGACGAYGGNATHGAYCARAAYYTNTCNGT36(2) INFORMATION FOR SEQ ID NO:13:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 38 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: DNA (synthetic)(xi) SEQUENCE DESCRIPTION: SEQ ID NO:13:TGTCCTCGAGACCATGACCAAACGGCTGCAGGCTCGGA38(2) INFORMATION FOR SEQ ID NO:14:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 35 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: DNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:14:GTACCTCGAGTCAGGGTTGGAGCTCTTTCCACTTG35__________________________________________________________________________
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Disclosed are isolated DNAs encoding a kynurenine aminotransferase selected from the group consisting of: (a) an isolated DNA sequence which encodes rat KAT; (b) an isolated DNA sequence which hybridizes to the isolated DNA sequence of (a) above and which encodes a KAT enzyme; and (c) an isolated DNA sequence differing from the isolated DNA sequences of (a) and (b) above in codon sequence due to the degeneracy of the genetic code, and which encodes a KAT enzyme. Also disclosed are vectors and host cells containing the same; oligonucleotide probes for identifying kynurenine aminotransferase; and isolated and purified kynurenine aminotransferase.
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BACKGROUND OF THE INVENTION
Residential and commercial air conditioners include a condenser arranged externally of the building being cooled. A refrigerant is circulated through a coil in the condenser for heat exchange. During operation of the condenser, the coils become quite warm. The hotter the coils, the harder and longer the condenser must operate to cool the building. The present invention relates to a simple device for cooling the condenser coils by spraying a fine mist of water thereon during condenser operation.
BRIEF DESCRIPTION OF THE PRIOR
Air conditioning condenser unit cooling devices are well-known in the patented prior art as evidenced by the U.S. patents to Welker U.S. Pat. No. 4,542,627, Welker et al U.S. Pat. No. 4,685,308 and Faxon U.S. Pat. No. 4,170,117 and U.S. Pat. No. 4,240,265. The Welker et al patent U.S. Pat. No. 4,685,308, for example, discloses a temperature responsive air conditioner cooling apparatus which sprays water over the air conditioner coils. The apparatus uses a non-electrical temperature responsive valve for controlling the flow of the cooling water. A water treatment device is also provided which filters the nonevaporative components of the water before it is sprayed on the coils. The Faxon devices are also temperature responsive so that a spray mist is applied to the coils and fins of an air conditioner condenser only when predetermined temperature conditions exist.
While the prior devices normally operate satisfactorily, the fact that they are temperature responsive limits their effectiveness. Moreover, such devices have a tendency to spray the coils when the condenser is not in use, particularly if the ambient air temperature is above the threshold of the device. This results in waste of water and damage to the surrounding environment.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide an apparatus for cooling the coils of an air conditioning condenser including a fluid supply and a spray nozzle connected with the fluid supply and arranged adjacent the coils for spraying a fluid mist thereon. A valve is arranged between the fluid supply and the nozzle and is operable between open and closed positions to deliver and interrupt the flow of fluid from the supply. A valve control circuit is connected with the valve for opening the valve when the condenser is operating and for closing the valve when the condenser is not operating.
The valve control circuit is operated by a portable power source such as a battery, a solar collector or a combination of the two. The circuit includes a vibration transducer which senses vibrations of the condenser when the condenser is operating and produces control signals in response to the sensed vibrations. A pulse circuit is connected with the transducer and produces switching pulses used to open the valve when vibrations are sensed and to close the valve when vibrations are terminated.
BRIEF DESCRIPTION OF THE FIGURES
Other objects and advantages of the invention will become apparent from a study of the following specification when viewed in the light of the accompanying drawing, in which:
FIGS. 1 and 2 are perspective views illustrating the condenser coil cooling apparatus of the present invention mounted on differently configured condensers;
FIG. 3 is a perspective view of the condenser coil cooling apparatus of the invention including a plurality of spray nozzles for cooling large size condensers;
FIGS. 4 and 5 are top and bottom perspective views, respectively, of the housing of the cooling apparatus;
FIG. 6 is a partially exploded perspective view of the valve and valve control circuit arranged in the housing of the cooling apparatus; and
FIG. 7 is a partial cutaway view of a filter and fluid pressure reducing device for use with the cooling apparatus.
DETAILED DESCRIPTION
As shown generally in FIGS. 1-3, the condenser coil cooling apparatus 2 of the present invention includes a fluid supply line 4, which may be connected with a fluid source such as a water spigot, a housing 6 containing the fluid flow control mechanisms, and one or more spray nozzles 8 arranged at the end of a fluid outlet line 10 from the housing.
As shown in FIG. 5, the housing 6 has a plurality of magnets 12 connected with the bottom wall 14 thereof for removably connecting the housing with an metal surface. In the example shown in FIG. 1, the housing is placed vertically on a canister style condenser 16 while in FIG. 2, the housing is arranged horizontally on a rectangular condenser unit 18. In each embodiment, the magnets at the bottom of the housing connect the housing with the condenser unit. Of course, other mounting devices such as brackets may be used.
There is shown in FIG. 3 the cooling apparatus housing 6 mounted horizontally on a large commercial condenser 20. This embodiment differs from that of FIGS. 1 and 2 in that a plurality of spray nozzles 8 are provided. In each embodiment, it is important that the spray nozzles be positioned adjacent to the coils of the condenser to direct a fine spray mist of water or other suitable fluid onto the coils to cool them while the condenser is operating. The larger the condenser, the greater the number of spray nozzles provided.
Although not shown in the drawing, the cooling apparatus of the present invention can easily be adapted for use in connection with window type air conditioners as well as specially designed units such as those for recreational vehicles. The apparatus may also be used with other refrigeration devices.
The flow control mechanism of the cooling apparatus according to the invention will be described with reference to FIG. 6. As shown therein, a solenoid valve 22 is mounted on the bottom wall 14 of the housing. The valve 22 is connected at one end with the fluid supply line 4. The fluid outlet line 10 is connected with the other side of the valve. The solenoid valve is electrically operable to shift between open and closed positions to start and stop the flow of fluid from the supply line 4 to the outlet line 10.
Control of the solenoid valve is provided by a valve control circuit board assembly 24 mounted on the housing bottom wall by spacers 26. The circuit board has a conventional pulse circuit 28 and a vibration transducer 30 mounted on the undersurface thereof. The vibration transducer produces control signals in response to sensed vibrations. Since the housing is mounted on the condenser, it vibrates when the condenser vibrates. These vibrations, and the absence of these vibrations, are sensed by the transducer to produce the control signals. Accordingly, when the condenser is turned on, it vibrates resulting in a first control signal from the transducer. When the condenser is turned off, the vibrations cease, resulting in a second control signal from the transducer.
The control signals from the vibration transducer are delivered to the pulse circuit 28 which produces switching pulses to open the solenoid valve when vibrations are sensed and to close the valve when vibrations are terminated.
A power supply is necessary to operate the solenoid valve, the transducer, and the pulse circuit. Accordingly, a battery 32 is mounted on the housing bottom wall 14 to supply power to the circuit board assembly 24 via a connector 34. Auxiliary power many also be provided to the circuit board assembly from solar collectors 36 provided on the outer surface of the housing as shown in FIGS. 4 and 6. The solar collectors supply power to the circuit board assembly via a connector 38.
Power and pulse signals are supplied to the solenoid valve from the circuit board assembly via a connector 40. Auxiliary connectors may also be provided for the circuit board assembly. For example, connector 42 is provided for a small heater 44, and a recharging connector 46 is provided for an AC plug 48. The heater is provided to prevent the cooling apparatus from freezing in the event of an early frost. Of course, once the air conditioning condenser is turned off at the end of the cooling season, the cooling apparatus is removed from the condenser and stored for the winter. Cables from the connectors 34, 38, 40, 42 to the associated devices are necessary but have been omitted from the drawing for clarity.
At the remote end of the fluid supply line 4 is provided a filter and pressure regulator assembly 50 which is shown in FIG. 7. This assembly is connected with one branch of a Y-connector 52 having a threaded end 54 adapted for connection with a water source such as a spigot or hose bib. The other branch of the Y-connector is adapted for receiving a hose and includes a conventional shut-off valve 56.
The assembly 50 includes a pressure reducing mechanism 58 including a disk 60 containing a plurality of holes through which the water passes. A spring 62 biases the pressure reducing mechanism against a seat (not shown) of the Y-connector. Beneath the spring is a water chamber 64 which delivers water to the interior of an axially arranged filter 66. The filter removes particulates from the water which passes from the filter into the supply line 4. By filtering the water, the spray nozzles are less likely to become clogged.
As set forth above, installation of the cooling apparatus of the present invention is quite simple. The filter and pressure regulator assembly 50 is connected with a spigot and the housing is attached to the condenser whose coils are to be cooled with the spray nozzles arranged adjacent to the coils.
With the present invention, there is no messy run-off of water because, unlike prior art of the heat sensor design, the unit's valve is closed completely when the air conditioner condenser is not in operation. Scale build up can become a problem with some of the other design types of cooling apparatuses because the water flow is not stopped completely when the condenser is not in operation. Because the condenser is cool during this period, evaporation of the mist does not take place and a scale is formed. This scale insulates the coils and inhibits the condenser from running efficiently. Other models of the prior art actually go inside the coils of the condenser to aid in cooling. This voids the condenser warranty and may shorten the life of the condenser. The unit of the present invention is self contained and therefore does not void the warranty of the condenser. Also, due to the fact that the condenser is in operation less but is running more efficiently, the life of the condenser is increased.
While in accordance with the provisions of the patent statute the preferred forms and embodiments of the invention have been illustrated and described, it will be apparent to those skilled in the art that various changes and modifications may be made without deviating from the inventive concepts set forth above.
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An air conditioning condenser cooling device is characterized by a unique valve assembly which delivers a spray mist to the coils of the condenser only while the condenser is operating. A vibration transducer is provided which senses vibrations of the condenser when the condenser is in operation. The transducer produces a signal which opens a valve to supply fluid such as water from a fluid supply to a spray nozzle adjacent the condenser coils. When the condenser is off and thus not vibrating, the valve closes and the spray is terminated.
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This application is a continuation-in-part application based on U.S. patent application Ser. No. 06/849/116 filed Apr. 7, 1986, now U.S. Pat. No. 4,651,953; which is a continuation of Ser. No. 06/701/856 filed Feb. 14, 1985, now U.S. Pat. No. 4,667,900 which application, in turn, is a continuation of application Ser. No. 240,615 filed Mar. 5, 1981, now U.S. Pat. No. 4,429,775.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the propulsion system of an aircraft. It utilizes a liquid fuel prevaporization and back burning induction jet oval thrust nozzle which is fitted onto the exit nozzle of a conventional turbojet engine having a ram constriction air inlet plenum-engine pod located forward of the aerodynamic generating channel. The aerodynamic generating channel is located forward and above a vacuum cell induction lift wing and below recycling air inductor vanes
2. Description of the Prior Art
Tail pipes having round exit nozzles adapted to be affixed to the exit nozzle of conventional turbojet engines are known in the art.
SUMMARY OF THE PRESENT INVENTION
This invention relates to a round engine exit nozzle transition to a vertically converging and horizontally diverging oval thrust nozzle wherein the thrust nozzle has main airflow inducing nozzles, fuel injecting airflow inducing nozzles, combustion chambers, inductor vanes, liquid fuel prevaporization chambers, vaporized gas distributing manifolds with discharge nozzles, fuel injectors, ignitors and empty spaces adjacent the engine pod which forms a plenum. Air intake bellmouths of airflow inducing nozzles are installed inside the ram constriction air inlet plenums which are empty spaces in the engine pod on both sides of engine throat downstream of airflow inducing nozzles. The outlet of the airflow inducing nozzles are diverging and enter into the combustion chambers. The downstream ends of the combustion combustion chambers are parallel vertical equally spaced and downstreamwardly curved inductor vanes. Hollow spaces between the plenum wall and the flat span of transition walls comprise vaporization chambers fitted with fuel injecting sprays and vaporized gas distributing manifolds with discharge nozzles. The discharge nozzles are downstreamwardly inclined and connected on the minor axes span areas of the oval thrust nozzle. The openings of the inclined discharge nozzles are adequate for the slipflow of the thrust stream and the discharge nozzles are positioned slightly upstream from throat of the oval thrust nozzle for accommodation of ignition time span and to process the temperature reactants of back firing combustion downstream of the oval thrust nozzle. The dynamic pressure of the turbojet engine exhaust stream slipflows over the inductor vanes and induces induction air flow from the plenums through the airflow inducing nozzles. This results in increased airstream volume at the oval thrust nozzle. The turbo-induction jet air breathing is operative when the aircraft is on the ground with engine idling, during low speed operation of the aircraft or deceleration of the aircraft during flight.
When the the induction jet air breathing stream is injected with prevaporized liquid fuel to produce a combustable mixture which when ignited produces a flame thrust stream on downstream of the oval thrust nozzle. The expansion of the flame stream through the diverging contour of aerodynamic generating channel causes the flame thrust stream dynamic pressure to induce streams of air from surrounding air through the slot gap between the flat span of oval thrust nozzle and the leading edge of wing. This results in a recycled airstream at the forward upper portion of the aerodynamic generating channel which passes-through the reverse flow duct which is caused by the peripheral flow of rarefied thrust. These airstreams are merged with flame thrust which then produce the expanding combustion thrust stream in the diverging contour of the aerodynamic generating channel over the vacuum cell induction lift wing. The dynamic pressure of the expanding combustion thrust stream slipflows over the downstreamwardly inclined slot openings of vacuum cell wing. This stream action on the wing induces vacuum in internal cells of the wing which creates aerodynamic lift and drag forces on the wing. These forces correspond with the incidence angle of the wing which is the angle between the center-line of thrust stream and the wing chord line. The forces generated on the wing results in the drag force which counteracts the forward thrust of engine and stabilizies the horizontal moment of the airframe. The lift forces balance the weight of the aircraft during hovering of the aircraft Hovering capacity for the aircraft is accomplished by the turbo-inducting jet air breathing rocket thrust aerodynamic generating channel
Forward speed of the aircraft generates additional lift forces on the airfoil shaped airframe. These additional lift forces correspond to the reduction of the incident angle of the wing which reducts the drag forces on the vacuum cell wing. Forward acceleration is accomplished by the aircraft, from the aircraft hovering to the aircraft operating at hypersonic flight, by use of the liquid fuel prevaporization and backburning induction jet oval thrust nozzle.
The ram constriction air inlet plenums produce ram-static pressures when the aircraft is in high speed flight.
The ram airstream from the plenum pass through the airflow inducing nozzles and flow into the oval thrust nozzle. When fuel injectors are turned on downstream of the throat of the fuel injecting airflow inducing nozzles, a combustable mixture is produced. The combustion mixture is ignited and produces a flame stream which flows downstream of the main airflow inducing nozzles and enter the combustion chamber. The expanded combustion streams product ramjets through the diverging contours of the combustion chambers. The expanding ramjet airstream are combined with the turbojet stream at oval thrust nozzle. The oval thrust nozzle handles the turbojet stream and the ramjet streams creating a turbo-ram induction jet air breathing engine The turbo-ram induction jet air breathing engine operates on the principle of free stream air intake, which are tangential oblique stream flows, interacting with a throat constriction to achieve a critical pressure The free stream throat, located inside the low velocity air plenums, results in first a constraining of the ram airflow and then the expanding of the ram-airstream which controls the ram pressure on air intake bellmouths of the ram-airflow inducing nozzles which are ramjet components of the induction jet oval thrust nozzle. The turbo-ram induction jet air breathing oval thrust stream is operated when the aircraft is in supersonic flight.
When the turbo-ram induction jet air breathing oval thrust stream receives an injection of prevaporized liquid fuel prevaporization a combustable mixture is produced. The combustable mixture is ignited and produces a flame thrust stream downstream of the oval thrust nozzle in the forward section of aerodynamic generating channel. The dynamic pressure of back burning oval thrust stream induces a recycled peripheral thrust airstream which diverts the stream into the forward and upper portion of channel through the reverse flow duct and recycling inductor vanes. The leading edge of wing on airstream which interacts with the flame stream of a turbo-ram induction jet air breathing rocket thrust. The streams are tangentially constricted to develop a critical pressure and form a high velocity free stream throat in the forward section of channel. These streams are merged with the expanding ignited combustion mixture downstream of the free stream throat and the expansion of thrust stream in the diverging contours of channel results in a hypersonic velocity which is accomplished by the turbo-ram induction jet air breathing rocket thrust aerodynamic generating channel.
The liquid fuel prevaporization and back burning induction jet oval thrust nozzle which is fitted on the round exit pipe of conventional ram-axialflow turbine having a ram constriction air inlet plenum which is installed in the ram-stream zone of airframe. The ram-axialflow turbine is operated during high speed flight and the fuel injectors in the ram-airflow inducing nozzles are activated to ignite the combustible mixture to produce, downstream of the airflow inducing nozzles, the ramjet streams in the combustion chambers. The expanding ramjet streams slipflow over the exit pipe of axialflow turbine and induce a negative pressure region downstream of the turbine which, result in an increased pressure differential on the turbine inlet and outlet. This enhances the power of the ram-axialflow turbine and operates an electric generator. The ramjet-induction axialflow turbine operation is obtsined by the liquid fuel prevaporization and back burning induction jet oval thrust nozzle fitted onto the conventional axialflow turbine. When the ramjet induction axialflow turbine thrust stream is mixed with the prevaporized liquid fuel at the throat of ramjet induction oval thrust nozzle and the combustible mixture is ignited, hypersonic flame thrust is produced which provides the capacity of hypersonic flight and the ability to generate a high capacity electrical power source for future developments.
The liquid fuel prevaporization and back burning induction jet oval thrust nozzle is technically feasibile for use with conventional air breathing engine to convert the same to a multi-stage power plant using an induction jet air breathing engine. The multi-stage power plant can be used in an induction lift aircraft. The multi-stage power plant using the air breathing jet engine is based on the principal of management of fuel injection, as described above, and on the principals of induction and free stream constriction where the induction is based on the freedom balancing beyond-dynamic pressure of thermal thrust stream interacting on the diverging contours of the transition tail pipe and aerodynamic generating channel. A free stream formed of tangentially flowing oblique stream intersects with and is shaped by a throat constriction to develop a critical pressure in a constricted free stream flow and the constricted free air stream flow is then expanded on the air intake zone of the low velocity air plenums and in the aerodynamic generating channel The power plant stages are summarized below:
Stage 1: Turbo-induction jet air breathing engine;
Stage 2: Turbo-induction jet air breathing rocket engine;
Stage 3: Turbo-ram induction jet air breathing engine; and
Stage 4: Turbo-ram induction jet air breathing rocket engine.
DESCRIPTION OF THE DRAWINGS
This invention is described in accompanying drawings which are:
FIG. 1 is a plan view of a liquid fuel prevaporization induction jet oval thrust nozzle which is adapted to be attached to a conventional turbojet engine;
FIG. 2 is a side view of FIG. 1 showing the round engine exit nozzle;
FIG. 3 is a cross section of FIGS. 1 and 2 showing the throat of the airflow inducing nozzles;
FIG. 4 is a cross section at the throat of the oval thrust nozzle;
FIG. 5 is a plan view of the induction jet air breathing power plant having a conventional turbojet engine and the liquid fuel prevaporization and back burning induction jet oval thrust nozzle which includes a plenum containing an inclined air intake opening fitted with rigidly fixed straight vanes and deflectable tailing sectin of vanes;
FIG. 6 is a side view of FIG. 5 showing inclined air intake of the plenum showing the fixed and deflectable vanes;
FIG. 7 is a partial paln view of the ram constriction air inlet plenum;
FIG. 8 is a plan view of the aerodynamic generating channel;
FIG. 9 is a longitudinal section of the aerodynamic generating channel having an a vacuum cell induction lift wing with an acoustically treated hollow interior wherein the airfoil has airtight partitions containing downstream inclined slot openings;
FIG. 10 is a side elevation cf the induction lift aircraft;
FIG. 11 is a longitudinal sectional view of an induction lift flying saucer;
FIG. 12 is a schematic view of a turbo induction jet aircraft when the aircraft is operated in a neutral position, low speed flight or deceleration of flight;
FIG. 13 is a schematic showing the air distribution of turbo-induction jet air breathing thrust stream in the aerodynamic generating channel when the aircraft is operated in a neutral position, low speed flight or deceleration of flight;
FIG. 14 is a schematic diagram of a turbo induction jet air breathing engine when the aircraft is operated in VTOL;
FIG. 15 is a schematic diagram showing the distribution of turbo-induction jet rocket air breathing thrust stream in the aerodynamic generating channel when the aircraft is operated in maximum hovering capacity with extreme incidence of angle of wing;
FIG. 16 is a schematic diagram of turbo-induction jet air breathing thrust stream when the aircraft is operated in supersonic flight;
FIG. 17 is a schematic diagram showing the distribution of turbo-ram induction jet air breathing thrust stream in the aerodynamic generating channel when the aircraft is operated in supersonic flight;
FIG. 18 is a schematic diagram of turbo-ram induction jet rocket air breathing thrust stream when the aircraft is operated in hypersonic flight;
FIG. 19 is a schematic diagram showing the distribution of turbo-ram induction jet air breathing rocket thrust stream in the aerodynamic generating channel when the aircraft is operated in hypersonic flight;
FIG. 20 is a plan view of the liquid fuel prevaporization and back burning induction jet oval thrust nozzle attached to the round exit pipe of an air breathing jet engine;
FIG. 21 is a schematic diagram showing the air distribution of the ramjet induction axialflow turbine when the aircraft is in supersonic flight;
FIG. 22 is a schematic diagram showing the air breathing of the ramjet induction axial flow turbine ehaust stream which receives the prevaporized liquid fuel to produce the flame thrust stream during hypersonic flight;
FIG. 23 is a bottom plan view of the central power plant section of the induction lift flying saucer showing the vacuum lifting wing airfoils;
FIG. 24 is a pictorial representation showing the relationship of a jet engine, aerodynamic generating channel and vacuum lift wing of the induction lift flying saucer;
FIG. 25 is a rear elevational plan view of the central power plant section of the induction lift flying saucer;
FIG. 26 is a pictorial representation showing that portion of the central power plant section of the induction lift flying saucer which supports the air intakes and acoustic ceiling of the/aerodynamic generating channel;
FIG. 27 is a right side plan view of the induction lift flying saucer;
FIG. 28 is a front elevational plan view of the induction lift flying saucer;
FIG. 29 is a partial sectional and top elevational plan view of the circular outer surface of the induction lift flying saucer;
FIG. 30 is a rear elevational plan view showing the output of the jet thrust stream generating means used as an input to the aerodynamic generating channels;
FIG. 31 is a pictorial representation of the bottom of air breathing jet engines of FIG. 23 together with the air intake control;
FIG. 32 is a side elevational view of the pictorial representation of the air breathing jet engines and air intake controls of FIG. 32; and
FIG. 33 is a front elevational view of the bell mouth air intakes for the jet thrust stream generating means.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As illustrated in FIGS. 1 through 4, the outside of the power plant has a shape which defines a low velocity air plenum-engine pod. Multiple vanes are fitted on the inclined air intake opening at the forward section of the plenum. The induction jet oval thrust transition tail pipe is fitted on the rear end of the plenum. The conventional turbojet engine is installed inside of and on the center-line of the plenum.
The air inlet of the ram constriction system is illustrated in FIGS. 5, 6 and 7. Multiple inflective vertical vanes assemblies are fitted on the inclined opening at the forward portion of the low-velocity air plenum-engine pod. The vanes are fabricated with rigidly fixed straight vanes 17 and are positioned in the center-zones of the low velocity air plenums 16 located in the empty spaces on both sides of engine 1.
Deflectable trailing section of vanes 19 are hinged with rigidly fixed forward section of vanes 18 and are equally spaced from the rigidly fixed straight vanes 17. The deflectable trailing section of vanes 19 are linked with conventional hydraulic actuators for adjusting the position of vanes such as in the closed or open position. Deflectable vanes 19 are positioned straightly and parallel with the rigidly fixed straight vanes 17 when the air intake is wide open as illustrated in FIGS. 12 and 14. The postion of the vanes illustrated in FIGS. 12 and 14 applies when the aircraft is in stationary or low speed and deceleration of flight.
FIGS. 16 and 18 illustrate the positon of the vanes when actuated by the hydrauic actuators to deflect the trailing sections thereof toward the straight vanes 17. This position applies when the aircraft is in high speed flight. The sahping action of the ram-stream inside the low velocity air plenums are illustrated in FIG. 7. This occurs when the deflected trailing sections of vanes 19 are bent toward the rigidly fixed straight vanes 17 positioned on the center-line of the low velocity air plenums, which occurs during supersonic flight
The ram-stream impacts on the rigidly fixed forward section of the vanes 18. The ram-stream is restricted and deflected by the trailing section of vanes 19. The stream flow directions are inflected by the vanes 19 to produce the oblique streams 20. These streams are tangentally constrained towards the center-line zone of the low velocity air plenums 16 The shaping action of the ram-constriction causes the ram-stream to reach the critical pressure to form the free stream throat 21 and controls the stream pressure which is achieved by the ram-stream and controls the ram-air volume and ram-pressure inside the low velocity plenums 16. This results in a reduction of the dynamic drag force on the engine section diffuser during high speed flight. The ram drag is reduced on the front of the air intake opening. This is caused by the variable ram back pressure gradient downstream of the vanes where the center zones of ram constriction portion has more pressure drag force 23 on the front of the vanes and less pressure drag force 24 on the front of the engine suction and on both sides the air separation zones downstream of the vanes. The ram drag force on the front of the vanes, which is ram pressure, exceeds the critical pressure downstream of the vanes. This results in the pressure drag dynamic slip-down on the inclined face of the air intake which is a reduction of the ram drag force on the front of the air intake opening. Ram stream constrictions enhance the ram static pressure inside the low velocity air plenums which enhance the efficiency of ramjets on the ram-axialflow inducing nozzles 4 and 5 of turbo-induction jet air breathing engine.
The ram-stream constriction air intake system for ramjets induction axialflow is illustrated in FIGS. 20, 21 and 22. Rigidly fixed straignt vane 17 is positioned on the center-line of the axial flow turbine. Deflectable trailing section of vanes 18 and 19 are equally spaced and located on both sides of the rigidly fixed straight vans and deflect the trailing section of vanes 19 which are bent towards the rigidly fixed straignt vane 17. A stream shaping action occurs downstream of the vanes at the front of the axialflow turbine during supersonic flight. The streams are constrained and control the stream properties and the conversation of ram dynamic pressure to static pressure at the stream critical pressure on the front of the axialflow turbine to enhance the power of the axialflow turbine.
The power plant of an aircraft utilizing the liquid fuel prevaporization induction jet oval thrust nozzle is illustrated in FIGS. 1, 2, 3 and 4. The engine has a round engine exit nozzle 2 and the fuel prevaporization induction jet oval thrust nozzle has an oval thrust nozzle 3 and the interior of the thrust nozzle provides the transition from the round exit nozzle 2 to the oval thrust nozzle 3. The thrust nozzle is fabricated with main airflow inducing nozzles 4, fuel injecting airflow inducing nozzles 5 fitted with conventional fuel injectors 6 and ignitors 7, combustion chambers 8, inductors vanes 9, liquid fuel prevaporization chambers 10 fitted with fuel injecting sprays 11 and pressurized vapor gas distributing manifolds 12 having discharge nozzles 13 fitted with ignitors 14. Airflow inducing nozzles 4 and 5 having bellmouths, which enable the air to enter the nozzles, are installed inside of the ram-constriction air inlet plenums 16 which are empty spaces in the engine pod on both sides of the engine.
The downstream throat of the airflow inducing nozzle are diverging throats and direct the airflow into the combustion chamber 8. The combustion chamber 8 has major axes span which extend from the round exit nozzle to the oval transition tail pipe and encloses the parallel, verically, equally spaced curved inductor blades which curve in the direction of the downstream flow. The hollow spaces between the envelope of the plenum 15 and flat span of the major axes transition wall comprise the open pressure vessel for vaporization boiling chambers 10 fitted with liquid fuel injecting sprays 11. The chambers are connected with prevaporization and pressurized gas distributing manifolds 12 with discharge nozzles 13. The discharge nozzles 13 are inclined in a downstream direction and are connected to the minor axes areas of the oval thrust nozzle. The discharge nozzles 13 are fitted with ignitors 14 which are located at the vaporized gas air mixing point The openings of the discharge nozzles 13 are adequate for slip flows of thrust stream and are positioned slightly upstream from the throat of the oval thrust nozzle for accommodation of ignition time span and to process the temperature reactants of the after/back burning combustions at downstream throat of the oval thrust nozzles. The vaporization boiling chambers are installed in the center portion of the diverging major axes exhaust stream zones of the oval thrust nozzles. This results in the boiling chambers 10 inner walls increasing in temperature due to heat transmitted from the engine exhaust stream.
The pressure inside the vaporization boiling chambers fluctuates in response to the injecting rates of the liquid fuel sprays. When the fuel injection is turned off, the boiling chambers are maintained at a high temperature and a negative pressure. Cavitation is caused by the dynamic pressure of the oval thrust stream as it slipflows over the downstreamwardly inclined openings and induces the negative pressure inside the hollow chamber through the throats of the inclined suck nozzles 13 and the distributing manifolds 12. When this occurs, the boiling chambers are maintained at a high temperature and negative pressure. The means that the air mass inside the boiling chambers is maintained at a minimum for preventing explosion when the fuel injection is started and continuous combustion cannot occur in inside the vaporization boiling chambers
In order to turn-on the liquid fuel prevaporization and back burning, liquid fuel spray is injected into the high temperature-negative pressure of the boiling chambers. The liquid fuel is vaporized which expands its volume and builds up the local pressure inside the boiling chambers. The thermal energy of the engine exhaust is converted into dynamic pressure inside the boiling chambers. The temperature of the engine jet stream after the engine exit nozzle and before the throat of the oval thrust nozzle is reduced which increases the nozle efficiency and enhances the random velocity of the thrust stream at downstream of the oval thrust nozzle. The vaporized and pressurized gases expand and are discharges through the convergent-divergent inclined nozzles 13.
The liquid fuel prevaporization and pressurization afterburners result prevaporization and pressurization of liquid fuel before mixing of the same in the airstream and to reduce the time required for vaporization and expansion of the gas in the airstream. The expansion/combustion in the short span of the airstream and the explosion in the downstream throat of the oval thrust nozzle increases the thermal head/dynamic pressure of the oval thrust rarefied stream. Any excess of the flamable vaporized gas flow resulting from the fuel injection flows into the throat of the oval thrust nozzle. As a result, continuous combustion will occur downstream of the nozzle exit and preceeding the back-fire on the surrounding airstream interaction which is an oblique shock stream induced from the forward speeding edge of the wing. The actuation of the oval thrust nozzle produces a real high temperature thrust stream from the rocket nozzle. As a result, a liquid fuel prevaporization and backburning induction jet oval thrust nozzle is achieved. This is power source operates on the induction principal and is the aerodynamic system of the aircraft.
The induction jet power plant as illustrated in FIGS. 5 and 6 is a prefabricated liquid fuel prevaporization and back round exit nozzle 2 of the conventional air breathing engine 1 which is enveloped with ram constriction air inlets plenums 15, 16, 17, 18 and 19.
Installation of the power plant is illustrated in FIGS. 8, 9, 10 and 11 and the power plant is installed forward of the aerodynamic generating channel located forward of and above the vacuum cell induction lift wing 25 and below the recycling air inductor vanes 31. The transition tail pipe of the oval thrust nozzle is designed such that their major axes are horizontal and their minor axes are vertical. The engine jet stream passes through the engine exit nozzle 2, then through the transition tail pipe where the stream is constrained vertically. The converging jet stream is converted into an adverse pressure in the direction of flow and this adverse pressure reconverts into a velocity head in the direction of flowing in the diverging region of the oval thrust transition tail pipe.
The converging of the stream with the diverging transition tail pipe functions to shape the stream and to reduce turbulence in the round vorticity engine exhaust stream. The stream is constrained in the converging zones. The stream geometric contours are subject to stream separation at the horizontal divergent region. Thus, the stream underexpands in the direction of flow and the conversion into a velocity in the diverging zones is achieved through adverse pressure from the converging portion of the tail pipe. Conversion into a velocity is achieved by the thermal head effect occuring on the diverging contours of the transition tail pipe. The conversion velocity effect is proportional to the contours of nozzle and to the thermal head.
The stream shaping action inside the transition tail pipe develops the momentum equilibrium-freedom balancing of the stream dynamic pressure developed by the induction airflow inducing nozzles and inductor vanes.
The stream shaping action results in a vertically constrained, laminated stream which gains adverse pressure in the direction of flow in the converging zones and which underexpands in the direction of flow on the diverging zones. This action stimulates random velocity flow in the diverging zones of the oval thrust transition tail pipe.
The random velocity of underexpanding airstream contours will slipflow over the downstreamwardly curved inductor blades 9 and generate a cavitation at the intermediate area of the inductor vanes. This cumulative cavitation is equal to the pulling force which occurs beyond the thermal stream dynamic pressure in the diverging stream contours. The pulling force of the stream dynamics induces the induction airflow from the low velocity air plenums through the airflow inducing nozzles. This results in the induction airflow balancing the pulling pressure of the thermal stream dynamics. The balancing occurs because of the freedom balancing of stream shaping action with the momentum equilibrium of the stream dynamic pressure of the induction jet oval thrust transition tail pipe.
The inductor vanes 9 are so positioned near the boundary layers which surround the underexpanded region of the engine exhaust stream inside the diverging area of the oval transition tail pipe. FIGS. 12 and 16 show the boundary layers 40 and 40' which exists at the interface of the turbojet stream 38 and the induction airstream 39 or ram jets 59
The position of boundary layers will shift in response to changes in the speed of flight FIG. 12 shows the boundary layers 40, which are located near the inductor vanes 9, when the aircraft is stationary or during low speed flight of the aircraft. FIG. 16 shows the boundary layers 40', which shift toward the center-line of the engine jetstream 38, when the aircraft is in supersonic flight
The processing of the thrust stream inside the induction jet oval thrust transition tail pipe's result in a cylindrical vortex engine jet stream passing first through the round section of the engine nozzle 2 and then through the transiton tail pipe. The strong random velocity of the engine exhaust stream will be constained by the adverse pressure gradient at the vertical convergence zone. The stream will be underexpanded in the direction of flow in the region of horizontal divergence. The diverging contours are subject to stream separation illustrated in FIG. 12. The underexpanding generates the induction airstreams 39 through the airflow inducing nozzles 4 and 5. This results in an induction airflow having a reduction in separation of engine exhaust stream at the diverging contours of the tail pipe and an increase in the volume cf the oval thrust stream. A drastic reduction of stream separation occurs at the horizontal divergent due to the vertical constriction of stream-strain action resulting in a vertical converging, airstream shaping action taking over which nearly dies-out the stream rotation vorticity distribution and fully develops the stream flow into a nearly uniform profile, which means a laminated high volume thrust stream is achieved in the oval thrust nozzle. The above can be achieved by an induction jet oval thrust nozzle being fitted onto a conventional air breathing engine.
The prime force behind the induction air flowing is that a turbojet stream is achieved by means of the turbo-induction jet air breathing engine wherein the thrust stream is processed by the principle of induction which is freedom balancing beyond the dynamic pressure of thermal thrust stream on the diverging contours of transition tail pipe. A laminary high volume rarefied flow results which is used for the produciton of aerodynamic forces.
These streams shaping actions are processed by the local component of the induction jet oval thrust tail pipe before the stream passes through the exit nozzle of the oval thrust nozzle. This results in reduced vorticity turbulences of engine exhaust stream and the lamination of the stream by the transition tail pipe's convergance combining with the diverging shaping action of the induction airflow. The induction jet oval thrust transition tail pipe induces a high volume air breathing effect while reducing turbulance in the rarefied jet thrust which flows through the aerodynamic generating channel over the vacuum cell induction lift wing. The vacuum cell induction lift wing has an acoustically treated hollow interior and the airfoil has airtight partitions which contain downstream inclined slot openings and the jet thrust stream flows over the slots.
The turbo-induction jet air breathing oval thrust stream in the aerodynamic generating channel is illustrated in FIG. 13. The dynamic pressure of the oval thrust stream 41 is an induced airstream which recycles and surrounds the aerodynamic generating channel. The airstream 44 is recycled as the thrust peripheral flow diverts the stream flow into the forward upper portion of channel as a diverting flow 42 turning vanes 30 and as a reversed flow 43 through duct 29 and recycling air inductor vanes 31. The surrounding airstream 45 is induced at the forward portion of the channel through the slot gap between the flat span of the oval thrust nozzle and leading edge of wing. These airstreams increase in volume at the forward section of the aerodynamic generating channel and are merged with the induction jet thrust stream. This increases the airstream 46 flowing through the aerodynamic generating channel over the vacuum cell induction lift wing and generates the aerodynamic lift 50 and drag 52 forces. The drag force on the wing counter balances the forward thrust of engine idling operation when the aircraft is stationary.
The operation of a turbo-jet air breathing rocket oval thrust stream is illustrated in FIG. 14. During hovering operation or forward acceleration, which occurs with turned on fuel injecting sprays in the vaporization chambers, a prevaporized and pressurized gas stream 52 flows into the induction air stream zones 39 of the oval thrust nozzles 13. As a result, the turbo-jet air breathing oval thrust stream receives the prevaporized liquid fuel. Ignition of the combustible air mixture 53 produces a flame thrust stream 54 downstream of the oval thrust nozzle. This results in a high thermal rocket thrust stream which creats a turbo-induction jet air breathing rocket thrust engine. This is accomplished by the liquid fuel prevaporization and back burning induction jet oval thrust nozzle which fits onto the convention air breathing engine.
The hovering capacity is generated by the turbo-induction jet air breathing engine rocket oval thrust channel as illustrated in FIG. 15. In FIG. 15, the dynamic pressure of the oval thrust flame stream induces recycling and surrounding air streams. The recycling airstream 44 is the thrust peripheral flow which is diverted into the forward and upper portions of the channel through the turning vanes 30, through the reversed flow duct 29, and through the recycling air inductor vanes 31. The surrounding airstream 45 is located at the forward and lower portion of channel, and passes through the slot gap between the flat span of the oval thrust nozzle and the leading edge of wing. These streams increase the volume of airstream in the channel and are merged with flame of the turbo-induction jet air breathing rocket thrust. The merging of these streams produces the expanding combustion thrust stream and flow through the diverging contours of the aerodynamic generating channel over the vacuum cell induction lift wing.
The dynamic pressure of the expanding combustion thrust stream 55 slipflows over the downstreamwardly inclined slot openings of vacuum cell wing. This stream action on the wing induces a vacuum in the internal cells of the wing which creates aerodynamic lift and drag forces on the wing. These forces correspond with the incidence angle 47 of the wing. The incidence angle 47 is the angle between the center-line of thrust stream and chord line of wing. The forces generated on the wing result in the drag force counteracting the foreward thrust of engine and stablizing the horizontal moment of the airframe. The lift force balances the weight of the aircraft. Hovering is produced by the turbo-induction jet air breathing rocket thrust aerodynamic generating channel. Aircraft VTOL hovering manoeuvers are achieved by the turbo-induction jet air breathing rocket thrust aerodynamic generating channel.
The operation of a turbo-ram induction jet air breathing oval thrust stream, during supersonic flight, is illustrated in FIG. 16. FIG. 16 shows that the ram constriction air inlet plenums 16 gain in ram-static pressure and that the ramstream flows through the airflow inducing nozzles 4 and 5 past turned on fuel injectors 56 located downstream of the fuel injection airflow inducing nozzles 5. The combustion mixture 57 is ignited and produces a flame stream 58 which flows into and combines, downstream of the main airflow inducing nozzle 4, with the airstream as the flame stream enters the combustion chamber. The expanding combustion streams produce ramjet streams through the diverging contours of the combustion chamber and the expansion of the ramjets streams 59 which combine with turbojet stream 38 at oval thrust nozzle. The oval thrust nozzle handles the turbojet air stream and the ramjets streams to create a turbo-ram induction jet air breathing engine. The air intake free stream is a tangentially flowing, oblique-stream which interacts with the throat constriction inside the low velocity air plenums to producing critical pressures in the ram-airstream resulting first in the constraining and then the expansion of the ram-airstream which controls the ram pressure on air intake bellmouths of airflow inducing nozzles which function as the ramjet components of the induction jet oval thrust nozzle.
The turbo-ram induction jet air breathing rocket oval thrust stream, during hypersonic flight, is illustrated in FIG. 18. As illustrated in FIG. 18, the fuel injecting sprays are turned on in the vaporization chambers to produce the prevaporized and pressurized gas stream 52 which is discharged into the ramjet stream zones located at the oval thrust nozzle. The prevaporized and pressurized gas stream 52 passes through the distributing manifolds and inclined discharge nozzles into the ramjet stream. The turbo-ram induction jet air breathing stream receives the prevaporized liquid fuel and when the mixture is ignited, the combustible mixture 53 produces flame thrust stream 64 downstream of the oval thrust nozzle The ignited mixture products a high thermal stream, such as a rocket thrust stream, creating the turbo-ram induction air breathing rocket thrust engine.
As illustrated in FIG. 19, hypersonic flight is generated with the turbo-ram induction jet air breathing rocket oval thrust stream flow through the diverging contours of aerodynamic generating channel The dynamic pressure of the back burning oval thrust stream induces the recycled airstream 44 which is the thrust peripheral flow diverted into the forward and upper portion of the channel and through the reverse flow duct 43 and the recycling air inductor vanes 31.
The forward leading edge 60 of wing at the airspeed of the aircraft induces the oblique shock airstream 61 to interact with the flame stream 64 of the turbo-ram induction jet air breathing rocket thrust. These streams are tangentially constriction to develop the critical pressure and to form the high velocity free stream in throat 65 located in the forward section of the channel. These streams are merged which produces the expanding combustion downstream of the free stream throat and expanded to produce the hypersonic velocity of thrust stream 66 in the diverging contours of channel thus creating a turbo-ram induction jet air breathing rocket aerodynamic thrust channel.
The ramjet induction axialflow turbine is achieved by the liquid fuel prevaporization and back burning induction jet oval thrust nozzle, illustrated in FIGS. 20, 21 and 22, during high speed flight. The liquid fuel prevaporization and back burning induction jet oval thrust nozzle slip fits on the exit pipe 67 of a conventional axialflow turbine (rotators 68, 70 and stators 69). An electric generator is installed inside the exhaust pipe 72 of the axialflow turbine which has a ram constriction air inlet plenum.
Ram constriction assembly having multiple vanes 17, 18 and 19 is fitted on the inclined ram-air intake opening forward of the plenum pod located on the front of the axial flow turbine inlet diffuser. The forward speed of aircraft generates a ram-stream which passes through the deflectable multiple vanes 18 and 19 of the air intake and then flows into the plenum pod. The trailing sections of multiple vanes 19 are deflected towards the rigidly fixed straight vane 17 at the center-line of the axialflow turbine. The ram-stream passing through the multiple vanes is inflected in the flow direction and is tangentially constrained to produce a critical pressure on front of the axialflow turbine inlet diffuser. The critical ram pressure flow impinges on the axialflow turbine blades 68 and 70 rotating the turbine wheels.
The expanding ramjet thrust streams 59 flow through the inductor vanes 9 and induce a negative pressure differential on the turbine inlet and outlet. This enhances the power of the ram-axialflow turbine and operates the electric generator. The ramjet-induction axialflow turbine operation is obtained by the liquid fuel prevaporization and back burning induction jet oval thrust nozzle fitted onto the conventional axialflow turbine having a ram constriction air inlet plenum located in ram stream zone of airframe.
The liquid fuel prevaporization and backburning induction jet oval thrust nozzle of this invention is used for an induction lift aircraft.
In FIGS. 23 and 24, the circular airframe 101 of the inductive lift flying saucer houses the central power plant section of the induction lift flying saucer. The air breathing jet engines 104 have air intake controls 106 to control the air flow into the jet engines 105 and through channel 105 to the jet thrust means generating means located rearward of and behind the jet engines. This is shown in greater detail in FIGS. 31 and 32. The vacuum lift wing airfoils 118 are located rearward of the jet thrust stream generating means. Air Brakes 139 are provided. Additional jet engines 141 and air pods 142 are provided adjacent the main power section.
FIG. 24 shows the oval shaped thrust nozzle 114 from the jet stream thrust producing means. The circular airframe 101 has a sharp outer peripheral edge defined by the upper section 103 and a lower section 102. The aerodynamic thrust generating channel is shown as 125 and the acoustical channel 130 is shown to form the reverse channel 127.
FIG. 25 the shape of the outlet of the aerodynamic channel, the location of the reverse channels 127 and the location of the vacuum lift wings 118. Wheels 161 are shown which support the aircraft for takeoff and landing.
The additional jet engines 141 likewise have outlets for the jet thrust stream generating means shown as 160. A ramp 162 is provided for ingress into the spacecraft 101.
FIGS. 26 and 27 include the same elements described above in connection with FIGS. 23 through 25 with the addition of outlets 126 positioned rearward of the aerodynamic generating channels.
FIG. 28 shows the the air controls 106 at the front of the spacecraft.
FIG. 29 show the entry 162 for providing access to the interior of the induction lift flying saucer.
FIG. 30 shows the outlets 114 of the jet thrust stream generating means used as the inputs to the aerodynamic generating channel, the bottom of which is enclosed by the vacuum lift wing.
FIGS. 31 and 32 show the details of the air controls having deflectable member 106 controlled by actuator 107 which determines the volume of air being passed to the air breathing jet engine 104 and the air passing through channel 105 which is used as the input to the jet thrust stream generating means.
The air passing through channel 105 is passed through a bell mouth intakes 108, 109 and 110. The air is compressed and injected with fuel to produce the jet thrust stream in the chamber 111 which is passed through chamber 112 to compress the same as it passes out of the exit nozzle 114.
FIG. 33 shows the relationship of the bell mouth air intakes 108 and 109, and the position of the same relative to the jet engine 104 and the air path 105.
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An induction lift flying saucer having a circular shaped air frame which houses a vacuum cell induction lift wing adapted to be used in an aerodynamic generating channel wherein the lift wing includes an airfoil having a leading edge and a trailing edge, a top panel and an acoustically treated hollow interior, and wherein the airfoil includes airtight partitions forming individual cells within the hollow interior and the airfoil has inclined slots extending from the top panel into each of the individual cells wherein the inclined slots extend at an angle from each of the individual cells toward the trailing edge of the airfoil and wherein the airfoil is adapted to be positioned within an aerodynamic generating channel with the top panel of the airfoil being adapted to form a lower boundary of the aerodynamic generating channel and to define a slip thereacross from an airstream passing through the aerodynamic generating channel, a bearing support operatively coupled to the airfoil adjacent the trailing edge to enable the airfoil to be rotated therearound to change the angle of incidence of the top panel to an airstream passing thereacross and a pivot support operatively couples to the airfoil adjacent the leading edge for moving the airfoil leading edge relative to an airstream by rotating the airfoil around the support member to change the angle on incidence of a top panel relative to an airstream enabling the airflow thereof to generate a vacuum within the individual cells is shown. A jet thrust peripheral flow recycling system and induction lift aerodynamic generating channel using the vacuum cell induction lift wing is also shown.
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CROSS REFERENCE TO OTHER APPLICATIONS
The following issued patents and co-pending applications of common assignee contain some common disclosure:
U.S. Pat. No. 6,167,489 to Bauman et al. “System and Method for By-Passing Supervisors Memory Intervention for Data Transfers Between Devices Having Local Memories” issued Dec. 26, 2000, incorporated herein by reference in its entirety.
“High-Speed Memory Storage Unit for a Multiprocessor System Having Integrated Directory and Data Storage Subsystems”, filed Dec. 31, 1997, Ser. No. 09/001,588, now U.S. Pat. No. 6,415,364, incorporated herein by reference in its entirety;
“A Directory-Based Cache Coherency System” filed Nov. 5, 1997, Ser. No. 08/965,004, incorporated herein by reference in its entirety; and
“Directory-Based Cache Coherency System Supporting Multiple Instruction Processor and Input/Output Caches”, filed Dec. 31, 1997, Ser. No. 09/001,598, incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to an improved system and method for maintaining cache coherency within a hierarchical memory system shared between multiple processors; and more particularly, relates to a system that provides by-pass interfaces to provide for the direct exchange of data between cache memories existing at the lower hierarchical levels in the hierarchical memory system in a manner that maintains memory coherency.
2. Description of the Prior Art
Data processing systems are becoming increasing complex. Some systems, such as Symmetric Multi-Processor (SMP) computer systems, couple two or more Instruction Processors (IPs) and multiple Input/Output (I/O) Modules to shared memory. This allows the multiple IPs to operate simultaneously on the same task, and also allows multiple tasks to be performed at the same time to increase system throughput.
As the number of units coupled to a shared memory increases, more demands are placed on the memory and memory latency increases. To address this problem, high-speed cache memory systems are often coupled to one or more of the IPs for storing data signals that are copied from main memory. These cache memories are generally capable of processing requests faster than the main memory while also serving to reduce the number of requests that the main memory must handle. This increases system throughput.
While the use of cache memories increases system throughput, it causes other design challenges. When multiple cache memories are coupled to a single main memory for the purpose of temporarily storing data signals, some system must be utilized to ensure that all IPs and I/O Modules are working from the same (most recent) copy of the data. For example, if a copy of a data item is stored, and subsequently modified, in a cache memory, another IP requesting access to the same data item must be prevented from using the older copy of the data item stored either in main memory or the requesting IP's cache. This is referred to as maintaining cache coherency. Maintaining cache coherency becomes more difficult as more caches are added to the system since more copies of a single data item may have to be tracked.
Many methods exist to maintain cache coherency. Some earlier systems achieve coherency by implementing memory locks. That is, if an updated copy of data exists within a local cache, other processors are prohibited from obtaining a copy of the data from main memory until the updated copy is, returned to main memory, thereby releasing the lock. For complex systems, the additional hardware and/or operating time required for setting and releasing the locks within main memory cannot be justified. Furthermore, reliance on such locks directly prohibits certain types of applications such as parallel processing.
Another method of maintaining cache coherency is shown in U.S. Pat. No. 4,843,542 issued to Dashiell et al., and in U.S. Pat. No. 4,755,930 issued to Wilson, Jr. et al. These patents discuss a system wherein each processor has a local cache coupled to a shared memory through a common memory bus. Each processor is responsible for monitoring, or “snooping”, the common bus to maintain currency of its own cache data. These snooping protocols increase processor overhead, and are unworkable in hierarchical memory configurations that do not have a common bus structure. A similar snooping protocol is shown in U.S. Pat. No. 5,025,365 to Mathur et al., which teaches a snooping protocol that seeks to minimize snooping overhead by invalidating data within the local caches at times when other types of cache operations are not occurring. However, the Mathur system can not be implemented in memory systems that do not have a common bus structure.
Another method of maintaining cache coherency is shown in U.S. Pat. No. 5,423,016 to Tsuchiya, which is assigned to the assignee of the current invention. The method described in this patent involves providing a memory structure called a “duplicate tag” that is associated with each cache memory. Each duplicate tag records which data items are stored within the associated cache. When a data item is modified by a processor, an invalidation request is routed to all of the other duplicate tags in the system. The duplicate tags are searched for the address of the referenced data item. If found, the data item is marked as invalid in the other caches. Such an approach is impractical for distributed systems having many caches interconnected in a hierarchical fashion because the time required to route the invalidation requests poses an undue overhead.
For distributed systems having hierarchical memory structures, a directory-based coherency system becomes more practical. Directory-based coherency systems utilize a centralized directory to record the location and the status of data as it exists throughout the system. For example, the directory records which caches have a copy of the data, and further records whether any of the resident copies have been updated. When a cache makes a request to main memory for a data item, the central directory is consulted to determine where the most recent copy of that data item resides. Based on this information, the most recent copy of the data is retrieved so that it may be provided to the requesting cache. The central directory is then updated to reflect the new status for that unit of memory. A novel directory-based cache coherency system for use with multiple Instruction Processors coupled to a hierarchical cache structure is described in the copending application entitled “Directory-Based Cache Coherency System Supporting Multiple Instruction Processor and Input/Output Caches” referenced above and which is incorporated herein by reference in its entirety.
The use of the afore-mentioned directory-based cache coherency system provides an efficient mechanism for sharing data between multiple processors that are coupled to a distributed, hierarchical memory structure. Using such a system, the memory structure may be incrementally expanded to include any multiple levels of cache memory while still maintaining the coherency of the shared data. As the number of levels of hierarchy in the memory system is increased, however, some efficiency is lost when data requested by one cache memory in the system must be retrieved from another cache.
As an example of performance degradation associated with memory requests in a hierarchical cache memory system, consider a system having a main memory coupled to three hierarchical levels of cache memory. In the exemplary system, multiple third-level caches are coupled to the main memory, multiple second-level caches are coupled to each third-level cache, and at least one first-level cache is coupled to each second-level cache. This exemplary system includes a non-inclusive caching scheme. This means that all data stored in a first-level cache is not necessarily stored in the inter-connected second-level cache, and all data stored in a second-level cache is not necessarily stored in the interconnected third-level cache.
Within the above-described system, one or more processors are respectively coupled to make memory requests to an associated first-level cache. Requests for data items not resident in the first-level cache are forwarded to the intercoupled second-level, and in some cases, the third-level caches. If neither of the intercoupled second or third level caches stores the requested data, the request is forwarded to main memory.
Assume that in the current example, a processor makes a request to the intercoupled first-level cache for a read-only copy of specified data. Assume further that the requested data is not stored in this first-level cache. However, another first-level cache within the system stores a read-only copy of the data. Since the copy of the data is read-only, the request can be completed without involving the other first-level cache. That is, the request may be processed by one of the inter-connected second or third-level caches, or if neither of these caches has a copy of the data, by the main memory.
In addition to requests for read-only copies of data, requests may be made to obtain “exclusive” copies of data that can be updated by the requesting processor. In these situations, the cache line data will be provided to the requesting cache, and any previously cached copies of the data will be marked as invalid. That is, in this instance, copies of the data may not be shared among multiple caches. This is necessary so that there is only one “most-current” copy of the data existing in the system and no processor is working from outdated data. Returning to the current example, assume the request to the first-level cache is for an exclusive copy of data. This request must be passed via the cache hierarchy to the main memory. The main memory forwards this request back down the hierarchical memory structure to the first-level cache that stores the requested data. If this first-level cache stores a shared copy of the cache line, or alternatively stores an exclusive copy that has not been modified, then this first-level cache must invalidate the stored copy of the data, indicating that this copy may no longer be used. If this first-level cache stores an exclusive copy of the data, and has further modified the data, the modified data is passed back to the main memory to be stored in the main memory and to be forwarded on to the requesting first-level cache. In this manner, the requesting cache is provided with an exclusive copy of the most recent data.
The steps outlined above with respect to the exclusive data request are similar to those that must be executed if a read-only copy of the data is requested when a copy of the requested data resides exclusively in another cache. The previous exclusive owner must forward a copy of the updated data to main memory to be returned to the requester.
As may be seen from the current example, in a hierarchical memory system having multiple levels of cache that are not all interconnected by a common bus structure, obtaining an exclusive copy of data that can be utilized by a processor for update purposes may be time-consuming. As the number of these so-called “ownership” requests for obtaining an exclusively “owned” data copy increases within the system, throughput may decrease. This is especially true as additional levels of hierarchy are included in the memory structure.
One mechanism for increasing throughput involves providing a high-speed data return path within the main memory. When data is returned from a previous owner, the high-speed interface forwards the data directly to the requester without the need to perform any type of main memory access. A high-speed interface of this type can be used to route both modified and unmodified data between the various units in the system. Such a system is described in the U.S. Pat. No. 6,167,489 to Bauman et. al. entitled “System and Method for By-Passing Supervisory Memory Intervention for Data Transfers Between Devices Having Local Memories”, issued Dec. 26, 2000, and which is referenced above. While this type of interface decreases the time required to complete the data return operation, data must never-the-less be provided to the main memory in all cases before the data can be forwarded to the requesting processor. This unnecessarily increases traffic on interfaces between main memory and other cache memories. Additionally, some latency is still imposed by the length of the data return path, which extends from the lowest levels of memory hierarchy, to main memory, and back to the lowest memory levels. What is needed, therefore, is a system that minimizes the time required to return data to a requesting processor coupled to the hierarchical memory system by shortening the data return path and by reducing request traffic on the main memory interfaces.
3. Objects
The primary object of the invention is to provide an improved shared memory system for a multiprocessor data processing system;
Another object is to provide a hierarchical memory including a main memory coupled to multiple cache memories and further including at least one data return path to provide data between respectively coupled cache memories without intervention of main memory;
A yet further object is to provide data routing logic at multiple levels in a hierarchical memory system for routing data between memories residing within predetermined levels in the memory system and without intervention of a main memory controller;
A still further object is to reduce data traffic on the main memory interfaces of a hierarchical memory system that includes multiple levels of cache memory;
A yet further object is to provide a by-pass data path system for a modular, expandable memory;
Another object is to provide an improved method of transferring shared, read-only copies of data signals from one cache memory to another in a hierarchical memory system in which the cache memories are intercoupled via a directory-based main memory;
Another object is to provide an improved method of transferring exclusive read/write data copies from one cache memory to another in a hierarchical memory system in which the cache memories are intercoupled via a directory-based main memory;
A still further object is to provide an improved system for maintaining cache coherency within a main memory coupled to multiple cache memories; and
A further object is to provide a hierarchical, directory-based shared memory system having improved response times.
SUMMARY OF THE INVENTION
The objectives of the present invention are achieved in a hierarchical, multi-level, memory system that provides by-pass paths between storage devices located at predetermined levels within the memory hierarchy. The hierarchical memory system of the preferred embodiment includes a main memory coupled to multiple first storage devices, wherein ones of the first storage devices are third-level cache memories, and other ones of the storage devices are Input/Output (I/O) Buffers. These first storage devices each stores addressable portions of data signals retrieved: from the main memory. A directory-based coherency scheme is employed to ensure that the memory system stores a single, most recent copy of all data signals. According to this scheme, a directory associated with the main memory records the location of the latest copy of any of the data signals stored in the memory system. When a request issued by one of the storage devices is received by the main memory, the directory is consulted to determine which storage device stores the most recent copy of the requested data signals. In some instances, the main memory issues a request to retrieve this latest copy of the data signals from another target storage device in the system so the data can be forwarded by the main memory to the original requester.
To facilitate a more efficient transfer of data between the various storage devices in the memory system, the system includes at least one by-pass interface coupling associated ones of the first storage devices. Data retrieved from a target one of the first storage devices in response to a main memory request can be routed to a different requesting one of the first storage devices via the by-pass system without requiring the use of the main memory data interfaces. The by-pass system includes a control mechanism that performs the routing function based on the identity of the original requester. That is, the request from main memory to the target one of the first storage devices includes the identity of the storage device that issued the original request. If data is returned from the target storage device, a by-pass operation is enabled if the identified requester is one of the storage devices associated with the by-pass interface. According to one embodiment of the invention, the requested data signals are also provided by the target storage device to the main memory only if these data signals comprise an updated copy of the data stored in main memory. This reduces traffic on the main memory interfaces while allowing the main memory to retain an updated data copy. The by-pass system also provides an indication of the occurrence of any by-pass transfer operations to the main memory so that the directory can be updated to reflect the new location of any addressable portion of the data signals.
According to another aspect of the hierarchical memory system, ones of the first storage devices are each coupled to respective second storage devices. In the preferred embodiment, these second storage devices are each second-level cache memories. Each of the second storage devices store data signals retrieved from the coupled first storage device. Requests to retrieve data signals may be provided by a second storage device to a respectively coupled first storage device to be forwarded for processing to main memory. In a manner similar to that discussed above, the main memory may be required to retrieve the latest copy of the requested data signals from a different one of the storage devices in the system, including possibly one of the second storage devices, before the request can be completed.
To make the return of data signals between the second storage devices more efficient, the by-pass system includes at least one interface that allows for the transfer of data directly between predetermined first and second ones of the second storage devices. These by-pass operations are performed in a manner that is similar to that discussed above. The by-pass interfaces thereby significantly reduce the length of the return path during the transfer of data from a target to a requesting storage device. According to one embodiment, data signals are only returned to the main memory when these signals have been modified to reduce traffic on the interfaces in the manner discussed above. In all instances, an indication is provided to the main memory of any by-pass operations so that the directory status may be updated.
The system of the preferred embodiment includes multiple by-pass interfaces coupling respectively associated ones of the second storage devices, and other multiple by-pass interfaces interfacing respectively associated ones of the first storage devices. According to one aspect of the system, the circuits to identify the respectively associated ones of the storage devices are programmable.
According to yet another aspect of the system, the main memory is modular. The by-pass system is adapted to receive data requests from each of the main memory modules for use in generating by-pass responses. The by-pass system is further adapted to route updated data returned from a target storage device to an addressed one of the main memory modules.
The by-pass system includes logic that is capable of transferring various predetermined types of data copies between the storage devices of the hierarchical memory depending on the type of the original data request. In some instances, the by-pass system transfers shared, read-only data copies, whereas in other instances, an exclusive read-write copy is provided. In all situations, an indication of the type and location of each portion of the transferred data signals is provided to the directory so that data coherency is maintained.
One embodiment of the by-pass system allows by-pass responses to be generated before it is known whether a data by-pass operation may be completed. In this embodiment, a by-pass response is generated by the by-pass system upon receipt of a request from the main memory to retrieve specified data from a predetermined target storage device, and before it is known whether the requested data is available within that target storage device. If the data signals can be made available by the target storage device, the pre-generated response is available to be appended to the data signals for immediate routing to the requesting unit. In some instances, the target storage device may not store the requested data signals. This occurs when the target storage device writes the requested data back to main memory after the main memory issued the request to retrieve this data but before the request is received by the target device. In these instances, the pre-generated by-pass response is discarded, and the original request must be processed by main memory instead of by the by-pass system.
Still other objects and advantages of the present invention will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiment and the drawings, wherein only the preferred embodiment of the invention is shown, simply by way of illustration of the best mode contemplated for carrying out the invention. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various respects, all without departing from the invention. Accordingly, the drawings and description are to be regarded to the extent of applicable law as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE FIGURES
The present invention will be described with reference to the accompanying drawings.
FIG. 1 is a block diagram of a Symmetrical MultiProcessor (SMP) system platform according to a preferred embodiment of the present invention;
FIG. 2 is a block diagram of a Processing Module;
FIG. 3 is a block diagram of the Sub-Processing Module;
FIG. 4 is a block diagram of the TCM of the preferred embodiment;
FIG. 5 is a block diagram of the Main Storage Unit;
FIG. 6 is a block diagram of Command/Function Routing Logic; and
FIG. 7 is a block diagram of the TLC by-pass logic.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
System Platform
FIG. 1 is a block diagram of a Symmetrical Multi-Processor (SMP) System Platform according to a preferred embodiment of the present invention. System Platform 100 includes one or more Memory Storage Units (MSUs) in dashed block 110 individually shown as MSU 110 A, MSU 110 B, MSU 110 C and MSU 110 D, and one or more Processing Modules (PODs) in dashed block 120 individually shown as POD 120 A, POD 120 B, POD 120 C, and POD 120 D. Each unit in MSU 110 is interfaced to all PODs 120 A, 120 B, 120 C, and 120 D via a dedicated, point-to-point connection referred to as an MSU Interface (MI) in dashed block 130 , individually shown as 130 A through 130 S. For example, MI 130 A interfaces POD 120 A to MSU 110 A, MI 130 B interfaces POD 120 A to MSU 110 B, MI 130 C interfaces POD 120 A to MSU 110 C, MI 130 D interfaces POD 120 A to MSU 110 D, and so on.
In one embodiment of the present invention, MI 130 comprises separate bi-directional data and bi-directional address/command interconnections, and further includes unidirectional control lines that control the operation on the data and address/command interconnections (not individually shown). The control lines run at system clock frequency (SYSCLK) while the data bus runs source synchronous at two times the system clock frequency (2×SYSCLK).
Any POD 120 has direct access to data in any MSU 110 via one of MIs 130 . For example, MI 130 A allows POD 120 A direct access to MSU 110 A and MI 130 F allows POD 120 B direct access to MSU 110 B. PODs 120 and MSUs 110 are discussed in further detail below.
System Platform 100 further comprises Input/Output (I/O) Modules in dashed block 140 individually shown as I/O Modules 140 A through 140 H, which provide the interface between various Input/Output devices and one of the PODs 120 . Each I/O Module 140 is connected to one of the PODs across a dedicated point-to-point connection called the MIO Interface in dashed block 150 individually shown as 150 A through 150 H. For example, I/O Module 140 A is connected to POD 120 A via a dedicated point-to-point MIO Interface 150 A. The MIO Interfaces 150 are similar to the MI Interfaces 130 , but in the preferred embodiment have a transfer rate that is approximately half the transfer rate of the MI Interfaces because the I/O Modules 140 are located at a greater distance from the PODs 120 than are the MSUs 110 .
Processing Module (POD)
FIG. 2 is a block diagram of a processing module (POD) according to one embodiment of the present invention. POD 120 A is shown, but each of the PODs 120 A through 120 D has a similar configuration. POD 120 A includes two Sub-Processing Modules (Sub-PODs) 210 A and 210 B. Each of the Sub-PODs 210 A and 210 B are interconnected to a Crossbar Module (TCM) 220 through dedicated point-to-point Sub-POD Interfaces 230 A and 230 B, respectively, that are similar to the MI interconnections 130 . TCM 220 further interconnects to one or more I/O Modules 140 via the respective point-to-point MIO Interfaces 150 . TCM 220 both buffers data and functions as a switch between the Sub-POD Interfaces 230 A and 230 B, the MIO Interfaces 150 A and 150 B, and the MI Interfaces 130 A through 130 D. When an I/O Module 140 or a Sub-POD 210 is interconnected to one of the MSUs via the TCM 220 , the MSU connection is determined by the address provided by the I/O Module or the Sub-POD, respectively. In general, the TCM maps one-fourth of the memory address space to each of the MSUs 110 A- 110 D. According to one embodiment of the current system platform, the TCM 220 can further be configured to perform address interleaving functions to the various MSUs. The TCM may also be utilized to perform address translation functions that are necessary for ensuring that each processor (not shown in FIG. 2) within each of the Sub-PODs 210 and each I/O Module 140 views memory as existing within a contiguous address space as is required by certain off-the-shelf operating systems.
In one embodiment of the present invention, I/O Modules 140 are external to Sub-POD 210 as shown in FIG. 2 . This embodiment allows system platform 100 to be configured based on the number of I/O devices used in a particular application. In another embodiment of the present invention, one or more I/O Modules 140 are incorporated into Sub-POD 210 . Each of the I/O Modules includes an I/O Buffer shown as 240 A and 240 B of FIG. 2 . These I/O Buffers may be cache memories that include tag and coherency logic as is known in the art.
Sub-Processing Module
FIG. 3 is a block diagram of a Sub-Processing Module (Sub-POD). Sub-POD 210 A is shown, but it is understood that all Sub-PODs 210 have similar structures and interconnections. In this embodiment, Sub-POD 210 A includes a Third-Level Cache (TLC) 310 and one or more Coherency Domains 320 (shown as Coherency Domains 320 A, 320 B, 320 C, and 320 D). TLC 310 is connected to Coherency Domains 320 A and 320 B via Bus 330 A, and is connected to Coherency Domains 320 C and 320 D via Bus 330 B. TLC 310 caches data from the MSU, and maintains data coherency among all of Coherency Domains 320 , guaranteeing that each processor is always operating on the latest copy of the data.
Each Coherency Domain 320 includes an Instruction Processor (IP) 350 (shown as IPs 350 A, 350 B, 350 C, and 350 D). Each of the IPs includes a respective First-Level Cache (FLC). Each of the IPs is coupled to a Second-Level Cache (SLC) 360 (shown as SLC 360 A, 360 B, 360 C and 360 D) via a respective point-to-point Interface 370 (shown as Interfaces 370 A, 370 B, 370 C, and 370 D). Each SLC further interfaces to Front-Side Bus (FSB) Logic 380 (shown as FSB Logic 380 A, 380 B, 380 C, and 380 D) via a respective one of Interfaces 385 A, 385 B, 385 C, and 385 D. FSB Logic is also coupled to a respective one of Buses 330 A or 330 B.
In the preferred embodiment, the SLCs 360 operate at a different clock speed than Buses 330 A and 330 B. Moreover, the request and response protocols used by the SLCs 360 are not the same as those employed by Buses 330 A and 330 B. Therefore, FSB logic is needed to translate the SLC requests into a format and clock speed that is compatible with that used by Buses 330 .
Directory-Based Data Coherency Scheme of the System Architecture
Before discussing the data by-pass system of the current invention in more detail, the data coherency scheme of the current system is discussed. Data coherency involves ensuring that each processor within Platform 100 operates on the latest copy of the data, wherein the term “data” in the context of the current Application refers to both processor instructions, and any other types of information such as operands stored within memory. Since multiple copies of the same data may exist within platform memory, including the copy in the MSU 110 and additional copies in various local cache memories (local copies), some scheme is needed to control which data copy is considered the “latest” copy.
The platform of the current invention uses a directory protocol to maintain data coherency. In a directory protocol, status information is associated with units of data stored within the main memory. In the preferred embodiment, status information is stored in Directory Memories 160 A, 160 B, 160 C, and 160 D of FIG. 1 for each 64-byte segment of data, or “cache line”, residing within the MSUs 110 . For example, the status information describing a cache line of data stored in MSU 110 A is stored in Directory Memory 160 A, and so on. Status information is monitored and updated by a controller when a copy of a cache line is requested by one of the Sub-PODs 210 so that the Directory Memories record which Sub-PODs 210 or I/O Modules 140 have copies of each cache line in the system. The status also includes information on the type of copies that reside within the system, as is discussed below. In the present invention, a cache line copy may be one of several types. Copies residing within caches in the Sub-PODs may be either “shared” or “exclusive” copies. If a cache line is shared, one or more Sub-PODs may store a local copy of the cache line for read-only purposes. A Sub-POD having shared access to a cache line may not update the cache line. Thus, for example, Sub-PODs 210 A and 210 B may have shared access to a cache line such that a copy of the cache line exists in the Third-Level Caches 310 of both Sub-PODs for read-only purposes.
In contrast to shared status, exclusive status, which is also referred to as “exclusive ownership”, may be granted to only one Sub-POD at a time for any given cache line. When a Sub-POD has exclusive ownership of a cache line, no other Sub-POD may have a copy of that cache line in any of its associated caches. A cache line is said to be “owned” by the Sub-POD that has gained the exclusive ownership.
A Sub-POD is provided with a copy of a cache line after the Sub-POD makes a fetch request on Sub-POD Interface 230 A to the TCM 220 . The TCM responds by providing a fetch request to the appropriate MSU 110 based on the cache line address. The type of fetch request made to memory is determined by the type of cache line copy that is requested by the Sub-POD.
A. Fetch Copy Requests
When a Sub-POD requests a read-only copy of a cache line, the TCM responds by issuing a “Fetch Copy” command to the addressed one of MSUs 110 A- 110 D on the command lines of the corresponding MSU Interface (MI) 130 . At the same time, the cache line address is asserted on the MI address lines. The MSU receiving this request consults its Directory Memory 160 to determine the current status of the requested cache line. If the MSU stores the most recent copy of the cache line as indicated by a cache line status of “Present”, the MSU can provide the cache line data accompanied by a response indication directly to the requesting Sub-POD 210 via the TCM on MI 130 . The response indication is encoded on unidirectional, MSU-to-TCM control lines included within each of the MIs 130 .
The MSU may not have the most recent copy of the cache line because another Sub-POD is the exclusive owner of the data. In this instance, the MSU must request that this owner Sub-POD return any updated data to the MSU. To accomplish this, the MSU issues a “Return Function” to the owner Sub-POD via the associated TCM 210 . The Return Function is encoded on the command lines of the MI 130 , along with the address of the requested cache line, is received by the associated TCM, and forwarded to the target Sub-POD.
Several types of Return Functions exist. In the current example, the requesting Sub-POD is requesting a read-only, shared copy of the cache line. This means that although the owner Sub-POD must provide any cache line updates to the MSU so these updates can be provided to the requesting Sub-POD, the owner Sub-POD may also keep a read-only copy of this cache line. To communicate this, the MSU issues a special Return Function called a “Return Keep Copy”. The TCM responds by returning the requested cache line on the data lines of the MI 130 , and by further asserting a “Return Command” on the MI command lines. If this Sub-POD retains a read-only copy of the cache line, that Sub-POD is no longer considered the “owner”, since no write operations may be performed to the cache line. Thus, the Sub-POD is said to return both data and ownership to the MSU with the Return Command.
After data is returned from the Sub-POD, a special POD-to-POD interface within the MSU routes the data from the returning MI 130 to the MI associated with the requesting unit. This POD-to-POD interface is described in the above-referenced application entitled “System and Method for By-Passing Supervisory Memory Intervention for Data Transfers Between Devices Having Local Memories”. It may be noted that data is routed in this manner even if the previous owner did not modify the cache line. Providing unmodified returned data in this manner is more expedient then reading the cache line from the MSU. The returned data need only be written back to the MSU if the cache line was actually modified as is indicated by the type of Return Command issued by the Sub-POD. A Sub-POD issues a “Return Block” command to indicate the presence of a modified cache line, whereas a “Return Fast” command is issued to indicate the return of an unmodified cache line. In either instance, the MSU Directory Memory 160 is updated to reflect the new cache line status.
B. Fetch Original Requests
In a manner similar to that discussed above with regards to read-only cache line copies, a Sub-POD gains exclusive ownership of a cache line by making a “Fetch Original” fetch request to the MSU via the TCM 220 , which encodes the request on the command lines of the MI 130 . In response, the MSU may provide the cache line directly if the cache line is “Present” in the MSU such that no other Sub-POD has a copy of the cache line.
When a Sub-POD makes a request to gain exclusive ownership of a cache line, and the cache line is stored within another Sub-POD in the system, the request is handled in one of several ways. If another Sub-POD has exclusive ownership of the cache line, the MSU issues a Return Function to the owner Sub-POD requesting the return of the cache line data in the manner discussed above. In this instance, a “Return Purge” function is issued to indicate that the previous Sub-POD owner may not keep a copy of the cache line, but instead must purge it from all cache memories. This is necessary since only one Sub-POD may have exclusive ownership of a cache line at one time.
Upon receipt of the Return Purge function, the Sub-POD determines whether the cache line has been modified. If so, the Sub-POD returns both the data and ownership to the MSU by directing the corresponding TCM 220 to issue a Return Command on the MI 130 . Alternatively, if the owner Sub-POD has not modified the cache line, the Sub-POD may return just the ownership to the MSU:using a “Return Fast” command in the manner discussed above. In this instance, the owner Sub-POD may not keep a copy of the cache line for any purpose, and the cache line is marked as invalid in the local cache.
The MSU responds to the Return Commands by providing the most recent cache line data, along with exclusive ownership, to the requesting Sub-POD via the associated TCM. The MSU provides this response by encoding an acknowledgment on the command lines of the MI along with the data provided on the MI data lines. Additionally, the MSU updates the corresponding Directory Mernory 160 with the cache line status indicating the new Sub-POD owner, and stores any returned data.
The above description relates to the return of data when a requested cache line is exclusively owned by another Sub-POD. According to another scenario, the cache line may reside as a read-only, shared copy within a cache of one or more Sub-PODs. In this instance, the MSU issues a “Purge Function” to these Sub-PODs such that all local copies are invalidated and can no longer be used. The MSU then provides the cache line and ownership to the requesting Sub-POD and updates the Directory Memory status in the manner discussed above.
C. Fetch Conditional Requests
In instances in which the Sub-POD is requesting an operand, the TCM issues a “Fetch Conditional” command to the addressed MSU 110 . Upon receipt of this command, the MSU consults the state of the cache line in Directory Memory 160 . If the cache line data must be retrieved from another Sub-POD, an optimization algorithm is used by the MSU to determine whether a “Return Keep Copy” or a “Return Purge” is issued to the Sub-POD. In other words, the algorithm determines whether an exclusive or shared copy of the cache line will be provided to the requesting Sub-POD. The algorithm, which is largely beyond the scope of the current invention, is based on the current cache line state, and is designed to optimize the sharing of operand data, whenever possible, so that performance is enhanced. After the selected Return function is issued by the MSU to the owner Sub-POD, Fetch Conditional Requests are handled in the manner discussed above with respect to other Fetch requests.
D. Flush Operations
In addition to returning cache line data to the MSU 110 following the receipt of a Return Function, Sub-PODs may also provide data to the MSU in other situations. For example, a Sub-POD may provide data to be written back to an MSU during Flush operations. When a Sub-POD receives a cache line from an MSU, and the cache line is to be copied to a cache that is already full, space must be allocated in the cache for the new data. Therefore, a predetermined algorithm is used to determine which older cache line(s) will be disposed of, or “aged out of”, cache to provide the amount of space needed for the new information. If the older data has never been modified, it may be merely overwritten with the new data. However, if the older data has been modified, the cache line including this older data must be written back to the MSU 110 during a Flush Operation so that this latest copy of the data is preserved.
F. I/O Operations
As discussed above, cache lines residing within a Sub-POD will have either a shared or exclusive status. Other types of status indications are used when a cache line resides within a storage device of an I/O Module 140 shown as I/O Buffers 240 A and 240 B of FIG. 2 . For example, a status of “I/O Copy” is used to describe a read-only copy of a cache line stored within an I/O Buffer 240 . In a manner similar to that described above for shared cache lines, a cache line in the I/O Copy state may not be modified. Unlike a cache line having a status of “shared”, a cache line in the I/O Copy state may only be stored in one I/O Buffer at a time. No other TLC or I/O Module may have a copy of any kind, shared or exclusive, while an I/O Module has an I/O Copy of a cache line.
I/O Buffers 240 may also store exclusive copies of cache lines. Such cache lines are said to have a status set to “I/O Exclusive”. Both read and write operations may be performed to a cache line that is exclusively owned within an I/O Buffer. Unlike cache lines that are exclusively owned by a Sub-POD (that is, have a status of “exclusive”), a cache line that is exclusively owned by an I/O Buffer will remain in the I/O Buffer until the I/O Module flushes the data back to the MSU without prompting. The MSU will not initiate a Return operation when the cache line is in this state, and any requests for the cache line will remain pending until the I/O Module performs a flush operation.
Finally, as indicated above, a cache line may have a status of “Present”. This status is assigned to the cache line when the MSU has the most current copy of the data and no other Sub-PODs or I/O Modules have a valid local copy of the data. This could occur, for example, after a Sub-POD or I/O Module having an exclusive copy of the cache line performs a Flush operation so that the MSU thereafter has the only valid copy of the data. This status indication is also assigned to a cache line after an I/O Module initially stores that cache line in the MSU during what is referred to as an “I/O Overwrite” operation. An I/O Overwrite is performed whether or not any other Sub-PODs or I/O Modules have local copies of the overwritten cache line. The MSU issues a Purge function to these Sub-PODs or I/O Modules so that the outdated data is invalidated.
Coherency Scheme Within a Sub-POD
As discussed above, in the system of the preferred embodiment, directory information is stored in Directory Memories 160 in the MSU to record which of the Sub-POD(s) or I/O Modules store particular cache lines. The MSU directory does not, however, indicate which of the cache memories within a Sub-POD has a copy of the cache line. For example, within a Sub-POD, a given cache line may reside within the TLC 310 , one or more SLCs 360 , and/or one or more First-Level Caches of a Sub-POD IP. Information pertaining to the specific cached data copies is stored in a directory memory within the TLC.
In a manner similar to that described above with respect to the MSU, the TLC stores status information about each cache line in TLC Directory 315 of FIG. 3 . This status information indicates whether the TLC was granted either exclusive ownership or a read copy of a particular cache line by the MSU 110 . The status information also indicates whether the TLC has, in turn, granted access to one or more SLCs in the respective Sub-POD. If the TLC has exclusive ownership, the TLC may grant exclusive ownership to one of the SLCs 360 in a Sub-POD 210 so that the IP 350 coupled to the SLC may update the cache line. Alternatively, a TLC having exclusive ownership of a cache line may also grant a read copy of the cache line to multiple ones of the SLCs in a Sub-POD. If the TLC only has a read copy of a cache line, the TLC may grant a read copy to one or more of the SLCs 360 in a Sub-POD 210 such that the interconnected IP may read, but not write, the cache line. In this case, the TLC may not grant any of the SLCs write access to the cache line.
The TLC tracks the copies that exist within a Sub-POD by recording an indicator identifying one or both of the Buses 330 to which it is coupled. For example, if TLC 310 granted exclusive ownership of a cache line to SLC 360 A, the indicator stored in the TLC directory for that cache line identifies Bus 330 A as having exclusive ownership. If TLC 310 granted read copies to both SLCs 360 A and 360 C, the TLC directory identifies both Buses 330 A and 330 B as having read copies.
When data is provided to an SLC 360 , it may also be provided to the respective First-Level Cache (FLC) within the IP 350 coupled to that SLC. Generally, whenever an IP requests a read copy of data, the read copy will be provided by the SLC to be stored within the IP's FLC. An exception to this rule occurs for certain system-level clock information that will become outdated, and therefore is not forwarded to the FLC. In contrast to read data, a cache line that is obtained by the SLC from the TLC on an exclusive ownership basis is not generally forwarded to the FLC for storage. An exception to this rule occurs for certain resources that are associated with software locks, and which must be cached within the FLC until the IP releases the lock. The SLC includes Tag RAM Logic (not shown in FIG. 3) to record whether the associated FLC stores a copy of a particular cache line, and which is largely beyond the scope of this invention.
As discussed above, the directory status information stored within the MSU 110 is used to maintain data coherency throughout the entire system. In a similar manner, the directory status information within the TLC is used to maintain data coherency within the respective Sub-POD 210 . Within the Sub-POD, data coherency is maintained for each of the Buses 330 , and is also maintained for the Sub-POD as a whole.
Data coherency is maintained for each of the Buses 330 using a snooping mechanism. If an IP 350 makes a request for an address that is not present in either the respective FLC or SLC, the SLC initiates a request via the respective FSB Logic 380 to the associated Bus 330 . The request will indicate the type of request (read or write), and will also indicate the request address. Each SLC monitors, or “snoops” the Bus 330 via its respective FSB logic for these types of requests from the other SLC on Bus 330 . When such a request is detected, the SLC that detected the request checks its internal Tag RAM to determine whether it stores a modified copy of the requested data. If it does store a modified copy of the requested data, that data is provided on Bus 330 so that a copy can be made within the requesting SLC. Additionally, if the requesting SLC is requesting exclusive ownership of the data, the other (non-requesting) SLC must also mark its resident copy as invalid, since only one SLC may have write ownership at a given time. Furthermore, if the SLC detecting the request determines that its associated FLC also stores a copy of the cache line that is requested for exclusive ownership, that SLC must direct the FLC to invalidate its local copy.
If an SLC is requesting a cache line that has not been modified by the other SLC that resides on the same Bus 330 , the TLC 310 will handle the request. In this case, the SLC presents the request to Bus 330 , and because the associated SLC does not respond to the request in a pre-determined period of time with snoop results, the TLC handles the request.
A TLC 310 processes requests from the SLCs in the associated Sub-POD by determining if that Sub-POD has been granted the type of access that is being requested, and if so, by then determining how the requested cache line may be obtained. For example, a TLC may not grant exclusive ownership of a cache line to an SLC if the TLC itself has not been granted exclusive ownership. If the TLC has been granted exclusive ownership, the TLC must further determine if the other (non-requesting) Bus 330 has, in turn, been granted exclusive ownership. If the other Bus 330 has exclusive ownership of the data, the TLC issues a request to that Bus to initiate return of the data. Because the SLCs are snooping the Bus, this request will be detected, and an SLC owning the data will return any modified copy of the data to the TLC. Additionally, any copies of the requested cache line residing within the caches of the previous owner SLC will be marked as invalid. The TLC may then provide the data to the requesting SLC and update its directory information to indicate that the other Bus 330 now has the exclusive ownership.
A similar mechanism is used if the SLC is requesting read access. If the TLC has been granted read access by the MSU for the requested cache line, the data is provided to the requesting SLC and the directory information is updated to reflect that the associated Bus 330 has read access of the data. Both Buses may be granted read access to the cache line simultaneously.
In yet another scenario, the TLC may not have a copy of the requested cache line at all, or may not have the type of access that is requested. This could occur for a number of reasons. For example, a TLC may obtain a copy of a cache line from the MSU, provide it to one or more of the SLCs in its Sub-POD, then later age the cache line out of memory to make room for another cache line. This aging out of the cache line in the TLC may occur even though an SLC in the Sub-POD still retains a copy. This is allowed because the cache memories of the preferred embodiment are not inclusive caches. That is, each cache line residing within an SLC does not necessarily reside in the associated TLC 310 . As a result of this non-inclusive cache configuration, a request by any of the SLCs in the Sub-POD for the cache line may result in a cache miss at the TLC even if the cache line is stored in another SLC within the same Sub-POD. A cache miss could also occur because the requested cache line does not reside in the TLC or in any other one of the caches in the respective Sub-POD, In yet another instance, an SLC may be requesting exclusive ownership of a cache line, but the associated TLC has only been granted a read copy of a requested cache line. In any of these cases, the TLC must make a request for the cache line via the associated Sub-POD Interface 230 to the TCM 220 , which then issues an appropriate fetch request on the MI 130 to the addressed MSU 110 as described above.
After a TCM makes a request via the respective MI Interface for access to a cache line, the request is presented to MSU 110 , and the directory logic within the MSU determines where the most current copy of the data resides. This is accomplished in the manner discussed above. If the MSU owns the most recent copy of the data, the data may be provided immediately to the requesting TLC with the requested permission as either a read copy or with exclusive ownership. Similarly, if only a read copy of the data is being requested, and the MSU has granted only read copies to other Sub-PODs 210 , the MSU may immediately provide the additional read copy to the requesting TLC. However, if exclusive ownership is being requested, and the MSU has already granted exclusive ownership to another Sub-POD, the MSU must initiate a Return operation so that the TLC currently owning the data returns any updated data. These MSU requests may take a substantial amount of time, especially if a large number of requests are already queued to use the MI 130 associated with Sub-PODs having current copies of the requested cache line.
From the above discussion, it is apparent that the necessity to return data from a Sub-POD to the MSU for forwarding to the same Sub-POD, or a different Sub-POD, may substantially increase the time required to gain exclusive ownership prior to performing a write operation. This is particularly true if a large number of requests are being processed across the MI Interfaces. The current invention minimizes the time required to obtain exclusive ownership in the cases involving routing of data between the two Sub-PODs within the same POD. The current invention also minimizes the time requested to transfer data between two SLCs in the same Sub-POD in those instances in which the TLC did not have a record of the cache line. Recall that this may occur when the TLC ages out a cache line that was still stored in one of the SLCs in its Sub-POD, so that when a request for the cache line is presented to the TLC, the TLC does not initiate the return of data from the owning SLC within that Sub-POD. In this instance, the TLC forwards the request to the MSU, which initiates a return operation to the same Sub-POD that originated the request.
Description of the Data By-Pass System of the Current Invention
The current invention provides a by-pass system that directly routes returned cache line data between the two Sub-PODs 210 A and 210 B in those instances in which the requesting Sub-POD and the owner Sub-POD are in the same POD 120 A. The system also provides logic to enable a Sub-POD to route cache line data from one Bus 330 to another in those situations in which the non-inclusive TLC has aged out a cache line still residing in one of the associated SLCs. Use of these “by-pass operations” significantly reduces the time required to gain access to a cache line, and also reduces the traffic on MIs 130 .
FIG. 4 is a block diagram of the TCM of the preferred embodiment. The TCM receives requests from Sub-POD 210 A and 210 B on Sub-POD Interfaces 230 A and 230 B, respectively. TCM further receives requests from I/O Modules 140 A and 140 B via MIO Interfaces 150 A and 150 B, respectively. Each of these four interfaces is associated with a storage device for temporarily storing requests received from the respective interface. These storage devices are shown as I/O 1 IN 402 A, Sub-POD 0 IN 402 B, Sub-POD 1 IN 402 C, and I/O 1 IN 402 D. The requests stored in these storage devices are received by Command/Function Routing Logic 404 on Input Interfaces shown as 406 A, 406 B, 406 C, and 406 D, and are processed according to a predetermined priority scheme.
Command/Function Routing Logic 404 translates the requests provided by the I/O Modules and Sub-PODs to a format that is compatible with the MIs 130 , and routes the translated requests to the appropriate one of the MI based on the request address. As mentioned above, each MI services a respective MSU 110 , with each MSU providing storage for one-fourth of the memory address space of Platform 100 .
In addition to routing requests received from the I/O Modules and Sub-PODs to the addressed MSUs, the TCM also routes functions received from the MSUs via MIs 130 to the appropriate Sub-POD or I/O Module. As discussed above, these functions initiate various Return and Purge operations so that memory coherency is maintained in Platform 100 . When a function is received on one of the MIs, it is stored in Command/Function Routing Logic 404 , and is eventually handled according to a predetermined priority scheme. When selected for processing, it will be translated to the format required by the I/O Modules and Sub-PODs, and routed to the appropriate one of the output storage devices associated with either an MIO Interface 150 or a Sub-POD Interface 230 . These storage devices are shown as I/O 0 OUT 408 A, Sub-POD 0 OUT 408 B, Sub-POD 1 OUT 408 C, and I/O 1 OUT 408 D. These devices interface to Command/Function Routing Logic via Output Interfaces 410 A, 410 B, 410 C, and 410 D, respectively. The functions stored in the output storage devices are provided to corresponding I/O Module or Sub-POD as controlled by the respective control logic shown as I/O 0 Control 412 A, Sub-POD 0 Control 412 B, Sub-POD 1 Control 412 C, and I/O 1 Control 412 D. The control logic uses control lines included in the respective MIO or Sub-POD Interface to determine when the transfer of the function to the I/O Module or Sub-POD may occur.
FIG. 5 is a block diagram of the Main Storage Unit (MSU) 110 A. Although MSU 110 A is shown and described, it will be understood that the following description applies equally to all MSUs in Platform 100 . MSU 110 A may receive a request on one or more of the MIs 130 A, 130 B, 130 C and 130 D at a given time. A request received on MI 130 A is stored in Request Storage Device 502 , which is capable of storing multiple requests. Each of the MIs is associated with a similar Request Storage Device.
A request received from the MI includes several fields. Field 504 includes the request address, which is an address mapped to the address space of the Main Store. 506 of MSU 110 A. Main Store 506 includes one or more banks of storage devices such as Random Access Memories (RAMs) mapped to approximately one-fourth of the address space of Platform 100 . Field 508 is a command that indicates the type of request being performed. As discussed above, command types include Flushes, Fetches, Returns, and I/O Overwrites. Also included in the request is a Job Number 510 used by the I/O Modules 140 and TLCs 310 to match responses provided by the MSU to the initial requests. This is required since responses are not necessarily returned in the same order the requests are issued by the TCMs 220 . Finally, each request includes both a Bus and TLC indication shown as Fields 512 and 514 , respectively. These Fields are appended to the original command by the TCM 220 to indicate which I/O Module 140 or TLC 310 within a particular POD 120 initiated the request. The TLC Field is set to “1” for a Sub-POD-initiated request, and is set to “0” for a request initiated by an I/O Module. The Bus Field identifies one of the two I/O Modules or TLCs associated with a particular POD 120 . Exemplary settings for these Fields are shown in association with the Command/Function Routing Logic 404 of FIG. 4 and Input Interfaces 406 .
A request received on MI 130 A is stored in Request Storage Device 502 until Processing Logic 516 selects the request for processing according to a predetermined priority scheme. Processing Logic reads the request from Request Storage Device, then reads the entry in Directory Memory 160 A corresponding to the requested cache line address. The state of the cache line as indicated by the status information stored in Directory Memory 160 A will determine the manner in which the request is processed. In some instances the request may be processed immediately, as is the case if the request includes a Fetch command for a cache line owned by the MSU. In other situations, the MSU may have to generate a request to another POD to obtain the latest copy of the requested data in the manner discussed above.
If Processing Logic 516 determines based on the state of the requested cache line that a request must be performed to another POD, Processing Logic provides a signal on Line 518 to Function Generation Logic 520 . This logic uses the state of the cache line provided on Line 522 from Directory Memory 160 A, along with the Command Field 508 to build the MSU-to-POD request. This request is stored in a storage device shown as MSU Request Storage Device 524 .
Many of the fields included in the MSU-to-POD request are copied from Request Storage Device 502 . These copied fields include the Address, Job Number, Bus, and TLC indications shown in Fields 526 , 528 , 530 , and 532 of MSU Request Storage Device, respectively. This request also includes Function Field 534 , which is an encoded value generated by Function Generation Logic 520 that indicates the type of operation being requested. Functions include Purges and the various types of Return Functions discussed above.
An MSU-to-POD request also includes Destination Address Field 536 . This field indicates which device within the target POD is to receive the request. For all Return Function types, this Destination Address will always identify a single TLC 220 . As discussed above, this is because MSUs do not require I/O Modules to perform Return operations. Instead, I/O Modules are allowed to retain cache lines in the I/O Buffers until all pending I/O operations are completed on the buffered data and the cache lines are thereafter returned without prompting. In contrast, a Destination Address associated with a Purge Function may specify either one or more TLCs, or a single I/O Module.
The MSU-to-POD request further includes an indication of the requesting POD as shown in Field 538 . This value is appended to the other request information using a POD identifier stored in a storage device shown as Register 540 associated with MI 130 A. Each MI is associated with a similar storage device having a uniquely associated identifier, which in the preferred embodiment is a two-bit encoded value. According to the preferred embodiment, these storage devices may be scanned to a particular POD identification value at initialization time using a scan-set interface as is known in the art.
When the MSU-to-POD request has been constructed by Function Generation Logic 520 , it may be provided to Routing Logic 542 for routing to the particular one of the MIs 130 A, 130 B, 130 C or 130 D based on the POD ID Field 538 .
As discussed above, the foregoing description relates to requests received from MI 130 A. However, it will be understood that Function Generation Logic 520 and Routing Logic 542 processes requests received on all of the MIs 130 in a similar manner.
Before continuing a discussion related to MSU-to-POD request processing, several aspects of the data by-pass system are discussed further in reference to prior art memory platforms. The U.S. patent application entitled “Directory-Based Cache Coherency System Supporting Multiple Instruction Processor and Input/Output Caches”, referenced above, discusses a multi-processor platform that does not employ the by-pass mechanism of the current invention. Because a by-pass mechanism is not utilized, the destination unit that receives a Return Function, as is identified by Destination Address Field 536 , is not required to know which I/O Module 140 or TLC 310 initiated a particular request. This is because the destination unit will always respond to the MSU, which, in turn, will route any modified cache line data along with an appropriate response back to the requesting unit. For this reason, the POD ID, Bus and TLC Fields 538 , 530 , and 532 , respectively, need not be included in the request. However, in the system of the current invention, this information must be transmitted to the destination unit so that appropriate by-pass responses may be generated in a manner to be discussed below.
The current by-pass system further requires that the Job Number indicator in Field 528 be provided to the POD in the MSU-to-POD request. This would not be necessary if a by-pass mechanism were not employed, since the MSU would ultimately be responsible for providing the Job Number along with the response back to the requesting unit. As discussed above, this Job Number allows the requesting unit to match a response to the original request, which is necessary because responses are not returned in the same order as the requests are submitted. However, when a by-pass operation is used, the MSU does not provide the response. Instead, a TCM or TLC is responsible for generating the response that includes the appropriate Job Number, and thus these units must have visibility to this information.
According to one embodiment of the current Platform 100 , the MSU stores a portion of the information received in any Fetch request in a storage device shown as Request Memory 544 before providing the resulting MSU-to-POD Return function to the TCM. This stored information includes Job Number Field 502 , a portion of Address Field 504 , and an additional field (not shown in FIG. 5) that specifies “container order” information. The container order indicates the order in which the current owner is to return a 64-byte cache line of data to the requesting POD. In some instances, the container order field specifies that data should be returned in an out-of-order fashion so that the requesting IP can obtain requested instructions and operands as quickly as possible.
Information saved in Request Memory 544 is included with any MSU-to-POD Return function. However, this information is not returned by the TCM with the POD-to-MSU Return command. This data is omitted because of the encoded format required by the command field. Each MI 130 is not wide enough to accommodate the format of the command while also transferring all address and container field bits. Thus, this information must be retained within the MSU, and associated with any modified returned data using the Job Number Field. This can be accomplished because the Job Number Field is both stored in Request Memory 544 with the saved request information, and is further returned by the TCM with any Return command.
The MSU uses the information saved in Request Memory 544 to write any modified cache line data to Main Store 506 after a Return command is issued by a TCM. For example, the container information indicates the order data is returned from the previous owner so that the MSU can write any updated data to Main Store 506 in natural order. The use of the request data is discussed further below.
FIG. 6 is a block diagram of Command/Function Routing Logic 404 . MSU-to-POD requests are provided on bi-directional MIs 130 A, 130 B, 130 C, and 130 D to be stored in one of the storage devices shown as MSU IN 0 602 A, MSU IN 1 602 B, MSU IN 2 602 C, and MSU IN 3 602 D. The various fields of the request are shown for the storage device MSU IN 0 602 A, and it will be understood requests stored in the other storage devices 602 B, 602 C, and 602 D are similar in content.
MSU Function Processing Logic 604 processes the stored MSU-to-POD requests according to a predetermined priority scheme. MSU Function Processing Logic translates a selected request to the format required by the Sub-POD Interfaces 230 A and 230 B, and routes the request on one of the Interfaces 410 B or 410 C to the unit indicated by the Destination Address Field. Recall that the I/O Modules will not be indicated as the destination unit for Return function types since I/O Modules are allowed to store cache lines until all I/O operations are completed.
In addition to routing the request to the appropriate TLC, the TCM Compare Logic further performs a compare function to determine if the current request is eligible to be performed as a by-pass operation. The Compare Logic for performing the by-pass compare function is shown for storage device MSU IN 0 602 A, however, it will be understood that similar logic is associated with each of the storage devices 602 A- 602 D. According to one embodiment of the invention, a TCM by-pass operation may occur if the request POD ID Field 538 matches the POD ID stored in Identification Register 606 of the TCM, and the original requester is not. the TLC 310 indicated by the Destination Address Field 536 . In other words, the requesting unit may be either a TLC or an I/O Module associated with the same POD as the destination TLC, so long as the requesting unit and the destination unit are not the same TLC.
According to another embodiment, by-pass operations are limited to those instances in which the requesting unit is a TLC, and not an I/O Module. In this alternative embodiment, the Compare Logic identifies those instances in which the request POD ID Field 538 matches the POD ID value provided by the TCM, and the Destination Address Field 536 and Bus and TLC Fields 530 and 532 identify two different TLCs in the same POD 120 . This alternative embodiment may be used in those systems in which I/O Modules only receive memory data from an MSU and are not involved in any by-pass operations. In some instances, this may simplify the design of Platform 100 .
In either of the above-described embodiments, Identification Register 606 is scannable, and the POD ID value is loaded at system initialization time. POD ID Compare Logic receives the programmable POD ID and provides a signal on Line 612 to enable Response Generation Logic 614 to generate a provisional response if this request is eligible to perform a by-pass operation. This response will include the Job Number Field 510 copied from the MSU-to-POD request, and further includes an encoded value that identifies the data as a response. This provisional response is stored in Response Generation Logic until the TCM determines if the by-pass operation can be completed.
Returning to a discussion related to handling of the request, the TLC 310 addressed in the Destination Address Field 536 will receive the request from the TCM. If the request includes a Return Function, the TLC will determine if it, or one of the SLCs in the Sub-POD, stores a modified copy of the requested cache line. This is accomplished by checking the TLC Directory 315 and, if necessary, placing a request for the cache line on Buses 330 A or 330 B in the manner discussed above. In some cases, the Sub-POD may not have the requested cache line at all. This will occur if the cache line was flushed from the Sub-POD after the initial request was submitted to the Directory Memory 160 to determine cache line location but before the Return function was provided to the TLC. In these instances, the TLC responds with an indication that the data is not present, and the MSU must supply the most recent cache line copy to the requester.
If the Sub-POD does have a copy of the cache line, the TLC returns its most-recent copy to the TCM along with an indication of the type of return operation being performed. The TLC indicates return type by asserting various control lines on Sub-POD Interface 230 A or 230 B. The type of return indication will be based, in part, on whether the TLC retains a read-only copy of the cache line as is permitted if the original request is requesting a read-only copy. The type of return indication also depends on whether the cache line was modified. Return types are discussed further below.
After the Sub-POD issues the response to the MSU-to-POD request on Interface 230 A or 230 B, this response is stored along with any returned data in the associated storage device shown as Sub-POD 0 IN 402 B or Sub-POD 1 IN 402 C, respectively (FIG. 4 ). TLC Request Processing Logic 616 processes the stored TLC responses according to a predetermined priority scheme. The TLC response will include the Job Number Field 528 of the original request. This Job Number Field is compared by TCM Job Number Compare Logic 618 to all provisional responses stored in the Response Generation Logic 614 . If a match is detected and the response provided by the TLC includes returned data, a by-pass operation may be performed. The returned data is provided by TLC Request Processing Logic 616 to Response Generation Logic 614 via Interface 620 , and is appended to the provisional response. This response is made available to MSU Function Processing Logic 604 via Line 622 , and will be selected for handling according to a predetermined priority scheme.
In an alternative embodiment, Response Generation Logic 614 does not generate a provisional response at the time the initial request is received. Instead, Response Generation Logic 614 waits until the TLC returns any requested data. At this time, Response Generation Logic uses fields provided in the TLC response, including the Bus Field 530 , the TLC Field 532 , and Destination Address Field 536 , to determine that a bypass operation should be performed. Response Generation Logic generates and buffers the desired response including the response indication, the Job Number Field 528 , and the returned data. This response is then provided to MSU Function Processing Logic 604 in the manner discussed above. This alternative embodiment simplifies the design. However, since the by-pass response generation is performed only after the TLC response is received, the response data is available for use in performing the by-pass operation slightly later than in the embodiment discussed above.
When selected for handling by MSU Function Processing Logic 604 , a request stored in Response Generation Logic 614 will be translated into the appropriate format as required by MIO Interfaces 150 or Sub-POD Interfaces 230 . Then it will be routed to the requesting unit as is indicated by Bus and TLC Fields 530 and 532 . That is, instead of routing the data from the TCM 220 to the MSU and back to the same TCM as had been done in prior art systems, the response is routed directly by the TCM to the requesting Sub-POD. This decreases latency, and also decreases the amount of traffic on the MIs 130 so that the efficiency of Platform 100 is improved.
When a by-pass operation is performed, a response is provided directly by the MSU Function Processing Logic 604 to the original requesting unit. A By-pass Return command is also provided by the TCM to the MSU so that the MSU may update the Main Store 506 with any updated data, and further update the Directory Memory 160 A with cache line status. The Return command is formatted by TLC Request Processing Logic 616 in response to a signal received by TCM Job Number Compare Logic 618 . This Return command is provided to Command Storage 624 via Line 626 to be stored until it can be provided to the addressed one of the MSUs according to a predetermined priority scheme. When the Command Routing Logic 628 determines that a requested one of the MIs 130 is available for use, Command Routing Logic retrieves the respective pending one of the commands stored in Command Storage 624 and routes the command to the addressed MSU 110 .
Several types of By-pass Return commands are available for return by the TCM 220 to an MSU 110 . A By-pass Return Block command is issued by the TCM when the updated cache line is provided by the previous Sub-POD owner to the requesting unit during a by-pass operation. In this situation, the updated cache line is also returned along with the By-Pass Return Block command to the MSU to allow the MSU to store the updated data. A variation of this command is used when the previous Sub-POD owner retained a copy of the updated cache line for future use. Recall that this is permitted if the requesting unit was only requesting a read-only copy, since read-only copies can be shared by multiple units. In this case, the TCM returns the updated cache line data to the requesting unit during the by-pass operation, and also returns this data to the MSU along with a By-pass Return Update Copy command. The By-pass Return Update Copy command indicates the new shared-copy status of the cache line.
Several other types of By-pass Return commands are used when the previous Sub-POD owner does not have an updated copy of the cache line. In this instance, there is no need for the MSU to store the returned copy of the cache line since the MSU already retains this version of the data. Therefore, according to one embodiment of the by-pass system, the TCM provides the data to the requesting unit during a by-pass operation, but does not return data to the MSU. Instead, the TCM issues a By-pass Return Fast command to the MSU to indicate the occurrence of the by-pass operation, and to allow the MSU to update the status of the cache line in Directory Memory 160 . In a similar situation, a previous Sub-POD owner may elect to retain a read-only copy of the unmodified cache line for future use. As discussed above, this is permitted if the requesting unit is only requesting read-only access. To indicate this cache line status to the TCM, the TCM issues a By-pass Return Copy. As in the foregoing example, no cache line data is returned to the MSU with this type of Return command, since the MSU already stores this version of the cache line. This embodiment reduces traffic on the MIs 130 by omitting the extraneous return of data to the MSUs.
According to alternative embodiment of the invention, data may be returned to the MSU with both the By-pass Return Fast and By-pass Return Copy commands to simplify the design. TCM logic is simplified by stipulating that data is to be returned to the MSU in all situations involving a Return command, regardless of whether a by-pass operation occurred or not. The MSU responds by discarding the returned data after it has been determined that a by-pass operation has been performed with an unmodified cache line.
When a By-pass command is received by the MSU 110 , the request is stored in Request Storage Device 502 in the manner discussed above with respect to the original requests. Additionally, according to one embodiment of the current system, Processing Logic 516 will compare the Job Number Field that is returned along with each of the Return commands to the Job Number Fields of each of the entries stored in Request Memory 544 . In this manner, the Return command is matched with the entry in Request Memory 544 that is associated with the original request. Recall that this entry stores information that was contained in the original request, and which is needed by the MSU in processing the request and providing the response. However, it is not transmitted along with the POD-to-MSU Return command because the number of Address/control lines available on the MI 130 is limited.
Processing Logic 516 uses the information in Request Memory 544 to write any modified returned cache line data to Main Store 506 , and to further generate any needed response to the requester. Complete address and container information are provided to the requester with the request acknowledgement and the requested data. Processing Logic further updates the Directory Memory 160 A with modified cache line status. After the MSU completes processing of the Return command, Processing Logic 516 deletes the associated entry in Request Memory 544 , and the operation is considered complete.
The above scenarios describe TCM by-pass operations in which a TCM 220 provides data from one TLC 310 to another TLC 310 or I/O Module 140 in the same POD 120 . The current by-pass system also provides a TLC by-pass mechanism for allowing a TLC to provide data directly from one SLC 360 on a first Bus 330 to another SLC 360 on a second Bus 330 within the same Sub-POD. These types of operations may occur in those situations in which non-inclusive TLC has aged out a cache line, but a copy of the cache line remains resident in one of the SLCs in the Sub-POD. In these instances, another SLC within the same Sub-POD may request the cache line. If the requesting SLC does not reside on the same Bus 330 as the SLC that retains the cache line copy, the FSB Logic 380 of the SLC retaining the copy will not detect the request, and will not respond with data. As a result, the TLC will forward the request to the addressed one of the MSUs 110 A through 110 D to be handled in the manner discussed above. MSU will respond by providing the Return function to the appropriate TCM 220 , which, in turn, will provide the appropriate function to the TLC associated with the Destination Address Field 536 . This TLC may then perform a TLC By-pass operation using logic that is similar to that described above in reference to FIG. 6 to transfer a cache line directly from one Bus 330 to another Bus 330 . This greatly reduces the latency imposed in prior art systems wherein a cache line is passed from the TLC to the associated TCM, forwarded to the MSU to be returned back to the TCM, and finally passed to the same TLC as originated the transmission.
FIG. 7 is a block diagram of the TLC by-pass logic. Although TLC 310 of Sub-POD 210 A is shown and discussed, it will be understood the description applies equally to all other TLCs in all other Sub-PODs 210 of Platform 100 . Return functions are received on Sub-POD Interface 230 A from TCM 220 . These Return functions are stored in Sub-POD Request Storage 702 . Eventually, each request is selected for processing by Function Processing Logic 704 according to a predetermined priority scheme. Function Processing Logic reads cache line state information from TLC Cache Tag Logic 705 to determine which of the Buses 330 A or 330 B should be issued a return indication for the cache line. The appropriate return indication is then issued on either Bus 330 A or 330 B via Lines 706 or 708 , respectively. If the TLC has aged the cache line out of memory so that no record of the data exists (recall that this is possible because of the non-inclusive cache scheme utilized by the preferred embodiment), the return indication must be provided on both Buses 330 A and 330 B. As discussed above, this return indication will either direct an SLC to return the cache line and purge all copies, or will allow one or more SLCs to retain a read-only copy.
The request is also processed by Sub-POD Response Generation Logic 710 . Sub-POD Response Generation Logic is enabled by TLC Compare Logic 712 to generate a provisional response if the requesting unit and the unit indicated by Destination Address Field 536 are the same TLC 310 . This determination is made by comparing POD ID Field 538 to the POD ID in POD ID Register 714 of the TLC, and by further comparing Bus and TLC Fields 530 and 532 to Destination Address Field 536 . This provisional response will contain the same fields as those included in responses provided by the MSU, including the Job Number Field 528 , and an encoded field indicating that the data is part of a request response. The provisional response is stored in Sub-POD Response Generation Logic 710 along with additional request information such as Bus Field 512 , and is available for use in performing a by-pass operation if data is returned to the TLC 310 by an SLC 360 . According to one embodiment of the invention, POD ID Register 714 is programmable using a scan-set interface as is known in the art. This register is loaded when the system is initialized with a predetermined POD ID value.
The data return indication provided by TLC 310 is processed by the FSB Logic 380 of both SLCs on the target Bus 330 . An SLC retaining a copy of the requested cache line will respond to the function by placing an indication of the return operation on Bus 330 along with the cache line data. In these instances, the responding SLC will also either invalidate the cache line, or retain a read-only copy, as will be determined by the Return function and other SLC state information. In other instances, neither SLC will have a copy of the requested cache, since the cache line was flushed back to the MSU after the Directory Memory 160 A was referenced during processing of the original request, and the SLCs will respond accordingly with a no-data-present indication to the TLC.
When the response and any cache line data are returned to the TLC 310 , the information is stored in SLC Request/Response Storage Logic 716 until it can processed by SLC Request/Response Processing Logic 718 . At this time, TLC Job Number Compare Logic 720 compares the Job Number of the response to the Job Number Fields of all provisional responses stored in Sub-POD Response Generation Logic 710 . If a match is detected and data is returned with the response, the returned cache line data is copied from SLC Request/Response Storage Logic 716 to Sub-POD Response Generation Logic via Interface 719 to be appended to the matching provisional response. This response is made available to Function Processing Logic 704 via Interface 722 . Function Processing Logic 704 will process all MSU-to-Sub-POD requests along with the responses stored in Sub-POD Response Generation Logic 710 according to a predetermined priority scheme. Each of the stored provisional responses will eventually be routed by Function Processing Logic 704 via Lines 706 or 708 to the one of the Buses 330 that is identified by Bus Field 512 associated with the response.
In addition to performing the by-pass operation, the TLC also provides a return indication to the TCM to notify that the by-pass operation has occurred. This indication is provided on Line 723 to Sub-POD Interface 230 A. The types of return indications provided by the TLC to the TCM are similar to those discussed above in reference to the TCM. These include return indications provided with modified cache line data indicating that the previous owner either purged the cache line or retained a read-only copy. Other return designations are used to indicate that an unmodified cache line is provided to the requester, with the previous owner's copy either being purged or retained in a read-only capacity. Yet another indication may be provided if data was not present in either SLC. In this case, the MSU must process the request and provide the cache line data to the requester in the manner discussed above. In the preferred embodiment, unmodified cache line data is not returned to the MSU with a return indication since the MSU already has a copy of the cache line in Main Store 506 . This minimizes traffic on the MIs 130 . According to an alternative embodiment, the data may be returned to simplify design of the TCM in the manner discussed above.
When a by-pass operation is performed within the TLC, Function Processing 704 compares the by-pass response retrieved from Sub-POD Response Generation Logic to locate a corresponding entry in Pending Request Storage Logic 724 . Pending Request Storage Device stores a copy of each original TLC-to-MSU request when Sub-POD Request/Response Processing Logic 718 processes these original requests. In this manner, any outstanding and unacknowledged requests that are recorded as pending for more than a predetermined period of time can be used to generate an error indication to the MSU. In the current example, the by-pass response is matched to the original fetch request using the Job Number indication, and the matching request entry is removed from the Pending Request Storage Logic. This process is also performed for responses received from the MSU, which are provided via Interface 230 A to Sub-POD Request Storage 702 , and which are provided to Pending Request Storage Logic on Line 728 for comparison to original requests.
The above description relates to by-pass operations performed by either a TCM 220 or a TLC 310 . In those situations in which a by-pass operation may not be performed because the requesting unit and the previous owner TLC are not in the same POD 120 , or because the previous owner did not have a copy of the requested data, the return responses and data are provided solely to the MSU. The Return command is provided on the MI 130 to the addressed one of the MSUs along with the returned data. The MSU utilizes the expedited routing capability discussed above to route the returned data to the requesting POD specified in POD ID Field 538 . This cache line data is provided with a request acknowledgement that includes the original Job Number Field, a response indication, the Bus Field 512 , and the TLC Field 514 . In turn, the TCM routes the response to the appropriate TLC 310 or I/O Module 140 for processing in the manner discussed above.
In addition to performing the MSU by-pass operation, the MSU also stores the Return command with the associated Job Number Field and cache line address in Request Storage Device 502 with other requests received from the Sub-PODs 210 . When the request is processed by Processing Logic 516 , Directory Memory 160 A is updated with modified cache line status, and any updated cache line data is written to Main Store 506 . These memory operations are completed using the matching request entry retrieved from Request Memory 544 in the manner discussed above.
As mentioned above, in some instances a by-pass operation can not be performed because the Sub-POD that is identified as the destination unit does not store the requested cache line. This will occur if the cache line was flushed from the Sub-POD after the request was initially submitted to the Directory Memory 160 to determine cache line location but before the Return function was provided to the TLC. In these instances, the TLC responds with an indication that the data is not present. The absence of data is detected by the TLC Request Processing Logic 616 , and a by-pass operation is not performed. Instead, the response is routed to the appropriate MI Interface via Command Routing Logic 628 , and is processed by the MSU 110 in the manner described above. That is, the MSU retrieves the requested data from Main Store 506 , updates the Directory Memory 160 A with new status, and provides the requested cache line to the requester along with the Job Number, a response indication, the Bus Field 512 , and the TLC Field 514 . The entry associated with the Job Number stored in Request Storage Device 502 is deleted after the response has been provided to the requester.
It may be noted that the data by-pass system of the current invention minimizes the time required to complete the aforementioned type of requests even for those requests that do not utilize one of the cache by-pass mechanisms. This is so because the by-pass system eliminates some of the data transfers that would otherwise occur on the MIs, allowing the remaining transfers to be completed more quickly.
While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not as a limitation. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following Claims and their equivalents.
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A data by-pass system for a hierarchical, multi-level, memory is disclosed. The by-pass system provides by-pass interfaces between storage devices located at predetermined levels within the memory hierarchy. The hierarchical memory system of the preferred embodiment includes a main memory coupled to multiple first storage devices that each stores addressable portions of data signals retrieved from the main memory. To facilitate a more efficient transfer of data between the various storage devices in the memory system, at least one by-pass interface coupling associated ones of the first storage devices is provided. Data retrieved from a target one of the first storage devices in response to a main memory request can be routed to a different requesting one of the first storage devices via the by-pass system without requiring the use of the main memory data interfaces.
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This application is a continuation application of application Ser. No. 08/117,933, filed on Sep. 7, 1993, abandoned.
BACKGROUND OF THE INVENTION
The present invention relates generally to packaging technology for mounting a stack of a plurality of semiconductor elements to form a semiconductor device, and more particularly to such a semiconductor device comprising semiconductor elements that can be mounted with high mounting efficiency.
With the recent requirements for reducing the size and weight of and improving the operating performance of electronic and electrical apparatuses, an improvement in the mounting density is now increasingly strongly demanded for semiconductor parts. In an effort to comply with such needs, researches and studies for reducing the size, weight and thickness of a package have been positively promoted up to now. Especially, a variety of improvements have hitherto been made on the structure of the semiconductor package too, so that large chips can be accommodated in a package that is as small as possible. A package structure for semiconductor parts is commonly widely known. In this known package structure, a semiconductor element is fixed by the use of an electrically conductive adhesive to a die-pad part of a lead frame, and, after wire bonding inner leads of the lead frame to the electrodes on the surface of the semiconductor element, the peripheral part of the semiconductor element is sealed by the use of an encapsulant.
The needs for packaging semiconductor parts with a high mounting density becomes recently increasingly stronger, and a package of the LOC (lead on chip) type is known as a new package structure. In this known package, a semiconductor element is directly fixed to inner leads of a lead frame having no die-pad part, and, after wire bonding the inner leads of the lead frame to the electrodes on the surface of the semiconductor element, the peripheral part of the semiconductor element is sealed by the use of an encapsulant. (Such a package is described in a magazine entitled "Nikkei Microdevice", February issue, 1991, pages 89-97.)
Also, a method called TAB (tape automated bonding) or a method called TSOP (thin small outline package) in which a plurality of thin packages are mounted in a stacked relation is known. (Such a method is described in "Nikkei Microdevice", April issue, 1992, page 51.) In addition, a method of sealing a plurality of chips in a single package by an encapsulant is also known. (Such a method is described in "Nikkei Microdevice", April issue, 1991, page 80.)
Especially, a method of connecting a plurality of semiconductor elements by the use of filmy leads and pins (as disclosed in JP-A-61-32560) and a method of connecting a plurality of semiconductor elements by the use of a wiring board disposed along one of the side surfaces of the elements (as disclosed in JP-A-62-293749) are known as a technique for stacking a plurality of semiconductor elements.
By various modes of contrivance applied to the package structure as described above, the efficiency of mounting a plurality of semiconductor elements in a package can be greatly improved as compared to the case of the use of the prior art package. However, in spite of such an improvement in the mounting efficiency for the package itself, the mounting efficiency for the semiconductor device as a whole has not necessarily been still satisfactory. This is because, for example, a frame is inevitably required for fixing stacked packages or for establishing electrical connections with other elements. Also, because all of outer leads extending from the individual packages are joined as required to be combined or reshaped into a single outer lead to be connected to a printed wiring board by soldering, the area required for mounting the chips becomes considerably larger than the projected area of the chips.
Further, because the packaged semiconductor elements are connected on the wiring board, the number of connection points requiring soldering, wire bonding, etc. is inevitably increased, resulting in an undesirably long wiring distance between the electrodes of one of the semiconductor elements and those of another semiconductor element. This requirement has also given rise to an undesirable increase in the wiring resistance. Further, the method of stacking a plurality of chips and accommodating the stacked chips in a single package has not been satisfactory in that the package size becomes larger than the chip size, and the number of chips that can be stacked is also limited. With such a structure too, it is apparent that the increase in the distance required for wiring leads inevitably to degradation of the structural reliability and also lowering of the overall electrical response speed of the circuit.
When the aforementioned method of stacking a plurality of semiconductor elements in a package is employed, the problem regarding the size of the package may be solved. In this method, for example, filmy leads led out from the peripheral part of each of the semiconductor elements are used for establishing electrical connections between the semiconductor elements by pins connected to the individual filmy leads. Because the pins which are not integral with the filmy leads extend in the direction of stacking the semiconductor elements, the electrical connections between the semiconductor elements can be conveniently achieved, and the electrical distance of the connecting wiring can be shortened. However, this structural arrangement requires many connection points connecting the electrodes of one of the semiconductor elements to those of another semiconductor element by the filmy leads, and, from this requirement too, the resultant structure has also the problem in regard to the electrical reliability.
In the case of the aforementioned method in which a wiring board is disposed along one of the side surfaces of semiconductor elements for electrically connecting these semiconductor elements (as disclosed in JP-A-62-293749), the semiconductor elements are inevitably adversely affected by the heat generated during operation of the semiconductor elements thereby causing expansion and contraction of the semiconductor elements. This is because the semiconductor elements are firmly fixed together by the wiring board and have no operational flexibility.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a semiconductor device comprising a stack of semiconductor elements that can be mounted with high mounting efficiency.
Another object of the present invention is to provide a semiconductor device in which the problem of the stress due to generation of heat can be substantially solved.
Still another object of the present invention is to provide a semiconductor device which has high operational reliability and can be easily assembled.
In summary, the present invention provides a high mounting density semiconductor device in which a plurality of semiconductor elements each having a bump deposited on each of electrodes formed on the surface are stacked, and a plurality of leads disposed closely adjacent to the semiconductor elements to extend in a direction perpendicular with respect to the semiconductor elements are bonded to the bumps respectively thereby integrally assembling the plural semiconductor elements.
Some of preferred embodiments of the high mounting density semiconductor device according to the present invention have features which will now be described.
FIRST EMBODIMENT
This first embodiment of the high mounting density semiconductor device comprises a stack of a plurality of semiconductor elements each having a bump deposited on each of electrodes formed on the marginal edges of the surface, and a plurality of corresponding leads disposed closely adjacent to the stacked semiconductor elements, the leads being bonded to the bumps respectively thereby electrically integrally assembling the plural semiconductor elements.
SECOND EMBODIMENT
This second embodiment of the high mounting density semiconductor device comprises a stack of a plurality of semiconductor elements each having a plurality of electrodes formed near the marginal edges of the surface and a plurality of bumps electrically connected to the electrodes respectively, and a plurality of leads disposed closely adjacent to the stacked semiconductor elements, the leads being bonded to the bumps respectively thereby electrically integrally assembling the plural semiconductor elements.
THIRD EMBODIMENT
This third embodiment of the high mounting density semiconductor device comprises a stack of a plurality of semiconductor elements each having many electrodes formed near the marginal edges of the surface and a plurality of bumps corresponding to the surface electrodes respectively, and a plurality of leads disposed closely adjacent to the stacked semiconductor elements, the leads being electrically and mechanically bonded to the bumps respectively thereby integrally assembling the plural semiconductor elements.
FOURTH EMBODIMENT
This fourth embodiment of the high mounting density semiconductor device comprises a stack of a plurality of semiconductor elements each having a plurality of electrodes formed near the marginal edges of the surface and a plurality of bumps electrically connected to the surface electrodes respectively, a plurality of leads disposed closely adjacent to the stacked semiconductor elements, the leads being bonded to the bumps respectively thereby electrically integrally assembling the plural semiconductor elements, and an encapsulant sealing to shield the integrally assembled semiconductor elements from the outside.
FIFTH EMBODIMENT
This fifth embodiment of the high mounting density semiconductor device comprises a stack of a plurality of semiconductor elements each having many electrodes formed near the marginal edges of the surface and a plurality of bumps corresponding to the surface electrodes respectively, a plurality of leads disposed closely adjacent to the stacked semiconductor elements, the leads being electrically and mechanically bonded to the bumps respectively thereby integrally assembling the plural semiconductor elements, and an encapsulant molding the integrally assembled group of the semiconductor elements.
SIXTH EMBODIMENT
This sixth embodiment of the high mounting density semiconductor device comprises a stack of a plurality of semiconductor elements each having a bump deposited on each of surface electrodes, and a plurality of leads disposed closely adjacent to the stacked semiconductor elements to extend in a direction perpendicular with respect to the semiconductor elements, the leads being bonded to the bumps respectively thereby integrally assembling the plural semiconductor elements.
The lead preferably used in the present invention is, for example, that of the J type or gull wing type.
In the semiconductor device of the present invention, the semiconductor elements are connected by the leads disposed closely adjacent to and extending in a direction perpendicular with respect to them, so that the area required for mounting the completed semiconductor device does not substantially differ from the chip size, and a very high mounting efficiency can be achieved. The present invention which enables the desired high density mounting of the semiconductor elements is thus quite useful for reducing the size and weight of and improving the operating performance of electronic and electrical apparatuses.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view of an embodiment of the high mounting density semiconductor device of the present invention which includes a stack of two semiconductor elements 1.
FIG. 2 is a schematic perspective view of another embodiment of the high mounting density semiconductor device of the present invention which includes a stack of four semiconductor elements 1.
FIG. 3 is a schematic perspective view of still another embodiment of the high mounting density semiconductor device of the present invention which includes a stack of twelve semiconductor elements 1.
FIGS. 4A to 4F are schematic sectional views showing various combinations of leads 3 and bumps 2 used for connecting the leads 3 to surface electrodes 2' of the semiconductor elements 1 respectively.
FIG. 5 is a schematic sectional front elevational view of the high mounting density semiconductor device of the present invention formed by mounting a stack of semiconductor elements 1 on a printed wiring board 6.
FIG. 6 is a schematic top plan view of the semiconductor elements shown in FIG. 5.
FIG. 7 is a schematic sectional view taken along the line A-A' in FIG. 6.
FIG. 8 is a schematic sectional view showing a bump 2 deposited by plating gold on the electrode 2' shown in FIG. 7.
FIG. 9 is a schematic sectional view showing the case where a gold wire used for wire bonding is used to deposit the bump 2 on the electrode 2' by fusion of a ball of gold.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the high mounting density semiconductor device according to the present invention will now be described in detail. FIG. 1 shows the structure of an embodiment of the semiconductor device which includes a stack of two semiconductor elements 1. The semiconductor device shown in FIG. 1 can be made by bonding bumps 2 deposited on electrodes formed on the marginal edges of the semiconductor elements 1 to various kinds of leads 3 shown in FIG. 4A to FIG. 4F. (In FIG. 1, the leads 3 shown in FIG. 4B are used.)
The semiconductor elements 1 shown in FIG. 1 are, for example, silicon chips each having a circuit formed on its surface and include, for example, those used for memories, logic circuits and microcomputers. The present invention can be applied to semiconductor elements having a wide range of dimensions. In a prior art semiconductor device, the length of wiring between semiconductor elements tends to become long when a plurality of such semiconductor elements are mounted one by one on a printed wiring board, and this long wiring distance leads frequently to the problem of an undesirable delay of the signal propagation speed and generation of noise. In contrast, the manner of mounting semiconductor elements in the case of the present invention is advantageous in that the required wiring distance between the semiconductor elements can be shortened as compared to the prior art and is thus effective for accelerating the signal propagation speed and reducing the noise.
Although the present invention is applicable to various kinds of semiconductor elements, application of the present invention to a DRAM (a dynamic random access memory) will be described by way of example. The chip sizes of a 16MDRAM (a prototype) and a 64MDRAM (a prototype) are 8.15×15.58×0.4 t mm and 11.43×19.93×0.4 t mm respectively. In the case of a 256MRDAM, its chip size is presumed to become larger. The larger the chip size, the package size will naturally become larger, and the area required for mounting one element will also become correspondingly larger. The present invention is useful for high density mounting of such semiconductor elements tending to become larger and larger in size. Also, such an increase in the chip size leads generally to a lowered yield rate of production. However, when the chip is divided into a plurality of elements, and these elements are assembled according to the method of the present invention, both the desired improvement in the yield rate of production and the desired improvement in the mounting density can be simultaneously attained.
Another embodiment of the semiconductor device shown in FIG. 2 includes a stack of four semiconductor elements 1, and still another embodiment of the semiconductor device shown in FIG. 3 includes a stack of twelve semiconductor elements 1. Each of these semiconductor devices can be made in a manner similar to that described by reference to FIG. 1. The bump 2 deposited on each surface electrode of each semiconductor element 1 is preferably formed of gold, and it is also preferable that the bump of gold is deposited to entirely cover the associated electrode on the surface of the semiconductor element 1. For example, such a bump of gold may be deposited on the electrode surface by fusion of a ball of gold formed during wire bonding by the use of a gold wire or by plating a bump of gold or by transfer printing a bump of gold formed on a substrate of glass.
FIG. 4A shows that the bump 2 deposited on the associated electrode partly protrudes in the form of an overhang from the side surface of each semiconductor element 1. In such a case, a lead 3 having a J-like shape as shown in FIG. 4A is preferably bonded to the bumps 2 at the side surfaces of the semiconductor elements 1. FIG. 4B shows that the bump 2 is deposited on the upper surface of each semiconductor element 1. In such a case, a lead 3 having also a J-like shape as shown in FIG. 4B is preferably bonded to the bumps 2 at the upper surfaces of the semiconductor elements 1. In the present invention, the shape of the tip part of such a lead 3 is not especially limited. For example, as shown in FIGS. 4B, 4D and 4F, the tip part of the lead 3 has projections to be bonded to the bumps 2. Besides the leads 3 of the J type shown in FIGS. 4A and 4B, leads 3 of the gull wing type as shown in FIGS. 4C and 4D or leads 3 of the straight type as shown in FIGS. 4E and 4F may also be used when so required.
The term "bump" is used in the present invention to indicate a built-up bead-like form of an electrically conductive material deposited on an electrode of, for example, a semiconductor chip. Although the semiconductor chip is formed with a plurality of electrodes on its surface, it is difficult to simply electrically connect those electrodes to corresponding leads respectively. Therefore, the electrically conductive material is deposited in a built-up bead-like form on the associated electrode so as to facilitate the electrical connection between the electrode and the lead. A metal, for example, aluminum (Al) or gold (Au) is commonly used as the material of both the electrode and the conductor.
An example of the dimensions of the bump 2 and the lead 3 will now be described. The size of each electrode on the surface of the element 1 is, for example, about 60 to 100 μm square, and the size of the bump 2 deposited on the surface of the electrode is equal to or slightly smaller than that of the electrode. The lead 3 is electrically connected to this bump 2, and its size is about 60 to 100 μm wide and 20 to 200 μm thick. The minimum values of the dimensions of the electrode and the lead are referred to as 60 μm and 20 μm by way of example only, and the present invention is equally effectively applicable to the case where these minimum values become further smaller as a result of a further future improvement in the integration density of the semiconductor elements 1.
FIG. 5 schematically shows a practical form of the high mounting density semiconductor device of the present invention formed by mounting the stack of the semiconductor elements 1 on a printed wiring board 6 having built-in wiring 7. FIG. 6 is a schematic top plan view of the stack of the semiconductor elements 1 shown in FIG. 5 to show the electrodes 2' formed on their upper surfaces, and FIG. 7 is a schematic sectional view taken along the line A-A' in FIG. 6. In FIG. 7, the reference numeral 4 designates a chip coating layer. FIG. 8 is a schematic sectional view to show that the bump 2 is deposited by plating gold on each electrode 2'. FIG. 9 is also a schematic sectional view to show that the bump 2 is deposited on the electrode 2' by fusion of a ball of gold by the use of a gold wire used for wire bonding.
The lead 3 of the straight type may be first mounted and may then be shaped into the form of the J type or the gull wing type. Although each lead 3 may be bonded to the associated bump 2 of gold by various heating methods, a method of localized heating and fusion by a laser beam is most preferable so that unnecessary heat may not be applied to areas other than the bonding area.
As described above, the chip coating layer 4 in the form of a polyimide layer, an epoxy resin layer, a silicone resin layer or the like is formed on the surface of each of the semiconductor elements 1 used in the present invention, so that sufficient operational reliability can be ensured even when all the semiconductor elements 1 may not be especially sealed by the use of an encapsulant after being assembled. However, when higher reliability is demanded, it is preferable that the assembly is to be entirely encapsulated by the use of a resin composition, such as, an epoxy resin or that the lower and upper surfaces of the chips, the gaps between the chips or the side surfaces of the chips are to be coated or impregnated with a low-elasticity rubber-like resin of the non-solvent type. See FIG. 5, showing encapsulant 10. FIGS. 5 and 7 to 9 schematically illustrate the case where a polyimide coating layer 4 is used as an α-ray shielding layer for the purposes of protection of the surface of each semiconductor element 1 and prevention of occurrence of soft errors.
|
A semiconductor device is provided with a stack of a plurality of semiconductor elements each having a bump deposited on each of surface electrodes, and a plurality of leads disposed closely adjacent to the stacked semiconductor elements, the leads being bonded to the bumps respectively thereby structurally integrally assembling the plural semiconductor elements.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
TECHNICAL FIELD
[0002] The present invention generally relates to a compressor component having an airfoil and more specifically to an airfoil having a profile that is configured to improve performance of a gas turbine combustor.
BACKGROUND OF THE INVENTION
[0003] A compressor typically comprises a plurality of stages, where each stage includes a set of stationary compressor vanes which direct a flow of air into a rotating disk of compressor blades, where each stage of the compressor decreases in diameter, causing the pressure and temperature of the air to increase. Compressor components having an airfoil, such as compressor blades and compressor vanes, are held within disks or carriers and are designed to aid in compressing a fluid, such as air, as it passes through stages of blades and vanes of the compressor.
[0004] Axial compressors having multiple stages are commonly used in gas turbine engines for increasing the pressure and temperature of air to a pre-determined level at which point a fuel can be mixed with the air and the mixture ignited. The hot combustion gases then pass through a turbine to provide either a propulsive output or mechanical output.
[0005] Compressor components, such as blades and vanes, have an inherent natural frequency, and when the compressor component is excited, as can occur during normal operating conditions, the compressor component vibrates or moves at different orders of the engine's natural frequency. When the natural frequency of the compressor component coincides or crosses an engine order, the compressor component can start to resonate or vibrate in such away that it is excited and can cause cracking or failure of the compressor component.
SUMMARY
[0006] In accordance with the present invention, there is provided a novel and improved compressor component having an improved tip region optimized to improve the airflow coming off the compressor blade.
[0007] In an embodiment of the present invention, a compressor component has an attachment and an airfoil extending radially outward from the attachment, where the airfoil has a leading edge and a trailing edge, concave and convex surfaces, and a thickness based on the Cartesian coordinate values X, Y, and Z as set forth in Table 1, where Y is a distance measured radially from a root datum plane extending through the attachment of the blade.
[0008] In an alternate embodiment of the present invention, a compressor component is disclosed having an attachment and an airfoil extending radially outward from the attachment. The airfoil has an uncoated profile substantially in accordance with Cartesian coordinate values of X, Y, and Z as set forth in Table 1, where Y is a distance measured radially from a root datum plane extending through the attachment to which the airfoil is mounted. The X and Z values are joined by smooth connecting splines to form a plurality of airfoil sections and the sections are joined to form the airfoil profile.
[0009] In yet another embodiment, a compressor stator having an altered tip configuration and airfoil tilt in which the compressor stator comprises an attachment and an airfoil extending radially outward from the attachment with the airfoil having a thickness and extending to a generally planar tip.
[0010] Although disclosed as an airfoil that is uncoated, it is envisioned that an alternate embodiment of the present invention can include an airfoil that is at least partially coated with an erosion resistant coating, corrosion resistant coating, or a combination thereof. In this case, the coordinates of the airfoil as listed in Table 1 are prior to a coating being applied to any portion of the airfoil.
[0011] Additional advantages and features of the present invention will be set forth in part in a description which follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned from practice of the invention. The instant invention will now be described with particular reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0012] The present invention is described in detail below with reference to the attached drawing figures, wherein:
[0013] FIG. 1 is a perspective view of a compressor component in accordance with the prior art;
[0014] FIG. 2 is an alternate perspective view of the compressor component of FIG. 1 having an airfoil in accordance with an embodiment of the present invention;
[0015] FIG. 3 is an alternate perspective view of the compressor component of FIG. 2 in accordance with an embodiment of the present invention;
[0016] FIG. 4 is yet another perspective view of the compressor component of FIG. 2 in accordance with an embodiment of the present invention;
[0017] FIG. 5 is an elevation view of a compressor blade depicting an airfoil in accordance with the prior art component overlaid with an airfoil in accordance with an embodiment of the present invention;
[0018] FIG. 6 is a cross section view of the airfoil of the present invention taken towards its tip region compared to a tip cross-section of the prior art airfoil;
[0019] FIG. 7 is a cross section view of the airfoil of the present invention taken towards its mid-span compared to a mid-span section of the prior art airfoil;
[0020] FIG. 8 is a cross section view of the airfoil of the present invention taken towards its base compared to a base section of the prior art airfoil;
[0021] FIG. 9 is a perspective view depicting overlays of the prior art compressor airfoil and the present invention in accordance with an embodiment of the present invention;
[0022] FIG. 10 is a set of Campbell diagrams depicting a comparison of operating frequencies for the prior art component and the present invention; and
[0023] FIG. 11 is a cross section view of a portion of a compressor including a portion of a diffuser.
DETAILED DESCRIPTION
[0024] The subject matter of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. Rather, the inventors have contemplated that the claimed subject matter might also be embodied in other ways, to include different components, combinations of components, steps, or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies.
[0025] Referring initially to FIG. 1 , a prior art compressor blade 100 is depicted. The prior art blade 100 includes a cropped blade tip 102 . Because of critical aerodynamic crossings occurring in the airfoil at the tip of the blade 100 , vibrations within the airfoil caused a portion of the blade tip to crack and break off during operation. As a fix to this design flaw, suppliers proceeded to remove a portion of the blade tip during manufacturing in order to prevent the blade tip from cracking. However, this cropped blade tip, as shown in FIG. 1 creates a loss in both compressor blade efficiency and overall compressor efficiency.
[0026] The present invention seeks to overcome the shortcomings of the prior art, including the “cropped airfoil” configuration, by providing a redesigned airfoil portion of a compressor blade that eliminates the cracking of the blade tip and the need to remove a portion of the blade tip during manufacturing. Referring to FIGS. 2-4 , the present invention is directed towards a compressor component, such as a compressor blade, where the compressor component 200 has a redesigned shape to the airfoil 202 . While the general profile of the airfoil 202 has changed, the changes are most noticeable towards a tip 204 of the airfoil 202 , as can be seen in the comparison between compressor blades in FIG. 9 , where the solid line represents the present invention and the dashed line represents the prior art airfoil configuration.
[0027] An embodiment of the present invention also comprises an attachment 206 for securing the compressor component 200 to a disk (not shown). The airfoil 202 , which is preferably solid, extends radially outward from the attachment 206 and has a leading edge 208 and a trailing edge 210 with the trailing edge 210 spaced a distance from the leading edge 208 and separated by a concave surface 214 and convex surface 212 , as shown in FIG. 4 .
[0028] The airfoil 202 has an uncoated profile substantially in accordance with Cartesian coordinate values of Table 1, as set forth below, having a set of X, Y, and Z coordinates, where the Y coordinate extends in a radially outward direction from the attachment region. The airfoil 202 is formed by applying smooth continuing splines between the X and Z coordinate values at each Y distance to form an airfoil section. Example airfoil sections 216 , 218 , and 220 are depicted in FIGS. 6-8 . Then, each of the airfoil sections 216 , 218 , 220 , and others not depicted, but described in Table 1, are joined together smoothly to form the profile of the airfoil 202 . The coordinate values, which when taken together, generate the profile of airfoil 202 have a plurality of sections of data at spaced intervals in the Y direction that are measured from a datum plane B that is indicative of the center plane along root faces of the attachment 206 , as shown in FIGS. 2 and 3 . The datum plane B is located a distance of approximately 0.205 inches from the bottom surface of attachment 206 . The airfoil 202 extends a radial distance of approximately 3 inches and varies in its longitudinal length and thickness depending on the radial span.
[0029] A compressor component for a land-based compressor is typically fabricated from a relatively low temperature alloy since the air temperature of the compressor typically only reaches upwards of 700 deg. F. In an embodiment of the present invention, the compressor component 200 is fabricated from a lower temperature alloy such as a stainless steel alloy. The compressor component 200 can be fabricated by a variety of manufacturing techniques such as forging, casting, milling, and electro-chemical machining (ECM). For example, when milling or electro-chemical machining processes are used, the compressor component 200 is machined from bar stock.
[0030] Because of the limited precision of certain manufacturing techniques, the compressor component 200 has manufacturing tolerances for the surface profile of the airfoil 202 that can cause the airfoil 202 to vary by approximately +/−0.008 inches from a nominal state. In addition to manufacturing tolerances affecting the overall position of the airfoil 202 , it is also possible to scale the airfoil 202 to a larger or smaller airfoil size, approximately 80%-120% of its present size. However, in order to maintain the benefits of this airfoil shape and size, in terms of stiffness and stress, it is necessary to scale the airfoil uniformly in X and Z directions, but Y direction may be scaled separately.
[0031] While an embodiment of the present invention provides an uncoated compressor component 200 such as a compressor blade, it is possible to add a coating to at least a portion of the airfoil 202 in an alternate embodiment. A coating can be applied to the airfoil 202 in order to provide corrosion resistance protection to the material of the airfoil portion. In this embodiment, the coating would preferably be applied approximately 0.001-0.003 inches thick.
[0032] As one skilled in the art of blade and vane airfoil design will understand, the airfoils move at various modes due to their geometry and the aerodynamic forces being applied thereto. Should this excitation occur for prolonged periods of time at a natural frequency or order thereof, the airfoil 202 can fail due to high cycle fatigue as occurred in the prior art design. Such modes include bending, torsion, and various higher order modes. For example, a critical bending mode for the compressor component of the present invention is the chordwise bending mode initiated by vibrations imparted by upstream vanes (qty. 138 ) or downstream vanes (qty. 142 ). Where the seventh bending mode crosses either of these frequency ranges for a particular speed range, this creates an excitement in the blade causing it to cycle and eventually fail in high cycle fatigue. For the prior art airfoil configuration of blade 100 , the seventh mode crossed within a tolerance range of the 138 engine order (caused by the upstream vanes), as shown in FIG. 10 . This crossing is the root cause for the vibrations that led to failure of a portion of a portion of the blade tip and the temporary work around of cropping the blade tip in the prior art configuration. Referring to the plot of frequency versus percent speed for the present invention (compressor component 200 ), it can be seen that the seventh mode no longer crosses the engine orders of the upstream vane pack ( 138 ) or downstream vane pack ( 142 ), nor either tolerance range. As such, the present invention is no longer subjected to potentially damaging vibrations associated with the seventh mode and the blade tip will no longer crack due to this excitation.
[0000]
TABLE 1
X
Y
Z
0.197
0.059
−0.907
0.170
0.059
−0.841
0.144
0.059
−0.775
0.117
0.059
−0.710
0.092
0.059
−0.646
0.067
0.059
−0.583
0.043
0.059
−0.521
0.021
0.059
−0.461
−0.001
0.059
−0.401
−0.021
0.059
−0.343
−0.039
0.059
−0.286
−0.057
0.059
−0.230
−0.072
0.059
−0.174
−0.087
0.059
−0.119
−0.099
0.059
−0.064
−0.111
0.059
−0.009
−0.120
0.059
0.047
−0.128
0.059
0.103
−0.134
0.059
0.159
−0.139
0.059
0.216
−0.141
0.059
0.275
−0.142
0.059
0.334
−0.140
0.059
0.394
−0.137
0.059
0.455
−0.131
0.059
0.517
−0.122
0.059
0.580
−0.111
0.059
0.644
−0.096
0.059
0.707
−0.079
0.059
0.770
−0.058
0.059
0.832
−0.032
0.059
0.892
−0.003
0.059
0.950
0.032
0.059
1.005
0.072
0.059
1.055
0.088
0.059
1.072
0.090
0.059
1.074
0.092
0.059
1.076
0.094
0.059
1.077
0.097
0.059
1.078
0.099
0.059
1.078
0.102
0.059
1.078
0.105
0.059
1.077
0.107
0.059
1.076
0.109
0.059
1.075
0.111
0.059
1.073
0.112
0.059
1.071
0.114
0.059
1.069
0.114
0.059
1.066
0.115
0.059
1.064
0.115
0.059
1.061
0.114
0.059
1.058
0.110
0.059
1.002
0.105
0.059
0.946
0.100
0.059
0.890
0.096
0.059
0.833
0.092
0.059
0.776
0.088
0.059
0.718
0.085
0.059
0.660
0.082
0.059
0.601
0.080
0.059
0.542
0.078
0.059
0.482
0.077
0.059
0.422
0.077
0.059
0.361
0.077
0.059
0.300
0.078
0.059
0.239
0.079
0.059
0.177
0.082
0.059
0.116
0.085
0.059
0.054
0.089
0.059
−0.007
0.094
0.059
−0.068
0.099
0.059
−0.130
0.106
0.059
−0.190
0.113
0.059
−0.250
0.120
0.059
−0.310
0.129
0.059
−0.370
0.138
0.059
−0.428
0.148
0.059
−0.486
0.158
0.059
−0.544
0.169
0.059
−0.600
0.181
0.059
−0.657
0.192
0.059
−0.712
0.204
0.059
−0.768
0.217
0.059
−0.822
0.229
0.059
−0.877
0.234
0.059
−0.898
0.235
0.059
−0.903
0.235
0.059
−0.907
0.234
0.059
−0.911
0.233
0.059
−0.914
0.231
0.059
−0.918
0.228
0.059
−0.920
0.225
0.059
−0.922
0.221
0.059
−0.924
0.217
0.059
−0.924
0.213
0.059
−0.924
0.210
0.059
−0.923
0.206
0.059
−0.921
0.203
0.059
−0.918
0.201
0.059
−0.915
0.199
0.059
−0.911
0.197
0.059
−0.907
0.129
0.322
−0.914
0.107
0.322
−0.848
0.085
0.322
−0.783
0.063
0.322
−0.718
0.043
0.322
−0.653
0.022
0.322
−0.590
0.003
0.322
−0.527
−0.015
0.322
−0.465
−0.032
0.322
−0.403
−0.048
0.322
−0.343
−0.063
0.322
−0.283
−0.076
0.322
−0.224
−0.088
0.322
−0.165
−0.099
0.322
−0.106
−0.108
0.322
−0.048
−0.116
0.322
0.010
−0.123
0.322
0.069
−0.128
0.322
0.127
−0.132
0.322
0.186
−0.134
0.322
0.245
−0.134
0.322
0.304
−0.133
0.322
0.364
−0.130
0.322
0.424
−0.126
0.322
0.484
−0.119
0.322
0.545
−0.110
0.322
0.606
−0.099
0.322
0.667
−0.086
0.322
0.727
−0.069
0.322
0.787
−0.050
0.322
0.846
−0.028
0.322
0.903
−0.001
0.322
0.958
0.029
0.322
1.011
0.064
0.322
1.060
0.078
0.322
1.077
0.080
0.322
1.080
0.083
0.322
1.082
0.085
0.322
1.084
0.088
0.322
1.085
0.091
0.322
1.085
0.093
0.322
1.086
0.096
0.322
1.085
0.098
0.322
1.084
0.101
0.322
1.083
0.102
0.322
1.081
0.104
0.322
1.079
0.105
0.322
1.076
0.106
0.322
1.073
0.106
0.322
1.070
0.106
0.322
1.067
0.106
0.322
1.064
0.102
0.322
1.007
0.098
0.322
0.951
0.094
0.322
0.895
0.090
0.322
0.838
0.086
0.322
0.780
0.082
0.322
0.722
0.079
0.322
0.664
0.076
0.322
0.605
0.073
0.322
0.545
0.071
0.322
0.485
0.069
0.322
0.424
0.067
0.322
0.364
0.066
0.322
0.302
0.065
0.322
0.241
0.065
0.322
0.179
0.065
0.322
0.117
0.066
0.322
0.055
0.067
0.322
−0.007
0.070
0.322
−0.068
0.072
0.322
−0.130
0.076
0.322
−0.191
0.080
0.322
−0.252
0.085
0.322
−0.312
0.090
0.322
−0.372
0.096
0.322
−0.431
0.103
0.322
−0.490
0.110
0.322
−0.548
0.117
0.322
−0.606
0.125
0.322
−0.663
0.134
0.322
−0.720
0.143
0.322
−0.776
0.152
0.322
−0.831
0.161
0.322
−0.887
0.164
0.322
−0.908
0.165
0.322
−0.912
0.165
0.322
−0.916
0.164
0.322
−0.920
0.162
0.322
−0.924
0.160
0.322
−0.926
0.158
0.322
−0.929
0.154
0.322
−0.931
0.151
0.322
−0.932
0.147
0.322
−0.932
0.143
0.322
−0.931
0.140
0.322
−0.930
0.137
0.322
−0.928
0.134
0.322
−0.925
0.132
0.322
−0.922
0.131
0.322
−0.918
0.129
0.322
−0.914
0.013
0.847
−0.910
−0.001
0.847
−0.846
−0.016
0.847
−0.782
−0.030
0.847
−0.718
−0.043
0.847
−0.655
−0.056
0.847
−0.591
−0.068
0.847
−0.527
−0.079
0.847
−0.464
−0.089
0.847
−0.400
−0.098
0.847
−0.337
−0.106
0.847
−0.274
−0.113
0.847
−0.211
−0.119
0.847
−0.148
−0.124
0.847
−0.086
−0.128
0.847
−0.023
−0.130
0.847
0.039
−0.132
0.847
0.101
−0.132
0.847
0.162
−0.132
0.847
0.224
−0.130
0.847
0.285
−0.127
0.847
0.346
−0.123
0.847
0.406
−0.118
0.847
0.466
−0.111
0.847
0.526
−0.103
0.847
0.585
−0.094
0.847
0.643
−0.083
0.847
0.700
−0.071
0.847
0.756
−0.056
0.847
0.812
−0.040
0.847
0.866
−0.021
0.847
0.919
0.000
0.847
0.970
0.024
0.847
1.019
0.051
0.847
1.066
0.062
0.847
1.084
0.065
0.847
1.087
0.068
0.847
1.090
0.070
0.847
1.093
0.073
0.847
1.095
0.076
0.847
1.096
0.079
0.847
1.097
0.081
0.847
1.097
0.084
0.847
1.096
0.086
0.847
1.094
0.088
0.847
1.092
0.089
0.847
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[0033] In addition to the structural improvements gained by the reconfigured airfoil shape of compressor component 200 , the present invention also helps to improve overall compressor performance by improving the performance at the compressor diffuser 300 . The compressor diffuser 300 , as one skilled in the art understands and as shown in FIG. 11 , receives the compressed air from an engine compressor at inlet region 302 and directs the air to the combustor(s). Due to the configuration of diffuser 300 and its support structure, efficiency losses are expected within the diffuser. In an embodiment of the invention, compressor component 200 is positioned in the last stage of rotating compressor blades and is the last point where it is possible to modify the total pressure profile along the height of the compressor section entering the diffuser. Efficiency losses at this stage are especially undesirable. Therefore, because of the improved airfoil configuration of compressor component 200 , especially at its blade tip, the last stage of compressor blades is able to impart additional energy to the compressor and improve efficiency in the diffuser. Based on the aerodynamic changes described above, an increase in overall efficiency of approximately 0.2% is expected across the compressor and diffuser.
[0034] In order to introduce more energy through this last stage of the compressor, it is necessary to energize the flow in the regions near the compressor walls, which requires a greater pressure rise at the blade tip and root sections. However, because of the boundary layer present in these same areas, increasing pressure in these locations can be difficult. Pressure can be increased by increasing the amount of turning in these regions, as shown in FIGS. 6-8 . To increase the turning, for a given airfoil chord length, the camber, or arc shape of the airfoil must be increased. However, with an increase in camber comes flow separation as the passing airflow approaches the airfoil trailing edge. To minimize flow separation for an airfoil with increased camber, the chord length of the airfoil must be adjusted wherever possible, as shown in FIGS. 5-8 . That is, geometric constraints of the compressor component 200 must be balanced with structural integrity constraints in order to improve overall compressor efficiency.
[0035] Due to the changes in the physical profile of compressor component 200 , the present invention airfoil profile also alters the natural frequency of the compressor component 200 . As a result previously-damaging engine crossings, especially with the 7 th mode, have been eliminated and are depicted by the Campbell diagrams of FIG. 10 .
[0036] The present invention has been described in relation to particular embodiments, which are intended in all respects to be illustrative rather than restrictive. Alternative embodiments will become apparent to those of ordinary skill in the art to which the present invention pertains without departing from its scope.
[0037] From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects set forth above, together with other advantages which are obvious and inherent to the system and method. It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations. This is contemplated by and within the scope of the claims.
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A compressor component having an improved airfoil profile so as to eliminate previously known vibratory issues in the blade tip is disclosed. By altering the airfoil profile throughout its span, the natural frequency of the airfoil is altered so as to not coincide with a critical engine order of the compressor. Further, the present invention provides a novel airfoil profile in accordance with the coordinates of Table 1.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to cooling devices for devices that generate heat such as semiconductor chips, and particularly, to an apparatus that improves the capability and reliability of cooling devices for semiconductor chips. The invention is in the field of heat transfer and cooling of semiconductor chips used in computers and telecommunication equipment.
[0003] 2. Description of the Prior Art
[0004] As the power of semiconductor chips increases, more efficient cooling device for semiconductor chips is therefore required. Current known cooling solutions have drawbacks in providing an adequate cooling to chips in small spaces and, drawbacks in lowering acoustic noise. For instance, U.S. Pat. Nos. 5,297,617, 5,309,983, and 5,445,215 each describe methods of using miniature “muffin fans” with multi-bladed propellers that drive cooling air toward heat collector fins at the periphery. These muffins fans tend to be nosier because the air is stirred up and pushed to the heat collector fins. U.S. Pat. No. 5,419,679 teaches a method using parallel disks to create air flow to draw air through an opening in an attached chassis for cooling electronic devices. U.S. Pat. No. 5,335,143 teaches a method using parallel disks between fins of a heat exchanger to provide cooling of chips. The arrangement is rather bulky, however, with only a small portion of a disk pumping air at any given time. U.S. Pat. No. 5,794,687 teaches a method of placing parallel disks in close fitting slots formed in a heat conducting housing. Methods of ducting incoming and outgoing air are additionally described.
[0005] U.S. Pat. No. 5,388,958 describes a “bladeless impeller” consisting of a plurality of disks and introduces a mechanism to transfer heat to the impeller shaft. However, the device needs to be positioned adjacent to an element to provide a complimentary surface to the disks to define a space in which pressure drop would occur on the operation of the impeller. U.S. Pat. No. 6,503,067 teaches a method using parallel disks to create laminar air flow for intake into an Internal combustion engine.
[0006] It would be highly desirable to provide a cooling apparatus for heat generating devices such as semiconductor chip devices that obviates the aforementioned deficiencies in the prior art.
SUMMARY OF THE INVENTION
[0007] The present invention relates to a cooling apparatus for heat generating devices such as semiconductor chips and devices, e.g., in computers and telecommunications equipment.
[0008] The apparatus includes a plurality of parallel disks that rotate at the center of a set of heat transfer fins and periodic radial elements placed between disks to generate air flow more efficiently while maintaining the air stream less turbulent. The air leaving the edge of the parallel disks as the disks rotate is more easily directed into the surrounding heat transfer fins. This arrangement of rotating disks creates air flow more efficiently. Furthermore, an array of heat pipes carrying heat from the source to the rotating disks increases the surface area of heat dissipation, leading to more efficient cooling. Additionally provided is a mechanism of transferring heat from a heat generating device to the rotating disks.
[0009] Thus, according to the invention, there is provided a cooling apparatus comprising: a fan means for creating a smooth, less turbulent air flow including a plurality of disk fan elements spaced apart in a stack configuration and adapted for rotation to create an air flow; multiple heat sink means surrounding the plurality of disk fan elements; a heat distribution means for receiving heat generated from a heat generating device; and, a plurality of heat pipe elements communicating with the heat distribution means and the multiple heat sinks, the heat distribution means and heat pipe elements transferring heat from a heat generating device for distribution to the heat sinks, wherein the plurality of disk fan elements are rotated to create efficient air flow in an outward direction such that heat is uniformly eliminated from the surrounding multiple heat sink means.
[0010] In a further embodiment, the cooling apparatus further comprises a heat transfer means for transferring additional heat from the heat distribution block to one or more of the plurality of disk fan elements.
[0011] Still in a further embodiment, the plurality of disk fan elements may be mounted on a hollow shaft whereby a motor drive means for rotating the shaft is integrated in the shaft. Further, the hollow shaft is configured to include a plurality of air slots located along a length of the shaft for permitting air to pass through the shaft as the shaft rotates and exit the formed air gaps. Thus, further cooling efficiency is enhanced as heat is dissipated through the parallel disks of the fan.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The objects, features and advantages of the present invention will become apparent to one skilled in the art, in view of the following detailed description taken in combination with the attached drawings in which:
[0013] FIG. 1 depicts a three-dimensional (3-D) view of a cooling device with a parallel disk fan in the middle according to the invention;
[0014] FIG. 2 ( a ) depicts a top view of the cooling device with a parallel disk fan of the invention, and, FIG. 2 ( b ) depicts a cross-sectional view of the cooling device when taken along section ‘A-A’ of FIG. 2 ( a );
[0015] FIG. 3 depicts a 3-D view of an active cooling device according to a further embodiment of the invention
[0016] FIG. 4 ( a ) depicts a top view of the cooling device with a parallel disk fan according to a further embodiment of the invention, and, FIG. 4 ( b ) depicts a cross-sectional view of the cooling device when taken along section ‘A-A’ of FIG. 4 ( a );
[0017] FIGS. 5 ( a ) and 5 ( b ) depict the detailed mounting of heat pipes to the parallel disks according to the embodiment of the invention depicted in FIGS. 4 ( a ), 4 ( b );
[0018] FIGS. 6 ( a ) and 6 ( b ) depict two different embodiments respectively, of the parallel disk fan in the cooling device with a flat parallel disk configuration as shown FIG. 6 ( a ) and a corrugated disk configuration as shown in FIG. 6 ( b ); and,
[0019] FIGS. 7 ( a )- 7 ( c ) each depict an implementation of the parallel disk fan using a hollow shaft integrated with an electric motor according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] FIG. 1 depicts generally, the cooling device of the present invention. As shown in FIG. 1 , the cooling device includes a plurality of ring-shaped heat sink fins 51 oriented parallel in a stacked configuration with a gap 57 between each ring-shaped heat sink fin, a plurality of circular disk fans 41 oriented parallel in a stacked configuration and coaxial with the plurality of ring-shaped heat sink fins 51 , the plurality of stacked circular disk fans 41 being mounted for rotation within the stacked plurality of circular heat sink fins 51 via a shaft under motor control 21 . As shown in FIG. 1 , and described in greater detail herein, the plurality of heat sink fins 51 are in communication with a structure comprising heating pipe elements 33 a , . . . , 33 d interconnected with a heat distribution block 31 that receives and distributes heat generated by a semiconductor chip to the heat sink fins. Preferably, as shown in FIG. 1 , the parallel circular disk fans 41 each include radial elements 43 between disks 41 in the middle of the set of circular parallel-stacked heat sink fins 51 . More specifically, the parallel disk fans include a plurality of disks 41 stacked in parallel on a shaft of an electric motor 21 and the disks 41 are separated by the radial elements 43 such that many air gaps are formed between disks 41 . When the parallel disks 41 are rotated by the electric motor 21 , a centrifugal force is generated that drives the air in the air gaps to move outward and, hence, a steady stream of less turbulent air is generated. Air comes into the fan from the both sides of fan inlets 42 provided near the center of the parallel disk unit 41 as shown in FIGS. 1 and 2 ( a ).
[0021] Particularly, FIG. 2 ( a ) depicts a top view of the cooling device with a parallel disk fan of the invention, and, FIG. 2 ( b ) depicts a cross-sectional view of the cooling device when taken along section ‘A-A’ of FIG. 2 ( a ). The cross-sectional view of FIG. 2 ( b ) particularly details the structure comprising the heating pipe elements, e.g., two elements 33 a , 33 b , which are L-shaped and interconnect the heat distribution box 31 with the parallel-stacked heat sink fins 51 . Located above heat distribution block 31 is the motor 21 and the motor shaft 23 extending upward therefrom that rotatably support the parallel circular disk fans 41 . With more particularity, as shown in FIG. 2 ( a ), each parallel circular disk fan 41 is supported by arm members 44 which are mounted on the motor shaft 23 . The set of radial elements 43 is placed between disks 41 with three (3) shown in FIGS. 1 and 2 ( a ). It is understood however, that the number and the shape of the radial elements 43 as well as the spacing distance between disk fans 41 may vary. The diameter of the parallel disks may range anywhere from about 25 mm to 200 mm. The number of radial members separating two adjacent disks may range between three (3), as shown in the FIG. 1 , to fifteen (15). The radial members can be straightly radial, forward inclined, or backward inclined. The shape of the radial members is preferred to be aerodynamically aligned with the air stream, and may include a circular (rounded) or elliptic shape.
[0022] Further, as shown in FIG. 2 ( a ), the multiple heat sink fins 51 that form a ring have an inner diameter that is larger than the diameter of the rotating circular disk fans 41 leaving a small gap 49 , e.g., ranging between 0.05 mm to 5 mm, between the fans and the heat sink fins 51 such that the parallel disks 41 can be rotated freely to generate air streams which are forced to pass through the heat sink fin gaps 57 (shown in FIG. 1 ), that may range, for example, between 0.2 mm to 3 mm. The heat sink fins 51 are additionally separated by spacer elements 52 a , 52 b to result in gaps 57 and may be soldered, brazed, or glued to the corresponding spacer elements 52 a , 52 b which have heat pipe elements 33 inserted therein. The exemplary heat sink fins 51 in FIG. 2 ( b ) have four sections and each has its designated spacers and heat pipes labeled as 52 a , 52 b , 52 c , 52 d , and 33 a , 33 b , 33 c , 33 d , respectively, however, it should be understood that the number of the heat sink fins, spacers, and heat pipes may be varied and should not be limited to four (4) as shown in the figures. As mentioned, the lower end of each heat pipe 33 is inserted into the heat distribution block 31 that is to be placed on a heat generating semiconductor chip (not shown).
[0023] In operation, heat generated in the semiconductor chip are collected by heat distribution block 31 and transferred by the heat pipes 33 and distributed to the heat sink fins 51 . The air stream driven by the parallel disk fans 41 pass through the air gap 57 between the heat sink fins 51 and carry away the heat from the semiconductor chip. While the number of disk fans 41 may vary, i.e., are not limited to seven (7) fins as shown in FIG. 2 ( b ), the heat sink fin spacers 52 are stacked closely up along the heat pipes 33 such that heat can be distributed evenly to all the heat sink fins 51 . Preferably, the distance between adjacent disks may range between 0.2 mm to 3 mm and the distance between adjacent fins 51 additionally ranges from 0.2 mm to 3 mm. It is understood however, that the distance between adjacent disks does not have to match the distance between adjacent fins.
[0024] It should be understood that in accordance with each of the embodiments of the invention depicted herein, the amount of air flow generated by the parallel disk fan depends primarily upon the rotational speed of the disks, the diameter of the disks, the spacing between disks, and the number of the radial elements 43 between disks 41 . The range of the rotational speed may range between about 100 rpm to 10,000 rpm, for example.
[0025] FIG. 3 depicts a 3-D view of an active cooling device according to a further embodiment of the invention. Particularly, in the embodiment depicted in FIG. 3 , the active cooling device of FIG. 1 is provided with a heat transfer mechanism 110 attached to the parallel disk fan such that the disks are also used to dissipating heat to the air streams. The active cooling device has a set of parallel disks 41 coaxial therewith and functioning as a fan for the surrounding plurality of heat sink fins 51 . The parallel disks 41 are mounted on the shaft of an electric motor 21 that rotates the disks 41 to generate air streams. Air streams coming in from the top and bottom of the fan inlets 42 are driven out from the edge of the disks toward the heat sink fins 51 and will pass through the fin gaps 57 . The heat transfer mechanism 110 in the device includes heat pipes connecting with one or more of the parallel disks 41 to transfer heat to the connected discs while allowing them to rotate freely to generate air streams.
[0026] The details of the heat transfer mechanism 110 are now described herein with respect to FIGS. 4 ( a ) and 4 ( b ). Particularly, FIG. 4 ( a ) depicts a top view of the cooling device with a parallel disk fan according to a further embodiment of the invention, and, FIG. 4 ( b ) depicts a cross-sectional view of the cooling device when taken along section ‘A-A’ of FIG. 4 ( a ). It is understood that all elements except the heat transfer mechanism 110 are the same as included in the first embodiment described with respect to FIGS. 1 and 2 ( a )- 2 ( b ). The heat transfer mechanism 110 includes an outer stationary part comprising a fixed outer casing 12 and one inner cylindrical rotational part 11 located coaxially therewith that rotates with respect to the outer casing 12 that is hollowed for receiving heat from the heat distribution block 31 . Preferably, a cylindrical outer surface of the rotational part 11 is separated from the inner surface of the stationary part 12 by a narrow gap 17 , for example, ranging from about 0.01 mm to 1 mm. The cylindrical rotational part 11 is mounted on the shaft of the motor 21 such that the rotational part can be rotated freely within the stationary part 12 . The gap 17 is filled with thermally conductive lubricants such as Krytox lubricants from Dupont, or like equivalent, for conducting heat from the fixed outer casing to the rotating inner part. Suitable sealing mechanisms (not shown) are provided on the shaft of the rotational part 11 to protect the lubricants as is well known in the art. As further shown in FIG. 4 ( b ), there are two heat pipes 36 a and 36 b that connect between the fixed outer casing 12 and the heat distribution block 31 such that heat can be additionally transferred to the stationary part 12 from the heat distribution block 31 . It is understood that additional heat distribution pipes may communicate heat from the heat distribution block to the stationary part 12 . Further, heat transferred to the outer stationary part may then be transferred to the rotational part 11 through the intermediary of the thermally conductive lubricants. Heat is further transferred to the set of parallel disks 41 through the heat pipes 15 a , 15 b that are shown connecting the inner rotational part 11 to several disks 41 by suitable mounting means (such as shown herein with respect to FIGS. 5 ( a ) and 5 ( b )) and are rotatable therewith. Because of this heat transfer mechanism 110 , heat can now be distributed to the parallel disks and dissipated there while generating less turbulent air flows.
[0027] FIGS. 5 ( a ) and 5 ( b ) depict alternate embodiments for mounting the heat pipes to the rotational disks 41 . FIG. 5 ( a ) particularly depicts the end portion of a heat pipe 15 b that is bent at an upper end to lie in parallel to one of the disks near a radial member 43 . That portion of the heat pipe may be soldered, epoxied or otherwise equivalently attached to the disk 41 and the radial member 43 at location indicated as 46 in FIG. 5 ( a ). Additionally shown in FIG. 5 ( a ) is the attachment of a bent upper portion of heat pipe 15 a attached between two disks in a gap 47 near radial member. FIG. 5 ( b ) illustrates another embodiment of the mounting method in which the end of the heat pipes, 315 a , 315 b , and 315 c , are not bent. Rather, a solid metal extension 316 may be used to bridge the radial members 43 and the heat pipes as depicted in FIG. 5 ( b ).
[0028] FIG. 6 depicts two versions of the parallel disks, one is flat configuration as shown FIG. 6 ( a ) and the other is corrugated as shown in FIG. 6 ( b ). In the flat parallel disks version depicted in FIG. 6 ( a ), the disks are separated by the radial elements 43 between disks to create air gaps 47 . Air comes from the inlets 42 from both sides of the parallel disks. In the corrugated disks set depicted in FIG. 6 ( b ), the radial elements are not needed because of the corrugated nature of the disks 141 . Rather, the adjacent disks 141 are aligned in a way that the disks can be joined together at locations 149 and form air outlets 47 all around the disks. Thus, in the corrugated disk set, air comes from the inlets 142 . As shown in FIG. 6 ( b ), a trough 145 of the corrugated disk fan element is connected to a peak 146 of an immediately adjacent corrugated disk fan element to form the air channels 147 enabling a smooth air flow with less turbulence when the disk fans rotate. As shown in FIG. 6 ( b ), these air channels 147 are cone shaped.
[0029] FIGS. 7 ( a )- 7 ( c ) depict another embodiment of the cooling device of the invention that utilizes a hollow shaft to hold the plurality of parallel disks with an electric motor integrated in the shaft with FIG. 7 ( c ) depicting a cross-sectional view of the cooling device when taken along section ‘A-A’ of FIG. 7 ( b ). As shown in FIG. 7 ( c ), each disk 241 of the parallel disk set is mounted on the hollow shaft 223 as indicated by disk mounting holes 246 where the disks 241 will anchor on the hollow shaft 223 . As further shown in FIG. 7 ( c ), at locations located between each disk anchor mount 246 of the shaft are air slots 248 that permit air to pass through the shaft. Returning to the exploded view of FIG. 7 ( a ), radial elements 243 are placed between the disks 241 as in the other embodiment described herein to form gaps 247 between each disks. In operation, as the shaft rotates, air will enter into the hollow shaft 223 from a top opening 242 ( FIG. 7 ( a )), and pass through the air passing slots 248 , and will exit between disk gaps 247 . At one end of hollow shaft 223 , a magnetic ring 224 is provided that is supported by a shaft member 225 . The magnetic ring 224 has alternating magnetic poles (north and south) such that when an electric winding plate 221 is mounted beneath and energized, the magnetic ring 224 will be driven to rotate accordingly. The details of the windings in the electric winding plate 221 are not shown however, are similar to well-known brushless motor configurations. Control circuitry is provided that is similar to brushless motor devices as would be known to skilled artisans.
[0030] It is understood that the arrangement of rotating disks according to the invention, creates a more turbulent-free air flow, and accordingly increases heat transfer efficiencies.
[0031] While there has been shown and described what is considered to be preferred embodiments of the invention, it will, of course, be understood that various modifications and changes in form or detail could readily be made without departing from the spirit of the invention. It is therefore intended that the invention be not limited to the exact forms described and illustrated, but should be constructed to cover all modifications that may fall within the scope of the appended claims.
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A cooling apparatus for heat generating devices such as semiconductor chips comprises a parallel disk fan in the middle of a set of heat sink fins. The parallel disk fan has radial elements placed between the disks to efficiently create air flow without turbulence. Cooling efficiency is further enhanced when heat dissipation through the parallel disks of the fan is introduced.
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This application is a continuation-in-part of application serial number 08/368,285 filed on Jan. 4, 1995 now abandoned, which in turn is a continuation-in-part of application Ser. No. 08/297,187 filed on Aug. 26, 1994 now abandoned. The entire contents of both of these applications are hereby incorporated by reference.
FIELD OF THE INVENTION
This invention relates to endothelin antagonists useful, inter alia, for treatment of hypertension.
BRIEF DESCRIPTION OF THE INVENTION
Compounds of the formula I ##STR2## its enantiomers and diastereomers, and pharmaceutically acceptable salts thereof are endothelin receptor antagonists useful, inter alia, as antihypertensive agents. Throughout this specification, the above symbols are defined as follows:
one of X and Y is N and the other is O;
R 1 , R 2 , R 3 and R 4 are each directly bonded to a ring carbon and are each independently
(a) hydrogen;
(b) alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkylalkyl, cycloalkenyl, cycloalkenylalkyl, aryl, aryloxy, aralkyl or aralkoxy, any of which may be substituted with Z 1 , Z 2 and z3;
(c) halo;
(d) hydroxyl;
(e) cyano;
(f) nitro;
(g) --C(O)H or --C(O)R 5 ;
(h) --CO 2 H or --CO 2 R 5 ;
(i) --Z 4 --NR 6 R 7 ;
(j) --Z 4 --N(R 10 )--Z 5 --NR 8 R 9 ; or
(k) R 3 and R 4 together may also be alkylene or alkenylene, either of which may be substituted with Z 1 , Z 2 and Z 3 , completing a 4- to 8-membered saturated, unsaturated or aromatic ring together with the carbon atoms to which they are attached;
R 5 is alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, cycloalkenyl, cycloalkenylalkyl, aryl or aralkyl, any of which may be substituted with Z 1 , Z 2 and Z 3 ;
R 6 , R 7 , R 8 , R 9 and R 10 are each independently
(a) hydrogen; or
(b) alkyl, cycloalkyl, cycloalkylalkyl, cycloalkenylalkyl, aryl or aralkyl, any of which may be substituted with Z 1 , Z 2 and Z 3 ; or
R 6 and R 7 together may be alkylene or alkenylene, either of which may be substituted with Z 1 , Z 2 and Z 3 , completing a 3- to 8-membered saturated or unsaturated ring together with the nitrogen atom to which they are attached; or any two of R 8 , R 9 and R 10 together are alkylene or alkenylene, either of which may be substituted with Z 1 , Z 2 and Z 3 , completing a 3- to 8-membered saturated or unsaturated ring together with the atoms to which they are attached;
R 11 , R 12 , R 13 and R 14 are each independently
(a) hydrogen;
(b) alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkylalkyl, cycloalkenyl, cycloalkenylalkyl, aryl, aryloxy, aralkyl or aralkoxy, any of which may be substituted with Z 1 , Z 2 and Z 3 ,
(c) halo;
(d) hydroxyl;
(e) cyano;
(f) nitro;
(g) --C(O)H or --C(O)R 5 ;
(h) --CO 2 H or --CO 2 R 5 ;
(i) --SH, --S(O) n R 5 , --S(O) m --OH, --S(O) m --OR 5 , --O--S(O)m--OR 5 , --O--S(O) m OH or --O--S(O) m --OR 5 ;
(j) --Z 4 --NR 6 R 7 ; or
(k) --Z 4 --N(R 10 )--Z 5 --NR 8 R 9 ;
Z 1 , Z 2 and Z 3 are each independently
(a) hydrogen;
(b) halo;
(c) hydroxy;
(d) alkyl;
(e) alkenyl;
(f) aralkyl;
(g) alkoxy;
(h) aryloxy;
(i) aralkoxy;
(j) --SH, --S(O) n Z 6 , --S(O) m --OH, --S(O) m --OZ 6 , --O--S(O) m --Z 6 , --O--S(O) m OH or --O--S(O) m --OZ 6 ;
(k) oxo;
(l) nitro;
(m) cyano;
(n) --C(O)H or --C(O)Z 6 ;
(o) --CO 2 H or --CO 2 Z 6 ;
(p) --Z 4 --NZ 7 Z 8 ;
(q) --Z 4 --N(Z 11 )--Z 5 --H;
(r) --Z 4 --N(Z 11 )--Z 5 --Z 6 ; or
(s) --Z 4 --N(Z 11 )--Z 5 -NZ 7 Z 8 ;
Z 4 and Z 5 are each independently
(a) a single bond;
(b) --Z 9 --S(O) n --Z 10 --;
(c) --Z 9 --C(O)--Z 10 --;
(d) --Z 9 --C(S)--Z 10 --;
(e) --Z 9 --O--Z 10 --;
(f) --Z 9 --S--Z 10 --;
(g) --Z 9 --O--C(O)--Z 10 --; or
(h) --Z 9 --C(O)--O--Z 10 --;
Z 6 is alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, cycloalkenyl, cycloalkenylalkyl, aryl or aralkyl;
Z 7 and Z 8 are each independently hydrogen, alkyl, cycloalkyl, cycloalkylalkyl, cycloalkenylalkyl, aryl or aralkyl, or Z 7 and Z 8 together are alkylene or alkenylene, completing a 3- to 8-membered saturated or unsaturated ring together with the nitrogen atom to which they are attached;
Z 9 and Z 10 are each independently a single bond, alkylene, alkenylene or alkynylene;
Z 11 is
(a) hydrogen; or
(b) alkyl, cycloalkyl, cycloalkylalkyl, cycloalkenylalkyl, aryl or aralkyl;
or any two of Z 7 , Z 8 and Z 11 together are alkylene or alkenylene, completing a 3- to 8-membered saturated or unsaturated ring together with the atoms to which they are attached;
J is O, S, N or NR 15 ;
K and L are N or C, provided that at least one of K or L is C;
R 15 is hydrogen, alkyl, hydroxyethoxy methyl or methoxyethoxy methyl;
each m is independently 1 or 2;
each n is independently 0, 1 or 2; and
p is 0 or an integer from 1 to 2.
For compound I, it is preferred that:
R 1 and R 2 are each independently hydrogen, alkyl, alkoxy, aryl, hydroxyalkyl, --CO 2 R 5 or --Z 4 --NR 6 R 7 ;
R 3 and R 4 are each independently alkyl; and
R 11 and R 12 are each independently hydrogen, hydroxy, amino or substituted lower alkyl.
Most preferred compounds are those wherein:
R 1 and R 2 are each independently lower alkyl or hydrogen;
R 3 and R 4 are each independently lower alkyl, especially methyl; and
R 11 and R 12 are each independently hydrogen, hydroxy or substituted lower alkyl.
DETAILED DESCRIPTION OF THE INVENTION
Listed below are definitions of terms used in this specification. These definitions apply to the terms as used throughout this specification, individually or as part of another group, unless otherwise limited in specific instances.
The term "alkyl" or "alk-" refers to straight or branched chain hydrocarbon groups having 1 to 10 carbon atoms, preferably 1 to 7 carbon atoms. The expression "lower alkyl" refers to alkyl groups of 1 to 4 carbon atoms.
The term "alkoxy" refers to alkyl-O--.
The term "aryl" or "ar-" refers to phenyl, naphthyl and biphenyl.
The term "alkenyl" refers to straight or branched chain hydrocarbon groups of 2 to 10 carbon atoms having at least one double bond. Groups of two to four carbon atoms are preferred.
The term "alkynyl" refers to straight or branched chain groups of 2 to 10 carbon atoms having at least one triple bond. Groups of two to four carbon atoms are preferred.
The term "alkylene" refers to a straight chain bridge of 1 to 5 carbon atoms connected by single bonds (e.g., --(CH 2 ) x -- wherein x is 1 to 5), which may be substituted with 1 to 3 lower alkyl groups.
The term "alkenylene" refers to a straight chain bridge of 2 to 5 carbon atoms having one or two double bonds that is connected by single bonds and may be substituted with 1 to 3 lower alkyl groups. Exemplary alkenylene groups are --CH═CH--CH═CH--, --CH 2 --CH═CH--, --CH 2 --CH═CH--CH 2 --, --C(CH 3 ) 2 CH═CH-- and --CH(C 2 H 5 )--CH═CH--.
The term "alkynylene" refers to a straight chain bridge of 2 to 5 carbon atoms that has a triple bond therein, is connected by single bonds, and may be substituted with 1 to 3 lower alkyl groups. Exemplary alkynylene groups are --C.tbd.C--, --CH 2 --C.tbd.C--, --CH(CH 3 )--C.tbd.C-- and --C.tbd.C--CH(C 2 H 5 )CH 2 --.
The term "alkanoyl" refers to groups of the formula --C(O)alkyl.
The terms "cycloalkyl" and "cycloalkenyl" refer to cyclic hydrocarbon groups of 3 to 8 carbon atoms.
The term "hydroxyalkyl" refers to an alkyl group including one or more hydroxy radicals such as --CH 2 CH 2 OH, --CH 2 CH 2 OHCH 2 OH, --CH(CH 2 OH) 2 and the like.
The terms "halogen" and "halo" refer to fluorine, chlorine, bromine and iodine.
Throughout the specification, groups and substituents thereof are chosen to provide stable moieties and compounds.
The compounds of formula I form salts which are also within the scope of this invention. Pharmaceutically acceptable (i.e., non-toxic, physiologically acceptable) salts are preferred, although other salts are also useful, e.g., in isolating or purifying the compounds of this invention.
The compounds of formula I may form salts with alkali metals such as sodium, potassium and lithium, with alkaline earth metals such as calcium and magnesium, with organic bases such as dicyclohexylamine, t-butyl amine, benzathine, N-methyl-D-glucamide and hydrabamine, and with amino acids such as arginine, lysine and the like. Such salts may be obtained by reacting compound I with the desired ion in a medium in which the salt precipitates or in an aqueous medium followed by lyophilization.
When the R 1 to R 4 or R 11 to R 14 substituents comprise a basic moiety, such as amino or substituted amino, compound I may form salts with a variety of organic and inorganic acids. Such salts include those formed with hydrochloric acid, hydrogen bromide, methanesulfonic acid, sulfuric acid, acetic acid, maleic acid, benzenesulfonate, toluenesulfonate and various other sulfonates, nitrates, phosphates, borates, acetates, tartrates, maleates, citrates, succinates, benzoates, ascorbates, salicylates and the like. Such salts may be formed by reacting compound I in an equivalent amount of the acid in a medium in which the salt precipitates or in an aqueous medium followed by lyophilization.
In addition, when the R 1 to R 4 or R 11 to R 14 substituents comprise a basic moiety such as amino, zwitterions ("inner salts") may be formed.
Certain of the R 1 to R 4 and R 11 to R 14 substituents of compound I may contain asymmetric carbon atoms. Such compounds of formula I may exist, therefore, in enantiomeric and diastereomeric forms and in racemic mixtures thereof. All are within the scope of this invention. Additionally, compound I may exist as enantiomers even in the absence of asymmetric carbons. All such enantiomers are within the scope of this invention.
The compounds of formula I are antagonists of ET-1, ET-2 and/or ET-3 and are useful in treatment of conditions associated with increased ET levels (e.g., dialysis, trauma and surgery) and of all endothelin-dependent disorders. They are thus useful as antihypertensive agents. By the administration of a composition having one (or a combination) of the compounds of this invention, the blood pressure of a hypertensive mammalian (e.g., human) host is reduced. They are also useful in pregnancy-induced hypertension and coma (preeclampsia and eclampsia), acute portal hypertension and hypertension secondary to treatment with erythropoietin.
The compounds of the present invention are also useful in the treatment of disorders related to renal, glomerular and mesangial cell function, including acute and chronic renal failure, glomerular injury, renal damage secondary to old age or related to dialysis, nephrosclerosis (especially hypertensive nephrosclerosis), nephrotoxicity (including nephrotoxicity related to imaging and contrast agents and to cyclosporine), renal ischemia, primary vesicoureteral reflux, glomerulosclerosis and the like. The compounds of this invention may also be useful in the treatment of disorders related to paracrine and endocrine function.
The compounds of the present invention are also useful in the treatment of endotoxemia or endotoxin shock as well as hemorrhagic shock.
The compounds of the present invention are also useful in hypoxic and ischemic disease and as anti-ischemic agents for the treatment of, for example, cardiac, renal and cerebral ischemia and reperfusion (such as that occurring following cardiopulmonary bypass surgery), coronary and cerebral vasospasm, and the like.
In addition, the compounds of this invention may also be useful as anti-arrhythmic agents; anti-anginal agents; anti-fibrillatory agents; anti-asthmatic agents; anti-atherosclerotic and anti-arteriosclerotic agents; additives to cardioplegic solutions for cardiopulmonary bypasses; adjuncts to thrombolytic therapy; and anti-diarrheal agents. The compounds of this invention may be useful in therapy for myocardial infarction; therapy for peripheral vascular disease (e.g., Raynaud's disease and Takayashu's disease); treatment of cardiac hypertrophy (e.g., hypertrophic cardiomyopathy); treatment of primary pulmonary hypertension (e.g., plexogenic, embolic) in adults and in the newborn and pulmonary hypertension secondary to heart failure, radiation and chemotherapeutic injury, or other trauma; treatment of central nervous system vascular disorders, such as stroke, migraine and subarachnoid hemorrhage; treatment of central nervous system behavioral disorders; treatment of gastrointestinal diseases such as ulcerative colitis, Crohn's disease, gastric mucosal damage, ulcer and ischemic bowel disease; treatment of gall bladder or bile duct-based diseases such as cholangitis; treatment of pancreatitis; regulation of cell growth; treatment of benign prostatic hypertrophy; restenosis following angioplasty or following any procedures including transplantation; therapy for congestive heart failure including inhibition of fibrosis; inhibition of left ventricular dilatation, remodeling and dysfunction; and treatment of hepatotoxicity and sudden death. The compounds of this invention may be useful in the treatment of sickle cell disease including the initiation and/or evolution of the pain crises of this disease; treatment of the deleterious consequences of ET-producing tumors such as hypertension resulting from hemangiopericytoma; treatment of early and advanced liver disease and injury including attendant complications (e.g., hepatotoxicity, fibrosis and cirrhosis); treatment of spastic diseases of the urinary tract and/or bladder; treatment of hepatorenal syndrome; treatment of immunological diseases involving vasculitis such as lupus, systemic sclerosis, mixed cryoglobulinemia; and treatment of fibrosis associated with renal dysfunction and hepatotoxicity. The compounds of this invention may be useful in therapy for metabolic and neurological disorders; cancer; insulin-dependent and non insulin-dependent diabetes mellitus; neuropathy; retinopathy; maternal respiratory distress syndrome; dysmenorrhea; epilepsy; hemorrhagic and ischemic stroke; bone remodeling; psoriasis; and chronic inflammatory diseases such as rheumatoid arthritis, osteoarthritis, sarcoidosis and eczematous dermatitis (all types of dermatitis).
The compounds of this invention can also be formulated in combination with endothelin converting enzyme (ECE) inhibitors, such as phosphoramidon; thromboxane receptor antagonists; potassium channel openers; thrombin inhibitors (e.g., hirudin and the like); growth factor inhibitors such as modulators of PDGF activity; platelet activating factor (PAF) antagonists; angiotensin II (AII) receptor antagonists; renin inhibitors; angiotensin converting enzyme (ACE) inhibitors such as captopril, zofenopril, fosinopril, ceranapril, alacepril, enalapril, delapril, pentopril, quinapril, ramipril, lisinopril and salts of such compounds; neutral endopeptidase (NEP) inhibitors; dual NEP-ACE inhibitors; HMG CoA reductase inhibitors such as pravastatin and mevacor; squalene synthetase inhibitors; bile acid sequestrants such as questran; calcium channel blockers; potassium channel activators; beta-adrenergic agents; antiarrhythmic agents; diuretics, such as chlorothiazide, hydrochlorothiazide, flumethiazide, hydroflumethiazide, bendroflumethiazide, methylchlorothiazide, trichloromethiazide, polythiazide or benzothiazide as well as ethacrynic acid, tricrynafen, chlorthalidone, furosemide, musolimine, bumetanide, triamterene, amiloride and spironolactone and salts of such compounds; and thrombolytic agents such as tissue plasminogen activator (tPA), recombinant tPA, streptokinase, urokinase, prourokinase and anisoylated plasminogen streptokinase activator complex (APSAC). If formulated as a fixed dose, such combination products employ the compounds of this invention within the dosage range described below and the other pharmaceutically active agent within its approved dosage range. The compounds of this invention may also be formulated with, or useful in conjunction with, antifungal and immunosuppressive agents such as amphotericin B, cyclosporins and the like to counteract the glomerular contraction and nephrotoxicity secondary to such compounds. The compounds of this invention may also be used in conjunction with hemodialysis.
The compounds of the invention can be administered orally or parenterally to various mammalian species known to be subject to such maladies, e.g., humans, in an effective amount within the dosage range of about 0.1 to about 100 mg/kg, preferably about 0.2 to about 50 mg/kg and more preferably about 0.5 to about 25 mg/kg (or from about 1 to about 2500 mg, preferably from about 5 to about 2000 mg) in single or 2 to 4 divided daily doses.
The active substance can be utilized in a composition such as tablet, capsule, solution or suspension containing about 5 to about 500 mg per unit dosage of a compound or mixture of compounds of formula I or in topical form for wound healing (0.01 to 5% by weight compound of formula I, 1 to 5 treatments per day). They may be compounded in a conventional manner with a physiologically acceptable vehicle or carrier, excipient, binder, preservative, stabilizer, flavor, etc., or with a topical carrier such as Plastibase (mineral oil gelled with polyethylene) as called for by accepted pharmaceutical practice.
The compounds of the invention may also be administered topically to treat peripheral vascular diseases and as such may be formulated as a cream or ointment.
The compounds of formula I can also be formulated in compositions such as sterile solutions or suspensions for parenteral administration. About 0.1 to 500 milligrams of a compound of formula I is compounded with a physiologically acceptable vehicle, carrier, excipient, binder, preservative, stabilizer, etc., in a unit dosage form as called for by accepted pharmaceutical practice. The amount of active substance in these compositions or preparations is such that a suitable dosage in the range indicated is obtained.
The compounds of the present invention may be prepared as follows. ##STR3##
As depicted by the above Scheme I, the title compounds 4 may be prepared by a Pd(O) catalyzed coupling of an appropriately protected phenylsulfonamide-2-boronic acid intermediate 2 with a 4-heterocyclic aryl halide 1 in the presence of a suitable base, such as aqueous potassium carbonate, and solvent, such as a mixture of toluene and ethanol.
A boronic acid intermediate 2 may be prepared from a 2-bromophenylsulfonamide 5 (preparation of which is described in EP Publication number 0,569,193 (1993)) by lithiation with a suitable alkyl lithium (such as n-butyl lithium), subsequent treatment with a trialkylborate (e.g., triisopropyl borate) and finally adding an aqueous acid such as aqueous hydrochloric acid (SCHEME II): ##STR4## "Prot" is an appropriate protecting group for the sulfonamide function, also described in EP Publication number 0,569,193 (1993).
The title compounds may also be synthesized by an alternate route shown below (SCHEME III): ##STR5## As depicted above, a 4'-Heterocyclic aryl halide 6 (see also compound 1) can be converted to a boronic acid intermediate 7 via the sequence shown. This compound 7, upon Pd(O) catalyzed coupling with a compound 5 can provide a biaryl analog 3, which upon deprotection can lead to the title compound 4. In certain instances, the heteroatoms J and K or L may require protection to prepare the boronic acid 7, and/or to facilitate the coupling reaction to make compound 3. (For example, when J and K or L are N, one of the groups may be protected by a suitable protecting group such as t-butoxycarbonyl, etc). Also, in certain instances, the boronic acid may be replaced with a tin species and/or the halo group may be replaced by a --OSO 2 CF 3 moiety to perform the Pd-catalyzed coupling reaction. For general strategies in biaryl synthesis, see: Bringmann et al., Angew. Chem. Inst., Ed. Engl. 29 (1990) 977-991.
SYNTHESES OF COMPOUNDS 1 AND 6
Compounds 1 and 6 can be prepared by the following Schemes. 2-Aryloxazoles are prepared as depicted by SCHEME IV, Methods A-H; 4-Aryloxazoles are prepared as depicted by SCHEME V, Methods A-B; 5-Aryloxazoles are prepared as depicted by SCHEME VI, Methods A-B; Thiazoles are prepared as depicted by SCHEME VII, Methods A-B; Imidazoles are prepared as depicted by SCHEME VIII; 2-Phenylalkyloxazoles are prepared as depicted by SCHEME IX, Methods A-B; Pyrazoles are prepared as depicted by SCHEME X; 3-Arylisoxazoles are prepared as depicted by SCHEME XI; 5-Arylisoxazoles are prepared as depicted by SCHEME XII; and N-Arylimidazoles are prepared as depicted by SCHEME XIII.
A. 2-Aryloxazoles ##STR6##
An acyl amino compound 9 is prepared as depicted above and may be cyclized to an oxazole 10 using a variety of dehydrating agents. For a review of this and other methods of oxazole synthesis, see: Lakhan et al., Adv, Het. Chem., 17 (1974), 99. ##STR7##
As shown, heating together a mixture of a benzamide 11 and an α-halo carbonyl compound 12 provides the corresponding oxazole 13. This method has been used extensively to provide 2,4-disubstituted oxazoles. For a review, see: Lakhan et al., Adv. Het. Chem., 17, (1979) 99-211. ##STR8##
An ester 15 can be prepared either by allowing an α-haloketone to react with a benzoic acid 14 in the presence of a base such as triethylamine, or by esterification with an appropriate α-hydroxyketone. Compound 15, upon treatment with ammonium acetate in acetic acid, provides an oxazole 16. ##STR9##
Certain acetylenic carbinols such as compound 17 can react directly with an arylnitrile 18 to provide a 5-methyl oxazole, 19. (See, for example, Y. Yura, Japanese Patent 29849 (1964).) ##STR10##
An acetylenic amide 22, upon heating, cyclizes to an oxazole derivative 23. ##STR11##
A 4,5-unsubstituted oxazole 26 may be prepared by condensing a 4-bromobenzamide 11with a vinylene carbonate 25 at high temperature in the presence of an agent such as polyphosphoric acid. (See, for example, Ferrini, et al., Angew. Chem. Internat. Ed., Vol. 2, 1963, 99.) ##STR12##
Cyclization of the N-(2,2-dichloroethyl)amide derivative 27, prepared by methods known in the art, in the presence of a suitable base such as sodium ethoxide, may also provide the oxazole derivative 26. (See, for example, U.S. Pat. No. 3,953,465.) ##STR13##
Heating together a mixture of aroylchloride 21 with an oxime 29 where R 1 and R 2 are alkyl, prepared by methods known in the art, may provide the oxazole derivative 10. (See, for example, Bhatt, M. V. and Reddy, A. S., Tet. Lett., 21, 2359 (1980).) ##STR14##
Heating together a mixture of aroylchloride 21 with a triazole 25' where R is trimethylsilyl, prepared by methods known in the art, in a suitable solvent such as toluene may provide the oxazole derivative 26. (See, for example, Williams, E. L., Tet. Lett., 33, 1033-1036 (1992).)
It is also possible to prepare the oxazole derivative 26 by treatment of aroylchloride 21 with triazole (where R is hydrogen) in the presence of suitable base such as potassium carbonate followed by heating the mixture to an optimal temperature.
B. 4-Aryloxazoles ##STR15##
Treatment of an α-Bromoacetophenone derivative 30 with an amide at high temperatures (typically 130°-150° C.) provides a 4-aryl oxazole 31. ##STR16##
Certain α-metallated isonitriles 32, prepared by methods known in the art, react with acyl halides, imidazoles or other activated acyl groups, to provide 2-unsubstituted oxazoles 33 where R 2 is alkyl or aryl.
C. 5-Aryoxazoles ##STR17##
Acylation of an α-aminoacetophenone 34, with an acyl chloride, provides compound 35. Compound 35, upon cyclization using a suitable dehydrating agent such as sulfuric acid, provides an oxazole 36. (This method is similar to the one described in SCHEME IV, Method A). ##STR18##
A 4-Halobenzaldehyde 37 is treated with tosylmethylisocyanide 38 in the presence of a base, such as potassium carbonate, in a suitable solvent, such as methanol, to provide a 5-aryloxazole derivative 39. (See, for example, A. M. Van Leusen, et al., Tet. Lett., 2369 (1972).)
D. Thiazoles ##STR19##
A 4-Bromophenyl boronic acid 41 can be coupled with an appropriately substituted 2-bromothiazole 42 in the presence of a Pd(O) catalyst and a suitable base (e.g., aqueous potassium carbonate) and solvent to provide a thiazole 40. ##STR20##
Condensation of p-bromobenzonitrile 18 with an α-thioketone directly provides a thiazole derivative 44.
E. Imidazoles ##STR21##
Condensation of a benzaldehyde derivative 37 with glyoxal and ammonia provides a 2-aryl imidazole derivative 45. (See, e.g., U.S. Pat. No. 3,682,949.) This compound can be further substituted by reacting it with an alkyl halide in the presence of a suitable base to provide, e.g., an N-alkylderivative 46.
For a review on imidazole synthesis, see: Adv. Het. Chem., 27, (1980), 241-323.
F. 2-Phenylalkyloxazoles ##STR22##
2-Phenylalkyloxazoles 48, where p is 1 or 2, unsubstituted at the 4 and 5 positions, may be prepared by heating together a phenylalkylamide 47 with vinylene carbonate 25 in the presence of an agent such as polyphosphoric acid. ##STR23##
2-Arylalkyl-4-substituted-oxazole 51, where R 1 is alkyl and n is 1 or 2, may be prepared starting from a nitrile 49 as shown above. (See, for example, U.S. Pat. No. 4,168,379.)
G. Pyrazoles ##STR24##
The pyrazole derivative 52 may be prepared by heating together the aryl hydrazine 53 with epichlorohydrin in the presence of a suitable base such as triethyl amine.
H. 3-Arylisoxazoles ##STR25##
Treatment of the oxime 54, prepared by methods know in the art, with HCl/Oxone, and subsequent treatment with a base such as triethylamine, provides an arylnitrile oxide. The arylnitrile oxide typically is not isolated, but is reacted with vinylacetate, and then the mixture is heated in an acid (e.g., HCl) in a suitable solvent such as ethanol to provide the 3-aryl isoxazole derivative 55.
I. 5-Arylisoxazoles ##STR26##
An α,β-unsaturated ketone 56, prepared by methods known in the art, upon treatment with hydroxylamine provides the corresponding oxime derivative. Cyclization of this material in the presence of iodine and potassium iodide provides the 5-arylisoxazole derivative 57. R 1 in this scheme is alkyl or aryl. (See for example, J. Het. Chem., 30, 467 (1993).)
J. N-Arylimidazoles ##STR27##
The N-arylimidazole analog 59 may be prepared by a standard Ullmann coupling, known in the art, of the 1,4-dibromobenzene 58 with imidazole in the presence of a copper salt such as CuBr.
The invention will now be further described by the following working examples, which are preferred embodiments of the invention. These examples are meant to be illustrative rather than limiting.
EXAMPLE 1
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide ##STR28## A. 2-(4-Bromophenyl)oxazole
A mixture of 4-bromobenzenecarboxamide (4 g, 20 mmol), vinylene carbonate (1.72 g, 20 mmol) and 10 g polyphosphoric acid was heated at 170° C. for 3 hours. After cooling, the mixture was partitioned between 200 mL water and 200 mL ethyl acetate. The aqueous layer was extracted with 2×150 mL ethyl acetate. The combined organic liquid was washed with 100 mL water and 50 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 10:1 hexane/ethyl acetate to afford compound A (2.49 g, 56%) as a white solid.
B. 2-Borono-N-(3,4-dimethyl-5-isoxazolyl)-N'-(methoxyethoxymethyl)benzenesulfonamide
To a solution of 2-Bromo-N-(3,4-dimethyl-5-isoxazolyl)-N'-(methoxyethoxymethyl)benzenesulfonamide (5.67 g, 13.52 mmol, prepared as described in EP 0,569,193 (1993)) in 70 mL of tetrahydrofuran at -78° C., n-butyl lithium (2M solution in cyclohexane, 8.11 mL, 16.23 mmol) was added over 10 minutes. The resulting solution was stirred at -78° C. for 15 minutes and triisopropylborate (1.52 g, 8.06 mmol) was added. The mixture was then warmed to room temperature and stirred for 2 hours. The mixture was cooled to 0° C., 10% aqueous hydrochloric acid (120 mL) was added, and the solution was stirred for 10 minutes. The mixture was concentrated to 120 mL and extracted with 4×60 mL ethyl acetate. The combined organic extracts were washed once with 100 mL brine, dried (MgSO 4 ) and concentrated to give compound B (4.25 g, 82%) as a light yellow gum.
C. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-(2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound B (315 mg, 0.82 mmol), compound A (456 mg, 2.05 mmol) in 7.5 ml of toluene and 6 mL of 95% ethanol under argon, tetrakis (triphenylphosphine)palladium(O) (95 mg, 0.082 mmol) was added, followed by 4.5 mL of 2M aqueous sodium carbonate. The reaction mixture was heated at 75° C. for 4 hours, cooled and diluted with 50 mL of ethyl acetate. The organic liquid was separated and washed with 10 mL water and 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 2:1 hexane/ethyl acetate to afford compound C (279 mg, 70%) as a colorless gum.
D. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound C (276 mg, 0.57 mmol) in 10 mL of 95% ethanol, 10 mL of 6N aqueous hydrochloric acid was added and refluxed for 1 hour and 10 minutes. The reaction mixture was concentrated and the pH of the solution was adjusted to 8 using sodium bicarbonate solution. It was then acidified to pH 5 with glacial acetic acid. The mixture was extracted with 3×40 mL ethyl acetate. The organic liquid was washed with 10 mL water and 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 100:1 dichloromethane/methanol to afford the title compound (117 mg, 52%) as a white solid.
M.p. 90°-98° C.(amorphous).
Analysis calculated for C 20 H 17 N 3 O 4 S: Calculated: C, 60.75; H, 4.33; N, 10.63; S, 8.11; Found: C, 60.80; H, 4.15; N, 10.38; S, 8.12.
EXAMPLE 2
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(2-thiazolyl)[1,1'-biphenyl]-2-sulfonamide ##STR29## A. 2-(4-Bromophenyl)thiazole
To a solution of 4-Bromophenylboronic acid (3.01 g, 15 mmol), 2-bromothiazole (9.84 g, 60 mmol) in 120 mL of toluene and 96 mL of 95% ethanol under argon, tetrakis(triphenylphosphine)palladium(O) (1.04 g, 0.9 mmol) was added, followed by 72 mL of 2M aqueous sodium carbonate. The reaction mixture was heated at 75° C. for 1 hour and 15 minutes, cooled and diluted with 300 mL of ethyl acetate. The organic liquid was separated and washed with 100 mL water and 100 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 30:1 Hexane/ethyl acetate to afford compound A (2.0 g, 56%) as a white solid.
B. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-(2-thiazoyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound B from Example 1 (320 mg, 0.83 mmol) and compound A (400 mg, 1.67 mmol) in 7.5 mL of toluene and 6 mL of 95% ethanol under argon, tetrakis(triphenyl-phosphine)palladium(O) (96 mg, 0.083 mmol) was added, followed by 4.5 mL of 2M aqueous sodium carbonate. The reaction mixture was heated at 75° C. for 3 hours cooled and diluted with 50 ml of ethyl acetate. The organic liquid was separated and washed with 10 mL water and 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 2.5:1 hexane/ethyl acetate to afford compound B (291 mg, 70%) as a colorless gum.
C. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(2-thiazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound B (290 mg, 0.58 mmol) in 10 mL of 95% ethanol, 10 mL of 6N aqueous hydrochloric acid was added and refluxed for 1 hour. The reaction mixture was concentrated and the pH of the solution was adjusted to 8 using sodium bicarbonate solution. It was then acidified to pH 5 with glacial acetic acid. The mixture was extracted with 3×40 mL ethyl acetate. The organic liquid was washed with 10 mL water and 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 100:1 dichloromethane/methanol to afford the title compound (180 mg, 75%) as an off-white solid.
M.p. 87°-97° C.(amorphous).
Analysis calculated for C 20 H 17 N 3 O 3 S 2 . 0.34H 2 O: Calculated: C, 57.52; H, 4.27; N, 10.06; S, 15.35; Found: C, 57.68; H, 4.08; N, 9.90; S, 15.06.
EXAMPLE 3
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(4,5-dimethyl-2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide ##STR30## A. 4-Bromobenzoic acid, 2-oxo-1-methylpropyl ester
To 3-hydroxy-2-butanone (1.32 g, 15 mmol) and 4-bromobenzoyl chloride (3.29 g, 15 mmol) in 15 mL dichloromethane at 0° C., 5 mL pyridine was added dropwise. The reaction was stirred at room temperature for 5 hours, 150 mL ethyl acetate was added and filtered. The filtrate was washed with 2×50 mL 10% hydrochloric acid, 30 mL water and 30 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 10:1 hexane/ethyl acetate to afford compound A (3.4 g, 84%) as a white solid.
B. 2-(4-Bromophenyl)-4,5-dimethyloxazole
A mixture of compound A (3.4 g, 12.54 mmol), ammonium acetate (9.67 g, 125.4 mmol) and 10 mL acetic acid was heated at 100° C. for 4 hours. After cooling, the mixture was partitioned between 150 mL water and 200 mL ethyl acetate. The organic liquid was washed with 50 mL water and 50 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 25:1 hexane/ethyl acetate to afford compound B (1.52 g, 48%) as a white solid.
C. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(4,5-dimethyl-2-oxazolyl)-N-[(2-methoxyethoxy)methyl][1,1'-biphenyl]-2-sulfonamide
To a solution of compound B from Example 1 (320 mg, 0.83 mmol) and compound B above (420 mg, 1.67 mmol) in 7.5 mL of toluene and 6 ml of 95% ethanol under argon, tetrakis(triphenylphosphine)palladium(O) (96 mg, 0.083 mmol) was added, followed by 4.5 mL of 2M aqueous sodium carbonate. The reaction mixture was heated at 75° C. for 4 hours, cooled and diluted with 50 mL of ethyl acetate. The organic liquid was separated and washed with 10 mL water and 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 2:1 hexane/ethanol to afford compound C (300 mg, 70%) as a colorless gum.
D. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(4,5-dimethyl-2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound C (300 mg, 0.59 mmol) in 10 mL of 95% ethanol, 10 mL of 6N aqueous hydrochloric acid was added and refluxed for 1 hour. The reaction mixture was concentrated, and the pH of the solution was adjusted to 8 using sodium bicarbonate solution. It was then acidified to pH 5 with glacial acetic acid. The mixture was extracted with 3×40 ml ethyl acetate. The organic liquid was washed with 10 mL water and 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 1:1 hexane/ethyl acetate to afford the title compound (178 mg, 72%) as a white solid.
M.p. 96°-102° C.(amorphous).
Analysis calculated for C 22 H 21 N 3 O 4 S . 0.24H 2 O: Calculated: C, 61.76; H, 5.06; N, 9.82; S, 7.49; Found: C, 61.67; H, 4.76; N, 9.91; S, 7.59.
EXAMPLE 4
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(5-oxazolyl)[1,1'-biphenyl]-2-Sulfonamide ##STR31## A. 5-(4-Bromophenyl)oxazole
A mixture of 4.74 g (25.6 mmol) of p-bromobenzaldehyde, 5.0 g (25.6 mmol) of tosylmethyl isocyanide and 4.25 g (30.7 mmol) of anhydrous potassium carbonate in 150 mL of methanol was refluxed for 3 hours. The solvent was then evaporated, and 150 mL of water was added to the residual solid. The tan-white solid was filtered and washed several times with water and then dried to yield compound A (3.65 g, 64%).
B. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-(5-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of 0.8 g (2.08 mmol) compound B from Example 1 and 0.12 g (0.1 mmol) of tetrakis(triphenylphosphine)-palladium(O) in 25 mL of toluene under argon, 15 mL of 2M aqueous sodium carbonate was added followed by 0.70 g (3.12 mmol) of compound A in 15 mL of 95% ethanol. The mixture was refluxed for 3 hours, diluted with 100 mL of water and extracted with 3×75 mL of ethyl acetate. The combined organic extracts were washed once with 100 mL of brine, dried and evaporated. The residue was chromatographed on 50 g of silica gel using Hexanes/ethyl acetate 2:1 to afford 0.49 g (49%) of compound B as a colorless gum.
C. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(5-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of 0.49 g (1.01 mmol) of compound B in 10 mL of 95% ethanol, 10 mL of 6N aqueous hydrochloric acid was added and refluxed for 1 hour. The mixture was then concentrated and diluted with 50 mL of water. The solution was neutralized to pH 7 using saturated aqueous sodium bicarbonate and then acidified to pH 4 using glacial acetic acid. The white solid obtained was filtered and dried (0.37 g). Crystallization from dichloromethane/ethyl acetate/Hexanes afforded 0.23 g (58%) of the title compound as a white solid.
M.p. 189°-191° C.
Analysis Calculated for C 20 H 17 N 3 O 4 S.0.28 H 2 O: C, 60.00; H, 4.42; N, 10.49; S, 8.01; Found: C, 60.10; H, 4.17; N, 10.39; S, 8.04.
EXAMPLE 5
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(4-oxazolyl)[1,1'-biphenyl]-2-sulfonamide ##STR32## A. 4-(4-Bromophenyl)oxazole
A mixture of 5.0 g (18 mmol) of α, p-dibromoacetophenone and 4.05 g (89.9 mmol) of formamide was stirred in an oil bath at 130° C. for 3 hours. The mixture was then poured into 150 mL of ice/water and the solution was extracted with 3×100 mL of ether. The combined ether extracts were washed once with water, dried and evaporated. The residue was chromatographed on 200 mL of silica gel using Hexanes/ethyl acetate 3:1 to afford 1.3 g (32%) of compound A as a light brown solid.
B. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-(4-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of 0.668 g (1.74 mmol) of compound B from Example 1 and 0.104 g (0.09 mmol) of tetrakis(tri-phenylphosphine)palladium(O) in 25 mL of toluene under argon, 15 mL of 2M aqueous sodium carbonate was added followed by 0.52 g (2.32 mmol) of compound A in 15 mL of 95% ethanol. The mixture was refluxed for 3 hours, diluted with 100 mL of water and extracted with 3×75 mL of ethyl acetate. The combined organic extracts were washed once with 100 mL of brine, dried and evaporated. The residue was chromatographed on 50 g of silica gel using Hexanes/ethyl acetate 2:1 to afford 0.43 g (51%) of compound B as a colorless gum.
C. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(4-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of 0.75 g (1.55 mmol) of compound B in 8 mL of acetonitrile at 0° C. under argon, trimethylsilyl chloride (2.01 g) and sodium iodide (2.73 g) were added and the mixture was stirred at room temperature for 1 hour. The mixture was then diluted with 10 mL of water and extracted with 100 mL of ethyl acetate. The organic layer was washed with 10 mL of saturated aqueous sodium thiosulfate, dried and evaporated. This material was purified by reverse phase preparative HPLC on 30×500 mm ODS S10 column using 68% solvent A (90% methanol, 10% water, 0.1% trifluoroacetic acid) and 32% solvent B (10% methanol, 90% water, 0.1% trifluoroacetic acid). The appropriate fractions were collected and neutralized with aqueous sodium bicarbonate to pH 7 and concentrated to 10 mL. The solution was acidified to pH 4 using glacial acetic acid and the white solid was filtered and dried to provide 0.33 g (54%) of the title compound.
M.p. 85°-93° C. (amorphous).
Analysis Calculated for C 20 H 17 N 3 O 4 S.0.21 H 2 O: C, 60.18; H, 4.40; N, 10.53; S, 8.03; Found: C, 60.27; H, 4.05; N, 10.44; S, 7.88.
EXAMPLE 6
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(2-methyl-4-oxazolyl)[1,1'-biphenyl]-2-sulfonamide ##STR33## A. 4-(4-Bromophenyl)-2-methyloxazole
A mixture of 2,4-dibromoacetophenone (2.78 g, 10 mmol) and acetamide (1.48 g, 25 mmol) was heated at 130° C. for 3 hours. This mixture was poured onto 30 g ice, and 150 mL ethyl acetate was added. The organic layer was separated and washed with 30 mL 1N sodium hydroxide, 30 mL 1N hydrochloric acid and 30 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 15:1 hexane/ethyl acetate to afford compound A (1.29 g, 54%) as a white solid.
B. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-(2-methyl-4-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound A (402 mg, 1.7 mmol) and compound B from Example 1 (259 mg, 0.68 mmol) in 6.5 mL of toluene and 5.2 mL of 95% ethanol under argon, tetrakis (triphenylphosphine)palladium(O) (78 mg, 0.068 mmol) was added and followed by 3.9 mL of 2M aqueous sodium carbonate. The reaction mixture was heated at 75° C. for 3.5 hours, cooled and diluted with 40 mL of ethyl acetate. The organic liquid was separated and washed with 10 mL water and 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 2:1 hexane/ethyl acetate to afford compound B (183 mg, 54%) as a colorless gum.
C. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(2-methyl-4-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound B (180 mg, 0.36 mmol) in 6 mL of 95% ethanol, 6 mL of 6N aqueous hydrochloric acid was added and the combination was refluxed for 55 minutes. The reaction mixture was concentrated and the pH of the solution was adjusted to 8 using sodium bicarbonate solution. It was then acidified to pH 5 with glacial acetic acid. The mixture was extracted with 3×30 mL ethyl acetate. The organic liquid was washed with 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 100:1 dichloromethane/methanol to afford the title compound (56 mg, 38%) as a light yellow solid.
M.p. 90°-100° C.(amorphous).
Analysis calculated for C 21 H 19 N 3 O 4 S: Calculated: C, 61.60; H, 4.68; N, 10.26; S, 7.83; Found: C, 61.56; H, 4.33; N, 9.85; S, 7.94.
EXAMPLE 7
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(4-methyl-2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide ##STR34## A. 2-(4-Bromophenyl)-4-methyloxazole
4-bromobenzonitrile (9.1 g, 50 mmol) and propargyl alcohol (2.8 g, 50 mmol) were added portionwise into 12.5 mL concentrated sulfuric acid at -15° C. The reaction was stirred at 0° C. for 3 hours, warmed to room temperature slowly and stirred overnight. The mixture was poured into 200 mL ice water, neutralized with sodium bicarbonate and extracted with 3×200 mL ethyl acetate. The combined organic liquid was washed with 50 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 30:1 Hexane/ethyl acetate to afford compound A (1.44 g, 12%) as a white solid.
B. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-(4-methyl-2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound B from Example 1 (320 mg, 0.83 mmol) and compound A (397 mg, 1.67 mmol) in 7.5 mL of toluene and 6 mL of 95% ethanol under argon, tetrakis(triphenylphosphine)palladium(O) (96 mg, 0.083 mmol) was added, followed by 4.5 mL of 2M aqueous sodium carbonate. The reaction mixture was heated at 75° C. for 4 hours, cooled and diluted with 50 mL of ethyl acetate. The organic liquid was separated, washed with 10 mL water and 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 2:1 Hexane/ethyl acetate to afford compound B (300 mg, 72%) as a colorless gum.
C. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(4-methyl-2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound B (300 mg, 0.60 mmol) in 10 mL of 95% ethanol, 10 mL of 6N aqueous hydrochloric acid was added and refluxed for 1 hour. The reaction mixture was concentrated and the pH of the solution was adjusted to 8 using sodium bicarbonate solution. It was then acidified to pH 5 with glacial acetic acid. The mixture was extracted with 3×40 mL ethyl acetate. The organic liquid was washed with 10 mL water and 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 100:1 dichloromethane/methanol to afford the title compound (200 mg, 81%) as a white solid.
M.p. 85°-95° C.(amorphous).
Analysis calculated for C 21 H 19 N 3 O 4 S . 0.25 H 2 O: Calculated: C, 60.92; H, 4.75; N, 10.15; S, 7.74; Found: C, 61.15; H, 4.60; N, 9.89; S, 7.62.
EXAMPLE 8
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(5-methyl-2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide ##STR35## A. 2-(4-Bromophenyl)-5-methyloxazole
To 4-bromobenzoyl chloride (4.39 g, 20 mmol) in 40 mL dichloromethane at 0° C., propargylamine (1.10 g, 20 mmol) was added, followed by triethylamine (4.05 g, 40 mmol). The mixture was stirred at room temperature for 40 minutes. 150 mL ethyl acetate was added and filtered. The filtrate was washed with 2×40 mL water and 40 mL brine, dried and concentrated to give 4-Bromo-N-(2-propynyl)benzamide. 4-Bromo-N-(2-propynyl)benzamide was added into ice cooled 47 mL concentrated sulfuric acid. The reaction was stirred at 5°-10° C. for 3 hours and at room temperature overnight. The mixture was poured into 500 mL ice water, neutralized with sodium carbonate to pH 8 and extracted with 3×250 mL ethyl acetate. The combined organic extracts were washed with 200 mL water and 100 mL brine, dried and concentrated to afford compound A (4.5 g, 95%) as a light yellow solid.
M.p. 61°-63° C.
B. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-(5-methyl-2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound B from Example 1 (320 mg, 0.83 mmol) and compound A (397 mg, 1.67 mmol) in 7.5 mL of toluene and 6 mL of 95% ethanol under argon, tetrakis(triphenylphosphine)palladium(O) (96 mg, 0.083 mmol) was added, followed by 4.5 mL of 2M aqueous sodium carbonate. The reaction mixture was heated at 75° C. for 3 hours, cooled and diluted with 50 mL of ethyl acetate. The organic liquid was separated and washed with 10 mL water and 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 2:1 Hexane/ethyl acetate to afford compound B (298 mg, 72%) as a colorless gum.
C. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(5-methyl-2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound B (298 mg, 0.60 mmol) in 10 mL of 95% ethanol, 10 mL of 6N aqueous hydrochloric acid was added and refluxed for 1 hour. The reaction mixture was concentrated and the pH of the solution was adjusted to 8 using sodium bicarbonate solution. It was then acidified to pH 5 with glacial acetic acid. The mixture was extracted with 3×40 mL ethyl acetate. The organic liquid was washed with 10 mL water and 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 100:1 dichloromethane/methanol to afford the title compound (147 mg, 60%) as an off-white solid.
M.p. 90°-100° C. (amorphous).
Analysis calculated for C 21 H 19 N 3 O 4 S: Calculated: C, 61.60; H, 4.68; N, 10.26; S, 7.83; Found: C, 61.39; H, 4.11; N, 10.03; S, 7.61.
EXAMPLE 9
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1H-pyrazol -1-yl)[1,1'-biphenyl]-2-sulfonamide ##STR36## A. 1-(4-Bromophenyl)-1H-pyrazole
To epichlorohydrin (4 g, 43.23 mmol) and 4-bromophenyl hydrazine hydrochloride (19.32 g, 86.46 mmol) in 20 mL 60% ethanol, triethylamine (8.75 g, 12.05 mmol) was added dropwise. The mixture was warmed slowly and then refluxed for 1 hour. The solvent was evaporated, and the residue was heated at 170° C. for 30 minutes and at 200° C. for a further 10 minutes. 150 mL water was added, and the mixture was extracted with 3×200 mL ethyl acetate. The combined organic liquid was washed with 50 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 40:1 Hexane/ethyl acetate to afford compound A (2.92 g, 30%) which was crystallized from hexane to give yellow needles.
M.p. 72°-74° C.
B. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-(1H-pyrazol-1-yl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound B from Example 1 (320 mg, 0.83 mmol) and compound A (372 mg, 1.67 mmol) in 7.5 mL of toluene and 6 mL of 95% ethanol under argon, tetrakis(triphenylphosphine)palladium(O) (96 mg, 0.083 mmol) was added, followed by 4.5 mL of 2M aqueous sodium carbonate. The reaction mixture was heated at 75° C. for 2.5 hour, cooled and diluted with 50 mL of ethyl acetate. The organic liquid was separated, washed with 10 mL water and 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 2.5:1 Hexane/ethyl acetate to afford compound B (280 mg, 70%) as a colorless gum.
C. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1H-pyrazol-1-yl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound B (280 mg, 0.58 mmol) in 10 mL of 95% ethanol, 10 mL of 6N aqueous hydrochloric acid was added and refluxed for 1 hour. The reaction mixture was concentrated and the pH of the solution was adjusted to 8 using sodium bicarbonate solution. It was then acidified to pH 5 with glacial acetic acid. The mixture was extracted with 3×40 mL ethyl acetate. The organic liquid was washed with 10 mL water and 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 100:0.8 dichloromethane/methanol to afford the title compound (161 mg, 70%) as an off-white solid.
M.p. 88°-98° C.(amorphous).
Analysis calculated for C 20 H 18 N 4 O 3 S . 0.12H 2 O: Calculated: C, 60.56; H, 4.64; N, 14.12; S, 8.08; Found: C, 61.26;H , 4.52; N, 13.96; S, 8.06.
EXAMPLE 10
N-(3,4-Dimethyl-5-isoxazolyl)-4'-[1-[(2-methoxyethoxy)methyl]-1H-imidazol-2-yl][1,1'-biphenyl]-2-sulfonamide ##STR37## A. 2-(4-Bromophenyl)-1H-imidazole
To 4-Bromobenzaldehyde (9.25 g, 50 mmol) and glyoxal (40% wt. aqueous solution, 11.6 mL, 80 mmol) in 20 mL methanol, 60 mL 30% aqueous ammonium hydroxide was added dropwise. The mixture was stirred at room temperature overnight. The solvent was evaporated under vacuum. The residue was made slightly alkaline by the addition of aqueous sodium hydroxide, and extracted with 3×300 mL ethyl acetate. The combined organic extracts were dried and concentrated. The residue was dissolved in 100 mL methanol and filtered. The filtrate was concentrated and the residue was triturated with 20 mL ethyl ether to give compound A as a brown solid as (1.8 g, 16%).
B. 2-(4-Bromophenyl)-1-[(2-methoxyethoxy)methyl]-1H-imidazole
To compound A (400 mg, 1.79 mmol) in 18 mL tetrahydrofuran, sodium hydride (60% in mineral oil, 86 mg, 2.15 mmol) was added. The mixture was stirred at room temperature for 10 minutes. Methoxyethoxymethyl chloride (335 mg, 2.59 mmol) was added dropwise. The reaction was stirred at room temperature for 2 hours, and concentrated. 100 mL ethyl acetate was added and the organic liquid was washed with 20 mL water and 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 100: 400:1 Hexane/ethyl acetate/triethylamine to afford compound B (390 mg, 70%).
C. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-[1-[(2-methoxyethoxy)methyl]-1H-imidazol-2-yl][1,1'-biphenyl]-2-sulfonamide
To a solution of compound B from Example 1 (722 mg, 1.88 mmol) and compound B above (390 mg, 1.25 mmol) in 11.25 mL of toluene and 9 mL of 95% ethanol under argon, tetrakis(triphenylphosphine)palladium(O) (145 mg, 0.125 mmol) was added, followed by 6.75 mL of 2M aqueous sodium carbonate. The reaction mixture was heated at 75° C. for 3 hours, cooled and diluted with 75 mL of ethyl acetate. The organic liquid was separated, washed with 15 mL water and 15 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 100:0.2 ethyl acetate/triethylamine to afford compound C (400 mg, 56%) as a colorless gum.
D. N-(3,4-Dimethyl-5-isoxazolyl)-4'-[1-[(2-methoxyethoxy)methyl]-1H-imidazole-2-yl][1,1'-biphenyl]2-sulfonamide
To a solution of compound C (400 mg, 0.70 mmol) in 12 mL of 95% ethanol, 12 mL of 6N aqueous hydrochloric acid was added and refluxed for 1 hour. The reaction mixture was concentrated and the pH of the solution was adjusted to 8 using sodium bicarbonate solution. It was then acidified to pH 5 with glacial acetic acid. 200 mL ethyl acetate was added, and the organic liquid was washed with 20 mL water and 20 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 100:4:0.2 dichloromethane/methanol/ammonium hydroxide to afford the title compound (210 mg, 62%), which was crystallized from ethyl acetate/Hexane to provide white crystals.
M.p. 81°-84° C.
Analysis calculated for C 24 H 26 N 4 O 5 S . 0.24 H 2 O: Calc'd: C, 59.20; H, 5.48; N, 11.51; S, 6.58; Found: C, 59.25; H, 5.42; N, 11.46; S, 6.39.
EXAMPLE 11
N-3,4-Dimethyl-5-isoxazolyl)-4'-[1-[(2-hydroxyethoxy)methyl]-1H-imidazol -2-yl][1,1'-biphenyl]-2-sulfonamide ##STR38## A. N-(3,4-Dimethyl-5-isoxazolyl)-4'-[1-[(2-hydroxyethoxy)methyl]-1H-imidazol-2-yl][1,1'-biphenyl]-2-sulfonamide
To the title compound of Example 10 (120 mg, 0.25 mmol) in 2.5 mL dichloromethane at 0° C., boron tribromide (1M solution in dichloromethane, 0.37 mL, 0.37 mmol) was added dropwise. The reaction mixture was stirred at 0°-3° C. for 45 minutes. 5 mL saturated aqueous sodium bicarbonate was added and stirred for 10 minutes. The mixture was then acidified to pH 5 with glacial acetic acid and extracted with 3×40 ml 100:5 dichloromethane/methanol. The combined organic extracts were dried and concentrated. The residue was purified by preparative HPLC on a 30×500 mm ODS S10 column using 62% solvent A (10% methanol, 90% water, 0.1% trifluoroacetic acid) and 38% solvent B (90% methanol, 10% water, 0.1% tetrahydrofuran) to provide the title compound (80 mg, 69%) as a white solid.
M.p. 93°-103° C.
Analysis calculated for C 23 H 24 N 4 O 5 S . 0.75 H 2 O: Calculated: C, 57.31; H, 5.33; N, 11.62; S, 6.65; Found: C, 57.61; H, 5.04; N, 11.33; S, 6.55.
EXAMPLE 12
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1-methyl-1H-imidazol-2-yl)[1,1'-biphenyl]-2-sulfonamide, lithium salt ##STR39## A. 2-(4-Bromophenyl)-1-methyl-1H-imidazole
To compound A from Example 10 (700 mg, 3.14 mmol) in 7.8 mL tetrahydrofuran and 7.8 mL dimethylformamide, sodium hydride (60% in mineral oil, 151 mg, 3.77 mmol) was added. The mixture was stirred at room temperature for 10 minutes. Iodomethane (891 mg, 6.28 mmol) was added dropwise. The reaction mixture was stirred at room temperature for 1 hour, and concentrated. 100 mL ethyl acetate was added and the organic liquid was washed with 20 mL water and 20 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 100:1:0.1 dichloromethane/methanol/ammonium hydroxide to afford compound A (500 mg, 67%).
B. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-(1-methyl-1H-imidazole-2-yl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound B from Example 1 (320 mg, 0.83 mmol) and compound A (395 mg, 1.67 mmol) in 7.5 mL of toluene and 6 mL of 95% ethanol under argon, tetrakis (triphenylphosphine) palladium(O) (96 mg, 0.083 mmol) was added, followed by 4.5 mL of 2M aqueous sodium carbonate. The reaction mixture was heated at 75° C. for 3 hours, cooled and diluted with 50 mL of ethyl acetate. The organic liquid was separated and washed with 10 mL water and 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 100:1.5:0.1 dichloromethane/methanol/ammonium bicarbonate to afford compound A (254 mg, 61%) as a colorless gum.
C. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1-methyl-1H-imidazol-2-yl)[1,1'-biphenyl]-2-sulfonamide, lithium salt
To a solution of compound B (250 mg, 0.50 mmol) in 9 mL of 95% ethanol, 9 mL of 6N aqueous hydrochloric acid was added and refluxed for 1 hour. The reaction mixture was concentrated and the pH of the solution was adjusted to 8 using sodium bicarbonate solution. It was then acidified to pH 5 with glacial acetic acid. The mixture was extracted with 200 mL ethyl acetate and the organic layer was washed with 20 mL water and 20 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 100:6:0.3 dichloromethane/methanol/ammonium bicarbonate to afford N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1-methyl-1H-imidazol-2-1)[1,1'-biphenyl]-2-sulfonamide (189 mg, 92%), which was dissolved in 1N lithium hydroxide, added on to a HP-20 column and eluted with water and then 10:3 water/methanol to provide the title compound as a white solid.
M.p. >200° C. dec.
Analysis calculated for C 21 H 19 N 4 O 3 SLi . 2.75H 2 O: Calculated: C, 54.37; H, 5.32; N, 12.08; S, 6.91; Found: C, 54.58; H, 5.05; N, 11.87; S, 6.80.
EXAMPLE 13
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1H-imidazol-2-yl)[1,1'-biphenyl]-2-sulfonamide, lithium salt ##STR40## A. 2-(4-Bromophenyl)-1H-imidazole-1-carboxylic acid, 1,1-dimethylethyl ester
To compound A from Example 10 (446 mg, 2 mmol) in 20 mL acetonitrile, di-t-butyl dicarbonate (524 mg, 2.4 mmol) and 4-dimethylaminopyridine (24.4 mg, 0.2 mmol) were added. The reaction mixture was stirred at room temperature overnight and concentrated. The residue was chromatographed on silica gel using 6:1 hexane/ethyl acetate to afford compound A (500 mg, 77%) as a light yellow oil.
B. 4'-[1-[(1,1-Dimethylethoxy)carbonyl]-1H-imidazol-2-yl]-N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl][1,1'-biphenyl]-2-sulfonamide
To a solution of compound B from Example 1 (496 mg, 1.29 mmol) and compound A (500 mg, 1.55 mmol) in 11.25 mL of toluene and 9 mL of 95% ethanol under argon, tetrakis (triphenylphosphine)palladium(O) (149 mg, 0.29 mmol) was added, followed by 6.75 mL of 2M aqueous sodium carbonate. The reaction mixture was heated at 75° C. for 3 hours, cooled and diluted with 75 mL of ethyl acetate. The organic liquid was separated and washed with 15 mL water and 15 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 40:60:0.2 hexane/ethyl acetate/triethylamine to afford compound B (380 mg, 51%) as a colorless gum.
C. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1H-imidazole-2-yl)[1,1'-biphenyl]-2-sulfonamide, lithium salt
To a solution of compound B (380 mg, 0.65 mmol) in 12 mL of 95% ethanol, 12 mL of 6N aqueous hydrochloric acid was added and refluxed for 1 hour and 45 minutes. The reaction mixture was concentrated and the pH of the solution was adjusted to 8 using sodium bicarbonate solution. It was then acidified to pH 5 with glacial acetic acid, extracted with 3×80 mL 100:5 dichloromethane/methanol. The organic extracts were dried and concentrated. The residue was dissolved in 1N lithium hydroxide and chromatographed on HP-20 column eluted with water and then 10:2 water/methanol to provide the title compound as a white solid (180 mg, 69%).
M.p. >220° C. dec.
Analysis calculated for C 20 H 17 N 4 O 3 SLi . 2.06H 2 O: Calculated: C, 54.91; H, 4.87; N, 12.81; S, 7.33; Found: C, 54.99; H, 4.78; N, 12.73; S, 6.95.
EXAMPLE 14
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(5-methyl-4-oxazolyl)[1,1'-biphenyl]-2-sulfonamide ##STR41## A. 4-(4-Bromophenyl)-5-methyloxazole
To 4'-Bromopropiophenone (3.52 g, 16.5 mmol) and formamide (10.81 g, 240 mmol) at 50° C., bromine (2.40 g, 15 mmol) was added dropwise over 10 minutes. The reaction mixture was heated from 50° C. to 130° C. over 20 minutes and then heated at 130° C. for 4 hours. After cooling, 150 mL ethyl acetate was added and the liquid was washed with 2×20 mL water and 20 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 40:1 Hexane/ethyl acetane to afford compound A (1.59 g, 45%).
B. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-(5-methyl-4-oxazolyl)[1,'-biphenyl]-2-sulfonamide
To a solution of compound B from Example 1 (384 mg, 1.0 mmol) and compound A (408 mg, 1.7 mmol) in 9 mL of toluene and 7.2 mL of 95% ethanol under argon, tetrakis (triphenylphosphine)palladium(O) (116 mg, 0.10 mmol) was added, followed by 5.4 mL of 2M aqueous sodium carbonate. The reaction mixture was heated at 75° C. for 3 hours, cooled and diluted with 60 mL of ethyl acetate. The organic liquid was separated and washed with 15 mL water and 15 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 2.5:1 Hexane/ethyl acetate to afford compound B (317 mg, 64%) as a colorless gum.
C. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(5-methyl-4-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound B (300 mg, 0.60 mmol) in 10 mL of 95% ethanol, 10 mL of 6N aqueous hydrochloric acid was added and refluxed for 1 hour. The reaction mixture was concentrated and the pH of the solution was adjusted to 8 using sodium bicarbonate solution. It was then acidified to pH 5 with glacial acetic acid. The mixture was extracted with 3×40 mL ethyl acetate and the organic extracts were washed with 10 mL water and 10 mL brine, dried and concentrated. The residue was purified by preparative HPLC on a 30×500 mm ODS S10 column using 30% solvent A (10% methanol, 90% water, 0.1% trifluoroacetic acid) and 70% solvent B (90% methanol, 10% water, 0.1% tetrahydrofuran) to provide the title compound (150 mg, 61%) as a white solid.
M.p. 86°-96° C.(amorphous).
Analysis calculated for C 21 H 19 N 3 O 4 S . 0.16H 2 O: Calculated: C, 61.17; H, 4.72; N, 10.19; S, 7.77; Found: C, 61.20; H, 4.35; N, 10.16; S, 7.58.
EXAMPLE 15
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1H-imidazol-1-ylmethyl)[1,1'-biphenyl]-2-sulfonamide ##STR42## A. N-(3,4-Dimethyl-5-isoxazolyl)-2-bromo-benzenesulfonamide
To a solution of 3.0 g (11.74 mmol) of 2-bromobenzenesulfonyl chloride in 10 mL of pyridine was added 1.32 g (11.74 mmol) of 3,4-dimethyl-5-isoxazolamine. The mixture was stirred at room temperature under argon overnight, added to 150 mL of ice water and filtered. The filtrate was acidified to pH 2 using 6N aqueous hydrochloric acid and the grey solid was filtered and dried. The solid was crystallized from methanol/water to afford 4.0 g (>100%) of compound A as tan crystalline needles (m.p. 125°-126° C.; R f =0.51 (10% methanol/dichloromethane)).
B. 2-Bromo-N-(3,4-dimethyl-5-isoxazolyl)-N'-(methoxyethoxymethyl)benzenesulfonamide
To a solution of 1.1 g (3.33 mmol) of compound A in 15 mL of THF at room temperature under argon was added 0.19 g (4.8 mmol) of sodium hydride (60% suspension in mineral oil ) in portions, and the solution was stirred at room temperature for 10 minutes. Methoxyethoxymethyl chloride (0.55 g, 4.4 mmol ) was then added and the solution was stirred overnight. The mixture was concentrated and diluted with 30 mL of water, and extracted with 40 mL of ethyl acetate. The combined organic extracts were washed with 50 mL of brine, dried and evaporated to provide 1.2 g (87%) of compound B as a brown gum.
C. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-methyl[1,1'-biphenyl]-2-sulfonamide
To a solution of compound B, 4-methylbenzeneboronic acid (4.76 g, 35 mmol) in 250 mL of toluene and 200 mL of 95% ethanol under argon, tetrakis(triphenylphosphine)palladium(O) (2.43 g, 2.1 mmol) was added, followed by 150 mL of 2M aqueous sodium carbonate. The reaction mixture was heated at 80° C. for 2.5 hours, cooled and diluted with 300 mL of ethyl acetate. The organic liquid was separated and washed with 200 mL water and 200 ml of brine, dried and concentrated. The residue was chromatographed on silica gel using 5:1 hexane/ethyl acetate to afford compound C (9.0 g, 60%) as a colorless gum.
R f =0.74, silica gel, 1:1 Hexane/ethyl acetate.
D. 4'-(Bromomethyl)-N-(3,4-dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl][1,1'-biphenyl]-2-sulfonamide
To compound C (7.7 g, 17.89 mmol) in 180 mL carbon tetrachloride, n-bromosuccinimide (4.14 g, 23.25 mmol) and benzoyl peroxide (385 mg, 1.59 mmol) were added. The reaction was refluxed for 1.5 hours. After cooling, the reaction mixture was diluted with 200 mL dichloromethane, washed with 2×100 ml water and 100 mL brine, dried and concentrated. The residue was chromatographed on silica gel eluting with 4:1 hexane/ethyl acetate to provide compound D (3.64 g, 40%) as a colorless gum.
R f =0.38, silica gel, 2:1 Hexane/ethyl acetate.
E. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1H-imidazol-1-ylmethyl)-N-[(2-methoxyethoxy)-methyl][1,1'-biphenyl]-2-sulfonamide
To compound D (400 mg, 0.79 mmol) and imidazole (133 mg, 1.95 mmol) potassium carbonate (K 2 CO 3 ) (326 mg, 2.36 mmol) was added. The reaction was stirred at room temperature for 10 hours and then at 50° C. for 1 hour. The mixture was diluted with 50 mL ethyl acetate, washed with 10 mL water and 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 100:1.5 dichloromethane/methanol to afford compound E (220 mg, 56%) as a colorless gum.
R f =0.52, silica gel, 10:1 trichloromethane/methanol.
F. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1H-imidazol-1-ylmethyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound E (220 mg, 0.44 mmol) in 6 mL of 95% ethanol, 6 mL of 6N aqueous HCl was added. The reaction was refluxed for 2 hours, cooled and concentrated. The reaction mixture was neutralized with saturated aqueous sodium bicarbonate (NaHCO 3 ), and then acidified to pH <5 with acetic acid. Filtration of the mixture provided a white solid (91 mg, 50%) which was dissolved in 1N HCl and concentrated under vacuum to give the hydrochloride salt of the title compound as a white solid (m.p. 150° C. dec.)
R f =0.27, silica gel, 10:1 dichloromethane/methanol.
Analysis calculated for C 21 H 20 N 4 O 3 S 1.1 H 2 O . 0.8 HCl:
C, 55.02; H, 5.28; N, 12.22; S, 6.99; Cl, 6.19. Found: C, 54.67; H, 4.88; N, 11.97; S, 6.93; Cl, 6.30.
EXAMPLE 16
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(3-isoxazolyl)[1,1'-biphenyl]-2-sulfonamide ##STR43## A. 4-Bromo-N-hydroxybenzenecarboximidoyl bromide
To a 0.5M solution of hydrochloric acid in dimethylformamide, 8.5 g (42.5 mmol) of 4-Bromobenzaldehyde oxime was added and cooled to 5° C. 13 g of oxone was then added in portions. The mixture was slowly warmed to room temperature and stirred for 8 hours. The reaction mixture was poured into 300 mL of cold water and extracted with 2×150 mL of ether. The combined organic extracts were washed once with 150 mL of 0.5N aqueous hydrochloric acid and brine (150 mL), dried and evaporated to provide 7.9 g (79%) of compound A.
B. 5-(Acetyloxy)-3-(4-bromophenyl)-4,5-dihydroisoxazole
A mixture of 4.0 g (17.06 mmol) of compound A, 7.34 g (85.3 mmol) of vinyl acetate and 1.9 g (18.76 mmol) of triethylamine in 50 mL of toluene was stirred at 75° C. for 2 hours. The mixture was cooled and added to 150 mL of water. The organic layer was separated and the aqueous layer was extracted with 2×50 mL of ethyl acetate. The combined organic extracts were washed once with 100 mL of brine, dried and evaporated. The residue was crystallized from Hexanes/ethyl acetate to afford 3.6 g (74%) of compound B as a white solid.
C. 3-(4-Bromophenyl)isoxazole
To a solution of 3.0 g (10.56 mmol) of compound B in 100 mL of absolute ethanol, 5 mL of 6N aqueous hydrochloric acid was added and the solution was refluxed for 3 hours. The mixture was concentrated to about 10 mL and the solution was neutralized using aqueous sodium bicarbonate. The resulting mixture was extracted with 2×50 mL of ether. The combined organic extracts were washed once with 100 mL of brine, dried and evaporated. The residue was chromatographed on 100 g of silica gel using Hexanes/ethyl acetate 9:1 to afford 1.6 g (68%) of compound C as a white solid.
D. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-(3-isoxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of 0.45 g (1.17 mmol) of compound B from Example 1 and 0.058 g (0.05 mmol) of tetrakis(triphenylphosphine)palladium(O) in 20 mL of toluene under argon, 12 mL of 2M aqueous sodium carbonate was added followed by 0.315 g (1.4 mmol) of compound C in 12 mL of 95% ethanol. The mixture was refluxed for 2 hours, diluted with 100 mL of water and extracted with 3×50 mL of ethyl acetate. The combined organic extracts were washed once with 100 mL of brine, dried and evaporated. The residue was chromatographed on 50 g of silica gel using Hexanes/ethyl acetate 2:1 to afford 0.27 g (56%) of compound D as a colorless gum.
E. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(3-isoxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of 0.26 g (0.54 mmol) of compound D in 10 mL of 95% ethanol, 10 mL of 6N aqueous hydrochloric acid was added and refluxed for 1 hour. The mixture was then concentrated, diluted with 50 mL of water and extracted with 3×25 ml of ethyl acetate. The combined organic extracts were washed once with water, dried and evaporated (0.21 g). This material was purified by reverse phase preparative HPLC on a 30×500 mm ODS S10 column using 67% solvent B (90% methanol, 10% water, 0.1% trifluoroacetic acid) and 33% solvent A (10% methanol, 90% water, 0.1% trifluoroacetic acid). The appropriate fractions were collected, neutralized with aqueous sodium bicarbonate to pH 7 and concentrated to 10 mL. The solution was then acidified to pH 4 using glacial acetic acid and the white solid was filtered and dried to provide 0.13 g (61%) of the title compound.
M.p. 85°-90° C.
Analysis Calculated for C 20 H 17 N 3 O 4 S . 0.26 H 2 O: Calculated: C,60.04; H,4.41; N,10.50; S,8.01; Found : C,60.04; H,4.30; N,10.50; S,8.15.
EXAMPLE 17
N-(3,4-Dimethyl-5-isoxazoyl)-4'-(2-oxazolylmethyl)[1,1'-biphenyl]-2-sulfonamide ##STR44## A. 4-Bromobenzeneacetamide
To a solution of 6 g (27.9 mmol) of 4-bromophenylacetic acid in 200 mL of dichloromethane under argon, 14 mL of 2M solution of oxalyl chloride in dichloromethane was added. Then four drops of dimethylformamide was added and the mixture was stirred at room temperature for 1 hour. The solution was evaporated and dried in vacuo. The residue was dissolved in 150 mL of methanol, and 30 mL of 28% aqueous ammonium hydroxide was added to the mixture. The solution was stirred at room temperature overnight and then diluted with 150 mL of water. The resulting white solid was filtered, washed with water and dried to afford 5.1 g (85%) of compound A.
B. 2-[(4-Bromophenyl)methyl]oxazole
A mixture of compound A (2 g, 9.34 mmol) and vinylene carbonate (0.9 g, 10.45 mmol) in 6 g of polyphosphoric acid was heated at 170° C. for 3 hours. The residue was added to 100 mL of water and extracted with 2×100 mL of ethyl acetate. The combined organic extracts were washed once with water, dried and evaporated. The residue was chromatographed on 200 mL of silica gel using Hexanes/ethyl acetate 2:1 to provide 1.12 g (50%) of compound C as a white solid.
C. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-(2-oxazolylmethyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of 0.6 g (1.56 mmol) of compound B from Example 1 and 0.092 g (0.08 mmol) of tetrakis(triphenylphosphine)palladium(O) in 30 mL of toluene under argon, 15 mL of 2M aqueous sodium carbonate was added followed by 0.45 g (1.87 mmol) of compound B above in 15 mL of 95% ethanol. The mixture was refluxed for 2 hours, diluted with 100 mL of water and extracted with 3×50 mL of ethyl acetate. The combined organic extracts were washed once with 100 mL of brine, dried and evaporated. The residue was chromatographed on 200 mL of silica gel using Hexanes/ethyl acetate 2:1 to afford 0.72 g (93%) of compound C as a colorless gum.
D. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(2-oxazolylmethyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of 0.7 g (1.41 mmol) of compound C in 15 mL of 95% ethanol, 15 mL of 6N aqueous hydrochloric acid was added and refluxed for 1 hour. The mixture was then concentrated, diluted with 250 mL of water and extracted with 3×50 ml of ethyl acetate. The combined organic extracts were washed once with water, dried and evaporated to provide 0.41 g of a colorless gum. The residue was purified by reverse phase preparative HPLC on a 30×500 mm ODS S10 column using 67% solvent B (90% methanol, 10% water, 0.1% trifluoroacetic acid) and 23% solvent A (10% methanol, 90% water, 0.1% trifluoroacetic acid). The appropriate fractions were collected and neutralized with aqueous sodium bicarbonate to pH 7 and concentrated to 10 mL. The solution was then acidified to pH 4 using dilute hydrochloric acid and the resulting white solid was filtered and dried to provide 0.098 g (17%) of the title compound.
M.p. 65°-70° C.
1 H NMR (CDCl 3 ): δ1.80 (s,3H), 2.11 (s, 3H), 4.16 (s,2H), 7.04 (s, 1H), 7.27-8.02 (m, 10H). 13 C NMR (CDCl 3 ): δ6.99, 11.20, 34.67, 108.10, 127.54, 128.32, 128.92, 129.47, 130.82, 133.15, 133.44, 135.95, 137.91, 138.51, 139.37, 141.25, 154.69, 162.27, 163.42.
EXAMPLE 18
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(5-isoxazolyl)[1,1'-biphenyl]-2-sulfonamide ##STR45## A. 1-(4-Bromophenyl)-3-(dimethylamino)-2-propen-1-one
A solution of 7.0 g (35.2 mmol) of 4-bromoacetophenone in 7 mL of N,N-dimethylformamide diethyl acetal was refluxed for 20 hours. The solution was then diluted with 100 mL ether and cooled to 0° C. The yellow crystalline solid was filtered and dried to provide compound A (6.85 g, 77%).
B. 5-(4-Bromophenyl)isoxazole
To a solution of 6.2 g (24.4 mmol) of compound A in 70 mL of methanol at 0° C. was added a solution of 3.31 g (29.27 mmol) of hydroxylamine-0sulfonic acid in 20 mL of methanol over a period of 3 minutes. After stirring at room temperature for 1 hour, the reaction mixture was poured into a mixture of cold saturated sodium bicarbonate solution (200 mL) and ice-water (200 mL). The resulting mixture deposited 5.1 g of a light yellow solid. Recrystallization of this material in Hexane/ethyl acetate then provided 3.12 g (57%) of compound B as an off-white solid.
C. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-(5-isoxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of 0.56 g (1.46 mmol) of compound 1 from Example 1 and 0.081 g (0.07 mmol) of tetrakis(triphenylphosphine)palladium(O) in 25 mL of toluene under argon, 15 mL of 2M aqueous sodium carbonate was added followed by 0.49 g (2.18 mmol) of compound B in 15 mL of 95% ethanol. The mixture was refluxed for 2 hours, diluted with 100 mL of water and extracted with 3×50 mL of ethyl acetate. The combined organic extracts were washed once with 100 mL of brine, dried and evaporated. The residue was chromatographed on 50 g of silica gel using Hexanes/ethyl acetate 2:1 to afford 0.26 g (37%) of compound C as a colorless gum.
D. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(5-isoxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of 0.25 g (0.52 mmol) of compound C in 10 mL of 95% ethanol, 10 mL of 6N aqueous hydrochloric acid was added and refluxed for 1 hour. The mixture was then concentrated, diluted with 100 mL of water and extracted with 3×50 ml of ethyl acetate. The combined organic extracts were washed once with water, dried and evaporated (0.21 g). This material was purified by reverse phase preparative HPLC on a 30×500 mm ODS S10 column using 69% solvent B (90% methanol, 10% water, 0.1% trifluoroacetic acid) and 31% solvent A (10% methanol, 90% water, 0.1% trifluroacetic acid). The appropriate fractions were collected and neutralized with aqueous sodium bicarbonate to pH 7 and concentrated to 10 mL. The solution was acidified to pH 4 using glacial acetic acid and the white solid was filtered and dried to provide 0.11 g (53%) of the title compound.
M.p. 85°-90° C.
Analysis Calculated for C 20 H 17 N 3 O 4 S . 0.27 H 2 O: Calculated: C,60.02; H,4.42; N,10.50; S,8.01; Found: C,60.16; H,4.24; N,10.36; S,8.17.
EXAMPLE 19 ##STR46##
N-(3,4-Dimethyl-5-isoxazolyl)-2'-hydroxy-4'-(2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
A. 4-Bromo-3-hydroxybenzoic acid
Bromine (58 g, 19 mL, 0.36 mol) in acetic acid (50 mL) was slowly added over 2 hours to a solution of 3-hydroxybenzoic acid (50 g, 0.36 mol) in acetic acid (145 mL) with stirring at 15° C. After stirring at 15° C. for an additional hour and then at ambient temperature for 17 hours, the solid formed was filtered and rinsed with acetic acid (20 mL). Drying by pulling air through the filter pack for 4 hours afforded 23.5 g (30%) of compound A.
B. 4-Bromo-3-hydroxybenzoic acid, methyl ester
Sulfuric acid (concentrated, 9.4 mL) was added to a solution of compound A (23.5 g, 0.11 mol) in methanol (350 mL). After refluxing for 19 hours, the reaction was allowed to cool to room temperature and the pH was brought to about 4 with saturated sodium bicarbonate. After evaporating the methanol, the remaining solution was transferred to a separatory funnel. Extraction with ether (2×200 mL), washing the combined organic layers with brine (50 mL), and drying over magnesium sulfate afforded 25 g of crude product after evaporation of the solvent. Recrystallization from ether/hexane afforded 13.3 g (53%) of compound B.
C. 4-Bromo-3-methoxybenzoic acid, methyl ester
Dimethyl sulfate (6.4 mL, 67 mmol) and potassium carbonate (10 g) were added to a solution of compound B (13.3 g, 57 mmol) in acetone (86 mL). After refluxing for 19 hours, the reaction was cooled, the precipitate filtered off and the filtrate evaporated in vacuo to afford 14.7 g of crude product. Flash chromatography (silica, 50 mm diameter, 10% ethyl acetate/hexane) afforded 13.9 g of compound C (100%).
D. 4-Bromo-3-methoxybenzoic acid
Potassium hydroxide (2N, 120 mL, 240 mmol) was added to a solution of compound C (19 g, 79 mmol) in methanol (570 mL). After stirring at ambient temperature for 5.5 hours, water (100 mL) was added and the methanol removed in vacuo. The remaining solution was extracted with methylene chloride and then acidified with 6N hydrochloric acid to pH 1.5. Extraction with methylene chloride (1×500 mL and 2×200 mL) afforded 17 g (93%) of compound D after evaporation of the solvent.
E. 4-Bromo-3-methoxybenzamide
A solution of compound D (17 g, 73 mmol) and dimethylformamide (0.3 mL) in thionyl chloride (18 mL, 3.5 mol) was heated at 60° C. for 2 hours. After evaporating the reaction in vacuo and azeotroping with toluene (twice), the residue was dissolved in tetrohydrofuran (30 mL) and added slowly to a vigorously stirring concentrated ammonium hydroxide solution (95 mL). The precipitate was filtered, washed with water and dried in a vacuum desiccator overnight to afford 17 g (100%) of compound E.
F. 2-(4-Bromo-3-methoxyphenyl)oxazole
Polyphosphoric acid (18 g) was added to compound E (8.5 g, 37 mmol) and the mixture was heated and stirred until it was homogeneous. Vinylene carbonate (3.2 g, 2.4 mL, 37 mmol) was added and the reaction mixture was stirred at 160° C. for 2 hours during which Lime the reaction mixture evolved gas and turned black and gummy. After cooling, water and ether were added, mixed and decanted (three times). The decanted layers were filtered through Celite® and the filtrate transferred to a separatory funnel. The organic layer was washed with water (10 mL) and 1N sodium hydroxide (30 mL), and dried over magnesium sulfate to afford crude product after evaporation of the solvent. Any solid remaining in the reaction flask and the Celite® filter pad were rinsed with dichloromethane (3×10 mL) which was then washed with in sodium hydroxide (30 mL) and dried over magnesium sulfate. The two portions of crude product totaled 3.6 g. Flash chromatography (silica, 50 mm diameter, 30% ethyl acetate/hexane) afforded 2.3 g (24%) of compound F.
M.p. 68.5°-70.5° C.
G. N-(3,4-Dimethyl-5-isoxazolyl)-2'-methoxy-N-(2-methoxyethoxymethyl)-4'-(2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
A solution of compound B from Example 1 (2.3 g, 2.9 mmol) in ethanol (sparged with argon 20 minutes, 16 mL) was added to a solution of compound F (1.1 g, 4.4 mmol) in toluene (sparged with argon 20 minutes, 32 mL). To this solution was added a solution of sodium carbonate (1.0 g) in water (sparged with argon 20 min, 16 mL) followed by tetrakis(triphenylphosphine)palladium(O) (0.28 g, 0.24 mmol). After refluxing under argon for 2 hours, the solution was cooled and poured into brine (40 mL). Extraction with ethyl acetate (2×150 mL) and drying the combined organic layers over magnesium sulfate afforded 4.1 g of crude product after evaporation of the solvent. Flash chromatography (silica, 50 mm diameter, 40% ethyl acetate/hexane) afforded 0.50 g (34%) of compound G.
H. N-(3,4-Dimethyl-5-isoxazolyl)-2'-methoxy-4'-(2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
A solution of compound G (0.45 g, 0.88 mmol) in ethanol (13.4 mL) and 6N hydrochloric acid (13.4 mL) was stirred at 90° C. After 3.5 hours, the ethanol was evaporated in vacuo, and the residue transferred to a separatory funnel with dichloromethane/water. Extraction with dichloromethane (2×50 mL) and drying over magnesium sulfate afforded 0.37 g (100%) of compound H after evaporation of the solvent.
I. N-(3,4-Dimethyl-5-isoxazolyl)-2'-hydroxy-4'-(2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
Boron tribromide (1M in dichloromethane, 6.2 mL, 6.2 mmol) was added to a solution of compound H (0.33 g, 0.77 mmol) in methylene chloride (27 mL) with stirring at -78° C. After stirring at -78° C. for 30 minutes, the cold bath was removed. After stirring a total of 2.5 hours, the reaction mixture was transferred to a separatory funnel with dichloromethane/water. The pH was brought to 3.5 with saturated sodium bicarbonate. Extraction with dichloromethane (2×70 mL), and drying over magnesium sulfate afforded 0.68 g of crude product after evaporation of the solvent. Two flash chromatographies (silica, 25 mm diameter, 6% methanol/dichloromethane and silica, 15 mm diameter, 50% ethyl acetate/dichloromethane) afforded 60 mg (19%) of the title compound.
M.p. 111.0°-115.0° C.
Analysis calculated for C 20 H 17 N 3 O 5 S . 0.15 C 4 H 8 O 2 . 0.40 H 2 O: Calculated: C, 57.29; H, 4.43; N, 9.73; S, 7.42; Found: C, 57.30; H, 4.58; N, 9.37; S, 7.18.
EXAMPLE 20 ##STR47##
2-[2'-[[(3,4-Dimethyl-isoxazoly)amino]sulfonyl][1,1'-biphenyl]-4-yl]-4-oxazolecarboxamide
A. 2-(4-Bromophenyl)-4-oxazolecarboxaldehyde
A mixture of compound A from Example 7 (810 mg, 3.40 mmol) selenium dioxide (1.89 g, 17 mmol) and 6.8 mL dioxane was refluxed for 24 hours. After cooling the mixture was filtered and the filtrate was concentrated. The residue was chromatographed on silica gel using 60:1 dichloromethane/ethyl acetate to afford compound A (406 mg, 47%) as a light yellow solid.
B. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(4-formyl-2-oxazolyl)-N-[(2-methoxyethoxy)methyl][1,1'-biphenyl]-2-sulfonamide
To a solution of compound B from Example 1 (772 mg, 2.0 mmol), compound A (390 mg, 1.55 mmol) in 15 mL of toluene and 12 mL of 95% ethanol under argon, tetrakis(triphenylphosphine)palladium(O) (116 mg, 0.1 mmol) was added, followed by 9 mL of 2M aqueous sodium carbonate. The reaction mixture was heated at 75° C. for 1 hour, cooled and diluted with 80 mL of ethyl acetate. The organic liquid was separated, washed with 15 mL water and 15 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 3:2 hexane/ethyl acetate to afford compound B (290 mg, 37%) as a colorless gum.
C. 2-[2'-[[(3,4-Dimethyl-5-isoxazoyl)[(2-methoxyethoxy)methyl]amino]sulfonyl][1,1'-biphenyl]-4-yl]-4-oxazolecarboxamide
To compound B (285 mg, 0.56 mmol) above and sulfamic acid (108 mg, 1.11 mmol) in 5.6 mL tetrahydrofuran at 0° C., an ice cooled solution of sodium chlorite (101 mg, 1.11 mmol) in 5.6 mL water was added. The mixture was stirred at 0° C. for 3 minutes. 50 mL dichloromethane was added and the organic liquid was washed with 10 mL brine, dried and concentrated to give 2-[2'-[[(3,4-Dimethyl-5-isoxazolyl)[(2-methoxyethoxy)methyl]amino]sulfonyl][1,1'-biphenyl]-4-yl]-4-oxazolecarboxylic acid.
To 2-[2'-[[(3,4-Dimethyl-5-isoxazolyl)[(2-methoxyethoxy)methyl]amino]sulfonyl][1,1'-biphenyl]-4-yl]-4-oxazolecarboxylic acid and 0.014 mL dimethylformamide in 5.6 mL dichloromethane, oxalyl chloride (2M in dichloromethane, 0.56 mL, 1.11 mmol) was added, stirred for 0.5 hours and concentrated. To this mixture, 10 mL tetrahydrofuran and 2 mL concentrated ammonium hydroxide were added. The reaction mixture was stirred at room temperature for 50 minutes and concentrated. The organic liquid was washed with 15 mL water and 15 mL brine, dried and evaporated. The residue was chromatographed on silica gel using 1:4 hexane/ethyl acetate to afford compound C (245 mg, 84% for three steps) as a colorless gum.
D. 2-[2'-[[(3,4-Dimethyl-5-isoxazolyl)amino]sulfonyl][1,1'-biphenyl]-4-yl]-4-oxazolecarboxamide
To a solution of compound C (240 mg, 0.46 mmol) in 4.6 mL acetonitrile at 0° C., trimethylsilicon chloride (297 mg, 2.74 mmol) was added followed by sodium iodide (410 mg, 2.74 mmol). The mixture was stirred at room temperature for 1 hour. 5 mL water was added and extracted with 50 mL ethyl acetate. The organic liquid was washed with 5 mL saturated aqueous sodium thiosulfate and 5 mL brine, dried and concentrated. The residue was purified by preparative HPLC on a 30×500 mm ODS S10 column using 37% solvent A (10% methanol, 90% water, 0.1% trifluoroacetic acid) and 63% solvent B (90% methanol, 10% water, 0.1% tetrahydrofuran) to provide the title compound (122 mg, 61%) as a white solid.
M.p. 195° C. dec.
Analysis calculated for C 21 H 18 N 4 O 5 S . 0.23H 2 O: Calculated: C, 57.00; H, 4.20; N, 12.66; S, 7.24; Found: C, 57.01; H, 4.10; N, 12.65; S, 7.18.
EXAMPLE 21
N-(3,4-Dimethyl-5-isoxaolyl)-2'-[(formylamino)methyl]-4'-(2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide ##STR48## A. 4-Bromo-3-methylbenzamide
To a solution of 10 g (46.5 mmol) of 4-bromo-3-methyl benzoic acid in 200 mL of dichloromethane under argon, 30 mL of 2M solution of oxalyl chloride in dichloromethane was added. Four drops of dimethylformamide was then added and the mixture was stirred at room temperature for 1 hour. The solution was evaporated and dried in vacuo. The residue was dissolved in 100 mL of methanol, and 25 mL of 28% aqueous ammonium hydroxide was added to the mixture. The solution was stirred at room temperature for 3 hours, and then diluted with 500 mL of water. The resulting white solid was filtered, washed with water and dried to afford 8.9 g (89%) of compound A.
B. 2-(4-Bromo-3-methylphenyl)oxazole
A mixture of compound A (12 g, 56 mmol) and vinylene carbonate (6.5 g, 75.5 mmol) in 25 g of polyphosphoric acid was heated at 170° C. for 3 hours. The residue was then added to 700 mL of water and extracted with 3×250 mL of ethyl acetate. The combined organic extracts were washed once with water, dried and evaporated. The residue was chromatographed on 200 g of silica gel using dichloromethane to provide 6.7 g (50%) of compound B as a white solid.
C. 2-[4-Bromo-3-(bromomethyl)-phenyl]oxazole
A mixture of compound B (6.5 g, 27.3 mmol), N-bromosuccinimide (9.72 g, 54.6 mmol) and benzoyl peroxide (250 mg) in 250 mL of carbon tetrachloride was refluxed for 8 hours while illuminating the solution with a sun lamp. The mixture was then cooled and filtered. The filtrate was concentrated to provide 10 g of a light yellow solid which was used in the next step without any further purification.
D. 2-Bromo-5-(2-oxazolyl)benzaldehyde
To a solution of 7 g of crude compound C in 15 mL of anhydrous dimethylsulfoxide under argon, 5.5 g of anhydrous trimethylamine N-oxide (prepared as described in Soderquist et. al. Tet. Letters., 27, 3961(1986)) was added and the mixture was stirred at 55° C. for 6 hours. The mixture was then cooled, added to 150 mL of ice/water and extracted with 3×100 mL of ethyl acetate. The combined organic extracts were washed once with 100 mL of brine, dried and evaporated. The residue was chromatographed on 300 mL of silica gel using Hexanes/ethyl acetate 8:1 to afford 2.2 g (46% for two steps) of compound D as a white solid.
E. N-(3,4-Dimethyl-5-isoxazolyl)-2-formyl-N-[(2-methoxyethoxy)methyl]-4'-(2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of 2.3 g (6 mmol) of compound B from Example 1 and 0.3 g (0.26 mmol) of tetrakis(triphenylphosphine)palladium(O) in 40 mL of toluene under argon, 20 mL of 2M aqueous sodium carbonate was added followed by 1.0 g (6.28 mmol) of compound D in 20 mL of 95% ethanol. The mixture was refluxed for 2 hours, diluted with 100 mL of water and extracted with 3×50 mL of ethyl acetate. The combined organic extracts were washed once with 100 mL of brine, dried and evaporated. The residue was chromatographed on 200 mL of silica gel using Hexanes/ethyl acetate 1:1 to afford 1.69 g (55%) of compound E as a colorless gum.
F. N-(3,4-Dimethyl-5-isoxazolyl)-2'-formyl-4'-(2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of 1.68 g (3.28 mmol) of compound E in 30 mL of 95% ethanol, 30 mL of 6N aqueous hydrochloric acid was added and refluxed for 1 hour. The mixture was then concentrated and diluted with 250 mL of water and extracted with 3×150 mL of ethyl acetate. The combined organic extracts were then washed once with water, dried and evaporated to provide 1.46 g (90%) of compound F as a colorless gum.
G. 2'-(Aminomethyl)-N-(3,4-dimethyl-5isoxazolyl)-4'-(2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of 0.28 g (0.66 mmol) of compound F in 25 mL of methanol, 5 g of ammonium acetate and 1 g of 3 Å molecular sieves were added and stirred at room temperature for 1 hour. Sodium triacetoxyborohydride (0.42 g, 1.98 mmol) was added and the mixture was stirred for an additional 45 minutes. The solution was filtered, concentrated to 10 mL, diluted with 25 mL of water and extracted with 3×25 mL of ethyl acetate. The combined organic extracts were then washed once with water, dried and evaporated. The residue was chromatographed on 15 g of silica gel using 5% methanol in dichloromethane to afford 0.1 g (36%) of compound G as a white solid.
H. N-(3,4-Dimethyl-5-isoxazolyl)-2'-[(formylamino)methyl]-4'-(2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of 0.06 g (0.14 mmol) of compound G in 10 mL of dichloromethane at 0° C., 0.02 g of acetic formic anhydride and 0.02 g triethylamine were added. The mixture was slowly warmed to room temperature and stirred for 1 hour. The mixture was diluted with 10 mL of dichloromethane, washed with 20 mL of 0.1N aqueous hydrochloric acid and then with 20 mL of water. The organic layer was dried and evaporated. The residue was purified by reverse phase preparative HPLC on a 30×500 mm ODS S10 column using 56% solvent B (90% methanol, 10% water, 0.1% trifluroacetic acid) and 44% solvent A (10% methanol, 90% water, 0.1% trifluroacetic acid). The appropriate fractions were collected, neutralized with aqueous sodium bicarbonate to pH 7 and concentrated to 10 mL. The solution was then acidified to pH 4 using dilute hydrochloric acid, and the white solid was filtered and dried to provide 0.013 g (21%) of the title compound.
M.p. 105°-109° C.
1 HNMR(CDCl 3 ): δ1.87 (s, 3H), 2.12 (s, 3H) 3.89 (ABq, J=4.1, 15.8 Hz, 1H), 4.50 (ABq, J=7.6, 15.8 Hz, 1H), 6.63 (br s, 1H), 7.03-7.93 (m, 10H), 8.14 (s, 1H).
13 C NMR (CDCl 3 ): δ6.83, 10.90, 39.80, 108.68, 124.26, 124.95, 127.29, 128.18, 128.79, 129.77, 130.26, 130.26, 130.52, 132.19, 133.58, 137.44, 137.61, 138.42, 138.88, 139.58, 154.37, 161.53, 162.25.
EXAMPLE 22
N-(3,4-Dimethyl-5-isoxazolyl)-2'-[[(methoxycarbonyl)amino]methyl]-4'-(2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide ##STR49## A. N-(3,4-Dimethyl-5-isoxazolyl)-2'-[[(methoxycarbonyl)amino]methyl]-4'-(2-oxazolyl)[1,1'-biphenyl]-2-sulfonamide
To compound G from Example 21 (75 mg, 0.18 mmol) in 3.5 mL tetrahydrofuran, triethylamine (35 mg, 0.35 mmol) was added, followed by methyl chloroformate (17 mg, 0.18 mmol). The reaction was stirred at room temperature for 1 hour. Additional triethylamine (18 mg, 0.18 mmol) and methyl chloroformate (17 mg, 0.18 mmol) were added and the reaction was stirred at 40° C. for another 1.5 hours. The reaction mixture was concentrated and the residue was purified by preparative HPLC on a 3×500 mm ODS S10 column using 42% solvent A (10% methanol, 90% water, 0.1% trifluoroacetic acid) and 58% solvent B (90% methanol, 10% water, 0.1% trifluoroacetic acid) to provide the title compound (30 mg, 35%) as a white solid.
M.p. 110°-120° C.(amorphous).
Analysis calculated for C 23 H 22 N 4 O 6 S . 0.41H 2 O: Calculated: C, 56.39; H, 4.69; N, 11.44; S, 6.54; Found: C, 56.11; H, 4.48; N, 11.19; S, 6.49.
EXAMPLE 23
N-[[2'-[[3,4-Dimethyl-5-isoxazolyl)amino]sulfonyl]-4-(2-oxazolyl)[1,1'-biphenyl]-2-yl]methyl]N'-methylurea ##STR50## A. N-[[2'-[[3,4-Dimethyl-5-isoxazolyl)amino]sulfonyl]-4-(2-oxazolyl)[1,1'-biphenyl]-2-yl]methyl]N'-methylurea
To compound G from Example 21 (75 mg, 0.18 mmol) in 7.1 mL tetrahydrofuran, methyl isocyanate (71 mg, 1.24 mmol) was added. The reaction was stirred at room temperature overnight and concentrated. The residue was purified by preparative HPLC on a 30×500 mm ODS S10 column using 46% solvent A (10% methanol, 90% water, 0.1% trifluoroacetic acid) and 54% solvent B (90% methanol, 10% water, 0.1% trifluoroacetic acid) to provide the title compound (38 mg, 45%) as a white solid.
M.p. >150° C., dec.
Analysis calculated for C 23 H 23 N 5 O 5 S . 0.45H 2 O 0.2CH 2 Cl 2 : Calculated: C, 55.00; H, 4.83; N, 13.82; S, 6.33; Found: C, 54.57; H, 4.58; N, 13.61; S, 5.95.
EXAMPLE 24
N-(3,4-Dimethyl-5-isoxazolyl)-2'[[(methylsulfonyl)amino]methyl]-4'-(2-oxazolyl)-1,1'-biphenyl]-2-sulfonamide ##STR51## A. N-(3,4-Dimethyl-5-isoxazolyl)2'[[(methylsulfonyl)amino]methyl]-4'-(2-oxazolyl)1,1'-biphenyl]-2-sulfonamide
To compound G from Example 21 (75 mg, 0.18 mmol) and triethylamine (54 mg, 0.53 mmol) in 7.1 ml tetrahydrofuran, methanesulfonyl chloride (57 mg, 0.5 mmol) was added. The reaction was stirred at 45° C. for 2 hours. The reaction mixture was concentrated and the pH of the solution was adjusted to 8 using sodium bicarbonate solution. It was then acidified to pH 5 with glacial acetic acid. The mixture was extracted with dichloromethane. The organic liquid was concentrated and the residue was purified by preparative HPLC on a 30×500 mm ODS S10 column using 47% solvent A (10% methanol, 90% water, 0.1% trifluoroacetic acid) and 53% solvent B (90% methanol, 10% water, 0.1% trifluoroacetic acid) to provide the title compound (27 mg, 30%) as a white solid.
M.p. 110°-120° C.(amorphous).
Analysis calculated for C 22 H 22 N 4 O 6 S 2 . 0.14CH 3 COOH: Calculated: C, 52.37; H, 4.45; N, 10.96; S, 12.56; Found: C, 52.43; H, 4.37; N, 10.76; S, 12.11.
EXAMPLE 25
N-[[2'-[[(3,4-Dimethyl-5-isoxazolyl)amino]sulfonyl]-4-(2-oxazolyl)[1,1'-biphenyl]-2-yl]methyl]acetamide ##STR52## A. N-[[2'-[[(3,4-Dimethyl-5-isoxazolyl)amino]sulfonyl]-4-(2-oxazolyl)[1,1'-biphenyl]-2-yl]methyl]acetamide
To a solution of 0.075 g (0.177 mmol) of compound G from Example 21 in 10 mL of dichloromethane at 0° C., 0.019 g (0.19 mmol) of acetic anhydride and 0.019 g triethylamine were added. The mixture was then slowly warmed to room temperature and stirred for 1 hour. The mixture was diluted with 10 mL of dichloromethane and washed with 20 mL of 0.1N aqueous hydrochloric acid and then with 20 mL of water. The organic layer was dried and evaporated. The residue was purified by reverse phase preparative HPLC on a 30×500 mm ODS S10 column using 58% solvent B (90% methanol, 10% water, 0.1% trifluoroacetic acid) and 42% solvent A (10% methanol, 90% water, 0.1% trifluoroacetic acid). The appropriate fractions were collected and neutralized with aqueous sodium bicarbonate to pH 7 and concentrated to 10 mL. The solution was acidified no pH 4 using dilute hydrochloric acid, and the white solid was filtered and dried to provide 0.041 g (50%) of the title compound.
M.p. 105°-107° C.
Analysis calculated for C 23 H 22 N 4 O 5 S . 0.42H 2 O: Calculated: C,58.27; H,4.86; N,11.82; S,6.76; Found: C,58.38; H,4.71; N,11.71; S,6.93.
EXAMPLE 26
N-[[2'-[[3,4-Dimethyl-5-isoxazolyl)amino]sulfonyl]-4-(2-oxazolyl)[1,1'-biphenyl]-2-yl]N'-phenylurea ##STR53## A. N-[[2'-[[3,4-Dimethyl-5-isoxazolyl)amino]sulfonyl]-4-(2-oxazolyl)[1,1'biphenyl]-2-yl]methyl]N'-phenylurea
To compound G from Example 21 (25 mg, 0.059 mmol) in 3 mL tetrahydrofuran, phenyl isocyanate(56 mg, 0.47 mmol) was added. The reaction was stirred at room temperature overnight and concentrated. The residue was purified by preparative HPLC on a 30×500 mm ODS S10 column using 33% solvent A (10% methanol, 90% water, 0.1% trifluoroacetic acid) and solvent B (90% methanol, 10% water, 0.1% trifluoroacetic acid) to provide the title compound (18 mg, 56%) as a white solid.
1 HNMR(CDCl 3 ): δ1.82 (s, 3H), 2.16 (s, 3H), 3.99-4.38 (m, 2H), 6.06 (s, br, 1H), 6.91-8.03 (m, 15H).
13 C NMR (CDCl 3 ): δ7.60, 11.81, 42.65, 109.39, 119.92, 123.29, 124.13, 127.10, 128.26, 129.61, 130.68, 130.79, 132.96, 134.80, 137.72, 139.56, 140.00, 140.25, 140.43, 155.63, 156.58.
EXAMPLE 27
N-[[2'-[[3,4-Dimethyl-5-isoxazolyl)amino]sulfonyl]-4-(2-oxazolyl)[1,1'-biphenyl]-2-yl]N'-propylurea ##STR54## A. N-[[2'-[[3,4-Dimethyl-5-isoxazolyl)amino]sulfonyl]-4-(2-oxazolyl)[1,1'-biphenyl]-2-yl]methyl]N'-propylurea
To compound G from Example 21 (20 mg, 0.047 mmol) in 3 mL tetrahydrofuran, propyl isocyanate (36 mg, 0.424 mmol) was added. The reaction mixture was stirred at room temperature overnight and concentrated. The residue was chromatographed on silica gel using 100:4.5 dichloromethane/methanol to provide the title compound (16 mg, 67%) as a light yellow solid.
1 H NMR (CD 3 OD): δ0.89 (t, J=7 Hz, 3H), 1.46 (m, 2H), 1.70 (s, 3H), 2.10 (s, 3H), 3.06 (t, J=7 Hz, 2H), 4.08 (s, 2H), 7.10-8.12 (m, 9H).
13 C NMR (CD 3 OD): δ6.57, 10.58, 11.62, 24.37, 42.91, 124.83, 125.06, 127.97, 129.10, 129.62, 130.34, 131.67, 133.11, 133.74, 139.83, 140.44, 140.87, 141.24, 141.96, 160.91, 162.99, 163.42.
EXAMPLE 28
N-[[2'-[[(3,4-Dimethyl-5-isoxazolyl)amino]sulfonyl]-4-(2-oxazolyl)[1,1'-biphenyl]-2-yl]methyl]-N-methylacetamide ##STR55## A. N-[[2'-[[(3,4-Dimethyl-5-isoxazolyl)amino]sulfonyl]-4-(2-oxazolyl)[1,1'-biphenyl]-2-yl]methyl]-N-methylacetamide
To a solution of 0.15 g (0.35 mmol) of compound F from Example 21 in 15 mL of dichloromethane, methyl amine (33% solution in absolute ethanol, 0.13 mL, 1.06 mmol), glacial acetic acid (0.12 g, 2 mmol) and 1 g of 3 Å molecular sieves were added. The mixture was stirred at room temperature for 1 hour. Sodium triacetoxyborohydride (0.22 g, 1.06 mmol) was added and the mixture was stirred overnight. The solution was then filtered, washed once with water, dried and evaporated. The residue thus obtained was dissolved in 10 mL of dichloromethane, and 0.072 g (0.70 mmol) of acetic anhydride and 0.071 g (0.70 mmol) of triethylamine were added. The mixture was stirred at room temperature for 16 hours and evaporated. The residue was purified by reverse phase preparative HPLC on a 30×500 mm ODS S10 column using 58% solvent B (90% methanol, 10% water, 0.1% trifluoroacetic acid) and 42% solvent A (10% methanol, 90% water, 0.1% trifluoroacetic acid). The appropriate fractions were collected, neutralized with aqueous sodium bicarbonate to pH 7 and concentrated to 10 mL. The solution was acidified to pH 4 using glacial acetic acid and the white solid was filtered and dried to provide 0.069 g (41%) of the title compound as a light yellow solid.
M.p. 105°-115° C.
EXAMPLE 29
N-[[2'-[[(3,4-Dimethyl-5-isoxazolyl)amino]sulfonyl]-4-(2-oxazolyl)[1,1'-biphenyl]-2-yl]methyl]benzamide ##STR56## A. N-[[2'-[[(3,4-Dimethyl-5-isoxazolyl)amino]sulfonyl]-4-(2-oxazolyl)[1,1'-biphenyl]2-yl]methyl]benzamide
To compound G from Example 21 (70 mg, 0.17 mmol) and benzoyl chloride (23 mg, 0.17 mmol) in 3.3 mL dichloromethane, triethylamine (37 mg, 0.36 mmol) was added. The reaction was stirred at room temperature for 1.5 hours and concentrated. The residue was purified by preparative HPLC on a 30×500 mm ODS S10 column using 33% solvent A (10% methanol, 90% water, 0.1% trifluoroacetic acid) and 67% solvent B (90% methanol, 10% water, 0.1% trifluoroacetic acid) to provide the title compound (30 mg, 34%) as a white solid.
M.p. 128°-135° C.(amorphous)
1 H NMR (CDCl 3 ): δ1.91 (s, 3H), 2.18 (s, 3H), 4.16-4.76 (m, 2H), 7.13-8.13 (m, 14H).
EXAMPLE 30
N-[[2'-[[(3,4,-Dimethyl-5-isoxazolyl)amino]sulfonyl]-4-(2-oxazolyl)-[1,1'-biphenyl]-2-yl]methyl]-2,2-dimethylpropanamide ##STR57## A. N-[[2'-[[(3,4-Dimethyl-5-isoxazolyl)amino]sulfonyl]-4-(2-oxazolyl)-[1,1'-biphenyl]-2-yl]methyl]-2,2-dimethylpropanamide
To compound G from Example 21 (105 mg, 0.25 mmol) and trimethylacetyl chloride (30 mg, 0.25 mmol) in 4.9 mL dichloromethane, triethylamine (55 mg, 0.54 mmol) was added. The reaction was stirred at room temperature overnight and concentrated. The residue was purified by preparative HPLC on a 30×500 mm ODS S10 column using 33% solvent A (10% methanol, 90% water, 0.1% trifluoroacetic acid) and solvent B (90% methanol, 10% water, 0.1% trifluoroacetic acid) to provide the title compound (52 mg, 34%) as a white solid.
M.p. 122°-128° C.
1 H NMR (CDCl 3 ): δ1.18 (s, 9H), 1.93 (s, 3H), 2.18 (s, 3H), 3.96-4.46 (m, 2H), 7.24-8.05 (m, 9H).
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Compounds of the formula ##STR1## inhibit the activity of endothelin. The symbols are defined as follows: R 1 , R 2 , R 3 and R 4 are each directly bonded to a ring carbon and are each independently
(a) hydrogen;
(b) alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkylalkyl, cycloalkenyl, cycloalkenylalkyl, aryl, aryloxy, aralkyl or aralkoxy, any of which may be substituted with Z 1 , Z 2 and Z 3 ;
(c) halo;
(d) hydroxyl;
(e) cyano;
(f) nitro;
(g) --C(O)H or --C(O)R 5 ;
(h) --CO 2 H or --CO 2 R 5 ;
(i) --Z 4 --NR 6 R 7 ;
--Z 4 --N(R 10 )--Z 5 --NR 8 R 9 ; or
(k) R 3 and R 4 together may also be alkylene or alkenylene, either of which may be substituted with Z 1 , Z 2 and z 3 , completing a 4- to 8-membered saturated, unsaturated or aromatic ring together with the carbon atoms to which they are attached; and the remaining symbols are as defined in the specification.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to International Application PCT/EP/2006/068183, which was filed Nov. 7, 2006. This application claims priority to Italian Application TV2005A000169 filed Nov. 7, 2005.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method and a device providing a safety system for roller blinds, sun awnings, gates and the like.
2. Description of the Related Art
It is known that the actuating systems for roller blinds, to which reference will be made by way of example although the invention is also applicable to other movable barriers, are provided with safety devices for detecting when the roller blind, during its movement—especially its downwards movement—strikes an obstacle. After making impact, normally the roller blind is driven so as to reverse its direction of travel.
Many solutions of this type are known. In particular, a subassembly of such solutions makes use of a mechanical play existing between the drive shaft of the actuating system and the roller onto which the roller blind is wound. EP 0,552,459 describes an actuating system in which play is provided between two teeth projecting from the casing of the motor (of the actuating system) and a bar perpendicular to a rod fixed to the wall, which rod supports the entire actuating system. The bar is provided with deformation sensors for detecting the deformation thereof and therefore, indirectly, the load acting on the motor, from which data for controlling it is obtained.
EP 0,497,711 describes an actuating system in which a free wheel is arranged between the shaft and the roller. Two concentric members in the free wheel have, associated with them, means which act so that the relative movement of these two members when the free wheel starts to function after the roller blind strikes an obstacle causes, by means of a switch arranged in the electric power supply circuit of the motor, the automatic reversal of the direction of rotation of the roller and the immediate upward movement again of the roller blind.
FR 2,721,62 describes an actuating system where the roller is connected to a sensor, the signal of which representing the angular speed of the roller—here as below relative to the stationary part of the actuating system which is fixed to the wall—is processed by a logic unit in order to produce a stopped condition for the motor of the roller blind. A free wheel is provided, arranged between the motor and the roller, and zeroes the speed of the roller when it strikes an obstacle.
DE 196 10 877 describes a control system for an actuating system of roller blinds, comprising a pressure bar (Druckbalken). This bar is activated upon rotation of the motor which actuates the roller blind and, by means of the pressure sensors in contact with the bar, a signal is obtained and used to control the actuating system. In particular, this signal is used to detect an obstacle encountered by the roller blind.
DE 197 06 209 describes a system for measuring variations in weight acting on a roller which carries a roller blind, depending on which a motor-driven actuating system (of the roller blind) is controlled and in particular is stopped. In order to achieve this result a sensor in the form of a mechanical switching component is used, said component comprising two parts which co-operate and the relative angular position of which (along a same axis) is variable. When the roller blind reaches the end-of-travel stop or an obstacle, the relative rotation of the two parts changes and may be detected by mechanical switches so as to perform control of the actuating system.
U.S. Pat. No. 6,215,265 describes a system for controlling a motor-driven actuating system for a roller blind which measures the torque of the motor and stops it when it exceeds a fixed maximum torque value or following a maximum variation in the torque per unit of time. In addition, the speed of the roller is measured and the motor is stopped below a predefined speed value (which can be obtained from a stored profile). A further characteristic feature is to leave rotational play between the roller and the shaft of the motor, so as to make use of it as a further way of deactivating the motor. No further information is provided in this connection.
DE 44 45 978 relates to a safety device for roller blinds in which the stationary part of the actuating system is fixed with a certain degree of play, allowing a limited angular movement about the axis of the shaft (onto which the roller blind is wound) and in which at least one pivoting interrupt lever with an associated spring is provided. During a dangerous event the spring pulls the lever against a switch so as to produce a malfunction signal.
All these solutions have drawbacks.
The solutions which, in order to detect the presence of an obstacle, control the consumption or the load of the motor must necessarily rely upon a variation in the consumption or load produced by the obstacle. This variation, in order to activate a protection system, must exceed a minimum activation threshold below which it is still possible for dangerous impact situations to occur. Moreover, since the controlled (or monitored) component is the motor of the actuating system, the component which actually causes the impact, namely the roller blind, which sometimes has considerable dimensions, is not monitored. It is particularly difficult to control the motors which are fitted to roller blinds such as shutters, Venetian blinds or external roller shutters which have a “bellows” structure where the variation in load following an impact with an obstacle is difficult to predict because it depends on the obstacle itself and the impact conditions. In fact, it is the deformation of the roller blind during impact which produces the variation in the load on the motor. Moreover, since it is dependent upon the characteristics of the motor, each system must be set for the specific application, which varies greatly depending on whether it is required to operate shutters, awnings, blinds, doors or entranceways which have a varying size, weight and characteristics.
With the solutions which instead make use of mechanical play between the roller and motor, a degree of uncertainty may arise during their operation. When the play is used to obtain protection by means of a slider travelling along the entire length thereof in order to activate a switch or similar solutions, necessarily the play must be gauged in relation to the particular application. Too small a play may trigger protection without an obstacle actually being present, since the roller blind may encounter along its path not an insignificant amount of resistance, such as that produced by dust which has accumulated (especially with time) or ice formations, or may simply encounter more friction than predicted, usually as a result of an increase in dimensions due to variations in temperature which may even occur on a daily basis.
Too great a play may trigger the protection when the entire weight of the roller blind is already acting on the obstacle, which is very dangerous if, for example, the obstacle is a person.
It is therefore easy to appreciate the difficulty of designing a reliable system which has acceptable operating margins and at the same time can be used in more than one application, in order to reduce the re-designing and adaptation costs.
If the mechanical play is associated with control of the roller speed, here too the already mentioned problems exist of having to choose the degree of play with a compromise between efficiency and the possibility of standardisation. Where, however, there is only control of the angular speed of the roller, whether or not a free wheel is used on the roller, the risks exists that this speed may fall and trigger activation only when the roller blind is already bearing dangerously on the obstacle, something which is all the more likely where the roller blind has a fold-up structure (for example a blind with several horizontal slats) since the edge of the roller blind subject to impact disengages from the roller.
Where, instead, mechanical play is used to monitor indirectly the parameters of the motor, the general performance of the actuating system suffers from the drawbacks of the systems where only the parameters of the motor itself are monitored. In this case the mechanical play is nothing other than an alternative sensor for an electrical or physical characteristic of the motor.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a protection device which is devoid of the drawbacks of the prior art.
This object is achieved with a method for providing a protection system for barriers which are movable along an operating path and actuated by a motor, such as roller blinds, gates or the like, comprising the steps of:
connecting the barrier, with play, to a fixed part so that the barrier is able to move independently of the action of the motor over a travel section; defining within the section a set of safety positions corresponding to a safety position for the barrier; detecting along the travel section the actual position of the barrier with respect to the fixed part; preventing or reversing the action of the motor and/or the movement of the barrier when the barrier, inside the travel section, does not have a position included within the set of safety positions.
In order to implement this method, the invention envisages a protection device for movable barriers which can be actuated by a motor, such as roller blinds, gates or the like, for implementing the method, comprising:
a part fixed with respect to the movement of the barrier; a kinematic chain by means of which the fixed part can be connected to the barrier with play, the barrier being able to move independently of the action of the motor over a travel section; detection means for detecting, along the travel section, the relative position of the fixed part and the barrier; a processing unit which acquires position data from the detection means and prevents or reverses the action of the motor and/or the movement of the barrier when the barrier, along the travel section, does not have a position included within a set of safety positions.
BRIEF DESCRIPTION OF THE DRAWING
The advantages of a method and a device according to the invention will emerge more clearly from the following description, which refers mainly, by way of example, to an actuating system for a roller blind, but the comments of which are applicable to any variant of the invention, and which refers to the accompanying drawings, where:
FIG. 1 is an exploded view of an actuating system for roller blinds;
FIG. 2 is an exploded view of a device according to the invention;
FIG. 3 is a side view of one end of the actuating system according to FIG. 1 ;
FIG. 4 is a top plan view of the end according to FIG. 3 ;
FIG. 5 is a cross-sectional view along the plane B-B indicated in FIG. 4-4 ;
FIG. 6 is a cross-sectional view along the plane C-C indicated in FIG. 3 ;
FIG. 7 is a cross-sectional view along the plane A-A of FIG. 3 in a first operating condition;
FIG. 8 is a cross-sectional view along the plane A-A of FIG. 3 in a second operating condition;
FIG. 9 is a vertically and longitudinally cross-sectioned view of the actuating system according to FIG. 1 ;
FIG. 10 is an exploded view of a second actuating system for roller blinds;
FIG. 11 is an exploded view of a second device according to the invention;
FIG. 12 is a side view of one end of the actuating system according to FIG. 10 ;
FIG. 13 is a cross-sectional view along the plane F-F of FIG. 12 in a first operating condition;
FIG. 14 is a cross-sectional view along the plane F-F of FIG. 12 in a second operating condition;
FIG. 15 is a vertically and longitudinally cross-sectioned view of the actuating system according to FIG. 10 ;
FIG. 16 is a view of a detail according to FIG. 15 ;
FIG. 17 is a cross-sectional view of an accessory according to the invention.
FIG. 18 is an exploded view of a third device according to the invention for an actuating system for roller blinds;
FIG. 19 is another exploded view of the device in FIG. 18 ;
FIG. 20 is a side view of the device in FIG. 18 when assembled;
FIG. 21 is a front view of the device in FIG. 18 when assembled;
FIG. 22 is a cross-sectional view along the plane H-H indicated in FIG. 20 ;
FIG. 23 is a cross-sectional view along the plane J-J indicated in FIG. 21 .
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 , 18 denotes an actuating system for roller blinds, composed of:
a device 50 for implementing the method according to the invention, associated with an end group 20 ; a tubular body 22 which: at one end contains a motor and all the devices for operation thereof (not shown), the output shaft of which is connected to a pinion 23 inserted inside a toothed adaptor 24 for a roller 25 (on which the roller blind—not shown—is wound). The roller 25 is arranged over the tubular body 22 in a coaxial position; at the other end it is joined to a rotating part 70 by means of forced engagement between reliefs 28 on the rotating part 70 and corresponding recesses 29 of the tubular body 22 ; a prism-shaped support body 26 which is fixed rotatably to a wall and in which one end of the roller 25 is engaged, a metal ring 27 being inserted inside the other end of the roller 25 .
The device according to the invention has been shown separately and in greater detail in FIG. 2 . It comprises a base piece 30 and a rotating part 70 substantially with a circular cross-section, an electronic circuit board 99 and a wall bracket 90 . The latter is fixed to a wall and the base piece 30 is housed inside it. The tubular body 22 is inserted inside the roller 25 of the roller blind.
The base piece 30 acts as a fixed base on which the rotating part 70 is able to rotate over a limited section of angular travel, the amplitude of which is defined by mutual mechanical play. For this purpose, the base piece 30 comprises a cylindrical base 32 from which there projects a circular lip 34 which has, on the inside, in a cavity 33 , three identical teeth 36 which are situated in a relative 120° radial arrangement, with respect to the centre of the lip 34 where there is a hollow cylindrical relief 38 which is as high as the lip 32 . Two identical circular seats 40 are situated at the bottom of the relief 38 and contain two identical magnets 42 with corresponding dimensions.
With a screw 94 , tightened by a nut 96 which passes inside the relief 38 , the base piece 30 is rotatably connected to the rotating part 70 which also has a circular lip 72 , but with a diameter smaller than the lip 34 so as to be able to fit perfectly inside it and rotate with frictionless contact. The lip 72 , opposite the teeth 36 , is inset towards the centre, forming three identical concavities 74 with an arched bottom and width greater than that of the teeth 36 such that, when the rotating part 70 rotates relative to the base piece 30 , the teeth 36 move inside the concavities 74 .
The lip 72 , in the region of a concavity 74 , terminates in a shoulder 76 or continues directly with a circular edge 78 from the bottom surface 79 of which (see FIGS. 5 and 6 ) a hollow cylindrical spacer 80 projects centrally, inside which spacer the nut 96 and part of the body of the screw 94 are contained. By tightening the screw 94 not too tightly using the nut 96 , the rotating part 70 rests against the relief 38 and is able to rotate inside the base piece 30 without becoming detached. The difference in width between the teeth 36 and the concavities 74 defines a limited angular section of travel (play)—denoted by 98 —along which the rotating part 70 is able to travel inside the base piece 30 .
The bottom surface 79 has a diametral slit (not shown) inside which the circuit board 99 (shown in schematic form) is inserted and retained by means of its fork-shaped end 82 with two sides 81 a , 81 b ; therefore, the two sides 81 a,b surround snugly the spacer 80 and extend beyond the bottom surface 79 into the space surrounded by the lip 34 (see FIGS. 5 and 6 , where, in order to facilitate understanding thereof, the tubular body 22 not shown in FIGS. 3 and 4 is also cross-sectioned). The ends of the sides 81 a,b each support a Hall sensor 95 which is positioned, once the board is inserted, opposite a magnet 42 . It should be noted that the board 99 is shown in very schematic form, but contains all the logic components, the signal processing components and the connections necessary for the functions which will be described. Moreover, in order to increase the sensitivity of the system, the magnets 42 are directed so that a pole of their magnetic field is directed towards the sensors 95 .
Advantageously, resilient means 97 , for example a spring or rubber piece, may be inserted inside the section 98 so as to push resiliently the rotating part 70 into a zero reference angular position where each tooth 36 is situated approximately in a central position with respect to the width of the corresponding concavity 74 (see FIG. 7 ), which condition is achieved only when the actuating system for roller blinds 18 is not installed. After installation of the actuating system 18 and the roller blind, the position of the teeth 36 with respect to the corresponding concavity 74 is mainly the result of the simultaneous action of the weight force of the roller blind and the opposing force provided by the resilient means 97 . Moreover, also present is the action of any friction or resistance which the roller blind encounters during its travel and which may in fact vary during the life of the roller blind and must be alternately added to or subtracted from the action of the weight force of the roller blind. By varying the resilience factor of the means 97 (or their size) it is possible to optimise the sensitivity of the system, preventing also false alarms or stray signals being emitted by the sensors 95 .
Operation of the device 50 is now described, with reference to FIGS. 7 , 8 and 9 .
The actuating system 18 comprises a kinematic chain consisting of the following components:
the roller 25 is joined to the motor of the actuating system via the adaptor 24 and the pinion 23 ; the motor is joined to the tubular body 22 (being rigidly contained inside it) and the latter is joined to the rotating part 70 .
During rotation of the roller 25 , the roller blind is wound onto or unwound from the roller 25 . The moment exerted by the weight of the roller blind on the roller 25 therefore varies and is transmitted via the kinematic chain to the rotating part 70 , which assumes a certain angular reference position within the section of play 98 . This position is the result of the action of the moment generated by the weight of the roller blind on the roller 25 and the opposing force of the resilient means 97 to which the moment of the motor is indirectly applied (the motor is controlled so as to rotate at a practically constant angular speed so as to move the roller blind at a constant speed).
If the roller blind encounters an obstacle and is stopped or in any case slowed down by it, the relative angular position of the rotating part 70 and base piece 30 varies and the sensors 95 detect instantaneously this variation. This is explained with reference to FIGS. 7 and 8 where two different angular positions of the rotating part 70 with respect to the base piece 30 are shown.
In the angular position of the rotating part 70 shown in FIG. 7 , the two sensors 95 detect a strong magnetic field (resulting from the proximity to the magnets 42 ). When the rotating part 70 is rotated as shown in FIG. 8 , the magnetic field in the space occupied by the sensors 95 is smaller, as is the signal output by the latter and analysed by the board 99 . It is easy to understand that, in general, for each angle covered by the rotating part 70 within the section of play 98 , the magnetic field detected by the sensors 95 , and therefore their output signal, will be different and uniquely linked to the angular position of the rotating part 70 (suitable screening systems—not shown—prevent any interference from outside the system).
The board 99 processes the signal of the sensors 95 so as to extract the information relating to the angular position of the rotating part within the section 98 . At the same time, the board 99 may also acquire the current position of the roller blind (detected, calculated or estimated by means of devices of the known type, usually encoders, associated directly with the motor, inside the tubular body 22 , or with the roller 25 ).
During operation of the actuating system 18 , when the roller blind is moving, it is possible to detect a signal which corresponds to the actual angular position of the rotating part 70 within the section 98 . This signal may be sampled and stored so as to obtain a response curve (RC), namely a very compact sequence of data which correspond to the different positions occupied by the rotating part 70 within the play section 98 . Each sample may be associated with a precise instant or with the actual position of the roller blind, during the movement of the latter along the operating path.
All this allows at least two advantageous operating modes to be obtained:
i) it is possible to define a set of safety positions consisting simply of a range of positions of the rotating part 70 within the play section 98 . Each position outside this range is regarded as a danger signal and the actuating system is correspondingly controlled. Therefore the protection consists of operation which is of a “stepped” nature, but able to be adjusted with a programmable margin of freedom so as to take account of the tolerances during operation.
ii) at the time of installation, in order to adapt the actuating system 18 to the specific operating situation, or also afterwards, if it is considered that some operating conditions have varied considerably and it is necessary to re-configure the system, an actuating system which is fitted with the device 50 may perform an adaptation step during which:
the roller blind completes one or more opening/closing cycles along the operating path; at the same time the relative angular deviation of the base piece 30 and the rotating part 70 is sampled, if necessary averaged and/or filtered and stored in a memory of the board 99 . This thus produces a response curve (RC) for the angular deviation corresponding to the specific operating condition, in which the sampled data are associated with the position of the roller blind; a tolerance value T to be added to the RC is defined, in order to take account of small variations—which are not significant for safety purposes—associated in a variable and unpredictable manner with the path of the roller blind; subsequently the RC and the tolerance T are stored in a suitable non-volatile memory (not shown).
During subsequent operation of the actuating system 18 , the current position of the roller blind along the operating path and the corresponding current relative angular deviation of rotating part 70 and base piece 30 are detected, the latter is compared with the point of RC+T (which corresponds to a set of safety positions) relating to the current position and, if the limits values for the tolerance T are exceeded, the board 99 activates protection, for example reversing the direction of rotation of the motor or causing stoppage thereof and activating a danger signal.
Advantageously it is possible to store a set of positions of the barrier along the operating path. In this way it is possible to associate, biunivocally, a set of safety positions with a set of positions of the barrier along the operating path, namely a plurality of points is considered along the operating path and a value of the angular deviation is associated with each of them in a set of safety positions. When the barrier reaches a point belonging to the predetermined set of positions along the operating path, the current angular deviation is compared with the corresponding value present in the set of safety positions, and action is taken consequently.
This self-learning procedure may be activated by the user or performed by the actuating system automatically at periodic intervals.
Another advantage of the invention is that by detecting continuously and point-by-point the relative angular deviation of base piece 30 and rotating part 70 —this parameter indicating the resistance encountered by the roller blind along its travel path—it is possible to associate with different angular positions of the rotating part 70 within the section 98 one or more activation thresholds or different RC+T values within the memory, corresponding to different danger situations. These threshold values are not fixed, but may be established very easily in each case (configuring the electronic board 99 , advantageously via software), depending on the application and the operating environment of the said application.
On the basis of different threshold or tolerance levels, which are programmed and stored in the electronic board, it is possible to determine, during installation, the behaviour mode of the system depending on the environment. For example, it is possible to establish a “level 1” (low sensitivity), where the tolerance T will be 20% since the roller blind is used in industrial applications, “level 2” where the tolerance T will be 15% since the roller blind is used on a window of a dwelling, “level 3” where the tolerance T will be 10% since the roller blind is used on French windows which are frequently used in a home, “level 4” (high sensitivity), where the tolerance T will be 5% since the roller blind is used in special environments such as nurseries or shops. Obviously, said levels may also be used for applications in particular climatic conditions, where ice is present or large variations in temperature frequently occur.
Therefore the mechanical characteristics of the device 50 do not change, even though its functional capabilities change, allowing it to be easily mass-produced. The capacity for adaptation of the device 50 to each operating situation of a roller blind, or even to changes—as a result of ageing or environmental variations—encountered during its movement, are effectively compensated for in real time. This may be performed either by the user, who may re-program the activation thresholds as desired, or automatically, using the self-learning procedure described.
The safety device 50 may also be battery-powered and/or provided with a wireless transmission system (for example of the radiofrequency, infrared or Bluetooth type) for signalling, advantageously to a remote receiver component, the danger condition or transmitting the angular deviation. Alternatively it is possible to envisage integrated network and/or fast connection means.
Obviously, in order to measure the relative angular displacement of the base piece 30 and rotating part 70 , it is possible to use other transducers, such as a potentiometer, an optical system, an additional encoder, etc.
An actuating system, which comprises a second device according to the invention, is shown in FIG. 10 and is denoted by the number 118 . It is composed of:
a device for implementing the method according to the invention, associated with an end group 120 ; a tubular body 122 which: at one end contains a motor and all the devices for operation thereof (not shown), the output shaft of which is connected to a pinion 123 inserted inside a toothed adaptor 124 for a roller 125 (on which the roller blind—not shown—is wound), said roller being arranged over the tubular body 22 in a coaxial position; at the other end is joined to connector 170 by means of forced engagement between reliefs 128 on the connector 170 and corresponding recesses 129 of the tubular body 122 ; a prism-shaped support body 126 which is fixed rotatably to a wall and in which one end of the roller 125 is engaged, a metal ring 127 being inserted inside the other end of the roller 125 .
The end group 120 has been shown separately and in greater detail in FIGS. 11 and 12 . It comprises a base piece 130 , the connector 170 and a wall bracket 190 . The latter is fixed to a wall and the base piece 130 is housed inside it. The tubular body 122 is inserted inside the roller 125 of the roller blind.
The base piece 130 —see FIGS. 15 and 16 —is joined to the connector 170 by means of a through-screw 194 which is tightened by a nut 196 and passes through these two parts.
The base piece 130 —see FIGS. 13 and 14 , which for the sake of simplicity shows only some reference numbers—has a cross-section in the form of a cross with four equal rounded sides 134 which each have, between them, a zone 126 inset towards the centre and house a corresponding cavity 132 of the bracket 190 which follows the profile thereof. The cavity 132 also has a cross-section in the form of a cross with four equal rounded sides 194 , between each of which there is a zone 196 inset towards the centre. The extension of the inset zones 196 extends along an arc which is smaller than that of the inset zones 126 and therefore a mutual rotational mechanical play 198 is obtained between the bracket 190 and the base piece 130 (which has the function of a rotating part). This rotational play 198 has an angular amplitude which is equal to the difference between the widths of the inset zones 126 and 196 .
The base piece 130 , when it enters into the bracket 190 , touches the bottom of the cavity 132 , which is denoted by 138 . The bottom 138 is provided with a rectangular groove 140 inside which the electronic board 199 is housed; when the base piece 130 is inserted inside the cavity 132 , two circular seats 144 in the base piece 130 containing two magnets 142 are arranged opposite the said board. The board 199 comprises a Hall sensor 195 which is situated opposite each magnet 142 . It should be noted that the board is shown in very schematic form, but may contain all the logic components, the signal processing components and the connections necessary for the functions which will be described. Moreover, in order to increase the sensitivity of the system, the magnets 142 are directed so that a pole of their magnetic field is directed towards the sensors 195 .
Advantageously—as in the device already described—it is possible to insert within the angular play 198 resilient means 197 so as to push resiliently the base piece 130 and therefore the connector 170 into a zero reference angular position. The comments made in this connection for the first device are also applicable in this case and will not be repeated.
Operation of the second device is now described with reference to FIGS. 10-16 . The actuating system 118 comprises a kinematic chain consisting of the following components:
the roller 125 is integral to the motor of the actuating system via the adaptor 124 and the pinion 123 ; the motor is integral to the tubular body 122 (being rigidly contained inside it) and the latter is integral to the connector 170 which is in turn integral to the base piece 130 .
During rotation of the roller 125 , the roller blind is wound onto or unwound from the roller 125 . The moment exerted by the weight of the roller blind on the roller 125 therefore varies and is transmitted via the kinematic chain to the base piece 130 , which assumes a certain angular position within the section of play 198 . This position is the result of the action of the moment generated by the weight of the roller blind on the roller 125 and the opposing force of the resilient means 197 to which the moment of the motor is indirectly applied (the motor is controlled so as to rotate at a practically constant angular speed so as to move the roller blind at a constant speed).
If the roller blind encounters an obstacle and is stopped or in any case slowed down by it, the relative angular position deviation of the base piece 130 and the bracket 190 varies and the sensors 195 detect instantaneously this variation. This is explained with reference to FIGS. 13 and 14 where two different angular positions of the base piece 130 with respect to the bracket 190 are shown as an example. In the angular position of the connector 170 shown in FIG. 14 , the two sensors 195 detect a strong magnetic field resulting from the proximity to the magnets 142 . Two axes X 1 and X 2 which respectively pass through the two sensors 195 and the two magnets 142 are arranged on top of each other. When the rotating part (connector) 170 is rotated as shown in FIG. 13 , where the axes X 1 and X 2 are inclined with respect to each other at a certain angle, the magnetic field in the space occupied by the sensors 195 is smaller, as is the signal output by the latter and analysed by the board 199 . It is easy to understand that, in general, for each angle covered by the base piece 130 within the section 198 , the magnetic field detected by the sensors 195 , and therefore their output signal, will be different and uniquely linked to the angular position of the base piece 130 with respect to the bracket 190 (suitable screening systems—not shown—prevent any interference from outside the system).
The board 199 processes the signal of the sensors 195 so as to extract the information relating to the angular position of the base piece 130 within the section 198 . At the same time, the board 199 may also acquire the current position of the roller blind (detected by means of devices of the known type, usually encoders, associated directly with the motor, inside the tubular body 122 , or with the roller 125 ).
With the actuating system 118 it is possible to implement the same two control procedures indicated by i) and ii) (adjustable stepwise operation or acquisition of an RC for the angular position of the base piece 130 , definition of a tolerance T, etc.) which were described for the actuating system 18 , with the same advantages, and which will not be repeated here. In the same way it is possible to use for the actuating system 118 the constructional options already described for the actuating system 18 .
Advantageously the safety device according to the invention may also be constructed separately from the actuating system, and therefore also as an external accessory, able to be added, if necessary, to an actuating system which is without one, with a considerable cost saving as regards both production and warehouse management.
An accessory of this type can be seen in FIG. 17 where it is shown in cross-section and denoted by 218 . An electronic board 299 and sensors 295 , which are fixed thereon, are inserted in a suitable seat formed in a fixed outer disk 290 , to which an inner disk 230 is coaxially connected in a rotatable manner with a holed rivet 220 . As can be seen, the cross-sections of the two disks 290 , 230 have the same form as the bracket 190 and the base piece 130 , respectively, and provide an identical degree of rotational mechanical play 298 with an angular amplitude equal to the difference between the widths of the perimetral inset zones on the two disks—as in the case of the actuating systems 18 and 118 . The relative operation of the two disks 290 , 230 is identical to that of the bracket 190 and the base piece 130 in the actuating system 118 and the base piece 30 and the rotating part 70 in the actuating system 18 : the angular position of the inner disk 230 with respect to the outer disk is detected by means of the two sensors 295 which are situated on the outer disk and which detect the magnetic field of two magnets 242 situated on the inner disk opposite the sensors 295 . Between the two disks 290 , 230 it is possible to arrange resilient means 297 , with the same aims described above for the means 97 and 197 .
The functional properties, the advantages and the constructional possibilities for the accessory 218 are the same as for the two actuating systems 18 and 118 already described, and for the sake of brevity are not repeated. It is obvious that, in order to achieve anti-obstacle control of the roller blind in an actuating system which is without the safety device according to the invention, it is sufficient to install the accessory 218 , using it in place of the wall bracket of the actuating system. The actuating system must be fixed to the inner disk 230 , while the outer disk 290 is fixed to the wall. The accessory may comprise only the outer disk 290 with the board 299 integrated, without inner disk 230 , in place of which the end group of the actuating system to be controlled is inserted in the disk 290 . Magnets are mounted on the end group of the actuating system so that they are able to interact with the sensors of the board present in the outer disk.
Moreover, the board 299 may also be absent, being arranged either in a remote position or already equipping the actuating system, which may be enabled and/or re-programmed to manage the signal supplied by the accessory.
For the devices already described another applicational possibility is that of installing them with a pre-set RC and T, for example in the case of very standardized applications. As an unrestrained connection, in addition to the play as described, it is possible to employ other connection systems, for example the play between one gear and another or a rack, or linear play and not angular play as in the embodiments described, or a combination of the two. Moreover, the barrier may be directly connected to the rotating part, without the intermediate arrangement of a kinematic chain as described; a possible example would be a driving crown wheel which meshes with play in a rack arranged longitudinally and joined to a gate so as to move it backwards and forwards.
Even the play resulting from the assembly or manufacturing tolerances may be exploited with the invention. In precision applications or when desirable, it is also possible to consider a zero tolerance, i.e. T=0. Another variant relates to the form of the parts which define the angular play, from their shape to the number of projections/inset zones for defining the angular play, or the arrangement of the latter (on the fixed part or the rotating part). Another variant relates to the number of magnets and magnetic field sensors, or their arrangement. Another variant relates to the design of the control system for the actuating system: here a digital control system has been described, but it is also possible to use any similar signal processing and storage technology.
A third device according to the invention is shown in FIG. 18 and the following. It comprises a head (or end group) 520 , while the other components of the actuating device which are not shown are similar to those previously described for the systems 18 and 118 , thus for sake of conciseness they are omitted.
The head 520 comprises, as before, a base piece 530 and a rotating part 570 substantially with a circular cross-section, an electronic circuit board 599 with sensors 595 (both functionally identical to those previously described) and a wall bracket 590 . The latter is fixed to a wall and the base piece 530 is joined to it. As before, the base piece 530 acts as a fixed base on which the rotating part 570 is able to rotate over a limited section of angular travel. The head 520 , for which all the technical considerations and ways of working described for the systems 18 and 118 still apply, differs from the preceding systems for the embodiment of the resilient means between the rotating part 570 and the base piece 530 .
Only these resilient means and related elements will be now described, for brevity. The rest of the system is similar to that of the other variants.
The base piece 530 comprises a cylindrical base 532 from which there projects a circular lip 534 which has, on the inside, in a cavity 533 , a set of identical flexible fins 536 (only some numerated), of rectangular section, which are situated in a radial arrangement, with respect to the centre of the lip 534 where there is a hollow cylindrical relief 538 which is as high as the lip 532 .
With a screw 591 tightened by a nut (not shown) which passes inside the relief 538 , the base piece 530 is rotatably connected to the rotating part 570 which also has a circular lip 572 , but with a diameter smaller than the lip 534 so as to be able to fit perfectly inside it and rotate with frictionless contact.
The lip 572 is provided with a set of identical slits 586 (only some numerated), of rectangular shape, which are situated in a radial arrangement, with respect to the centre of the lip 534 where there is a cylindrical cavity 573 . The radial arrangement and dimensions of the slits 586 corresponds to that of the fins 536 , such that each of the fins 536 can be inserted in a corresponding slit 586 , optionally with a little play, when the rotating part 570 is inserted in the base piece 530 (the relief 538 is mounted inside the cavity 573 ).
The play of the relative rotation of the part 570 in respect of the base piece 530 can be determined by two factors. First, an optional mutual mechanical play between the fins 536 and the slits 586 (the former being smaller than the latter and moving therein) and, second, the flexibility of the fins 536 . With or without play, when the part 570 , subject to torsion, rotates enough in respect of the base piece 530 the fins 536 begin to flex. This flexion has two effects: (i) it defines a mechanical play between the part 570 and the base piece 530 , and (ii) it provides a counter-force, able to withstand an excessive torsion of the part 570 and able to resiliently move the part 570 back in its original angular position when the torsion thereon zeroes.
Clearly, the shape and the material of the fins 536 are reliably chosen to over-resist the maximum expected torsion while providing at the same time the desired elastic response. The number of the fins 536 and the slits 586 can be variable, from one to a multiplicity. Another variant is possible, wherein the fins 536 are not flexible and/or resilient means, such as those previously described, are provided in the slits 586 to exert a force on the fins 536 against the torsion thereof.
It is understood that minor deviations from the inventive idea expressed by the above description and accompanying drawings are nevertheless included within the scope of protection of the following claims.
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Method—and device for the implementation thereof intended to provide a protection system for barriers which are movable along an operating path and actuated by a motor, such as roller blinds, gates or the like, comprising the steps of connecting the barrier, with play, to a fixed part ( 30 ) so that the barrier is able to move independently of the action of the motor over a travel section ( 98 ); defining within the section ( 98 ) a set of safety positions corresponding to a safety position for the barrier; detecting along the travel section ( 98 ) the actual position of the barrier with respect to the fixed part ( 30 ); preventing or reversing the action of the motor and/or the movement of the barrier when the barrier, inside the travel section ( 98 ), does not have a position included within the set of safety positions.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an optical recording device and method for recording information on an optical disc having a plurality of recording layers, and more particularly to optimum power control (OPC).
[0003] 2. Description of the Related Art
[0004] OPC is carried out by performing a test write on an optical disc to make an optimal calibration of the recording power before recording the intended information on the disc. In a multilayer optical disc with a plurality of recording layers, when the recording is carried out on a layer in a deep position as seen from the side of incidence of the recording light, the optimal recording power differs depending on whether or not information has already been recorded on the shallower intervening recording layers. It is therefore desirable to provide recording power settings that produce stable recording performance in the information recording area, without performance variations even when the layer or layers shallower than the recording target layer present a mixture of recorded and unrecorded states.
[0005] Japanese Patent Application Publication (JP) No. 2008-192258 (pp. 1-12, FIGS. 1-6) discloses one method of finding such settings. The test write area is divided into a plurality of subareas, information is recorded on the shallower layers so as to create a different combination of recorded and unrecorded shallower layers in each subarea, OPC is performed in each subarea, and in recording on the target layer in the information recording area, the optimum recording power found for the relevant combination is used.
[0006] JP 2008-108388 (pp. 1-12, FIGS. 1-5) discloses a method that forms a similar plurality of subareas with differing combinations of recorded and unrecorded states in the shallower layers in the test write area, performs OPC in each of the subareas, and then uses the average of the OPC results as the optimal recording power.
[0007] JP 2006-179153 (pp. 1-10, FIGS. 1-4) discloses a method that decides from the amount of light reflected from spaces whether the shallower layers are in the recorded or unrecorded state, and switches the recording power accordingly.
[0008] The methods employed in JP 2008-192258 and JP 2008-108388 are excessively time-consuming because of the time required to record information so as to form a plurality of subareas with differing combinations of recorded and unrecorded states in the shallower layers in the test write area, and then perform OPC in each subarea. With these methods too much time elapses before actual recording starts. The number of times the recording power can be optimally calibrated is also limited, because each OPC operation uses up considerable amount of disc area; consequently, the number of times additional information can be recorded on a disc is limited.
[0009] The method of JP 2006-179153, which discriminates between the recorded and unrecorded states by the amount of light reflected from spaces, is apt to discriminate incorrectly because of reflectance variations due to irregularities in the formation of the recording layers and other layers in the optical disc, in which case information cannot be recorded with the optimal recording power.
SUMMARY OF THE INVENTION
[0010] An object of the present invention is to provide an optical recording device and method which is capable of providing recording power settings that ensure stable recording performance without performance variations even when the shallower layers present a mixture of recorded and unrecorded states.
[0011] The invention provides an optical recording device for recording information on an optical recording medium having a plurality of recording layers by irradiation with laser light, comprising:
[0012] a target value reading unit that reads a standard target value for calibrating recording power from the optical recording medium or from within the optical recording device, the standard target value being determined in advance for each class of optical recording medium;
[0013] a recording power calibration unit that calibrates the recording power by performing a test write in a recording power calibration area provided in a recording layer having an information recording area;
[0014] an information recording unit that records information on the recording layer having the information recording area, by use of the recorded power calibrated by the recording power calibration unit;
[0015] a recorded state discrimination unit that determines a recorded state of one or more shallower recording layers in front of the recording layer to be recorded by the information recording unit, as seen from a laser light incidence side in a position corresponding to the recording power calibration area; and
[0016] a target value correction unit that corrects the standard target value to generate a corrected target value, based on a difference in a reproduced signal parameter between a first recorded state of one or more shallower recording layers in front of a recording layer in which test data is to be recorded, as seen from a laser light incidence side, and a second recorded state of the shallower recording layers, and on the recorded state as determined by the recorded state discrimination unit;
[0017] wherein the recording power calibration unit calibrates the recording power by use of the corrected target value.
[0018] With the present invention, even when the layers shallower than the recording layer for recording information present a mixture of recorded and unrecorded states in the information recording area, variations in recording performance due to changes in their states are suppressed and stable recording can be performed. In addition, OPC is carried out only in the layer in which the information will be recorded, so that the optimal recording power can be found by OPC without the excessive use of time and recording area.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] In the attached drawings:
[0020] FIG. 1 is a block diagram of an optical recording and reproducing device embodying the invention;
[0021] FIGS. 2A , 2 B, and 2 C show examples of asymmetry in the reproduced signal measured by the reproduction characteristic measurement unit in FIG. 1 ;
[0022] FIG. 3 shows an example of the modulation depth of the reproduced signal measured by the reproduction characteristic measurement unit in FIG. 1 ;
[0023] FIG. 4 shows the disc structure of a multilayer recordable optical disc having three recording layers, as an example of the optical disc in FIG. 1 ;
[0024] FIG. 5 shows an exemplary configuration of areas on the optical disc in FIG. 1 ;
[0025] FIG. 6 shows an exemplary configuration of the lead-in area of the exemplary multilayer recordable optical disc in FIG. 5 ;
[0026] FIG. 7 is a flowchart showing an exemplary recording procedure used in the optical recording and reproducing device in FIG. 1 ;
[0027] FIG. 8 is a flowchart showing an exemplary OPC parameter correction procedure used in the optical recording and reproducing device in FIG. 1 ;
[0028] FIG. 9 is a graph showing exemplary relations between recording power and recording performance in a multilayer recordable optical disc;
[0029] FIG. 10 is a graph showing exemplary relations between recording power and asymmetry in a multilayer recordable optical disc; and
[0030] FIG. 11 is a graph showing exemplary relations between asymmetry and recording performance in a multilayer recordable optical disc.
DETAILED DESCRIPTION OF THE INVENTION
[0031] An embodiment of the invention will now be described with reference to the attached drawings.
[0032] FIG. 1 shows an exemplary basic configuration of the optical recording and reproducing device 100 in the embodiment of the invention. The optical disc 500 shown in FIG. 1 is, for example, a Blu-ray disc (BD).
[0033] A servo control unit 180 controls a spindle motor 181 that turns the optical disc 500 , a sled motor 182 that moves an optical head 300 , and an actuator 183 (shown as a functional block) of the optical head 300 .
[0034] The reproduced signal from the optical head 300 is amplified in a preamplifier circuit 110 and input to a central control unit 200 . The central control unit 200 decodes address information from the input signal to ascertain the present position of the optical head 300 .
[0035] The difference between the address information obtained at the present position and the address information of the position to be accessed (the access target position) is given to the servo control unit 180 , which controls the sled motor 182 to move the optical head 300 to the access target position. On the basis of a servo error signal from the preamplifier circuit 110 , the servo control unit 180 drives the actuator 183 to carry out focus control and tracking control.
[0036] During data reproduction, a laser beam emitted from a semiconductor laser 310 with an output value (reproducing power) necessary for data reproduction passes through a collimating lens 330 , beam splitter 340 , and objective lens 350 and is focused onto the optical disc 500 . The light reflected from the optical disc 500 passes through the objective lens 350 , is separated from incident light by the beam splitter 340 , and is received, via a detection lens 360 , by a photodetector (PD) 370 .
[0037] Of the above components, the semiconductor laser 310 , collimating lens 330 , beam splitter 340 , objective lens 350 , and detection lens 360 constitute the optical system, and the optical system and the photodetector 370 , laser driver 320 , and actuator 183 constitute the optical pick-up 300 . In some configurations, elements or lenses that correct spherical aberration may be provided in the optical system in the optical pick-up 300 , to achieve optimal control for the optical disc 500 .
[0038] The photodetector 370 converts the light signal to an electrical signal. The converted electrical signal output by the photodetector 370 is input, via the preamplifier circuit 110 , to the central control unit 200 and a reproduced signal processing unit 120 .
[0039] The reproduced signal processing unit 120 equalizes (reshapes) the electrical signal from the preamplifier circuit 110 and inputs the reshaped signal to a recording quality measurement unit 130 and a data decoder 140 . The reproduced signal processing unit 120 also inputs the electrical signal as received, before equalization, to a reproduction characteristic measurement unit 150 .
[0040] The reproduction characteristic measurement unit 150 determines the value of a parameter used in the recording power calibration needed for recording, such as an asymmetry value or modulation depth of the reproduced signal. The recording quality measurement unit 130 determines the quality of the reproduced signal, based on a jitter value or error rate.
[0041] The data decoder 140 binarizes the input reproduced signal and generates (reproduces) the data recorded on the optical disc 500 by performing such processes as decoding and error correction. The central control unit 200 stores the generated data in a buffer memory 190 , then sends the data to a host controller 400 to which the optical recording and reproducing device 100 is connected.
[0042] When the reproduction characteristic measurement unit 150 determines an asymmetry value, the reproduction characteristic measurement unit 150 passes the electrical signal (the signal output from the preamplifier circuit 110 ) through an alternating current (AC) coupling and calculates the asymmetry value β from the AC-coupled electrical signal.
[0043] Exemplary AC-coupled electrical signals are shown in FIGS. 2A to 2C . The reproduction characteristic measurement unit 150 detects a peak level A 1 and a bottom level A 2 of the signals illustrated in FIGS. 2A to 2C , and calculates the asymmetry value β from the detected peak level A 1 and bottom level A 2 , using the following equation (1).
[0000] β=( A 1+ A 2)/( A 1 −A 2) (1)
[0044] The peak level A 1 and the bottom level A 2 appear in an area where the longest spaces and the longest marks occur alternately. The values of the peak level A 1 and the bottom level A 2 are calculated relative to a zero level equal to the mean of the peak level and bottom level in an area where the shortest spaces and the shortest marks appear alternately.
[0045] Among the asymmetry values β detected by the reproduction characteristic measurement unit 150 from the exemplary reproduced signals (the signals output from the preamplifier circuit 110 ) in FIGS. 2A to 2C , FIG. 2A shows a case in which β is less than zero, FIG. 2B shows a case in which β equals zero, and FIG. 2C shows a case in which β is greater than zero.
[0046] The asymmetry calculation method is not limited to the method given above. Any method that calculates the degree of asymmetry between the recorded signal with the longest mark (an 8T signal for a BD) and the recorded signal with the shortest mark (a 2T signal for a BD) may be used.
[0047] When the reproduction characteristic measurement unit 150 determines the modulation depth, the reproduction characteristic measurement unit 150 detects the peak level PK and bottom level BM of the input electrical signal, but the peak level PK and the bottom level BM are detected from a signal obtained through DC coupling, instead of through AC coupling as in the calculation of an asymmetry value. The modulation depth is calculated from PK and BM by the following equation (2).
[0000] Modulation depth=( PK−BM )/ PK (2)
[0048] FIG. 3 shows an exemplary signal obtained by DC coupling. As shown, the peak PK and bottom BM values are measured relative to a zero level equal to the output offset value when there is no input to the photodetector 370 (no input of reflected light from the optical disc). The peak PK and bottom BM values correspond to the levels of the longest space and longest mark, respectively.
[0049] During data recording, the central control unit 200 stores data received from the host controller 400 in the buffer memory 190 , then uses a data encoder 160 to add an error correction code, modulate the data according to a modulation rule, and generate data to be recorded according to the format of the optical disc 500 .
[0050] On the basis of the data to be recorded, the write strategy control unit 170 generates a write strategy signal. The write strategy is set by the central control unit 200 . Then when the data encoder 160 sends the write strategy control unit 170 data specifying a mark with a length of n periods, the write strategy control unit 170 outputs a corresponding write strategy signal (a signal generated according to the write strategy, having substantially the same waveform as the train of light pulses to be emitted).
[0051] The laser driver 320 drives the semiconductor laser 310 by supplying drive current responsive to the generated write strategy signal. A laser beam having an output value (recording power) necessary for recording the data is emitted from the semiconductor laser 310 and focused on the optical disc 500 via the collimating lens 330 , the beam splitter 340 , and the objective lens 350 . A recorded pattern of marks and intervening spaces is thereby formed.
[0052] The central control unit 200 controls the overall operation of the optical recording and reproducing device 100 when it writes data on and reads data from the optical disc 500 . The central control unit 200 receives information on recording quality represented by jitter or the like from the recording quality measurement unit 130 , receives an asymmetry value or modulation depth value from the reproduction characteristic measurement unit 150 , receives reproduced data from the data decoder 140 , and provides the data encoder 160 , the write strategy control unit 170 , the laser driver 320 , and the servo control unit 180 with control signals.
[0053] The central control unit 200 also controls the correction of OPC parameters, as will be described below with reference to FIGS. 7 to 11 .
[0054] The central control unit 200 includes, for example, a CPU 210 , a ROM 220 that stores programs for operating the CPU 210 , and a RAM 230 for storing data. The programs stored in the ROM 220 include programs that carry out calculations for OPC parameter corrections, as described below with reference to FIG. 8 , and set values necessary for those calculations.
[0055] Next, the configuration of a one-sided recordable optical disc having a plurality of recording layers will be described and phenomena particular to multilayer recording will be discussed.
[0056] The exemplary three-layer optical disc 500 shown in FIG. 4 has a substrate 510 , a first recording layer 521 , a second recording layer 522 , a third recording layer 523 , a cover layer 530 , and a protective layer 540 . The light from the objective lens 350 of the optical pick-up 300 shown in FIG. 1 is incident from the side of the protective layer 540 .
[0057] In the exemplary optical disc configuration shown in FIG. 5 , a lead-in area LIA, in which information unique to the optical disc, control information for controlling recording and reproducing operations, and other information is recorded, is positioned near the inner edge of the disc. The areas in which OPC (optimal control and calibration of the recording power) is performed are also positioned in the lead-in area LIA. In an alternative configuration, these information and areas may also be positioned in the lead-out area LOA.
[0058] The exemplary OPC areas in the lead-in area LIA in FIG. 6 include an OPC area OA 1 for the first recording layer 521 , an OPC area OA 2 for the second recording layer 522 , and an OPC area OA 3 for the third recording layer 523 . The lead-in area LIA also includes a control information area CA. The OPC areas OA 1 , OA 2 , OA 3 may also be referred to as recording power calibration areas.
[0059] As shown in FIG. 6 , the OPC areas OA 1 , OA 2 , and OA 3 are positioned with guard areas GS 12 and GS 23 interposed in the radial direction between the OPC areas, so that the OPC areas do not overlap each other in the radial direction.
[0060] The guard areas GS 12 and GS 23 are provided to avoid possible effect of eccentricity between the layers, and effect of beam diameter in the shallower layer or layers, when recording and reproduction are carried out on a deeper layer.
[0061] Although not shown in the drawing, areas for recording disc management information and like information may also be provided, within the lead-in area LIA, in positions outside the OPC areas and CA area. When an area for recording disc management information is located in a shallower layer in front of an OPC area, the state (recorded or unrecorded) of the layer shallower than OPC area differs depending on whether or not information has been recorded in the disc management information area.
[0062] The areas for recording disc management information are used to record information indicating the areas used for OPC, and the information indicating the recorded/unrecorded states of the lead-in areas, lead-out areas, and data areas. This information may be recorded in the form of recording end address information or flag information.
[0063] Whether the above information is recorded or not, and how it is recorded, differs depending on the specifications of the optical disc.
[0064] Before information is recorded on an optical disc inserted in a recording and reproducing device, the recording power is generally optimized by performing a test write. In a multilayer optical disc having a plurality of recording layers, recording power is optimized using the OPC area provided on the recording layer for recording information. Next, this procedure will be described.
[0065] First, a test write in the optical disc 500 is performed, by using a random test data pattern and varying the recording power, for example. The area of the optical disc 500 on which this test pattern is recorded is reproduced, the reproduction characteristic measurement unit 150 detects an asymmetry value as a reproduced signal parameter, and the central control unit 200 compares the detected asymmetry value with a target asymmetry value (OPC target value) to calculate the optimal recording power.
[0066] In general, the higher the recording power is, the higher the asymmetry value is, while the lower the recording power is, the lower the asymmetry value is. An asymmetry value is frequently used to optimize the recording power in write-once optical recording media.
[0067] The central control unit 200 compares the detected asymmetry values corresponding to a plurality of different recording power values with the target value, and sets the recording power that gives the detected value nearest the target value as an optimal recording power.
[0068] Alternatively, a test write in the optical disc 500 may be performed with one recording power, reproduction may be performed, an asymmetry value may be detected from the reproduced results, the detected asymmetry value may be compared with the target asymmetry value, and the recording power may be increased or decreased according to the result of the comparison to arrive at the optimal recording power.
[0069] An asymmetry value is generally used as the OPC target value for a write-once disc (DVD-R, BD-R, etc.). For a rewritable disc (DVD-RW, BD-RE, etc.), modulation depth is generally used instead of an asymmetry value. Also, for a rewritable disc, the modulation depth that generates the optimal recording power is not used as a target value. Instead, the modulation depth in a range of recording power where changes in modulation depth are large in relation to changes in the recording power (a range where the recording power is lower than the optimal recording power) is generally used as the target value, and the optimal recording power is calculated by multiplying the calculated recording power by a preset coefficient.
[0070] The procedure followed in the optical recording method of the present embodiment will now be described with reference to FIG. 7 .
[0071] When the optical disc 500 used for recording intended information is first inserted in the optical recording and reproducing device 100 , a sensor (not shown) detects the insertion (step S 10 ) and notifies the central control unit 200 of the insertion, and the central control unit 200 causes the servo controller 180 to drive the optical head 300 , and determines the kind of the optical disc 500 (CD, DVD, BD or the like) inserted into the optical recording and reproducing device 100 , and the number of layers in the optical disc 500 (step S 11 ).
[0072] Next, after adjustment of the servo conditions (servo settings), adjustment for the tilt angle of the optical disc 500 , and so on in step S 12 , the information unique to the optical disc, control information for controlling recording and reproducing operations, and other such information are read from the optical disc 500 in step S 13 .
[0073] Next, in step S 14 , recording parameters are determined on the basis of the information (ID or the like) unique to the optical disc read in step S 13 . The ROM 220 in the central control unit 200 of the optical recording and reproducing device 100 includes a prestored table of recording parameters to be used as target values (standard target values of the recording parameters) under standard conditions for each value of the information unique to the optical disc. The recording parameters (standard target values) corresponding to the information unique to the optical disc are read and set as the recording parameters to be used for recording. These recording parameters include write strategy parameters (a standard write strategy) that determine the shape of emitted light pulses, and an OPC parameter for determining the recording power (OPC standard target value).
[0074] The same table also stores information necessary for correcting the OPC parameter. This information, which is also read in this step, will be described below.
[0075] The unique information has different values for each group or class of optical disc, such as kind, model, or lot. Therefore, the standard target values of the recording parameters for each unique information value can be considered as standard target values of the recording parameters for each class of optical disc, such as kind, model, or lot.
[0076] As an alternative to the above method in which the recording parameters are determined from a table stored in advance, a method can also be used in which prerecorded recommended values of the recording parameters are read from the optical disc 500 and used as standard target values.
[0077] Still alternatively, calculations may be carried out on the recommended values read from the optical disc 500 and modified recording parameters may be used as standard target values for recording.
[0078] After the process in step S 14 , when a recording command is given by means not shown in the drawings (Yes in step S 15 ), the OPC parameter is corrected in step S 16 , as detailed below.
[0079] This correction is conducted when there are one or more recording layers shallower than the recording layer (intended information recording layer) including the information recording area (data recording area) in which the intended information is to be recorded and also including the area in which OPC will be carried out, as seen from the side of the disc on which recording light is incident (laser light incidence side), i.e., when there are one or more recording layers disposed between the intended information recording layer and the laser light incidence side.
[0080] In step S 17 , a test write is performed on the optical disc 500 , using the OPC parameter as corrected in step S 16 and the recording parameters set in step S 14 . Specifically, the write strategy given by the recording parameters set in the central control unit 200 in step S 14 is set in the write strategy control unit 170 , the write strategy control unit 170 generates a write strategy based on the test pattern, and a test write is performed on the optical disc 500 using the optical head 300 . The optical head 300 then reproduces the area on the optical disc 500 where the test pattern was recorded. The central control unit 200 compares the reproduced signal parameter (asymmetry value or modulation depth) detected by the reproduction characteristic measurement unit 150 with the OPC parameter (asymmetry value or modulation depth) as corrected in step S 16 , performs control to make the reproduced signal parameter and OPC parameter match, and selects the recording power that makes these parameters match as the optimal recording power.
[0081] Finally in step S 18 , the writing of the intended data (intended information) intended to be written in the optical disc 500 is started, using the write strategy given by the recording parameters set in step S 14 and the recording power determined in step S 17 .
[0082] Of the above processing, the processing in step S 10 is carried out by the central control unit 200 and by a sensor (not shown) that detects the insertion of the optical disc, the processing in steps S 11 and S 12 is carried out by the optical head 300 , the preamplifier circuit 110 , the servo control unit 180 and the central control unit 200 , the processing in step S 13 is carried out by the optical head 300 , the servo control unit 180 , the preamplifier circuit 110 , the reproduced signal processing unit 120 , the data decoder 140 , and the central control unit 200 , the processing in step S 14 is carried out by the central control unit 200 , the processing in step S 15 is carried out by the central control unit 200 and an interface unit (not shown) that receives recording commands, the processing in step S 16 is carried out by the servo control unit 180 , the preamplifier circuit 110 , the reproduced signal processing unit 120 , the reproduction characteristic measurement unit 150 , the central control unit 200 , the write strategy control unit 170 , and the optical head 300 , and the data recording processing in step S 17 and subsequent steps is carried out by the data encoder 160 , the write strategy control unit 170 , the servo control unit 180 , the central control unit 200 , and the optical head 300 .
[0083] Next the processing for the OPC parameter correction in step S 16 will be described with reference to FIG. 8 .
[0084] In step S 20 , the total number (Nr) of the one or more shallower recording layers (recording layers disposed between the intended information recording layer and the laser light incidence side) is obtained, and the state of the areas facing the area in which OPC will be carried out, in the recording shallower layers is checked.
[0085] For example, information (address information) indicating the position of OPC area to be used is read from the management area of the optical disc 500 , and the recorded/unrecorded state (recorded or unrecorded state) of the corresponding area in each shallower layer is determined from the recording management information stored in the management area of the optical disc 500 or another area in the lead-in area LIA.
[0086] The invention is not limited to the arrangement in which the states of the shallower layers are determined from information in the management area as described above. If the states of the shallower layers are predefined in the disc specifications, the states of the shallower layers can be determined from the specifications. If the states cannot be determined from information in either the management area or the disc specifications, the areas in the corresponding layers may be reproduced to find out whether a signal has been recorded or not.
[0087] In step S 21 , the states of the shallower layers as determined above are used to set the total number of shallower layers Nr, the number of recorded shallower layers R, and the number of unrecorded shallower layers U.
[0088] Next, in step S 22 , the OPC parameter is corrected by the following formula.
[0000] BT 2= BT 1+ BO ×( R−U )/ Nr (3)
[0089] BT 2 is the OPC parameter after the correction (the corrected target value).
[0090] BO is an OPC target offset (also referred to as a ‘standard target offset’) set for the individual optical disc, i.e., for each class of optical disc.
[0091] BT 1 is the OPC parameter before the correction, and is an OPC standard target value that optimizes overall recording performance. ‘Optimizes overall recording performance’ means that the recording performance obtained under different conditions, considered overall, is optimal. Frequently, the overall recording performance is optimized by optimizing the recording performance under average or median recording conditions.
[0092] The OPC standard target value BT 1 can be obtained by conducting experiments for each class of optical disc, as identified by the information unique to the optical disc, in advance, deriving characteristic curves like those shown in FIG. 11 , and finding the value that optimizes overall recording performance under a plurality of different recording conditions, for example, conditions using different recording power. BT 1 in FIG. 11 represents an optimal value overall. Alternatively, a recommended OPC target value recorded on the optical disc may be used as the OPC standard target value. The OPC standard target value BT 1 is not necessarily the value that gives the best recording performance. Instead, considering the range of variation in recording performance relative to a reproduced signal parameter, the OPC standard target value can be set to such a value that when the reproduced signal parameter varies in the plus and minus directions by equal amounts, recording performance degrades by equal amounts within an acceptable tolerance range.
[0093] The experiments for obtaining the characteristic curves like those shown in FIG. 11 include recording test data in an area (a test data recording area) in a recording layer (test data recording layer) in the optical disc used for recording and reproduction of the test data, with the shallower layers in different recorded states (different combinations of recorded and unrecorded states), reproducing the test data from the test data recording area, and evaluating the reproduced signal parameter, e.g., asymmetry value of the signals obtained when the test data is reproduced. Here, the “shallower layers” means recording layers disposed in front of the test data recording layer as seen from the side of the optical disc on which the laser light is incident, i.e., disposed between the test data recording layer and the laser light incidence side. The “different recorded states” are, for example, states with different numbers of recorded layers among the shallower layers, at a position corresponding to the test data recording area.
[0094] The OPC target offset BO is also determined in advance for each class of the optical disc, from the experiments for obtaining the characteristic curves like those shown in FIG. 11 , and is one-half the difference DB (the reproduced signal parameter difference) in the asymmetry value β between cases in which the shallower layers are all recorded and in which they are all unrecorded, with the recording power used being identical, and is given more specifically by the following equation.
[0000] BO =( BR−BU )/2 (4)
[0095] In this equation, BR and BU are asymmetry values β obtained from recording carried out at the same power. BR is the asymmetry value β when all the shallower layers are recorded and BU is the asymmetry value β when all the shallower layers are unrecorded. BR and BU are found for each class of optical discs having the same unique information identifying, for example, the disc kind, model, or lot, and BO is calculated from BR and BU. BO is stored together with the standard target value BT 1 described above in the ROM 220 in the central control unit 200 of the optical recording and reproducing device 100 , as a part of a table for possible value of unique information.
[0096] The ROM 220 therefore also serves as a means of storing an OPC target value offset, i.e., standard target value offset (BO) and a standard target value (BT 1 ) for each possible value for each possible value of the unique information.
[0097] Next the reason for correcting the OPC parameter in this way will be described with reference to the graphs in FIGS. 9 , 10 , and 11 , which show exemplary characteristic curves obtained by recording on and reproducing from an optical disc.
[0098] FIG. 9 shows the relation between recording power and recording performance in the first recording layer, which is the deepest layer as seen from the side of the disc on which the recording light is incident. It is assumed that the first recording layer is used as the intended information recording layer as well as the test data recording layer. Recording performance means reproducing performance when an area having signals recorded is reproduced. Recording performance can be represented by a jitter value, a Maximum Likelihood Sequence Error (MLSE) value, or an error rate. In FIG. 9 , the solid line represents the case in which all the shallower layers (all the layers shallower than the first recording layer, i.e., the second to fourth recording layers) are unrecorded, and the dashed line represents the case in which all the shallower layers (the second to fourth recording layers) are recorded. As shown in FIG. 9 , the recording power that gives the best reproducing performance differs depending on the states (recorded or unrecorded states) of the shallower recording layers. PO 1 in FIG. 9 represents the optimal recording power when all of the shallower recording layers are unrecorded, while PO 2 represents the optimal recording power when all of the shallower recording layers are recorded.
[0099] When recording is carried out at recording power PO 1 for example, the best recording performance can be obtained in areas where all the shallower recording layers are unrecorded, but recording performance deteriorates sharply to the value indicated by point Qa when recording is performed in an area where all the shallower recording layers are recorded.
[0100] Similarly, recording performance deteriorates sharply to the value indicated by point Qb if recording at recording power PO 2 is carried in an area above which all the shallower layers are unrecorded.
[0101] It would be desirable to perform recording at a recording power that can give good performance in both the case in which all the shallower recording layers are unrecorded and the case in which all the shallower recording layers are recorded. The desired recording power is accordingly PO, which yields the best recording performance under intermediate recording conditions and shows only slight degradation if the actual recording conditions deviate from the intermediate conditions.
[0102] FIG. 10 shows an example of the relation between recording power and asymmetry. The vertical axis in FIG. 10 represents the asymmetry value instead of the recording performance shown in FIG. 9 . As shown in FIG. 10 , the asymmetry values (dashed curve) when the shallower recording layers are in the unrecorded state are offset from the asymmetry values (solid curve) when the shallower recording layers are in the recorded state.
[0103] FIG. 11 shows an example of the relation between asymmetry value and recording performance. The horizontal axis in FIG. 11 represents the asymmetry value instead of the recording power shown in FIG. 9 . As shown in FIG. 11 , there is little difference in recording performance relative to asymmetry values between the recorded and unrecorded states of the shallower recording layers, and the optimal (best overall) asymmetry value is the value indicated by BT 1 . If the recording power is adjusted using the best overall asymmetry value BT 1 as the OPC target value, then when all the recording layers shallower than the area in which OPC is performed are in the unrecorded state, the recording power will be adjusted to PO 1 in FIG. 9 , and when all the recording layers shallower than the area in which OPC is performed are in the recorded state, the recording power will be adjusted to PO 2 in FIG. 9 .
[0104] Next, the OPC parameter correction carried out in the present embodiment will be described for several cases.
[0105] When all layers shallower than the recording layer including the area in which OPC will be performed are in the unrecorded state, to maintain an asymmetry value at BT 1 , as shown in FIG. 10 , it is necessary to increase the recording power to PO 1 ; if the recording power is PO (which is less than PO 1 ), then as shown in FIG. 10 the OPC target value (target asymmetry value) must be BU, which is less than BT 1 . Conversely, when all layers shallower than the recording layer including the area in which OPC will be performed are recorded, to maintain an asymmetry value at BT 1 , as shown in FIG. 10 , it is necessary to reduce the recording power to PO 2 ; if the recording power is PO (which is greater than PO 2 ), then as shown in FIG. 10 the OPC target value (target asymmetry value) must be BR, which is greater than BT 1 .
[0106] Since BT 1 is located at the midpoint between BU and BR, BU and BR can be obtained from BT 1 by adding or subtracting an offset of (BR−BU)/2.
[0107] It is assumed that the optical disc has four recording layers, for example, and recording is performed in the first recording layer (the deepest layer). If the recording layers shallower than the area in which OPC will be performed are all in the unrecorded state, the values of Nr, R, and U set in step S 21 are NR=3, R=0, and U=3, so from equation (3),
[0000] BT 2= BT 1+ BO ×(0−3)/3 =BT 1 −BO (3A)
[0108] Since BR>BU in FIG. 10 , the value of BO given by equation (4) is positive. It is therefore understood that the result of the calculation corresponds to BU.
[0109] Conversely, if all layers shallower than the area in which OPC is performed are already recorded, then Nr=3, R=3, and U=0, so from equation (3),
[0000] BT 2= BT 1+ BO ×(3−0)/3 =BT 1 +BO (3B)
[0000] Since BO has a positive value, it is understood that the result of the calculation corresponds to BR.
[0110] The description above applies to cases in which all of the recording layers shallower than the OPC area are unrecorded, and in which all of these layers have already been recorded. Next, a case in which only some of the recording layers shallower than the area for OPC have been recorded will be described.
[0111] If only some of the recording layers shallower than the recording layer in which recording will be carried out are already recorded, then the relation between recording power and asymmetry shown in FIG. 10 shifts to a curve (not shown) located between the solid curve for the case in which all shallower layers are unrecorded and the dashed curve for the case in which all shallower layers are already recorded. For example, if the numbers of recorded and unrecorded shallower layers are equal, an asymmetry value approximately halfway between the asymmetry value for the all-unrecorded case and the asymmetry value for the all-recorded case will be obtained. That is, the asymmetry value shifts according to the numbers of recorded and unrecorded layers among the shallower layers.
[0112] It is therefore so arranged that an offset which depends on the number R of the recorded layers, and the number U of the unrecorded layers, among the recording layers shallower than the area in which OPC is performed, and is added as shown by formula (3).
[0113] In view of the curves shown in FIG. 9 , shifting the recording power from the optimal recording power obtained as result of OPC might be considered, instead of shifting the OPC target value. But shifting the OPC target value has the following advantage.
[0114] As shown in FIG. 9 , the amount of variation in the recording performance occurring above the optimal recording power may differ from the amount of variation in the recording performance occurring below the optimal recording power. This is because in the curves shown in FIG. 10 , the relation between the recording power and the asymmetry value is not linear; the gradient on the low power side is steeper than the gradient on the high power side. In contrast, the change in recording performance relative to the asymmetry value is substantially the same on both the high power and low power sides as shown in FIG. 11 .
[0115] Another advantage of shifting the OPC target value is that the recording power curves tend to shift in response to factors such as temperature. Since the temperature conditions during actual recording may differ from the temperature conditions under which the power offsets are calculated, it is difficult to decide what the power offsets should be. If excessive power offsets are applied, recording performance becomes erratic.
[0116] The relation between the asymmetry value and recording performance, however, is not greatly affected by temperature, so that a proper correction can be applied by correcting the OPC target value.
[0117] According to the present Embodiment 1, the target asymmetry value used in performing OPC is corrected according to the number of unrecorded layers (U) and the number of recorded layers (R) among the recording layers shallower than the area in which OPC is performed, and the predefined amount of shift (BR−BU) of the asymmetry value in the way described above, so that even if the number of unrecorded layers (U) and the number of recorded layers (R) among the recording layers change in the recording area in which information is recorded, variations in recording performance are suppressed and stable recording can be carried out.
[0118] Furthermore, no additional OPC areas are needed, and the amount of processing time needed for OPC does not increase.
[0119] Although the optical disc 500 inserted in the optical recording and reproducing device 100 is a Blu-ray disc in the embodiment above, the invention can also be applied to any other kind of multilayer optical discs, or any other kind of optical recording medium having a plurality of recording layers.
[0120] Furthermore, in the present embodiment described above, the offset (standard offset) of the asymmetry value is determined from the asymmetry value obtained for the case in which recording has been performed when all the shallower recording layers are unrecorded and the asymmetry value obtained for the case in which recording has been performed when all the shallower recording layers, with the recording power used in both cases being identical, and the OPC target value is corrected based on the standard offset and on the numbers of recorded and unrecorded layers in the shallower recording layers in the optical disc used for the intended information recording.
[0121] However, the standard offset may be calculated by other procedures. For example, the offset of the asymmetry value between the case in which all the shallower recording layers are unrecorded and a case in which just one of the shallower recording layers is recorded may be used as the standard offset, and the OPC target value may be corrected on the basis of the standard offset thus determined, and the number of recorded and unrecorded layers in the shallower recording layers.
[0122] To generalize, if the standard target offset BO is determined on the basis of an asymmetry value (the first reproduced signal parameter) Ba obtained when one of the recording layers (the test data recording layer) has been recorded in a first recorded state (first combination of recorded and unrecorded states) in which the number of the recording layers shallower than the test data recording layer is a and an asymmetry value (the second reproduced signal parameter) Bb obtained when the test data recording layer has been recorded in a second recorded state (second combination of recorded and unrecorded states) in which the number of the recording layers shallower than the test data recording layer is b, and using the same recording power as in the first recorded state, then the following equation (5) is used instead of the above equation (4)
[0000] BO ={( Ba−Bb )/2 }×{Nt /( a−b )} (5)
[0123] In equation (5), Nt is the number of shallower recording layers in the optical disc used for the determination of standard target offset, in the first and second recorded states, and (Nt/(a−b)) is the ratio of the number Nt of the shallower recording layers to the difference between the number a of the shallower recorded layers in the first recorded state and the number b of the recorded layers in the second recorded state.
[0124] The standard target offset BO is determined in advance for each optical disc, for example, for each class of optical disc, i.e., for each unique information value, and stored in the ROM 220 or elsewhere.
[0125] When the corrected target value BT 2 is calculated for an optical disc inserted into the optical recording and reproducing device for the purpose of recording, the calculation in equation (3) is carried out using the stored standard target offset BO (determined using equation (5)). For example, the number of unrecorded recording layers (U) is subtracted from the number of recorded recording layers (R) to obtain a value, which is then is divided by the total number of recording layers (Nr) to obtain an offset correction coefficient ((R−U)/Nr), and the product of the standard target offset (BO) multiplied by the offset correction coefficient (R−U)/Nr is added to the standard target value (BT 1 ) to obtain the corrected target value (BT 2 ).
[0126] The value of a may be either Nt or zero. When a=Nt (and therefore Ba=BR), equation (5) changes as below.
[0000] BO ={( BR−Bb )/2 }×{Nt /( Nt−b )} (6)
[0000] When a=0 (and therefore Ba=BU), equation (5) changes as below.
[0000]
BO
=
{
(
BU
-
Bb
)
/
2
}
×
{
Nt
/
(
0
-
b
)
}
(
7
A
)
=
{
(
Bb
-
BU
)
/
2
}
×
{
Nt
/
b
}
(
7
B
)
[0127] In the embodiment described above, an asymmetry value offset (standard offset) between a case in which all the shallower recording layers in the optical disc used for the determination of standard target offset were unrecorded, and a case in which all the shallower recording layers in the optical disc used for the determination of standard target offset were recorded, with the recording power used for the recording in both cases being identical is determined, and a correction coefficient for the asymmetry value offset is determined from the numbers of recorded and unrecorded layers among the shallower recording layers of the optical disc used for the intended information recording, and is used for the correction of the OPC target value. However, in some cases, such as when the standard offset is small, the correction coefficient need not be calculated precisely from these numbers of layers. For example, approximate correction coefficients may be set for a case in which there are more recorded layers than unrecorded layers among the shallower recording layers, a case in which the numbers are about equal, and a case in which there are fewer recorded layers.
[0128] In the embodiment described above, the amounts of correction to the OPC target value under the condition of identical recording power are identical between the case where the shallower layers of the optical disc used for intended information recording are all unrecorded, and the case where the shallower layers of the optical disc used for intended information recording are all recorded are identical. But it is generally common to start recording from the deeper recording layers, and particularly when the number of recording layers is large, the shallower layers will rarely be all recorded. Accordingly, the OPC correction may be further offset, or multiplied by a coefficient, or modified in some other way, thereby bringing the corrected OPC target value closer to BU in FIG. 10 , in order to improve the recording performance when the shallower layers are unrecorded.
[0129] In the embodiment described above, the same-power asymmetry value offset obtained from the asymmetry value for the case in which the shallower layers are all recorded and the asymmetry value for the case in which the shallower layers are all unrecorded is determined in advance for each value of the information unique to the optical disc, but for a some class of optical discs for which the offset is not determined in advance, an average value of the offsets of the asymmetry values of a plurality of classes of optical discs for which offsets have been determined in advance may be used.
[0130] Alternatively, one or more areas with different states may be prepared in the shallower layers by use of test write areas such as OPC areas in the optical disc having been inserted in the optical recording and reproducing device for the purpose of information recording, the difference in the asymmetry value may be determined for the cases where recording is performed in the respective areas of the recording layer with the same recording power, and the results thus obtained may be used.
[0131] In the embodiment described above, an OPC method that uses an asymmetry value as a target value has been described. Similar methods can be used for OPC methods that use modulation depth as a target value. In this case, the modulation depth characteristic relative to recording power saturates in the area with high recording power. It is necessary to calculate the modulation depth offset at a low power free from saturation in modulation depth.
[0132] In the embodiment described above, the OPC target value is corrected on the basis of equations (3), (4), (5), (6), and (7B), but the OPC target value may be corrected on the basis of other equations provided they yield similar results.
[0133] In the embodiment described above, the difference in asymmetry value between the case in which all the shallower recording layers are unrecorded and the case in which all the shallower recording layers are recorded is found in advance for optical discs having each unique information value. It is also contemplated that the difference in asymmetry value may be set for each type of optical disc (write-once optical disc, rewritable optical disc), or each number of recording layers in the optical disc (a three-layer optical disc, a four-layer optical disc), but the difference is preferably found for each possible value of the unique information pertaining to the optical disc.
[0134] The asymmetry value difference is preferably found in advance for each layer on which recording may be performed. But if all the differences are alike, the same asymmetry value difference may be used for all layers in the same optical disc.
[0135] It suffices to calculate the asymmetry value difference once for each model of optical recording and reproducing device. The same value can be used for the many optical recording and reproducing devices of the same model. In other words, once an asymmetry value difference is found for a certain model of optical recording and reproducing device, that difference can be set in other optical recording reproducing devices of the same model before they are shipped.
[0136] Those skilled in the art will recognize that further variations are possible within the scope of the invention, which is defined in the appended claims.
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Before new information is recorded on a comparatively deep recording layer in a multilayer optical recording disc, a predetermined target value of a reproduced signal parameter is read from the disc itself or from a separate storage unit, the recorded/unrecorded states of the shallower recording layers are determined, and the target value is corrected on the basis of these states. The correction is based on a predetermined difference in the value of the reproduced signal parameter caused by a difference in the recorded/unrecorded states of the shallower recording layers. The corrected target value is used in calibration of the recording power by means of a test write. This correction of the target value permits reliable recording on a multilayer optical disc without delaying the start of the recording process.
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BACKGROUND OF THE INVENTION
This invention relates to a yoke mechanism for a printing apparatus using an electrophotographic method.
In order to reduce the cost of a yoke mechanism and reduce the mechanism to compact size, a double face tractor in which both sides of the tractor are used, as illustrated in FIGS. 1 and 2, is in general use. An electrophotographic printing apparatus 1 comprises a corona charger 3 for applying a charge to a photoconductor 2, an optical portion 4 for writing information on the photoconductor 2, a developing device 5, a yoke mechanism 7 for feeding printing paper 6 at a uniform speed and transferring an image on the photoconductor 2 onto the printing paper 6, a fixing device 8 for heat fixing the transferred image, and a stacker 9 for folding the printing paper after fixing.
A double face type (using both sides) tractor 10 for feeding the printing paper 6, a retractor 11 for bringing the paper into contact with and separating it from the photoconductor 2 at time of transfer, and a transfer charger 12 are disposed in the interior of the yoke mechanism 7. Paper presses 10a, 10b are freely pivotally supported on both sides of the tractor 10, respectively. One end of the yoke mechanism 7 is pivotally supported on a frame 13 by a hinge 7a in such a manner that when the yoke mechanism 7 is opened, the rear thereof is adapted to abut a stopper 13a projecting backwardly from the frame 13 to be stopped.
This position of the yoke mechanism is called the retract position. When the yoke mechanism 7 is closed, the forward end thereof is adapted to abut a pin 14 mounted on the front of the frame 13 to stop the yoke mechanism. This position of the yoke mechanism is called the transfer position, where the retractor 11 approaches the photoconductor surface 2 in such a manner as to perform a transfer step.
Conventionally, when loading such a yoke mechanism with printing paper, as shown in FIG. 2, the paper presses 10a, 10b on both sides of the tractor 10 are opened to place the paper 6 therein with the yoke mechanism 7 fixed perpendicularly. This method is very complicated to perform because the paper 6 is inserted from laterally of the tractor 10.
In another method, the paper 6 is placed on the side of the paper press 10a of the tractor 10 at the retracted position, and is then placed on the side of the press 10b of the tractor 10 with the yoke mechanism 7 closed. This is easy because the paper is placed in a substantially horizontal state. But when the yoke mechanism 7 is closed while the paper is fixed on only one side of the tractor 10, the slack paper 6 can directly contact the soft surface of the photoconductor 2, which sometimes causes the photoconductor 2 to be damaged. Accordingly, the expensive photoconductor 2 becomes unusable.
SUMMARY OF THE INVENTION
It is an object of this invention to overcome the above described disadvantages of the prior art, and to facilitate the paper loading operation in the yoke mechanism.
This invention is characterized by the fact that a yoke engagement mechanism, which is adapted to temporarily stop the yoke mechanism at a preparatory position where the paper is easily loaded before the yoke mechanism is completely closed, is disposed between the yoke mechanism and the frame.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a typical electrophotographic printing apparatus;
FIG. 2 is a side view showing a conventional yoke mechanism;
FIG. 3 is a side view showing one embodiment of a yoke mechanism according to the present invention;
FIG. 4 is a front view of the apparatus of FIG. 3; and
FIG. 5 is a side view showing the yoke mechanism of the present invention located at the transfer position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention will now be described by way of one embodiment thereof, wherein, as seen in FIGS. 3 to 5, a clamp lever 16 is freely pivotally supported on the side of the forward end of the yoke mechanism 7 by a pin 17. The clamp lever 16 is provided with a hole 18 above the support point thereof, in which a pin 19 mounted on the yoke mechanism 7 is loosely fitted, so that the range of movement of the clamp lever 16 is regulated by the interval between the hole 18 and the pin 19. A projection 20 is mounted on the central portion of the clamp lever 16, and a tension spring 21 is extended between the projection 20 and the pin 19 in such a manner as to always urge the clamp lever 16 clockwise, so that the clamp lever 16 is retained with the inner periphery of the hole 18 abutting the pin 19.
A handle 22 for operation is formed on the upper portion of the clamp lever 16, the lower portion of the lever being provided with a groove 23 opened laterally, and the bottom portion thereof being provided with an abutting surface 24. A stopper pin 25 is disposed on the front of the frame 13 in such a manner as to engage the abutting surface 24 of the clamp lever 16. When the yoke mechanism 7 is closed, the abutting surface 24 is adapted to engage the stopper pin 25, so that in such a condition, the forward end of the yoke mechanism 7 is stopped at a preparatory position slightly spaced from the photoconductor 2.
For paper loading, the yoke mechanism 7 is first opened to the retract position, and the paper press 10a mounted on the rear face of the tractor 10 is opened to place the printing paper 6 therein, and then closed. Secondly, the yoke mechanism 7 is closed and set to the preparatory position, the paper press 10b mounted on the front face of the tractor 10 being opened to place the printing paper 6 therein.
After that, when the clamp lever 16 is moved in the direction of the arrow by means of the handle 22, the surface 24 located at the lower end of the clamp lever 16 is released from the stopper pin 25, and the yoke mechanism 7 is further moved to stop at the transfer position. At this time the yoke mechanism 7 is adapted to engage the pin 14, with the clamp lever 16 engaging the stopper pin 25 by means of the groove 23, so that the yoke mechanism 7 is fixed at the transfer position.
It will be apparent that this invention, as described above, can provide a yoke mechanism having a double faced tractor, which is pivotally supported in such a manner as to freely move between a transfer position and a retracted position, which can ease the loading of the yoke mechanism with printing paper, by providing an engagement mechanism for stopping the yoke mechanism at a preparatory position between the retracted and transfer positions. The device can thus completely eliminate the danger of damaging the photoconductor, as the yoke mechanism is moved to the transfer position with the printing paper completely set thereon, so as to improve the reliability of the apparatus.
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A yoke mechanism for a copier is provided with an engagement mechanism capable of holding the yoke at a position intermediate the retracted and transfer positions, at which position the yoke may be easily loaded with paper, and then moved to the transfer position, in one simple operation.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. P2002-13262, filed on Jan. 22, 2002, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a medical image diagnosis apparatus and a display for a use in a medical image diagnosis apparatus, with a plurality of monitors to display medical images. The present invention further relates to a method of arranging such a plurality of monitors.
BACKGROUND OF THE INVENTION
[0003] Various kinds of medical diagnoses have been realized nowadays by interpreting medical images obtained from medical diagnosis apparatuses, such as, for example, an X-ray diagnosis apparatus, an X-ray CT (computed tomography) apparatus, an MRI (magnetic resonance imaging) apparatus, a nuclear medical diagnosis apparatus, an ultrasound diagnosis apparatus, and an endoscopic image apparatus. In the event that medical images are obtained from such medical diagnosis apparatuses, the obtained images are usually displayed in one or more monitors provided in the vicinity of the medical diagnosis apparatuses. This is, for example, for the purpose of checking the obtained images and seeing whether the images are correctly obtained or it is necessary to acquire substitute image at the same position again. Further, the obtained images are sometimes used for the image interpretation immediately right at the place in case of emergency, for example.
[0004] [0004]FIG. 1 is a diagram showing a configuration of an X-ray diagnosis apparatus with a display according to a prior art. The X-ray diagnosis apparatus shown in FIG. 1 is a so-called bi-plane apparatus which allows obtaining images from two directions at the same time. The X-ray diagnosis apparatus includes a first imaging system comprising a first X-ray tube 1 a , a first detector 2 a , and a first holder 3 . The X-ray diagnosis apparatus also includes a second imaging system comprising a second X-ray tube 1 b , a second detector 2 b , and a second holder 4 . Additionally, the apparatus includes a bed table 5 , a bed 6 , a display 7 , a display holder 7 a , a display panel 8 , an operation unit 9 , a first rail 10 a , and a second rail 10 b.
[0005] The first imaging system is for obtaining X-ray images from a first direction. The first X-ray tube 1 a generates (or radiates) an X-ray which is exposed to a patient to be examined from the first direction. The X-ray exposed to the patient is transmitted through the patient. The detector 2 a detects the transmitted X-ray. The first holder 3 holds the first X-ray tube 1 a and the first detector 2 a by means of an arm connecting the first X-ray tube 1 a and the first detector 2 a The first holder 3 further drives or moves a set of the first X-ray tube 1 a and the first detector 2 a in three-dimensional directions.
[0006] The second imaging system is for obtaining X-ray images from a second direction. The second X-ray tube 1 b generates (or radiates) an X-ray which is exposed to the patient to be examined from the second direction.
[0007] The X-ray exposed to the patient is transmitted through the patient. The detector 2 b detects the transmitted X-ray. The second holder 4 holds the second X-ray tube 1 b and the second detector 2 b by means of an arm connecting the second X-ray tube 1 b and the second detector 2 b . The second holder 4 further drives or moves a set of the second X-ray tube 1 b aid the second detector 2 b in three-dimensional directions.
[0008] The patient lies on the bed table 6 The bed 6 has a driving unit which drives and moves the bed table 5 vertically or horizontally. The display 7 comprises a plurality of monitors. In FIG. 1, the display 7 has four monitors. There are two monitors in the horizontal direction and also two monitors in the vertical direction. Each monitor can be used to display X-ray images obtained in the X-ray diagnosis apparatus. The display 7 is held by the display holder 7 a . The display panel 8 displays several information related to imaging conditions of the X-ray diagnosis apparatus.
[0009] The operation unit 9 is used for determining a position of the bed table 5 by providing designation signals to operate the bed 6 . The first rail 10 a is used for running the second holder 4 . The second rail 10 b is used for running the display holder 7 a.
[0010] Conventional monitors used for the display 7 are known to include CRT (cathode ray tube) monitors. Therefore, they occupy a wide space in the vicinity of the X-ray diagnosis apparatus. The display 7 can be moved along the second rail 10 b . However, an examination room where the X-ray diagnosis apparatus is usually placed is not so spacious to move away the display 7 . Keeping the display 7 around the bed table 5 limits an area where a radiological technologist moves around the patient. Further, it was also a big annoyance to a doctor when the doctor must examine the patient with, for example, a catheter.
[0011] Under such a circumstance, an image display monitor is being improved and newly developed with a LCD (crystal liquid display). An LCD monitor is much thinner and lighter than the CRT display monitor. Accordingly, the conventional CRT display monitors are challenged to be replaced with the LCD monitors. Such replacement can be very helpful to apply to the above-explained case. The replacement may be a solution to the prior art problem and may allow giving the radiological technologist and the doctor much more space.
[0012] As shown in FIG. 1, however, the display 7 has four monitors. Even if they are replaced with LCD monitors, it is a fact that this number of monitors still occupies a certain space. In practice, these monitors are moved around the bed table 5 in accordance with the manipulation of the doctor, for example. The doctor usually checks an ongoing manipulation status in the monitors. As he changes his position around the bed table 5 (i.e. around the patient) in accordance with his manipulation, the display 7 (or the monitors) must be changed its position so as to allow the doctor to observe images displayed in the display 7 .
[0013] Such position changes are sometimes performed across and over the patient. The doctor or his aide must be very careful about moving the display 7 over the patient, but, as a matter of fact, it was not easy to do so due to a size of the display comprising four monitors. Particularly, when there are a plurality of monitors in the vertical direction, it is obviously more difficult. The plurality of monitors in the vertical direction may also be a problem when a person, such as the radiological technologist, the doctor, and the aides, are tall enough to bump his or her head against the display. It disturbs their concentration on their work.
BRIEF SUMMARY OF THE INVENTION
[0014] According to a first aspect of the present invention, there is provided a medical image diagnosis apparatus, which comprises an image generator configured to generate a medical image, a display, comprising a plurality of monitors, configured to display the medical image, and a mechanism configured to change an arrangement of the plurality of monitors with respect to each of the monitors. According to a second aspect of the present invention, there is provided a display apparatus for a use in a medical image diagnosis apparatus that generates a medical image. The apparatus comprises a plurality of monitors configured to display the medical image, and a mechanism configured to change an arrangement of the plurality of monitors with respect to each of the monitors.
[0015] According to a third aspect of the present invention, there is provided a method of arranging a plurality of monitors which display a medical image in a medical image diagnosis apparatus. The method comprises steps of detecting an operation mode of the medical image diagnosis apparatus, and automatically placing at least one of the plurality of monitors, which is not used in the operation mode detected in the detecting step, behind at least one other of the monitors.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] A more complete appreciation of embodiments of the present invention and many of its attendant advantages will be readily obtained by reference to the following detailed description considered in connection with the accompanying drawings, in which:
[0017] [0017]FIG. 1 is a diagram showing a configuration of an X-ray apparatus with a display according to the prior art;
[0018] [0018]FIG. 2 is a diagram showing a configuration of an X-ray diagnosis apparatus with a display in a bi-plane mode according to an embodiment of the present invention;
[0019] [0019]FIG. 3 is a diagram showing another configuration of an X-ray diagnosis apparatus with a display in a single-plane mode according to an embodiment of the present invention;
[0020] [0020]FIG. 4 is a diagram showing a configuration of a display according to an embodiment of the present invention;
[0021] [0021]FIG. 5 is a diagram showing another configuration of the display according to an embodiment of the present invention;
[0022] [0022]FIG. 6 is a diagram showing a side aspect of the display and its peripherals with monitors placed at an original position according to an embodiment of the present invention;
[0023] [0023]FIG. 7 is a diagram showing a side aspect of the display and its peripherals with the monitors placed at a folded position according to an embodiment of the present;
[0024] [0024]FIG. 8 is a diagram showing side aspects of the display when the upper monitor frame 27 c is folded according to an embodiment of the present invention;
[0025] [0025]FIG. 9 a diagram showing another side aspect of the display and its peripherals with the monitors placed at an original position according to an embodiment of the present invention;
[0026] [0026]FIG. 10 is a diagram showing a side aspect of the display 27 and its peripherals with the monitors placed at a slid position according to an embodiment of the present invention;
[0027] [0027]FIG. 11 is a diagram showing side aspects of the display 27 when the upper monitor frame 27 c slides according to an embodiment of the present invention;
[0028] [0028]FIG. 12 is a diagram showing an alternative example of the sliding according to an embodiment of the present invention;
[0029] [0029]FIG. 13 is a diagram showing a first arrangement viewed from a front aspect of a display according to an embodiment of the present invention;
[0030] [0030]FIG. 14 is a diagram showing a second arrangement viewed from the front aspect of the display according to an embodiment of the present invention;
[0031] [0031]FIG. 15 is a diagram showing a third arrangement viewed from the front aspect of the display according to an embodiment of an present invention;
[0032] [0032]FIG. 16 is a diagram showing a fourth arrangement viewed from the front aspect of the display according to an embodiment of the present invention;
[0033] [0033]FIG. 17 is a diagram showing a fifth arrangement viewed from the front aspect of the display according to an embodiment of the present invention;
[0034] [0034]FIG. 18 is a diagram showing a sixth arrangement viewed from the front aspect of the display according to an embodiment of the present invention;
[0035] [0035]FIG. 19 is a diagram showing a seventh arrangement viewed from the front aspect of the display according to an embodiment of the present invention;
[0036] [0036]FIG. 20 is a diagram showing a eighth arrangement viewed from the front aspect of the display according to an embodiment of the present invention; and
[0037] [0037]FIG. 21 is a diagram showing still another configuration of an X-ray diagnosis apparatus with a display according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] Embodiments of the present invention will be described with reference to the accompanying drawings. The following embodiments of the present invention will be explained with an X-ray diagnosis apparatus as an example of a medical image diagnosis apparatus.
[0039] [0039]FIG. 2 is a diagram showing a configuration of an X-ray diagnosis apparatus with a display according to an embodiment of the present invention. The X-ray diagnosis apparatus shown in FIG. 2 is a so-called bi-plane apparatus which allows obtaining images from two directions at the same time. The X-ray diagnosis apparatus includes a first imaging system comprising a first X-ray tube 21 a , a first detector 22 a , and a first holder 23 . The X-ray diagnosis apparatus also includes a second imaging system comprising a second X-ray tube 21 b , a second detector 22 b , and a second holder 24 . The X-ray diagnosis apparatus further includes a bed table 25 , a bed 26 , a display 27 , a display holder 27 a , a display panel 28 , an operation unit 29 , a first rail 30 a , a second rail 30 b , a rail sensor 31 , a monitor link mechanism 32 , a position sensor 33 , a controller 34 , a link mechanism driver 35 , and a display supporter driver 36 .
[0040] The first imaging system is for obtaining X-ray images from a first direction, such as, for example, a direction from the front to the back of the patient. The first X-ray tube 21 a generates (or radiates) an X-ray which is exposed to the patient to be examined from the first direction. The X-ray exposed to the patient is transmitted through the patient. The detector 22 a detects the transmitted X-ray. The first holder 23 is fixed on the floor and holds the first X-ray tube 21 a and the first detector 22 a by means of an arm connecting the first X-ray tube 21 a and the first detector 22 a . The first holder 23 further drives or moves a set of the first X-ray tube 21 a and the first detector 22 a in three-dimensional directions.
[0041] The second imaging system is for obtaining X-ray images from a second direction, such as, for example, a direction from the right to the left of the patient. The second X-ray tube 21 b generates (or radiates) an X-ray which is exposed to the patient to be examined from the second direction. The X-ray exposed to the patient is transmitted through the patient. The detector 22 b detects the transmitted X-ray. The second holder 24 is hung from the ceiling and moves along the first rail 80 a . The second holder 24 holds the second X-ray tube 21 b and the second detector 22 b by means of an arm connecting the second X-ray tube 21 b and the second detector 22 b . Further, the second holder 24 also drives or moves a set of the second X-ray tube 21 b and the second detector 22 b in three-dimensional directions. The movement of the second holder 24 along the first rail 30 a may be sensed by the rail sensor 31 , such as a microswitch, at a predetermined position of the first rail 30 a so that it can be determined whether the second imaging system is in a position for its use.
[0042] The patient lies on the bed table 25 . The bed 26 has a driving unit which drives and moves the bed table 25 vertically or horizontally. The display 27 comprises a plurality of monitors.
[0043] In FIG. 2, the display 27 has four monitors. Each of the monitors may be an LCD monitor. There are two monitors in the horizontal direction and also two monitors in the vertical direction. For example, two of the monitors may be used for the first imaging system. One of the two monitors may be used for displaying an original image obtained in the first imaging system, and the other one may be used for displaying a processed image resulting from processing the original image or others. These two monitors may be laid in a lower stand of the display 27 . Another two of the monitors may be used for the second imaging system. One of these monitors may be used for displaying an original image obtained in the second imaging system, and the other one may be used for displaying a processed image resulting from processing the original image or others. These other two monitors may be laid in a upper stand of the display 27 .
[0044] The two monitors in the lower stand and the two monitors in the upper stand may be linked to each other by the monitor link mechanism 32 . The link mechanism driver 35 drives the monitor link mechanism 32 so as to move the position of the monitors relative to each other. The position sensor 33 may sense a status of the monitor link mechanism 32 . The details of the link mechanism driver 35 and the position sensor 33 will be explained later. The display 27 is held in a rotatable manner by the display holder 27 a and so hung from the ceiling. The display holder 27 a moves along the second rail 30 b . The display 27 Is also changed its height from the floor by the display supporter driver 36 . The display supporter driver 36 may control to adjust the height of the display 27 to a height appropriate for the doctor or the like to observe images displayed in the display 27 .
[0045] The display panel 28 displays several information related to imaging conditions of the X-ray diagnosis apparatus, such as positions of the first holder 23 , the second holder 24 , and the bed table 25 and X-ray quantities radiating from the first X-ray tube 21 a and from the second X-ray tube 21 b.
[0046] The operation unit 29 is used for determining a position of the bed table 25 by providing designation signals to operate the bed 26 . Further, the operation unit 29 may also be used for adjusting a position of the first holder 23 , a position of the second holder 24 , a position of the set of the first X-ray tube 21 a and the first detector 22 a , and a position of the set of the second X-ray tube 21 b and the second detector 22 b.
[0047] The controller 34 controls each component or unit of the X-ray diagnosis apparatus, which has been described above.
[0048] The X-ray diagnosis apparatus with a bi-plane feature may usually be used for, for example, an X-ray fluoroscopy with a contrast agent in an examination of a left ventriculography or a cardiac examination for an infant. Since the bi-plane examination makes it possible to obtain images from two different directions at the same time, it can reduce an amount of the enhancement agent to be used for a patient.
[0049] When the X-ray diagnosis apparatus is operated in a bi-plane mode, two monitors in a lower stand may be used to display images obtained in the first imaging system and two monitors in an upper stand may be used to display images obtained in the second imaging system, as mentioned above. When, however, the X-ray diagnosis apparatus is used in a single-plane mode, that is to say, when, for example, only the first imaging system is used to obtain images, it may not be necessary to use all the four monitors in the display 27 .
[0050] [0050]FIG. 3 is a diagram showing another configuration of an X-ray diagnosis apparatus with a display in the single-plane mode according to an embodiment of the present invention. As shown in FIG. 3, the second imaging system comprising the second X-ray tube 21 b , the second detector 22 b , and the second holder 24 may be slid back away from the bed table 25 when the X-ray diagnosis apparatus is operated in the single-plane mode. This makes it easier to perform an examination since it provides more space around the bed table 25 . The doctor and the radiological technologist are given more space to move around the bed table 25 . Further, the display 27 is made compact since an examination in the single-plane mode does not require all the four monitors to display images. Here is an example that only two monitors are required in the single-plane mode. In the display 27 , monitors in the upper stand have been moved behind the monitors in the lower stand. This can be accomplished by sliding one monitor behind or in front of another monitor. Likewise, such a re-arrangement can be accomplished by folding one monitor behind or in front of another monitor. In such a circumstance, the doctor or the radiological technologist is given still further more space to move around the bed table 25 . This example of the display 27 will be explained with reference to FIGS. 4 and 5.
[0051] [0051]FIG. 4 is a diagram showing a configuration of the display 27 according to an embodiment of the present invention. The display 27 is connected to the display holder 27 a via a supporter 27 d . The display 27 has a lower monitor frame 27 b and an upper monitor frame 27 c . The lower monitor frame 27 b fixes a first momtor 270 a and a second monitor 270 b . The display panel 28 may also be fixed in the lower monitor frame 27 b . The upper monitor frame 27 c fixes a third monitor 270 c and a fourth monitor 270 d . The monitor link mechanism 32 comprises a straight arm 32 a in a form similar to a letter ‘I’, an L arm 32 b in a form similar to a letter ‘L’, and an arm driver 32 c The arm driver 32 c may be, for example, an air cylinder, a hydraulic cylinder, or an electric power cylinder, so as to be controlled its length. An arm driving unit 27 e provided in the display holder 27 a drives the arm driver 32 c . The arm driving unit 27 e may be, for example, an air compressor, a hydraulic pump, or a power source, and be connected to the arm driver 32 c via an air tube, a hydraulic hose, or a power cord. The arm driving unit 27 e may be controlled by the link mechanism driver 35 .
[0052] As explained above, for example, when the X-ray diagnosis apparatus is operated in the single-plane mode, the second imaging system is slid away from the bed table 25 to the backward. Such movement of the second imaging system is sensed by the rail sensor 31 and is reported to the controller 34 . Responsive to the report from the rail sensor 31 , the controller 34 controls the link mechanism driver 35 so that the link mechanism driver 35 controls the arm driving unit 27 e . The arm driving unit 27 e drives the arm driver 32 c to change its length. In accordance with the length of the arm driver 32 c , the straight arm 32 a and the L arm 32 b are moved correspondingly. Accordingly, the upper monitor frame 27 c is moved and placed behind the lower monitor frame 27 b as shown in FIG. 5.
[0053] When the upper monitor frame 27 c is placed behind the lower monitor frame 27 b , the position sensor 33 senses an expanded position or a screw position of the arm driver 32 c and reports such a position to the controller 34 . In addition, when the upper monitor frame 27 c is placed behind the lower monitor frame 27 b , the center of the display 27 is changed its position. In this embodiment, the center of the display 27 is vertically lowered to the floor, compared to the position of before the position change.
[0054] The supporter 27 d includes a supporter driver 270 e . As similar to the arm driver 32 c , the supporter driver 270 e may be, for example, an air cylinder, a hydraulic cylinder, or an electric power cylinder, so as to be controlled its length. The supporter driver 270 e is driven by a supporter driving unit 27 f provided in the display holder 27 a . The supporter driving unit 27 f may be, for example, an air compressor, a hydraulic pump, or a servomotor, and be connected to the supporter driver 270 e . The supporter driving unit 27 f may be controlled by the display supporter driver 36 . In the above case, responsive to the report from the position sensor 33 and maybe also from the rail sensor 31 , the controller 34 may also control the display supporter driver 36 so that the display supporter driver 36 controls the supporter driving unit 27 f . The supporter driving unit 27 f drives the supporter driver 270 e to change its length. Accordingly, the display 27 may be pulled up towards the ceiling and adjust its position to the height appropriate to observe images displayed in the display 27 .
[0055] On the other hand, when the rail sensor 31 senses the second imaging system coming back towards the bed table 25 , the action of the display 27 and its peripherals may obviously be the opposite to the above description. As a result, the upper monitor frame 27 c can be lifted up to its original position, and accordingly the display 27 presents four monitors again.
[0056] In addition, the change of arranging the monitors of the display 27 is not limited to whether the X-ray diagnosis apparatus is operated in the bi-plane mode or in the single-plane mode. Sensing any other actions, triggers, or manual changes may be applicable as alternative embodiments of the present invention.
[0057] [0057]FIG. 6 is a diagram showing a side aspect of the display 27 and its peripherals with the monitors placed at an original position according to an embodiment of the present invention. As shown in FIG. 6, when the upper monitor frame 27 c gets placed behind the lower monitor frame 27 b , the upper monitor frame 27 c is folded towards the lower monitor frame 27 b so that a back 60 of the upper monitor frame 27 c is faced with a back 61 of the lower monitor frame 27 b . Here, the folding is achieved by rotation of the upper monitor frame 27 c around an axis A. Therefore, there is required quite a wide space behind the upper monitor frame 27 c and the lower monitor frame 27 b so as to allow the upper monitor frame 27 c to rotate around the axis A. A preferable height B of the display 27 may be determined to become a border between the upper monitor frame 27 c and the lower monitor frame 27 b . In other words, the center of the display 27 in the vertical direction may be set to the height B. When the center of the display 27 in the vertical direction is set to the height B, the center of the lower monitor frame 27 b in the vertical direction is positioned at the height C.
[0058] [0058]FIG. 7 is a diagram showing a side aspect of the display 27 and its peripherals with the monitors placed at a folded position according to an embodiment of the present invention. As shown in FIG. 7, when the upper monitor frame 27 c is folded to the lower monitor frame 27 b , the display 27 is controlled to change its height so that the center of the display 27 in the vertical direction still keeps the height B. Here, the center of the display 27 is identical with the center of the lower monitor frame 27 b . Therefore, the display 27 is pulled up a distance (B-C) to keep the preferable height B, by controlling the length of the supporter driver 270 e . When the upper monitor frame 27 c gets returned to its original position, that is, a position on top of the lower monitor frame 27 b , the upper monitor frame 27 c is rotated around the axis A again.
[0059] The folding aspects of the upper monitor frame 27 c described with FIGS. 6 and 7 will be clearer in FIG. 8 FIG. 8 is a diagram showing side aspects of the display 27 when the upper monitor frame 27 c is folded according to an embodiment of the present invention. In FIG. 8, to make it easy to understand the folding, the top end of the upper monitor frame 27 c is marked ‘K’ while the bottom end of the upper monitor frame 27 c is marked ‘L’. Similarly, the top end of the lower monitor frame 27 b is marked ‘M’ while the bottom end of the lower monitor frame 27 b is marked ‘N’. When the folding has been completed, the top end K of the upper monitor frame 27 c faces the bottom end N of the lower monitor frame 27 b Further, the bottom end L of the upper monitor frame 27 c faces the top end M of the lower monitor frame 27 b.
[0060] Alternatively, the upper monitor frame 27 c of the display 27 may be placed behind the lower monitor frame 27 b of the display 27 in the following manners.
[0061] [0061]FIG. 9 is a diagram showing another side aspect of the display 27 and its peripherals with the monitors placed at an original position according to an embodiment of the present invention. In FIG. 9, there is a variable arm 32 d in connection with the L arm 32 b and the arm driver 32 c , instead of the straight arm 32 a. The variable arm 32 d varies its length flexibly. When the upper monitor frame 27 c gets placed behind the lower monitor frame 27 b , the upper monitor frame 27 c slides to the backside of the lower monitor frame 27 b so that a front 62 of the upper monitor frame 27 c is faced with the back 61 of the lower monitor frame 27 b . Since the upper monitor frame 27 c slides quite linearly, there is required only a narrow space behind the upper monitor frame 27 c and the lower monitor frame 27 b so that the display 27 and its peripherals can become more compact and so allow the doctor and the radiological technologist a more space around the bed table 25 . The preferable height B of the display 27 may be determined to become a border between the upper monitor frame 27 c and the lower monitor frame 27 b . As similar to FIG. 6, the center of the display 27 in the vertical direction may be set to the height B. When the center of the display 27 in the vertical direction is set to the height 27 the center of the lower monitor frame 27 b in the vertical direction is positioned at the height C.
[0062] [0062]FIG. 10 is a diagram showing a side aspect of the display 27 and its peripherals with the monitors placed at a slid position according to an embodiment of the present invention. As shown in FIG. 10, when the upper monitor frame 27 c slides to the backside of the lower monitor frame 27 b , the display 27 is controlled to change its height so that the center of the display 27 in the vertical direction still keeps the height B. Here the center of the display 27 is identical with the center of the lower monitor frame 27 b . Therefore, as similar to FIG. 7, the display 27 is pulled up a distance (B-C) to keep the preferable height B, by controlling the length of the supporter driver 270 e . When the upper monitor frame 27 c gets returned to its original position, that is, a position on top of the lower monitor frame 27 b , the upper monitor frame 27 c slides back upwards.
[0063] The sliding aspects of the upper monitor frame 27 c described with FIGS. 9 and 10 will be clearer in FIG. 11 FIG. 11 is a diagram showing side aspects of the display 27 when the upper monitor frame 27 c slides according to an embodiment of the present invention. In FIG. 11, to make it easy to understand the sliding, each end of the upper monitor frame 27 c and the lower monitor frame 27 b is marked the same reference as in FIG. 8. When the sliding has been completed, the top end K of the upper monitor frame 27 c faces the top end M of the lower monitor frame 27 b . Further, the bottom end L of the upper monitor frame 27 c faces the bottom end N of the lower monitor frame 27 b.
[0064] [0064]FIG. 12 shows an alternative example of the sliding described in FIGE. 9 to 11 and is a diagram showing another side aspect of the display 27 when the upper monitor frame 27 c slides according to the embodiment of the present invention. The alternative example shown in FIG. 12 is a case that the upper monitor frame 27 c may slide to the front of the lower monitor frame 27 b so that the back 60 of the upper monitor frame 27 c is faced with a front 63 of the lower monitor frame 27 b . To make it easy to understand the sliding, each end of the upper monitor frame 27 c and the lower monitor frame 27 b is marked the same reference as in FIG. 11. When the sliding has been completed, the top end K of the upper monitor frame 27 c faces the top end M of the lower monitor frame 27 b . Further, the bottom end L of the upper monitor frame 27 c faces the bottom end N of the lower monitor frame 27 b.
[0065] According to embodiments of the present invention, the display arrangement can be performed in various ways. In the above description, holding and sliding techniques have been described in terms of viewing the display 27 from its side aspect. Embodiments of the present invention may not be limited to those described above. Further examples of the display arrangement will be described with reference to FIGS. 13 to 20 . FIGS. 13 to 20 show various arrangement forms of the monitors. However, these are only exemplary forms and embodiments of the present invention are not limited to these. Each of the arrangement forms may utilize one or more of the folding and/or the sliding techniques described above.
[0066] [0066]FIG. 13 is a diagram showing a first arrangement viewed from a front aspect of a display according to an embodiment of the present invention.
[0067] As shown in FIG. 13, the display may comprise four monitors P, Q, R, and S. The monitors P and Q may be placed behind the monitors R and S as described in FIG. 8 or 11 . Similarly, the monitors R and S may be placed in front of the monitors P and Q. In a third way, the monitor P may be placed behind the monitor Q and the monitors P and Q may be placed behind the monitor S by sliding. In a fourth way, the monitor P may be placed in front of the monitor Q and the monitors P and Q may be placed behind the monitor S by folding. In similar manner, there are more possible ways for achieving this arrangement. Accordingly, the monitors R and S are used to display images.
[0068] [0068]FIG. 14 is a diagram showing a second arrangement viewed from the front aspect of the display according to an embodiment of the present invention.
[0069] As shown in FIG. 14, the display may comprise four monitors P, Q, R, and S. The monitors R and S may be placed behind the monitors P and Q. Similarly, the monitors P and Q may be placed in front of the monitors R and S as described in FIG. 12. In a third way, the monitor S may be placed behind the monitor R and the monitors R and S may be placed behind the monitor P by sliding. In a fourth way, the monitor S may be placed in front of the monitor R and the monitors R and S may be placed behind the monitor P by folding. In similar manner, there are more possible ways for achieving this arrangement. Accordingly, the monitors P and Q are used to display images.
[0070] [0070]FIG. 15 is a diagram showing a third arrangement viewed from the front aspect of the display according to an embodiment of the present invention.
[0071] As shown in FIG. 15, the display may comprise four monitors P, Q, R, and S. The monitors Q and S may be placed behind the monitors P and R. Alternatively, the monitors P and R may be placed in front of the monitors Q and S. Further, the monitor Q may be placed behind the monitor S and the monitors Q and S may be placed behind the monitor R by sliding. Further still, the monitor Q may be placed in front of the monitor S and the monitors Q and S may be placed behind the monitor R by folding. In similar manner, there are more ways for achieving this arrangement. Accordingly, the monitors P and R are used to display images.
[0072] [0072]FIG. 16 is a diagram showing a fourth arrangement viewed from the front aspect of the display according to an embodiment of the present invention.
[0073] As shown in FIG. 16, the display may comprise four monitors P, Q, R, and S. The monitors P and R may be placed behind the monitors Q and S. Alternatively, the monitors Q and S may be placed in front of the monitors P and R. Further, the monitor R may be placed behind the monitor P and the monitors P and R may be placed behind the monitor Q by sliding. Further still, the monitor R may be placed in front of the monitor P and the monitors P and R may be placed behind the monitor Q by folding. In similar manner, there are more ways for achieving this arrangement. Accordingly, the monitors Q and S are used to display images.
[0074] [0074]FIG. 17 is a diagram showing a fifth arrangement viewed from the front aspect of the display according to an embodiment of the present invention.
[0075] As shown in FIG. 17, the display may comprise two monitors P and R. The monitor P may be placed behind the monitor R. It is another way that the monitor R may be placed in front of the monitor P. Accordingly, the monitor R is used to display images. Alternatively, the monitor R may be placed behind the monitor P. It is another way that the monitor P may be placed in front of the monitor R. Accordingly, the monitor P is used to display images.
[0076] [0076]FIG. 18 is a diagram showing a sixth arrangement viewed from the front aspect of the display according to an embodiment of the present invention.
[0077] As shown in FIG. 18, the display may comprise two monitors P and Q. The monitor Q may be placed behind the monitor P. It is another way that the monitor P may be placed in front of the monitor Q. Accordingly, the monitor P is used to display images. Alternatively, the monitor P may be placed behind the monitor Q. It is another way that the monitor Q may be placed in front of the monitor P. Accordingly, the monitor Q is used to display images.
[0078] [0078]FIG. 19 is a diagram showing a seventh arrangement viewed from the front aspect of the display according to an embodiment of the present invention.
[0079] As shown in FIG. 19, the display may comprise four monitors P, Q, R, and S. The monitor S may be placed behind the monitor Q. It is another way that the monitor S may be placed behind the monitor R. Accordingly, the monitors P, Q, and R are used to display images.
[0080] [0080]FIG. 20 is a diagram showing a eighth arrangement viewed from the front aspect of the display according to an embodiment of the present invention.
[0081] As shown in FIG. 20, the display may comprise four monitors P, Q, R, and S. It is the first way that the monitors Q and S may be placed behind the monitors P and R and the monitors R and S may be placed behind the monitors P and Q. It is the second way that the monitors R and S may be placed behind the monitors P and Q and the monitors Q and S may be placed behind the monitors P and R. It is the third way that the monitor S may be placed behind the monitors Q and the monitors Q and S may be placed behind the monitor P, and in addition, the monitor R may be placed behind the monitors P, Q, and S. In similar manner, there are more ways for achieving this arrangement. Accordingly, the monitor P is used to display images.
[0082] The arrangement of monitors of the display can be changed in various manners as described above. When the X-ray diagnosis apparatus is operated in the single-plane mode, it may not be necessary to move the second imaging system towards the back. Whether the second imaging system is moved or not, it may not be necessary that the display arrangement always automatically corresponds to the mode of whether bi-plane or single-plane.
[0083] Further, the X-ray diagnosis apparatus according to embodiments of the present invention is not limited to the bi-plane apparatus, but may also be applied to an ordinary X-ray diagnosis apparatus with only one imaging system as shown in FIG. 21.
[0084] Still further, the principles of the present invention may also be applied to other medical diagnosis apparatuses, such as, for example, an X-ray CT apparatus, an MRI apparatus, a nuclear medical diagnosis apparatus, an ultrasound diagnosis apparatus, and an endoscopic image apparatus.
[0085] For manual operations, by the doctor, the radiological technologist, or the like, of the display arrangement and/or the height of the display 27 , it may be possible to provide the operation unit 29 with one or more buttons or switches for an exclusive use in such manual operations. According to input operations with the buttons or switches in the operation unit 29 , the input information may be sent to the controller 34 . The controller 34 controls the link mechanism driver 35 and the display supporter driver 36 . The link mechanism driver 35 controls the arm driving unit 27 e which drives the arm driver 32 c so as to change the arrangement of the monitors. The display supporter driver 36 controls the supporter driving unit 27 f which drives the supporter driver 270 e so as to change the height of the display 27 .
[0086] Alternatively, if the arrangement of monitors and/or the height of the display 27 are changed in manual without any electrical input operations, it may be achieved by reducing or removing load or holding power of the arm driver 32 c and/or the supporter driver 270 e so as to allow the doctor or the like to make the arrangement of the display by himself. However, the weight of the display 27 or monitors may be a problem for such direct manual operations. Therefore, it may be necessary to prepare a fixer, such as fixing screws, to fix the display 27 or monitors to the supporter 27 d or the monitor link mechanism 32 at a desired position. Further, it may also be necessary to prepare a helper, such as gas springs, in the monitor link mechanism 32 for the purpose of helping manual operations of the doctor or the like.
[0087] Still furthermore, the mechanism of how to connect the monitors of the display is not limited to those disclosed in the embodiment of the present invention, but can apply any other mechanism including various well-known mechanism thereto.
[0088] According to embodiments of the present invention, the arrangement of a plurality of monitors of a display can advantageously be changed. In the arrangement of the monitors, the number of the monitors to be spread out can be reduced by superposing a part of the monitors on the rest of the monitors. Therefore, it may make it possible to reduce a space occupied by the display around the bed table (or a patient) so that a doctor, a radiological technologist, or the like can concentrate on his or her work. This results in improving a quality of his or her manipulation.
[0089] The embodiments of the present invention described above are examples described only for making it easier to understand the present invention, and are not described for the limitation of the present invention. Consequently, each component and element disclosed in the embodiments of the present invention may be redesigned or modified to its equivalent within a scope of the present invention. Furthermore, any possible combination of such components and elements may be included in a scope of the present invention as long as an advantage similar to those obtained according to the above disclosure in the embodiments of the present invention is obtained.
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A medical image diagnosis apparatus, comprises an image generator, a display, and a mechanism. The image generator is configured to generate a medical image. The display comprises a plurality of monitors and is configured to display the medical image. The mechanism is configured to change an arrangement of the plurality of monitors with respect to each of the monitors.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation, and claims the benefit under 35 U.S.C. §120, of U.S. application Ser. No. 14/334,056, filed Jul. 17, 2014, which claims the benefit under 35 U.S.C. §119 of U.S. Provisional Application No. 61/863,655, filed Aug. 8, 2013, the entire disclosures of which are hereby incorporated by reference.
FIELD OF THE INVENTION
The present disclosure is directed to a mounting system that merges the photo and video functionality of a mobile device, such as a smart phone, with an optical device, such as for example, binoculars, spotting scopes, telescopes, microscopes, rifle scopes, and the like. The mounting system orients the camera lens on the mobile device so the viewing screen displays the image captured by the optical device. The photo and video capabilities of the mobile device are enhanced by the optical capabilities (e.g., magnification) of the optical device. One or more software applications can optionally be installed on the mobile device that is complementary to the use of the optical device.
BACKGROUND OF THE INVENTION
Humans use a wide variety of optical devices, such as for example, binoculars, spotting scopes, telescopes, microscopes, rifle scopes, and the like. There is a growing movement by users of such devices to record their activities using video, and then “share” their video with other people using e-mail, text messaging, or social networking sites. To date, this has been done using special purpose cameras designed as part of, or mounted to, an optical device. The user typically must take the camera home, attach it to a personal computer to download the video, edit the video, and change the format to an up-loadable format. Only then can the video be shared with other users.
U.S. Pat. Publication No. 2013/0111798 (Russell) discloses a camera mounting apparatus that includes various tubes forming an interface between the rifle scope and the smart phone. The mounting apparatus includes various clamps that provide course adjustment of the camera relative to the rifle scope. At least one embodiment requires a support for the camera mounting apparatus that is attached to the stock of the firearm.
BRIEF SUMMARY OF THE INVENTION
Mobile device technology, such as for example the Apple iPhone and Droid, contain some of the functionality found in digital video cameras, telecommunications equipment, and personal computers. This functionality includes taking still and video images, editing the images, texting the images, emailing the images and written descriptions, sharing the images and written descriptions to social networking sites such as Facebook, reviewing video and still images.
The present disclosure merges the camera functionality of a mobile device to an optical device, such as binoculars, telescopes, microscopes, gun sights, and the like. The adapter orients the camera lens on the mobile device with the optical axis of the optical device and displays the image captured by the optical device on the touch screen. The touch screen and interface of the mobile device are oriented toward, and available for use by the user, while attached to the optical device.
One embodiment is directed to an adapter that optically couples a camera on a mobile device to an eye piece of an optical device. The adapter includes a base plate configured to retain the mobile device without obstructing a display screen on the mobile device. The base plate includes an optical interface configured to attach to the eye piece of the optical device. A mounting structure is configured to secure the optical interface to a single eye piece of the optical device. The mounting structure includes a high friction interface that prevents rotation of the adapter relative to the eye piece. An adjustment system with threaded micro-adjust mechanisms is configured to move the base plate relative to the optical interface in at least two degrees of freedom to optically couple the camera on the mobile device with an optical axis of the eye piece. Images captured by the optical device are displayed on a viewing screen of the mobile device.
The at least two degrees of freedom can be two linear or one linear and one rotational. In one embodiment, the adjustment system includes at least three degrees of freedom include two linear and one rotational.
The adapter includes a base plate that safely and securely holds a variety of mobile devices. The base plate and supports leave the operating buttons, speakers, and microphones on the mobile device accessible by the user.
The present adapter allows sportsmen to use their phone to film their hunts from the “user's perspective”. The adapter allows the hunter to view shot placement immediately after firing the shot. The present adapter can also be used as a training device for hunters.
One or more software applications are installed on the mobile device that is complementary to the use of the optical device. For hunters, the mobile device can be programmed to provide one or more of training, education, and coaching for the user; evaluate or enhance the user's performance; inform the user about the sport or the particular sports equipment; maintain compliance with regulatory or legal requirements for the sport; simulate game calls for hunters; provide targeting data for the shooter, such as images of game animal vital organs or sight mark generation; superimpose data and images on an actual image of the target; provide real-time data, such as scoring the user's shots, estimating the distance to the target, identifying the target species, size and weight, or estimating shot ballistics.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is an adapter attached to an optical device in accordance with an embodiment of the present disclosure.
FIG. 2 is a front perspective view of a mobile device mounted to the adapter in accordance with an embodiment of the present disclosure.
FIG. 3 is a front perspective view of the adapter of FIG. 2 with the mobile device removed.
FIG. 4 is a front view of the adapter of FIG. 2 with the mobile device removed.
FIG. 5 is a rear perspective view of the adapter of FIG. 2 with the mobile device removed.
FIG. 6 is a rear view of the adapter of FIG. 2 .
FIG. 7 is a brochure for the present adapter showing applications for telescopes and binoculars.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a perspective view of an adapter 50 that attaches a mobile device 52 to optical device 54 in accordance with an embodiment of the present disclosure. As used herein, “mobile device” refers to a smart phone, cell phone, or other portable telecommunications enabled device. In the illustrated embodiment, the optical device 54 is a spotting scope, but could be a variety of other devices, such as for example, a microscope, binoculars, a telescope, a rifle sight, and the like. An exemplary optical device 54 is disclosed in U.S. Pat. No. 7,271,954 (Perger), which is hereby incorporated by reference.
In the illustrated embodiment, the adapter 50 is releasably attached to eyepiece 56 on the optical device 54 by flexible adjustable device 58 , such as for example, a strap. The flexible adjustment device 58 permits the adapter 50 to be attached to eyepieces 56 of various sizes. The large surface area of engagement between the strap 58 and the eyepiece 56 reduces the risk of rotation of the adapter 50 relative to the eyepiece 56 . The strap 58 preferably wraps at least 180 degrees, and more preferably at least 220 degrees, of the outer surface of the eyepiece 56 . In one embodiment, the strap 58 include a high friction coating, such as rubber or silicone, to increase fixation.
The flexible strap 58 can be constructed from various woven fabrics, films, molded structures, and the like. A variety of other mounting structures can be used to attach the adapter 50 to the eyepiece of an optical device, such as for example, molded clips, adjustable compression members, suction cups, releasable adhesives, and the like.
The adaptor 50 serves to align the camera lens 100 (see FIG. 6 ) on the mobile device 52 with an optical axis 60 of the optical device 54 . As a result, touch screen 62 on the mobile device 52 displays the image captured by the optical device 54 . In the illustrated embodiment, the magnified image captured by the optical device 54 is displayed on the touch screen 62 .
FIGS. 2 through 4 illustrate the adapter 50 separated from the optical device 54 . Side supports 64 A, 64 B and bottom support 64 C (collectively “ 64 ”) are configured so as to not obscure the touch screen 62 or any input buttons on the mobile device 52 . In the illustrated embodiment, side support 64 B and bottom support 64 C are fixedly attached to base plate 68 . Side support 64 A slides on shafts 70 along axis 70 A relative to the base plate 68 . Springs 72 bias the side support 64 A toward the side support 64 B so as to compressively engage the mobile device 52 to the base plate 68 .
Optical interface 80 includes opening 82 surrounded by shroud 84 that preferably engages with rear surface of the mobile device 52 . The lens 100 of the mobile device 52 is aligned with the opening 82 and the shroud 84 serves to reduce the amount of ambient light reaching the lens 100 .
Latch 86 is attached to the optical interface 80 to capture distal end 88 of the flexible strap 58 . In the illustrated embodiment, the flexible strap 58 wraps around the eye piece 56 of the optical device 54 , around pin 90 , and back to the latch 86 . In the preferred embodiment, the flexible strap 58 is the sole mechanism for attaching the adapter 50 and mobile device 52 to the optical device 54 .
As best illustrated in FIGS. 5 and 6 , the base plate 68 is attached to housing 92 by traveler 94 . The traveler 94 rides in a slot 96 in the housing 92 along threaded member 98 . Knob 102 A extends beyond the adapter 50 to facilitate rotation of the threaded member 98 in order to displace the traveler 94 along axis 126 .
As best illustrated in FIGS. 3 and 4 , the traveler 94 includes an extension 104 that resides in slot 106 in the base plate 68 . Threaded member 108 engages with the extension 104 . Rotation of the knob 102 B moves the base plate 68 relative to the extension 104 along the axis 128 .
Turning back to FIG. 6 , the housing 92 is attached to the optical interface 80 by threaded member 120 . Thumb screw 122 is provided to secure the housing 92 to the optical interface 80 at the desired rotational orientation 124 .
The position of the mobile device 52 relative to the optical interface 80 can be adjusted by turning the knobs 102 A, 102 B (“ 102 ”). Rotation of the knob 102 A displaces the base plate 68 along axis 126 and rotation of the knob 102 B displaces the base plate 68 along the axis 128 . The threaded members 96 , 98 permit micro-adjustment of the position of the lens 100 on the mobile device 52 relative to the eye piece 56 of the optical device 54 , so that precise alignment is achieved.
With reference to archery and bow hunting, for example, the hunting experience can be greatly enhanced by adding one of the following applications to the mobile device 52 . Various applications are disclosed in commonly assigned U.S. Pat. No. 8,971,959, entitled Mounting Device for Attaching Mobile Devices to Sports Equipment, which is hereby incorporated by reference. Similar applications are available for firearms, bird watching, astronomy, spectator sports, and the like. There are also various applications for image capture and editing, video zoom and the like that can be loaded on the mobile device 52 .
Educational information—The mobile device 52 can be programmed to provide educational content for bow hunters, including shooting form and techniques, setups, gear selection, access to hunting forums and blogs, and the like. A mobile device 52 application for this purposes is sold under the trade name Realtree Archery Tips.
Range finder function—The mobile device 52 can provide a range finding function that estimates distance to the target. For example, a software application sold under the trade name Range Finder Field Helper evaluates the distance between the user and the target based on the principle of trigonometry and based on embedded sensors in the mobile device 52 . Parameters can be added for any type of target or game animal.
Ballistic calculator—The mobile device 52 can be programmed to calculate ballistic parameters, such as for example, arrow speed, kinetic energy based on individual arrows, arrow balance, and the like. A software application sold under the trade name Archery Pal calculates archery ballistics. A software application sold under the trade name Mil-Dot Ballistics provides firearm range estimation based on mil-dot and real time ballistics calculations.
Game animal targeting—Hunting game animal with a bow requires knowledge of the optimum trajectory through the vital organs. The mobile device 52 can optionally display a 3D simulation of the vital organs of the target game animal is superimposed on the actual image of the animal. The mobile device 52 preferably selects the 3D simulation based on digital analysis identifying the game animal. A software application sold under the trade name Shot Simulator displays a 3D simulation of the vital organs of a deer and the desired trajectory through the deer.
Species identification—The camera in the mobile device 52 can conduct a visual review of a game animal to automatically identify species. In another embodiment, the mobile device 52 can approximate age, weight, height, inside spread of the antlers, and other characteristics of the game animal, and display any of these variables on the touch screen 62 .
Scoring—The mobile device 52 can be programmed to function as an electronic score card, such as for PITA, NFAA Field and NFAA Indoor competitions. The mobile device 52 optionally analyzes the impact point of the arrow relative to the target and automatically records the score. A software application sold under the trade name Archery Score Free permits the user to create custom shots for varying distances and target size, stores past arrow placement, and the like.
Tracking shooting hours—The mobile device 52 can be programmed to automatically determine the hunter's location, applicable hunting regulations for that location, and calculate Sunrise and Sunset (and shooting hours) for various types of game. The mobile device 52 can automatically notify the user of the opening and closing of shooting hours, reducing the risk of non-compliance with local hunting laws.
Hunting regulations—Hunting regulations vary between jurisdictions. The mobile device 52 can be programmed to calculate current location using the GPS function and then display the relevant hunting regulations for the target game animal at that location. For example, a software application sold under the trade name Sportsmanregs Big Game Regulations permits the hunter to verify compliance with hunting regulation while in the field.
Shooting parameters—The mobile device 52 can be programmed to track shooting parameters for the bow, arrows, strings, and sights for future reference and analysis. For example, a software application sold under the trade name Archery Memo software keeps track of sight marks, nocking points, brace height, and arrow shaft spine.
Elapsed time and split time—Hunters, law enforcement officers, and military personnel often track elapsed time to the first shot and split time between shots to improve shooting skills. A software application sold under the trade name SureFire ShotTimer displays the elapsed time and the split time for every shot fired.
Game calls—The speaker in the mobile device 52 can be used to simulate game calls. The microphone on the mobile device 52 can monitor the calls from the target animals and automatically select the desired simulated game call response. A software application sold under the trade name Primos Hunting Calls provides an interactive game calls for deer, elk, turkey, waterfowl, etc.
Linking mobile devices—The mobile devices 52 mounted in the present mounting system can be linked to another mobile device 52 . For example, a software application sold under the trade name Hunting Call Remote allows the user to control a hidden mobile device 52 to transmit a remote game call.
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 this disclosure. The upper and lower limits of these smaller ranges which may independently be included in the smaller ranges is also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either both of those included limits are also included in the disclosure.
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 disclosure belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the various methods and materials are now described. All patents and publications mentioned herein, including those cited in the Background of the application, are hereby incorporated by reference to disclose and described the methods and/or materials in connection with which the publications are cited.
The publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present disclosure 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.
Other embodiments are possible. Although the description above contains much specificity, these should not be construed as limiting the scope of the disclosure, but as merely providing illustrations of some of the presently preferred embodiments. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of this disclosure. It should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes disclosed. Thus, it is intended that the scope of at least some of the present disclosure should not be limited by the particular disclosed embodiments described above.
Thus the scope of this disclosure should be determined by the appended claims and their legal equivalents. Therefore, it will be appreciated that the scope of the present disclosure fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present disclosure is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” All structural, chemical, and functional equivalents to the elements of the above-described preferred embodiment that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present disclosure, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims.
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An adapter that optically couples a camera on a mobile device to an eye piece of an optical device. The adapter includes a base plate configured to retain the mobile device without obstructing a display screen on the mobile device. The base plate includes an optical interface configured to attach to the eye piece of the optical device. A mounting structure is configured to secure the optical interface to the eye piece of the optical device. The mounting structure includes a high friction interface that prevents rotation of the adapter relative to the eye piece. An adjustment system with threaded micro-adjust mechanisms is configured to move the base plate relative to the optical interface in at least two degrees of freedom to optically couple the camera on the mobile device with an optical axis of the eye piece. Images captured by the optical device are displayed on a viewing screen of the mobile device.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This Application claims the benefit of the priority of Applicant's earlier filed U.S. Provisional Application No. 61/018,665 filed on Jan. 2, 2008, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to a portable multi-purpose illumination device, and more particularly to a light source that can be positioned for hands-free task lighting, magnified inspection, hand-held conventional flashlight use, or mirrored viewing of an otherwise obstructed object.
[0004] 2. Background of the Related Art
[0005] Light sources have many applications and are in widespread use. One common example is the ordinary flashlight. The flashlight has many advantages and it is safe and easily used by almost any person including children. Common flashlights come in many sizes and some are small enough to fit into a pocket or the like. Even though flashlights are small, they produce good illumination. However, despite these advantages flashlights have certain disadvantages. One big disadvantage is that flashlights are not suited for use in many situations where the user needs to employ both hands. Two hands are frequently required in situations where additional light is necessary or desirable. For instance, changing an automobile tire usually requires the use of both hands. If this is done at night, when there is no other person to hold the flashlight, the person changing the tire must find some way to support and aim the flashlight. The same problem exists when performing work on an engine under the hood of a car.
[0006] Another disadvantage of conventional flashlights is that often light will not reach an area in a crowded location that requires illumination. For example, the engine compartment of a modern car is so filled with hoses, belts, and wires that they limit access to tools. At times, it is necessary to illuminate a work area within the engine compartment, but this may not be possible due to the limited space available, the size of the flashlight, and the hand holding it. Consequently, the flashlight must be held at a considerable distance from the work area and thus the light can be interrupted by hoses, belts, etc. so that the intended work area or space is inadequately illuminated.
[0007] There are other portable lights with specialized uses, such as book lights for reading, that do not require the use of a hand to hold it, but again these are not versatile. A book light may be excellent for its intended purpose, but it does not function well as a multi-purpose flashlight.
[0008] There are some types of specialized flashlights, such as those secured to a hat or a belt by a clip, which project and direct light in front of the user. This type of light can be worn while walking and allows the hands to be free to carry equipment. However, it is designed for a specialized use and is not versatile.
[0009] There are some limited alternatives to flashlights for specialized purposes. Such devices may include a book light that includes a base, a neck portion, and a light. These devices are typically used in situations where localized light is required for reading a book. Book lights are designed to hold the light source at a designated and generally limited distance from the book. Thus, book lights are not versatile and they produce a light that has a bright illumination at the center of an illuminated area, which fades to poor light towards a periphery of the illuminated area. Consequently, the uses for such lights are relatively limited.
[0010] There are specialized light needs that do not have satisfactory light sources. An example of this is the keyboard of a computer, particularly the keyboard of a laptop computer. Frequently, computers are used in low light situations and, while the user is able to view the screen, the user has difficulty seeing the computer keyboard and associated reading material next to the keyboard. There are portable light devices available to the computer user, but such devices are simple too bulky and are not generally used for tasks that are not associated with the computers.
[0011] All of the previously mentioned lights are practically useless in situations where an area that is to be worked on or within cannot be viewed directly by the person that is attempting to perform a task in the obscured area. An example of this situation is working on an automobile engine where the bolts or the like that are to be removed cannot be viewed by the person working on the engine. This type of situation requires more than just direct illumination that a flashlight or the like can supply. In this situation, it is necessary to provide the person with a view of the area that he or she cannot see directly. Consequently, in this situation, some type of reflecting means is necessary to reflect an image of the work area, as well as an illumination source to illuminate the area where the work is to be preformed. There is a definite need for a device that provides a user with the capability of reflecting an image as well as illuminating a work area or an obscured area that is not possible with prior art flashlights and the like.
[0012] There are lighting devices that use flexible necks. These devices have a light at the tip of a neck. On some of these devices, the neck wraps around a base power source for storage. U.S. Pat. No. 5,154,483 to Noel E. Zeller (1992) discloses a flashlight with a flexible extension stored in a peripheral groove of a power-housing base. Zeller's peripheral groove is not designed to store precise lengths of neck, however. In addition, a user of Zeller's light is forced to manipulate the neck and power-housing base to free the neck. The present invention overcomes this problem by allowing a user to select a precise length of neck without touching, manipulating, or even using a power-housing base. The present invention allows a user to select a short length of neck to illuminate a small area, such as a paperback novel, or a longer length of neck to illuminate a larger area, such as several pages of sheet music. By not storing the neck around the power-housing base, the present invention retains an adjustable length neck when it is attached to other devices, such as a USB port on a computer or a cigarette lighter power source in a car. In addition, Zeller's light is designed for specialized use and is not as versatile as the portable multi-purpose illumination device of the present invention.
[0013] U.S. Pat. No. 1,036,000 to William H. Pease (1912) and U.S. Pat. No. 6,091,453 to Steven Coan and Gerald T. Mroch (2000) disclose devices designed for inspection of an obstructed field of view. However, these devices use necks that are not flexible and storable to precisely adjustable lengths. The present invention overcomes these limitations. In addition, the devices of Pease, Coan and Mroch are designed for specialized use and are not as versatile as the portable multi-purpose illumination device of the present invention.
[0014] U.S. Pat. No. 1,036,000 to William H. Pease (1912) uses a mirror and lamp where the mirror can rotate in only one plane. U.S. Pat. No. 6,840,643 to Gordon W. Clemmer, Jr. (2002) makes use of a mirror with two joints, to rotate the mirror in two planes. These devices are not designed to permit the user to quickly replace the mirror with lenses, color filters, and the like, however. The portable multi-purpose illumination device of the present invention overcomes these limitations by using a single joint, i.e., a ball and socket assembly, that is less expensive to manufacture, and allows the user to quickly and easily change from a mirror to a lens or the like. The present invention is more flexible by using a rotating ring that can mount on either side of the light source and has a stronger securing means by the use of a groove and ring design. In addition, the devices of Pease and Clemmer are designed for specialized use and are not as versatile as the present invention.
[0015] It is an object of the present invention to provide a portable and multi-purpose illumination device that overcomes the limitations of prior art illumination devices, such as flashlights and the like. It is an additional object to provide an illumination device that allows a user to illuminate and view obstructed areas that would normally not be possible. It is a further object of the invention to provide an illumination device that is self-supporting and configured to allow a user to readily position a lens, mirror, and a source of light precisely at a location where it will be most useful without a need to find additional objects or items to support the light source. It is yet another object of the present invention to provide a portable and multi-purpose illumination device that wraps and collapses around itself for compact storage.
SUMMARY OF THE INVENTION
[0016] These and other objects are accomplished by the present invention which provides a portable multi-purpose illumination device that wraps into a compact shape for storage, comprising: a holding and storage means; a positioning member that is extendable and that is connected to the holding and storage means and around which at least a portion of the positioning member is wrapped for storage; and a light source housed within the holding and storage means and powered by connection to a power source which is at least one of (a) a power supply electrically connected via the positioning member and (b) a detachable battery housed within the holding and storage means.
[0017] The positioning member may have electrical conduction means and may be electrically connected to the light source. In one embodiment, the power supply is electrically connected to the light source and includes a power supply switch for controlling the light source. In another embodiment, the detachable battery is alternately or additionally electrically connected to the light source.
[0018] The holding and storage means may include a switch connected between the light source and the power source for controlling the light source, e.g., at least one light emitting diode. The portable multi-purpose illumination device may further comprise a holding clamp attached to the exterior of the power supply for securing the holding and storage means to the power supply; and securing means for securing the power supply to an external structure or surface. The portable multi-purpose illumination device may further comprise pivot means provided on the power supply to join the positioning member to the power supply so that the positioning member pivotally extends from the power supply.
[0019] The holding and storage means may be provided with rotating means to which one end of the positioning member is attached and around which the positioning member rotates to vary the extension thereof and for storage. The positioning member may be manually deformable to provide at least one of articulation and a holding configuration to an external structure or surface. The positioning member may be detachable from at least the power supply and is then provided with one of (a) a clip for reattachment to an external structure or surface and (b) an electrical connector suitable for connecting to alternate power sources.
[0020] In an advantageous embodiment, the holding and storage means may be a housing having an outer cylinder wall in which is defined a circumferential storage channel to which one end of the positioning member is attached, and around which the positioning member wraps to vary the extension thereof and for storage. The portable multi-purpose illumination device may then further comprise mounting means for mounting the light source within the housing; a rear cover covering one side of the housing; and at least one rotating ring which is detachably mounted on the outer cylinder wall of the housing through which light emitted from the light source exits the holding and storage means. The device may then further comprise a connecting arm extending from the rotating ring and terminating in a female socket joint of a ball and socket assembly for detachable mounting of a detachable mounting means thereto. The detachable mounting means may be a retainer for one of a mirror, a lens, a diffuser, or a color filter, and the retainer may include a male ball member of the ball and socket assembly for detachable connection of the male ball member to the female socket joint. The male ball member and the female socket joint cooperate to articulate as a ball and socket assembly when engaged. The retainer advantageously retains a mirror.
[0021] These and other objects are further accomplished by the present invention which provides a method of viewing a target object obscured from direct view of a user by an intervening object; the method comprising: (a) providing the portable multi-purpose illumination device according to claim 16 ; and (b) positioning the mirror of the portable multi-purpose illumination device so that the user can view the target object despite the presence of the intervening object.
BRIEF DESCRIPTION OF THE DRAWING
[0022] While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as the invention, it is believed that the invention, the objects and features of the invention and further objects, features and advantages thereof will be better understood from the following description taken in connection with the accompanying drawings in which:
[0023] FIG. 1 is a perspective right-side exploded view of the portable multi-purpose illumination device;
[0024] FIG. 2 is a perspective right-side view showing elements from FIG. 1 in an assembled view;
[0025] FIG. 3 is a perspective right-side view of the portable multi-purpose illumination device showing the elements in a stored position;
[0026] FIG. 4 is a perspective view of a female socket joint protruding over a circumferential storage channel of storage and holding means;
[0027] FIG. 5 is a perspective view illustrating a power supply resting on a horizontal plane with a pivot joint rotated and a positioning member extended from a stored position;
[0028] FIG. 6 is an orthogonal view illustrating mirrored viewing of an otherwise obstructed object. Two objects are added for demonstration purposes.
[0029] FIG. 7 is a perspective view of an annuli ball and socket in the process of closing in a clam like manor to secure itself to a positioning member. A holding and storage means is removed for clarity;
[0030] FIG. 8 is a perspective view of the portable multi-purpose illumination device showing a switch and a rear plate; and
[0031] FIG. 9 is a perspective view of the portable multi-purpose illumination device illustrating a battery housed within a holding and storage means and showing a small clip on the end of a positioning member. A conventional battery holding means has been removed for clarity.
DETAILED DESCRIPTION OF THE INVENTION
[0032] In the following detailed description 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 preferred embodiments in which the inventions may be practiced. These preferred 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 preferred embodiments may be utilized and that logical, mechanical and electrical changes may be made without departing from the spirit and scope of the present inventions. The following detailed description is, therefore, not to be taken in a limiting sense, and scope of the present inventions is defined only by the appended claims.
[0033] Referring first to FIGS. 1 , 2 , and 3 a portable multi-purpose illumination device 10 is illustrated and is designated generally by the number 10 . The portable multi-purpose illumination device 10 comprises a holding and storage means 12 that is generally spool shaped, a positioning member 14 that is extendable and manually deformable, a ball and socket assembly 16 , and a power supply 18 that is detachable. The holding and storage means 12 supports a light source 20 in a manner that will be hereinafter described in detail.
[0034] As illustrated in FIG. 7 the positioning member 14 contains a negative electrical conductor 38 and a positive electrical conductor 40 for transmitting electrical power from a suitable power source. FIGS. 4 , 5 , and 7 illustrate a connector 22 attached to one end of the positioning member 14 and connecting to a connector 24 located in a circumferential storage channel 26 and protruding through a housing 28 (having an outer cylinder wall) and into a cavity 78 of the holding and storage means 12 . The connectors 22 and 24 are electrically and mechanically compatible and have a rotational means 25 . As illustrated in FIGS. 1 , 5 and 7 an electrical connector 30 attached to the other end of the positioning member 14 is connected through an opening in an exterior cylinder surface 118 of a pivot means 34 to an electrical connector 32 located inside the exterior cylinder surface 118 of the pivot means 34 . The pivot means 34 is located in an exterior surface 120 of the power supply 18 that houses a battery 36 for supplying electrical power to the light source 20 . A power supply switch 42 located on the power supply 18 permits a user to control the light source 20 in a conventional manner.
[0035] As illustrated in FIGS. 3 and 5 securing means 44 (spring activated and magnetized clip) is attached to the power supply 18 . This allows a user to secure the power supply 18 to numerous types of surfaces both during use and for storage purposes.
[0036] As illustrated in FIGS. 1 , 3 , and 8 a holding clamp 46 with arc spaced securing tabs 48 is attached to the exterior of the power supply 18 for securing the holding and storage means 12 . The securing tabs 48 are located in both interior parallel walls of the holding clamp 46 . A front circumferential groove 50 (best viewed in FIG. 1 ) and a back circumferential grove 52 (shown in FIG. 8 ) are located symmetrically on both external planes of the circumferential storage channel 26 of the holding and storage means 12 . This compatible configuration allows a user to snap the holding and storage means 12 to the holding clamp 46 for securing the holding and storage means 12 to the power supply 18 . FIG. 3 illustrates the holding clamp 46 securing the holding and storage means 12 .
[0037] As illustrated in FIGS. 3 and 5 the pivot means 34 rotates to reduce stress on the positioning member 14 and to increase a range of motion of the holding and storage means 12 . FIG. 3 shows position of the pivot means 34 when the holding and storage means 12 is in a stored position. FIG. 5 shows the pivot means 34 rotated in a different position that is suitable for task lighting and such.
[0038] As illustrated in FIG. 1 the ball and socket assembly 16 makes use of two components: (1) a combined rotating ring, connecting arm, and female socket joint 54 and (2) a combined retainer and male ball member 56 . These two components ( 54 and 56 ) attach to each other by joining a male ball member 58 to a female socket joint 60 to form the ball and socket assembly 16 .
[0039] As illustrated in FIGS. 1 and 2 , a rotating ring 62 of the combined rotating ring, connecting arm, and female socket joint 54 has an interior circumferential groove 64 located symmetrically on its interior wall. An exterior retaining ring 66 is located on exterior wall of the housing 28 (having an outer cylinder wall) of the holding and storage means 12 . The retaining ring 66 is compatible with the rotating ring 62 . This allows a user to attach or remove in a snap-like fashion the rotating ring 62 to or from the holding and storage means 12 . The interior circumferential grove 64 and the retaining ring 66 along with an inwardly biasing force of the rotating ring 62 helps secure the rotating ring 62 to the holding and storage means 12 . This configuration allows a user to rotate the combined rotating ring, connecting arm, and female socket joint 54 to any position around the retaining ring 66 of the holding and storage means 12 while maintaining firm contact and attachment.
[0040] As illustrated in FIGS. 1 and 4 a connecting arm 68 has two parallel planes that are parallel to the two parallel planes of the rotating ring 62 , and located between the female socket joint 60 , and the rotating ring 62 . The connecting arm 68 holds the female socket joint 60 at a radius greater than the outside radius of the circumferential storage channel 26 . This allows a user to secure either plane of the rotating ring 62 to the holding and storage means 12 . FIGS. 1 and 2 illustrates the combined rotating ring, connecting arm, and female socket joint 54 oriented with the female socket joint 60 protruding away from the circumferential storage channel 26 . FIG. 4 illustrates the combined rotating ring, connecting arm, and female socket joint 54 oriented with the female socket joint 60 protruding over the circumferential storage channel 26 . In this position, a user can further secure the positioning member 14 at a desired length. Note, the combined retainer and male ball member 56 is not shown in FIG. 4 because it is not needed, and so it can, and has been, removed from the combined rotating ring, connecting arm, and female socket joint 54 .
[0041] The combined retainer and male ball member 56 can rotate from a closed position shown in FIG. 3 , to a semi-open position shown in FIG. 2 , to a fully open or 235 degrees relative to the combined rotating ring, connecting arm, and female socket joint 54 . When the combined retainer and male ball member 56 is generally open 90 degrees or larger relative to the combined rotating ring, connecting arm, and female socket joint 54 , it can rotate completely around the male ball member 58 axes within the female socket joint 60 . FIG. 6 shows an orthogonal view of the combined retainer and male ball member 56 rotated around its axes.
[0042] To summarize previously described positions the ball and socket assembly 16 attached to the holding and storage means 12 allows a user to position the combined retainer and male ball member 56 and the combined rotating ring, connecting arm, and female socket joint 54 in a variety of useful positions that will hereinafter be described in detail.
[0043] The ball and socket assembly 16 is easily removed from the holding and storage means 12 and used independently or attached in a clam-like manner to the positioning member 14 as illustrated in FIG. 7 . This demonstrates how the ball and socket assembly 16 can function independently or in conjunction with the portable multi-purpose illumination device 10 .
[0044] FIG. 5 illustrates the illumination device 10 when used as a book or a task light. In this illustration, the ball and socket assembly 16 is removed from the holding and storage means 12 to simplify usage. Because the area illuminated increases proportional to the distance of the light source, companies manufacture different lengths of gooseneck to accommodate the need of their customers. Typically, a six-inch, twelve-inch, or eighteen-inch length of gooseneck is used for a light fixture. The illumination device 10 is more compact and does not require different lengths of goosenecks to be manufactured. For example, if a user requires only a small area to illuminate, such as a paperback book, only a small amount of the positioning member 14 needs to be unwound. If however, a user prefers to illuminate a larger area, such as three pages of sheet music, a longer length of the positioning member 14 can be unwound.
[0045] Although not illustrated, it should be obvious that by wrapping the positioning member 14 around an object, such as a pluming-pipe, the illumination device 10 can function similar to a conventional snake light.
[0046] Illustrated in FIGS. 1 , 3 , 6 and 7 is a retainer 70 (with detachable mounting means for a mirror, a lens, a diffuser, or a color filter) that is part of the combined retainer and male ball member 56 . The retainer 70 holds various known-in-the-art lenses and the like that are constructed of various materials and shapes to add uniqueness and versatility to the portable multi-purpose illumination device 10 . The retainer 70 shows anyone skilled in the art where to attach, with known in the art methods, a lens, film etc. The combined retainer and male ball member 56 can be manufactured as a single element with known in the art injection molding, or it can be manufactured in parts (the male ball member 58 and the retainer 70 for example) and then assembled. Various materials and shapes can be constructed and mounted at the retainer 70 location to add uniqueness and versatility to the illumination device 10 . For example, a frosted dome lens can be used to create a pleasant esthetic appearance. Various lenses or light transmitting and refracting means can be used to focus, color and/or diffuse the light source 20 . If the light source 20 emits light in a lambertian pattern, and a lens 122 such as a collimator type or the like is used in the retainer 70 , the light is focused and the illumination device 10 can be used in a similar manner as a conventional flashlight. FIG. 3 illustrates position of the lens 122 secured by the retainer 70 when the illumination device 10 is used like a flashlight. A magnifying lens (not shown) secured to the retainer 70 and rotated approximately 180 degrees from the rotating ring 62 is used to examine small objects. The light source 20 illuminates the subject to aid in this examination. A mirror 124 (and optional magnifier mirror on opposite side) secured to the retainer 70 is used to examine hidden or obstructed objects. This function will hereinafter be described in detail.
[0047] The manner in which a user positions the illumination device 10 to see objects that are obscured from the direct view is illustrated orthogonally in FIG. 6 . In this example the mirror 124 , secured to the retainer 70 , of the combined retainer and male ball member 56 is employed. In this illustration, a viewer's eye 72 needs to view a target object 74 , but an intervening object 76 makes it impossible for the viewer's eye 72 , to see the target object 74 . To see the target object 74 , first, if needed, a user unwinds the positioning member 14 to obtain a desired length. Then from the closed position (shown in FIG. 3 ) the member 56 is opened 180 degrees. Then the user turns the member 56 45 degrees as clearly illustrated in FIG. 6 . Then the user positions the holding and storage means 12 so the light source 20 is directed toward the target object 74 . This is represented by an arrow and a letter A. An arrow and a letter B represent the first reflection of the target object 74 . The user then directs his or her line of sight, represented by an arrow and a letter C, parallel to the holding and storage means 12 and 45 degrees relative to the member 56 . The user can now view the target object 74 . The angles previously described do not need to be precise, many other angles and positions can be used to view the target object 74 . In addition, because the ball and socket assembly 16 can detach fully from the illumination device 10 and used independently or clamp to the positioning member 14 as shown in FIG. 7 , a plurality of positions and options are available for viewing obstructed objects.
[0048] As illustrated in FIGS. 1 and 4 the inside the cavity 78 that extends inward from a front surface 80 of the holding and storage means 12 . There is a retaining ridge 82 located on an interior wall 84 of the cavity 78 of the holding and storage means 12 . As illustrated in FIGS. 1 and 2 a front cover 86 is located within the cavity 78 and secured by an outwardly biasing force from securing tabs 88 located on an outer peripheral edge 90 of the front cover 86 . The front cover 86 has a centrally located circular hole 92 . The outer peripheral edge 90 along with the securing tabs 88 of the front cover 86 is sized and shaped for manual positioning over the retaining ridge 82 . The securing tabs 88 deform slightly to secure the front cover 86 by means of a pressure fit within the cavity 78 .
[0049] As illustrated in FIGS. 1 , and 2 the centrally located circular hole 92 in the front cover 86 is sized and shaped to receive a generally hemispherical shaped light-emitting portion 94 of a light emitting diode (LED) 96 .
[0050] It should be noted that the front cover 86 can be manufactured from transparent material, and manufactured without the hole 92 , and then mounted by removing a rear cover 108 , and inserting the front cover 86 until it is secured by the retaining ridge 82 . This is important if the manufacturer desires more protection of the light source 20 , better waterproofing performance, and or an alternate assembly process. In addition, if the rear cover 108 is made of transparent material and side emitting LEDs are attached to the interior wall 84 of the cavity 78 , light will emit from both ends of the holding and storage means 12 . When the holding and storage means 12 projects light from both ends and is manufactured to hold the ball and socket assembly 16 on either side, then two ball and socket assemblies 16 can be utilized to provide additional uses for the portable multi-purpose illumination device 10 .
[0051] As illustrated in FIGS. 1 and 4 , a negative LED electrical contact 98 and a positive LED electrical contact 100 of the LED 96 are connected to a negative LED conductor 102 and a positive LED conductor 104 , and then connected to the connector 24 as shown in FIG. 4 . In this manner, electrical power supplied to the electrical conductors 38 and 40 (in the positioning member 14 ) passes through the connector 24 , through the conductors 102 and 104 , then through the electrical contacts 98 and 100 of the LED 96 to cause the LED 96 to emit light.
[0052] FIGS. 4 and 8 illustrate the portable multi-purpose illumination device 10 detached from the power supply 18 . If the electrical connector 30 is replaced by someone skilled in the art with a conventional connector such as a USB, BNC, XLR or the like, a user can then attach the illumination device 10 to a variety of alternate power sources other than the power supply 18 . It should be noted there are numerous examples of electrical conduits that do not connect to all of the available connections of a plug (do not utilize all the optional connections of said plug). A simple 2-line 4-connector telephone plug is one such example. Two wires are used for single line and four wires are used for two lines. In a similar fashion, the negative electrical conductor 38 and the positive electrical conductor 40 can be connected to a 4-wire connector such as a USB connector by someone skilled in the art. It should also be noted that the positioning member 14 could also be built with a plurality of electrical conductors. Thus, the portable multi-purpose illumination device 10 can be wired for other useful applications. For example, when the electrical connector 30 is replaced with a conventional USB connector, a user can attach the illumination device 10 to a computer with compatible USB connector. Note, many professional lighting and mixing boards have electrical BNC connectors specifically designed to accept lighting fixtures for lighting the mixing board. When the electrical connector 30 is replaced with a conventional BNC connector a user can then attach the illumination device 10 to a conventional audio or lighting mixing board.
[0053] The portable multi-purpose illumination device 10 can be hard wired without the electrical connector 30 by using the negative electrical conductor 38 and positive electrical conductor 40 located on the end of the positioning member 14 . The illumination device 10 is ideal for cabinet lighting (such as kitchen cabinets) because of the low profile of the holding and storage means 12 . The positioning member 14 attached to a mast or a pole then attached to a suitable base with means for supplying power enables the illumination device 10 to function as a conventional desk light. A larger scaled version of the illumination device 10 with the ball and socket assembly 16 attached to a power supplying pole can be used to safely examine the underside of a vehicles for security purposes.
[0054] FIG. 8 illustrates the portable multi-purpose illumination device 10 with a switch 106 (pushbutton type) located on the rear cover 108 of the holding and storage means 12 . The switch 106 is useful when another power source other then the power supply 18 is used. For this embodiment the power supply switch 42 located on the power supply 18 is not needed.
[0055] FIG. 9 illustrates the portable multi-purpose illumination device 10 equipped with an alternate location for its power supply. The front cover 86 has been removed from FIG. 9 for clarity. In this embodiment, the power supply is a detachable battery 110 such as a coin cell or cells that are secured substantially inside the cavity 78 of the holding and storage means 12 by conventional means. A negative small battery conductor 116 connects the negative contact of the detachable battery 110 to the negative LED electrical contact 98 . The positive LED conductor 104 connects to the positive LED electrical contact 100 . The negative LED conductor 102 (now functions as a positive conductor) connects to the positive contact of the detachable battery 110 . The electrical conductors 40 and 38 now function together as a positive conductor attached to a PM switch 112 located on the end of the positioning member 14 to regulate the light source 20 in a conventional manor. A clip 114 similar to an alligator style clip is secured to the end of the positioning member 14 enabling the user to attach the illumination device 10 to an object. The switch 106 as shown in FIG. 8 can also be used in place of the PM switch 112 as shown in FIG. 9 .
EXAMPLE
[0056] A portable multi-purpose illumination device 10 was manufactured using conventional materials and components known in the art and using conventional molding, and manufacturing techniques. In this connection, the holding and storage means 12 is custom machined from aluminum stock by Crow Corporation, 23715 F. M. 2978, Tomball, Tex. 77375. The positioning member 14 is made from 18-gauge solid core wire with 2 conductors, known in the art as 18/2 cable, and is approximately one foot long. The two solid core 18 gauge copper wires provide the positioning member 14 with temporarily manually deformability, support means, and convey electrical power. All other wires and various connectors are conventional. The front cover 86 is precession laser cut from thin 0.024-inch white PVC stock and manufactured by Gleicher Manufacturing Corporation, 851 Jerusalem Road, Scotch Plains, N.J. 07076. The power supply 18 and the ball and socket assembly 16 are manufactured using conventional injection molding techniques and the like. The LED 96 is available from Philips Lumileds Lighting Company or Seoul Semiconductor or Cree, Inc. By using the previous descriptions and figures, anyone skilled in the art, can assemble the illumination device 10 in a straight forward, very easy, and obvious way.
Operation
[0057] The portable multi-purpose illumination device 10 may be operated in the three most popular modes as follows.
[0058] As a conventional handheld flashlight, simply turn the power supply switch 42 on. In this example, the LED 96 projects a narrow beam. If the light source 20 or the LED 96 projects a lambertian pattern, the ball and socket assembly 16 is typically used with member 56 in a closed position as shown in FIG. 3 and the lens 122 of a collimator type or the like secured by the retainer 70 is used to project the light source 20 in a beam-like manor.
[0059] The second popular use of the illumination device 10 is as a task light. This is best illustrated in FIGS. 3 and 5 . In this mode, a user, if desired, removes the ball and socket assembly 16 from the holding and storage means 12 , and then unwinds the positioning member 14 from the holding and storage means 12 to obtain a desired length. Finally, the user bends the positioning member 14 to obtain the desired placement of the light source 20 .
[0060] The third popular mode is viewing an obstructed object. Here a user opens the combined retainer and male ball member 56 with the mirror 124 secured by the retainer 70 and then positions the illumination device 10 in a location to see the obstructed object.
[0061] While the present invention has been described in conjunction with embodiments and variations thereof, one of ordinary skill, after reviewing the foregoing specification, will be able to effect various changes, substitutions of equivalents and other alterations without departing from the broad concepts disclosed herein. It is therefore intended that Letters Patent granted hereon be limited only by the definition contained in the appended claims and equivalents thereof.
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A portable multi-purpose illumination device that wraps into a compact shape for storage and includes a holding and storage device; a positioning member that is extendable and that is connected to the holding and storage device and around which at least a portion of the positioning member is wrapped for storage; and a light source housed within the holding and storage device and powered by connection to a power source which is at least one of (a) a power supply electrically connected via the positioning member and (b) a detachable battery housed within the holding and storage means. The positioning member is manually deformable and may be attached to various structures. The holding and storage device additionally features a retainer for various lenses and mirrors. The illumination device may be used to view a target object obscured from direct view by an intervening object by positioning the mirror appropriately.
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FIELD OF THE INVENTION
The invention generally relates to implantable medical devices and in particular to a memory architecture for use with a microcontroller of an implantable medical device.
BACKGROUND OF THE INVENTION
A wide range of implantable medical stimulation devices are provided for surgical implantation into humans or animals. One common example is the cardiac pacemaker. Another is the implantable cardioverter defibrillator (ICD).
Current state of the art implantable medical devices typically include a microcontroller for controlling the functions of the device such as detecting medical conditions within the patient in which the device is implanted and administering appropriate therapy. Within a pacemaker, for example, the microcontroller monitors the detection of P-waves and R-waves to determine whether an episode of bradycardia has occurred and, if so, administers a pacing pulse to the heart. Within an ICD, for example, the microcontroller analyzes P-waves, R-waves and other electrical signals of the heart to determine if an episode of ventricular fibrillation has occurred and, if so, administers a defibrillation shock to the heart.
In addition to performing functions directed to administering immediate therapy, the microcontroller coordinates all other functions of the implantable device, such as: monitoring the power source of the device to determine if the power source needs to be replaced; switching of the mode of operation of the device from, for example, a single-chambered pacing mode to a dual-chambered pacing mode; and recording events such as detection of P-waves and R-waves mode switching events and the administration of therapy for diagnostic purposes. As implantable medical devices become more and more sophisticated, the number and complexity of functions that must be performed by the microprocessor increases as well. As a result, the software for controlling the microprocessor becomes increasingly complex and the amount of time required to design, test and debug the software also becomes more significant. Indeed, in many cases, the development of reliable software can significantly delay the overall development of a new implantable medical device. Accordingly, it is highly desirable to expedite the development of reliable software for use in an implantable medical device and aspects of the invention are directed to that general goal.
Typically, software is developed using random access memory (RAM) devices that can be programmed and reprogrammed many times during the development of the software. To reliably test the device, the software should be used in conjunction with the entire implantable medical device. Also, while testing software within the test device, it is also desirable to test various hardware components of the device, such as pulse generators, sensors and the like. Hence, test devices are built which incorporate all of the hardware of the implantable medical device with RAM chips for storing the software to be tested. Ideally, however, the final medical device incorporates read only memory (ROM) rather than RAM to reduce power consumption, increase processing speed, and prevent any corruption of the software, as may occur as a result of a power surge or perhaps as a result of the malfunction of some other component of the device, such as the microprocessor. However, the use of RAM during software design and test, rather than ROM, may affect the amount of current consumed by the device, or other device characteristics, possibly resulting in invalid tests of the hardware components of the device. For example, after the software is embodied in ROM for installation into a production device, the slight difference in current consumption caused by switching from RAM to ROM may result in sense amplifiers not operating precisely as expected. Moreover, in many cases, while software is being developed, the amount of memory required by the software exceeds the amount of memory expected to be used in the production device. As a result, to test intermediate versions of the software, additional RAM chips are used in the test device, further affecting the total current consumption, resulting in a still greater risk that the hardware components of the device, once RAM is replaced with ROM in the production device, will not operate precisely as expected.
Accordingly, it would be highly desirable to provide an improved method for designing, testing and debugging software for use in an implantable medical device and an improved device for receiving the software, which overcomes the aforementioned disadvantages. It is to this end that many aspects of the invention are specifically directed.
Another problem associated with employing ROM memory in the production unit of an implantable medical device, is that software upgrades or software bug fixes cannot easily be performed. Indeed, if the software to be upgraded or fixed resides within ROM, the ROM may need to be replaced, requiring explantation of the implanted device from a patient, then implantation of a new or modified device. As can be appreciated, this is a considerable inconvenience to the patient and a significant cost to the manufacturer of the device. Accordingly, it would also be desirable to provide a hardware memory configuration for use in the production unit of implantable medical devices, which facilitates expedient software upgrades or software bug fixes, and still other aspects of the invention are directed towards that goal.
SUMMARY OF THE INVENTION
In accordance with the invention, a memory system is provided for use in an implantable medical device having various computing components accessing a virtual memory space corresponding to a predetermined amount of memory. The memory system includes dynamic means for storing data, permanent means for storing data, and a memory controller means for mapping portions of the virtual memory space to either the dynamic means for storing data or the permanent means for storing data.
In an exemplary embodiment, the implantable medical device is a pacemaker or implantable cardioverter defibrillator. The dynamic storage means is RAM and the permanent storage means is ROM. The memory controller means includes a zone control register that specifies, for each of a predetermined number of zones of virtual memory, whether the zone is to be mapped to RAM or ROM. The zone control register is a binary register having one bit per memory zone with the bit set to indicate either ROM or RAM. In one specific implementation, the predetermined amount of memory of the virtual memory space is 256 kilobytes (256K) of memory. The RAM and ROM each provide 256K of memory as well, permitting the entire virtual memory space to be mapped either to RAM or ROM.
By providing the implantable medical device with both RAM and ROM, software for use in the device can be stored in the RAM while software is being designed, tested and debugged. Then, once the software design has been finalized, the final software design is embodied in ROM. In this manner, the actual production unit of the device may exploit the benefits of the ROM whereas testing may be performed while obtaining the benefits of RAM, without changing power consumption requirements or other device characteristics. Hence, both the software and hardware components of the implantable medical device can be reliably tested without risk that slight changes in current consumption caused by replacing RAM with ROM may invalidate the tests. Also, by providing each production unit with both RAM and ROM, software upgrades may be accomplished easily by downloading new software into a portion of the RAM, then controlling the memory controller means to map portions of the virtual memory space to access the RAM rather than the ROM. In this manner, any software bugs discovered in the software of the ROM may be easily corrected without requiring replacement of the ROM which, in the case of an implantable medical device, would likely require explantation of the device from the patient.
Other objects and advantages of the invention are achieved as well. Method embodiments of the invention are also provided.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the present invention may be more readily understood by reference to the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a functional block diagram of a dual-chamber implantable stimulation device illustrating the basic elements of a stimulation device, which can provide cardioversion, defibrillation and pacing stimulation;
FIG. 2 illustrates a memory configuration for use with the implantable device of FIG. 1;
FIG. 3 is a flow chart illustrating a method for use with the memory configuration of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description is of the best mode presently contemplated for practicing the invention. This description is not to be taken in a limiting sense but is made merely for the purpose of describing the general principles of the invention. The scope of the invention should be ascertained with reference to the issued claims. In the description of the invention that follows, like numerals or reference designators will be used to refer to like parts or elements throughout.
The description is of a system having an implantable cardiac stimulation device for implantation into a patient.
In FIG. 1, a simplified block diagram is shown of a dual-chamber implantable stimulation device 10 which is capable of treating both fast and slow arrhythmias with stimulation therapy, including cardioversion, defibrillation, and pacing stimulation. While a dual-chamber device is shown, this is for illustration purposes only, and one of skill in the art could readily eliminate or disable the appropriate circuitry to provide a single-chamber stimulation device capable of treating one chamber with cardioversion, defibrillation and pacing stimulation.
To provide atrial chamber pacing stimulation and sensing, the stimulation device 10 is shown in electrical communication with a patient's heart 12 by way of an implantable atrial lead 20 having an atrial tip electrode 22 and an atrial ring electrode 24 which typically is implanted in the patient's atrial appendage.
The stimulation device 10 is also shown in electrical communication with the patient's heart 12 by way of an implantable ventricular lead 30 having, in this embodiment, a ventricular tip electrode 32 , a ventricular ring electrode 34 , a right ventricular (RV) coil electrode 36 , and an superior vena cava (SVC) coil electrode 38 . Typically, the ventricular lead 30 is transvenously inserted into the heart 12 so as to place the RV coil electrode 36 in the right ventricular apex, and the SVC coil electrode 38 in the superior vena cava. Accordingly, the ventricular lead 30 is capable of receiving cardiac signals, and delivering stimulation in the form of pacing and shock therapy to the right ventricle.
While only two leads are shown in FIG. 1, it is to be understood that additional stimulation leads (with one or more pacing, sensing and/or shocking electrodes) may be used in order to efficiently and effectively provide pacing stimulation to the left side of the heart or atrial cardioversion and/or defibrillation. For example, a lead designed for placement in the coronary sinus region could be implanted to deliver left atrial pacing, atrial shocking therapy, and/or for left ventricular pacing stimulation. For a complete description of a coronary sinus lead, see U.S. patent application Ser. No. 09/457,277, “A Self-Anchoring, Steerable Coronary Sinus Lead” (Pianca et al.), and U.S. Pat. No. 5,466,254, “Coronary Sinus Lead with Atrial Sensing Capability” (Helland), which patents are hereby incorporated herein by reference.
The housing 40 (shown schematically) for the stimulation device 10 includes a connector (not shown) having an atrial pin terminal 42 and an atrial ring terminal 44 , which are adapted for connection to the atrial tip electrode 22 and the atrial ring electrode 24 , respectively. The housing 40 further includes a ventricular pin terminal 52 , a ventricular ring terminal 54 , a ventricular shocking terminal 56 , and an SVC shocking terminal 58 , which are adapted for connection to the ventricular tip electrode 32 , the ventricular ring electrode 34 , the RV coil electrode 36 , and the SVC coil electrode 38 , respectively. The housing 40 (often referred to as the “can”, “case” or “case electrode”) may be programmably selected to act as the return electrode, or anode, alone or in combination with one of the coil electrodes, 36 and 38 . For convenience, the names of the electrodes are shown next to the terminals.
At the core of the stimulation device 10 is a programmable microcontroller 60 , which controls the various modes of stimulation therapy. As is well known in the art, the microcontroller 60 includes a microprocessor, or equivalent control circuitry, designed specifically for controlling the delivery of stimulation therapy and may further include RAM or ROM memory, logic and timing circuitry, state machine circuitry, and I/O circuitry. Typically, the microcontroller 60 includes the ability to process or monitor input signals (data) as controlled by a program code stored in a designated block of memory. The details of the design and operation of the microcontroller 60 are not critical to the present invention. Rather, any suitable microcontroller 60 may be used that carries out the functions described herein. The use of microprocessor-based control circuits for performing timing and data analysis functions is well known in the art. As shown in FIG. 1, an atrial pulse generator 70 and a ventricular pulse generator 72 generate pacing stimulation pulses for delivery by the atrial lead 20 and the ventricular lead 30 , respectively, via a switch bank 74 . The pulse generators, 70 and 72 , are controlled by the microcontroller 60 via appropriate control signals, 76 and 78 , respectively, to trigger or inhibit the stimulation pulses. The microcontroller 60 further includes timing circuitry that controls the operation of the stimulation device timing of such stimulation pulses as known in the art. The controller also includes an auto-capture threshold detection system described in greater detail below.
The switch bank 74 includes a plurality of switches for switchably connecting the desired electrodes to the appropriate I/O circuits, thereby providing complete electrode programmability. Accordingly, the switch bank 74 , in response to a control signal 80 from the microcontroller 60 , determines the polarity of the stimulation pulses (e.g., unipolar or bipolar) by selectively closing the appropriate combination of switches (not shown) as is known in the art. An atrial sense amplifier 82 and a ventricular sense amplifier 84 are also coupled to the atrial and ventricular leads 20 and 30 , respectively, through the switch bank 74 for detecting the presence of cardiac activity. The switch bank 74 determines the “sensing polarity” of the cardiac signal by selectively closing the appropriate switches, as is also known in the art. In this way, the clinician may program the sensing polarity independent of the stimulation polarity.
Each sense amplifier, 82 and 84 , preferably employs a low power, precision amplifier with programmable gain and/or automatic gain control, bandpass filtering, and a threshold detection circuit, known in the art, to selectively sense the cardiac signal of interest. The automatic gain control enables the device 10 to deal effectively with the difficult problem of sensing the low frequency, low amplitude signal characteristics of ventricular fibrillation. The outputs of the atrial and ventricular sense amplifiers, 82 and 84 , are connected to the microcontroller 60 which, in turn, inhibit the atrial and ventricular pulse generators, 70 and 72 , respectively, in a demand fashion whenever cardiac activity is sensed in the respective chambers.
For arrhythmia detection, the invention utilizes the atrial and ventricular sense amplifiers, 82 and 84 , to sense cardiac signals to determine whether a rhythm is physiologic or pathologic. As used herein “sensing” is reserved for the noting of an electrical depolarization, and “detection” is the processing of these sensed depolarization signals and noting the presence of an arrhythmia. The timing intervals between sensed events (e.g., the P-P, P-R and R-R intervals) are then classified by the microcontroller 60 by comparing them to a predefined rate zone limit (i.e., bradycardia, normal, low rate VT, high rate VT, and fibrillation rate zones) and various other characteristics (e.g., sudden onset, stability, physiologic sensors, and morphology, etc.) in order to determine the type of remedial therapy that is needed (e.g., bradycardia pacing, antitachycardia pacing, cardioversion shocks or defibrillation shocks, also known as “tiered therapy”).
Cardiac signals are also applied to the inputs of an analog to digital (A/D) data acquisition system 90 . The data acquisition system 90 is configured to acquire intracardiac electrogram signals, convert the raw analog data into a digital signal, and store the digital signals for later processing and/or telemetric transmission to an external device 102 . The data acquisition system 90 is coupled to the atrial and ventricular leads, 20 and 30 , through the switch bank 74 to sample cardiac signals across any pair of desired electrodes.
The microcontroller 60 is further coupled to a memory 94 (to be described in greater detail below) by a suitable data/address bus 96 , wherein the programmable operating parameters used by the microcontroller 60 are stored and modified, as required, in order to customize the operation of the stimulation device 10 to suit the needs of a particular patient. Such operating parameters define, for example, pacing pulse amplitude, pulse duration, electrode polarity, rate, sensitivity, automatic features, arrhythmia detection criteria, and the amplitude, waveshape and vector of each shocking pulse to be delivered to the patient's heart 12 within each respective tier of therapy. Memory 94 also stores software to be loaded into the microcontroller for controlling the operation of the microcontroller.
Advantageously, the operating parameters of the implantable device 10 may be non-invasively programmed into the memory 94 through a telemetry circuit 100 in telemetric communication with an external device 102 , such as a programmer, transtelephonic transceiver, or a diagnostic system analyzer. The telemetry circuit 100 may be activated by the microcontroller by a control signal 106 . The telemetry circuit 100 advantageously allows intracardiac electrograms and status information relating to the operation of the device 10 (as contained in the microcontroller 60 or memory 94 ) to be sent to the external device 102 through the established communication link 104 .
In the preferred embodiment, the stimulation device 10 further includes a physiologic sensor 110 . Such sensors are commonly called “rate-responsive” sensors. The physiological sensor 110 is used to detect the exercise state of the patient, to which the microcontroller 60 responds by adjusting the rate and AV Delay at which the atrial and ventricular pulse generators, 70 and 72 , generate stimulation pulses. The type of sensor used is not critical to the invention and is shown only for completeness. The stimulation device additionally includes a battery 114 that provides operating power to all of the circuits shown in FIG. 1 . For the stimulation device 10 , which employs shocking therapy, the battery must be capable of operating at low current drains for long periods of time, and then be capable of providing high-current pulses (for capacitor charging) when the patient requires a shock pulse. The battery 114 must also have a predictable discharge characteristic so that elective replacement time can be detected. As further shown in FIG. 1, the invention preferably includes an impedance measuring circuit 120 , which is enabled by the microcontroller 60 by a control signal 122 . The impedance measuring circuit 120 is not critical to the invention and is shown for only completeness.
Depending upon the implementation, the device may function as an implantable cardioverter/defibrillator (ICD) device. In the case where the stimulation device 10 in intended to operate as an implantable cardioverter/defibrillator (ICD) device, it must detect the occurrence of an arrhythmia, and automatically apply an appropriate electrical shock therapy to the heart aimed at terminating the detected arrhythmia. To this end, the microcontroller 60 further controls a shocking circuit 130 by way of a control signal 132 . The shocking circuit 130 generates shocking pulses of low controlled by the microcontroller 60 . Such shocking pulses are applied to the patient's heart through at least two shocking electrodes, and as shown in this embodiment, using the RV and SVC coil electrodes, 36 and 38 , respectively. In alternative embodiments, the housing 40 may act as an active electrode in combination with the RV electrode 36 alone, or as part of a split electrical vector using the SVC coil electrode 38 (i.e., using the RV electrode as common).
Cardioversion shocks are generally considered to be of low to moderate energy level (so as to minimize pain felt by the patient), and/or synchronized with an R-wave and/or pertaining to the treatment of tachycardia. Defibrillation shocks are generally of moderate to high energy level (i.e., corresponding to thresholds in the range of 5-40 Joules), delivered asynchronously (since R-waves may be too disorganized), and pertaining exclusively to the treatment of fibrillation. Accordingly, the microcontroller 60 is capable of controlling the synchronous or asynchronous delivery of the shocking pulses.
FIG. 2 illustrates and exemplary implementation of memory 94 of the implantable device of FIG. 1 . Memory 94 includes, but is not limited to, static or dynamic RAM 150 , ROM 152 or other static memory and a memory controller 153 having a zone control register 154 which specifies, for each of eight memory zones, whether memory access commands received from microcontroller 60 (FIG. 1) are to be directed to RAM or ROM. In other examples, more or fewer memory zones may be employed. FIG. 2 also illustrates an exemplary virtual memory space map 156 having various memory zones. In the example of FIG. 2, the memory map covers 256K of memory. RAM 150 and ROM 152 each provide 256K of physical memory for a total of 512K. Zone control register 154 includes bits set to specify whether virtual memory within each of the predefined zones is mapped to RAM or ROM. To this end, the zone control register includes a sequence of eight bits, one bit for each of the eight predefined zones. If the zone control register bit for a zone is set to 1, all memory access commands specifying memory locations within that zone are routed to the RAM. If the bit is set to 0, then all memory access commands accessing memory within the zone are routed to ROM. The specific sequence of bits within the zone control register is set by the microcontroller or external device 102 based upon software operating therein.
Thus, 512K of physical memory is provided to correspond with 256K of virtual memory accessible by the microcontroller. With this implementation, software being developed is stored within RAM for the purposes of testing the operation of the software and the overall device. During testing, each of the bits of the zone control register is set to specify the RAM. Hence, during testing, all memory access commands of the microcontroller are automatically routed to RAM. Once the implantable device has been fully tested and all software and hardware components are functioning properly, the final version of software within the RAM is transferred to ROM, i.e., the ROM is hardwired to embody the final software design. Then, selected bits of the zone control register are reset to direct memory access commands to the ROM.
In this manner, the benefits of RAM are exploited during design, test, and debug of the implantable device, whereas the benefits of ROM are exploited within production copies of the device. More specifically, the dynamic capability of RAM is exploited during software development to permit the software to be repeatedly changed until any software bugs have been eliminated and the software is functioning properly. Moreover, if any changes to the hardware of the device are made during device development, which necessitate changes in software, the software can be readily changed or upgraded to accommodate the modified hardware. Within production units, however, the static storage aspect of ROM is exploited to ensure that the software of the production device cannot be accidentally corrupted or otherwise improperly modified, perhaps as a result of power surges within the implanted device or as a result of any software bugs which might corrupt software stored within RAM. Hence, the advantages of RAM and ROM storage devices are both exploited. Moreover, because the actual production device contains both RAM and ROM, the problems described above that can arise when switching from RAM chips within a test device to ROM chips within a production device are avoided, particularly problems arising when the number of RAM chips used during test is greater than the number of ROM chips used in the production device.
Another advantage of employing both RAM and ROM in the final production device is that, if software bugs are detected within the software incorporated within ROM, corrected software can be loaded into RAM, and the appropriate bits of the zone control register reset to reference the corrected software. For example, if a software bug is detected within software within zone 3 of the virtual memory map, corrected software is downloaded into zone 3 of the RAM from an external programmer via a telemetry unit and the bit within the zone control register corresponding to zone 3 is reset to identify RAM. Thereafter, whenever the microcontroller accesses memory locations within zone 3 , the memory access commands are automatically routed to RAM rather than ROM, thereby avoiding the defective software. Hence, software bug fixes are performed without requiring explantation of the device. As can be appreciated, if all software were stored only within ROM, the implanted device would need to be removed from the patient so that the ROM could be replaced with ROM containing corrected software.
Thus, selected portions of the virtual memory space are routed to either RAM or ROM depending upon the bits within the zone control register. However, any portions of memory that must remain dynamic are stored only within RAM. In one specific implementation, portions of the virtual memory space of the implantable device correspond with page zero, stack, mailbox, data and stored EIGM information. As this information is dynamic, memory zones containing the dynamic information are always routed to RAM. In one possible example, the page zero zone stores information for use in booting the microcontroller following a reset and may store dynamic status information and the like from a preceding session. Within the page zero zone, a copy of the zone control register bits may be stored to permit the device to reset with proper zone control bits. The stack zone provides a memory area for storing dynamic information used by software operating within the microcontroller. The mailbox zone provides for storage of certain types of communication information received from the external programmer. The data zone accommodates data used by the microcontroller during its operation and may store, for example, counts of the number of various events detected by the microcontroller, such as mode switching events, paced events, sensed events and the like. The stored IEGM data zone stores IEGM signals detected by the device while the device is operating to permit subsequent review by a physician during a follow-up session with the patient. Other uses may be provided for these various zones. For example, the page zero zone need not be used to store information for use in booting the microcontroller. Moreover, in other implementations, more or fewer zones may be exclusively mapped to RAM. The other zones not specifically labeled in FIG. 2 may be mapped to either RAM or ROM. Typically, these other zones store the actual operational software of the device for loading into the microcontroller subsequent to a reset or during an initial power up operation.
Another advantage of providing both RAM and ROM is that the overall virtual memory space for the device can be expanded to encompass both the RAM and the ROM. In the example wherein RAM and ROM both provide 256K of memory, the entire memory space may be expanded to as much as 512K by exploiting both RAM and ROM. Thus, for example, if a software upgrade is to be provided within the device, but the new software requires a greater amount of memory than can be accommodated within a total memory space of 256K, portions of RAM and ROM can be designated as both being accessible thereby expanding the overall memory space beyond 256K. This requires appropriate modification to the software controlling the zone control register to permit access to corresponding zones within both RAM and ROM. In this regard, the bits within the zone control register are dynamically controlled to switch back and forth between RAM and ROM. As one specific example, during a power up operation, various zone control bits may be set to point to ROM to permit software to be uploaded into the microcontroller from ROM. Then, once the software is operating within the microcontroller, the corresponding bits of the zone control register are set to RAM to permit the microcontroller to exploit the corresponding portion of RAM memory as dynamic memory for use in storing, for example, IEGM data or the like.
In other implementations, rather than using RAM as the dynamic memory, flash memory or electrically erasable and programmable ROM (EEPROM) is employed. Other types of static memory may alternatively be employed besides ROM. Also, although described with respect to an example wherein a single virtual memory space is employed, the principles of the invention may also be exploited within devices employing multiple virtual memory spaces and multiple corresponding physical memory devices. This may be desirable, for example, in devices having multiple microcontrollers. For example, a memory system may be provided generally as shown in FIG. 2 but with two sets of virtual memory spaces, each having corresponding RAM and ROM portions.
General operations performed using the dual RAM and ROM illustrated in FIG. 2 will now be briefly summarized with reference to the flow chart of FIG. 3 . At step 200 , an implantable medical device is fabricated having both RAM and ROM. At step 202 , software under development is loaded within RAM and tested. If changes need to be made to the software, step 203 , new software is loaded into the RAM at step 202 . Otherwise, at step 204 , the final production version of software is encoded within ROM. At step 206 , the device is implanted within a patient for use therein. If, at step 208 , the software needs to be upgraded, new software is downloaded into RAM at step 210 and the appropriate zone control register bits are reset to point to RAM.
The various functional components of the exemplary system may be implemented using any appropriate technology including, for example, microprocessors running software programs or application specific integrated circuits (ASICs) executing hard-wired logic operations. Although described primarily with respect to an ICD used in conjunction with an external programmer, aspects of the invention are applicable to other systems, such as systems employing other implantable medical devices or systems employing other types of external interfaces for use with the implantable device. The exemplary embodiments of the invention described herein are merely illustrative of the invention and should not be construed as limiting the scope of the invention.
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The implantable medical device is provided with typically equal portions of both random access memory (RAM) and read only memory (ROM) and a virtual memory space is defined equal to the amount of memory in one of the memory devices. In a specific example, the RAM and ROM provide 256K of memory each, with the virtual memory space also set to 256K. A zone control register is provided which specifies, for each of a set of predetermined zones within the virtual memory space, whether memory access commands are to be routed to RAM or ROM. Control bits within the zone control register may be reset to permit portions of memory to be remapped from one memory device to the other. By providing RAM and ROM each typically equal in size to the virtual memory space, software for use in the device may be tested and debugged using RAM then transferred to ROM for use in production devices. By providing dual RAM and ROM, software upgrades or software bug fixes are easily performed merely by downloading new software into RAM, then resetting the zone control register to point to RAM, rather than ROM. Additionally, when necessary, the overall virtual memory space may be expanded to encompass both the RAM and ROM thereby permitting access to greater quantities of memory.
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BACKGROUND OF THE INVENTION
a) Field of the Invention
This invention relates to a real image mode finder optical system.
b) Description of the Prior Art
The real image mode finder optical system can bring about a large magnification ratio from an adequate design, but nevertheless can diminish an effective aperture of the lens system and particularly the diameter of a front lens, so that it is largely used for a zoom finder. Further, the real image mode finder optical system needs some optical element to erect an image, which is broadly classified as a prism or a relay lens.
The variable magnification finder set forth in Japanese Patent Preliminary Publication No. Hei 1-131510, for instance, is the zoom finder making use of a Porro prism to erect the image. This arrangement is made so that the change of magnification is accomplished by a second lens unit and the correction of dipter by a thrid lens unit, thus having two moving lens units.
In addition to this, the use of a Dach prism and a mirror according to the optical path length and the layout of the arrangement is also known.
Also, like the variable magnification finder stated in Japanese Patent Preliminary Publication No. Hei 1-197717, the arrangement in which the correction of diopter is performed by a first lens unit and the change of magnification by a second lens unit is also available. Further, in the case of the mounting of the optical system, the method using the relay lens brings about increase of the overall length and therefore causes often the optical path to be bent by the mirror, with a view to incorporating effectively the optical system in a camera, like the finder stated in Japanese Utility Model Preliminary Publication No. Sho 64-13034, although not used exclusively for the finder. In this example, the lens system provided in front of the mirror is also used as a photographic lens system so that the change of magnification and the correction of diopter are attained by moving the plural lens units of the photographing lens system.
Each arrangement, however, described in the Hei 1-131510, Sho 64-13034 and Hei 1-197717 has two or more moving lens units as mentioned above and requires a driving mechanism such as a cam with resultant complicated design and manufacture.
In particular, the optical system employing the relay lens as described in each of the Sho 64-13034 and Hei 1-197717 requires to turn back the optical path when being intended for compaction, with the result that a return mirror will be required and the number of parts will be increased.
Although the number of parts may be reduced if the return mirror is moved to become a compensator, the direction of movement of the return mirror is complicated because the optical path is intricate and a device of avoiding the interference of the parts to be moved is required, thus making the design and manufacture difficult.
As such, it is proposed that a variable focal length lens, although not used yet in the real image mode finder optical system, is adopted in place of the moving lens unit.
For example, the variable magnification finder optical system set forth in Japanese Patent Preliminary Publication No. Sho 62-56918 is such that the lens units for the correction of diopter are replaced by the variable focal length lens into a single moving lens unit. Moreover, in each of an inverse Galilean finder stated in Japanese Patent Preliminary Publication No. Sho 61-77820, the variable magnification finder in Japanese Patent Preliminary Publication No. Sho 61-221720, and the lens in Japanese Patent Publication No. Sho 61-50281, the lens units for the change of magnification and the correction of diopter are replaced by the variable focal length lens to dispense with the moving lens units.
The foregoing Sho 61-77820, Sho 61-221720, and Sho 61-50281, however, involve problems that, since the change of the refracting power is made by the variation of the lens configuration, high electric energy will be consumed in order to maintain the lens configuration while being changed and deformation by gravity will be brought about. Furthermore, the arrangement stated in each of the Sho 61-77820 and Sho 61-221720 has encountered difficulties that, unless the lens has the transmittance equivalent to optical glass since it is necessary to be constructed with material corresponding to the thickness of the lens, the visual field of the finder colors, becomes dark, and fades.
Hence, the variable focal length lens designed so that the refracting power is changed by making use of the birefringent property of a liquid crystal to adjust a voltage applied from the external has been already proposed by Japanese Patent Preliminary Publication Nos. Sho 52-32348, Sho 54-99654, and Sho 59-224820.
As an example, a variable focal length liquid crystal lens stated in the foregoing Sho 59-224820 is used in such a way that the vibrating direction of a polarizing plate coincides with the direction of the longitudinal axis (optic axis) of liquid crystal molecules in an initial orientation of the liquid crystal. It follows from this that, in the state where the voltage is not applied, the liquid crystal lens exhibits the refracting power with respect to an extraordinary ray, while in the state where the voltage is sufficiently applied, enclosed liquid crystal molecules rotate to become parallel with the electric line of force and an apparent refracting power changes so that the lens exhibits the refracting power with respect to an ordinary ray. Further, in the intermediate application of voltage, it is possible to change continuously the refracting power in accordance with the value of the applied voltage.
Also, in Japanese Patent Preliminary Publication No. Sho 62-170933, a variable focal length mirror lens is proposed as not a transmission type but a reflection type.
Such a variable focal length lens utilizes its birefringent property, not to speak of the liquid crystal lens, and therefore is combined with the polarizing plate in general. Whereby, ordinary and extraordinary rays are separately used to derive the effect of the variable focal length. Unless the polarizing plate is employed, in the case of a positive lens by way of example, the light subjected to the refracting power relating to the ordinary ray and the light subjected to the refracting power relating to the extraordinary ray form two focal points, resulting in generation of a double image. For this reason, the polarizing plate has been indispensable for most of the variable focal length lenses.
In such conventional variable focal length lenses, however, there has been the defect that light (the amount of light) usable for the polarizing plate is reduced to a half of the required amount, with the resultant narrow range of use. For instance, the finder optical system set forth in the above Sho 62-56918 has had the defect that the visual field of the finder becomes dark because the polarizing plate is employed for the variable focal length lens.
Further, when light deviating from the direction of polarization is made incident, this optical system may change to the optical system having the same characteristics as the one including a polarizer and an analyzer. In such a case, the strain of the lens and the like of the optical system may also be viewed, so that there is the demand of general use of non-polarized light. The lens involving the conventional polarizing plate has been unable to fill this demand.
Moreover, a lens made with a birefringent material so that the optical axis of the lens is not parallel with the optic axis of the material has such a defect as to exhibit astigmatism even on the axis and a lens configuration free of aberration has been demanded.
In addition, any of the optical systems stated in the Sho 62-56918, Sho 61-77820, and Sho 61-221720 is based on the Galilean optical system or the inverse Galilean optical system and has also encountered the problem that, since the effective aperture becomes large with increasing magnification ratio, the optical system cannot be used for the design of a high magnification ratio.
SUMMARY OF THE INVENTION
It is, therefore, the object of the present invention to provide a real image mode finder optical system in which the reduction of the amount of light is minimized, the variation of characteristics by gravity is little, a small number of parts makes cost low, the strain of the lens and the like of the optical system is not viewed, aberrations are little produced, and the effective aperture of the entire optical system can be set at a minimum.
This object is accomplished, according to the present invention, by the arrangement that, in the real image mode finder optical system comprising an objective lens for forming an image of an object and an eyepiece for observing the image, the finder optical system is equipped with a liquid crystal type variable focal length mirror combined with a quarter-wave plate so that diopter change is corrected by the variation of the optical power of the variable focal length mirror.
According to the present invention, the variable focal length mirror functions as a compensator which does not move and consequently the number of parts is diminished. Further, the liquid crystal type variable focal length mirror combined with the quarter-wave plate utilizes natural light as a whole, so that, unlike the conventional variable focal length mirror involving the polarizing plate, the reduction of the amount of light is slight and the strain of the lens and the like of the optical system is not viewed. Moreover, since the layer of the liquid crystal is thin, the absorption of light is minimized and astigmatism is little produced. In this liquid crystal type variable focal length mirror, a driving power is low and the characteristics will not be changed by gravity. If distances among lens units are set to be practically afocal, the magnification change of an imaging system is slight even in the adjustment of the distances and a pupil position can be altered with comparative freedom, so that the effective aperture of the entire optical system can be set at a minimum.
This and other objects as well as the features and the advantages of the present invention will become apparent from the following detailed description of the preferred embodiment when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1C are views showing the arrangement of one embodiment of the real image mode finder optical system according to the present invention and the states in wide, standard and tele positions thereof;
FIG. 2 is a sectional view of a variable focal length mirror of the above embodiment; and
FIGS. 3 to 6 are explanatory views showing that it is more advantageous that a fourth lens unit is constructed as the variable focal length mirror in the embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In accordance with one embodiment shown in the drawings, the present invention will be described in detail below.
EMBODIMENT
FIGS. 1A-1C show the arrangement of the optical system of this embodiment and the states in wide, standard and tele positions.
Its data are as follows:
______________________________________ Refractive Abbe'sRadius of curvature Airspace index number______________________________________r.sub.1 = -193.17 d.sub.1 = 1.56 n.sub.1 = 1.49216 ν.sub.1 = 57.5r.sub.2 = 19.61 d.sub.2 = variabler.sub.3 = 27.01 d.sub.3 = 2.00 n.sub.2 = 1.72916 ν.sub.2 = 54.7r.sub.4 = -70.25 d.sub.4 = 1.21r.sub.5 = -13.20 d.sub.5 = 1.34 n.sub.3 = 1.80518 ν.sub.3 = 25.4r.sub.6 = -56.34 d.sub.6 = 1.00r.sub.7 = 60.59 d.sub.7 = 3.00 n.sub.4 = 1.49216 ν.sub.4 = 57.5r.sub.8 = -11.12(aspherical) d.sub.8 = variabler.sub.9 = 40.96 d.sub.9 = 1.00 n.sub.5 = 1.51633 ν .sub.5 = 64.2r.sub.10 = ∞ (reflectingsurface) d.sub.10 = 78.65r.sub.11 = 33.76 d.sub.11 = 1.00 n.sub.6 = 1.49216 ν.sub.6 = 57.5r.sub.12 = -37.30 [Fresnellens surface (liquidcrystal layer)] d.sub.12 = 0.01 n.sub.7 = 1.5-1.7 ν.sub.7 = 35-20r.sub.13 = ∞ (quarter-waveplate) d.sub.13 = 0.01 n.sub.8 = 1.6r.sub.14 = ∞ (reflectingsurface) d.sub.14 = 69.95r.sub.15 = 34.77 d.sub.15 = 3.92 n.sub.9 = 1.49216 ν.sub.8 = 57.5r.sub.16 = -34.77 d.sub.16 = 0.15r.sub.17 = 15.66(aspherical) d.sub.17 = 2.94 n.sub.10 = 1.49216 ν.sub.9 = 57.5r.sub.18 = 19.36Aspherical coefficient 8th surface a.sub.4 = 0.99800 × 10.sup.-4, a.sub.6 = -0.27700 × 10.sup.-6, a.sub.8 = 0.90600 × 10.sup.-817th surface a.sub.4 = -0.12198 × 10.sup.-4, a.sub.6 = -0.43095 × 10.sup.-7, a.sub.8 = -0.32416 × 10.sup.-9,Aspherical surface equation ##STR1##______________________________________
Here, first and second surfaces (r1 and r2) correspond to a first lens unit, third to eighth surfaces (r3 to r8) to a second lens unit, and ninth and tenth surfaces (r9 and r10) to a third lens unit. The tenth surface of the third lens unit is configured as a reflecting surface, at which the optical path is bent on the side of the first lens unit. Eleventh to fourteenth surfaces (r11 to r14) correspond to a fourth lens unit which is the variable focal length mirror comprising a liquid crystal lens, and the fourteenth surface (r14) is configured as the reflecting surface, at which the optical path is bent on the opposite side of the first lens unit (toward a fifth lens unit). Fifteenth to eighteenth surfaces (r15 to r18) constitute the fifth lens unit.
The paraxial arrangement of this embodiment is as shown in Table 1.
TABLE 1__________________________________________________________________________ 1st 2nd 3rd 4th 5thState lens unit lens unit lens unit lens unit lens unit γ diopter__________________________________________________________________________Wide Focal -36.08 23.03 40.00 35.14 27.28 0.621 -0.504 length Princi- 29.79 68.99 80.00 66.91 pal pt. distanceStan- Focal -36.08 23.03 40.00 40.00 27.28 0.951 -0.507dard length Princi- 19.42 79.36 80.00 66.91 pal pt. distanceTele Focal -36.08 23.03 40.00 43.10 27.28 1.366 -0.509 length Princi- 11.19 87.59 80.00 66.91 pal pt. distance__________________________________________________________________________
The first lens unit is fixed during the change of magnification, the second lens unit varies the magnification by moving along the optical axis, the third lens unit is also fixed during the change of magnification, the fourth lens unit, although spatially fixed during the change of magnification, is such that the optical power changes to maintain constantly the diopter, and the fifth lens power is fixed during the change of magnification. Also, the distance between the third lens unit and the fourth lens unit is set to be afocal. Reference symbol γ represents the angular magnification of the entire system.
Also, airspaces d2 and d8 change as shown in Table 2.
TABLE 2______________________________________ AirspaceState d2 d8______________________________________Wide 24.35 66.96Standard 13.98 77.32Tele 5.75 85.56______________________________________
FIG. 2 shows a detailed structure of the variable focal length mirror which is the fourth lens unit of the embodiment. It comprises a nematic liquid crystal 4 which is an optical material exhibiting the birefringent property, enclosed in a Fresnel lens-shaped space formed by cementing together a transparent substrate 1 and a quarter-wave plate 2 through an insulating spacer 3. Between the transparent substrate 1 and the quarter-wave plate 2 are formed ITO transparent conductive layers 5, 6 and liquid crystal orientation films 7, 8 of polyvinyl alcohol. A reflecting mirror 9 is provided on the opposite side of the liquid crystal layer with respect to the quarter-wave plate 2 and a substrate 10 for supporting the quarter-wave plate 2 is further provided in such a manner that the reflecting mirror 9 is sandwiched between them. Reference numeral 13 represents a sealing material and 14 denotes an adhesive, by which the liquid crystal 4 after being injected into the space is sealed. The transparent conductive layers 5, 6 are constructed so that a voltage can be applied, between them, from an alternating voltage source 12 through a resistor 11 for voltage adjustment and so that the refracting power of the liquid crystal 4 can be controlled by adjusting the voltage being applied between the transparent conductive layers.
That is, when the applied voltage is zero, as shown in FIG. 2, the longitudinal axis of each liquid crystal molecule is substantially normal to an optical axis O of the optical system, and a polarized light component following a vibrating direction parallel to the longitudinal axis of the liquid crystal molecule, of natural light incident on the variable focal length mirror, is subjected to a strong refracting action at the time of its incidence in virtue of the liquid crystal layer. When it traverses the quarter-wave plate 2, is reflected from the reflecting mirror 9, and tranverses again the quarter-wave plate 2, it is converted into a polarized light component following the vibrating direction normal to the longitudinal axis of the liquid crystal and is subjected to a weak refracting action at the time of its emergence by the liquid crystal layer. Further, although a polarized light component normal to the longitudinal axis of the liquid crystal, of the incident natural light, is subjected to only a weak refracting action on the incidence by the liquid crystal layer, it is already converted into a polarized light component in a normal vibrating direction on the emergence in virtue of the behavior of the quarter-wave plate 2, so that it is subjected to a strong refracting action by the liquid crystal layer. In either case, therefore, the incident light will be subjected to a strong refracting action.
When the applied voltage is high, on the other hand, the longitudinal axis of each liquid crystal molecule becomes parallel to the optical axis O of the optical system so that the polarized light component in any vibrating direction, of the natural light incident on the variable focal length mirror, is subjected to only a weak refracting action in either of the incidence or the emergence.
When the applied voltage is low, the polarized light component is subjected to the refracting action as an approximate average of the cases where the applied voltage is zero and high.
Individual states mentioned above are shown in Table 3.
TABLE 3______________________________________State Focal length Refractive index Applied voltage______________________________________Wide 34.14 1.70000 0Standard 40.00 1.63158 LowTele 43.10 1.50000 High______________________________________
Also, the radii of curvature r11, r12, r13, and r14 of the eleventh, twelfth, thirteenth, and fourteenth surfaces correspond to those of the surface on the airspace side of the transparent substrate 1, the surface on the liquid crystal side of the transparent substrate 1, the surface on the liquid crystal side of the quarter-wave plate 2, and the surface of the reflecting mirror 9, respectively, and the ITO transparent conductive layers 5, 6 and the liquid crystal orientation films 7, 8 of polyvinyl alcohol have the radii of curvature equivalent to the above corresponding surfaces. Further, the airspaces d11, d12, and d13 among the eleventh, twelfth, thirteenth, and fourteenth surfaces and the refractive indices n11, n12, and n13 are the values relative to the transparent substrate 1, the liquid crystal layer 4, and the quarter-wave plate 2, respectively, and the thicknesses of the ITO transparent conductive layers 5, 6 and the liquid crystal orientation films 7, 8 of polyvinyl alcohol are so thin as to be negligible in the above data.
The embodiment is constructed as described above and the image point of the first and second lens units of the embodiment moves toward an object over the range from the wide position to the tele position. A compound focal length of the first and second lens units is 19.394 mm at the wide position and 34.279 mm at the tele position which changes 1.77 times that of the case of the wide position and this change is attributed to the change of magnification of the second lens unit.
The angular magnification γ of the entire system, on the other hand, changes 2,20 times from 0.621-fold at the wide position to 1.366-fold at the tele position (refer to Table 1). The changes of the compound focal length and the magnification are caused by the magnification changes of the third and fourth lens units. This reason is that, since the fourth lens unit is constructed as the variable focal length mirror, the magnification change of the entire system has been made larger than that of the second lens unit.
If, contrary, the focal length of the fourth lens unit is fixed at 40 mm and the third lens unit is constructed as the variable focal length mirror, the angular magnification γ of the entire optical system changes 1.39 times over the range from 0.858-fold at the wide position to 1.194-fold at the tele position and, as a result, the magnification change of the entire system will become smaller than that of the second lens unit.
Also, in the case of such a power arrangement that, in contrast to the embodiment, the image point of the first and second lens units moves toward the eye when the magnification varies from the wide position to the tele position, it is evident paraxially that the construction of the third lens unit as the variable focal length mirror is more advantageous to the magnification change.
The foregoing will now be explained in detail.
FIG. 3 shows the paraxial arrangement of two positive lenses (the third and fourth lens units in the embodiment) maintaining the imaging relationship of a finite distance between the object and the image. The distance between a front lens unit (the third lens unit) and an object point O is represented by S1, the principal point distance between two lenses (the third and fourth lens units) by d, the distance from the front lens unit to an image point I' of the front lens unit where a rear lens unit (the fourth lens unit) is neglected, by S1', the distance from the rear lens unit to the object point (I') of the rear lens unit where the front lens unit is neglected, by S2, and the distance from the rear lens unit to an image point I formed by both lens units, by S2'. In this case, a compound magnification β of the preceding arrangement is calculated from the equation shown in the figure.
FIG. 4 depicts the situation where the positions of the object point O, two lens units and the image point I are constant and the focal length of the two lens units is varied to thereby change the compound magnification β. If the compound magnification β is divided into a magnification β1 caused by the front lens unit and a magnification β2 by the rear lens unit, the magnificent β1 will become constant and the change of the compound magnification β will depend on only the change of the magnification β2. As is evident from the figure, it is noted that the condition changes depending on whether the distance S1' is positive or negative.
Also, the meaning of 0>S1' described in the figure is as follows:
In FIG. 3., when the object point O is closer to the front lens unit than the case where the value of the distance S1 coincides with the focal length of the front lens unit (S1'=∞), the light beam passing through the front lens unit comes to divergent light with the resultant virtual image between the front lens unit and the object point O. That is, since the distance S1' exists before the front lens unit, it takes a negative value (0>S1').
FIGS. 5 and 6 show the situations that when the object point O moves, three positions of the two lens units and the image point I are constantly maintained by changing the focal length of either lens unit. That the position of the image point I is constantly maintained in this manner is hereinafter referred to as the "correction for the image point position". In either FIGS. 5 or 6, the distance between the two lens units becomes afocal (S1=∞) in a wide position state W. Further, two tele position states T and T' shown in FIG. 5 each indicate the case where the object point O has moved toward the left and those in FIG. 6 each indicate the case where the object point O has moved toward the right. In either FIGS. 5 or 6, the state T shows that the focal length of the front lens unit has been altered and the state T' shows that the focal length of the rear lens unit has been altered.
Now, in FIG. 5, the magnification β in the case of the state T will be compared with that of the state T'.
In this instance, if the correction for the image point position is made by the front lens unit, the value of the distance S1' will be infinitely maintained, while on the other hand, if the correction is made by the rear lens unit, the value of the distance S1' will be made positive. Thus, from the discussion of FIG. 4, it is seen that the way of making positive the value of the S1', namely, the correction for the image point position by the rear lens unit causes the magnification β of the system to be increased.
Next, in FIG. 6, the magnification β in the case of the state T will be compared with that of the state T'.
In this case, if the correction for the image point position is made by the front lens unit, the value of the distance S1' will be infinitely maintained, whereas if the correction is made by the rear lens unit, the value of the distance S1' will be made negative. It is thus seen from the discussion of FIG. 4 that the way of maintaining infinitely the value of the distance S1', namely, the correction for the image point position by the front lens unit causes the magnification β of the system to be increased.
Now, in the case where such a lens system is applied to the arrangement of the zoom lens, when the absolute value of the compound focal length of all the lens units located before the two lens units increases in virtue of the two lens units, it is desirable that the compound magnification of the two lens units becomes high and, contrary, even when the compound magnification diminishes, it is favorable that its diminishing extent is smaller since the magnification change of the entire system can be made large.
In this embodiment, the situation where the compound focal length of the third and fourth lens units is extended corresponds to that of FIG. 5 because the compound image point of the first and second lens units is shifted toward the object. In the embodiment, therefore, if the diopter is adjusted by either one of the third and fourth lens units, it is more favorable that the diopter adjustment is made by the fourth lens unit and, in fact, it has been done so.
Also, by changing properly the power of the third lens unit in accordance with the variation of the power of the fourth lens unit, a more advantageous magnification change is available.
Further, although the liquid crystal type variable focal length mirror in the embodiment has the negative power, the same effect is brougt about even in the combination with the liquid crystal type variable focal length mirror of the positive power.
The structure and function of the embodiment have been explained as the above. Briefly, in the embodiment, the variable focal length mirror of the fourth lens unit functions as the compensator which does not move, so that the number of parts is reduced. Further, since the liquid crystal type variable focal length mirror combined with the quarter-wave plate makes use of natural light as a whole, unlike the conventional variable focal length mirror involving the polarizing plate, the reduction of the amount of light is slight and the strain of the lens and the like of the optical system is not viewed. Moreover, since the layer of the liquid crystal is thin, the absorption of light is minimized and astigmatism is little produced. This liquid crystal type variable focal length mirror is such that a driving power is low and the characteristics are not changed by gravity.
For the optical system having considerable length as in the embodiment, the connection with the pupil is of importance. In the embodiment, since the distance between the third and fourth lens units is set to be substantially afocal, the change relative to the magnification of the imaging system is slight even though the distance between the third and fourth lens units is adjusted. As a result, the pupil position can be changed with comparative freedom by adjusting the distance between the third and fourth lens units, so that the effective aperture of the entire optical system can be set at a minimum.
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A real image mode optical system includes an objective lens forming an image of an object and an eyepiece for observing the image and is provided with a variable focal length mirror which dispenses with any polarizing plate so that a diopter change can be corrected due to the change of its optical power. Accordingly, the real image mode optical system has many advantages important for practical use that the reduction of the amount of light is slight, the characteristics are little changed by gravity, the number of parts is small with low manufacturing costs, the strain of the lens and the like of the optical system is not viewed, aberrations are little produced, and the effective aperture of the entire optical system can be set at a minimum.
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RELATED APPLICATIONS
[0001] This application is a continuation-in-part application of U.S. patent application Ser. No. 11/226,836 filed Sep. 14, 2005, which is a continuation of U.S. patent application Ser. No. 10/832,053 filed Apr. 26, 2004 which claims the benefit of U.S. Provisional Application Ser. No. 60/466,979 filed May 1, 2003 under 35 U.S.C. § 119(e) for all commonly disclosed subject matter. U.S. Provisional Application Ser. No. 60/466,979 is expressly incorporated herein by reference in its entirety to form part of the present disclosure.
FIELD OF THE INVENTION
[0002] This invention relates to seals for sealing a circumferential gap between two machine components that are relatively rotatable with respect to each other, and, more particularly, to a hybrid brush seal having seal bristles mounted in a ring shape on a first machine component with bristle ends directed at the sealing surface of the second, rotating machine component. The bristle ends are kept from direct contact with the rotating machine component via one or more shoes which create a non-contact seal with the rotating machine component which is enhanced by the imposition of one or more spring elements connected between the machine component and shoes.
BACKGROUND OF THE INVENTION
[0003] Turbomachinery, such as gas turbine engines employed in aircraft, currently is dependent on either labyrinth (see FIGS. 1A-1E ), brush (see FIGS. 2A and 2B ) or carbon seals for critical applications. Labyrinth seals provide adequate sealing, however, they are extremely dependent on maintaining radial tolerances at all points of engine operation. The radial clearance must take into account factors such as thermal expansion, shaft motion, tolerance stack-ups, rub tolerance, etc. Minimization of seal clearance is necessary to achieve maximum labyrinth seal effectiveness. In addition to increased leakage if clearances are not maintained, such as during a high-G maneuver, there is the potential for increases in engine vibration. Straight-thru labyrinth seals ( FIG. 1A ) are the most sensitive to clearance changes, with large clearances resulting in a carryover effect. Stepped labyrinth seals ( FIGS. 1B and 1C ) are very dependent on axial clearances, as well as radial clearances, which limits the number of teeth possible on each land. Pregrooved labyrinth seals ( FIG. 1D ) are dependent on both axial and radial clearances and must have an axial clearance less than twice the radial clearance to provide better leakage performance than stepped seals.
[0004] Other problems associated with labyrinth seals arise from heat generation due to knife edge to seal land rub, debris from hardcoated knife edges or seal lands being carried through engine passages, and excessive engine vibration. When seal teeth rub against seal lands, it is possible to generate large amounts of heat. This heat may result in reduced material strength and may even cause destruction of the seal if heat conducted to the rotor causes further interference. It is possible to reduce heat generation using abradable seal lands, however, they must not be used in situations where rub debris will be carried by leakage air directly into critical areas such as bearing compartments or carbon seal rubbing contacts. This also holds true for hardcoats applied to knife edges to increase rub capability. Other difficulties with hardcoated knife edges include low cycle fatigue life debits, rub induced tooth-edge cracking, and the possibility of handling damage. Engine vibration is another factor to be considered when implementing labyrinth seals. As mentioned previously, this vibration can be caused by improper maintenance of radial clearances. However, it can also be affected by the spacing of labyrinth seal teeth, which can produce harmonics and result in high vibratory stresses.
[0005] In comparison to labyrinth seals, brush seals can offer very low leakage rates. For example, flow past a single stage brush seal is approximately equal to a four knife edge labyrinth seal at the same clearance. Brush seals are also not as dependent on radial clearances as labyrinth seals. Leakage equivalent to approximately a 2 to 3 mil gap is relatively constant over a large range of wire-rotor interferences. However, with current technology, all brush seals will eventually wear to line on line contact at the point of greatest initial interference. Great care must be taken to insure that the brush seal backing plate does not contact the rotor under any circumstances. It is possible for severing of the rotor to occur from this type of contact. In addition, undue wire wear may result in flow increases up to 800% and factors such as changes in extreme interference, temperature and pressure loads, and rubbing speeds must be taken into account when determining seal life.
[0006] The design for common brush seals, as seen in FIGS. 2A and 2B , is usually an assembly of densely packed flexible wires sandwiched between two plates. The free ends of the wires protrude beyond the plates and contact a land or runner, with a small radial interference to form the seal. The wires are angled so that the free ends point in the same direction as the movement of the runner. Brush seals are sized to maintain a tight diametral fit throughout their useful life and to accommodate the greatest combination of axial movement of the brush relative to the rotor.
[0007] Brush seals may be used in a wide variety of applications. Although brush seal leakage generally decreases with exposure to repeated pressure loading, incorporating brush seals where extreme pressure loading occurs may cause a “blow over” condition resulting in permanent deformation of the seal wires. Brush seals have been used in sealing bearing compartments, however coke on the wires may result in accelerated wear and their leakage rate is higher than that of carbon seals.
[0008] One additional limitation of brush seals is that they are essentially unidirectional in operation, i.e., due to the angulation of the individual wires, such seals must be oriented in the direction of rotation of the moving element. Rotation of the moving element or rotor in the opposite direction, against the angulation of the wires, can result in permanent damage and/or failure of the seal. In the particular application of the seals required in the engine of a V-22 Osprey aircraft, for example, it is noted that during the blade fold wing stow operation, the engine rotates in reverse at very low rpm's. This is required to align rotor blades when stowing wings. This procedure is performed for creating a smaller aircraft footprint onboard an aircraft carrier. Reverse rotation of the engine would damage or create failure of brush seals such as those depicted in FIGS. 2A and 2B .
[0009] One attempt to limit wear of brush seals is disclosed in U.S. Pat. No. 5,026,252 to Hoffelner in which a sliding ring is interposed between the bristle pack of the seal and the moving element or rotor to avoid direct contact therebetween. The bristle ends are received within a circumferential groove in the sliding ring and are allowed to freely float or move within such groove. Although bristle wear may be reduced in this design, it is believed that the seal created at the interface of the sliding ring and rotor is unsatisfactory.
[0010] An improvement of prior brush seals, including that disclosed in the '252 patent to Hoffelner noted above, is found in my U.S. Pat. No. 6,428,009. In that design, one end of each of a plurality of seal bristles is fixed in an annular shape and mounted to the fixed machine component or stator while their opposite ends are attached to a number of individual shoes located proximate the rotating machine component or rotor. Prior to shaft rotation, the shoes are in contact with the rotor surface with preferably the leading edge of each shoe set to have less contact than the trailing edge of the shoe. When the rotor begins to rotate, a hydrodynamic wedge is created which lifts the shoe slightly off the surface of the shaft allowing the shoe to effectively float over the shaft at a design gap. It has been found that one limitation of the design disclosed in the '009 patent is a potential problem with “roll over” under pressure load, i.e. the shoes can tip or pivot in the axial direction thus creating a leakage path.
[0011] Carbon seals are generally used to provide sealing of oil compartments and to protect oil systems from hot air and contamination. Their low leakage rates in comparison to labyrinth or brush seals are well-suited to this application, however they are very sensitive to pressure balances and tolerance stack-ups. Pressure gradients at all operating conditions and especially at low power and idle conditions must be taken into account when considering the use of carbon seals. Carbon seals must be designed to have a sufficiently thick seal plate and the axial stack load path must pass through the plate as straight as possible to prevent coning of the seal. Another consideration with carbon seals is the potential for seepage, weepage or trapped oil. Provisions must be made to eliminate these conditions which may result in oil fire, rotor vibration, and severe corrosion.
[0012] According to the Advanced Subsonic Technology Initiative as presented at the NASA Lewis Research Center Seals Workshop, development of advanced sealing techniques to replace the current seal technologies described above will provide high returns on technology investments. These returns include reducing direct operating costs by up to 5%, reducing engine fuel burn up to 10%, reducing engine oxides of emission by over 50%, and reducing noise by 7 dB. For example, spending only a fraction of the costs needed to redesign and re-qualify complete compressor or turbine components on advanced seal development can achieve comparable performance improvements. In fact, engine studies have shown that by applying advanced seals techniques to just a few locations can result in reduction of 2.5% in SFC.
SUMMARY OF THE INVENTION
[0013] A hybrid brush seal is provided which is generally similar to the one disclosed in my prior U.S. Pat. No. 6,428,009, but which overcomes the tendency of the shoes to roll over under the application of a pressure load.
[0014] In one presently preferred embodiment, two sets or bundles of seal bristles are axially spaced from one another, i.e. in the direction of the longitudinal axis of two relatively rotating machine components such as the rotor and stator of a gas turbine engine. One end of the seal bristles in each bundle is fixed in an annular shape to either the stator or the rotor, while the opposite end of the seal bristles in each bundle extends to one or more shoes circumferentially disposed about the other machine component. The shoes are located with respect to the rotor or stator to create a seal between the two while avoiding contact of the seal bristles with the relatively rotating component. Each of the shoes is connected at discrete points to the end of the seal bristles such that the leading edge of the shoe is oriented to have less contact with the rotor or the stator than the trailing edge of the shoe. In one embodiment, each shoe is connected at two spaced locations to the abutting seal bristles by electron beam welding or similar mounting techniques, thus creating two hinge points for the shoe to translate about.
[0015] In alternative embodiments, one or more bundles or seal bristles are mounted at one end to either the rotor or the stator, and their opposite end extends toward one or more shoes located proximate the other of the rotor or stator. A spring element is connected between the shoes and the rotor or stator which is flexible in the radial direction, but axially stiff. The spring element functions to assist in preventing roll over of the shoes with respect to the rotor or stator where it is located, thus maintaining an effective seal under pressure load. In one embodiment, stops are provided to limit the extent of radial motion of the shoe with respect to the rotor or stator. It is contemplated that the ends of the seal bristles proximate the shoes can be either connected to the shoes such as by welding or other means of attachment, or spaced from the shoes. In either case, the seal bristles act as a secondary seal between the rotor and stator in combination with the shoes.
[0016] In operation, the shoes of this invention function very similarly to that of a tilting pad bearing shoe. Prior to rotation of the rotor, the shoe is in contact with the rotor or stator surface. Because the leading edge of the shoe has less contact with the rotor or stator than its trailing edge, when the rotor begins to rotate a hydrodynamic wedge is created that lifts the shoe slightly off of the surface of the rotor or stator. Consequently, the shoe “floats” over the rotor or stator at a design gap, such as 0.0005 to 0.0010 inches, thus forming a non-contact seal.
[0017] The advantages of the hybrid brush seal of this invention are many. It has the same sealing characteristics of existing brush seals, but will never change in performance due to bristle wear. The brush seal backing plate can be moved further outboard of the I.D. because the shoe prevents the bristles from bending over in high pressure applications. Each shoe may have a certain amount of interference with the rotor or stator prior to rotation. Thus, the seal can be slightly off center during assembly but once rotation begins, each pad will lift-off. Hence, tight tolerances can be relaxed.
[0018] The hybrid seal of this invention can be utilized in all seal applications, including labyrinth, brush and carbon. The robust design eliminates the careful handling now required of carbon seals utilized in lube system compartments. This seal may allow the engine designer to utilize less parts in the assembly as this seal will permit “blind” assemblies to occur.
[0019] The following table provides a comparison of the seal of the subject invention with currently available technology.
Dependence Contamination Seal Type Wear Rate Leakage on Clearances Potential Labyrinth High Low High High Seals Brush Seals Medium Low Medium Medium Carbon Seals Medium Very Low High Low Hybrid Seal Low Low Low Low
DESCRIPTION OF THE DRAWINGS
[0020] The structure, operation and advantages of this invention will become further apparent upon consideration of the following description, taken in conjunction with the accompanying drawings, wherein:
[0021] FIGS. 1A-1E are schematic views of a number of prior art labyrinth seals;
[0022] FIGS. 2A and 2B depict views of a prior art brush seal;
[0023] FIG. 3 is a cross sectional view of one embodiment of the hybrid brush seal of this invention;
[0024] FIG. 4 is a schematic, elevational view of the seal shown in FIG. 3 ;
[0025] FIG. 5 is a view similar to FIG. 4 , except of an alternative embodiment herein;
[0026] FIG. 6 is a schematic, elevational view of an alternative embodiment of the seal herein employing a single bundle of seal bristles and axially spaced spring elements;
[0027] FIG. 7 is a view similar to FIG. 6 , except employing two sets of axially spaced seal bristles;
[0028] FIG. 8 is a cross sectional view of a further embodiment of the brush seal of this invention;
[0029] FIG. 9 is a cross sectional view taken generally along line 9 - 9 of FIG. 8 ; and
[0030] FIG. 10 is a cross sectional view of another embodiment of this invention, similar to FIGS. 8 and 9 , but including stops to limit the radial movement of the shoes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] Referring initially to FIGS. 3-5 , the hybrid bush seal 10 of this invention is intended to create a seal between two relatively rotating components, namely, a fixed stator 12 and a rotating rotor 14 . In this embodiment, the seal 10 comprises a first group or bundle 16 of seal bristles 18 and a second bundle 20 of seal bristles 18 which are axially spaced from the first bundle 16 . As used herein, the term “axial” or “axially spaced” refers to a direction along the longitudinal axis of the stator 12 and rotor 14 , e.g. axis 22 in FIG. 3 , whereas “radial” refers to a direction perpendicular to the longitudinal axis 22 .
[0032] The seal bristles 18 in each bundle 16 and 20 have an inner end 24 and an outer end 26 . In the embodiment illustrated in FIGS. 3 and 4 , the outer end 26 of the seal bristles 18 in each bundle 16 , 20 is affixed to the stator 12 . For purposes of the present discussion, the construction and operation of the seal 10 herein is described with the seal bristles 18 in that orientation. It should be understood, however, that the inner end 24 of the seal bristles 18 could be affixed to the rotor 14 . Preferably, the seal bristles 18 are mounted to the stator 12 or rotor 14 by clamping, welding, brazing or other means of affixation. The seal bristles 18 in each bundle 16 and 20 are arranged in an annular shape corresponding to the circumferential gap between the stator 12 and rotor 14 . As best seen in FIGS. 4 and 5 , a spacer plate 28 is located in the axial space between the seal bristle bundles 16 and 20 . The seal bristles 18 in bundle 16 are captured between a high pressure backing plate 30 associated with the stator 12 and the spacer plate 28 , whereas the seal bristles 18 in bundle 20 extend between a second spacer plate 31 and a low pressure backing plate 32 .
[0033] In one presently preferred embodiment, the seal bristles 18 are formed of a wire material, but it is contemplated that different materials may be utilized depending upon environmental conditions of the particular sealing application. In the past, brush seal materials, including the seal bristles, were chosen primarily for their high temperature and wear capability properties. The bristle seals 18 of this invention do not contact the rotor 14 , as discussed below, and therefore different wear characteristics and other considerations are involved in the selection of appropriate materials for the bristle seals 18 as compared to conventional brush seals. The bristle seal 18 geometry may be angled in the direction of rotation of the rotor 14 , or, alternatively, the bristle seals 18 may be straight and have varied angles. The bristle seals 18 may be round, square, rectangular or other shapes, and, if round, the diameter of each bristle seal 18 can be varied depending on the nature of the sealing environment. The outer end 26 of the bristle seals 18 in each bundle 16 and 20 may be fused together or free to move independently. Further, the number of seal bristles 18 within each bundle 16 and 20 can be varied with the understanding that more seal bristles 18 generally leads to improved sealing.
[0034] The inner end 24 of the seal bristles 18 in each bundle abut one or more shoes 34 located in sealing relationship to the rotor 14 . In the embodiment of FIG. 4 , the shoes 34 are formed with axially spaced ridges 36 and 38 . One side of the bundle 16 of seal bristles 18 abuts the ridge 36 , and one side of the bundle 20 of seal bristles 18 abuts the ridge 38 . FIG. 5 depicts a slightly different construction of shoes 34 in which the ridge 36 is the same as that in FIG. 4 , but a ridge 40 is formed on the shoes 34 in position to contact the opposite side of the bundle 20 of seal bristles 18 compared to the FIG. 4 embodiment. In both cases, each shoe 34 is attached at discrete locations to the abutting seal bristles 18 such as by welding, brazing, clamping or other means. The arc length, width, height, geometry and surface characteristics of the shoes 34 can be varied to enhance hydrodynamic pressure between the rotor 14 and stator 12 , to balance the static pressures within the system to vary the pressure sealing capabilities of the seal 10 and for other purposes. Preferably, the shoes 34 are made from sheet metal stampings or similar materials, to reduce manufacturing costs.
[0035] Referring now to FIGS. 6-9 , alternative embodiments of a brush seal of this invention are shown. In FIG. 6 , a brush seal 40 is shown in which a single bundle 42 of seal bristles 18 is located between a high pressure backing plate 44 and a low pressure backing plate 46 . For purposes of the present discussion, and consistent with the description of the previous embodiments, an outer end 48 of each seal bristle 18 in bundle 42 is mounted to the stator 12 while the inner end 50 extends toward the rotor 14 . It should be understood that the seal bristles 18 in bundle 42 could be affixed to the rotor 14 instead of the stator 12 .
[0036] In the embodiments of FIGS. 3-5 , axial rigidity and radial compliance of the seal 10 is provided by the seal bristles 18 in the bundles 16 and 20 through their connection between the stator 12 and shoes 34 . In the embodiment of FIG. 6 , the seal bristles 18 in the bundle 42 need not be connected to a shoe 34 . Instead, a spring element 52 is connected between the high pressure backing plate 44 and the shoe 34 . The spring element 52 provides essentially the same resistance to roll over of the seal 40 as the bundles 16 and 20 of seal bristles 18 in the seal 10 of FIGS. 3-5 . Preferably, the spring element 52 is formed of spring steel or other material which is flexible in the radial direction but stiff in the axial direction.
[0037] The embodiment of FIG. 7 depicts a seal 55 which is similar to the seal 40 of FIG. 6 , except that two axially spaced bundles 56 and 58 of seal bristles 18 are employed instead of one. The bundle 56 of seal bristles 18 is retained between a low pressure backing plate 60 and a spacer plate 62 , whereas the bundle 58 is retained between a second spacer plate 64 and a high pressure backing plate 66 . As in the embodiment of FIG. 6 , the bristles 18 of each bundle 56 , 58 need not be connected to a shoe 34 . Axial rigidity and radial compliance are provided primarily by a spring element 68 connected between the low pressure backing plate 60 and shoe 34 , and a second spring element 70 connected between the high pressure backing plate 66 and the shoe 34 .
[0038] Referring now to FIGS. 8 and 9 , a still further embodiment of a seal 72 according to this invention is shown. The seal 72 is similar to that of seals 40 and 55 except for the spring elements 74 . Each spring element 74 is essentially a rectangular-shaped beam with an outer band 76 radially spaced from an inner band 78 . One end of each of the bands 76 and 78 is connected to a seat 80 formed in the stator 12 , and the opposite end of bands 76 , 78 mounts to a ridge 82 formed in a shoe 34 . The spring element 74 functions to maintain the shoe 34 in sealing relationship with the rotor 14 in the same manner as the spring elements 52 and 68 , 70 . A bundle 72 of seal bristles 18 is fixed at its outer end to the stator 12 , and the inner end of each seal bristle 18 extends toward the shoe 34 where it may or may not be affixed thereto. For purposes of illustration, three spring elements 74 each associated with a shoe 34 are shown in FIG. 8 .
[0039] A variation of the seal 72 described above in connection with a discussion of FIGS. 8 and 9 is shown in FIG. 10 . Under some operating conditions, particularly at higher pressures, it is desirable to limit the extent of axial movement of the shoe 34 with respect to the rotor 14 to maintain tolerances, e.g. the spacing between the shoe 34 and the facing surface of the rotor 14 . The seal 90 of FIG. 10 includes a number of circumferentially spaced springs 92 , the detail of one of which is shown in FIG. 10 . Each spring 92 is formed with an inner band 94 and an outer band 96 radially outwardly spaced from the inner band 94 . One end of each of the bands 94 , 96 is mounted to or integrally formed with the stator 12 and the opposite end thereof is connected to a first stop 98 . The first stop 98 includes a strip 99 which is connected to a shoe 34 (one of which is shown on FIG. 10 ), and has an arm 100 opposite the shoe 34 which may be received within a recess 102 formed in the stator 12 . The recess 102 has a shoulder 104 positioned in alignment with the arm 100 of the first stop 98 .
[0040] A second stop 106 is connected to or integrally formed with the strip 99 , and, hence connects to the shoe 34 . The second stop 106 is circumferentially spaced from the first stop 98 in a position near the point at which the inner and outer bands 94 , 96 connect to the stator 12 . The second stop 106 is formed with an arm 108 which may be received within a recess 110 in the stator 12 . The recess 110 has a shoulder 112 positioned in alignment with the arm 108 of second stop 106 .
[0041] The purpose of first and second stops 98 and 106 is to limit the extent of radially inward and outward movement of the shoe 34 with respect to the rotor 14 . A gap is provided between the arm 100 of first stop 98 and the shoulder 114 , and between the arm 108 of second stop 106 and shoulder 112 , such that the shoe 34 can move radially inwardly relative to the rotor 14 . Such inward motion is limited by engagement of the arms 100 , 108 with shoulders 104 and 112 , respectively, to prevent the shoe 34 from contacting the rotor 14 or exceeding design tolerances for the gap between the two. The arms 100 and 108 also contact the stator 12 in the event the shoe 34 moves radially outwardly relative to the rotor 14 , to limit movement of the shoe 34 in that direction.
[0042] In each of the embodiments of FIGS. 6-10 , the seal bristles 18 form essentially a secondary seal. The shoes 34 are maintained in position with respect to the stator 12 and rotor 14 by the spring elements 52 , 68 , 70 , 74 and 92 , which cooperate with the bristle bundles to resist roll over.
[0043] While the invention has been described with reference to a preferred embodiment, it should be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof.
[0044] For example, it has been found advantageous to provide a flow path in the shoes 34 of this invention to assist in balancing static pressure in the system. This flow path can take the form of a step 84 formed in the shoe 34 , as depicted in FIG. 6 .
[0045] Therefore, it is intended that the invention not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out the invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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A hybrid brush seal is provided for sealing a circumferential gap between two machine components that are relatively rotatable with respect to each other having seal bristles mounted in a ring shape on a first machine component with bristle ends directed at the sealing surface of the second, rotating machine component. The bristle ends are kept from direct contact with the rotating machine component via one or more shoes which create a non-contact seal with the rotating machine component which is enhanced by the imposition of one or more spring elements connected between the machine component and shoes.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority benefit of U.S. Provisional Patent Application No. 61/639,455 filed on Apr. 27, 2012 entitled “Method and Apparatus for Controlling the Flow of Well Bore Returns”, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention is directed to oil and gas drilling operations, and in particular to an apparatus and method for controlling the flow of wellbore returns.
BACKGROUND
[0003] During drilling operations, drilling fluid or drilling mud, is pumped down the drill string in the wellbore using what are known as mud pumps. The drilling fluid jets out of the drill bit and cleans the bottom of the hole. The drilling fluid moves back up the wellbore in the annular space between the drill sting and the side of the wellbore, flushing cuttings and debris to the surface. The returning drilling fluid provides hydrostatic pressure to promote the prevention of formation fluids from entering into the wellbore. Drilling fluids are also typically viscous or thixotropic to aid in the suspension of cuttings in the wellbore, both during drilling and during interruptions to drilling.
[0004] The mixture of drilling fluid, formation fluids, cuttings and debris travelling back up the wellbore to the surface is referred to as the ‘wellbore returns’ or ‘drilling returns’. The wellbore returns may also contain dissolved gas which moves from the surrounding formation being drilled into the drilling fluid in the annulus.
[0005] Upon arrival at the surface, a series of valves and pipes are utilized to controllably direct the wellbore returns to either a mud/gas separator or to a de-gasser. A separator typically comprises a cylindrical or spherical vessel and can be either horizontal or vertical. It is used to separate gas from the drilling fluid and gas mixture. In the separator, the mixture is usually passed over a series of baffles designed to separate gas and mud. Liberated free gas is moved to a flare line and the mud is discharged to a shale shaker and to a mud tank. A de-gasser is used when the gas content of the drilling fluid is relatively lower and it operates on much the same principles as the separator. A vacuum is applied to the fluid as it is passed over the baffles to increase surface area, thereby promoting the liberation of dissolved gas.
[0006] During drilling operations, it is important to maintain constant down-hole hydrostatic pressure to prevent formation fluids from entering into the wellbore as mentioned above. This can be challenging due to shifting wellbore conditions and interruptions to drilling operations, such as tripping pipe. To maintain down-hole hydrostatic pressure, conventional drilling operations utilize one or more chokes at the well head. The primary role of the choke is to regulate the flow of wellbore returns from the well head. The choke comprises an adjustable orifice that can be opened or closed to control the flow rate of the wellbore returns, which in turn regulates down-hole pressure. There are both fixed and adjustable chokes, the latter being more conducive to enabling the fluid flow and pressure parameters to be adjusted to suit process and production requirements. However, the chokes, whether fixed or adjustable, are prone to wear, erosion and becoming clogged with cuttings and debris. Further, the chokes do not accurately measure wellbore return volume.
[0007] There is a need in the art for an apparatus and a method of controlling wellbore returns to regulate down-hole hydrostatic pressure that may mitigate the problems of existing choke devices, or provide an alternative to existing choke devices.
SUMMARY OF THE INVENTION
[0008] In one aspect, the present invention provides a method of controlling a flow of wellbore returns to regulate the down-hole hydrostatic pressure of a wellbore, the method comprising the steps of:
(a) directing the flow of wellbore returns through an intake flow line from the wellbore into a gas/liquid separator having a gas outlet; (b) separating gas associated with the wellbore returns to produce a disassociated gas in the separator; and (c) selectively restricting the flow of the disassociated gas out of the separator through the gas outlet to regulate the internal gas pressure of the separator, wherein the internal gas pressure of the separator is opposed to the flow of the wellbore returns through the intake flow line from the wellbore into the separator.
In one embodiment, the method further comprises the step of introducing gas into the separator from a gas source to increase the internal gas pressure of the separator.
[0012] In another aspect, the present invention provides a method of controlling a flow of wellbore returns to regulate the down-hole hydrostatic pressure of a wellbore, the method comprising the steps of:
(a) directing the flow of wellbore returns through an intake flow line from the wellbore to a pump, and through the pump; and (b) selectively varying the speed of the pump to vary the resistance of the pump to the flow of wellbore returns through the intake flow line from the wellbore to the pump.
In one embodiment, the pump is a multiphase pump, a positive displacement pump, a twin screw pump, a centrifugal pump, or a diaphragm pump. In one embodiment, the method further comprises the step of measuring the volume of wellbore returns passing through the pump.
[0015] In another aspect, the present invention provides an apparatus for controlling a flow of wellbore returns to regulate the down-hole hydrostatic pressure of a wellbore. The apparatus comprises an intake flow line, a gas/liquid separator, and a back pressure valve. The intake flow line receives the flow of wellbore returns from the wellbore. The gas/liquid separator has an inlet for interconnection to the intake flow line for receiving the flow of wellbore returns, and a gas outlet. The back pressure valve is interconnected to the gas outlet and is adjustable to selectively restrict the flow of gas out of the separator and thereby regulate the internal gas pressure of the separator opposed to the flow of wellbore returns through the intake flow line from the wellbore into the separator.
[0016] In one embodiment, the apparatus further comprises a gas source interconnected to the separator.
[0017] In another aspect, the present invention provides an apparatus for controlling a flow of well bore returns to regulate the down-hole hydrostatic pressure of a wellbore. The apparatus comprises an intake flow line, and a pump. The intake flow line receives the flow of wellbore returns from the wellbore. The pump has a pump inlet interconnected to the intake line for receiving the flow of wellbore returns, and a pump outlet for discharging the flow of wellbore returns. The speed of the pump is adjustable to selectively vary the resistance of the pump to the flow of wellbore returns through the intake flow line from the wellbore to the pump.
[0018] In one embodiment, the pump is a multiphase pump, a positive displacement pump, a twin screw pump, a centrifugal pump, or a diaphragm pump.
[0019] In one embodiment, the apparatus further comprises a gas/liquid separator and a back pressure valve. The gas/liquid separator has a separator inlet and a gas outlet, the separator inlet being interconnected to the intake flow line for receiving the flow of wellbore returns. The back pressure valve is interconnected to the gas outlet and is adjustable to selectively restrict the flow of gas out of the separator and thereby regulate the internal gas pressure of the separator opposed to the flow of wellbore returns though the intake flow line from the wellbore into the separator.
[0020] In one embodiment, the apparatus further comprises an intake valve interconnected to the intake flow line for selectively restricting the flow of wellbore fluids through the intake flow line from the wellbore to either the pump, or the separator, or both.
[0021] In one embodiment, the apparatus further comprises a gas source interconnected to the separator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] In the drawings, like elements are assigned like reference numerals. The drawings are not necessarily to scale, with the emphasis instead placed upon the principles of the present invention. Additionally, each of the embodiments depicted are but one of a number of possible arrangements utilizing the fundamental concepts of the present invention. The drawings are briefly described as follows:
[0023] FIG. 1 is an elevated diagrammatic depiction of one embodiment of the present invention.
[0024] FIG. 2 is an elevated diagrammatic depiction of another embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0025] The invention relates to an apparatus and a method of controlling the flow of wellbore returns to regulate the hydrostatic force in a wellbore. When describing the present invention, all terms not defined herein have their common art-recognized meanings. To the extent that the following description is of a specific embodiment or a particular use of the invention, it is intended to be illustrative only, and not limiting of the claimed invention. The following description is intended to cover all alternatives, modifications and equivalents that are included in the scope of the invention, as defined in the appended claims.
[0026] As used herein, the term “down-hole hydrostatic pressure” means the pressure exerted at any given point in the wellbore by the column of fluid above that point, including any pressure exerted at the surface by the apparatuses described herein.
[0027] FIG. 1 depicts one embodiment of the apparatus ( 10 ) of the present invention. The apparatus ( 10 ) can be utilized to control and exert a selected pressure back on the wellbore, thus controlling the hydrostatic pressure on the formation surrounding the wellbore, the inflow of fluids from the surrounding formation into the wellbore, and the flow of the drilling fluid. In one embodiment, the apparatus ( 10 ) will also allow an operator to measure the volume of wellbore returns passing through the apparatus ( 10 ).
[0028] Referring to FIG. 1 , an intake flow line ( 19 ) receives the wellbore return flow (F) that is diverted from the blow-out-preventer (“BOP”) stack (not shown) at the wellhead. In one embodiment, a diversion manifold ( 26 ) provides two alternate flow paths for the wellbore returns which can be interchangeably selected by selectively opening and closing gate valves ( 18 , 15 , 17 ).
[0029] In further embodiments of the present invention, the diversion manifold ( 26 ) may be substituted for a rotating flow control diverter (“RFCD”) or rotating blow out preventer (“RBOP”). The gate valves ( 18 , 15 , 17 ) may also be closed to block the flow of wellbore returns if required for safety purposes. As shown in FIG. 1 , a choke valve ( 29 ) may be used with the present apparatus ( 10 ) and may be employed to quickly kill flow of the wellbore returns if required. It should be understood that the choke valve ( 29 ) is present for safety purposes only and is not essential to the method of or apparatus for controlling the down-hole hydrostatic pressure described herein.
[0030] The first flow path leads directly to the separator flow line ( 33 ) which is connected to a gas/liquid separator ( 14 ). Any suitable separator ( 14 ) may be used with the present invention provided that it has an adequate volume and pressure rating. In one embodiment, a gas source ( 16 ) is interconnected to the separator ( 14 ). The gas source ( 16 ) may consist of any suitable equipment capable of providing on-site generated nitrogen, liquid nitrogen, natural gas, propane or carbon dioxide, as is well known in the art. A liquid outlet line ( 20 ) may lead from the separator ( 14 ) to a tank ( 38 ) or de-gasser ( 36 ) or to a shaker ( 34 ) (shown in FIG. 2 ). A gas outlet line ( 24 ) leads from the separator ( 14 ) to a flare stack (not shown in the Figures). The gas outlet line ( 24 ) has an integral back pressure valve ( 22 ).
[0031] A second flow path follows the pump flow line ( 32 ) to a pump ( 12 ). The pump ( 12 ) can be any suitable pump that can be used to control the flow of the wellbore returns, including without limitation, a multiphase pump, a positive displacement pump, a twin screw pump, a centrifugal pump or a diaphragm pump. A fluid flow meter (not shown) may be associated with or integral with the pump. In one embodiment, a twin screw pump is used as it easily facilitates accurate measurement of the volume of the wellbore returns passing through it.
[0032] Operation of the apparatus ( 10 ) depicted in FIG. 1 will now be described. If an operator elects to flow the wellbore returns directly into the separator ( 14 ) from the BOP stack, the gate valves ( 15 , 17 ) on both sides of the pump ( 12 ) are closed, while the gate valve ( 18 ) and the choke valve ( 29 ), if present, mounted on the separator flow line ( 33 ) are opened thereby directing flow of the wellbore returns directly along the separator flow line ( 33 ) into the separator ( 14 ). Gas is separated from the wellbore returns in the separator ( 14 ). The back pressure valve ( 22 ) can be used to restrict the flow of gas out of the separator ( 14 ) into the gas outlet line ( 24 ). This causes an increase of the internal gas pressure in the separator ( 14 ) which inhibits the flow of the wellbore returns into the separator ( 14 ) from the separator flow line ( 33 ). The restricted flow of wellbore returns results in back pressure on the wellbore and an increase in down-hole hydrostatic pressure. In this manner, the down-hole hydrostatic pressure can be controlled and maintained at a constant level by the back pressure valve ( 22 ) on the gas outlet line ( 24 ).
[0033] In the event, that the wellbore returns do not have sufficient associated gasses to create the required back pressure in the separator ( 14 ) to restrict the flow of the wellbore returns into the separator ( 14 ), then the internal pressure of the separator ( 14 ) can be artificially increased as required by the introducing gas into the separator ( 14 ) from the gas source ( 16 ).
[0034] If the operator elects to flow the wellbore returns through the pump ( 12 ) from the BOP stack, then the gate valve ( 18 ) mounted on the separator flow line ( 33 ) will be closed and the gate valves ( 15 and 17 ) on both sides of the pump ( 12 ) and the choke valve ( 29 ), if present, will be opened. The flow of wellbore returns is accordingly directed through the pump flow line ( 32 ) into an inlet of the pump ( 12 ). The flow of the wellbore returns through the pump ( 12 ) can be restricted in a controlled manner by controlling the speed at which the pump ( 12 ) runs. The faster the pump ( 12 ) runs, the less that the pump ( 12 ) restricts the flow of wellbore returns. Conversely, the slower the pump ( 12 ) runs, the more that the pump ( 12 ) restricts the flow of wellbore returns. Inhibition of the flow of the wellbore returns results in back pressure on the wellbore and an increase in down-hole hydrostatic pressure. In this manner the down-hole hydrostatic pressure can be controlled and maintained at a constant level by the varying the speed or revolutions per minute (“rpm”) of the pump ( 12 ), as required. For example, if the down-hole hydrostatic pressure increases beyond a desirable level, then the speed of the pump ( 12 ) can be increased to lower the back pressure, thereby lowering the down-hole hydrostatic pressure. The flow of wellbore returns exits the pump ( 12 ) though a pump outlet and is directed to the separator flow intake line ( 33 ) (as shown in FIG. 1 ).
[0035] Use of a pump ( 12 ) also provides the operator with the means to accurately calculate the return volume of the wellbore returns. Such information is important to the operator who is continuously trying to achieve a net balance of liquid injection and liquid returns during operations.
[0036] While FIGS. 1 and 2 depict embodiments of the apparatus ( 10 ) having both a pump ( 12 ) and a separator ( 14 ), one skilled in the art will appreciate that the present invention can be practiced using a pump ( 12 ) without a separator ( 14 ), or using a separator ( 14 ) without a pump ( 12 ).
[0037] In the embodiment depicted in FIG. 2 , an additional flow line ( 35 ) and additional gate valves ( 23 , 21 ) may be utilized which allows the operator to direct the wellbore returns directly to a de-gasser ( 36 ), a shaker ( 34 ) or to a rig tank ( 38 ) without having to pass through the separator ( 14 ). Using the apparatus ( 10 ) shown in FIG. 2 , an operator could selectively run the wellbore returns through the pump ( 12 ) and then directly to the de-gasser ( 36 ) and the shaker ( 34 ) by closing the gate valve ( 21 ) mounted on the separator flow line ( 33 ) and by opening the gate valve ( 23 ) on flow line ( 35 ).
[0038] It should also be understood that the pump ( 12 ) and the separator ( 14 ) may be used independently to control the flow of the wellbore returns, or they may also be used cooperatively to control the flow of wellbore returns.
[0039] As will be apparent to those skilled in the art, various modifications, adaptations and variations of the foregoing specific disclosure can be made without departing from the scope of the invention claimed herein.
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A method and apparatus to regulate the down-hole hydrostatic pressure in a wellbore are provided which depend on regulating the resistance to the flow of wellbore returns produced by the wellbore. The resistance may be provided by the internal gas pressure in a gas/liquid separator receiving the flow of wellbore returns, where the internal gas pressure is regulated by an adjustable back pressure valve and a gas source. Alternatively or in addition, the resistance may be provided by a pump receiving the flow of wellbore returns, where the resistance of the pump is regulated by adjusting the speed of the pump.
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RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 11/350,675, filed Feb. 8, 2006, still pending, which is a continuation of application Ser. No. 10/733,058, filed Dec. 10, 2003, now issued U.S. Pat. No. 7,048,403, the contents of which applications are incorporated herein by reference in their entireties.
BACKGROUND
[0002] This invention relates to a portable light. In particular, it is concerned with a light which can be supported on a garment such as a cap, shirt, or jacket. In other instances, the light can be supported on a book, writing tablet, belt or the like.
[0003] Use of flashlights for mounting on clothing is known. This assists workers and security personnel in freeing the worker's hands so that other activities can be engaged in, while the light can be made to shine on a desired object.
[0004] The present invention is directed to an improved structure for mounting such a portable light on the garments or other paraphernalia associated with a person who needs to keep at least one hand, and preferably both hands, free for other activities.
[0005] The invention seeks to improve the known pocket lights and other techniques for mounting a flashlight in this manner.
SUMMARY
[0006] A portable flashlight includes a clip which has a base which is hingedly mounted with an anchor. A spring urges the base and the anchor together, and between the base and the anchor there can be located a support such as a garment or other paraphernalia associated with a user. The anchor and the base are engaged in the spring action by the clip effect so that the portable light can be securely mounted on the support which can be a user's garment.
[0007] On top of or as part of the anchor, there is a housing member, which mounts a movable, preferably, pivotally mounted head in which two LEDs are located. Movement of the head causes a protrusion on the head to move to a position different from a position when the head is closed on the support. The housing may be part of an overall housing for a combined anchor-housing structure.
[0008] When the head moves to the different position, it causes the protrusion to move relative to a circuit board in the housing and a circuit closes to activate the LEDs. This is effected by closing the circuit between batteries and the circuit board which are both located in the shell or casing formed the housing and the anchor.
[0009] The LEDs are mounted in the head which is located towards the rear of the portable light. A friction forming o-ring in the hinge which mounts the head with the housing acts to prevent the inadvertent closure or opening of the head relative to the housing. Accordingly, opening of the head on the housing causes the light to distend upwardly from the front face of the housing.
[0010] The light is further described with reference to the accompanied drawings and description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view viewed from the front of the portable light.
[0012] FIG. 2 is a side view of the portable light.
[0013] FIG. 3 is a top view of the portable light.
[0014] FIG. 5 is a front view of the portable light.
[0015] FIG. 6 is a rear view of the portable light.
[0016] FIG. 7 is an exploded view of the portable light showing the base plate, anchor plate, and hinge member with the head above the hinge member.
[0017] FIG. 8 is a view of the portable light with the head pivotably moved relative to the hinge member.
DETAILED DESCRIPTION
[0018] Features of an embodiment are now discussed from an illustrative perspective.
[0019] A portable light for mounting on a support comprises an anchor to be secured with a support. There is a housing portion mounted to the anchor, and the housing portion includes a head for the light source. A switch for the light source is operable by movement of the head for the light source relative to the housing. The head is hingedly movable relative to the housing, and the switch is operable to turn the light source on when the head is moved from the housing.
[0020] The anchor cooperates with a base plate and the light and is mounted on the anchor on a position opposite to the base. The base and the anchor are hingedly connected, and a spring urges the base plate and the anchor towards each other.
[0021] The base and the anchor effectively form a clip for securing the light to a support. As such that the material for the support is locatable between the base and the anchor, and thereby the light is secured to the support for the light.
[0022] The head includes at least two light sources. The light sources are angled relative to the head to the extend a field of illumination forwardly from the rear of the head toward the forward end of the head. The field of illumination partly overlaps in the area at the forward end of the housing. The two light sources are spaced apart at a position remote from the forward end of the housing and the rear end of the housing.
[0023] The head includes a protrusion for extending through an aperture in a top face the housing. The protrusion acts to operate a switch when the protrusion moves between a position relative to the housing thereby to activate a switch between closure and opening. The protrusion is relatively fixed on an under plate of the head. The activation of the switch is effected by the location of the head relative to the position of the housing.
[0024] The housing and anchor are fixedly formed relative to each other. There is a friction element in a hinge between the head and the housing, thereby to inhibit movement between the head and housing.
[0025] FIG. 1 shows an anchor, in the form of a plate or housing 10 , which has mounted on one side a base element or plate 11 . A spring hinge pivoting connection 12 is formed so that between the anchor 10 , base plate 11 and the pivot rod 12 , there is a biasing force to cause the anchor and base to be urged together to form a clip.
[0026] Movement of the tail, handle or finger grip 13 which extends from the base 11 about the pivot rod 12 a causes the front portion 14 of the base plate 11 to open. There is a leaf spring 12 b which is mounted at the area of the hinge 12 so that it applies the spring action on the hinge 12 . The hinge area has two downwardly directed pillars between which there is mounted a central portion of the base 11 in the spring-hinge relationship.
[0027] A garment or other paraphernalia of the user can enter through the mouth area 15 between the underside 16 of the anchor 10 and the top of the base element or plate 11 . The garment or other support will be located in the area 17 of the portable flashlight.
[0028] The anchor plate or housing 10 at its rear section has two upstanding pillars 18 and 19 . These form a second hinge about a pivot point or rod 20 .
[0029] A housing 21 is mounted on or with the anchor 10 , and there is also a slot 21 a which extends between the anchor 10 and the support 21 . The anchor 10 and the housing 21 are formed as a shell or casing.
[0030] Between the upstanding portions 18 and 19 there is a cylindrical sleeve 22 which is located for pivotal movement about the pivot or rod 21 . There is also a rubber o-ring 23 which is located around the axle rod 21 . This provides a friction effect so that the sleeve 22 is inhibited from unintentional movement about the axle rod 21 . The sleeve 22 is formed to extend from the rear portion of a head member 24 . The head member 24 also includes a base plate 25 .
[0031] On either side of 30 of the head 24 there are two tabs 24 a and 24 b . These tabs facilitate the opening and the closing of the head 24 and adjacency with the top panel 35 on top of the mating portion of the housing 21 . Portion 36 of the housing 21 extends from the plate 35 to the leading end of the housing 21 . The head 24 is mounted on a top of the housing, and the top is on the side remote from the anchor. The head has a small protrusion 24 c which clips into engagement in an indent 24 d formed on a step wall formation adjacent to a top face of the housing 21 . This ensures a positive locking engagement when the head 24 is in a closed position on the housing 21 .
[0032] At the forward end of the head member 24 there are two apertures 26 and 27 for accommodating two LEDs 28 and 29 respectively. The LEDs 28 and 29 are mounted on a plate 30 which in turn is connected to a circuit board 31 through appropriate connected through wiring 32 . There is a switch activating protrusion 33 from the base 25 of the head 24 . The protrusion 33 is fixed and is moveable as the head 24 moves so that it can have different positions to activate a switch related to the circuit board 31 . As such in the closed position the protrusion is accommodated in an aperture 34 which leads to one side of the circuit board 31 . The circuit board 31 is mounted in the support housing 21 in a cavity formed by the outer shell of the housing 21 , which mounts the head 24 . Movement of the protrusion 33 acts to close a circuit and open a circuit as necessary.
[0033] The anchor 10 provides a housing for batteries 36 and 37 which are connected through a spring conductor 38 mounted in the base of the anchor 10 . When the housing and the anchor are closed together with the batteries in position the circuit is essentially made. The protrusion 33 operates through the aperture 34 packs to open a close this up at so as to power and keep our the LEDs in the head formation 24 . The circuit board 31 is suitably and fixed to the top of the shell forming the housing 21 . The wires 32 runs from underneath the shell through the portion adjacent the cylindrical sleeve 22 and into the head member 24 to connect with the LEDs 28 and 29 .
[0034] Many other forms of the invention exist, each differing from the other in matters of detail only. For instance instead of a two part housing and anchor there can be more components or even a single component. Different kind of clip formations can be provided. There may not be a spring mechanism associated with the clip.
[0035] Instead of two LEDs there may more or less and instead of the LEDs there can be other light sources. The system can be used for different lighting needs, even without the mounting clip.
[0036] There can be other securing techniques for permitting the light to be affixed to a support. The base can be made of an inherently spring like type material with a bias towards the bottom of the anchor. Other structure can be used to permit the securing of the light to the support. For instance a clip like structure similar to a gem clip can be used. The anchor and support can be formed as a different form. It can be an integral unit in which the batteries and circuit are mounted.
[0037] It is to be understood that aspects of this invention could be used in other applications, such as for use where an artisan needs hands free to work a tool. The light can also be clipped in positions to aim at different targets while a persons hands are free for other functions. The angle of the light can change as necessary by opening the head to any desired degree. Arrows shown on FIG. 2 illustrate the movement possibilities of the head and the base. In some cases the clip may be dispensed with a releasable adhesive element employed on the anchor face for securing to a support. The head can be moved between a closed position and about 180 degrees opposite to the closed position.
[0038] The invention should be determined by the following claims.
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A portable light intended for mounting on a garment as support includes two LED light sources spaced apart towards the rear of the portable light. A clipped base below on anchor facilitates locating a garment between the anchor and the base, and a spring action urges the base toward the anchor. A hingedly movable head for the LEDs is mounted on the housing to move to and form the housing. An opening of the housing causes a switch in the housing to move between an opened and closed position such that a circuit actives or deactivates the LED lights when the head opens or closes relative to the housing.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/859,945, filed on Nov. 20, 2006. The disclosure of the above application is incorporated herein by reference.
FIELD
[0002] The present disclosure relates to vacuums, and in particular, to a vacuum with accessory storage features.
BACKGROUND
[0003] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0004] Many vacuum cleaners, especially shop vacuums, include a variety of accessories that may be attached to the vacuum to aid in the collection of waste matter. These accessories may include extensions to increase the reach of the vacuum, and a variety of nozzles and other attachments shaped to facilitate vacuuming on various surfaces and in tight spaces.
[0005] Typically, vacuums do not include satisfactory storage means for idle accessories. These vacuums fail to securely retain accessories in a space efficient manner. Accessories often must be stored separately from the vacuum, which requires the user to interrupt vacuuming to retrieve the accessories as needed.
SUMMARY
[0006] A vacuum including a housing, a suction device disposed within the housing, a plurality of accessories operable to engage the suction device, a plurality of wheels mounted to the housing and at least one bumper disposed on the housing. The at least one bumper includes a retaining feature operable to store at least one of the accessories, and the at least one bumper is operable to protect at least one of the wheels to minimize damage thereto. At least one pocket is defined by the bumper. The pocket is adapted to store at least one of the accessories.
[0007] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0008] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0009] FIG. 1 is a perspective view of a vacuum according to the principles of the present disclosure;
[0010] FIG. 2 is a partially exploded perspective view illustrating a bumper according to the principles of the present disclosure;
[0011] FIG. 3 is a partial perspective view illustrating the pocket shown in FIG. 1 ;
[0012] FIG. 4 is a partially exploded perspective view of the vacuum according to the principles of the present disclosure;
[0013] FIG. 5 is a partially exploded perspective view illustrating the crevasse tool shown in FIG. 1 ;
[0014] FIG. 6 is a partial perspective view of the vacuum according to the principles of the present disclosure;
[0015] FIG. 7 is a perspective view of a vacuum according to an alternative embodiment of the present disclosure;
[0016] FIG. 8 is a partially exploded perspective view of a vacuum according to an alternative embodiment of the present disclosure; and
[0017] FIG. 9 is a partially exploded bottom perspective view of the housing according to an alternative embodiment of the present disclosure.
DETAILED DESCRIPTION
[0018] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
[0019] Referring to FIGS. 1-6 , a vacuum with accessory storage features is shown, and is generally referred to as vacuum 10 . Vacuum 10 includes a housing 12 that encloses a suction device. The suction device is generally located within housing 12 at 14 , and includes a mechanism that creates a suction force operable to collect dirt, debris, and other wet or dry waste matter, as known in the art. For example, suction device 14 may include an electric motor driving a suction impeller (not shown).
[0020] Housing 12 may include one or more bumpers 16 . Vacuum 10 may include a plurality of wheels 18 and/or one or more caster wheel 20 to facilitate mobility and maneuverability. Bumpers 16 may extend laterally from housing 12 so as to be operable to shield wheels 18 and/or caster wheels 20 from damaging impacts and/or debris.
[0021] Suction device 14 provides a suction force to a flexible vacuum hose 21 extending from the housing, which may be adapted to receive a variety of accessories, such as extension wands 22 , crevasse tool 24 , floor nozzles 26 , 28 , and other attachments. Extension wands 22 may be in fluid communication with suction device 14 to extend the functional reach of vacuum 10 during operation. Crevasse tool 24 and floor nozzles 26 , 28 may be in fluid communication with suction device 14 to facilitate efficient vacuuming over a variety of surfaces and in restricted spaces. Any of floor nozzles 26 , 28 and crevasse tool 24 may be used in conjunction with extension wands 22 or independently therefrom.
[0022] In an exemplary embodiment, vacuum 10 can include a plurality of bumpers 16 fixedly mounted to housing 12 or integrally formed with housing 12 . As best shown in FIG. 3 , bumper 16 may be configured to provide a pocket 30 . Pocket 30 is adapted to slidably receive and retain extension wand 22 , as shown in FIG. 4 . In this manner, a substantial portion of extension wand 22 may be stored within the profile of bumper 16 , minimizing the overall footprint of vacuum 10 .
[0023] Crevasse tool 24 may be slidably received within extension wand 22 , as shown in FIG. 5 . Alternatively, crevasse tool 24 may be slidably engaged directly with pocket 30 , and may be stored therein when not in use. In an alternative embodiment, bumper 16 may be adapted to slidably receive floor nozzles 26 , 28 within pocket 30 .
[0024] As shown in FIG. 6 , bumper 16 may also include retention feature 32 adapted to retain floor nozzle 26 or 28 . Retention feature 32 may include one or more slots 34 . A stem 36 of floor nozzle 26 , 28 may be slidably received within slots 34 , and the friction therebetween may retain the floor nozzle 26 , 28 therein. In this manner floor nozzles 26 , 28 may be stored substantially flush to housing 12 to minimize the overall footprint of vacuum 10 .
[0025] Alternatively, retention feature 32 may include a protrusion 37 , as shown in FIG. 5 , whose width is substantially equal to the inner diameter of stem 36 . Stem 36 may be slidably engaged with the protrusion 37 . The friction between stem 36 and the protrusion 37 may retain the floor nozzle 26 , 28 to the protrusion 37 .
[0026] Accessories including, for example, extension wands 22 , crevasse tool 24 , and floor nozzles 26 , 28 may be stored substantially as shown in FIG. 1 while vacuum 10 is in operation. In this manner, a plurality of accessories are conveniently accessible, yet space-consciously and securely retained.
[0027] With reference to FIGS. 7-9 , wherein common reference numerals are used to represent common elements as disclosed in FIGS. 1-6 , an alternative embodiment is shown. Vacuum 100 includes a housing 12 , an internal suction device 14 , and a frame 170 . Frame 170 may include a handle 172 and a plurality of wheels 18 and/or caster wheels 20 . Frame 170 may also include accessory storage features (not shown) such as those provided in bumpers 16 , as described above.
[0028] In an exemplary embodiment, frame 170 may include a plurality of relatively larger wheels 18 and relatively smaller caster wheels 20 . The caster wheels 20 are pivotable to facilitate steering and maneuverability of vacuum 100 . It should be appreciated that the number and arrangement of wheels 18 and/or caster wheels 20 may be varied to facilitate stability and maneuverability.
[0029] Handle 172 may be utilized to apply pushing and pulling forces to cause movement of vacuum 100 . An operator may apply a downward force to handle 172 to cause caster wheels 20 to be lifted off of the ground or floor. Thus causing vacuum 100 to be in direct contact with the ground or floor surface only through wheels 18 . In this manner, vacuum 100 may be pushed or pulled to freely travel over job site impediments.
[0030] Housing 12 is disposed within an aperture 174 of frame 170 . Aperture 174 and a bottom portion of housing 12 may be tapered downward to limit the distance through which housing 12 may be inserted. Alternatively, housing 12 may be disposed within aperture 174 and may be supported therein by a cross-member (not shown). In still other embodiments, housing 12 may be mounted to frame 170 via conventional fastening methods such as latches, clips, bolts, pins, or straps.
[0031] As shown in FIG. 8 , housing 12 may be lifted and removed from frame 170 . Housing 12 may include one or more handles 176 to facilitate lifting and removal of housing 12 . Housing 12 may be repeatedly engaged and disengaged with frame 170 as desired. Vacuum 100 may be operated while housing 12 is disposed within frame 170 . Alternatively, vacuum 100 may be operated independently from frame 170 . Housing 12 may be disengaged from frame 170 to empty waste matter collected during operation. Housing 12 may also be disengaged from frame 170 to reduce the space occupied by vacuum 100 to promote ease of use and/or maneuverability in a space-limited environment.
[0032] As shown in FIG. 9 , vacuum 100 may include a plurality of auxiliary wheels 178 . Auxiliary wheels 178 may be pivotably engaged within housing 12 . Auxiliary wheels 178 facilitate mobility and maneuverability while housing 12 is disengaged from frame 170 . When engaged with frame 170 , housing 12 may be sufficiently spaced from the ground or floor so that auxiliary wheels 178 do not contact the ground or floor. It should be appreciate that the number and configuration of auxiliary wheels 178 may be varied to facilitate stability and maneuverability.
[0033] The description of the present disclosure is merely exemplary in nature and, thus, variations that do not depart from the gist of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.
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A vacuum including a housing, a suction device disposed within the housing, a plurality of accessories operable to engage the suction device, a plurality of wheels mounted to the housing and at least one bumper disposed on the housing. The at least one bumper includes a retaining feature operable to store at least one of the accessories, and the at least one bumper is operable to protect at least one of the wheels to minimize damage thereto. At least one pocket is defined by the bumper. The pocket is adapted to store at least one of the accessories.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a method of producing from a first device-dependent image data set, a second image data set matched to a real process, and a color management method for a printing process, wherein a device-independent image data set obtained from an original image is used to produce a first CMYB (cyan, magenta, yellow and black) image data set for a standard printing process, using a first transformation, and the first CMYB image data set is converted into a second CMYB image data set, which is matched to a real printing process, using a second transformation.
[0003] Such methods are needed in order to satisfy two conflicting requirements. On the one hand, it is of interest to print-job clients to be able to specify the desired printed result, in particular with regard to color reproduction, unequivocally in a manner which ensures that different printing operations deliver largely identical printed results. This means that the client must be in a position to specify color values to be achieved, not in an abstract manner, but rather, to specify directly the presettings of a printing machine with which the desired color values can be achieved. This necessarily presupposes a printing machine with a standardized behavior.
[0004] In contrast therewith is the problem that many printing plants do not operate in a standardized manner, and it is often inexpedient for them to operate in that manner because, sometimes, they can achieve better results for specific printing problems by deviating from the standard. It is obvious, however, that a non-standard printing machine will not deliver the result desired by the client by using presettings specified by a client, which are based upon a standard.
[0005] It is therefore important for the operator of the printing machine to know exactly the manner in which his machine deviates from the standard, so as to be able, accordingly, to convert the standard presettings into those suitable for his machine, which deliver the desired color reproduction.
[0006] For this purpose, it is necessary to print a test image by using the standard presettings in the real printing process of the non-standard machine, to compare the printed result with a predefined image and, by using this comparison, to determine a transformation rule which permits the standard presettings to be converted into those suitable for the real printing process.
[0007] Such a method has been developed by the Hell firm of Germany under the designation Pixon/PCT (programmed color transformation). This method is described, for example, in Hauser and Jung, “Pixon Verfahrenstechnik optimiert Reproduktionsanpassung an Druckbedingungen” (Pixon methodology optimizes the matching of reproduction to printing conditions), a special reprint from “Der Polygraph”, 3-88.
[0008] The predefined image for comparison with the test image is, in this heretoforeknown method, a copy of the test image printed in accordance with the standard. This standard copy is the master to which the color reproduction of the real printing process is to be matched. This is effected by a percentage increase or reduction in the feed of individual printing inks, in order to match, in this manner, the color tones, saturation or lightness of the printed result to the original.
[0009] If these percentage relationships are known, they can be used during any desired subsequent print job in order to convert or transform the standard presetting values in such a manner that the correct color reproduction can be expected during the non-standard real printing process.
[0010] One problem with this heretoforeknown method is based upon the fact that the entire color space detectable by the human eye cannot be represented by a combined printing of the colors cyan, magenta, yellow and black in a given printing process. However, such color tones which cannot be represented may quite possibly be contained in an original image and, during the scanning of such an image, such color tones can be registered, and the parameters of such color tones can quite possibly be represented in a device-independent color space, in an RGB or Lab representation. When printing an image, the original of which contains such color tones, a given distortion of the color reproduction is therefore unavoidable. The simplest possibility would be to replace color tones, respectively, which cannot be represented in the CMYB system, by that color tone which can be represented and is closest in the RGB or Lab color space, and to reproduce all the other color tones faithfully. However, this solution is found to be unsatisfactory, because it identically reproduces in the reproduced image, color tones which are different in the original. Information is therefore noticeably lost. Details of the defined or original image can no longer be seen in the printed image.
[0011] A different type of conversion, referred to as gamut mapping, of scanned data represented in the RGB or Lab system into the device-specific CMYB system is therefore widespread, wherein attention is given to faithful color reproduction only in a central area of the representable CMYB space and, in marginal areas, a deviating color reproduction is taken into consideration, wherein, however, to each color tone representable in the RGB or Lab system, a color tone in the CMYB space is uniquely assigned. This amounts to the device-independent RGB or Lab color tones in the central area being projected into the CMYB system “on a scale of 1:1”, whereas in the marginal areas, a “smaller scale” is used.
[0012] The CMYB color space is, therefore, always only a subset of the RGB color space or the Lab color space. Added to this is the fact that the shape of this subset, respectively, depends upon the real printing process. Color tones which, in a first printing process, are located in the central area of the CMYB color space and can therefore be reproduced faithfully, can quite possibly be located in the marginal area or even outside the area which can be represented in a second printing process. The conventional color management method cannot take this into account. Because the comparison original is produced in the standard printing process, it necessarily cannot contain any color tones which cannot be represented in this process. However, it is entirely possible for some of the color tones represented to be located in the marginal area of the CMYB color space of the standard process and, therefore, to exhibit differences in tone with respect to an hypothetical original of the test image. In practice, this means that an original image is subject to a first color distortion and reduction in the color space during the conversion of the image data thereof from the RGB or Lab representation into CMYB data for the standard process, and goes through a second such distortion and reduction in the color space during the matching to the real printing process. The color space used after this matching is therefore not matched optimally to the capabilities of the real printing process and, in addition, sharp color differences can occur in the print in comparison with the original.
SUMMARY OF THE INVENTION
[0013] It is an object of the invention to provide a method of producing, from a first image data set, a second image data set matched to a real process, and a color management method which avoid the foregoing problem and achieve a desired printing quality as quickly as possible.
[0014] With the foregoing and other objects in view, there is provided, in accordance with one aspect of the invention, a method of producing from a first device-dependent image data set, a second image data set matched to a real process, which comprises, by using inverse gamut mapping, transforming color values from the first image data set into color values of a device-independent color space and, by using gamut mapping, transforming these device-independent color values into the second image data set of an output device.
[0015] In accordance with another mode of the method invention, the device-dependent image data sets are CMYB image data sets.
[0016] In accordance with a further mode, the method invention includes using a build-up of black in the first image data set for producing the second image data set.
[0017] In accordance with an added mode, the method invention includes analyzing the build-up of black in the first image data set, and using it in identical form for the production of the second image data set, if the first and the second devices are based upon identical processes.
[0018] In accordance with an additional mode, the method invention includes analyzing the build-up of black in the first image data set and, for the output in accordance with the boundary conditions of the second device, setting the black build-up to the limits of the second device, if a direct transfer is not possible because of the process.
[0019] In accordance with yet another mode of the method invention, the device-dependent image data sets are RGB image data sets.
[0020] In accordance with yet a further mode of the method invention, the device-independent image data sets are Lab image data sets.
[0021] In accordance with another aspect of the invention, there is provided a color management method for a printing process, which includes producing, from a device-independent image data set obtained from an original image, a first CMYB image data set for a standard printing process, by using a first transformation, and then producing a second CMYB image data set matched to a real printing process, by using a second transformation, which is determined by printing a test image, which comprises comparing the printed result with a predefinition, and optimizing the second transformation in order to minimize deviations between the printed result and the predefinition, the predefinition for the comparison being the device-independent image data set of the test image.
[0022] In accordance with a further mode, the color management method includes selecting the device-independent data set from the group consisting of an Lab and an RGB data set, respectively.
[0023] In accordance with a concomitant mode, the color management method includes producing a device-independent image data set from the printed result, and performing the comparison by using the device-independent data sets from the test image and the printed result.
[0024] Thus, the invention of the instant application proposes that the device-independent image data set from the test image be used as a predefinition or predefined image data set for the comparison. This device-independent data set can exhibit virtually any desired representation, provided this makes it possible to represent all the color tones which can be registered by the human eye or by a scanner. For example, an Lab or RGB representation can be used.
[0025] In order to perform the necessary comparison, a device-independent image data set from the printed result is expediently produced, and the comparison is performed by using the two device-independent image data sets, respectively, the image data set from the test image and the image data set from the printed result.
[0026] An important feature of the invention is that inverse gamut mapping is used to transform color values from a first image data set into color values of a device-independent color space, gamut mapping being used to transform these device-independent color values into a second image data set of an output device, such as a printer.
[0027] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0028] Although the invention is illustrated and described herein as a method of producing from a first image data set, a second image data set matched to a real process, and a color management method, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0029] The method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings, wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] [0030]FIG. 1 is a flow chart showing, for purposes of comparison, the steps that are included in a conventional color management method;
[0031] [0031]FIG. 2 is a flow chart showing the sequence of steps in the color management method according to the invention; and
[0032] [0032]FIG. 3 is a flow chart showing a sequence of substeps of the step S 14 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] Referring now to the drawings, it is noted that the steps of a conventional color management method and of a color management method according to the invention, respectively, are summarized in FIGS. 1 and 2, mutually corresponding steps of both methods being illustrated in the two figures, respectively, at the same level on the first sheet of the drawings.
[0034] The starting point of the conventional method is the provision of a printed test image at step S 1 . This test image is scanned at S 2 , in order to obtain a data set which reproduces the entire image information in a process-independent or device-independent representation at step S 3 .
[0035] The method according to the invention essentially begins with the provision of a process-independent data set in step S 13 . The manner in which this data is obtained is unimportant; in the conventional method, it could be obtained by scanning a test image, as indicated by steps S 11 and S 12 , shown in boxes formed by broken lines, but this test image does not have to be printed. It could also be a manually produced unique set. It would also be conceivable to produce the process-independent data set exclusively by CAD methods on a computer.
[0036] Conventionally, the process-independent data is converted, in a step S 4 , into a CMYB representation for the standard printing process.
[0037] In order to convert the data set provided at step S 5 into a data set suitable for the real printing process, a transformation step S 6 is necessary. Because this transformation presumptively is not known, during a first pass, step S 6 is omitted; one could also speak of the standard CMYB data set being subjected to a unit transformation; and in step S 7 , printing is performed in accordance with this data set. A comparison, performed in step S 8 , between the printed result and the test image mentioned with reference to step S 1 supplies information as to how the CMYB values must be changed, i.e., the form which the transformation in step S 6 must have in order to arrive at a satisfactory color reproduction. The steps of transformation S 6 , S 7 and comparison S 8 may possibly be repeated many times, until a satisfactory transformation has been found. During subsequent print jobs, it is then sufficient only to perform the steps S 2 to S 6 , in order to arrive at a suitable presetting for the print job.
[0038] In the method according to the invention, a transformation of the process-independent data into a CMYB representation is likewise performed in step S 14 . In this case, however, it does not necessarily always have to be a transformation into the CMYB representation for the standard process. The CMYB data set provided at S 15 is used for printing at S 16 . The result is scanned at S 17 in order to obtain a process-independent data set at S 18 . This process-independent data set, together with that from step S 13 , form the basis of a comparison step S 19 . Because this comparison is performed only on digitized data, it can advantageously be completely automated.
[0039] Differences between the two data sets permit conclusions to be drawn as to how the transformation step S 14 has to be modified, if necessary, in order to improve the color reproduction. In this method, also, the sequence of steps S 14 to S 19 can be repeated many times until satisfactory agreement between the color reproduction and the predefinition is achieved.
[0040] When a usable transformation S 14 has been determined in this manner, the printing machine can be preset quickly and simply in the case of an actual print job in that, starting from the process-independent data set from this original, the CMYB data set S 15 for the real process is determined by the transformation determined in this manner.
[0041] The transformation step S 14 can include a combined computing step, which leads directly from the process-independent data set to the CMYB data set matched to the real printing process. The step can also be broken down, however, into a number of partial or substeps, as illustrated in FIG. 3. A first substep is a transformation S 14 a from the process-independent data set into the CMYB data set for the standard process, which can be performed by the print-job client. A further substep is a transformation in the opposite direction S 14 b. This can be performed, for example, by the printing plant. Because the transformed standard CMYB data set still contains the complete image information when gamut mapping is used, the transformation S 14 a is reversible, and because the gamut mapping by which the standard CMYB data is obtained is necessarily likewise standardized, the reversal can be performed in the printing plant, without requiring therefor any information from the client beyond the CMYB image data. A third substep is a transformation step S 14 c, which then converts the reproduced process-independent data set into a CMYB data set matched to the real printing process. During a first execution of the steps S 13 to S 19 , this step S 14 c can be identical to step S 14 a; it is the transformation S 14 c which, respectively, is matched, based upon the result of the comparison S 19 .
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A method of producing from a first device-dependent image data set, a second image data set matched to a real process, includes, by using inverse gamut mapping, transforming color values from the first image data set into color values of a device-independent color space and, by using gamut mapping, transforming these device-independent color values into the second image data set of an output device; and a color management method including the producing method.
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BACKGROUND
The present invention relates to power amplifiers for base stations in wireless communication systems and, in particular, to power amplifier control for Multiple Carrier Power Amplifiers (MCPA).
MCPAs presently account for more than half the equipment cost of a base station in a wireless communication system with the cost of a typical MCPA being directly proportional to maximum peak power provided thereby due to the corresponding increase in cost for higher capacity active components, cooling hardware, and the like. Base station costs thus can be correspondingly controlled by reducing or controlling the maximum peak power provided by an MCPA. However, degradation of performance beyond tolerable limits may occur when demands for peak power on traffic channels are at their greatest and exceed the maximum rating of the MCPA. Moreover specific functions which require nominal maximum power to be applied may be affected when MCPAs operate at reduced power levels.
When reducing peak power associated with MCPAs, often times, depending on algorithms used and peak traffic demand patterns, degradation may occur periodically and with differing levels of severity. According to a typical power dimensioning scheme, more carriers may be allocated to a base station than can typically be supported within peak power dimensions, for example, traffic maximums are achieved simultaneously on most or many channels. Presently, MCPA's may be dimensioned for “worst-case”, i.e. full RF power on all carriers. It is thus desirable to dimension the MCPA closer to the average power. Several MCPA control schemes attempt to provided power levels closer to average power. In particular, U.S. Pat. No. 5,384,547 to C. N. Lynk, et al, describes a linear device for attenuating a signal if a power threshold is exceeded. Japanese Patent abstract JP 9139679 A describes a peak power reduction circuit which detects envelope power level for a multicarrier signal and attenuates a predetermined amount for a predetermined time if a threshold is exceeded. Such solutions, however, in themselves, pose additional problems in that if an MCPA is dimensioned close to average needed power, a large negative impact on service quality may be felt, since all channels are affected at overload. Present systems may further experience relatively moderate overall changes in output power, since the power is related only to the number of active carriers. It would be desirable for systems to adapt to more dynamic changes and a lower average/peak ratio due to, for example, dynamic BS power control per carrier or time slot, downlink Discontinuous transmission (DTX), or the like.
Some MCPAs may include autonomous power reduction devices. Overdrive of MCPA's with autonomous devices power reduction normally results in MCPA switch-off and activation of an alarm output. The alarm output may be fed to an alarm printer and, in the case of autonomous MCPA control, service quality may deteriorate to a large degree. Lower carrier power implies more unreliable coverage, slower access times, unreliable handoff.
It may further be desirable for large providers of wireless communications equipment to have independent suppliers of different components associated with such equipment. It is thus desired that MCPA's be capable of reductions in power independently of whether or not, for example, a particular base station is configured to handle such reductions. Independent power reduction capabilities may allow “optimal” power reduction from, for example, an operating cost standpoint, and “optimal” communication system behavior is achieved. Such performance may be achieved, for example, when operating parameters such as power level, are adapted to match all components within particular equipment such that for example the impact of a network service in overload situations is reduced or eliminated.
To effect power reduction, an MCPA and an associated base station may reduce power on carriers and channels associated with the base station. In a typical wireless system such as, for example, a system in accordance with the Global System for Mobile communications (GSM) system governed by the specification contained, for example, in “Digital cellular telecommunications system (Phase 2+); Radio transmission and reception (GSM 05.05 version 6.3.0 Release 1997). In a typical wireless communication system in accordance with, for example, the GSM specification, there are typically two kinds of channels: control channels and traffic channels. Control channels normally transmit at nominal, or maximum, power so that control signals responsible for new call setup can reach all the way to the cell border and within the cell. Accordingly, the power with which the control channel transmits establishes the cell radius. It is further important for the control channel to transmit with maximum power so that extended services such as, for example, SMS service, broadcast/paging services, and the like may be offered. It should be noted that because control channels are assumed to transmit at full power, functions such as, for example, “consistency check” and Locating are made possible. Should transmit power levels associated with the control channel vary, some degradation can be expected.
For traffic channels, transmit power may be set by a base station typically to a level inverse to the expected attenuation. For example, power may be set low when a mobile station (MS) is close to the BS and may be set at a level closer to maximum power when the MS approaches the cell border. Depending on the system different permutations of power management may occur based on location, as described, and based on timeslot. For example, TDMA Cellular PCS standard, ANSI/TIA/EIA-136, published Mar. 22, 1999, by TR-45.3 Committee, does not exclude per-timeslot downlink power regulation although power levels associated with different timeslots on a carrier may not be allowed to differ much. However, it should be noted that in accordance with ANSI/TIA/EIA-136, power may be temporarily set to a maximum level just before to just after a handoff.
In other systems, power level control may be implemented in TDMA based telecommunications systems in a more straightforward manner. In such systems transmit power associated with certain downlink bursts, particularly those which are being transmitted with more power than the corresponding mobile station requires, is adjusted during a given timeslot, and in such a way, that the transmit power adjustment resembles that of a typical fading event, in terms of time of occurrence and rate of occurrence, e.g., dB per msec. In so doing, other mobile stations, using the same frequency carrier or an adjacent frequency carrier, receiving a downlink burst during that timeslot at a power level that is marginally adequate, such as mobile stations operating at or near the border of nearby cells, are better able to cope with the effects of fading, since they are subjected to less interference. For further details, see for example, U.S. patent application Ser. No. 09/475,640 entitled “METHOD AND SYSTEM FOR MEASURING AND REPORTING RECEIVED SIGNAL STRENGTH” filed Dec. 30, 1999, and U.S. patent application Ser. No. 09/399,764 entitled “DOWNLINK TIMESLOT POWER CONTROL IN A TDMA SYSTEM” filed Sep. 21, 1999.
It would therefore be desirable to provide power control in MCPA equipped base stations which would reduce average power to the greatest extent possible while maintaining nominal power for critical functions and acceptable power levels for traffic channels.
SUMMARY
It is therefore an object of the present invention to provide a method and apparatus for power control in MCPA equipped base stations.
It is a further object of the present invention to provide an interface such that independently supplied base stations and MCPAs may be operated according to a power reduction control interface specification.
Therefore, in accordance with one embodiment of the present invention, the foregoing and other objects are achieved in a method and apparatus for controlling power in a wireless communication system having a base station and a Multiple Carrier Power Amplifier (MCPA) split into at least two separate units. By splitting the base station and MCPA, advantages may gained over systems where base station and MCPA are integrated. Accordingly the base station and the MCPA may be coupled with an interface. The interface may preferably be standardized for interchangeability. The base station may provide an aggregate signal representing one or more carrier signals associated with one or more mobile stations served by the base station across the interface from the base station to the MCPA. The MCPA may accordingly adjust its a gain level to maintain a linear transmit power level associated with the aggregate signal. During transmission, the MCPA may measure the gain level during an interval associated with, for example, an amount of time or a regularly occurring time interval using a sensor or suitable transmit power level or gain measuring device. Feed back information associated with the measured gain level may further be provided across the interface from the MCPA to the base station.
In accordance with another embodiment of the present invention, a first and second control parameter may be provided from the base station to the MCPA across the interface for controlling, for example, how power is measured and the interval for measurement and, thus, the measuring of the gain level may be thereby controlled.
In accordance with yet another embodiment of the present invention, the interface may be digital and the first and second parameters may include, for example, power averaging period and sampling interval. Accordingly, providing feedback may include defining a 100% load level associated with the MCPA and feeding back information across the interface from the MCPA to the base station which is proportional to the measured gain level. It may be preferable for the information to be linearly related to the measured gain level when the measured gain level is greater than or equal to the 100% load level, although a normal level may also be provided, e.g. information which reflects measured gain level throughout the entire range of values including above and below the 100% load level. With regard to the sampling interval, it is preferable that the sampling interval may corresponds to a synchronous interval such as a time slot interval in a TDMA system or an asynchronous interval such as an irregular interval as may be found in a slotless system such as a CDMA system or the like.
In accordance with yet another embodiment, the wireless communication system in accordance with the present invention may further include a plurality of base stations, the plurality of base station providing a plurality of aggregate signals to the MCPA. The plurality of aggregate signals may each represent one or more carrier signals associated with one more mobile stations served by each base stations. Accordingly the plurality of base stations and the MCPA may be split into a plurality of separate units to provide advantages over integrated units and, in addition it may be appreciated that it would be difficult for one MCPA to serve several base stations if base station and MCPA are integrated. The plurality of separate units may be coupled to the MCPA with a plurality of interfaces, although it will be appreciated that the interfaces should be consistent with each other for interchangeability. The plurality of aggregate signals may be provided across the plurality of interfaces and least one of a plurality of gain levels of the MCPA may be adjusted to maintain a linear output level. It should be noted that the plurality of gain levels may refer to gains associated with respective ones of the plurality of aggregate signals required such that a linear output level or consistent output gain level may be maintained. The plurality of gain levels may be measured during an interval using a sensor as described herein above and feed back information provided across the interface from the MCPA to the base station associated with the measured plurality of gain levels.
In one exemplary embodiment, the MCPA maintains a linear transmit power level by autonomously adjusting output power level on all active carriers by the same amount. Alternatively, the MCPA may maintain a linear transmit power level by maintaining a first power level associated with a control channel signal in the aggregate signal to preserve, for example, access capability particularly at cell boundaries. Power levels associated with remaining signals in the aggregate signal may be autonomously adjusted or alternatively, power levels associated with remaining signals in the aggregate signal can be prioritized by either the MCPA or the base station and power levels adjusted accordingly based on the prioritization. It may further be desirable to assign a higher priority to the remaining signals having relatively low power associated therewith.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and advantages of the invention will be understood by reading the following detailed description in conjunction with the drawings, in which:
FIG. 1A is a diagram illustrating an exemplary prior art Fixed Gain MCPA;
FIG. 1B is a diagram illustrating an exemplary embodiment of an interface between an MCPA and a Base Station in accordance with the present invention;
FIG. 1C is a diagram illustrating an exemplary autonomous MCPA embodiment in accordance with the present invention;
FIG. 2A is a diagram illustrating an exemplary digital interface between a Base Station Transceiver and a MCPA in accordance with the present invention;
FIG. 2B is a graph illustrating an exemplary percent load curve as a function of exemplary load feed-back in accordance with the present invention;
FIG. 3 is a diagram illustrating portions of an exemplary BTS and exemplary MCPA in accordance with the exemplary digital interface embodiment illustrated in FIG. 2A ; and
FIG. 4 is a flowchart illustrating an exemplary power limitation algorithm which may be used for the power control in accordance with the present invention.
DETAILED DESCRIPTION
Therefore, in accordance with the present invention a method and apparatus are provided for reducing and controlling power in a wireless communication system.
An exemplary prior art fixed gain MCPA is illustrated in FIG. 1A where independent sections of system 100 , including Base Station (BS) 110 and MCPA 120 are shown. BS 110 may process signal energy from, for example, channel 1 111 , channel 2 112 , channel 3 113 , and up to N channels as in channel N 114 , where N may represent the number of mobile stations which BS 110 is servicing. Signal energy from channel 1 111 , channel 2 112 , channel 3 113 and channel N 114 may be summed into composite signal 130 at summing block 115 . In the present embodiment, MCPA 120 may apply a fixed gain to composite signal 130 prior to transmission over, for example, an air interface. It should be noted that fixed gain may be applied in accordance with the present invention as will be described herein below, however in a different manner and using information provided by the MCPA, for example, over an interface which is not available in the prior art.
In the present embodiment of system 100 in accordance with the present invention, BS 110 and MCPA 120 may be split and an interface provided therebetween. Splitting BS 110 and MCPA 120 accordingly provides advantages over more highly integrated base stations found in the prior art, particularly as better MCPA technology develops. An interface in accordance with the present invention would allow service providers to seek independent sources for MCPAs, and as new more efficient MCPAs are made available, installation could occur without requiring the simultaneous replacement of base station hardware as would be required in, for example, an integrated system. Moreover, as power control interface standards evolve, placing more intelligence at the base station, new base station technology could be installed for interfacing with existing MCPAs or, for example, additional base stations may be added to a single MCPA.
In another exemplary embodiment of system 100 , as illustrated in FIG. 1B , BS 110 and MCPA 120 , are shown with an interface provided therebetween which includes feedback information. Composite signal 130 may be input into MCPA 120 as previously described. However, power control signal 131 in the present embodiment may be input from MCPA 120 to BS 110 to provide feedback information useful for, for example, optimizing the use of available RF power by MCPA 120 . System 100 may also be provided with a maintenance control interface between BS 110 and MCPA 120 using maintenance control signal 132 . Maintenance control signal 132 may include supervisory and maintenance related signals for conducting, for example, system testing, and the like. Thus, a standardized interface may be provided such that MCPAs and base stations may communicate information related to power control. Accordingly, MCPA 120 and Base Station BST 210 may be manufactured independently and optimal system behavior of system 200 may nonetheless be achieved through compliance with an interface in accordance with the present invention.
It may further be desirable for MCPA 120 to be provided with the capability for autonomous detection of overload and autonomous detection of gain to be described in more detail hereinafter, so that overload situations may be dealt with when, for example, BS 110 does not support power reduction. MCPA 120 therefore, in accordance with the present embodiment, may be illustrated in more detail in FIG. 1 C. It can be seen that composite signal 130 may be input to variable attenuator 122 which may then be fed to amplifier 123 where output signal 140 may be generated for transmission over, for example, an air interface. Power control output 131 can be generated in power control feedback block 121 and may correspond preferably linearly to the attennuation applied at variable attennuator 122 . Accordingly, BS 110 may be able to determine how much total output power should be reduced, or alternatively, how to manage additional load levels after a maximum load level has been reached as may best be illustrated in FIGS. 2A and 2B .
Base Station Transceiver (BTS) 210 may receive load feedback information 230 which may preferably be a digital signal or digital data representing, for example, peak output power per sampling interval or the like. It should be appreciated by those skilled in the art that while load feedback signal 230 is described as a digital data signal, it could also be embodied, for example, as an analog signal, a digital level from, for example, an A/D converter, or a digital information signal transmitted either on a signal serial digital interface line or on a parallel data bus. Thus, in accordance with the present embodiment, MCPA 120 may act autonomously to reduce the gain of the aggregated RF signal 220 to keep output levels within the linear range as may be seen in FIG. 2B , e.g. within specified carrier-to-distortion levels.
Accordingly, MCPA 120 may provide load feedback signal 230 representing a linear measure of an overload factor, or digital approximation thereof, back to Base Station BST 210 . Load feedback signal 230 may be either a normal linear feedback signal with 100% full load level defined as in FIG. 2B at 290 , or may output a zero level as in FIG. 2B at 280 up to a 100% load level at, for example, 290 wherein load feedback signal 230 may provide an increased value linearly at higher levels proportional to the amount of load as in FIG. 2B at 270 .
A better understanding of an exemplary interface in accordance with the present invention may be gained by reference to a more detailed illustration of an exemplary digital interface embodiment as in FIG. 3 . In one embodiment, MCPA 320 may be provided with, for example, amplifier 321 , control logic 322 , and level sensor 323 for controlling and providing feedback information to BTS 330 . Level sensor 323 , for example, may provide a digital information signal proportional to, for example, the peak output power relative to a 100% load level each averaging period. The value, for example, may be sent as load feedback signal 230 , every sampling interval. MCPA 320 may send samples autonomously where a clock signal is provided from MCPA 320 to BTS 330 , or may be sent in response to a clock received from BTS 330 which further inherently establishes a sampling interval. Such an embodiment may be shown for example with BTS 330 sending sampling period signal 311 to MCPA 320 to establish the sampling interval; and MCPA 320 sending clock signal 312 back to BTS 330 to provide information as to when samples are available.
In one embodiment, sampling clock signal 313 and averaging period signal 314 may preferably be provided by BTS 330 since preferred sampling intervals are generally known by BTS 330 , for example, at the end of a time slot in a TDMA system where each time slot may have a unique RF transmit power. Preferred sampling intervals may further be associated with measurement, for example, at level sensor 323 . In one embodiment, measurement, e.g. sampling, may be performed at an optimum point in a time slot. For example, if power is constant over a time slot, sampling should be performed preferably at the end of the measurement period when the greatest amount of data related to power levels has been collected by, for example, level sensor 323 . Alternatively, the sampling interval may be set for a duration which is suitable to achieve accuracy while providing adequate correlation of feedback information to the controlled intervals e.g. time slots. Such a sampling interval would preferably be around one time slot such that, for example, RF Power Control logic 333 will know exactly which time slot caused an overload, thus improving the accuracy of the power reduction algorithm.
In yet another embodiment, BTS 330 may send sampling clock signal 313 at irregular time intervals. Such irregular sampling may be suited for, for example, hybrid systems, or systems that do not use time slot synchronized carriers. An example of a hybrid system may be a base station which supports ANSI/TIA/EIA-136, supra, and future revised and/or related standards such as, for example, enhanced GPRS (EGPRS). Irregular sampling may further be useful on CDMA systems where there is no practical stable clocking period. It would further be useful to allow several BTS 330 which are designed to different specifications to be connected to a single MCPA 320 . For example, all, or some combination of an ANSI/TIA/EIA-136 compatible, EGPRS compatible, and a CDMA compatible BTS 330 could be coupled to MCPA 320 by means of an interface in accordance with the present invention for optimal power control being possible for all BTS 330 s so coupled.
Traffic control block 335 and RF Power Reduction Logic 333 in BTS 330 may use algorithms which are aimed at limiting peak output power. If the peak output power from MCPA 320 at any instant would be larger than the limit, MCPA 320 would loose linearity and therefore violate the spectrum mask specificied, for example, by the GSM specification, supra. Therefore, it is important for BTS 330 to ensure that power does not exceed limitations.
One important consideration in increasing the efficient use of power from MCPA 320 is to allocate more users to BTS 330 than what can be supported within the peak power limit by assuming that the Power Control algorithms used, for example, in RF Power Reduction Logic 333 and Traffic Control logic 335 will manage to keep the peak power within the limitation. When these assumptions fail, as they will for example during peak traffic times on all channels, output power must be manipulated for some users.
One algorithm for handling such situations works on a measurement report period basis. Since it is not possible to predict the fast changes coming from, for example, Discontinuous Transmission mode, (DTX), such changes can not be taken into account when setting the power to each communication link. Accordingly, a Power Control algorithm operating at a slower rate may be useful.
Whenever the requested peak power is above the limit of MCPA 320 requested power from one or several users must be denied and transmission must be conducted with a lower power. Such a reduction in power from what is requested will generally result in a reduction of the quality for the specific user.
FIG. 4 is a flow chart illustrating an exemplary power limitation algorithm which may be used for power control in accordance with the present invention. A time slot is selected for consideration in step 401 . When the requested average output power for a certain time slot has been calculated for the next measurement report period, the possible peak power of MCPA 320 may be calculated in step 402 and is compared with the limitation of MCPA 320 in step 403 . If the possible peak power is larger than the limit, a random TCH frequency may be selected in step 404 and power for that slot changed in step 405 so that the limitation is met. At this point, peak power is calculated again in step 406 , and if setting the average output power of the selected frequency to the minimum is not enough as in step 405 , another TCH carrier may be selected and power changed for that frequency as well. When the peak power of the time slot can be met we can set the power of the latest changed frequency to the maximum power that can meet the limitation of MCPA 320 .
It should be noted that when calculating the possible peak power for the next iteration frequency hopping may be taken into account. The worst case is when the user with the lowest output power is to transmit on the BCCH carrier. We have to dimension the MCPA to be able to handle that, even when there is an idle channel on the BCCH carrier, which will produce dummy bursts.
It should be understood that while an exemplary power reduction algorithm has been described herein, other methods exist. For example methods exist for reducing the power for all the users or reducing the power for the user that is using the highest power. Regardless of the power reduction method used, BTS 330 may be assumed to have knowledge about the maximum output power from MCPA 320 . BTS 330 however may not know the capacity of MCPA 320 if, for example, MCPA 320 comes from a different vendor. The capacity might also vary with temperature and power supply conditions. For example, at a power failure when BTS 330 will be operated on batteries or in countries with unstable current, MCPA 320 capacity may vary. It should further be evident to one skilled in the art that near real-time load information transferred, for example, from MCPA 320 to BTS 330 in accordance with the exemplary embodiments of the present invention, may be input to power limitation algorithms, as described previously herein, for more accurate performance.
It will be appreciated by those skilled in the art that the present invention may be embodied in other specific forms without departing from the spirit or essential character thereof. For example, while the present invention may typically be associated with GSM, TDMA and CDMA systems, the teachings in accordance with the present invention may be applied in other technologies as well. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims rather than the foregoing description and all changes that come within the meaning and range of equivalents thereof are indicated to be embraced therein.
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A method and apparatus for controlling power in a Multiple Carrier Power Amplifier (MCPA) equipped base station in a wireless communication system. MCPA gain level is adjusted to maintain a linear transmit power, measured during an interval, and related information fed back across an interface to the base station. Two control parameters are provided from the base station to control gain measurement. The feedback includes defining a 100% load level associated with the MCPA and feeding back information proportional to the measured gain level. A plurality of base stations may be supported by one MCPA using several interfaces.
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TECHNICAL FIELD
[0001] This document discloses various methods and systems for detecting contaminant concentrations in a fuel. For example, this document discloses methods and systems for detecting sulfur concentrations in a fuel, such as diesel fuel. Still more specifically, this document discloses methods and systems for detecting if a low sulfur diesel (LSD) has been introduced into an engine intended to run on ultra-low sulfur diesel (ULSD).
BACKGROUND
[0002] Power systems for engines, factories, and power plants produce emissions that contain a variety of pollutants. These pollutants may include, for example, particulate matter (e.g., soot), nitrogen oxides (NOx), and sulfur compounds. Due to heightened environmental concerns, engine exhaust emission standards have become increasingly stringent. In order to comply with emission standards, engine manufactures have developed and implemented a variety of exhaust after-treatment components to reduce pollutants in exhaust gas prior to the release of exhaust gas into the atmosphere.
[0003] The exhaust after-treatment components may include, for example, a diesel particulate filter (DPF), one or more selective catalytic reduction (SCR) devices, a lean NOx trap (LNT), a diesel oxidation catalyst (DOC), an ammonia oxidation catalyst (AMOX), a heat source for regeneration of the DPF, an exhaust gas recirculation (EGR) system, a muffler, and other similar devices. This document is directed to power systems equipped with NOx aftertreatment components, with or without additional components.
[0004] A NOx abatement catalyst module converts nitrogen NOx, with the aid of a catalyst, into diatomic nitrogen, N 2 , and water, H 2 O. A reductant, typically anhydrous ammonia, aqueous ammonia or urea, is injected upstream of the NOx abatement catalyst module so the reductant is adsorbed onto a catalyst of the SCR. Gaseous or liquid reductant may be injected into the exhaust stream. Liquid reductants are often referred to as diesel emission fluids (DEFs). DEF has become popular because of its liquid form, which is easy to store and handle. Further, DEF reduces the need to rely upon EGR to meet modern emission requirements.
[0005] Both SCR and LNT components may utilize platinum group metal (PGM) catalysts. As a result, exhaust after-treatment systems are sensitive to sulfur content in fuel because sulfur adsorbs onto and fouls PGM catalysts. Desulfation of a PGM catalyst requires permitting the exhaust gas to reach high temperatures (e.g., a catalyst bed temperature of about 650° C.) at a rich air/fuel ratio for an extended period, typically requiring at least several minutes of high-idle operation and an inconvenience to the operator. Desulfation occurs periodically, typically every 50 to 150 hours of engine operation, depending on the level of sulfur in the fuel, fuel consumption of the engine, and the NOx storage capacity of the PGM catalyst. Further, the use of PGM catalysts typically requires the use of ultra-low sulfur diesel (ULSD) fuel having a sulfur concentration of 15 ppm or less as opposed to low sulfur diesel (LSD) fuel having a sulfur concentration of 500 ppm or less in order to extend the time period between desulfation events. The inadvertent use of LSD fuel will quickly reduce the NOx reducing ability of a PGM catalyst.
[0006] Thus, when the sulfur content in the fuel is higher than expected, such as when LSD is erroneously added to the fuel tank instead of ULSD, time-based regenerations are inadequate and the NOx reducing performance of the exhaust after-treatment system is quickly reduced. While systems and methods for monitoring the performance of exhaust after-treatment systems may be useful for maintaining the performance of the exhaust after-treatment system, such monitoring systems do not identify why the after-treatment system is performing in a substandard fashion. Further, if an operator mistakenly uses LSD fuel, more frequent desulfations of the PGM catalyst must be carried out, which leads to frustration over increased fuel consumption and reduced available utilization time corresponding to the time it takes to regenerate the PGM catalyst.
[0007] US Patent Publication No. 2011/0271569 discloses a sensor for detecting sulfur in an exhaust stream that is positioned upstream of an exhaust after-treatment system. However, US Patent Publication No. 2011/0271569 does not disclose a means for a real-time detection of whether the sulfur content of the fuel is fouling an SCR catalyst.
[0008] Thus, there is a need for an exhaust aftertreatment control system that can quickly identify if a reduced NOx abatement performance of an exhaust aftertreatment system is being caused by the sulfur content of the fuel or if the reduced NOx abatement performance has an alternative cause, such as an equipment malfunction.
SUMMARY
[0009] In one aspect, this document discloses a method for detecting if a fuel containing more than a sulfur concentration threshold value is being combusted in an engine. The engine may include a selective catalytic reduction (SCR) module. The disclosed method may include desulfating the NOx abatement catalyst module and detecting a proper functioning of the NOx abatement catalyst module. The detecting of the proper functioning of the NOx abatement catalyst module may be carried out by at least one of the following: detecting a NOx conversion ratio that is above a NOx conversion ratio threshold value; and detecting an ammonia slip value downstream of the NOx abatement catalyst module that is below an ammonia slip threshold value. The method may further include detecting a malfunction of the NOx abatement catalyst module by at least one of the following: detecting that the NOx conversion ratio is below the NOx conversion ratio threshold value; and detecting that the ammonia slip value downstream of the NOx abatement catalyst module is above the ammonia slip threshold value. The method may further include determining a first operating time of the engine between the desulfating and the detecting of the malfunction. If the first operating time is less than a predetermined maximum time and greater than a predetermined minimum time, the method may include increasing a frequent desulfation counter by 1. Further, the method may include sending a fault signal indicating that the sulfur concentration of the fuel exceeds the sulfur concentration threshold value concentration when the frequent desulfation counter exceeds a FDC threshold value.
[0010] In another aspect, this document discloses a system for detecting when an engine is combusting fuel containing more than a sulfur concentration threshold value. The system may include a selective catalytic reduction (SCR) module that includes an SCR catalyst. The system may further include at least one sensor for detecting at least one of the following: a NOx concentration downstream of the NOx abatement catalyst module; and a NH 3 concentration downstream of the NOx abatement catalyst module. The at least one sensor may be linked to a controller. The controller may be configured to calculate at least one of a conversion ratio of NOx by the NOx abatement catalyst module and a degree of ammonia slip. The controller may further be configured to initiate desulfation of the SCR catalyst if at least one of the conversion ratio or the degree of ammonia slip fails to meet at least one predetermined criteria. The controller may further be configured to record when a desulfation is complete and the controller may further be configured to determine a desulfation request time (DRT) between completion of a desulfation and initiation of a new desulfation. The controller may further be configured to increment a frequent desulfation counter (FDC) each time the DRT is greater than a predetermined minimum time and less than a predetermined maximum time. The controller may further be configured to initiate a sulfur alarm signal when the FDC reaches a NOx conversion ratio threshold value.
[0011] This document also discloses a power system. The disclosed power system may include an engine that includes a manifold exhaust passage in communication with a selective catalytic reduction (SCR) module that includes an SCR catalyst. The NOx abatement catalyst module may be in communication with an exhaust outlet. The power system may further include at least one sensor for detecting at least one of the following: a NOx concentration downstream of the NOx abatement catalyst module; and a NH 3 concentration downstream of the NOx abatement catalyst module. The at least one sensor may be linked to a controller. The controller may be configured to calculate at least one of a conversion ratio of NOx by the NOx abatement catalyst module and a degree of ammonia slip. The controller may be further configured to initiate desulfation of the SCR catalyst if at least one of the conversion ratio or the degree of ammonia slip fails to meet at least one of a predetermined criteria. The controller may further be configured to record when a desulfation is complete. The controller may further be configured to determine a desulfation request time (DRT) between completion of a desulfation and initiation of a new desulfation. The controller may further be configured to increment a frequent desulfation counter (FDC) each time the DRT is greater than a predetermined minimum time period and less than a predetermined maximum time period. The controller may further be configured to initiate a sulfur alarm signal when the FDC reaches a NOx conversion ratio threshold value.
[0012] The features, functions, and advantages discussed above may be achieved independently in various embodiments or may be combined in yet other embodiments, further details of which can be seen with reference to the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For a more complete understanding of the disclosed methods and apparatuses, reference should be made to the embodiments illustrated in greater detail on the accompanying drawings, wherein:
[0014] FIG. 1 is a schematic and diagrammatic illustration of an exemplary disclosed power system.
[0015] FIG. 2 is a time line that schematically illustrates the desulfation request timer (DRT), the frequent slip timer (FST) and the frequent desulfation timer (FDT).
[0016] FIG. 3 is a flow chart illustrating the action of a controller when the desulfation request timer (DRT) exceeds a predetermined maximum time period.
[0017] FIG. 4 is a flow chart illustrating the indexing of the frequent desulfation counter (FDC) and the infrequent desulfation counter (IDC).
[0018] FIG. 5 is a flow chart illustrating the disclosed system and method for determining whether the sulfur concentration in the fuel being combusted is causing the decreased conversion ratio or ammonia slip failure or whether a component malfunction is causing the failure.
[0019] The drawings are not necessarily to scale and illustrate the disclosed embodiments diagrammatically and in partial views. In certain instances, this disclosure may omit details which are not necessary for an understanding of the disclosed methods and apparatuses or which render other details difficult to perceive. Further, this disclosure is not limited to the particular embodiments illustrated herein.
DETAILED DESCRIPTION
[0020] FIG. 1 illustrates an exemplary power system 10 . For the purposes of this disclosure, the power system 10 is depicted and described as a diesel-fueled, internal combustion engine. However, it is contemplated that the power system 10 may embody any other type of combustion engine, such as, for example, a gasoline or a gaseous fuel-powered engine burning compressed or liquefied nature gas, propane, etc. The power system 10 may include an engine block 12 that may at least partially define a plurality of cylinders 13 , and a plurality of piston assemblies (not shown) disposed within the cylinders 13 . It is contemplated that power system 10 may include any number of cylinders 13 and that the cylinders 13 may be disposed in an “in-line” configuration, a “V” configuration, or any other conventional configuration.
[0021] Multiple separate sub-systems may be included within the power system 10 . For example, the power system 10 may include an air induction system 14 and an exhaust system 15 . The air induction system 14 may direct air or an air and fuel mixture into the power system 10 for subsequent combustion. The exhaust system 15 may exhaust the byproducts of combustion to the atmosphere. The operation of air induction and exhaust systems 14 , 15 may be controlled to reduce the production of regulated constituents and their discharge to the atmosphere.
[0022] The air induction system 14 may include multiple components that cooperate to condition and introduce compressed air into the cylinders 13 . For example, the air induction system 14 may include an air cooler 17 located downstream of a compressor 18 , although a plurality of compressors may be employed. The compressor 18 may connect to pressurize inlet air directed through the air cooler 17 . A throttle valve (not shown) may be located upstream of the compressor 18 to selectively regulate (i.e., restrict) the flow of inlet air into power system 10 . A restriction may result in less air entering the power system 10 and, thus, affect an air-to-fuel ratio of power system 10 . It is contemplated that the air induction system 14 may include different or additional components than described above such as, for example, variable valve actuators associated with each cylinder 13 , filtering components, compressor bypass components, and other known components that may be controlled to affect the air-to-fuel ratio of power system 10 . It is further contemplated that the compressor 18 and/or the air cooler 17 may be omitted, if the power system 10 is naturally aspirated.
[0023] The exhaust system 15 may include multiple components that condition and direct exhaust from the cylinders 13 to the atmosphere. For example, the exhaust system 15 may include an exhaust manifold conduit 19 , an exhaust outlet 21 and a turbine 22 . Although a single turbine 22 is shown in FIG. 1 for purposes of clarity, a plurality of turbines may be employed. The turbine 22 is driven by the exhaust flowing through exhaust manifold conduit 19 . The exhaust system 15 may further include a NOx abatement catalyst module 23 fluidly connected downstream of the turbine 22 . The NOx abatement catalyst module 23 may be a SCR module or another catalyst module capable of reducing NOx in the exhaust, as will be apparent to those skilled in the art. The exhaust system 15 may further include different or additional components than described above such as bypass components, an exhaust compression or restriction brake, a sound attenuation device, additional exhaust treatment devices, and other known components.
[0024] The turbine 22 may be located to receive exhaust leaving the engine block 12 , and may connect to the compressor 18 of the air induction system 14 by way of a common shaft 24 to form a turbocharger. As the hot exhaust gases exit the power system 10 and move through the turbine 22 and expand against the vanes (not shown) thereof, the turbine 22 may rotate and drive the connected compressor 18 to pressurize the inlet air. In one embodiment, the turbine 22 may be a variable geometry turbine (VGT) or include a combination of variable and fixed geometry turbines.
[0025] The NOx abatement catalyst module 23 may receive exhaust from the turbine 22 and reduce constituents of the exhaust to innocuous gases. In one example, the NOx abatement catalyst module 23 may include a catalyst substrate (not shown) located downstream from a reductant injector 25 . A gaseous or liquid reductant, most commonly urea ((NH 2 ) 2 CO), a water/urea mixture, a hydrocarbon for example diesel fuel, or ammonia gas (NH 3 ), may be sprayed or otherwise advanced into the exhaust upstream of the NOx abatement catalyst module 23 by the reductant injector 25 . For this purpose, an onboard reductant supply 26 and a pressurizing device or a pump 27 may be associated with the reductant injector 25 . As the reductant is adsorbed onto the surface of catalyst substrate (not shown) of the NOx abatement catalyst module 23 , the reductant may react with NOx (NO, NO 2 , and NO 3 ) in the exhaust stream to form water (H 2 O) and elemental nitrogen (N 2 ). The reduction process performed in the NOx abatement catalyst module 23 may be most effective when a ratio of NO to NO 2 supplied to the NOx abatement catalyst module 23 is adjusted to optimize the NOx reduction at the catalyst.
[0026] To help provide a more optimal concentration of NO to NO 2 at the NOx abatement catalyst module 23 , an oxidation catalyst, such as a diesel oxidation catalyst (DOC) may be located upstream of the NOx abatement catalyst module 23 , and in some embodiments, in the form of an optional combined diesel oxidation catalyst/diesel particulate filter (DOC/DPF) module 28 . The oxidation catalyst may include a porous ceramic honeycomb structure or a metal mesh substrate coated with a material, such as a precious metal that catalyzes a chemical reaction to alter the composition of the exhaust. For example, the oxidation catalyst may include palladium, platinum, vanadium, or a mixture thereof that facilitates the conversion of NO to NO 2 .
[0027] During operation of the power system 10 , it may be possible for too much urea or too much ammonia to be injected into the exhaust (i.e., urea or ammonia in excess of that required for appropriate NOx reduction). In this situation, known as “ammonia slip,” some amount of ammonia may pass through the NOx abatement catalyst module 23 to the atmosphere, if not otherwise accounted for. To minimize the magnitude of ammonia slip, an ammonia oxidation (AMOx) module 29 may optionally be located downstream of the NOx abatement catalyst module 23 . The AMOx module 29 may include a substrate coated with a catalyst that oxidizes residual NH 3 in the exhaust to form water and elemental nitrogen (N 2 ).
[0028] The power system 10 may include components configured to regulate the treatment of the exhaust prior to its discharge to the atmosphere. Specifically, the power system 10 may include a controller 31 in communication with a plurality of sensors 32 - 39 (the communication lines are not shown in FIG. 1 for purposes of clarity). The controller 31 may also be in communication with the pump 27 . Based on inputs from the sensors 32 - 39 , the controller 31 may determine an amount of NOx being produced by power system 10 , an operational parameter of the NOx abatement catalyst module 23 and an optimal amount of urea to be sprayed by the reductant injector 25 into the exhaust passageway 41 based on the NOx production amount and the operational parameter. Using the sensors 32 - 39 , the controller 31 may also determine a performance parameter of the NOx abatement catalyst module 23 and an adjustment of the urea injection based on the performance parameter. The controller 31 may then regulate operation of the reductant injector 25 and the pump 27 such that the adjusted amount of urea is sprayed into the exhaust flow upstream of the NOx abatement catalyst module 23 .
[0029] The controller 31 may embody a single or multiple microprocessors, field programmable gate arrays (FPGAs), digital signal processors (DSPs), etc. that include a means for controlling an operation of power system 10 in response to signals received from the various sensors. Numerous commercially available microprocessors may perform the functions of the controller 31 . The controller 31 may embody a microprocessor separate from that controlling other non-exhaust related power system functions, or the controller 31 may be integral with a general power system microprocessor and be capable of controlling numerous power system functions and modes of operation. If separate from the general power system microprocessor, the controller 31 may communicate with the general power system microprocessor via datalinks or other methods. Various other known circuits may be associated with the controller 31 , including power supply circuitry, signal-conditioning circuitry, actuator driver circuitry (i.e., circuitry powering solenoids, motors, or piezo actuators), communication circuitry, and other appropriate circuitry.
[0030] A first sensor 32 of the power system 10 may be a constituent sensor configured to generate a signal indicative of the presence of a particular constituent within the exhaust flow. For example, the sensor 32 may be an engine-out NOx sensor configured to determine an amount (i.e., quantity, relative percent, ratio, etc.) of NO and/or NO 2 present within the exhaust of the power system 10 . If embodied as a physical sensor, the engine-out NOx sensor 32 may be located upstream or downstream of the optional DOC/DPF module 28 . Whether located upstream or downstream of the oxidation catalyst of the optional DOC/DPF module 28 , the engine-out NOx sensor 32 may be situated to sense a production of NOx by the power system 10 . The engine-out NOx sensor 32 may generate a signal indicative of these measurements and send the signal to the controller 31 .
[0031] The engine-out NOx sensor 32 may alternatively embody a virtual sensor. A virtual sensor may produce a model-driven estimate based on one or more known or sensed operational parameters of the power system 10 and/or the optional DOC/DPF module 28 . For example, based on a known operating speed, load, temperature, boost pressure, ambient conditions (humidity, pressure, temperature), and/or other parameters of the power system 10 , a model may be referenced to determine an amount of NO and/or NO 2 produced by power system 10 . Similarly, based on a known or estimated NOx production of the power system 10 , a flow rate of exhaust exiting the power system 10 , and/or a temperature of the exhaust, the model may be referenced to determine an amount of NO and/or NO 2 leaving the optional DOC/DPF module 28 and entering the NOx abatement catalyst module 23 . As a result, the signal directed from engine-out NOx sensor 32 to the controller 31 may be based on calculated and/or estimated values rather than direct measurements. Rather than employing a separate element, virtual sensing functions may be accomplished by the controller 31 .
[0032] The operational parameters of the NOx abatement catalyst module 23 may be monitored by way of the temperature sensor 34 and/or the flow meter sensor 35 . The temperature sensor 34 may be located anywhere within exhaust system 15 to generate a signal indicative of an operating temperature of the NOx abatement catalyst module 23 . In one example, the temperature sensor 34 may be located upstream of the NOx abatement catalyst module 23 . In another example, the temperature sensor 34 may be located in contact with or downstream of the NOx abatement catalyst module 23 . The flow meter sensor 35 may embody any type of sensor utilized to generate a signal indicative of an exhaust flow rate through the NOx abatement catalyst module 23 . The temperature and/or flow rate signals may be utilized by the controller 31 to determine a NOx reducing capacity of the NOx abatement catalyst module 23 . That is, based on known dimensions and the age of the catalyst of the NOx abatement catalyst module 23 , and based on the measured operational parameters, a NOx reducing performance of the NOx abatement catalyst module 23 may be predicted. It is contemplated that the flow meter sensor 35 may alternatively embody a virtual sensor, similar to the engine-out NOx sensor 32 .
[0033] Similar to the NOx abatement catalyst module 23 , the operation of the optional DOC/DPF module 28 may be monitored by way of the temperature sensor 34 or another dedicated temperature sensor (not shown). The temperature signal may be utilized by the controller 31 to determine a model driven estimate of the ratio or split of NO:NO 2 exiting the optional DOC/DPF module 28 .
[0034] Thus, a NOx production signal, a temperature signal, and a flow rate signal from sensors 32 , 34 , 35 , may be utilized by the controller 31 to determine an optimal amount of reductant to be injected via the reductant injector 25 to reduce the produced NOx to a regulated level or less. The controller 31 may also subsequently adjust the injection amount based on actual performance parameters measured downstream of the NOx abatement catalyst module 23 . That is, after an initial reductant injection of the quantity determined above, controller 31 may sense the actual performance of the NOx abatement catalyst module 23 and adjust future reductant injections accordingly. For this purpose, the power system 10 may include a post-aftertreatment NOx sensor 36 located downstream of the NOx abatement catalyst module 23 . This process of adjusting the injection amount based on a measured performance parameter is known as feedback control.
[0035] Similar to the engine-out NOx sensor 32 , the post-aftertreatment NOx sensor 36 may also generate a signal indicative of the presence of NOx within the exhaust flow. For instance, the post-aftertreatment NOx sensor 36 may determine an amount (i.e., quantity, relative percent, ratio, etc.) of NO and/or NO 2 present within the exhaust flow downstream of the NOx abatement catalyst module 23 . The post-aftertreatment NOx sensor 36 may generate a signal indicative of these measurements and send it to the controller 31 . If the amount of NOx monitored by the post-aftertreatment NOx sensor 36 exceeds a threshold level, the controller 31 may provide feedback to the reductant injector 25 to increase the amount of urea (or ammonia) injected into the exhaust passageway 41 to reduce NOx within the NOx abatement catalyst module 23 . In contrast, if the amount of NOx monitored by the post-aftertreatment NOx sensor 36 is below a threshold level, less urea (or ammonia) may be injected in an attempt to conserve urea (or ammonia) and/or extend the useful life of oxidation catalyst within the AMO x module 29 . Alternatively, the post-aftertreatment NOx sensor 36 may embody a sensor useful in determining the amount of NH 3 entering the AMO x module 29 .
[0036] If the oxidation catalyst of the optional DOC/DPF module 28 is overloaded with particulate matter, the relative amount of NO 2 received by the NOx abatement catalyst module 23 could be negatively affected, even though the optional DOC/DPF module 28 may be properly converting NO to NO 2 . To accommodate this situation, the soot loading of the oxidation catalyst of the optional DOC/DPF module 28 may be monitored, and the operation of the NOx abatement catalyst module 23 adjusted accordingly. For this purpose, an additional sensor 33 may be associated with oxidation catalyst of the optional DOC/DPF module 28 . The sensor 33 may embody any type of sensor utilized to determine an amount of particulate buildup within an oxidation catalyst. For example, the sensor 33 may embody a pressure sensor or pair of pressure sensors, a temperature sensor, a model driven virtual sensor, an RF sensor, or any other type of sensor known in the art. The sensor 33 may generate a signal directed to the 31 indicative of a particulate buildup, and the controller 31 may adjust the injection of reductant through the reductant injector 25 accordingly.
[0037] The controller 31 may also adjust reductant injections based on an amount of urea available for injection. Thus, the power system 10 may include a sensor 37 associated with the reductant supply 26 . The sensor 37 may be a temperature sensor, a viscosity sensor, a fluid level sensor, a pressure sensor, or any other type of sensor configured to generate a signal indicative of an amount of urea (or ammonia or reductant) available for injection. This signal may be directed from sensor 37 to the controller 31 .
[0038] As noted above, in some situations, too much urea or reductant may be injected resulting in “ammonia slip.” Although the AMO x module 29 , if present, may oxidize the slipping ammonia such that little, if any, ammonia is exhausted to the atmosphere, the extra ammonia may still unnecessarily increase the operational costs of the power system 10 . For this reason, the controller 31 may adjust reductant injections based on a measured amount of ammonia downstream of the NOx abatement catalyst module 23 or upstream or downstream of the AMO x module 29 . Ammonia slip may be monitored by a sensor 38 , which may be a virtual sensor that generates an ammonia slip signal based on post processing of a signal generated by a true NOx sensor. Thus, the sensor 38 may be an NOx sensor that may be used to virtually detect ammonia slip.
[0039] The interaction of the controller 31 with the sensors 32 - 38 is further illustrated in FIGS. 2-5 . FIG. 2 is a timeline that illustrates certain times between events that are recorded and used by the controller 31 to determine whether fuel with a sulfur concentration above a threshold concentration (e.g., 15 ppm) is being combusted in the cylinders 13 . At 51 , the controller 31 has determined a failure in either: (1) a conversion ratio of the NOx (i.e., the concentration of NOx detected by the sensor 32 minus the concentration of NOx detected by the post-aftertreatment NOx sensor 36 divided by the concentration of NOx detected by the engine-out NOx sensor 32 ); or (2) a degree of ammonia slip detected by the sensor 38 . If either the NOx conversion ratio falls below an NOx conversion ratio threshold value or the ammonia slip falls above an ammonia slip threshold value, the controller 31 registers a failure and initiates a request for desulfation of the catalyst of the NOx abatement catalyst module 23 . Desulfation may be carried out in a variety of ways most of which include permitting the catalyst bed of the NOx abatement catalyst module 23 to reach an elevated temperature of about 550° C. When the desulfation is complete at 52 , a desulfation request time or timer (DRT) is initiated as shown in FIG. 2 . The DRT is the time between completion of a desulfation at 52 and a subsequent conversion ratio or slip failure and a request for a new desulfation at 53 . Typically, if a fuel containing too much sulfur, such as LSD, is combusted in the power system 10 , the time between a completed desulfation at 52 and a subsequent conversion ratio or ammonia slip failure at 53 will fall within a time range that is greater than about 3 hours and less than about 10 hours. Specifically, if the DRT, or the time between a completed desulfation at 52 and a subsequent conversion ratio or ammonia slip failure at 53 , is less than 3 hours, it is evident that a component of the power system 10 is malfunctioning and the subsequent conversion ratio or ammonia slip failure at 53 is not caused by a sulfur buildup on the catalyst because it takes a minimum of about 3 hours for LSD to foul a properly desulfated catalyst. Thus, if DRT is less than 3 hours, a malfunction in the exhaust system 15 cannot be caused exclusively by LSD or a fuel with an excessive amount of sulfur. Similarly, if DRT exceeds 10 hours, excess sulfur in the fuel may be ruled out as the cause of the subsequent conversion ratio or slip failure at 53 because, if the power system 10 was burning LSD fuel, the conversion ratio or slip failure would occur before the duration of 10 hours, not after 10 hours has elapsed. Thus, for a conversion ratio or ammonia slip failure to be attributable to sulfur in the fuel, the DRT should fall within the 3 to 10 hour time range in this example. Of course, the lower and upper limits for the DRT may vary, as will be apparent to those skilled in the art.
[0040] Still referring to FIG. 2 , if an ammonia slip sensor 38 ( FIG. 1 ) is employed, the controller 31 may send a signal to activate or deactivate the ammonia slip sensor 38 as needed. As shown in FIG. 2 , the time between an activation of the ammonia slip sensor 38 at 54 and the subsequent conversion ratio or slip failure at 53 is referred to as the frequent slip time or timer (FST). The FST must be greater than about 3 hours for sulfur in the fuel to cause the subsequent conversion ratio or ammonia slip failure at 53 . If the FST is less than 3 hours, the problem is attributed to a component malfunction or a problem other than fouling of the catalyst of the NOx abatement catalyst module 23 . Further, after a conversion ratio or slip failure at 51 and a subsequent desulfation at 52 , the controller 31 continuously monitors data from the sensors 32 , 36 , 38 . When a conversion ratio or ammonia slip measurement passes at 55 (i.e., the conversion ratio of NOx exceeds a threshold value and an ammonia slip value falls below a threshold value), the frequent desulfation timer (FDT) is initiated at 55 . As shown in FIG. 2 , FDT represents the time between a conversion ratio and ammonia slip pass at 55 and a subsequent conversion ratio or ammonia slip failure at 53 . To register a conversion ratio and ammonia slip pass at 55 , for the power system 10 shown in FIG. 1 , both the data from the NOx sensors 32 , 36 as well as the data from the ammonia slip sensor 38 must satisfy the threshold criteria. In other words, both NOx and ammonia slip (if both types of sensors are utilized) must pass at 55 while either the NOx conversion ratio or ammonia slip value can fail at 53 to register a failure.
[0041] FIG. 3 illustrates a situation where sulfur in the fuel is not causing a conversion ratio or ammonia slip failure. The controller 31 registers a conversion ratio or an ammonia slip failure at 51 (and requests desulfation) and the desulfation is complete at 52 . Then, the controller 31 registers a conversion ratio and an ammonia slip pass at 55 followed by a failure at 53 . If the DRT (desulfation request timer) and the FST (frequent slip timer) are both greater than 3 hours at 56 and the DRT is greater than 10 hours at 57 , then the fouling problem that occurred at 53 is not attributable to sulfur in the fuel and, therefore an equipment failure or alarm signal is issued at 58 . The equipment failure or alarm signal may be an audible tone or lamp in an operator cab or may be a flag readable as an error code on a diagnostic device among other potential signals.
[0042] Turning to FIG. 4 , when the controller 31 determines that desulfation is complete at 52 , a subsequent conversion ratio or slip failure occurs at 53 , and the FDT (frequent desulfation timer) is less than 5 hours at 59 , a frequent desulfation counter (FDC) is incremented by 1 at 61 . If the FDT is not less than 5 hours or is greater than 5 hours at 59 , then an infrequent desulfation counter is indexed by 1 at 62 . Further, if the IDC (infrequent desulfation counter) is equal to 2 or more at 63 , then the FDC is reset to 0 at 64 .
[0043] It will be noted that the time periods discussed above in connection with FIGS. 2-4 may be varied, depending upon the size and structure of the NOx abatement catalyst module 23 and various parameters of the power system 10 . For example, the threshold time period for the FDT (frequent desulfation timer) in order for the FDC (frequent desulfation counter) to be incremented may range from about 3 hours to about 7 hours as opposed to the 5 hours indicated in FIG. 4 . Further, the requisite time period for the FST (frequent slip timer) in order for fouling to be attributable to fuel may vary from the 3 hours set forth in FIGS. 2-3 and may range from about 2 to about 4 hours. Further, in order for fouling to be attributable to fuel, the indicated range for the DRT (desulfation request timer) may vary from the stated 3-10 hour change. The lower end of this range should correspond that of the FST, and may vary from about 2 to about 4 hours and the upper range for the DRT may range from about 6 to about 15 hours, again depending upon the structure of the NOx abatement catalyst module, the particular power system 10 , the particular catalyst utilized, and a host of other factors.
[0044] FIG. 5 explains the disclosed method and system for detecting when an engine is combusting fuel containing more than a threshold concentration of sulfur. A conversion ratio or ammonia slip failure is detected at 51 a by the controller 31 based on signals from the sensors 32 , 36 , 38 and the controller 31 initiates a desulfation at 51 b . The controller determines if the DRT (desulfation request timer) is less than 10 hours at 71 and, if the DRT is less than 10 hours at 71 , the FDC (frequent desulfation counter) is incremented at 72 . If the FDC exceeds 4 (or an alternative threshold value) at 73 , the controller initiates a sulfur contamination alarm/signal at 74 . After the desulfation is requested at 51 b and the desulfation is complete at 52 , the DRT (desulfation request timer) is reset to 0 at 75 . If the controller 31 registers a conversion ratio or ammonia slip pass at 76 , the controller 31 determines if the FST (frequent slip timer) is less than 3 hours at 77 . If the FST is less than 3 hours at 77 , the conversion ratio or ammonia slip failure at 51 a is not due to sulfur in the fuel because, as discussed above in connection with FIG. 2 , sulfur in the fuel takes more than 3 hours to foul the catalyst of the NOx abatement catalyst module 23 . Thus, if the FST is less than 3 hours at 77 , an equipment failure alarm/signal is initiated at 78 , which indicates to the operator that the failure is not due to sulfur in the fuel. If the conversion ratio and ammonia slip passes at 76 , the controller considers it a successful desulfation at 79 and the frequent desulfation timer is reset to 0 at 81 .
[0045] Again, while FIG. 5 indicates specific values for threshold values, such as that for the DRT, FDC and FST, these values may vary, as will be apparent to those skilled in the art. Referring to block 71 of FIG. 5 , the DRT is less than 10 hours, fuel is considered to be the problem and the FDC is incremented at 72 . The 10-hour value for the DRT in block 71 may vary and may range from about 6 to about 15 hours, depending upon the specific NOx abatement catalyst module employed. Similarly, because conversion ratio and ammonia slip failures can result from noise or other problems with the power system 10 , prior to the issuance of a fuel sulfur contamination alarm/signal at 74 , the FDC must exceed 4 or, there must be at least 4 conversion ratio or ammonia slip failures prior to the issuance of a fuel sulfur contamination alarm/signal. Of course, the value of 4 for the FDC may vary and may range from as few as 2 to several or more. Similarly, as discussed above, the time required for sulfur and fuel to foul a catalyst is typically about 3 hours, but depending upon the NOx abatement catalyst module 23 utilized, the lower limit or the 3-hour limit for the FST may range from about 2 to about 4 hours.
INDUSTRIAL APPLICABILITY
[0046] The method and system for detecting when an engine is combusting fuel containing more than a threshold concentration of sulfur may be applicable to any power system 10 having a reduction catalyst and which employs injection of a reductant into the exhaust upstream of the reduction catalyst. Referring to FIG. 1 , the air induction system 14 may pressurize and force air or a mixture of air and fuel into the cylinders 13 for combustion. The fuel and air mixture may combust to produce mechanical work and an exhaust flow of hot gases through the exhaust manifold conduit 19 . The exhaust flow may contain a complex mixture of air pollutants composed of gassiest material, which can include oxides of nitrogen (NOx). Following the optional DOC/DPF module 28 shown in FIG. 1 , the exhaust flow may be directed towards the reduction catalyst of the NOx abatement catalyst module 23 , where the NOx may be reduced to water and elemental nitrogen.
[0047] Prior to reaching the reduction catalyst of the NOx abatement catalyst module 23 , the controller 31 may, based on input from the NOx sensors 32 , 36 , determine an amount of reductant required for the NOx abatement catalyst module 23 to sufficiently reduce the NOx produced by the power system 10 . The amount of reductant injected by the reductant injector 25 may be adjusted, based on input from the sensors 33 , 37 , 38 , and/or 39 . After reduction takes place within the NOx abatement catalyst module 23 , the exhaust may pass through the AMO x module 29 to the atmosphere. Within the AMO x module 29 , any additional ammonia may be reduced to innocuous substances, unless the catalyst of the NOx abatement catalyst module 23 is fouled.
[0048] To determine if the catalyst of the NOx abatement catalyst module is fouled, various time periods are kept track of. Specifically, if the time period between a conversion ratio and an ammonia slip pass and subsequent conversion ratio or ammonia slip failure (see the blocks 55 and 53 of FIG. 2 ) is less than 3 hours or the FDT is less than 3 hours, the failure is deemed to be not attributable to sulfur in the fuel. This is because it typically takes more than a threshold value of time to foul the catalyst of the NOx abatement catalyst module 23 . In the example set forth above, this threshold time value is about 3 hours. However, this time value may vary and, in order for a conversion ratio or a slip failure to be attributable to sulfur in the fuel, the time between a previous pass (see the block 55 of FIG. 2 ) and a subsequent failure (see the block 53 of FIG. 2 ) must be more than a threshold time value. This threshold time value may be about 3 hours, but may range from about 2 to about 4 hours. Further, if an ammonia slip sensor 38 is utilized, a FST (frequent slip timer) is also utilized. In the examples set forth above, when the FST is less than 3 hours, a conversion ratio or slip failure is attributed to equipment failure, and not sulfur in the fuel as shown in FIG. 5 (see blocks 77 and 78 ). This 3-hour threshold value may vary, of course, and may range from about 2 to about 4 hours. Still further, the time between a completed desulfation (see block 52 of FIG. 2 ) and a subsequent conversion ratio or ammonia slip failure (see block 53 of FIG. 2 ) is deemed the DRT (desulfation request timer). In order for a failure to be attributable to sulfur in the fuel, the DRT should exceed the time limit for the FST (e.g., 3 hours or a range from about 2 to about 4 hours) and the DRT must not exceed a certain time period as well. In the example set forth above, if the DRT exceeds 10 hours, (see block 71 of FIG. 5 ), the FDC is not incremented and a sulfur contamination alarm/signal is not generated. This is because if fuel having too much sulfur is being combusted in the power system 10 , a conversion ratio or slip failure will be registered by the controller 31 within a certain time period, which may be about 10 hours or less. The 10-hour threshold value may be modified and may range from about 6 to about 15 hours, depending upon the NOx abatement catalyst module 23 utilized, the details of the power system 10 and other factors as well. Thus, the 10-hour example shown in FIGS. 3 and 5 is but an example, as will be apparent to those skilled in the art.
[0049] Alternative embodiments and various modifications will be apparent from the above description to those skilled in the art. These and other alternatives are considered equivalents and within the spirit and scope of the present disclosure.
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A method and a system for determining if fuel containing more than the desired concentration of sulfur is being combusted in an engine. The engine includes a selected catalytic reduction (SCR) module or a lean NOx trap (LNT) and the system includes various sensors and a controller for calculating NOx conversion ratio and ammonia slip. Timers are utilized for purposes of positively identifying when sulfur in the fuel is causing a substandard performance of the exhaust system. If the timers or time periods are not satisfied, a conversion ratio failure or an ammonia slip failure is attributable to equipment failure, and not sulfur in the fuel. However, if the timers are satisfied, then sulfur in the fuel is positively identified as the problem thereby enabling the operator to eliminate equipment failure as a possible source of the conversion ratio or ammonia slip failure.
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BACKGROUND OF THE INVENTION
The present invention relates in general to a regulating valve suitable for controlling the flow of a fluid in response to a sensed condition, and more particularly, to such a regulating valve suitable for controlling the flow of a heating or cooling medium in response to changes in temperature at a selected location, which temperature changes are sensed by a thermal element, and designed to either permit or prevent flow of the heating or cooling medium upon failure of the thermal element.
Regulating valves are commonly used for controlling the flow of a heating or cooling medium internally within a surrounding jacket of, for example, engines, compressors, heat transfer equipment and the like. The temperature of the heating or cooling medium in the jacket is sensed by a thermal element. These thermal elements are typically of the expansion type incorporating liquid, vapor, gas, wax or bi-metallic members to produce the necessary force and movement. In heating operations, the flow of the heating medium is increased when the sensed temperature drops and reduced when the sensed temperature increases. On the other hand, in cooling operations, the flow of the cooling medium is reduced when the sensed temperature drops and increased when the sensed temperature increases.
In a typical situation where cooling water or brine is supplied to the jacket of an internal combustion engine or a compressor, the fluid in the thermal element expands and elongates a bellows assembly in response to an increase in the temperature of the cooling water or brine flowing through the jacket. The elongated bellows is operative to extend a shaft to move a pilot mechanism in a preferred direction to cause the regulating valve to open and increase the flow of cooling water or brine to the jacket. On the other hand, a drop in temperature of the cooling water or brine causes the collapse of the bellows assembly and the retraction of the shaft. This results in the pilot mechanism moving in another preferred direction to cause the regulating valve to close, to a varied degree, thereby reducing the flow of the cooling water or brine until the temperature of same within the jacket to the engine returns to within the desired range.
In the foregoing situation, failure of the thermal element corresponds to the thermal element sensing an extremely low temperature which results in the collapse of the bellows assembly and the retraction of the shaft. This results in the pilot mechanism moving to a position which closes off the flow of the cooling water or brine to the jacket, despite the fact that the temperature of the cooling water or brine within the jacket may be excessively high. As a consequence, there is a serious potential to cause irreparable damage to the engine. This problem is also present when using a heating medium such as oil or steam in heat transfer equipment such as reaction vessels and the like. The failure of the thermal element will accordingly correspond to the sensing of a very low temperature which, in turn, causes the pilot mechanism to move to a position to open the flow of hot oil or steam to the jacket of the reactor vessel. As a consequence, the chemical reaction may be adversely effected with potentially dangerous consequences.
In order to overcome the foregoing problem resulting from the failure of the thermal element, complex circuits and auxiliary controls have been devised to provide what has been commonly referred to as a fail-safe type action. In addition, thermal elements have been constructed by being filled under vacuum so that their filled normal working length is shorter than their relaxed or unfilled length. Although these alternative designs perform the desired function, they are often complex and expensive, limited in application range, less reliable than the standard known thermal elements, more vulnerable to hostile conditions, and often not readily available as stocked items.
SUMMARY OF THE INVENTION
It is broadly an object of the present invention to provide a regulating valve which overcomes or avoids one or more of the foregoing disadvantages resulting from the use of the above-mentioned prior art regulating valves and the associated failure of their thermal elements, and which fulfills the requirements of such a regulating valve for controlling the flow of a heating or cooling medium under conditions which provide a fail-safe type action.
Specifically, it is within the contemplation of one aspect of the present invention to provide a regulating valve which, upon failure of the thermal elements, opens when supplying a cooling medium and closes when supplying a heating medium.
Another object of the present invention is to provide a regulating valve which is inexpensive to manufacture, is operative over a wide range of applications, reliable in use, and not susceptible to being damaged or broken under adverse operating conditions.
Another object of the present invention is to provide a regulating valve which employs a standard thermal element adapted for either heating or cooling applications.
In accordance with the present invention there is provided a valve for controlling the flow of a fluid in response to a sensed condition. The valve is constructed from a body having a body inlet and a body outlet through which a fluid to be regulated flows, regulating means within the body for regulating the flow of the fluid between a first and a second state, sensing means for sensing a condition to be controlled by regulating the flow of the fluid between the states, control means for controlling the regulating means in response to the sensing means, and adjusting means for adjusting the control means such that the fluid is maintained by the regulating means at one of the states upon the sensing means becoming inoperative.
In accordance with another embodiment of the present invention, the valve is constructed from a body having a body inlet and a body outlet through which a fluid to be regulated flows, regulating means within the body for regulating the flow of the fluid between a first state permitting the flow of at least a portion of the fluid through the body and a second state preventing the flow of the fluid through the body, sensing means for sensing a condition to be controlled by regulating the flow of the fluid between the states, a chamber in fluid communication with the body inlet and the body outlet, a diaphragm for controlling the regulating means in response to the sensing means, the diaphragm having an upper and lower portion each in fluid communication with the chamber for receiving the fluid from the body inlet, the lower portion in further fluid communication with the body outlet, the diaphragm connected to the regulating means for controlling the flow of the fluid through the body in response to the movement of the diaphragm caused by the pressure differential of the fluid within the upper and lower portions, and a lever within the chamber including a channel extending therethrough and having a lever inlet and a lever outlet, the lever inlet closed by a portion of the sensing means when the sensing means is operative and opened when the sensing means is inoperative, the lever inlet in fluid communication with the body inlet and the lower outlet in fluid communication with at least the body outlet when the lever inlet is opened, the lever adjusting the control means such that the fluid is maintained by the regulating means at one of the states upon the opening of the lever inlet.
BRIEF DESCRIPTION OF THE DRAWINGS
The above description, as well as other objects, features and advantages of the present invention will be more fully understood by reference to the following detailed description of the presently preferred, but nonetheless illustrative, regulating valve in accordance with the present invention, when taken in conjunction with the accompanyng drawings, wherein:
FIG. 1 is a cross-sectional view of a regulating valve adapted for use in a cooling operation and provided with a lever having a channel extending therethrough to provide a fail-safe action in the event of failure of the thermal element;
FIG. 2 is a cross-section view of a regulating valve adapted for use in a heating operation and provided with a lever having a channel and extending therethrough to provide a fail-safe action in the event of failure of the thermal element.
DETAILED DESCRIPTION
Referring to the drawings, wherein like reference numerals represent like elements, there is shown in FIG. 1 a cross-sectional view of a regulating valve suitable for use in a cooling mode and generally designated by reference numeral 100. The valve 100 is constructed from an overall body 102 having a body inlet 104 and a body outlet 106. Regulating means 108 is arranged centrally within the body 102 and operatively connected to control means 110 which is arranged in an upper portion of the body. The fail-safe action of the valve 100 is achieved by adjusting means 112 which is responsive to the operation of a sensing element 114. The specific construction and arrangement of each of the foregoing components will now be described in greater detail.
The regulating means 108 is constructed from a longitudinally extending shaft 116 which is movable along the longitudinal axis of the valve 100 in a direction substantially transverse to the direction of fluid flow through the body 102. A ring-shaped seat 118 is secured about the lower portion of the shaft 116 within that portion of the body 102 which is in fluid communication with the body inlet 104. The lower end of the shaft 116 is slidingly received within a bushing 120 secured within an opening 122 provided within a cap 124. A coiled spring 126 is provided within an annular-shaped recess 128 formed between the bushing 120 and the cap 124. The spring 116 is arranged circumscribing the lower portion of the shaft 116 and engaged by the seat 18 for biasing the regulating means 108 in an upward direction away from the cap 124. The upward movement of the regulating means 108 by the spring 126 causes sealing engagement of the seal 118 with a corresponding ring-shaped seat ring 130 arranged within the body 102 between the body inlet 104 and the body outlet 106. As such, the engagement of the seat 118 with the seat ring 130 by movement of the shaft 116, in reponse to the spring 126, closes the valve 100 and prevents fluid flow through the body 102.
The control means 110 is constructed from a diaphragm 132 overlying a diaphragm disk 134 which divides a chamber 136 into an upper portion 138 and a lower portion 140. The central portion of the body 102 contains a guide 142 having packing material 144 which slidingly receives the upper portion of the shaft 116 which in turn is attached to the diaphragm disk 134. As a result of the foregoing construction, movement of the diaphragm 132 and diaphragm disk 134 is effective to cause longitudinal movement of the shaft 116 to affect engagement and disengagement of the seat 118 with the seat ring 130 for controlling the flow of a fluid between the body inlet 104 and body outlet 106.
A bonnet 146 is provided overlying the upper portion of the body 102 to define a chamber 148. Contained within the chamber 148 is a further portion of the control means 110 including a first nozzle 150 and a second nozzle 152 having respective openings 154, 156 extending therethrough. Each of the openings 154, 156 are arranged in fluid communication with the chamber 148 defined by the bonnet 146. The opening 154 of the first nozzle 150 is further arranged in fluid communication with the upper portion 138 of the chamber 136 by means of a first conduit 158. The opening 154, as well as the first conduit 158, are also arranged in fluid communication with the body inlet 104 by means of a tube 160 arranged in fluid communication therebetween. The opening 156 of the second nozzle 152, in addition to being in fluid communication with the chamber 148, is arranged in fluid communication with the body oulet 106 by means of a tube 162 arranged in fluid communication therebetween. A conduit 164 is provided between the nozzles 150, 152 in fluid communication with the chamber 148. A tube 166 is connected between the conduit 164 and the lower portion 140 of the chamber 136 to provide fluid communication therebetween. As a result of the foregoing construction, fluid from the body inlet 104 is communicated to the chamber 148 via tube 160 and nozzle 150, to the upper portion 138 of the chamber 136 via conduit 158, to the lower portion 140 of the chamber via conduit 164 and tube 166, and to the body outlet 106 via nozzle 152 and tube 162.
The adjusting means 112 is constructed from a lever 168 pivotally mounted about pivot point 170 within the chamber 148 overlying the openings 154, 156 of the nozzles 150, 152. The lever 168 includes a longitudinally extending channel 172 having a lever inlet 174 and a lever outlet 176. A spring 178 is positioned within the chamber 148 to normally bias the lever in a clockwise direction to uncover the opening 154 of the nozzle 150 while closing the opening 156 of the nozzle 152.
The sensing means 114 comprises a conventional fluid filled thermal element which is available from Leslie Company of Parsippany, N.J. Briefly, the sensing means 114, i.e., thermal element, is constructed from a thermal sensor 180 and sealed tube 182 which contain a working fluid. The tube 182 is attached in fluid communication with a bellows assembly 184 which includes a bellows (not shown) and a spring (not shown) coupled to a longitudinally extending shaft 186. The bellows assembly 184 is attached to the upper portion of the bonnet 146 by means of a guide 188 containing packing material 190. The shaft 186 is adapted for reciprocal movement along its longitudinal axis in response to the bellows assembly 184. Under normal operating conditions, the terminal end of the shaft 186 engages the lever inlet 174 of the lever 168 to effect closure thereof.
The detailed construction of the valve 100 having been described, the reader's attention is now directed to the operation of the valve and its providing a fail-safe action. The thermal sensor 180 is positioned in the jacket of, for example, an engine or compressor containing cooling water or brine to prevent overheating. When the temperature sensed is within the desired range, the shaft 186 of the bellows assembly 184 is retracted such that the lever 168 is pivoted clockwise by the spring 178 to open the opening 154 of the nozzle 150 while closing the opening 156 of the nozzle 152. In turn, the lever inlet 174 of the lever 168 is maintained closed by the terminal end of the shaft 186 when the sensing means 114, i.e., thermal element, is operating properly in a non-failure mode. Under these conditions, fluid from the body inlet 104 flows through tube 160 into the chamber 148 via nozzle 150 and to the upper portion 138 of the chamber 136 via conduit 158. In turn, the fluid within the chamber 148 flows through conduit 164 into the lower portion 140 of the chamber 136 via tube 166. As the fluid pressure within the upper portion 138 and lower portion 140 of the chamber 136, i.e., above and below the diaphragm 132 and diaphragm disk 134, is substantially equal, the control means 110 is dynamically balanced. As such, the seat 118 engages the seat ring 130 by upward longitudinal movement of the shaft 116 caused by the upward force exerted by the spring 126. Fluid from the body inlet 104 is thereby prevented from flowing through the body 102 to the body outlet 106.
As the temperature of the cooling water or brine increass, such temperature increase is sensed by the thermal sensor 180 causing expansion of the contained fluid. In turn, the bellows assembly 184 causes the extension of the shaft 186 which causes pivoting of the lever 168 in a counterclockwise direction. As the lever 168 pivots in this direction, the opening 156 of the nozzle 152 begins to open, while the opening 154 of the nozzle 150 begins to close, thus producing a throttling effect. As the opening 156 of the nozzle 152 is uncovered, fluid pressure within the lower portion 140 of the chamber 136 is dissipated as a result of the fluid communication established between the lower portion and the body outlet 106 via tube 166, conduit 164, nozzle 152, and tube 162. In turn, fluid pressure in the chamber 148, which supplies fluid pressure to the lower portion 140 of the chamber 136 is also reduced due to the closing of the opening 154 of the nozzle 150 by the lever 168. However, full fluid pressure of the fluid from the body inlet 104 is maintained within the upper portion 138 of the chamber 136 irrespective of the position of the lever 168.
As the pressure of the fluid in the upper portion 138 is greater than the pressure of the residual fluid within the lower portion 140, the regulating means 108 is urged downward by means of the diaphragm disk 134 to effect a variable opening between the seat 118 and seat ring 130, thereby regulating the flow of fluid through the body 102 between the body inlet 104 and body outlet 106. The flow of fluid through the body 104 is therefore directly related to the pressure differential of fluid within the upper portion 138 and lower portion 140 of the chamber 136. From the foregoing description, it will be appreciated that the valve 100 controls the flow of fluid through the body 104 in response to the temperature sensed by the sensing means 114.
As previously explained, failure of the sensing means 114, i.e., thermal element, is the equivalent of the thermal sensor 180 detecting a very low fluid temperature, which would therefore cause the regulating means 108 to close the gap formed between the seat 118 and seat ring 130 to prevent fluid flow through the body 102. Under such circumstances, the valve 100, in the absence of the present invention, would be incapable of preventing potentially irreparable damage to an engine or compressor caused by overheating and whose cooling is being controlled by the valve. In this regard, upon failure of the sensing means 114, the bellows assembly 184 retracts shaft 186 so as to uncover the lever inlet 174 within the lever 168. The lever 168 is pivoted clockwise by spring 178 to close nozzle 152 while opening nozzle 150. Fluid within chamber 148 received from the body inlet 104, now flows through the lever inlet 174 and channel 172, and exits through the lever outlet 176 into the opening 156 of the nozzle 152. Fluid pressure within chamber 148 is therefore vented to the body outlet 106 via tube 162. This venting prevents fluid pressure from being established within the lower portion 140 of the chamber 136 via its fluid communication to the chamber 148 by means of the conduit 164 and tube 166.
As the fluid within the upper portion 138 of the chamber 136 corresponds generally to that of the fluid pressure within the body inlet 104, the positive pressure differential across the diaphragm 132 causes downward movement of the regulating means 108 so as to disengage the seat 118 from the seat ring 130, thereby allowing fluid flow from the body inlet 104 to the body outlet 106. From the foregoing description, the valve 100 provides a fail-safe action which, upon failure of the sensing means 114, i.e., thermal element, results in the supply of cooling water or brine to the jacket of the engine or compressor being cooled.
Although the invention herein has been described with reference to cooling, this invention is equally applicable for heating. An embodiment of the present invention which is specifically adapted for heating, while also providing a fail-safe action, is disclosed in FIG. 2. As shown in FIG. 2, there is disclosed a regulating valve 100' adapted for supplying a heating medium such as oil or steam to the jacket of, for example, heat transfer equipment, such as reaction vessels and the like. As the basic construction of the regulating valve 100' adapted for heating is substantially similar to that of the regulating valve 100 adapted for cooling, like elements have been designated by like numerals. For the purpose of brevity, only the constructional and functional differences between the regulating valve 100, as shown in FIG. 1, and the regulating valve 100', as shown in FIG. 2, will be described, all other aspects being substantially identical. Referring to the central portion of the valve 100', tube 160' from the body inlet 104' communicates directly to the chamber 148' via the opening 154' of the nozzle 150'. Conduit 164' provides direct fluid communication between the chamber 148' and the upper portion 138' of the chamber 136'. The opening 156' of the nozzle 152' provides direct fluid communication between the chamber 148' and the body outlet 106' via tube 162' and direct fluid communication to the lower portion 140' of the chamber 136' via tube 192.
The theory of operation of the valve 100' adapted for use in a heating mode is the same as that of the valve 100 adapted for use in a cooling mode. More specifically, when the temperature sensed by the thermal sensor 180' is below the desired range, the bellows assembly 184' is operative to retract shaft 186'. As such, the lever 168' is pivoted clockwise by the spring 178' to close the opening 156' of the nozzle 152' and to simultaneously open the opening 154' of the nozzle 150'. However, as previously noted, the lever inlet 174' is continuously maintained closed by engagement with the terminal end of the shaft 186' as long as the sensing means 114, i.e., thermal element, is functioning in its normal operating mode, that is, absence of failure. Hot fluid, e.g., oil or steam, from the inlet body 104' is supplied to the chamber 148' within the bonnet 146' via tube 160' and nozzle 150'. In turn, the hot fluid within the chamber 148' is supplied to the upper portion 138' of the chamber 136', while the lower portion 140' is vented to the body outlet 106' via tubes 162', 192. Hot fluid from the chamber 148' is prevented from flowing into the lower portion 140' by the lever 168' closing the opening 156' of the nozzle 152'. As there is now a positive pressure differential across the diaphragm 132', the higher pressure in the upper portion 138' of the chamber 136' urges the regulating means 108' downward to separate the seat 118' from the seat ring 130', thereby allowing fluid flow through the body 102' from the body inlet 104' to the body outlet 106'.
By controlling the extent of the opening and closing of the nozzles 150', 152' by the pivoting of the lever 168' by means of shaft 186' via expansion and contraction of the bellows assembly 184', the flow of heating fluid is regulated through the body 102' by varying the spacing through seat 118' and seat ring 130'. Upon the thermal sensor 180' sensing a fluid temperature within or greater than the desired range, the bellows assembly 184' functions to extend the shaft 186' to pivot the lever 168' in a counterclockwise direction, thereby closing the opening 154' of the nozzle 150'. As such, heating fluid from the body inlet 104' is prevented from flowing into the chamber 148' and therefore the upper portion 138' and lower portion 140' of the chamber 136'. As the pressure of any contained residual fluid within the upper portion 138' and lower portion 140' is now substantially equal, the regulating means 108' is urged upwardly by means of spring 126' to engage the seat ring 130' by the seat 118', thereby preventing fluid flow through the body 102'. It should now be understood that by pivoting the lever 168' in response to the expansion and contraction of the bellows assembly 184', the valve 100' is operative to regulate the flow of heating fluid through the body 102' from the body inlet 104' to the body outlet 106'.
In the event of failure of the sensing means 114', i.e., thermal element, the bellows assembly 184' retracts the shaft 186' such that the lever inlet 174' is uncovered while the lever 168 pivots in a clockwise direction uncovering the opening 154' of the nozzle 150' and closing opening 156' of nozzle 152'. Hot fluid from the body inlet 104' flows into the chamber 148' via tube 160' and nozzle 150'. The fluid within the chamber 148' in turn flows into the upper portion 138' of the chamber 136' via conduit 164' and into the lower portion 140' via channel 172' within the lever 168', nozzle 152' and tube 192. By supplying fluid into the upper portion 138' and lower portion 140' from the body inlet 104', the pressure differential across the diaphragm 132' is substantially zero, i.e., dynamically balanced, thereby enabling the regulating means 108' to be urged upward by the spring 126' to cause engagement of the seat 118' with the seat ring 130' to prevent any fluid flow through the body 104'. Thus, in accordance with the present invention, the foregoing construction and operation of the valve 100' provides a fail-safe action to protect the heat transfer equipment from being overheated in the event of failure of the sensing means 114', i.e., thermal element.
As thus far described, the regulating valves 100, 100' of the present invention, upon failure of the sensing means 114, 114', i.e., thermal element, opens when supplying a cooling medium and closes when supplying a heating medium. This mode of operating of the regulating valves 100, 100' provides a fail-safe type action which is reliable in use and not susceptible to being damaged or broken under adverse operating conditions. Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and application of the present invention. It is therefore to be understood that numerous modifications may be made in the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
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A regulating valve having a fail-safe action which is suitable for controlling the flow of either a heating or cooling medium in response to a sensed condition is disclosed. The flow of heating or cooling medium is responsive to changes in temperature at a selected location, which changes are sensed by thermal element. The fail-safe action of the regulating valve either permits or prevents flow of the heating or cooling medium upon failure of the thermal element.
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FIELD OF THE INVENTION
[0001] The present invention is in the field of telephony communications, including public-switched telephony communications, Internet protocol telephony communications, and cellular telephony communications. The invention pertains particularly to a system for facilitating parallel data transfer into a communications center from a wireless caller.
BACKGROUND OF THE INVENTION
[0002] In the field of telephony services communications centers also termed call-in centers are used by enterprises to service clients. An example of such a center might be a technical support group of a computer manufacturer where clients call in to gain technical assistance.
[0003] State-of-art communications centers have connection to the well-known public-switched-telephony-network (PSTN) for receiving connection-oriented-switched-telephony (COST) calls. These centers also often have connection to the well-known Internet network, and perhaps connection to a variety of wireless telephone networks.
[0004] In communication networks of today, calls handled between major communications carriers may be exchanged digitally, either as COST calls, or in some newer cases, as voice over Internet protocol (VoIP) or Internet protocol network telephony (IPNT), also termed data network telephony (DNT).
[0005] One with skill in the art of modern telecommunications will appreciate that calls sourcing from anywhere in network or sub-network may be routed in between networks and connected to a destination in a network or sub-network in a seamless fashion as a dedicated connection or as a shared-bandwidth connection.
[0006] In communications center architecture known to the inventor, telephone calls into the center may, in some cases, be intercepted at the network level and routed to individual agents within the center along with data about the call and caller. This may be accomplished by providing a separate data network accessible to the communications center and accessible to the local switch handling calls for the center. For example, a computer-telephony-integration (CTI) processor may be connected to the local telephony switch handling calls for the center. Interactive-voice-response (IVR) technology may also be provided to interact with a caller at the point of the switch to identify the caller and determine the purpose for the call.
[0007] Within the communications center, a central office switch may also be enhanced with a CTI processor. The two CTI processors, one at network level, and one within the center, may be linked together via a separate data network. Using this technique, calls may be routed at the level of the network and data about the call and caller can be forwarded to an agent ahead of the actual call. Assuming the call is a PSTN incoming call, the target agent (the agent the call is routed to) can have data about the call and caller may appear on a computer display screen perhaps seconds before he or she answers the call.
[0008] While this technology greatly enhances customer service for callers, it requires interaction with each caller via IVR or equivalent technologies and the supporting data network set-up between network level switches and the communications center. Moreover, if the caller is calling from a wireless network the amount of time translating the IVR interface and navigating a long menu or series of voice prompts may consume valuable minutes. Likewise, a wireless caller may have call blocking services wherein standard techniques for determining a source number for a call are not successful in revealing the caller's telephone number. In many of these cases, the only reference a destination has as to the ID of a caller is a virtual telephone number of a particular telephone carrier.
[0009] What is clearly needed is a system and method for acquiring caller ID of a wireless caller without tying up the caller with lengthy pre-connect interaction before routing while still enabling agent access to ID and additional data about the caller.
SUMMARY OF THE INVENTION
[0010] A system is provided for identifying and interacting with callers including a telephone switch for receiving and distributing incoming calls; a messaging server for sending or receiving messages and attachments; and, a software routine for identifying wireless callers and for matching them to messages in the messaging server. In preferred embodiments, the telephone switch is one of a private branch exchange or an automated call distributor. Also in a preferred embodiment, the messaging server generates and serves automated SMS messages.
[0011] In one embodiment, the messaging server generates and serves automated e-mail messages, session initiated protocol (SIP) messages, or PCS-email messages. In one embodiment, the messaging server and the software routine execute on a single machine and the machine is one of an agent workstation or a telephony switch In an alternate embodiment of the invention, the telephone switch is connected at network level to another telephone switch using a data network separate from the telephone line.
[0012] In one aspect, the software routine is distributed to the switch. Also in one embodiment, the software routine is called only to interact with wireless callers identified by the system.
[0013] According to another aspect of the present invention, a software routine integrated with a CTI routine is provided for determining the existence of knowledge about a caller associated with an incoming call from the point of a communications center and includes, a first sub-routine for determining if a caller identification is known to the system; and, a second sub-routine for controlling an automated messaging server to interact with the caller.
[0014] In this aspect of the invention the CTI routine determines the number identity of the incoming call and if the call is from a wireless caller. In one embodiment, the software routine is integrated with the CTI routine resident on a CTI processor. In a variation to this embodiment, the software routine is integrated with a CTI routine resident on a server having access to a CTI processor. In one aspect of the embodiment, the software routine of further includes a sub-routine or determining whether a call is from a wireless caller or not. In still another variation the software routine is integrated with IP routing software.
[0015] According to another aspect of the invention, a method for interacting with a caller at a point of access to a communications center is provides and includes steps for (a) receiving an incoming call; (b) determining caller identification; (c) determining if existing data is available about the identified caller; (d) if data exists, retrieving the data associated with the identified caller; and (e) routing the retrieved data along with the call.
[0016] In one embodiment, in step (a), the point of access is a local telephony switch in a telephone network. In another embodiment, the point of access is a central switch in a communications center. In still another embodiment the point of access is a web server. In one aspect of the method in step (b), determining caller identification is performed by a CTI software routine.
[0017] In one embodiment, in step (b), if identification cannot be determined, an automated message is generated and sent to the caller during the session, the message asking for caller identification. In this aspect, the automated message is one of an SMS message, an SIP message, a PCS mail, or an e-mail message.
[0018] In one aspect of the method, in step (c) a database is searched based on the caller identification. In this aspect, if no data is found, an automated message is generated and sent to the caller, the message asking for input data. In still another aspect in step (d) the data is retrieved by an IP routing software routine.
[0019] In one aspect, in step (e) the data is pushed from the database to the target of routing. Alternatively, the data is pulled by the routing target, the target using a key previously generated and sent to the caller, the key subsequently sent to the routing target during the time of the call.
[0020] In one aspect, in step (d) the data is an SMS message including any attachments queued in an agent station having connection with the caller, a caller providing the telephone number during interaction which is then used to access the message from queue.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0021] FIG. 1 is an architectural overview of a communications network practicing parallel data transfer into a communications center according to an embodiment of the present invention.
[0022] FIG. 2 is a process flowchart illustrating steps for acquiring data for parallel transfer into the communications center according to an embodiment of the present invention.
[0023] FIG. 3 is a block diagrams illustrating components of an IP/CIS server according to an embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] FIG. 1 is architectural overview of a communications network 100 practicing parallel data transfer into a communications center 104 according to an embodiment of the present invention. Communications network 100 includes a public-switched-telephone-network (PSTN), a Data network 102 , and a wireless telephony and data network 103 . PSTN network 101 includes a local telephony switch (LS) 105 , and may also include, in one embodiment, a computer-telephony-integration (CTI) processor 106 . LS 105 may be an automatic call distributor (ACD), a public branch exchange (PBX), or any other suitable call switch. It is noted herein, that computer-telephony-integration is not required to practice the present invention.
[0025] CTI processor 106 is, in this example, connected to LS 105 via a CTI link. CTI processor 106 provides intelligent enhancement to switch 105 , which may include call-routing intelligence. In one embodiment, no CTI processor is present. Also in one embodiment, CTI functionality may be included within a telephone switch such as LS 105 , which may be an ACD-type switch. Moreover, in cases of DNT, no CTI processor is required. In a most simple embodiment, ergo in most basic cases, simple caller ID (telephone number) may be used to link a call and a short message service (SMS) message or e-mail containing the telephone number in the header entirely in the agents PC. The inventor illustrates CTI functionality only as one possible embodiment that is available for interacting with callers.
[0026] Data network 102 may be an Internet network, an intranet network, or another type of data network such as a private or corporate data network without departing from the spirit and scope of the present invention. In a preferred embodiment however the Internet network is exemplified because of its public-access characteristics. Hereinafter data network 100 and to may be referred to herein as Internet network 102 . Internet network 102 in this example includes an Internet backbone 118 . Internet backbone 118 represents lines, connection points, and equipment that make up the Internet network as a whole. A Web-server 117 is illustrated within Internet 102 and is connected to backbone 118 . Web server 117 is adapted to serve electronic information pages to clients of communications center 104 and might be a client access point, in one embodiment, so that clients may access communications center 104 . Although not illustrated in this embodiment, Internet 102 may have connection to PSTN 101 through a Bell core (SS-7) translation gateway or other translation gateway.
[0027] LS 105 within PSTN 101 and WS 117 within Internet 102 have connection to a wireless gateway 120 within a wireless network 103 by way of trunks 123 and 124 respectively. Gateway 103 may be hosted by any wireless carrier providing services to wireless callers. Within a wireless network 103 two wireless towers are illustrated, 121 a and 121 b . A client of wireless network 103 is illustrated by a wireless handset 122 . In this example client 122 is negotiating with gateway 120 or wireless tower 121 b . Wireless network 103 may be a cellular data network, a WIFI network or another type of wireless communications network.
[0028] One with skill in the art of network communications will appreciate that more than one wireless gateway may be provided, and that dedicated processors may similarly be provided and may be used to handle data and calls or call data (in case of VoIP call delivery) separately. Also, rather than or additionally to WS 117 , a soft switch (not shown) may be present in the call center site to handle incoming VoIP calls. Links may be dedicated as shown (typical for SMS), or shared or by the way of public Internet (typical for e-mail or PCS mail), Inter Exchange Carriers etc.
[0029] A communications center 104 , sometimes termed a call center, is illustrated in this example and is connected to both the PSTN 101 and to Internet 102 . A central office switch (CS) 110 is provided within communications center 104 and is connected to LS 105 within PSTN 101 by a telephony trunk 108 . CS 110 may be a PBX or another type of telephony switch. A CTI processor 109 , although not required, is provided in this example and is connected by a CTI link to CS 110 . Processor 109 has connection in this example with processor 106 within PSTN 101 by way of a separate data network 107 . Processor 109 enables intelligent routing routines and other client-interaction routines to be executed within PSTN 101 at the point of LS 105 .
[0030] Communications center 104 is equipped with a local-area-network (LAN) 112 . LAN 112 connects to workstations 113 a , 113 b , and 113 n for communication and routing of messages and calls. Workstations 113 a - n typically include computer and monitor capabilities, and capabilities for answering both IP and PSTN telephone calls within communications center 104 . In this example, telephones in workstations 113 a - n may be connected to CS 110 by way of internal telephone wiring 111 .
[0031] An Internet protocol/customer information system (CIS) server 116 is provided within communications center 104 and is connected to LAN 112 . Server 116 , among many other tasks, is adapted, in one embodiment, as an IP router capable of receiving IP communications from Internet 102 over data link 119 . Server 116 has a data connection 114 to CTI processor 109 . When a PSTN call is received at CS 110 , data about the call and caller is received at processor 109 and can be routed over LAN 112 to an appropriate workstation through link 114 and IP server 116 . Server 116 is also responsible, in this example, for serving customer and product information to agents operating workstations 113 a - n . A customer information system database (CIS) 115 is provided for the purpose of storing customer information, identification, account information, and so on. In this example CIS 115 has direct connection to server 116 .
[0032] In one embodiment of the present invention, the functions of server 116 may be represented by a plurality of machines connected to LAN 112 instead of just one machine without departing from the spirit and scope of the present invention. In this example, the functions of IP routing, parallel data transfer, information serving, and automated messaging are all performed on machine 116 .
[0033] In typical application with regard to normal client traffic within communications center 104 , PSTN callers access communications center 104 through LS 105 , and Internet caller's access communications center 104 through web server 117 . At the point of LS 105 , PSTN callers can be identified in typical telephony number identification protocols such as automated number identification (ANI) and destination number identification service (DNIS). In addition to caller identification, caller interaction is typically provided using IVR technology or some other intelligent peripheral. For each PSTN call incoming into switch 105 and destined for center 104 , the actual call is routed over telephony trunk 100 to CS 110 while the data about the call may be routed from processor 106 to processor 109 if, as in this case, CTI functionality is provided. Internet callers using messaging or IP telephony conventions access communications center 104 through web server 117 as previously described. IP calls, messages and data (forms and attachments) may be transmitted to IP server 116 over Internet link 119 .
[0034] Client 122 calling into center 104 from network 103 may access, in some embodiments, either LS 105 or WS 117 in order to communicate with communications center 104 as long as the client is Internet-enabled. If client 122 accesses LS 105 and reaches an agent within communications center 104 , he or she will receive the same basic identification and interaction services as PSTN callers. However, mobile clients are not as easy to identify as tethered clients are. As was described further above, mobile callers often have blocked telephone numbers and may therefore, not be successfully identified at a point of interaction. Moreover, mobile clients may be roaming and therefore may be paying a higher price for communication with center 104 . Therefore, a mobile client may not wish to sit through a long IVR interaction before being routed to an available agent within communications center 104 . With respect to WS 117 , if client 122 has an IP telephony application and e-mail or instant message capabilities, he or she may connect to an available agent through Internet 102 bypassing PSTN 101 altogether. Still client 122 may have to pay for the wireless carrier portion of the access.
[0035] In a preferred embodiment of the present invention, an instance of software (SW 116 a ) is provided to server 116 and is adapted to assist communications center 104 in identifying wireless callers and, if necessary, enabling a different mode of parallel data transfer from a wireless caller to a target agent within communications center 104 . SW 116 a is adapted to interact with the wireless caller attempting to connect to communications center 104 through LS 105 or through WS 117 . In one embodiment of the present invention a version of SW 116 a is provided on WS 117 as an instance of SW 117 a . In the latter case or WS 117 would be hosted by communications center 104 and would be a dedicated client access server.
[0036] In one embodiment of the present invention routine 116 a , including version 117 a , can be used as an interaction option for land-based callers sourced from PSTN 101 or from Internet 102 . Such an option could be used to replace the IVR interaction option. The system may, however, be configured solely for wireless callers identified by the system because of the special problems wireless callers have with standard interaction services geared more for tethered callers. The system may identify wireless callers based on the difference in telephone number geographic prefix, or by deducing the routing path leading back to an identifiable wireless carrier node or service.
[0037] In one embodiment where CTI software is available, CTI software is adapted to determine if an incoming call has been routed through or is being carried by a wireless service before calling routine 116 a . If not, normal IVR interaction and solicitation of additional data through IVR methods may be practiced according to technology known to the inventor.
[0038] Software 116 a provides intelligence to LS 105 within PSTN 101 by way of a separate data network link 114 , processor 109 , link 107 and processor 106 . The intelligence comprises a routine for acquiring the identification of a wireless caller and in the event the caller is not known to the system, acquiring further information from the caller in a fashion that is convenient to the caller. Software 117 a is adapted to provide essentially the same intelligence routine versioned for wireless access protocol (WAP), or other HTTP-related wireless protocols.
[0039] In practice of the present invention, client 122 may access gateway 120 through tower 121 b and be ported into the PSTN network 101 over link 123 to switch 105 . LS 105 is provided with software-enabled intelligence to discern wireless callers from tethered callers. Tethered callers receive the typical IVR solution whereas a special routine is selected for wireless callers. If in practice, the wireless caller is already known to the system (having an identity and sufficient data stored) then no interaction is specifically required, and the caller may be immediately routed from switch 105 to switch 110 and an available agent over wiring 111 . In this embodiment, the caller may have an associated digital key, which may be used, by communications center 104 to access data about the identified caller from CIS 115 while the call is being routed.
[0040] In one embodiment of the present invention, a wireless caller is not identifiable at the point of interaction in terms of caller ID (telephone number). In this case, the caller may simply send a short SMS message to the same destination number used to place the call. In this case, the SMS message provides the caller identification. The advantage of using SMS, unlike e-mail or some other messaging protocols is that it cannot be spoofed and therefore provides some authenticity that the number identified is actually that of the wireless caller.
[0041] In one embodiment of the present invention identification of the caller is not specifically known to the system other than knowledge of the client's telephone number, which may also, as described above, in some cases not be available to the system. In a case where a caller's number may be identified but further information is not known, SW 116 a may generate a short message service (SMS) request adapted for the purpose of obtaining additional identification and call-purpose information from the client sufficient so that the system can use to service the client. Such further identification and information may include, in some embodiments, data that is already stored on the client's device ( 122 ) that may be triggered for send when a SMS is received from the system. In other embodiments client 122 may receive an SMS from communications center 104 including a simple electronic form with which to add data to for a SMS reply to center 104 . Such a reply may include client identification and additional data required to enable the center to better serve the client.
[0042] In a PSTN embodiment, the SMS path extends from client 122 through the network architecture to IP server 116 . In this case IP server 116 generates the automated SMS messages. However, software 116 a may reside in either processors 109 or processor 106 , if CTI is present, including automated message capabilities. In one embodiment software 116 a may reside in either CS 110 or in LS 105 or both. In some embodiments of the invention other types of messaging can be used in place of SMS such as e-mail, instant message, or session initiated protocol (SIP) messaging. In a preferred embodiment SMS messaging is used because it already identifies the client by telephone number and can be sent over the same data paths as the telephone call is self.
[0043] In one embodiment of the present invention, the SMS path takes Route 124 through Internet 102 over link 119 to server 116 while the caller is waiting at switch 105 . When the system completes the routine and identifies the caller and any additional data required, the call may then be routed from LS 105 to CS 110 for distribution to one of workstations 113 a - n.
[0044] In one embodiment of the invention an SMS path extends from client 122 through gateway 120 over link 124 and backbone 118 , to WS 117 . In this case, IP routing over LAN 112 to one of agents 113 a - n includes data from CIS 115 and the actual IP call or live message. More detail about interaction capabilities of SW 116 is provided later in the specification.
[0045] In yet another embodiment of the present invention, calls from wireless callers may be matched up with SMS or other messages by simply using caller ID (telephone number) either directly provided or solicited from the client at the agent station to pull SMS or other messages from a message queue, wherein the message header contains at least one element with the number of the caller (i.e. 14085551212@carrier-pcs.net), typically its address or SMS header.
[0046] It will be apparent one with skill in the art that the system of the present invention can be implemented in conjunction with a PSTN or other telephone network, the Internet, an Intranet, or a corporate wide-area-network (WAN), accessible from a variety of wireless network carriers. It will also be apparent one with skill in the art that the functions of server 116 a may be distributed to a variety of machines without departing from the spirit and scope of the present invention. Likewise, software 116 may be distributed in parts to various machines such as processors 109 , 106 , gateway 120 , and WS 117 .
[0047] FIG. 2 is a process flowchart illustrating steps for acquiring data for parallel transfer into the communications center according to an embodiment of the present invention. With respect to the embodiment described above, a method is provided and enabled by software 116 a for verifying identification of wireless callers and, if necessary, acquiring additional data and having the data flow into the communications center in a parallel manner with the routed call.
[0048] It is important to note herein that the process flow of this example may vary substantially without departing from the spirit and scope of the present invention. For example, a wireless caller may send an SMS message or other message in sync with a telephone call. The call can be routed according to destination number. The message may also be routed according to destination number. Interaction with the caller at the time of the call may then be used to solicit a caller's number, which may then be used to pull the message from a queue on the same station. The inventor provides the following example has just one possible example of routine flow.
[0049] At step 200 , a local switch analogous to LS 105 in the embodiment described above receives an incoming call destined for a communications center analogous to center 104 of the same embodiment. Typically, the incoming call is bridged to a gateway such as gateway 120 also described with reference to FIG. 1 above.
[0050] At step 201 , the software determines if there is a caller ID accompanying the call. Typically, the caller ID would be a caller's cellular telephone number. If at step 201 , if there is no caller identification for the incoming call, then at step 202 , an automated SMS request is sent to the caller asking for identification such as a telephone number, or some other piece of identification that the system can use. In this case because there is no telephone number identifying the caller, the SMS message would be sent in real time over the same dedicated path used by the caller.
[0051] In one embodiment, at step 200 interaction between and IVR or other automated is used to solicit the caller's telephone number. Moreover, in addition to SMS, e-mail, I am, or PCS-mail may be used instead in light of today's communications devices typically supporting a variety of messaging systems and protocols.
[0052] At step 203 the caller sends a SMS reply revealing the telephone number or other piece of identification to identify the caller. In one embodiment of the present invention, the caller, upon receiving an SMS request for identity, is configured to automatically send an SMS reply containing a customer information services (CIS) key that can be used by the system to access the caller's data.
[0053] If the incoming call of step 200 already has identification at step 201 , then at step 204 the system performs a lookup in a customer information system database such as CIS 115 of FIG. 1 to determine if the caller is known to the system, such as having done business with the enterprise previously. The lookup task can be ordered from the distributed version of software local to the client access hardware and can be performed from within communications center 104 such as by server 116 .
[0054] At step 204 , if the caller is not known even after caller ID has been provided, an automated SMS request is sent to the caller at step 205 . This SMS request may ask for additional information such as a stated purpose of the call, a preferred routing destination, or other information to help the center further process routing of the call. In one embodiment of the invention, the SMS sent at step 205 may include a Java applet or link that executes or loads at the client's end as a displayable, electronic form. The applet can source from server 116 , processors 109 or 106 , or from gateway 120 if enabled.
[0055] According to another embodiment of the present invention instead of an SMS request for additional data, an e-mail, instant message, or SIP request may be sent instead. The latter case assumes that the wireless client analogous to client 122 can utilize voice and Internet access simultaneously.
[0056] After receiving the SMS request at step 205 the client may provide the required data in an SMS reply at step 206 . After receiving data supplied by the client, the system again determines at step 204 if the caller is known. Presumably, after step 206 the system receiving the data about the caller may input such data into the current CIS database. At step 204 , if the caller is known to the system, then at step 207 the system may get data about the caller. The data may be retrieved from a CIS database such as CIS 115 of FIG. 1 .
[0057] Once the appropriate client data is gathered, it is sent at step 208 to the routing target of the call, typically an agent or automated service provided by the center. In the case of agent workstations 113 a - n of FIG. 1 , an agent would pick up the call from CIS 110 and would already have the data displayed on his or her computer monitor. At step 209 the actual call and data are merged at a merge point, presumably on the agent's computer, such that the data is physically associated with the caller at the time the call is answered.
[0058] Once the call and data arrive at the routing target, the target may connect the voice call at step 210 . Wireless callers accessing communications center 104 through Internet 102 and web server 117 may also experience short messages being sent from communications center 104 in an attempt to acquire additional data. However, in this case the data may be merged as it travels over the same path and is eventually routed to the same terminal or target routing point.
[0059] One with skill in the art will recognize that the process in this example may utilize a differing number or order of steps without departing from the spirit and scope of the present invention. For example, an SMS request sent at step 202 might request both identification and the additional data required in order successfully route the call thereby eliminating steps 205 and 206 . In another embodiment, instead of polling data at step 207 or sending data in step 208 , agents may subscribe to caller CIS keys such that when a caller sends a key the agent may use the key to pull the appropriate data about the caller. In a variation of this embodiment, a CIS key may be retrieved from the caller and used to unlock data in a CIS system, wherein the system pushes data to the appropriate agent. There are many possibilities.
[0060] FIG. 3 is a block diagram illustrating components of IP/CIS server 116 of FIG. 1 according to an embodiment of the present invention. Server 116 has a number of interfaces to outside systems in this example. These are a LAN interface 305 , a CIS interface 306 , a CTI interface 307 , and a Web interface 308 . In a preferred embodiment server 116 has a server bus illustrated logically herein as a bus structure 309 . Logical bus 309 connects all of the components with server 116 for communication internally as well as through interfaces 300 through 308 .
[0061] Server 116 has a client identification/interaction routine 301 , which is analogous to software 116 a described with reference to FIG. 1 . Server 116 also has a Java applet server 300 , which is also capable of serving automated messages upon command. In a preferred embodiment of the present invention, component 301 interacts with Java applet server and automated messenger 300 according to switch notification of incoming wireless calls. Notification of incoming wireless calls is received through CTI interface 307 . When an incoming call is present in the system component 301 launches the routine described with respect to FIG. 2 described above. Component 301 cooperates with component 300 to (if required) enable an automated SMS or other type of message including, possibly, a Java Applet carrying a form to better facilitate client provision of data.
[0062] Server 116 has an instance of IP routing server 302 provided therein and adapted for routing incoming IP communications through LAN interface 305 two available agents. IP routing server 302 is also responsible, in one embodiment, for accessing data through CIS interface 306 and routing the data through LAN interface 305 two available agents in conjunction with incoming PSTN calls.
[0063] Server 116 has a CTI routing software instance 303 adapted to communicate through CTI interface 307 two external CTI processors. Instance 303 may provide routing intelligence and exchange data with a local CTI processor connected to a local telephony switch as was described with respect to the architecture of FIG. 1 .
[0064] According to one embodiment of the present invention, server 116 has a CIS key generator 304 adapted to generate CIS keys for wireless callers, which may be stored on virtually in a cellular telephone. In this embodiment, client identification/interaction routine 301 may be used to retrieve a CIS key for wireless caller for use by server 116 in accessing the client's data. In this example server 116 provides all of the functionality of the present invention in terms of identification and parallel data transfer internally to available agents operating on a LAN. IP routing server 302 and CTI routing software 303 cooperate to insure that the correct data about a client is routed over the LAN to the agent that will receive the telephone call. This may be accomplished using any number of tagging means such as by providing the client identification number or code both to the call and to the additional routed data. In one embodiment, a lightweight client may be distributed to agent workstations, and the light client may function as a merge point for queued calls and associated data arriving at the workstations.
[0065] It will be apparent one with skill in the art that the methods and apparatus of the present invention may be used in conjunction with any type of communications center whether it is CTI-enabled or void of CTI functionality and can receive and route data according to data packet or data frame technology. Such a communications center need not be a large communications center, but can be any type of enterprise center that minimally utilizes a call distributor and, in some embodiments, an IP router on an internal data network.
[0066] The methods and apparatus of the present invention can be applied in a variety of communication environments and architectures and should therefore be provided the broadest scope under examination. The spirit and scope of the present invention should be limited only by the claims, which follow.
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A system for identifying and interacting with callers has: a telephone switch for receiving and distributing incoming calls; a messaging server for sending or receiving messages and attachments; and, a software routine for identifying wireless callers and for matching them to messages in the messaging server. The system is characterized in that upon receiving a call the system attempts to identify the call to a caller and of the caller is not already known in the system or identified an automated message is generated and sent to the caller asking for the desired information. In one embodiment the caller sends a message when the call is placed to optimize identification.
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This application is a division of application Ser. No. 08/098,708, filed Jul. 28, 1993, now U.S. Pat. No. 5,496,439.
BACKGROUND OF THE INVENTION
The present invention relates to improvements in processing baled waste material containing waste paper articles of various types for recycling the contents of the bale to recover a maximum amount of cellulosic fibers from the various categories and types of paper fiber containing articles that are contained in the bale of waste material with a minimum degradation or damage to the recovered paper fibers.
To enhance the conservation of material resources, particularly forest land, and to reduce the amount of waste material that is disposed in ever increasing landfill areas, widespread interest has developed in recycling waste matter of which a significant portion comprises waste paper articles of assorted types and compositions for recovering the fibers of the waste paper articles that are used in producing recycled paper products. Waste matter of various categories normally is packaged as tightly compacted bales of considerable size and weight for ease of handling and storage. The nature of these tightly compacted and very heavy bales presents serious problems in processing the miscellaneous tightly compacted contents of the bale in an economical and efficient manner such that the fibers recovered from the miscellaneous types of waste paper articles in the bale are of a high quality and free of contaminants with minimal damage to the fibers from being cut, broken or shortened in the recycling defibration operations. Our U.S. Pat. Nos. 5,147,502 and No. 5,203,966 discuss this problem at considerable length and disclose measures by which the contents of the tightly compacted bales of waste material can be subjected to a pre-recycling conditioning treatment which causes the fibers of waste paper articles contained in the tightly compacted bale to become swollen and the fiber bonding forces substantially weakened prior to defibration of the waste paper articles and separation of the fibers into a liquid suspension slurry. As discussed in our aforesaid patents, this pre-recycling conditioning treatment involves a thorough wetting impregnation of the contents of the compacted baled waste material by discharging a high velocity jet of cellulosic fiber softening and swelling fluid into the interior of the bale as saturates the waste material in the bales with the fluid to a degree as establishes the desired debonding swelling of the fibers of the waste paper articles in the baled waste material. This debonding swelling reduces the bonds between the fibers of the waste paper articles and between the waste paper fibers and contaminants that form a portion of the waste paper articles. Other previously known measures by which the contents of compacted baled waste material can be subjected to pre-recycling conditioning treatment comprise the submergence of the baled waste material in a water-filled trough for a protracted period prior to breaking up the bale and defibrating the water saturated waste paper as in the manner disclosed in U.S. Pat. No. 4,458,845 of Marcalus, et al. However, this old procedure has the serious disadvantage of requiring an excessive time period for the waste paper contents of a tightly compacted bale to become sufficiently saturated with the debonding fluid. Entrapped air within a bale submerged in a water filled trough prevents a high degree of saturation of the waste paper in the bale within a reasonable period of time.
Waste paper contained in baled waste material normally includes a wide variety of types of cellulosic fiber containing articles of which the fibers of some articles are substantially free of contaminants such as wax, plastics, latex, asphalt or other non-fibrous matter. Relatively uncontaminated fiber articles of this nature are broke, post-consumer paper products such as corrugated boxes, discarded office papers, stationery, toweling, etc. The fibers comprising other types of paper articles contain contaminated matter in which the fibers and their outer walls have been penetrated to various degrees by and contain non-fibrous contaminants in which the contaminants provide special qualities to the fibers of the article such as wet strength. Other types of paper articles have fluid barrier coated surfaces in which the contaminant coating establishes a barrier to the penetration of fluids into the interior fibrous portion of the article. Typical of this latter type of article, and which presents serious problems in penetration of a debonding fluid into the barrier coated fibrous matter, are milk cartons, aseptic juice boxes, freezer wrap, foil laminated cartons, coated sanitary products, moisture barrier shipping sacks, etc. After the defibration separation out of the relatively uncontaminated cellulosic fibers of waste paper contained in bales subjected to the pre-recycling conditioning treatment procedures disclosed in the above mentioned patents, it has been the general practice to dispose the non-debonded and contaminant containing or contaminant coated fibrous matter to landfill along with the non-fibrous waste matter and contaminants contained in the bales due to the difficulty of a further separation out of the cellulosic fibers of waste paper articles containing a high degree of contaminated fibrous matter or whose surfaces are coated with a fluid barrier contaminant.
SUMMARY OF THE INVENTION
The object of this invention is to establish a recovery of the maximum amount of high quality cellulosic fibers from all types of fiber containing waste paper articles that are to be found in compactly baled waste material, including such waste paper articles as those having one or more fluid barrier coatings. In furthering the above indicated objective, a series of three experiments were performed in determining the degree of penetration and penetration time for a liquid to penetrate through the exposed edges into the interior of a polymer coated paperboard sandwich (i.e., milk carton samples) by subjecting the samples to one or more liquid impregnation cycles comprising immersion of the sample in a liquid under varying degrees of vacuum pressure environment followed by the reapplication of atmospheric pressure, which is referred to in subsequent discussions as over pressure and can be greater than ambient atmospheric pressure under certain conditions subsequently discussed. The experiments were conducted on polymer coated milk carton samples of which the outer edges had been severed for exposure of the outer edges to liquid penetration into the fibrous interior of the sandwich sample.
Circular discs 14.2 centimeters (cm) in diameter were subjected to three different conditions and the depth of penetration measured after 60 seconds and 180 seconds:
A. A circular disc was subjected to a vacuum of 25" Hg below atmospheric pressure, water was introduced after 3 minutes of evacuation and atmospheric pressure restored after which penetration was observed. This procedure was repeated twice more while the partially penetrated disc was submerged in the water.
B. A circular disc was subjected to a vacuum of 29.4" Hg below atmospheric pressure, water was introduced after 3 minutes of evacuation and atmospheric pressure restored after which penetration was observed. This procedure was repeated while the partially penetrated disc was submerged in the water.
C. A circular disc was subjected to a vacuum of 29.4" Hg below atmospheric pressure, water was introduced after 3 minutes of evacuation and atmospheric pressure restored after which penetration was observed. This procedure was repeated after first draining the water introduced in the first evacuation.
______________________________________ Penetration Depth (%) AfterTrialVacuum Stage Condition After 60" 180"______________________________________A 25" HG 1st Evac. Not submerged 37 5825" 2nd Submerged 66 7225" 3rd Submerged 74 76B 29.4" Hg 1st Evac. Not submerged 54 7329.0" Hg 2nd Submerged 92 96C 29.4" Hg 1st Evac. Not submerged 49 7529.0" Hg 2nd Not submerged 96 99______________________________________
In Trials "A" and "B" the 2nd evacuation without removal of water, fine air bubbles were observed emanating from the edges of the discs.
The conclusions from these trials were:
1. One stage of treatment at a vacuum of 29.4" Hg is equivalent to 3 stages at 25" Hg in penetration depth.
2. Removal of the water before the 2nd evacuation appeared to be somewhat beneficial, but to a minor degree.
3. Air is trapped in the interior of the paper-polymer sandwich after the first stage of penetration, which inhibits further penetration, and further evacuation of the air is required to obtain more complete penetration of the fluid.
4. Since air is trapped by the impervious polymer barriers, an over pressure of atmospheric or greater would be an aid increasing the depth of fluid penetration. For instance, the depth of penetration after a 29.4" Hg vacuum followed by one atmosphere (14.7 psi) over pressure would be 75% after 180 seconds; and 99%+after the 2nd evacuation @ 29.0" Hg followed by one atmosphere over pressure. At the lower vacuum of 25" Hg, one atmosphere of over pressure would increase the penetration from 58% after the 1st evacuation to 72% after the second evacuation, and to only 76% after the 3rd evacuation.
5. From these trial results the combination of 29" Hg or more of vacuum, followed by over pressure, and/or removing the fluid after each stage of treatment, will permit effective penetration treatment of polymer sandwiched paper-board. The effects quantified in the above trials have been observed in the depth of penetration of densely packed bales of waste containing paper; bale densities of 20 to 35 pounds per cubic foot.
6. A modelling of these test results to determine the effectiveness of the application above atmospheric pressure after the evacuation shows that the calculated depth of penetration of trial "B" if conducted at a 500 psig over pressure instead of 14.7 psia, the expected depth of penetration would be increased from 73% to 95% after a 34 second penetration time.
7. A further significant finding derived from observation of the tests is that the polymer outer coating of the samples became separated from the fibrous material comprising the central portion of the sandwich and remained as an integral unit of contaminant matter having little or no reduction in size from its original outer covering dimensions. As such, the relatively large segments of integral contaminant matter separated from the fibrous center of the sandwich are more easily separable from the cellulosic fibers of the center portion of the sandwich in the recycling defibration of the cellulose matter.
From these experiments and computer modelling based thereon, we have discovered the effects which the degree of vacuum pressure and subsequent over pressure environment and the number of sequential applications of vacuum and over pressure environments have on the degree to which liquid penetrates into the interior of a polymer coated paperboard sandwich under the imposed pressure environments. Through computer modelling of the above indicated experimental data, certain conclusions can be derived relative to the pressure environment which would be optimum for penetration into paper fiber containing articles which contain significant amounts of contaminants or whose surfaces have a fluid barrier coating of a contaminant. The test results were modelled in applying the results to strips of polycoated paperboard sandwiches as well as to discs and also to the application of over pressures (subsequent to liquid submergence under vacuum) that are greater than atmospheric pressure to include a number of combinations of applications of vacuum and over pressure.
All of the modelling results apply to treatments of bales containing polycoated paperboard which remain submerged throughout the second and subsequent cycles and to that polycoated paperboard which is located in the bottom of a submerged bale. Therefore, the amount of vacuum applied in the modelling in the 2nd and subsequent cycles is corrected for immersion in three feet of water.
The penetration times are first estimated for discs which are 14.2 centimeters in diameter and for strips which are 14.2 centimeters wide. Times for other diameters and widths are estimated by multiplying them by the square of the ratio of their diameters or widths as the case may be. The results are illustrated for one inch discs and strips.
In the Table below, the column titled Initial & Cycle Time includes estimates of the times required for 1 inch discs and strips:
to open and close the treatment vessel door, load and unload a bale, establish the initial vacuum, add the fluid, repressurize and withdraw the treatment fluid--a one-time total of six minutes;
and, in the 2nd and subsequent cycles, to reestablish vacuum and maintain it for an additional three minute dwell time which was observed to be required to complete the period of bubbling from the polycoated board which was observed in the experiments--a total of 5 minutes for each cycle of treatment after the first.
Total bale treatment time is Initial plus Cycle Time (includes Penetration Time).
The following Table indicates the extended results derived from modelling the above indicated Test Results:
__________________________________________________________________________EXTENDED RESULTS FROM MODELLINGBoard Initial plusgeometry Number Vacuum Over Pressure Penetration time Cycle Time& depth of in pressure Ratio in min. & sec. in mins forpenetration cycles Hg.g in psig 1st/2nd+ 14.2 cm 1.0 in. 1" discs & strips__________________________________________________________________________Disc/95% 1 -28.9 500 1051 34" 1" 6'Disc/95% 2 -28.9 53 137/38 7' 11" 14" 11'Disc/95 3 -28.8 0 28/8.0 39' 20" 1' 16" 16'Disc/95% 4 -26.5 0 8.8/4.9 42' 20" 1' 21" 21'Disc/95% 5 -23.9 0 4.9/3.4 43' 1' 23" 26'Strip/98% 1 -28.9 500 1051 13" 1" 6'Strip/98% 2 -28.9 203 444/121 38" 1" 11'Strip/98% 3 -28.9 24 80/20 3' 19" 6" 16'Strip/98% 4 -28.1 0 17/6.8 8' 20" 16" 21'Strip/98% 5 -25.9 0 7.4/4.5 7' 50" 15" 26'Strip/98% 6 -23.7 0 4.8/3.4 7' 22" 14" 31'__________________________________________________________________________
CONCLUSIONS
Penetration times for 1 inch discs and stripes are not significant. Therefore, for design purposes total treatment time is the initial plus cycle times which becomes excessive as the number of cycles exceeds six. The preferred treatment is a one-cycle process with an over pressure of 500 psig and a vacuum of -29 inches Hg. gage, both of which are easily incorporated into equipment for an operating bale treatment process.
The three experiments and the resultant modelling indicate that an effective pre-recycling conditioning penetration of liquid into a bale containing paper and paperboard articles of a nature that exposure of the fibers of the articles to fluid wetting are restricted can be expected within a reasonable bale treatment time under the following parameters:
(1) introducing fluid into the bale in which the bale is subjected to consecutive cyclic environments of a vacuum pressure of at least 25" of mercury below atmospheric pressure (-25" Hg gage) followed by an over pressure of at least one atmosphere.
(2) When the applied vacuum pressure is less than -25" Hg gage, an over pressure greater than one atmosphere is required.
(3) A ratio of the absolute pressures of the over pressure and vacuum pressure of six is required for an effective cycle.
(4) When minimum intensities of acceptable vacuum pressure followed by an over pressure are involved, a cycle of at least five applications of vacuum and over pressure are needed.
(5) A preferable single cycle of bale treatment would comprise a vacuum pressure application as low as -29" Hg gage prior to admission of treating fluid, followed by an over pressure of 500 psig.
(6) Single cycle bale treatment time is estimated at six minutes or less, with an additional five minutes required for subsequent cycles.
Whereas a convenient manner of practicing the invention in which the debonding liquid is caused to penetrate into the interior of a waste material bale by extracting a substantial amount of air from a sealed chamber in which the bale is isolated by subjecting the chamber to a negative pressure environment prior to introducing liquid into the chamber after which the chamber containing sufficient liquid to submerge the bale is subjected to an over pressure of at least one atmosphere during which the liquid penetrates throughout the bale contents, the same result could be achieved by subjecting the bale to differential positive pressure environments, instead of a negative pressure followed by a positive pressure, in establishing a flow of liquid throughout the contents of the tightly compacted bale.
A basic feature of the invention, applicable as the initial operation in the recycling of baled waste material prior to initiating a defibration of fibrous matter in the bale, is establishing a wetting impregnation of the bale contents with a fiber swelling and debonding fluid by isolating the bale within a closed chamber and subjecting the closed chamber and contained bale to one or more cycles of liquid insertion under multiple pressure environments each comprising:
(1) establishing a first (preferably vacuum) pressure within the interior of the closed chamber,
(2) introducing into the pressurized chamber a sufficient amount of debonding liquid as submerges the bale,
(3) subjecting the interior of the liquid containing chamber to a second (preferably positive) pressure greater than the first pressure and
(4) maintaining the chamber containing the fluid and bale at the second pressure for a sufficient time as establishes a penetration of the liquid substantially throughout the interior of the bale.
After a thorough wetting impregnation of the bale with the swelling and debonding liquid, the bale is removed from the chamber and maintained in a quiescent condition for a sufficient time as establishes a debonding swelling of the waste paper article cellulosic fibers exposed to the debonding liquid after which the contents of the liquid impregnated bale are subjected to defibration and separation out of the swollen cellulosic fibers from the remaining bale reject contents. If the baled waste paper articles comprise fibrous material sufficiently contaminated or coated with a fiber barrier contaminant that the bale reject contents contain a significant amount of non-debonded fibers, this bale reject portion preferably is again subjected to one or more cycles of liquid impregnation under multiple pressure environmental conditions and further defibration recycling.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram illustrating waste material bale multiple pressure liquid impregnation apparatus and process of the invention.
FIG. 2 is schematic diagram illustrating apparatus and method for recycling the contents of the waste material bale impregnated in accordance with FIG. 1.
DESCRIPTION OF THE INVENTION
First referring to FIG. 1, representing a schematic arrangement by which the bale multiple pressure liquid impregnation aspect of the invention can be carried out, an infeed conveyor system 10 is arranged in a manner to transport waste material bales 11 supported in a shallow tray 36 into the interior of a vacuum treatment chamber 12 through an access door 13, illustrated in dotted lines in its open position, and an outfeed conveyor system 14 is arranged to remove the liquid impregnated bale 15 from within the treatment chamber 12 for further processing in the manner subsequently described in FIG. 2. Treatment chamber 12 connects through a line 17 and a three-way reservoir valve 18 to a treatment liquid reservoir 16 and through the three-way valve 18 and drain line 35 to a treatment fluid make-up tank 22. To minimize the interior dimensions of the treatment chamber 12 in accommodating the largest bale intended for treatment, the treatment chamber capacity can be supplemented by connecting through a line 20 to an overflow header 19. However, the header can be eliminated if the treatment chamber is of sufficient size to accommodate the total volume of treatment liquid that would be required for the treatment cycles discussed herein. Various other obvious alternative arrangements can be utilized to ensure that a sufficient amount of treatment liquid is maintained in the treatment chamber to submerge the bale during the treatment cycles. Reservoir 16, having an atmosphere connection line 21, is connected to a treatment fluid make-up tank 22 through a replenishing line 34 containing a valve and pump assembly 23. A rinsing fluid tank 22a is connected to the treatment chamber 12 through a line containing a shut-off valve 22b. The suction side of a vacuum pump 24 connects to the interconnected header 19 and treatment chamber 12 through line 25 containing a shut-off valve 26. A second source 61 of a treatment gas, typically of the nature of ammonia or oxidizing gas also connects into line 20 through line 61a and valve 61b. A high pressure pump 27 with its suction side connected to the liquid reservoir 16 through line 28 connects through its pressure side and a three-way pressurizing valve 30 through line 29 to the interconnected header 19 and treatment chamber 12, the third side 31 of the three-way pressurizing valve connecting to atmosphere when set to the third position. A bale stabilizing arm 32 supported within the treatment chamber 12 for vertical movement by an actuating mechanism 33 is adjustable vertically into and out of contact with a bale contained in the treatment chamber.
Referring now to FIG. 2, representing a schematic arrangement by which the bale of waste material impregnated in the manner of the invention represented in FIG. 1 can be optimally recycled for the recovery of a maximum amount of cellulosic fibers of high quality from all types of paper articles. The waste material bale 15, previously subjected to multiple pressure debonding fluid impregnation in the manner of FIG. 1, is supported in a shallow tray 36 for removal and transportation by the outfeed conveyor system 14 and deposited into a fiberizer or fiber dispersion unit 37 containing water or other suitable pulping liquid supplied from a suitable source (not illustrated). The fiberizer is a conventional type in which sufficient agitation is generated in the pulping liquid as separates or prepares for separation the waste paper fibers that have become swollen and debonded in the liquid impregnated bale but the agitation is not sufficient to damage the fibers significantly or significantly diminish the size of agglomerations of contaminated fibers or segments of contaminants such as foils, laminates, etc. that become debonded from the fibrous material in the vacuum treatment chamber 12. A typical fiberizer tank 37 contains a rotor 38 mounted for rotation substantially flush with an interior sidewall of the fiberizer tank to prevent entanglement with segments of contaminated material. Preferably a vertical baffle 39 extends downwardly into the interior of the fiberizer tank 37 between the rotor 38 and the outlet at the top of the fiberizer leading into the intake 40 of a pulp separator 41 conveniently of the type of a Trommel Screen. The pulp receiver 42 of the separator 41 connects to the suction of a slurry recovery pump 43 which discharges into a pulp cleaning or processing system from which reclaimed paper products are produced. A waste reject conveyor 44 extending from the waste discharge conduit 45 of the pulp separator 41 has a two-position diverter 46 which channels reject waste material at the exit end of the conveyor 44 either into the intake 48 of a second pulp separator 49 or into a shredder 47 that empties into the intake 48 of the second pulp separator 49, also of the nature of a Trommel Screen which has a pulp receiver 50 connecting to the suction of a slurry pump 51 that discharges into the pulp cleaning or processing system. The waste outlet 52 of the second separator connects through a waste discharge line 53 to a hydraulic liquid extractor and baler 54 which both extracts liquid from the reject waste material contained in the extractor and compacts the extractor contents into a semi-wet reject bale 55. A discharge end of the extractor-baler 54 communicates with a disposal conveyor 56 at the discharge end of which is a two-position diverter 57 which channels the reject bale 55 either to a waste disposal destination 58 (e.g., landfill) or to a secondary recycling conveyor system 59 arranged to redeposit the reject baled material 55 onto the infeed conveyor system 10 of the vacuum-pressurizer liquid treatment system of FIG. 1 or a CTDS unit 60 subsequently discussed. Inasmuch as a second vacuum-pressurized liquid treatment of a reject bale 55 received into the treatment chamber 12 from the secondary bale recycling conveyor system 59 would decrease the productive capacity of the vacuum-pressurized liquid treatment system of FIG. 1, alternatively the secondary bale recycling conveyor system 59 can be adapted to divert selected reject baled material 55 into a "combined-treatment-dispersion-separation" (CTDS) unit 60 of the type described in our U.S. Pat. No. 5,231,805 arranged to discharge separated pulp slurry into the second pulp separator intake 48 and reject materials into the extractor and baler 54.
Referring again to FIG. 1, the cycle for establishing the multiple pressure or vacuum-pressurizing impregnation treatment of an untreated bale 11 is initiated by the introduction into the treatment chamber 12 of the bale on shallow tray 36 and closing the chamber door 13 to seal the chamber after which the vacuum pump valve 26 is opened to connect the suction side of the vacuum pump 24, which most conveniently can be continuously operated, to the interconnected header 19 and treatment chamber 12 which have been isolated from the remainder of the system by placing the three-way reservoir valve 18, the three-way pressurizing valve 30 and the rinsing valve 22b in a closed position, thereby establishing a vacuum pressure within the bale containing treatment chamber 12 to the capacity of the vacuum pump. During this evacuation period the reservoir 16 can conveniently be resupplied with a treatment fluid from the make-up tank 22 through the connecting line 34 and its normally closed valve and pump assembly 23. The treatment fluid can be any of the well-known fiber swelling and debonding fluids of the nature of plain water or preferably an alkaline fluid having a pH of about 7.0-11.5 of the nature of dilute ammonium hydroxide or fluid containing an oxidizing agent, etc. Obviously, stronger treatment fluids are required when the fibrous matter comprising the waste paper articles is heavily contaminated or coated with a fluid barrier contaminant. During or prior to evacuating air from the treatment chamber 12 the stabilizing arm 32 is lowered into contact with the bale to clamp it into a fixed position by activating the arm actuating mechanism 33. Following air evacuation from the interconnected header 19 and treatment chamber 12 to substantially the capacity of the vacuum pump 24, the three-way reservoir valve 18 is set to an open position interconnecting the treatment chamber 12 and the reservoir 16 whereby treatment liquid from the reservoir 16 flows through the line 17 filling the treatment chamber 12 and header 19.
Following evacuation and filling of the treatment chamber 12 with treatment liquid, atmospheric over pressure is established in the fluid filled treatment chamber 12 and header 19 by closing the three-way reservoir valve 18 and the vacuum pump valve 26 and positioning the three-way pressurizing valve 30 to its third position 31 atmosphere connection, thereby establishing an atmospheric over pressure in the liquid filled treatment chamber 12 containing the submerged bale through the line 29 connected into the header 19. If a super atmospheric over pressure is to be established in the liquid filled treatment chamber 12 containing the submerged bale, the three-way reservoir valve 18 and vacuum pump valve 26 are closed to isolate the treatment chamber, the high pressure pump 27 is activated and the three-way pressurizing valve 30 is opened to connect the discharge of the high pressure pump 27 into the header 19 and treatment chamber 12 through the line 29, the high pressure pump drawing liquid from the reservoir 16 through line 28.
If the bale conditioning treatment is to comprise a single evacuation-pressurizing cycle, after the over pressure has been applied for a sufficient time that the treatment liquid penetrates throughout the bale and its voids to substantially the extent the over pressure can provide, excess treatment liquid may be drained from the treatment chamber 12 into the make-up tank 22 by setting the three-way reservoir valve 18 to its third position connecting line 17 into the drain line 35 leading into the make-up tank 22 and setting the three-way pressurizing valve 30 to its atmospheric opening side 31 with the vacuum pump valve 26 closed and the high pressure pump deactivated. After drawing excess liquid from the treatment chamber 12 the bale stabilizing arm 32 is raised, the treatment chamber door 13 opened and the liquid impregnated bale 15 removed by the outfeed conveyor system 14 and transported into the recycling processing system of FIG. 2 in which the swollen and debonded fibers of the waste paper in the impregnated bale 15 are separated from the non-fibrous contaminated matter of the bale contents in the manner subsequently described with respect to FIG. 2. If the nature of the waste paper articles in the bale are such that multiple vacuum-pressurizing cycles are considered necessary to obtain the desired degree of debondment of the paper fibers from contaminants, after the initial application of over pressure, a second or more evacuation-pressurizing cycles are initiated by utilizing the same procedure discussed for the first cycle prior to draining excess fluid from the treatment chamber 12 and removal of the impregnated bale. Also prior to removal of the liquid impregnated bale from the treatment chamber and before or after excess treatment fluid is drained into the make-up tank, the impregnated bale can be rinsed with a suitable rinsing fluid or second type of treating fluid drawn from the contents of the rinsing tank 22a by placing the vacuum pump valve 26 in its open position connecting the suction side of the operating vacuum pump 24 through line 25 into the interconnected header 19 and treatment chamber 12 and opening the rinsing tank valve 22b, the reservoir connecting valve 18 being closed.
It should be understood that the devices and procedures described above are illustrative only of the basic aspects of the invention and many other devices and procedures can be utilized in establishing the multiple pressure environments of the invention to which the baled waste material is subjected in practicing the invention. For instance, the discharge side of the vacuum pump can be connected through valving and connection arrangements that are obvious to those skilled in the art as would apply a low degree of over pressure greater than atmospheric onto the liquid filled treatment chamber.
Referring again to FIG. 2, the bale 15 impregnated with the swelling and debonding liquid is maintained in a quiescent state on the outfeed conveyor system 14 for a sufficient time for the debonding liquid to come into contact with and be sorbed by exposed fibers of the waste paper articles in the bale after which the waste bale 15 is deposited in the fiberizer 37 in which agitation of the fiberizer pulping fluid initiates a separation between the swollen waste paper fibers and between these fibers and agglomerate masses of contaminated fibers and non-fibrous contaminant masses debonded from the fibrous material by the vacuum-pressurizing conditioning treatment previously described. The agglomeration of separated fibers and non-debonded fiber material and integral masses of contaminants agitatively separated in the fiberizer 37 flow under the fiberizer baffle 39 and out of the fiberizer under the pressure generated by the fiberizer rotor 38 into the accumulator 40 of the screen separator 41 in which the agglomerate wetted masses are separated into the two components of: (1) a fiber-liquid slurry collected in the separator receiver 42, which is discharged through pump 43 to a source of further pulp refining, and (2) rejects comprising wetted masses of contaminant containing or coated fibrous material and non-fibrous contaminants that flow through the separator discharge line 45 and are deposited on the waste conveyor 44. The wetted reject masses deposited on the waste conveyor 44 may contain a substantial amount of fibers with some degree of contamination and from which separation is possible, e.g., plastic bags filled with relatively uncontaminated paper articles, contamination coated or impregnated paper, etc. If the reject masses on the conveyor 44 include paper articles of a nature that the surfaces are coated or the articles are protected by some type of fluid barrier, the diverter 46 at the end of the conveyor is positioned to channel the reject mass into the shredder 47 in which the reject mass material is sufficiently severed to expose end surfaces to liquid penetration after which it is deposited in the accumulator 48 of the second separator 49. Otherwise, the diverter 46 is positioned to channel the reject masses on the conveyor directly into the accumulator 48 of the second separator 49 in which the material is segregated into the same two components as in the first separator 41 of a fiber-liquid slurry collected in the receiver 40 from which pump 51 discharges the slurry into the pulp cleaning and processing system and a reject mass flowing from the second separator waste outlet 52 through the waste discharge line 53 into the hydraulic liquid extractor 54 which extracts liquid and presses the reject mass into a compacted semi-wetted bale 55 which is deposited onto the disposal conveyor 56. If the compacted wetted bale 55 has a significant paper fiber content of about 5% or more, as would make it worthwhile to reprocess the contents of the compacted wetted bale 55 for a second time through the vacuum-pressurizing treatment conditioning in the treatment chamber 12 displayed in FIG. 1, the disposal conveyor diverter 57 can be positioned to channel the semi-wetted reject bale 55 onto a secondary bale recycling conveyor system 59 which deposits the bale onto the infeed conveyor system 10 of the vacuum-pressure treatment system of FIG. 1 from which the wetted reject bale is again processed for extraction of paper fibers in the same manner as previously described. If reintroduction of the semi-wetted reject bale 55 into the vacuum-pressure impregnation system of FIG. 1 is determined to overload the productive capacity of that system and the semi-wetted reject bale 55 is diverted by the secondary bale recycling conveyor system into the CTDS unit, this unit pumps the pulp slurry recovered from the bale into the accumulator 48 of the second separator unit 49 and deposits the remaining contaminated masses into the hydraulic liquid extractor baling unit 54.
The baled waste material, after being subjected to liquid impregnation under the described cycles of multiple pressure environmental conditions, is of a nature that moderate agitation of the bale causes the contents to become dispersed into a flotsam comprising a slurry of liquid suspended cellulosic fibers and other small particles mixed with chunks of contaminated, non-debonded fibrous material, contaminant coatings separated from fibrous material and non-fibrous contaminants largely retaining their original dimensions. Due to the lack of an appreciable diminution in the size of contaminant containing bonded fibrous material and contaminant matter contained in the flotsam created in and discharged from the fiberizer 37, the slurry that passes through the screen of the separator and collected in the receiver 42 contains small amounts of contaminant particles which results in a low degree of clogging of the screen separators. Due to the nature of the flotsam produced in the fiberizer and the rejected matter discharged from the screen separator or being processed through the recycling system, this reject matter does not flow through pumps in being processed, but flow establishing means, such as the flush mounted rotor 38 of the fiberizer are utilized in causing the liquidized reject flotsam to pass through the recycling system. Accordingly, the usual problem encountered in recycling systems of clogged pumps is not present in the system of the described invention. It should be further recognized that the number of screen separators incorporated in a recycling system of the nature of this invention can vary in accordance with the nature of the types of waste paper that are contained in the waste material.
It should be further understood that the foregoing disclosure involves typical embodiments of the invention and that numerous modifications or alterations may be made therein without departing from the spirit and scope of the invention as set forth in the appendant claims.
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An improved method of processing baled waste material containing waste paper having fibers contaminated to various degrees for recovering usable cellulosic fiber pulp from the bale in which the bale contents are impregnated with a fiber swelling and debonding fluid by enclosing the bale within a closed chamber and subjecting the chamber and contained bale to multiple pressure environmental conditions, that preferably includes a vacuum, while submerging the bale in the debonding fluid. The impregnated bale contents are allowed to soak for a sufficient period that the lesser degree contaminated fibers become swollen after which the bale is subjected to a sufficiently low degree of pulping agitation as initiates separation of the swollen fibers without significant damage to the fibers and which does not significantly decrease the sheet size of higher degree contaminated bonded fibers and other contaminants. The agitated bale contents are separated in a screen separator into a pulp containing slurry and a reject mass of higher degree contaminated, unswollen fibers and contaminants. If the reject mass contains a significant degree of fibrous material, it is compressed into bale form and again subjected to a multiple pressure liquid impregnation treatment in a closed chamber after which the multiple pressure impregnated bale is subjected to the same or similar recycling operations in separating out the fiber pulp slurry.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of U.S. Provisional Application No. 61/843,290, filed Jul. 5, 2013, which application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Excavators, dozers, and backhoes are a few examples of heavy equipment commonly used at, for example, mining, forestry or construction sites. Most types of heavy equipment are mobile, and the drive system may include wheels or a track-type undercarriage. A continuous track undercarriage is typically used to move the heavy equipment and large amounts of material over dirt or natural type terrain. Track undercarriages include a track assembly underneath the equipment on each side in place of axels and wheels on wheeled equipment. Depending on the environment, the undercarriage track can be exposed to hard rock that can infiltrate into the undercarriage causing damage to the components. To reduce damage to the lower rollers caused by rooks, the undercarriage may be equipped with roller guards sometimes referred to as rook guards. Roller guards are heavy metal shields that cover the rollers of an undercarriage and reduce the ability for rocks and/or other foreign debris from entering the roller areas causing premature wear and damage to the undercarriage. To maintain the safety and performance of the heavy equipment manufacturers suggest that the undercarriage be inspected as part of the routine maintenance. During the routine maintenance of a machine, it is necessary to check the condition of individual undercarriage components by measuring the amount of wear. To measure undercarriage rollers with roller guards installed, the bucket of the machine is pushed into the ground to lift the equipment and expose the rollers. Once the machine is lifted and the rollers are exposed, a hand held caliper is used to manually measure the diameter of the roller. As a result of the inherent dangers of measuring undercarriage rollers with roller guards, roller wear is rarely measured.
BRIEF SUMMARY OF THE INVENTION
In accordance with the purposes of the present invention, as embodied and broadly described herein, the present invention includes an undercarriage wear measurement tool having a housing with an elongated passage. A sleeve is attached to the proximal end of the housing for centering over a component bolt head therewith and includes a fastener magnet for attaching to a metal component. The undercarriage wear measurement tool includes an elongated measurement pin slidably disposed within the elongated passage.
BRIEF DESCRIPTION OF THE DRAWINGS
The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the views, and wherein:
FIG. 1 is a schematic view of an exemplary undercarriage wear measurement tool including a sleeve:
FIG. 2 is a schematic view of an exemplary undercarriage wear measurement tool having a flat surface;
FIG. 3 is a side cross-sectional view of the undercarriage wear measurement tool taken along section 2 - 2 of FIG. 1 , illustrating a measurement pin removed;
FIG. 4 is a side cross-sectional view of the undercarriage wear measurement tool taken along section 2 - 2 of FIG. 1 , illustrating a measurement pin installed;
FIG. 5 is a schematic view of a portion of a track type undercarriage, including a schematic view of an exemplary undercarriage wear measurement tool;
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the discussion that follows and also to the drawings, illustrative approaches to the disclosed invention are shown in detail. Although the drawings represent some possible approaches, the drawings are not necessarily to scale and certain features may be exaggerated, removed, or partially sectioned to better illustrate and explain the present invention. Further, the descriptions set forth herein are not intended to be exhaustive or otherwise limit or restrict the claims to the precise forms and configurations shown in the drawings and disclosed in the following detailed description.
Referring to FIGS. 1-4 , an exemplary undercarriage wear measurement tool 10 may include a housing 20 having an elongated internal passage 30 extending lengthwise along a longitudinal axis A-A of housing 20 . Internal passage 30 may extend entirely through housing 20 from a proximal end 32 to an opposite flat surface distal end 28 . Attached to proximal end 32 of housing 20 is a sleeve 22 configured for receiving a component, for example, a conventional bolt head 52 , as illustrated in FIG. 5 . The sleeve 22 may be fixedly attached to housing 20 , such as by welding, brazing, soldering and gluing, to name a few, or integrally formed with housing 20 . For purposes of discussion, sleeve 22 is illustrated as being integrally formed with housing 20 . The exemplarily configuration for housing 20 are shown in FIGS. 1-5 as cylinder shaped and may alternatively employ other non-circular shapes, for example, square, rectangular, triangular and polygonal, to name a few.
With continued reference to FIGS. 1-4 , undercarriage wear measurement tool 10 may include one or more fastener magnets 24 disposed within internal passage 30 of housing 20 for reasonably securing the undercarriage wear measurement tool to the component being measured. Alternatively, fastener magnet 14 may not extend the complete length of internal passage 30 or may be outside the internal passage 30 . For purposes of discussion, fastener magnet 24 is illustrated as within the complete length of internal passage 30 .
Undercarriage wear measurement tool 18 may include an elongated measurement pin 28 disposed within internal passage 30 of housing 20 . A longitudinal axis of measurement pin 26 may substantially coaxially align with longitudinal axis A-A.
Exemplary undercarriage wear measurement tool 10 may be used in a variety of applications, including but not limited to, measuring wear of lower roller 60 of a heavy equipment track type undercarriage 70 , as illustrated in FIG. 5 . A portion of a track type undercarriage 70 which is schematically illustrated in FIG. 5 may include components such as a track shoe 66 , a track link 68 , and a lower roller 10 . An exemplary undercarriage lower roller 60 may be attached to a heavy equipment undercarriage 70 by a lower roller bolt 52 . The lower roller 60 of an undercarriage 70 may be enclosed within a roller guard 64 for protection.
The need to calculate lower roller 60 wear is essential to determine the life remaining of lower roller 60 . To calculate the wear of lower roller 60 the diameter of the lower roller 60 must be measured. To measure the diameter of lower roller 60 with lower roller guard 64 installed, the heavy equipment is lilted, causing the undercarriage 70 to sag allowing access to the lower roller 60 . Measuring the lower roller 60 with rock guard 64 installed without lifting the heavy equipment can be accomplished using the undercarriage wear measurement tool 10 .
As illustrated in FIG. 5 , sleeve 22 of undercarriage wear measurement tool 10 is positioned over a lower roller bolt 52 . The undercarriage wear measurement tool 10 fastener magnet 24 securely attaches the undercarriage wear measurement tool 10 to the lower roller bolt 52 . The measurement pin 26 is now aligned with the center of the lower roller bolt 52 creating a centered reference point of the lower relief 60 extending beyond the lower roller guard 64 . The distance between the center point of the measurement pin 26 and the lower track shoe 66 is measured, illustrated by Measurement B. The track link 68 is measured to determine the track link 68 height, illustrated by Measurement C. The lower roller 60 diameter can now be determined by subtracting Measurement C from Measurement B and multiplying by a factor of 2.
It is to be understood that the above description is intended to be illustrative and not restrictive. Many embodiments and applications other than the examples provided would be apparent to those of skill in the art upon reading the above description. The scope of the invention should be determined, not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. It is anticipated and intended that future developments will occur in the arts discussed herein, and that the disclosed systems and methods will be incorporated into such future embodiments. In sum, it should be understood that the invention is capable of modification and variation and is limited only by the following claims.
All terms used in the claims are intended to be given their broadest reasonable constructions and their ordinary meanings as understood by those skilled in the art unless an explicit indication to the contrary is made herein. In particular, use of the singular articles such as “a,” “the,” “said,” etc. should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary.
The foregoing description relates to what is presently considered to be the most practical embodiment. It is to be understood, however, that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.
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An undercarriage wear measurement tool includes a housing with an elongated passage. A sleeve is attached to the proximal end of the housing for centering over a component, such as, a bolt head therewith and includes a fastener magnet for attaching to a metal component. The undercarriage wear measurement tool includes an elongated measurement pin slidably disposed within the elongated passage.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a small-sized food chopper, and more particularly, to a small food chopper for chopping up foodstuff.
[0003] 2. Description of the Related Art
[0004] Food choppers mainly use a handle to connect itself with a reset spring and further control a W-shaped blade, the foodstuff is repetitively cut by repetitively pushing down the handle, and each time the handle is pushed down, the handle, together with the W-shaped blade will rotate a certain angle so that the foodstuff is chopped up by the blade. There are two designs in the prior art technology: one is an apparatus with a stainless steel outer case completely wrapping the interior parts, comprising a reset spring, a W-shaped blade and a through shaft with inside sprocket. However, this design has a defect, for the whole food chopping apparatus is hidden in the stainless steel outer case, and thus it is rather difficult to cleanse it each time after chopping up the foodstuff. In addition, this known technical design has other defects, besides its large volume, which occupies a relatively large space, although the material of this design is mainly stainless steel, many interior parts are made of metal, therefore, after a long period of use, it contaminates the foodstuff due to the rusting problem, which is a problem that cannot be neglected.
[0005] Besides, another designing method is an apparatus with a plastic outer case wrapping the interior parts; comprising a lower half handle, a W-shaped blade and a through shaft with inside sprocket, whereas the upper half handle and the reset spring are exposed. However, this design has a defect: the exposed reset spring is more prone to damage, which renders the food chopper not durable enough; although the food chopper uses a plastic outer case instead, many other parts are still made of metal, and thus the rusting problem of the food chopper still exists; in addition, the principles of the rotation of the aforesaid two food choppers are both that: the handle which is on the through shaft with inside sprocket is pushed down, and when it is raised and returns to the original state, the pit lines on the handle of this portion will be shifted from one sprocket tooth inside the through shaft to another sprocket tooth next to it so as to achieve the rotation effect; however, this design will result in the parts in charge of rotation and the parts in charge of the pushing-down action locating at the same place and thus affecting each other, wherein the biggest problem is that when the handle is pushed down and when it begins to rotate and rise, the handle will readily be stuck and thus cannot successfully accomplish the whole chopping process.
SUMMARY OF THE INVENTION
[0006] To solve the aforesaid problems, it is an object of the present invention to provide a small-sized food chopper, which has an exterior which is pleasing to the eye, its volume is smaller than any prior food chopper, its operation is more convenient and reliable, and it does not rust.
[0007] To achieve the aforesaid objects, the present invention provides a small-sized food chopper for chopping up foodstuffs, characterized in that it comprises: an outer case including a lower casing removably connected with an upper casing and a button mounted on the upper casing; a blade connection holder installed inside said outer case, said blade connection holder can move axially up and down in the outer case; a plurality of blades installed on the lower end of the blade connection holder; a reset spring sheathed on the blade connection holder which restores the blade connection holder axially up; a means which makes the blade connection holder rotates a predetermined angle circumferentially each time the blade connection holder operates axially; said button is configured such that it can slide up and down axially, and said button acts on the upper end of the blade connection holder to make the blade connection holder move axially downwardly.
[0008] Preferably, the small-sized food chopper further includes a blade inner cover installed inside the lower casing, and axially fixed with respect to the lower casing, and when the small-sized food chopper is in a non-operation state, the blade is located in the blade inner cover.
[0009] Preferably, the blade inner cover is in the shape of a cup, and a slot is formed at its bottom which is in the same shape as that of the blade section and which allows the blade to move axially, the blade inner cover can rotate circumferentially along with the blade connection holder.
[0010] Preferably, axially extending projection columns or grooves are formed on the inner wall surface of the blade inner cover, whereas corresponding grooves or projection columns form on the blade connection holder to engage with the projection columns or the grooves formed on the inner wall surface of the blade inner cover.
[0011] Preferably, the blade connection holder consists of a cylindrical barrel body and a disc-shaped stand base, the blade is fixed on the stand base, the grooves or projection columns are formed on the stand base, while projections are formed on the flange at the top of the blade inner cover, and they lean against the stand base of the blade connection holder and it counterchecks the axial movement of the blade connection holder.
[0012] Preferably, the small-sized chopper further comprises a sleeve removably installed in the upper casing, the barrel body of the blade connection holder is inserted in the sleeve, a plurality of barrel body ribs axially extending from disc-shaped stand base upward are disposed on the outer wall of the barrel body of the blade connection holder, while a plurality of in-cap ribs extending axially upwardly are disposed on the inner wall of the sleeve, when the small-sized food chopper is in the non-operation state, each of the plurality of barrel body ribs is engaged between a pair of adjacent sleeve in-cap ribs to contain the circumferential rotation of the blade connection holder, whereas when the small-sized food chopper is in the operation state, the plurality of barrel body ribs can get disengaged axially from the sleeve in-cap ribs, inclined planes in the same slanting direction are formed on the upper ends of the barrel body ribs and on the lower ends of the in-cap ribs for impelling the barrel body ribs to be inserted between the in-cap ribs.
[0013] Preferably, a crown-like support cap is installed on the upper end of the blade connection holder, a plurality of sprocket-shaped cap top sprockets are formed by left and right bevel edges on the top of the crown-like support cap, while the button is cylindrical in shape with its top enclosed, on whose top a plurality of sprocket-shaped cover bottom sprockets are formed by left and right bevel edges on the inner wall.
[0014] Preferably, a plurality pairs of axially extending projection column tracks are disposed at a predetermined space circumferentially on the inner wall of the upper casing, a guiding groove track is thus defined between each pair of projection column tracks; a plurality of arc-shaped projections extending radially outwardly are formed at the flange of the lower end of the button, and the arc-shaped projections are engaged in the guiding groove tracks defined by each pair of the projection column tracks.
[0015] Preferably, a plurality of notches is disposed at a predetermined space circumferentially on the upper casing, the sleeve consists of a barrel body and a flange disposed at the lower end of the barrel body; a plurality of cap legs circumferentially spaced and extending upwardly are disposed on the flange, a clip hook is formed at the top end of the cap legs, and the sleeve is removably fixed on the upper casing by clipping the clip hook of the sleeve into the notches on the upper casing.
[0016] Preferably, the upper casing comprises an upper portion having a bigger diameter and a lower portion having a smaller diameter, and thus a step is formed between them, a plurality of circumferentially spaced projections are disposed at the axial positions of the lower portion having a smaller diameter adjacent to the step; a plurality of circumferentially spaced grooves are formed on the flange at the top end of the lower casing, and projections are disposed adjacent to the grooves, and the two portions are removably fixed to each other by inserting the lower portion having a smaller diameter of the upper casing into the lower casing and engaging the projections of the lower portion having a smaller diameter with the grooves on the flange at the top end of the lower casing, and then by relatively rotating the upper casing and the lower casing and making the projections of the upper casing go over the projections of the lower casing.
[0017] Preferably, a plurality of cap legs axially extending downwardly are formed on the crown-like support cap, clip hooks are formed at the ends of the cap legs, and locating groove columns are formed on the crown-like support cap; while a plurality of corresponding grooves are formed on the inner wall at the top of the barrel body of the blade connection holder, and locating grooves are formed on the barrel body of the blade connection holder; the crown-like support cap is removably fixed on the blade connection holder by clipping the clip hooks of the cap legs on the crown-like support cap into the grooves on the inner wall at the top of the barrel body of the blade connection holder, while the crown-like support cap is circumferentially located with respect to the blade connection holder by inserting the locating groove columns on the crown-like support cap into the grooves on the barrel body of the blade connection holder.
[0018] Preferably, the small-sized chopper further comprises a food container disposed at its bottom.
[0019] Preferably, the blades are Z-shaped blades.
[0020] The present invention provides a food chopper which is made of plastic except the blades which are made of stainless metal. This food chopper not only has an exterior pleasant to the eye, and is smaller in volume than any existing chopper, but it has solved the cleansing problem of the existing food choppers, it enables the user to disassemble the whole food chopper after use so as to cleanse it thoroughly. In addition, except the blades, the other parts of the small-sized food chopper are all made of plastic, and thus it greatly reduces the occurrence of the food contamination problem caused by the rusting of some composite parts due to long period of use. Furthermore, the design of a hidden inner reset spring makes the reset spring more difficult to be damaged, and makes the food chopper more durable; the most important point is that the part in charge of rotation and the part in charge of the pushing-down action in this design are operated at different positions of the composite parts, and thus when the handle is pushed down and just begins to rise, the handle will never be stuck and thus can successfully accomplish the whole chopping-up process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 depicts a front view of the food chopper in the present invention;
[0022] FIG. 2 depicts a section view along the line 2 - 2 shown in FIG. 1 ;
[0023] FIG. 3 depicts an exploded perspective view of the food chopper in the present invention;
[0024] FIG. 4 depicts a perspective view of the plastic main body shown in FIG. 3 ;
[0025] FIG. 5 depicts a front view of the plastic main body shown in FIG. 4 ;
[0026] FIG. 6 depicts a section view along the line 6 - 6 shown in FIG. 5 ;
[0027] FIG. 7 depicts a perspective view of the top cover button shown in FIG. 3 ;
[0028] FIG. 8 depicts a front view of the top cover button shown in FIG. 7 ;
[0029] FIG. 9 depicts a section view along the line 9 - 9 shown in FIG. 8 ;
[0030] FIG. 10 depicts a perspective view of the sleeve shown in FIG. 3 ;
[0031] FIG. 11 depicts a front view of the sleeve shown in FIG. 10 ;
[0032] FIG. 12 depicts a section view along the line 12 - 12 shown in FIG. 11 ;
[0033] FIG. 13 depicts a perspective view of the crown-like support cap shown in FIG. 3 ;
[0034] FIG. 14 depicts a front view of the crown-like support cap shown in FIG. 13 ;
[0035] FIG. 15 depicts a section view along the line 15 - 15 shown in FIG. 14 ;
[0036] FIG. 16 depicts a front view of the blade connection holder shown in FIG. 3 ;
[0037] FIG. 17 depicts a top view of the blade connection holder shown in FIG. 16 ;
[0038] FIG. 18 depicts a bottom view of the blade connection holder shown in FIG. 16 ;
[0039] FIG. 19 depicts a section view along the line 19 - 19 shown in FIG. 16 ;
[0040] FIG. 20 depicts a perspective view of the blade inner cover shown in FIG. 3 ;
[0041] FIG. 21 depicts a top view of the blade inner cover shown in FIG. 20 ;
[0042] FIG. 22 depicts a bottom view of the blade inner cover shown in FIG. 20 ;
[0043] FIG. 23 depicts a top view of the transparent outer case shown in FIG. 3 ;
[0044] FIG. 24 depicts a section view of the transparent outer case shown in FIG. 23 ;
[0045] FIG. 25 depicts an operation diagram of the food chopper in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0046] Firstly referring to FIG. 1 and FIG. 2 , a small-sized food chopper in the assembled state in the present invention is shown. As shown in FIGS. 1 and 2 , the small-sized food chopper in the present invention comprises: a transparent outer case 6 ; a blade inner cover 8 mounted inside the upper half of the transparent outer case 6 ; a blade connection holder 5 mounted in the blade inner cover 8 which can slide axially; two Z-shaped blades 9 mounted on the lower end of the blade connection holder 5 ; a sleeve 4 sheathed on the blade connection holder 5 ; a reset spring 10 sheathed on the blade connection holder 5 ; a crown-like support cap 7 mounted on the upper end of the blade connection holder 5 ; a plastic main body 1 whose lower end is connected with the transparent outer case 6 , and is located on the upper end of the food chopper; and a top cover button 2 disposed on the topmost of the small-sized food chopper and is slidably connected to the plastic main body 1 . Furthermore, FIGS. 1 and 2 also show a container 3 disposed at the bottom of the small-sized food chopper and for containing the foodstuffs to be processed.
[0047] In addition, referring to FIG. 3 , its perspective view shows the composite parts of the food chopper of the present invention and the configuration relationship of them. The container 3 is disposed at the bottom of the small-sized food chopper, and the transparent outer case 6 comprises an upper portion having a larger diameter and a lower portion having a smaller diameter, and thus a step is formed in between. The lower portion of the transparent outer case 6 is inserted into the container 3 and is sheathed by it. The blade connection holder 5 comprises a cylindrical barrel body 56 and a stand base 57 , two V-shaped slots 55 are formed in the stand base 57 , while a V-shaped connection brim 91 corresponding to the shape of the V-shaped slots 55 are disposed at the top of the blade 9 , the V-shaped connection brim 91 is inserted right into the two V-shaped slots 55 in the stand base 57 of the blade connection holder 57 , a plurality of connection through holes 92 are disposed in the V-shaped connection brim 91 as a bridge for firmly connecting the two. As shown in FIGS. 16-19 , a plurality of barrel body ribs 52 extending axially downwardly are disposed on the base of the barrel body 56 , the barrel body ribs 52 are functional components for realizing the rotation function of the small-sized food chopper (will be depicted in detail in combination with FIG. 25 in the following text). The sleeve 4 is sheathed on the blade connection holder 5 from the top down and is supported by the stand base 57 of the blade connection holder 5 . As shown in FIGS. 10-12 , the sleeve 4 consists of a barrel body and a flange at the lower end of the barrel body; three cap legs 42 spaced circumferentially and extending upwardly are disposed on the flange, a clip hook 43 is formed on the top end of each cap leg 42 ; further, recessed grains 41 extending axially are disposed between the adjacent cap legs; a plurality of in-cap ribs 44 are disposed on the upper portion of the inner wall of the barrel body of the sleeve 4 , and the in-cap ribs 44 are functional components for realizing the rotation function of the small-sized food chopper (will be depicted in detail in combination with FIG. 25 in the following text). The reset spring 10 is sheathed on the barrel body 56 of the blade connection holder 5 , and its lower end leans against the sleeve 4 , while its top end leans against the crown-like support cap, as shown in FIG. 1 .
[0048] The crown-like support cap 7 is disposed on the blade connection holder 5 . As shown in FIGS. 13-15 , three cap legs 71 extending axially downwardly are formed on the crown-like support cap 7 , a clip hook 73 is formed on the end of each cap leg 71 ; and three corresponding grooves 51 are formed on the inner wall at the top of the barrel body of the blade connection holder 5 . Consequently, when the crown-like support cap 7 is mounted on the blade connection holder, the clip hooks 73 on the ends of the cap legs are blocked into the three grooves 51 in the inner wall at the top of the barrel body of the blade connection holder 5 so that the crown-like support cap 7 is fixedly located with respect to the blade connection holder 5 . Further, a groove column 74 (as shown in FIG. 13 ) is formed on the crown-like support cap 7 , while a groove 58 (as shown in FIG. 17 ) is formed on the barrel body 56 of the blade connection holder 5 , when the blade connection holder S is mounted on the crown-like support cap 7 , the groove column 74 on the crown-like support cap 7 is inserted into the groove 58 on the barrel body 56 of the blade connection holder 5 so that it positions the crown-like support cap 7 circumferentially.
[0049] After the sub-assembly composed of the blade connection holder 5 , the sleeve 4 , the Z-shaped blades 9 , the reset spring 10 and the crown-like support cap 7 are assembled, the sub-assembly is inserted into the blade inner cover 8 , and the Z-shaped blade body 93 is located in the space within the blade inner cover 8 . Two axially extending projection columns 82 (as shown in FIGS. 20-22 ) are formed opposite each other on the inner wall of the blade inner cover 8 , and two small protrusions 83 (as shown in FIGS. 20-22 ) are formed opposite each other on the top end; two grooves 53 and two oppositely disposed notches 54 are formed on the stand base 57 of the blade connection holder 5 . In the assembled state, the projection columns 82 are engaged with the grooves 53 so that the projection columns 82 serve as a track for guiding the blade connection holder 5 , and allow the blade connection holder 5 to move up and down in the blade inner cover without rotation; furthermore, the two small protrusions 83 and the two small notches 54 collaboratively operate as a small obstacle so that some force is needed to insert the sub-assembly into the blade inner cover 8 ; after the assembling of the sub-assembly and the blade inner cover 8 is accomplished, the combination of the protrusions 83 and the notches 54 serves a stopping function, which makes it difficult for the blade inner cover 8 to come off after the assembling is accomplished, and the sleeve 4 disposed on the stand base 57 prevents the blade inner cover 8 from further moving upward.
[0050] FIGS. 4-6 show the plastic main body 1 . As shown in FIGS. 4-6 , the plastic main body 1 comprises an upper portion having a larger diameter and a lower portion having a smaller diameter, and thus a step is formed in between; a flange extending radially inwardly is formed on the end of the upper portion having a larger diameter of the plastic main body 1 , the flange defines a top hole 15 of the plastic main body 1 ; a notch 11 is formed on the top of the lower portion having a smaller diameter of the plastic main body 1 . Three pairs of projection column tracks 13 are formed on the inner wall of the plastic main body 1 , and each pair of projection column tracks define a groove track in between.
[0051] FIGS. 7-9 show the top cover button 2 . As shown in FIGS. 7-9 , the top cover button 2 is a sleeve-shaped member with the top end enclosed, and three arc-shaped projections 21 extending radially outwardly are formed on the flange of the lower end.
[0052] When being assembled, the top cover button 2 is inserted into the plastic main body 1 through a bottom hole 14 of the plastic main body 1 from the top down, and is drilled through from the top hole 15 of the plastic main body 1 , the three arc-shaped protrusions 21 lean against the flange formed on the upper end of the plastic main body 1 so that the top cover button 2 will not come off from the top hole 15 . Further, the three arc-shaped protrusions 21 of the top cover button 2 are respectively engaged in the groove tracks defined by the three pairs of the projection column tracks 13 on the inner wall of the plastic main body 1 so that the top cover button 2 will not rotate when it moves up and down in the plastic main body 1 .
[0053] Then, the top cover button 2 and the plastic main body 1 which are connected with each other are sheathed on the sub-assembly composed of the blade connection holder 5 , the sleeve 4 , the Z-shaped blades 9 , the reset spring 10 and the crown-like support cap 7 , and the drooping clip hooks 43 on the three cap legs 42 of the sleeve 4 are to be inlaid into the notches 11 on the plastic main body 1 so that the two are connected with each other. Consequently, the blade inner cover 8 , the blade connection holder 5 , the Z-shaped blades 9 , the sleeve 4 , the reset spring 10 , the crown-like support cap 7 , the plastic main body 1 and the top cover button 2 are successfully connected; meanwhile, the cap top sprockets 72 (as shown in FIGS. 13-15 ) of the crown-like support cap 7 are right engaged with the cover bottom sprockets 22 (as shown in FIGS. 7-9 ) of the top cover button 2 .
[0054] Finally, the aforesaid assembly is inserted into the transparent outer case 6 and thus the assembly of the small-sized food chopper is accomplished. When being assembled, since the outer diameter of the blade inner cover 8 and the inner diameter of the upper portion having a larger diameter of the transparent outer case 6 are the same, the blade inner cover 8 can be right inserted into the upper half of the transparent outer case 6 and be sheathed, and it leans against the step formed between the upper half and the lower half of the transparent outer case 6 . In addition, three protrusions 12 (see FIG. 5 ) formed on the plastic main body 1 are right inserted into the three grooves 61 (see FIGS. 23 and 24 ) formed on the transparent outer case 6 , and as long as the plastic main body 1 is rotated clockwise till its protrusions 12 go over the protrusions 62 disposed adjacent to the grooves 61 on the transparent outer case 6 , the two will be firmly attached to each other so that the assembling of the small-sized food chopper is accomplished. The whole assembling process of the small-sized food chopper does not use any metal connection members.
[0055] In the figures, FIGS. 4-6 show the plastic main body 1 , FIGS. 7-9 show the top cover button 2 , FIGS. 10-12 show the sleeve 4 , FIGS. 13-15 show the crown-like support cap 7 , FIGS. 17-19 show the combination of the blade connection holder 5 and the Z-shaped blades 9 , FIGS. 20-22 show the blade inner cover 8 and FIGS. 23-24 show the transparent outer case 6 .
[0056] Finally, please refer to FIG. 25 , the figure is an operation diagram of the food chopper of the present invention, and the whole operation flow is shown in the order of (1) to (3), and each figure is a relationship diagram between the barrel body ribs 52 and the in-cap ribs 44 in this state.
[0057] FIG. 25 ( 1 ) shows the state when the small-sized food chopper starts operation. During the operation, firstly, the top cover button 2 is pushed down, the cover bottom sprockets 22 of the top cover button 2 cling to the cap top sprocket 72 on the crown-like support cap 7 to drive the crown-like support cap 7 , the blade connection holder 5 and the Z-shaped blades 9 to push down so that the Z-shaped blades 9 are pushed downward to cut the foodstuff. In this process, the barrel body ribs 52 slide vertically downward along the pit grooves between the in-cap ribs 44 .
[0058] FIG. 25 ( 2 ) shows the situation after the small-sized food chopper has accomplished the first cutting-down action, the cover bottom sprockets 22 of the top cover button 2 still cling to the cap top sprockets 72 on the crown-like support cap 7 ; meanwhile, the blade connection holder 5 has been completed pushed down to the position where the barrel body ribs 52 are separated completely from the in-cap ribs 44 , here, the barrel body ribs 52 having bevel edges will slightly rotate clockwise, which makes the blade connection holder 5 , the crown-like support cap 7 and the Z-shaped blades 9 slightly rotate clockwise along with it, and this is for preparing the blade connection holder 5 to make the next rotation when it returns to the original state while it is rising to collaborate with the other in-cap ribs 44 of the sleeve 4 , whereas the Z-shaped blades 9 have passed through the two V-shaped slots 81 (see FIG. 22 ) in the stand base in the space within the blade inner cover 8 to get into the container 3 .
[0059] FIG. 25 ( 3 ) shows the small-sized food chopper when there is no additional force to push down the top cover button 2 again, the counterforce of the reset spring 10 lifts the crown-like support cap 7 high, whereas when the blade connection holder 5 rises, and when the barrel body ribs 52 having bevel edges touch the in-cap ribs 44 the next time, the slightly rotating barrel body ribs 52 will enter the adjacent in-cap ribs 44 so that the whole of the blade connection holder 5 , the crown-like support cap 7 and the Z-shaped blade 9 together rotates one case clockwise, whereas when the blade connection holder 5 continues to rise, the cap top sprockets 72 cling to other adjacent cover bottom sprockets 22 so that the top cover button 2 is lifted up at the same time. When the actions shown in FIGS. 25 ( 1 ) to 25 ( 3 ) are accomplished, the small-sized food chopper has processed a cutting action and the Z-shaped blades 9 rotate a case, and different kinds of foodstuffs can be successfully chopped by merely repeating the aforesaid process.
[0060] The theory for making the blade connection holder 5 , the crown-like support cap 7 and the Z-shaped blades 9 slightly rotate circumferentially is described below. In the state when the small-sized food chopper is assembled, the barrel body ribs 52 on the blade connection holder 5 are respectively engaged between two in-cap ribs 44 on the inner wall of the barrel body of the sleeve 4 so as to stop the rotation of the blade connection holder 5 with respect to the sleeve 4 . In addition, in the state when the small-sized food chopper is assembled, the cap top sprockets 72 on the crown-like support cap 7 positioned with respect to the blade connection holder 5 are not right opposite the sprocket grooves between the cover bottom sprockets 22 of the top cover button 2 , while they are properly staggered axially, as shown in FIG. 2 and FIG. 25 ( 1 ). Therefore, in the initial phase of the operation of the small-sized food chopper, before the barrel body ribs 52 on the blade connection holder 5 separate axially from the in-cap ribs 44 on the inner wall of the barrel body of the sleeve 4 , although force is applied circumferentially by the cover bottom sprockets 22 of the top cover button 2 to the cap top sprockets 72 on the crown-like support cap 7 , the blade connection holder 5 cannot rotate with respect to the sleeve 4 so that the crown-like support cap 7 cannot rotate with respect to the top cover button 2 ; whereas when the barrel body ribs 52 on the blade connection holder 5 are axially separated from the in-cap ribs 44 on the inner wall of the barrel body of the sleeve 4 , the restriction stopping the rotation of the blade connection holder 5 is released, and thus the blade connection holder 5 and the crown-like support cap 7 which are fixed to each other can slightly rotate with respect to the sleeve 4 .
[0061] It can be seen from the aforesaid structure that since the present invention provides a brand-new design, all the parts of the food chopper of the present invention are made of plastic except the Z-shaped blades 9 which are made of stainless metal; in addition, the whole inlaying process of the present invention does not involve any metal made connection members. Thus, the present food chopper not only has an exterior pleasing to the eye, and is smaller in volume than any existing chopper, but it further resolves the problem of cleansing the food chopper conveniently, that is, it allows the user to disassemble the whole food chopper and cleanse it thoroughly. Further, this design of the small-sized food chopper has absolutely greatly reduced the occurrence of the food contamination problem due to the rust of some of the parts after long use. Furthermore, the design of the hidden inner reset spring 10 makes the reset spring 10 more difficult to be damaged, and makes the food chopper more durable; the most important point is that the parts in charge of rotation (the barrel body ribs 52 on the blade connection holder 5 and the in-cap ribs 44 of the sleeve 4 , respectively) and the parts in charge of the pushing-down action (the top cover button 2 , the blade connection holder 5 , the crown-like support cap 7 and the Z-shaped blades 9 , respectively) in this design are operated at different positions of the composite parts, and thus when the handle is pushed down and just begins to rise, the handle will never be stuck and thus can successfully accomplish the whole chopping-up process.
[0062] While the preferred embodiments of the invention have been described with combination of the figures, it should be understood by those skilled in the art that the embodiments are not so limited and modifications may be made without departing from the spirit and the scope of the present invention. For instance, the setting of the sleeve 4 may be omitted, and the in-cap ribs 44 can be directly disposed on the inner wall of the plastic main body 1 ; the blades 9 may not be Z-shaped and other types of blades may be adopted; the means which makes the blade connection holder rotate circumferentially a predetermined angle each time the blade connection holder is operated axially can be replaced with other structure familiar to those skilled in the art.
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The present invention discloses a small-sized food chopper for chopping up foodstuffs, characterized in that it comprises: an outer case including a lower casing removably connected with an upper casing and a button mounted on the upper casing; a blade connection holder installed inside said outer case, said blade connection holder can move axially up and down in the outer case; a plurality of blades installed on the lower end of the blade connection holder; a reset spring sheathed on the blade connection holder which restores the blade connection holder axially up; a means which makes the blade connection holder rotate a predetermined angle circumferentially each time the blade connection holder operates axially; said button is configured such that it can slide up and down axially, and said button acts on the upper end of the blade connection holder to make the blade connection holder move axially downwardly.
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The present application is a continuation of PCT application PCT/CN2006/001586, filed on Jul. 6, 2006, entitled “A METHOD AND APPARATUS FOR OBTAINING GROUP INFORMATION BY THE INVITED USER DURING THE SESSION”, which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The present invention relates to a Push-to-Talk over Cellular (PoC) session technology in the technical field of communications, particularly to a method and apparatus for obtaining group information by an invited user during a PoC session.
BACKGROUND OF THE INVENTION
Users of the PoC service may initiate a 1-1 (one-to-one), 1-M (one-to-more) or 1-M-1 (one-to-more-to-one) session through a PoC mobile phone. In the 1-M or 1-M-1 mode, multiple users participate in the session. When initiating a session, an initiator may adopt an Ad hoc (temporary) mode, or a Pre-arranged (predefined) mode. In the Ad hoc mode, the initiator temporarily selects a participant from a contact person list to initiate a group session; and in the Pre-arranged mode, group information is defined before a user initiates a session, and the initiator initiates a group session only with a group identification.
A user may be invited in two scenes as follows: firstly, a participant is designated when a session is established and in this case, either the Ad hoc mode or the Pre-arranged mode may be adopted; secondly, a session participant invites a user to join in the way of adding a participant during the session.
The existing PoC session includes a sender end signal procedure and a receiver end signal procedure. In those two procedures, an invitation information is described with a SIP invite request or a SIP re-invite request. A session request message that is sent to a PoC server by a PoC session initiating end contains session participant information and initiator information. A session request message that is sent to an invited user by the PoC server contains initiator information, but no session participant information.
According to Open Mobile Alliance (OMA) PoC standards, there exit two kinds of servers in the PoC session, i.e. a participating function server and a controlling function server. The controlling function server is in charge of centralized session control and media distribution. The participating function server cooperates with the controlling function server to control a session and store a user's session configuration. The session configuration includes the user's answer modes—automatic answer mode or manual answer mode, coming call screening and personal instant message screening etc. A calling user may override the use's answer mode if necessary. When the use's answer mode is a specified answer mode—automatic answer mode or manual answer mode, the calling user may put relevant description information into an invitation, so as to reverse the use's answer mode. In other words, the use's manual answer mode may become the automatic answer mode; or the automatic answer mode may become the manual answer mode. The premise for the override operation is that the called user has granted the calling user right to override the use's answer mode. A corresponding authentication will be performed by the participating function server.
In the PoC session, the invited user may decide whether to participate in the session according to the session group member information. Because a exiting session request message sent to the invited user doesn't contain the session group member information, the invited user may not know the group information before participating in an Ad hoc session. When the invited user finds that there is a member whom the invited user is unwilling to communicate with after participating in the session, and then quits, unnecessary cost may be caused.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus for obtaining group information by an invited user during a session, so as to solve the problem that a user cannot know the group information before participating in an Ad hoc session in the prior art.
The present invention provides the following solution.
A method for obtaining group information by a second PoC client in a Push-to-Talk over Cellular (PoC) session, comprising:
initiating, by a first PoC client, a PoC session;
receiving, by a PoC server, a session request message carrying information about the user initiating the session and session group member information from the first PoC client;
sending, by the PoC server, the session group member information to a second PoC client;
obtaining, by the second PoC client, the session group member information.
Before the sending the session group member information to the second PoC client, by the PoC server, sending the session request message to the second PoC client, the method further comprises:
configuring parameters in the second PoC client, indicating whether to obtain the session group member information;
determining to obtain the session group member according to the parameters, by the second PoC client, after receiving the session request message from the PoC server;
sending, by the second PoC client, a request message of obtaining the group member information to the PoC server.
The sending the session group member information to the second PoC client, further comprises:
sending, by the PoC server, the session request message to the second PoC client carrying the session group member information.
A Push-to-Talk over Cellular (PoC) client, comprises: a user side management module, and a control side management module connected with the user side management module;
the user side management module adapts to process transmission and reception of a voice stream as well as process a request of a right to speak;
the control management module adapts to manage and control signal;
the control side management module comprises:
a session management sub-module, adapted to determine whether to further query group member information when receiving a session request message;
an information subscription and reception sub-module connected with the session management sub-module, adapted to send a request message of obtaining group member information to a PoC server, when the group member information needs to be queried.
A PoC server comprises: a user side management module, and a control side management module connected with the user side management module, wherein
the user side management module adapts to process transmission and reception of a voice stream as well as process a request of a right to speak;
the control side management module adapts to manage and control signal, wherein the control side management module comprises:
a session management sub-module, adapted to process initiation and release of a session as well as participation and quitting of a member in the session, and send session group member information to a PoC client with a session request message;
an information subscription and notification sub-module connected with the session management sub-module, adapted to support information subscription and information notification, and send the session group member information to the PoC client according to a request message of obtaining group member information of the PoC client.
A PoC system comprises a PoC client and a PoC server, the PoC client and the PoC server having a user side management module and a control side management module respectively, wherein the control side management module of the PoC client comprises:
a session management sub-module, adapted to determine whether to further query group member information when receiving a session request message;
an information subscription and reception sub-module connected with the session management sub-module, adapted to send a request message of a group member information to the PoC server, when the group member information needs to be queried;
the control side management module of the PoC server comprises:
a session management sub-module, adapted to process initiation and release of a session as well as participation and quitting of a member in the session, and send session group member information to a PoC client with a session request message;
an information subscription and notification sub-module connected with the session management sub-module, adapted to support information subscription and information notification, and send the session group member information to the PoC client according to a request message of obtaining group member information of the PoC client.
In the present invention, when sending the session request message to the invited user, the PoC server sends the session group member information at the same time, or after sending the session request message, the PoC server sends the session group member information to the invited user according to his/her request. So that before participating in the session, the user may know in time the member who participates in the session, so as to determine whether to participate in the session or not. Thereby, the user experience may be enhanced, and unnecessary cost for the user may be avoided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing the architecture of a PoC system according to an embodiment of the present invention;
FIG. 2A is a schematic diagram showing the architecture of a PoC client according to an embodiment of the present invention;
FIG. 2B is a schematic diagram showing the architecture of a PoC server according to an embodiment of the present invention;
FIG. 3 is a flow chart showing the process of a PoC client requesting member information of a temporary group from a PoC server according to an embodiment of the present invention;
FIG. 4 is a flow chart showing the process of adding a user when initiating a session according to an embodiment of the present invention;
FIG. 5 is a flow chart showing the process of adding a user during the session according to an embodiment of the present invention;
FIG. 6A is a flow chart showing the process of carrying member information in a session request message when initiating a session according to an embodiment of the present invention;
FIG. 6B is a flow chart showing the process of carrying member information in a session request message when adding a user during a session according to an embodiment of the present invention;
FIG. 7 is a flow chart showing the process of automatic answering a session according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
To enable an invited user to obtain session group member information before participating in the session in the PoC Ad hoc session, the session group member information is sent by a PoC server to a PoC client where the invited user is located, so that the invited user may obtain the member information in the session. Consequently, the invited user may decide whether to perform subsequent operations such as joining in the session by referring to the obtained member information.
As shown in FIG. 1 , the PoC system includes a plurality of PoC clients and a PoC server for controlling the PoC clients to accomplish sessions. The PoC clients, PoC servers and SIP/IP Cores may be connected with each other through a network. There may exist a plurality of PoC servers.
As shown in FIG. 2 , the PoC client includes a user side management module and a control side management module.
The user side management module is adapted to process the transmission and reception of a voice stream as well as a request the right to speak.
The control side management module is adapted to perform the signal-relevant management and control.
The control side management module includes an information subscription and reception sub-module and a session management sub-module.
The session management sub-module is adapted to process initiation and release of a session as well as participation and quitting of a member during the session, and determine whether to further query group member information when receiving a session request message.
The information subscription and reception sub-module is connected with the session management sub-module, and is adapted to support information subscription and information notification, and send a request message of obtaining group member information to the PoC server so as to obtain group member information when the user needs the group member information.
As shown in FIG. 2B , a PoC server includes a user side management module and a control side management module.
The user side management module is adapted to process the transmission and reception of a voice stream, a request and an arbitration of the right to speak.
The control side management module is used for signal-relevant management and control.
The control side management module includes two sub-modules:
a session management sub-module is adapted to process initiation and release of the session as well as participation and quitting of a member during the session, and transmit the session group member information to the PoC client via the session request message;
an information subscription and notification sub-module is connected with the session management sub-module, and is adapted to support information subscription and information notification, respond to a request message of obtaining the group member information from the PoC client and send the group member information to the PoC client.
For the PoC Ad hoc session mode, the session request message may be sent by the PoC server to an invited client where the invited user is located when initiating a session, or may be sent by the PoC server during the session.
The session group member information may be sent to the PoC client where the invited user is located in the following two ways.
(1) The session management sub-module of the PoC server puts the session group member information into the session request message and then sends the session request message to the PoC client where the invited user is located.
(2) After the PoC client where the invited user is located receives the session request message, the information subscription and reception sub-module sends a request message of obtaining session group member information to the PoC server, and the information subscription and notification sub-module in the PoC server sends the session group member information to the PoC client according to the request message of obtaining session group member information.
In the second way, the PoC client where the invited user is located requests the session group member information by sending a SUBSCRIBE message, and the PoC server sends the group member information to the PoC client with a NOTIFY message.
After the PoC client receives the session request message, the user may manually control the information subscription and reception sub-module on the PoC client to send the SUBSCRIBE message to the PoC server, so as to request the group member information. The user may also set configuration parameters on the PoC client in advance for indicating whether the session group member information needs to be requested. After the PoC client receives the session request message, the session management sub-module determines whether to request the session group member information according to the configuration parameters. If yes, the SUBSCRIBE message is sent by the information subscription and reception sub-module automatically; otherwise, no SUBSCRIBE message will be sent. In this way, frequency of manual operations of a user, such as key-pressing operations, during the session may be reduced.
In some cases, if amount of the group information is very large, the PoC server may put an overriding configuration parameter instruction into the session request message. After the PoC client receives the session request message, if the overriding configuration parameter instruction is detected, the user is required to manually confirm whether the group information should be further transmitted, no matter whether the user has set the configuration parameters for requesting the group member information or not. So it may be avoided transmitting the large amount of information when a user set the configure parameter which indicates automatically requesting the group number information. Accordingly, the occupied network resources are reduced.
Besides the necessary information, the PoC server may also put group description information, such as group type, group size, etc. into the session request message. Therefore, the invited user may determine whether to request the group member information or participate in the session and so on by referring to the group description information. If the group type is a predefined group, the user does not need to request the member information. If the group description information indicates that there are a lot of group members, the user may also not request the member information.
The session group member information may be information that can uniquely identify a user, such as IP address, user nickname, phone number or uniform resource identifier.
As shown in FIG. 3 , the interaction process of requesting the temporary group member information from the PoC server by the PoC client is as follows.
Step 1 , the session management sub-module of a PoC server sends a session request message to a PoC client where the invited user is located.
Step 2 , after receiving the session request message, the session management sub-module of the PoC client interacts with the user or reads configuration parameter to determine whether it is needed to further query the group information (in the present example, the user needs to query group member information).
Step 3 , if the user needs to query the group member information, an information subscription and reception sub-module of the PoC client sends a SUBSCRIBE message of querying the group member information.
Step 4 , an information subscription and notification sub-module of the PoC server sends a NOTIFY message carrying the group member information to the PoC client.
Step 5 , after the user interacts with the PoC client, the PoC client returns a result of whether the user accepts the session request message to the PoC server via the session management module.
As shown in FIG. 4 , when the answer mode of the invited user is the manually answer mode, the process of initiating a session is as follows:
Steps 1 - 5 , a PoC server sends an INVITE message that contains group description information to a PoC client B.
Steps 6 - 10 , the PoC client B responds to the PoC server, so as to generate a ring back tone.
Steps 11 - 15 , the PoC client B sends a request message of obtaining group member information to the PoC server.
Steps 16 - 20 , the invited user sends a SUBSCRIBE message to the server to request the group member information.
Steps 21 - 25 , the invited user B confirms whether to participate in the session to the PoC server.
After step 10 , if the user determines not to obtain the group member information, step 21 is performed directly.
As shown in FIG. 5 , when the answer mode of the invited user is the manually answer mode, the process of adding a user during the session is as follows.
Steps 1 - 5 , a PoC server sends an INVITE message containing group member information to a PoC client B.
Steps 6 - 10 , the PoC client B sends a request message of obtaining group member information to the PoC server.
Steps 11 - 15 , the invited user B receives the group member information sent by the PoC server.
Steps 16 - 20 , the invited user B confirms whether to participate in the session to the server.
After step 5 , if the user determines not to obtain the group member information, step 16 is performed directly.
In the way of putting the session group member information into the session request message and sending the session request message to the PoC client where the invited user is located, a participating function server where the invited user is located may directly forward the session request message containing the group member information to the PoC client. In a preferred way, it firstly refers to the user's answer mode and supplementary information of the answer mode in the invitation to determine whether to send the group member information to the invited user. If the answer mode of the invited user is the automatically answer mode, and the calling user does not indicate adopting the automatically answer overriding in the invitation, no group member information is sent to the invited user. If the user's answer mode is the manually answer mode, and the calling user indicates adopting manually answer overriding (MAO) in the invitation, and the calling user possesses the right of overriding the manually answer mode, no group member information is sent to the invited user. If the user's answer mode is the manually answer mode, and the calling user does not indicate adopting the manual answer overriding in the invitation, the group member information is sent to the invited user. If the answer mode of the invited user is the automatically answer mode, and the calling user indicates adopting the automatic answer overriding in the invitation, and the calling user possesses the right of overriding the automatically answer mode, the group member information is sent to the invited user.
As shown in FIG. 6A , when initiating an Ad hoc mode session, the process of sending the group member information to the PoC client with an INVITE message is as follows.
Steps 1 - 3 , a PoC client A sends an INVITE message carrying group member information to a PoC client B by a POC server, the message is transmitted to a participating function server where the PoC client B is located.
Steps 4 - 5 , the function server where the PoC client B is located determines whether to send the group member information to the invited user according to the user's answer mode and supplementary information of the answer mode in the invitation. (In this embodiment, it is assumed that the calling user does not adopt MAO and the answer mode of the called user B is the manually answer mode, so the member information is sent to the PoC client B).
Steps 6 - 10 , the PoC client B responds to the PoC server, so as to generate a ring back tone.
Steps 11 - 15 , the invited user B confirms whether to participate in the session according to the member information to the server.
As shown in FIG. 6B , during the Ad hoc mode session, the process of adding a user and sending the group member information to the PoC client with an INVITE message is as follows.
Steps 1 - 5 , a PoC server sends an INVITE message carrying group member information to a PoC client B.
Steps 6 - 10 , the invited user B confirms to the server whether to participate in the session according to the member information.
As shown in FIG. 7 , when the called user adopts the automatic answer mode, the process of deleting, by the server, the called user's identity information in the request and forwarding the request to the called user is as follows.
Steps 1 - 3 , a PoC server A, namely the controlling function server, sends an INVITE request to a participating function server where the called user is located. After receiving the request, the participating function server where the called user is located determines to answer the session request automatically, if the called user has configured the automatically answer mode and the calling user is in the acceptance list of the called user.
Steps 4 - 6 , the PoC server B answers the session automatically. After receiving the request message, the controlling server notifies the calling user that the called user automatically answers the session. The automatic answer message, namely AUTO-ANSWER, may be a temporary response to the INVITE message.
Steps 7 - 8 , the PoC server B sends a request without the member information to the PoC client B.
Steps 9 - 10 , the PoC client B participates in the session.
Steps 11 - 13 , the PoC server B notifies the PoC server A that the PoC client B has practically participated in the session.
From above, it can be seen that in the present invention, when sending a session request message to an invited user, the PoC server sends the session group member information at the same time. Alternatively, after sending the session request message, the PoC server sends the session group member information to the user who is invited to participate in the session according to the request. Therefore, before participating in the session, the user may know in time the member participating in the session, so as to determine whether to participate in the session. Thereby, the user experience may be enhanced, and an unnecessary cost for the user may be avoided.
Of cause, those skilled in the art will be able to make variations and modifications according to the present invention without departing from the spirit of the present invention. So, if the modifications and variations to the present invention belong to the present claims and are within the scope of equivalent technologies, the present invention is intended to contain these variations and modifications.
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The present invention relates to a method for obtaining group information by an invited user in a Push-to-Talk over Cellular (PoC) session. The method comprises: sending, by a PoC client where a user initiating the session is located, a session request message carrying information about the user initiating the session and the session group member information to a PoC server; and sending, by the PoC server, the session request message carrying the information about the user initiating the session to a PoC client where the invited user is located. The PoC server sends session group member information to the PoC client where the invited user is located, so that the invited user is able to know the session group member, or refer to the session group member information to determine subsequent operations. The present invention has also disclosed a PoC system.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2009-0078701, filed on Aug. 25, 2009, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
The following disclosure relates to a method for preparing zinc oxide (ZnO) nanoparticles by adding an alkali salt to a Zn salt solution, and a method for preparing ZnO nanofluids using the same.
More particularly, the following disclosure relates to a method capable of producing ZnO nanoparticles having spherical shape and narrow particle size distribution of 10 to 50 nm in short time via a low-temperature, normal-pressure process without using any additives for particle size control such as a dispersant.
BACKGROUND
Zinc oxide (ZnO) nanoparticles have been traditionally used to block sunlight in a wide spectrum range. Due to superior semiconducting property with a very large band gap energy, as well as biocompatibility, piezoelectricity, fluorescence and optical conductivity, applications in various fields, including solar devices, biochips, gas sensors, catalysts and electronic devices, are expected.
ZnO nanoparticles are prepared by a gas phase synthesis process wherein gaseous Zn is reacted with oxygen, by a coprecipitation process wherein a Zn precursor is dissolved in water, precipitated as zinc carbonate, and then heat-treated to obtain ZnO nanoparticles, or by a solution process wherein a Zn precursor is dissolved and then an alkali salt solution is added to obtain ZnO precipitate.
The gas phase synthesis process is disadvantageous in that control of ZnO particle size is difficult, preparation of ZnO particles having size of tens of nanometers is difficult, and process and facility to conduct the relevant gas phase reaction at high temperature are complicated. Thus, it is not suited for large-scale production.
The coprecipitation process is disadvantageous in that, since ZnO is prepared by heat treatment, ZnO aggregates produced by sintering during the heat treatment should be pulverized by a post-treatment process. Also, it is difficult to prepare ZnO nanoparticle with uniform shape and narrow particle size distribution of tens of nanometers.
The solution process requires addition of a dispersant to control the size of ZnO nanoparticles. Even when the dispersant or other additive is used, ZnO particles of an order of hundreds of nanometers are prepared, and needle-shaped particles are obtained rather than spherical ones. Further, an expensive organozinc compound is used as a Zn precursor. Although the synthesis proceeds at relatively low temperature (300° C. or lower) as compared to the gas phase synthesis or coprecipitation process, a long time is required until the reaction is completed.
Zinc oxide (ZnO) nanofluid wherein ZnO nanoparticles are dispersed in a fluid has very high thermal conductivity as compared to a fluid without containing the nanoparticles. Hence, researches are increasing for utilizing the property with industrial purposes. The nanofluid having improved thermal conductivity may be used to improve thermal efficiency of heat exchangers, automobile engines, or the like, and therefore is widely applicable in the fields of electricity, electronics, machinery and others.
The technical problems in the preparation of nanofluid are how to keep the fluid stably dispersed for a long period of time and how to produce the nanofluid with good dispersion stability in large scale via a simple process.
At present, commercially available nanoparticles are mixed with a medium such as water or alcohol, dispersed for 30 to 40 hours using ultrasonic wave, and then mixed for 30 to 40 hours after adding a solution of benzonite, phosphate, nitrate, etc. in ethylene glycol to prepare nanofluid (Korean Patent Publication No. 2007-0096505), or commercially available nanoparticles are dispersed in liquid solvent, physically pulverized using a bead mill or high-pressure homogenizer, surface-modified, passed through an ultrafiltration membrane, and then dispersed in oil after removing water to prepare nanofluid (Korean Patent Publication No. 2008-0038625).
However, these processes are disadvantageous since each step of the processes requires a long time of 30 to 40 hours or the process of pulverization, high-pressure homogenization or filtration is complicated and requires expensive equipments, which makes them inapplicable to large-scale production. Further, a new preparation process has to be designed for a different dispersion medium.
SUMMARY
An embodiment of the present invention is directed to providing a method for preparing zinc oxide (ZnO) nanoparticles of an order of tens of nanometers without using a dispersant, to providing a method for preparing ZnO nanoparticles having spherical shape, to providing a method for preparing ZnO nanoparticles having narrow particle size distribution, and to providing a method for preparing ZnO nanoparticles in short time via a low-temperature, normal-pressure process using inexpensive materials.
Another embodiment of the present invention is directed to providing a method for preparing nanofluid having high thermal conductivity, specifically ZnO nanofluid wherein ZnO nanoparticles are dispersed, to providing a method for preparing ZnO nanofluid via a single process, to providing a method for preparing ZnO nanofluid stably dispersed in various media, and to providing a method for preparing ZnO nanofluid enabling large-scale production with a simple low-temperature, normal-pressure process.
The major factors enabling the preparation of spherical ZnO nanoparticles, the preparation of highly pure ZnO nanoparticles without generation of other phases, and the preparation of uniform ZnO nanoparticles of an order of tens of nanometers without using a dispersant are pH during preparation of ZnO, conditions of addition of alkali salt, and states of solvent for preparation of Zn precursor.
In one general aspect, a method for preparing ZnO nanoparticles includes: a) heating deionized water; b) dissolving Zn salt in the deionized water to prepare a precursor solution; c) adding solid alkali salt to the precursor solution to prepare a dispersion of ZnO nanoparticles; and d) separating the ZnO nanoparticles by solid-liquid separation and washing them with deionized water.
The steps a) to c) may be performed in the state where the solvent deionized water is heated. Specifically, each of the steps a), b) and c) may be performed at 95 to 100° C.
The pH of the dispersion of ZnO nanoparticles prepared in the step c) may be 7 to 8. Specifically, in the step c), the addition amount of the solid alkali salt is determined to adjust the pH of the dispersion of ZnO nanoparticles to 7 to 8. As a result of the addition of the solid alkali salt to the precursor solution, ZnO nanoparticles are produced at pH 7 to 8.
The solid alkali salt added in the step c) may be a solid alkali salt pellet which is in the form of a compressed aggregate or a melt-solidified powder.
Specifically, the alkali salt added in the step c) may be a single alkali salt pellet.
Specifically, the alkali salt may be a pellet satisfying Inequality (1), and the step c) may be performed by adding a plurality of the pellets at once so that the pH of the dispersion of ZnO nanoparticles is 7 to 8:
0.002× V sol ≦V pell ≦0.004× V sol (1)
wherein V sol is the volume of the deionized water in the step a), and V pell is the volume of the pellet.
The precursor solution in the step b) may have a Zn ion concentration of 200 to 300 mM. The step c) may be accompanied by agitation, which may be performed at 50 to 300 rpm.
The Zn salt may be zinc halide, specifically zinc chloride, and the alkali salt may be sodium hydroxide.
The separation and washing in the step d) may be performed once or more times, preferably 2 to 4 times, with agitation of the ZnO nanoparticles in deionized water and solid-liquid separation using a centrifuge as a unit process.
The ZnO nanoparticles prepared by the preparation method are spherical wurtzite (hexagonal crystal system, P6 3 mc space group) crystalline zinc oxide (ZnO) nanoparticles and have an average particle size of 10 to 50 nm.
In another general aspect, a ZnO nanofluid (I) wherein the ZnO nanoparticles are dispersed in a water-based medium such as water, ethylene glycol or antifreeze or a ZnO nanofluid (II) wherein the ZnO nanoparticles are dispersed in an oil-based medium such as kerosene, mineral oil or transformer oil is prepared.
The ZnO nanofluid (I) is prepared by adding deionized water or ethylene glycol to the ZnO nanoparticles preparedby the aforementioned method so that the content of the ZnO nanoparticles is 0.1 to 10 vol % and then by dispersing the mixture using ultrasonic wave.
The ZnO nanofluid (II) is prepared by a process including: e) adding deionized water to the ZnO nanoparticles prepared by the method according to any one of claims 1 to 8 and adjusting pH to 9 to 11; f) adding a lipophilic dispersant to the pH-adjusted deionized water to prepare a lipophilic dispersion of ZnO nanoparticles wherein the ZnO nanoparticles are coated with the lipophilic dispersant; g) adjusting the pH of the lipophilic dispersion of ZnO nanoparticles to 3 to 7 so that the lipophilic ZnO nanoparticles are separated from a liquid phase, and recovering the separated lipophilic ZnO nanoparticles; and h) washing the recovered lipophilic ZnO nanoparticles using a polar solvent by means of solid-liquid separation, adding oil to the washed lipophilic ZnO nanoparticle, and then performing ultrasonic dispersion.
The lipophilic dispersant in the step f) maybe a C 12 -C 18 organic fatty acid, and the C 12 -C 18 organic fatty acid may be oleic acid, lauric acid, an organic fatty acid having a C 12 -C 18 alkyl chain, or a mixture thereof.
In the step f), after the addition of the lipophilic dispersant, themixturemaybeheatedto 90 to 100° C. so that the lipophilic dispersant is coated on the ZnO nanoparticles.
In the step h), the oil may be added in such an amount that the content of the washed lipophilic ZnO nanoparticles is 0.1 to 10 vol %.
The oil may be kerosene, mineral oil, transformer oil or a mixture thereof, and the polar solvent used in the step h) may be deionized water, ethanol, acetone or a mixture thereof.
The washing in the step h) may be performed once or more times, preferably 2 to 4 times, with agitation of the lipophilic ZnO nanoparticles in a polar solvent and solid-liquid separation of the lipophilic ZnO nanoparticles as a unit process. If the washing is performed two or more times, different polar solvents may be used.
The method for preparing ZnO nanoparticles according to the present invention is advantageous in that ZnO nanoparticles having spherical shape and very narrow particle size distribution of 10 to 50 nm can be prepared in high purity and in short time via a stable low-temperature process, at very low cost using inexpensive materials. Further, the associated low-temperature, normal-pressure process produces few harmful materials andmaybe easily employed for production of ZnO nanoparticles.
The method for preparing ZnO nanofluid according to the present invention is advantageous in that a nanofluid with improved thermal conductivity wherein ZnO nanoparticles are stably dispersed in various dispersion media can be prepared via a very simple single process. Further, effective large-scale production is possible because no complicated facilities are required and production cost is very low.
Further, the method for preparing ZnO nanofluid according to the present invention is advantageous in that it provides a nanofluid with improved thermal conductivity as compared to a general cooling fluid, which provides excellent cooling effect when used to cool heat-producing equipments and thereby improves energy efficiency.
Other features and aspects will be apparent from the following detailed description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a process of a method for preparing zinc oxide (ZnO) nanoparticles according to an exemplary embodiment of the present invention.
FIG. 2 illustrates a process of a method for preparing ZnO nanofluid (I) according to an exemplary embodiment of the present invention.
FIG. 3 illustrates a process of a method for preparing ZnO nanofluid (II) according to an exemplary embodiment of the present invention.
FIG. 4 illustrates a lipophilic dispersant coating process in a method for preparing ZnO nanofluid (II) according to an exemplary embodiment of the present invention.
FIG. 5 shows an X-ray diffractogram of ZnO nanoparticles prepared according to an exemplary embodiment of the present invention.
FIG. 6 shows a transmission electron micrograph (TEM) of ZnO nanoparticles prepared according to an exemplary embodiment of the present invention.
FIG. 7 shows a thermal conductivity measurement result of an ethylene glycol-based ZnO nanofluid (nanofluid (I)) and a kerosene-based ZnO nanofluid (nanofluid (II)) prepared according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS
The advantages features and aspects of the present invention will become apparent from the following description of the embodiments with reference to the accompanying drawings, which is set forth hereinafter. The present invention may, however, be embodied in different forms and shouldnot be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present invention to those skilled in the art. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising”, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
Hereinafter, exemplary embodiments will be described in detail with reference to the accompanying drawings.
FIG. 1 illustrates a process of a method for preparing zinc oxide (ZnO) nanoparticles according to an exemplary embodiment of the present invention. As seen in FIG. 1 , a preparation method according to an exemplary embodiment of the present invention comprises: heating deionized water (S 110 ); dissolving Zn salt in the heated deionized water to prepare a precursor solution (S 120 ); adding solid alkali salt to the precursor solution to prepare a dispersion of ZnO nanoparticles (S 130 ); and separating the ZnO nanoparticles by solid-liquid separation and washing them with deionized water (S 140 ).
In the present invention, the precursor solution is prepared using heated deionized water in order to prevent generation of other phases in preparation for pure ZnO nanoparticles. Specifically, in operation S 110 , the deionizedwater is heated to 95 to 100° C., preferably 100° C. (boiling temperature).
After the deionized water is heated to 95 to 100° C., Zn salt, which is a Zn precursor, is added to the heated deionized water to prepare the precursor solution. Specifically, the precursor solution may be prepared by adding the Zn salt to the deionized water heated at 95 to 100° C. and dissolving the Zn salt by agitation in order to obtain the precursor solution at 95 to 100° C. Preferably, the precursor solution has a Zn ion concentration of 200 to 300 mM. The concentration is adequate to prevent generation of other phases in preparation for ZnO nanoparticles with uniform size and shape. The Zn salt may be zinc halide, preferably zinc chloride.
Subsequently, in order to prevent generation of other phases in preparation for ZnO nanoparticles with narrow particle size distribution of an order of tens of nanometers, the alkali salt in solid state, not in solution state, is added to the precursor solution. While the solid alkali salt is added and the dispersion of ZnO nanoparticles is prepared in operation S 130 , the temperature is maintained at 95 to 100° C.
It is preferred that the solid alkali salt is added immediately after the Zn salt is completely dissolved and the precursor solution is prepared. Preferably, the solid alkali salt is added under an agitation at 50 to 300 rpm.
The solid alkali salt may be an alkali salt pellet. Considering scale-up for large-scale production, one or more alkali salt pellet(s) satisfying Inequality (1) may be added at once to the precursor solution at 95 to 100° C.:
0.002× V sol ≦V pell ≦0.004× V sol (1)
wherein V sol is the volume of the deionized water in operation S 110 , and V pell is the volume of the pellet.
In order to prepare spherical ZnO nanoparticles, not needle-shaped ones, the alkali salt may be added to the dispersion of ZnO nanoparticles such that the pH of the dispersion of ZnO nanoparticles is 7 to 8. Specifically, as the solid alkali salt is added to the precursor solution, ZnO nanoparticles are produced at pH 7 to 8. Preferably, the alkali salt is sodium hydroxide.
Then, the ZnO nanoparticles are recovered from the dispersion of ZnO nanoparticles obtained in operation S 130 bymeans of solid-liquid separation. Preferably, the solid-liquid separation to recover the ZnO nanoparticles is performed using a centrifuge.
The recovered ZnO nanoparticles may be separated and washed once or more times, preferably 2 to 4 times, with agitation of the ZnO nanoparticles in deionized water and solid-liquid separation using a centrifuge as a unit process. As a result of the separation and washing in operation S 140 , the ZnO nanoparticles according to the present invention are prepared.
Hereinafter, a method for preparing ZnO nanofluid (I) using the method for preparing ZnO nanoparticles according to the present invention will be described.
In the method for preparing ZnO nanofluid (I) according to the present invention, deionized water or ethylene glycol is added to the ZnO nanoparticles prepared above so that the content of the ZnO nanoparticles is 0.1 to 10 vol %, and then ultrasonic dispersion is performed.
Specifically, as seen in FIG. 2 , the method for preparing ZnO nanofluid (I) according to the present invention comprises: heating deionized water (S 110 ); dissolving Zn salt in the heated deionized water to prepare a precursor solution (S 120 ); adding solid alkali salt to the precursor solution to prepare a dispersion of ZnO nanoparticles (S 130 ); separating the ZnO nanoparticles by solid-liquid separation and washing them with deionized water (S 140 ); and adding deionized water or ethylene glycol to the washed ZnO nanoparticles so that the content of the ZnO nanoparticles is 0.1 to 10 vol % and performing ultrasonic dispersion (S 200 ). Preferably, the ultrasonic dispersion to disperse the ZnO nanoparticles in deionized water or ethylene glycol may be performed by applying ultrasonic wave for 5 to 30 minutes.
Since operations S 110 to S 140 are similar in those described in the method for preparing ZnO nanoparticles, description thereof will be omitted.
In order to improve thermal conductivity over deionized water or ethylene glycol, to avoid excessively high viscosity and to maintain high dispersibility, the content of the ZnO nanoparticles in the ZnO nanofluid is maintained at 0.1 to 10 vol %. Preferably, the ZnO nanoparticles prepared in operations S 110 to S 140 and dispersed in deionized water or ethylene glycol have an average particle size of 10 to 50 nm.
Hereinafter, a method for preparing ZnO nanofluid (II) using the method for preparing ZnO nanoparticles according to the present invention will be described.
In the method for preparing ZnO nanofluid (II) according to the present invention, deionized water is added to the ZnO nanoparticles prepared above, pH is adjusted to 9 to 11, and a lipophilic dispersant is added to the pH-adjusted deionized water to prepare a lipophilic dispersion of ZnO nanoparticles wherein the lipophilic dispersant is coated on the ZnO nanoparticles. Then, the pH of the lipophilic dispersion of ZnO nanoparticles is adjusted to 3 to 7 so that a liquid phase is separated from the lipophilic ZnO nanoparticles, the phase-separated lipophilic ZnO nanoparticles are recovered, the recovered lipophilic ZnO nanoparticles are washed with a polar solvent by means of solid-liquid separation, oil is added to the lipophilic ZnO nanoparticles, and then ultrasonic dispersion is performed to prepare ZnO nanofluid.
Specifically, as seen in FIG. 3 , the method for preparing ZnO nanofluid (II) according to the present invention comprises: heating deionized water (S 110 ); dissolving Zn salt in the heated deionized water to prepare a precursor solution (S 120 ); adding solid alkali salt to the precursor solution to prepare a dispersion of ZnO nanoparticles (S 130 ); separatingtheZnOnanoparticlesbysolid-liquid separation and washing them with deionized water by means of solid-liquid separation (S 140 ); adding deionized water to the washed ZnO nanoparticles, adjusting pH to 9 to 11, and adding a lipophilic dispersant to the pH-adjusted deionized water to prepare a lipophilic dispersion of ZnO nanoparticles wherein the lipophilic dispersant is coated on the ZnO nanoparticles (S 310 ); adjusting the pH of the lipophilic dispersion of ZnO nanoparticles to 3 to 7 so that a liquid phase is separated from the lipophilic ZnO nanoparticles, and recovering the phase-separated lipophilic ZnO nanoparticles (S 320 ); washing the recovered lipophilic ZnO nanoparticles with a polar solvent by means of solid-liquid separation (S 330 ); and adding oil to the washed lipophilic ZnO nanoparticles and performing ultrasonic dispersion (S 340 ).
Since operations S 110 to S 140 are similar in those described in the method for preparing ZnO nanoparticles, description thereof will be omitted.
In operation S 310 , the ZnO nanoparticles are coated with the lipophilic dispersant since the ZnO nanoparticles are to be dispersed in oil. Specifically, as seen in FIG. 4 , the operation S 310 is performed by: adding deionized water to the washed ZnO nanoparticle and adjusting the pH of the deionized water to 9 to 11 (S 311 ) ; adding a lipophilic dispersant to the pH-adjusted deionized water (S 312 ); and heating the pH-adjusted dispersion containing the ZnO nanoparticles and the lipophilic dispersant to 90 to 100° C., preferably under agitation, to prepare a lipophilic dispersion of ZnO nanoparticles wherein the lipophilic dispersant is coated on the ZnO nanoparticles (S 313 ). Preferably, the agitation in operation S 313 may be performed for 5 minutes to 2 hours.
Preferably, in operation S 311 , the pH of the deionized water is adjusted to 9 to 11 by adding ammonia water, sodium hydroxide or a mixture thereof to the deionized water.
Preferably, in operation S 312 , the lipophilic dispersant is a C 12 -C 18 organic fatty acid. The C 12 -C 18 organic fatty acid is preferably oleic acid, lauric acid, an organic fatty acid having a C 12 -C 18 alkyl chain, or a mixture thereof, more preferably oleic acid, lauric acid, or a mixture thereof. Preferably, the lipophilic dispersant is used in excess so that the dispersant not coated on the ZnO nanoparticle remains after the ZnO nanoparticles are coated.
Subsequently, acidic solution including hydrochloric acid is added to the lipophilic dispersion of ZnO nanoparticles prepared in operation S 310 to adjust the pH of the lipophilic dispersion of ZnO nanoparticles to 3 to 7. By the readjustment of pH, the lipophilic ZnO nanoparticles in the lipophilic dispersion of ZnO nanoparticles are separated from a liquid phase, and the phase-separated lipophilic ZnO nanoparticles are recovered.
The recovered lipophilic ZnO nanoparticles are mixed with a polar solvent such as deionized water, acetone, ethanol or a mixture thereof, agitated, and then washed preferably by means of solid-liquid separation using a centrifuge (S 330 ).
Preferably, the washing in operation S 330 is performed once or more times, preferably 2 to 4 times, with agitation of the lipophilic ZnO nanoparticles in a polar solvent such as deionized water, acetone, ethanol or a mixture thereof and solid-liquid separation of the lipophilic ZnO nanoparticles using a centrifuge as a unit process.
If the washing is performed two or more times, different polar solvents selected from deionized water, acetone, ethanol and a mixture thereof may be used.
Then, oil is added to the washed lipophilic ZnO nanoparticles and ultrasonic wave is applied for 5 to 30 minutes to prepare ZnO nanofluid (S 340 ). The oil maybe kerosene, mineral oil, transformer oil or a mixture thereof.
In order to improve thermal conductivity over oil, to avoid excessively high viscosity, and to maintain high dispersibility, the content of the ZnO nanoparticles in the ZnO nanofluid (ZnO nanofluid dispersed in oil) is maintained at 0.1 to 10 vol %. Preferably, the ZnO nanoparticles prepared in operations S 110 to S 140 and dispersed in oil have an average particle size of 10 to 50 nm.
EXAMPLES
The examples and experiments will nowbe described. The following examples and experiments are for illustrative purposes only and not intended to limit the scope of this disclosure.
Preparation of ZnO Nanoparticles
Deionized water (200 mL) was added to a 500 mL flask and heated to 100° C. Then, after adding ZnCl 2 (3.407 g, 250 mmol), the mixture was agitated using a magnetic bar to prepare a precursor solution. Immediately after ZnCl 2 was completely dissolved, seven 0.5 cm 3 sodium hydroxide pellets were added at once and a dispersion of ZnO nanoparticles was prepared by agitating at 100 rpm using a magnetic bar (pH of the dispersion of ZnO nanoparticles=7). As a result of the addition of the sodium hydroxide pellets, ZnO nanoparticles were produced as white precipitate. The reaction was terminated in 10 minutes. During the preparation of the precursor solution and the addition of the sodium hydroxide pellets, the temperature was maintained at 100° C.
After the reaction was terminated, the dispersion of ZnO nanoparticles was cooled to room temperature and ZnO nanoparticles were recovered by centrifuge at 10,000 rpm. The recovered ZnO nanoparticles were mixed with deionized water, agitated, and centrifuged at 10,000 rpm. This washing process was repeated 3 times.
The washed ZnO nanoparticles were washed with acetone and dried for X-ray diffraction and transmission electron microscopic (TEM) observation. FIG. 5 shows an X-ray diffractogram of the prepared ZnO nanoparticles.
As seen in FIG. 5 , pure crystalline ZnO nanoparticles were prepared, without generation of other phases. The sharp diffraction peaks show that highly crystalline ZnO nanoparticles were prepared.
Further, FIG. 5 reveals that ZnO nanoparticles having a single wurtzite (hexagonal crystal system, P6 3 mc space group) crystal structure were prepared.
FIG. 6 shows a transmission electron micrograph (TEM) of the prepared ZnO nanoparticles. As seen in FIG. 6 , spherical, not needle-shaped, ZnO nanoparticles having uniform size of 25 to 30 nm were prepared.
Preparation of Ethylene Glycol-based ZnO Nanofluid
Ethylene glycol (Aldrich, 99.9%) was added to the washed ZnO nanoparticles in the same manner as the preparation of the ZnO nanoparticles. Ethylene glycol was added such that the volume fractions of the ZnO nanoparticles were 0.01, 0.02, 0.03 and 0.04 (1%, 2%, 3% and 4%). After the addition of ethylene glycol, ultrasonic wave of 20 kHz and 200 W was applied for 10 minutes with 10 second periods using an ultrasonic generator (Branson Digital Sonifier Model 450). A ZnO nanofluid wherein ZnO nanoparticles are stably dispersed in ethylene glycol was prepared.
Preparation of Kerosene-based ZnO Nanofluid
Deionized water was added to the washed ZnO nanoparticles in the same manner as the preparation of the ZnO nanoparticles, and sodium hydroxide was added to adjust pH to 11. Then, after adding 15 parts by weight of oleic acid based on 100 parts by weight of the ZnO nanoparticles, the mixture was heated to 95° C. and agitated for 5 minutes to prepare a lipophilic dispersion of oleic acid-coated ZnO nanoparticles.
After cooling to room temperature, 1 mM hydrochloric acid solution was added to the cooled lipophilic dispersion of ZnO nanoparticles to adjust pH to 5. When the ZnO nanoparticles were separated from a liquid phase, the liquid was removed and the lipophilic ZnO nanoparticles were recovered.
After adding deionized water to the recovered lipophilic ZnO nanoparticles, the mixture was agitated and centrifuged at 10,000 rpm. This washing process was performed at least 2 times. Final washing was performed using acetone instead of deionized water.
Kerosene was added to the lipophilic ZnO nanoparticles washed with acetone such that the volume fractions of the ZnO nanoparticles were 0.01, 0.02, 0.03 and 0.04 (1%, 2%, 3% and 4%). After the addition of kerosene, ultrasonic wave of 20 kHz and 200 W was applied for 10 minutes with 10 second periods using an ultrasonic generator (Branson Digital SonifierModel 450). AZnOnanofluidwhereinZnOnanoparticles are stably dispersed in kerosene was prepared.
Thermal conductivity of thus prepared ethylene glycol-based ZnO nanofluid (hereinafter, nanofluid (I)) and kerosene-based ZnO nanofluid (hereinafter, nanofluid (II)) was measured according to ASTM D2717 using LAMBDA system (F5 Technologie GmbH, Germany, Model LAMBDA).
FIG. 7 shows the thermal conductivity measurement results of nanofluid (I) and nanofluid (II). The graph shows the ratio of the thermal conductivity k of each nanofluid to the thermal conductivity k f of the dispersion medium (ethylene glycol or kerosene) in which the ZnO nanoparticles are dispersed, i.e. k/k f , and the ratio of the increase of thermal conductivity of each nanofluid (k−k f ) to the thermal conductivity k f of the dispersion medium (ethylene glycol or kerosene) in which the ZnO nanoparticles are dispersed, i.e. (k−k f )/k f , for different volume fractions of the nanoparticles.
As seen in FIG. 7 , the thermal conductivity of nanofluid (I) exhibits increases linearly with the volume fraction. At the volume fraction of 0.028 (2.8 vol %), the thermal conductivity is about 9.2% higher than that of the medium. Further, it can be seen that improvement of the thermal conductivity is more significant at the same ZnO volume fraction when the dispersion medium is kerosene than when ethylene glycol is the medium. The thermal conductivity of nanofluid (II) is about 12% higher than that of the medium at the volume fraction of 0.03 (3 vol %). At the volume fraction of 0.04 (4 vol %), the thermal conductivity is about 29% higher than that of the medium.
While the present invention has been described with respect to the specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims.
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Provided are a method for preparing zinc oxide (ZnO) nanoparticles and a method for preparing ZnO nanofluid using the same. The method for preparing ZnO nanoparticles includes: a) heating deionized water; b) dissolving zinc (Zn) salt in the deionized water to prepare a precursor solution; c) adding solid alkali salt to the precursor solution to prepare a dispersion of ZnO nanoparticles; and d) separating the ZnO nanoparticles by solid-liquid separation and washing them with deionized water. Highly pure, crystalline ZnO nanoparticles with spherical shape and very narrow particle size distribution of 10 to 50 nm can be prepared quickly and at large scale and low cost using inexpensive materials via a stable low-temperature process, without using a dispersant. The associated low-temperature, normal-pressure process produces few harmful materials and may be easily employed for production of ZnO nanoparticles.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method and apparatus for drilling a tunnel, wherein there are two independent forces; the one driving the protecting tube and the other driving the drilling apparatus by means of a rotating spiral tube.
2. Description of the Prior Art
A previously known drilling apparatus as described in applicant's former patent application No. FI-891706, is one in which the protecting tube is forced into the excavated drilling head advances through the tunnel portion as the tunnel. Also the force for the tool in the drilling head is transmitted over the protecting tube. The conveying tube rests against the inner surface of the protecting tube and moves forward along with the protecting tube. There is a thrust bearing in the drill head, and so the force over the protecting tube is transmitted entirely through the thrust bearing as a force for the tool forward drive.
U.S. Pat. No. 2,669,441 the tools and the thrust bearing are in the working pit. No protecting tube is driven into the tunnel but the force into the drill head is simply brought forward by a rotating conveyor pipe.
The disadvantage of the prior art devices is lack of control of the force. On driving the drill head forward with the protecting tube, the required force changes as the length of the protecting tube grows and because of friction from different soil types. This means that the farther the drilling advances the more the information about the impact of tool forces against he front wall of the tunnel diminishes and possible obstacles cannot then be detected. Therefore, the risk of tool damage is great. In U.S. Pat. No. 2,669,441 drilling is possible only in rock or soil that needs no protecting tube to support the tunnel.
SUMMARY OF THE INVENTION
By means of the method according to this invention a crucial improvement of the said disadvantages has been achieved. In order to put this into practice, the method and apparatus of this invention are characterized in what has been presented in the patent claims.
It can be considered the main advantage of this invention that the tool driving force, which is smaller than the force driving the protecting tube, is separated as an independent and easily adjustable force. When the force has been separated by means of a hydraulic cylinder, which can yield because of pressure adjustment while functioning also as thrust bearing and therefore move freely in the longitudinal direction of the drilling apparatus, the tool hitting an obstacle can be detected immediately as rise of pressure in the hydraulic system.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following the invention is more closely described with reference to the enclosed drawings where
FIG. 1 is a driving and rotating unit in the working pit where the hydraulic cylinder functions as thrust bearing.
FIG. 2 is an optical driving and rotating unit placed in the working pit where the hydraulic cylinder functions as thrust bearing.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The solution in FIG. 1 provides a hydraulic cylinder (23) which functions as a thrust bearing comprised of a piston (24) and a piston rod (26). The piston rod (26) is a pipe through which the hydraulic pressure hoses (30,29) can be taken to the piston (24) and conduct the pressure fluid to the chamber space on both sides of the piston. The cylinder (23) is closed with a threaded ring flange (35). The cylinder (23) itself is a rotating drumlike part. The rotation is transmitted from the fluid motor (16) by means of a gear (25) which is attached to the cylinder (23) with a broad gear (31). The pressure fluid enters the fluid motor (16) along the hoses (20). The cylinder (23) is encircled with an immobile annular part (22), inside of which the cylinder (23) can rotate and also slide lengthwise. Part (22) is fixed to the actual frame (27) that conduits the driving force. The connecting surface between cylinder (23) and part (22) is a bearing area which also comprises an annular chamber space (32) into which compressed air is conducted through the air channels in the cylinder (23) over a hose (7) and further to rotating conveying tube (3). Tube (3) is fixed to the flange (21) by screwing. This flange (21) transmits the rotation from cylinder (23) to the conveying tube (3). The bellow rubber (34) fixed to part (22) prevents the cylinder sliding surface from getting dirty. The oil in the compressed air lubricates the sliding surface and leakage of compressed air is prevented with a retaining ring (33). The driving force to the tool from the conveying tube (3), which has a system of spiral ribs (2), is in this case transmitted over a hydraulic cylinder (23), which functions as thrust bearing, and can therefore be detected as hydraulic pressure in the hoses (29,30). Drilling waste (11) is removed through the openings in the frame (27) and between the frame beams (17) under the drilling unit.
The force driving the protecting tube (1) into the tunnel is transmitted from the power unit (19,28) direct over the rear frame (27) and its end flanges (18,4) to the protecting tube (1).
In FIG. 2 the cylinder (50) is fixed to the frame (15) with a flange (47) and screws (43). Therefore the cylinder (50) does not rotate but the piston (48) and the piston rod (40) are rotating. The fluid motor (46) comprises a grooved shaft (45) which can move longitudinally in chamber (41) formed outside the piston rod (40). Correspondingly, the chamber is also grooved to allow rotation. At piston rod rear end there is a threaded part (36) by means of which the conveying tube (3) is fixed to the piston rod (40). Around the piston rod (40) there is a not-rotating part (37) that comprises an annular chamber groove around the piston rod (40). Compressed air conducted to this chamber enters the piston rod (40) through a pick-up hole at the chamber and then the conveying tube (3) from where it reaches the tool in the drill head. Lateral movement of part (37) on the piston rod (40) is prevented by a ring spring (38) in the piston rod groove. The cylinder (50) is closed with a flange (51) attached to the cylinder (50) by screwing and joined to the piston rod (40) with a packing (42) allowing its rotation and sliding. The lines (39,44) are hydraulic hoses and the other cylinder end is sealed with a retaining ring (49).
The rotating motion of the fluid motor (46) can also easily be transmitted as a rotating motion for the piston rod (40) by connecting the motor shaft (45) e.g. by means of a flange joint to a corresponding flange in the piston rod. The fluid motor (46) must then be secured with respect to the frame (15) so that it can slide but not rotate. This can be done with conductors arranging them parallel to the frame and using them also as support for the motor (46).
This invention is not restricted to the embodiments of the prior art but it can be modified within the limits of the enclosed patent claims. The frame construction of the driving unit can be drumlike but, advantageously, also a beam construction.
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An apparatus and a method for drilling a tunnel utilize hydraulic means comprising a cylinder and a piston to enable independent adjustment of the driving force acting on the protecting tubes and the driving force acting on the drilling tool/conveying tubes. The hydraulic means acts as a thrust bearing and moves freely in the longitudinal direction of the drilling apparatus in response to forces acting on the drilling tool which are detected as changes in pressure in the hydraulic means.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a flexible multi-parameter cable having a plurality of different types of conductors for conducting signals relating to a plurality of different types of sensed parameters, and more particularly to a multi-conductor patient monitoring cable for conducting signals such as electrocardiogram, respiration, temperature and pulse oximetry signals, relating to a plurality of different types of sensed physiological conditions of a patient.
2. Description of the Prior Art
In hospitals and other health care environments, it is often necessary to continually collect and analyze a variety of different types of medical data from a patient. These data may include electrocardiogram (EKG) signals, body temperature, blood pressure, respiration, blood oxygen saturation, and other monitored physiological parameters.
Medical monitoring systems have typically fallen into one of two general categories: multi-parameter monitoring systems which collect, process and display all of the desired data; and small portable systems which monitor one or two of the various patient physiological parameters. Multi-parameter monitoring is typically provided at a higher care facility, such as an intensive care unit or hospital operating room, and generally results in a plurality of cables which extend between the patient and the monitor. For example, there may be anywhere from three to five cables for EKG, two for cardiac output, three for temperature, six for non-invasive pulse oximetry, etc. This array of cables interferes with the movement of personnel around the patient and furthermore presents an undesirable obstacle when the patient must be quickly transferred from one position to another, such as from his room bed to an operating room or an intensive care unit.
FIG. 1a illustrates a typical prior art arrangement wherein a patient 2 has a plurality of sensor leads, such as EKG leads 4, non-invasive pulse oximetry leads 6, temperature leads 8 and an air hose 10 for non-invasive blood pressure measurement, connected between the corresponding sensor apparatus on patient 2 and a respective one of monitor cables 12, 14, 16 and 18. Each of monitor cables 12-18 typically include a connector at one end which is received by a patient monitor 20 and a connector at its other end which receives the patient connected sensor leads 4-10.
One prior art attempt to provide management of the plurality of different types of leads and cables in a patient monitoring system is shown in, for example, Swiss Patent 524,992 and EPO 0 466 272. In these prior publications, it is indicated that a single junction box can receive each of the patient connected leads coupled to the individual patient sensors, and provide a common output cable from the junction box which is then connected to the patient monitor. Although the construction of the single output cable is not disclosed in these patents, it is expected that it merely comprises a bundling of the individual patient leads into a single jacketed structure, such as shown in FIG. 1b. Bundling is a conventional technique for cable management, as evidenced by U.S. Pat. No. 27,206. Although use of a single output cable improves cable management, there are serious electrical and mechanical problems associated with such a system. For example, the EKG sensors, being connected to the skin of the patient, are susceptible to picking-up very high voltage and/or high frequency signals when electrosurgery is being performed on the patient, or in the event that defibrillation becomes necessary. Under these circumstances the high voltage signals picked-up by the EKG leads may cause electromagnetic interference (EMI) which may be impressed upon the conductors carrying the other sensed patient signals, and thereby distort or otherwise corrupt these other signals. Furthermore, it is noted that when performing, for example, pulse oximetry sensing, it is required to provide relatively high current pulse signals to the oximetry sensor apparatus and a very low level and noise sensitive receive signal is required to be sensed and provided back to the monitor. Thus, when EKG cables are bundled in close proximity with pulse oximetry cables, the high level pulse currents on the pulse oximetry conductors can create electrical disturbances on the EKG signal conductors, and conversely, the high voltage signals on the EKG conductors can corrupt the data in the very sensitive pulse oximetry receive conductors. Still, furthermore, the EKG conductors can crosstalk among themselves, due to their being bundled together, and thereby degrade the common mode rejection of one pair of EKG conductors with respect to another pair. Even furthermore, the pick-up of high voltage defibrillation pulses by the EKG conductors can cause a breakdown of the voltage isolation between the closely spaced pins of the cable connector at the cable/monitor interface. Due to these electrical problems, a single cable which merely comprises a collection of the individual patient parameter cables bundled so as to be included in a single sheath, may be inadequate. Additionally, from a mechanical point of view, a cable as shown in FIG. 1b would be relatively heavy, thick, inflexible and bulky due to the plurality of individual shields and outer jackets included with each patient cable, as well as the requirement for a plurality of interstitial fillers which are added for improving the shape of the cable, but which unfortunately adds to its weight and inflexibility. Still further, due to the separated and non-symmetrically spaced arrangement of the cable bundles, each bundle, and each conductor in each bundle, must be constructed so as to have a maximum resistance to flexing failure. This necessarily increases the cost and complexity of the multi-parameter cable.
Another solution to the multi-parameter cable problem would be to provide active electrical signal processing inside of the junction box which would multiplex the multiple patient parameter signals onto a single output conductor or coaxial cable which is then received and demultiplexed by the monitor. Although this appears to be a satisfactory solution, it causes the junction box to become a much more expensive device, as well as undesirably increasing its size, introducing power requirements and decreasing its reliability. Additionally, since the junction box is positioned at the free end of the monitor cable, it is subject to being dropped on the floor, etc., when disconnected from the patient and therefore size, weight, flexibility and durability (as well as cost) are very important considerations.
Consequently, it is desirable to provide a multi-conductor cable which will provide continuity of the electrical signal handling properties of the leads connected to a plurality of different parameter sensors, when these leads are combined in a single multi-conductor cable, while at the same time prevent cross coupling of the signals. At the same time, it is desirable that this cable be flexible, light, of a small diameter, cost effective and relatively easy to construct.
SUMMARY OF THE INVENTION
In accordance with the principles of the present invention, a multi-parameter cable is provided for use to connect insulated conductors from a plurality of different types of sensors to a monitoring device, comprising a first tubular sheath to define a central zone of the multi-parameter cable for carrying signal to and/or from a first type of the sensors, and an electrically conductive second tubular sheath spaced a given distance symmetrically about the central zone to define an outer zone for containing a plurality of insulated conductors coupled to a second type of said sensors. The insulated conductors coupled to the second type of sensor are arranged in a single layer adjacent one another in the outer zone and include an electrically conductive outer jacket which is in electrical contact with the second tubular sheath.
In accordance with a further aspect of the invention, a plurality of insulated conductors coupled to a third type of sensor are also arranged in a single layer adjacent one another in the outer zone, with the insulated conductors coupled to said third type of sensor having an insulating outer jacket and the outer jackets of all of the insulated conductors coupled to both of the second and third types of sensors which are in said outer zone have an outer diameter which is substantially the same. Still further, the outer diameter is equal to the given distance between the first and second tubular sheaths.
In accordance with a still further aspect of the invention, the first sheath is also electrically conductive and thereby divides the multi-parameter cable into three electrically isolated zones, namely the central zone, and two portions in the outer zone, one comprising that portion of the outer zone wherein the conductors of the second type are arranged adjacent one another and the other zone being the remainder of the outer zone. This arrangement is particularly advantageous in that only two conductive shields, namely the first and second conductive sheaths, are required, thereby reducing the shielding requirement for each of the individual conductors from that which would normally be required when signal conductors are closely bundled in a common cable. The reduced shielding requirement for the individual conductors leads to a lower cost, lower weight, 772 smaller and more flexible multi-parameter cable.
In accordance with an even further aspect of the invention, the signal conductors which are contained in the central zone are twisted so that the lay or twist rate of the conductors in the central zone are different, and preferably twice, than the lay of the conductors in the outer zone. With this arrangement the electromagnetic coupling of the signals in the central zone to the conductors in the outer zone of the cable is minimized.
In accordance with a still further aspect of the invention, the conductors and shields of the outer zone are constructed of a material having a greater resistance to flexing failure than the conductors and shields of the central zone, thereby allowing lower cost materials to be used for constructing the central zone of the cable.
Other features and advantages of the invention will be suggested by the following description, with reference to the appended figures of which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a and 1b illustrate prior art cable arrangements for a patient monitoring system;
FIG. 2 illustrates a wiring schematic for connecting the conductors from a plurality of patient sensors to a single monitor, in accordance with the principles of the invention; and
FIG. 3 illustrates a cross-section view of the cable of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 illustrates a patient monitoring system which includes a multi-parameter cable constructed in accordance with the principles of the present invention. A patient 200 is symbolically illustrated as including a plurality of sensors mounted thereon for monitoring his vital signs, such as a temperature sensor 202, a non-invasive pulse oximetry sensor 204 and an EKG sensor 206. Respective ones of patient connection leads 208, 210 and 212 have one end connected to sensors 202-206, and their other end connected to a respective one of plugs 214, 216 and 218. The plugs make a mating connection with a respective one of receptacles 220, 222 and 224 of a junction box 226, referred to herein as a pod because it is preferably shaped as a streamline housing and therefore able to be conveniently placed near the patient, such as under his pillow or some other place near or on the patient bed. Pod 226 has a common output cable 228 constructed in accordance with the principles of the present invention, which makes electrical connection at pod 226 with the patient connected cables 208-212, and at its other end includes a plug 230 adapted to mate with a respective socket 232 in a patient monitor 234. The sensors 202-206, patient leads 208-212 and monitor 234 are all conventional patient monitoring apparatuses well known to those of ordinary skill in the art, which provide for the collection, analysis, display and recording of various physiological signs of the patient, and therefore further description of these components is not necessary and therefore omitted.
In a preferred embodiment, the plugs 214, 216, 218 and 230, as well as receptacles 220, 222, 224 and 232, should all provide electromagnetic interference (EMI) shielding for their respective conductors. U.S. Patent Application XXX,XXX entitled FULLY INSULATED, FULLY SHIELDED ELECTRICAL CONNECTOR ARRANGEMENT, filed simultaneously herewith and assigned to the same assignees as the present invention, disclose such a connector shielding technique suitable for use with plugs/receptacles 214/220, 216/222 and 230/232, and is incorporated herein by reference. Briefly, as described therein, the plug and receptacle portion of each connector should be designed so as to completely preserve the EMI shielding provided by the patient leads without compromising the safety of the patient. Additionally, the individual signal carrying conductors extending into pod 226 from plugs 214, 216 and 218 are handled or processed inside the pod for providing RF filtering and signal conditioning before the signals are brought into close proximity with each other in the multi-parameter cable 228. For example, each signal conductor associated with the EKG sensor 206 would preferably be coupled inside pod 226 to a tee-shaped signal processing circuit comprising a series low-pass filter followed by a limiting resistor, a spark gap coupled from the resistor to a common return, and finally a further low-pass filter coupled from the junction of the limiting resistor and spark gap to cable 228. The low-pass filters can each comprise a lossy inductive bead which individually surrounds each insulated EKG signal conductor for limiting the introduction into the monitoring system of, for example, interference signals in the 900 Mhz range from portable radio telephones, as well as electrosurgical signals. The spark gap and limiting resistor are included for attenuating any defibrillator signals which would be picked up by the EKG electrodes in the event that the patient is defibrillated. Inclusion of these filtering techniques within pod 226 is preferable in order to prevent these interference signals from introducing disturbance onto the other conductors within cable 228.
As shown in FIG. 2, multi-parameter cable 228 provides three conductors for monitoring temperature (labelled A, B and C), six conductors for operating the pulse oximetry sensing apparatus (labelled P and Q for carrying the pulse current signals for driving the red and infrared LEDs of the pulse oximetry sensor, labelled R and D for operating the calibration resistor of the sensor and labelled E and F which are connected to the SPO 2 optical receiver and are arranged in a coaxial cable arrangement) and five EKG conductors (labelled H, I, K, L and M) for carrying the EKG signals picked-up by the EKG sensors. Each of these signal conductors has to meet special requirements in order to properly carry its respectively assigned signal. More specifically, conductors A, B, C and R must have a large conductive center to ensure low resistance. Conductors P and Q must also have a large conductive center since they carry relatively high currents. The SPO 2 receive conductor, F, carries a very low-level signal, and therefore should provide a high-level of noise shielding, yet also be of low capacitance. Furthermore, each of the EKG conductors must be individually shielded for the reasons previously noted and the shielding must be accomplished in a manner such that flexing of the conductor shield does not create its own electrical noise. An extra conductor S is included in cable 228 for an as yet undecided purpose.
As schematically illustrated in FIG. 2, the shielding requirements for cable 228 are met by an outer or bundle shield 240 which surrounds all of the patient monitoring signal conductors included in cable 228, which is connected at one end to the shield in pod 226 and at its other end to the shield at connector 230, and additional shielding 242, 244 and 246 for other ones of the patient monitoring signal conductors. Shielding 242 is required for the SPO 2 signal conductors P and Q which carry pulse signals for driving the light emitting diodes of the conventional pulse oximetry sensor arrangement. Shield 244 is required to protect the SPO 2 receive signal conductor and individual shields 246 are required for each of the EKG conductors H, I, K, L and M. Merely bundling the individually shielded conductors, as shown in the FIG. 1a illustration of the prior art, results in a thick, inflexible and heavy cable.
In accordance with the principles of the present invention, all of the forenoted signal handling and shielding requirements for cable 228 are provided by a cable constructed as shown in the cross-section illustrated in FIG. 3. Starting from the inside of the cable, a central or inner zone of the cable is formed by an inner tubular sheath 302, which in the preferred embodiment comprises a copper tinned spiral shield but which, in accordance with a broadest concept of the invention, does not have to be electrically conductive and could merely comprise a plastic sheath. The inner zone defined by sheath 302 provides an ideal space to contain either signal conductors which need the most shielding between them and other conductors relating to the first type of physiological parameter, or signal conductors which should be twisted with respect to each other so that the lay of these conductors is different than the lay of other conductors in the cable in order to cancel the effect of their electromagnetic fields upon the signals carried by the other signal conductors. In the preferred embodiment, although the receive conductor for the pulse oximetry sensor is the most susceptible to noise contamination, it has a relatively small diameter and is therefore a less appropriate choice than bulky twisted conductors, for being located in the center of the multi-parameter cable. Thus, in the preferred embodiment, the central zone is used for carrying conductors P and Q of the pulse oximetry system, which conduct the forenoted relatively high level pulse current LED drive signals and therefore are required to have a large diameter center conductor and to be twisted along the length of the cable so as to have a different lay (twist rate) than other conductors in cable 228, in order to prevent their magnetic fields from differentially affecting the signals carried by the other signal conductors. An additional large diameter conductor, in this case R, which carries the SPO 2 return signal for the calibration resistor of the pulse oximeter sensor, is also included in the central zone and twisted with conductors P and Q in order to more effectively utilize the space defined by shield 302. Please note the term twisted is intended to include braiding and other forms of intertwining.
An outer electrically conductive shield 304 is symmetrically disposed and spaced a given distance out from shield 302, thereby defining a space between shields 302 and 304 wherein other ones of the signal carrying conductors can be located. In accordance with one aspect of the invention, these two conductive shields provide a novel and advantageous arrangement for providing electrical isolation between the various groups of signal carrying conductors bundled into the cable. More specifically, inner shield 302 clearly provides an electrically isolated central zone 306 which includes SPO 2 conductors P, Q and R arranged in a twisted manner therein. Similarly, spaced outer shield 304 creates an electrically isolated outer zone 308 which is between shields 302 and 304 and contains conductors D, E, and F which are the remaining conductors of the SPO 2 sensing arrangement, conductors H, I, K, L and M which conduct the picked-up EKG signals (a second type of physiological parameter) and conductors A, B and C for monitoring temperature (a third type of physiological parameter). In the preferred embodiment, the lay (twist rate) of the conductors in the central zone is twice that of the conductors in the outer zone. Furthermore, not only are the inner and outer zones electrically shielded from each other, but outer shield 304 also provides shielding from interference signals originating from outside cable 228.
In accordance with a further aspect of the invention, the EKG conductors each include an outer electrical conductive shield which is in electrical contact with at least one, and preferably both, of shields 302 and 304. When the conductive outer shields of the EKG electrodes are all adjacent and in physical contact with each other and with one or both of the inner and outer shields 302 and 304, an additional shielded zone 310 is formed, as illustrated by the dashed lines in FIG. 3. Furthermore, through a process of elimination, it is clear that the remainder of the curved space between the inner and outer shields 302 and 304 forms an additional separate electrically shielded zone 312 (illustrated by dashed lines) which comprises that portion of the space between shields 302 and 304 which is not within zone 310. Electrically shielded zone 312 includes conductors A-F and S each of which (except F) has no individual shield, and relies on zone 312 for its shielding requirements.
In accordance with an even further aspect of the invention, the space between shields 302 and 304 is substantially equal to the outside diameter of the shielded EKG conductors. This improves the packing density and shape of cable 228 (and as well as simplifying its construction costs) and efficiently provides for insulated conductors for a third-parameter (temperature) to be included in zone 312 when the insulated conductors of the third parameter are made so as to have substantially the same outside diameter as those of the second parameter (the EKG insulated conductors).
In accordance with a still further aspect of the invention, the symmetric nature of cable 228 is able to be exploited to cost-efficiently provide the necessary resistance to flexing failure for the various metallic conductors of the cable, by using low cost copper conductors in the inner zone and inner shield 302 and only using the more expensive copper alloy conductors in the outer zone and for the outer shield.
The construction and dimension of the individual conductors, shields and cable jacket is indicated in the following table.
______________________________________SPO.sub.2 P,Q,R TINNED COPPER STRANDS(SEND) INSULATED JACKET, OD 1.15 mmSPO.sub.2 D SILVERPLATED COPPER ALLOY(SEND) STRANDSTEMP A,B,C INSULATED JACKET, OD 1.05 mmSPARE SSPO.sub.2 (RCV) F SILVERPLATED COPPER ALLOY STRANDS INSULATED JACKET, OD 0.42 mm CARBON SHEET, OD 0.62 mm E COPPER TINNED SPIRAL SHIELD COVERED WITH INSULATING JACKET, FINAL OD 1.05 mmEKG H,I,K, SILVERPLATED COPPER ALLOY L,M STRANDS INSULATION JACKET WITH CARBON SHEET FINAL OD 1.05 mmINNER O COPPER TINNED SPIRAL SHIELDSHIELDBUNDLE G BRAID OF TINSEL WIRESSHIELD SILVERPLATEDJACKET J INSULATING JACKET OD 7.2 mm______________________________________
It is noted that the individual shields provided for the EKG conductors comprises a carbon-loaded plastic sheet in order to provide an electrically conductive shield which does not create electrostatic noise as a result of flexing. However, these individual EKG shields are not as electrically conductive as stranded copper shields and therefore merely connecting the individual EKG shields to appropriate conductors at the input end and output end of cable 228 would be ineffective, due to the relatively high resistance of the conductive plastic sheet and the length of cable 228. Thus, in accordance with an aspect of the present invention, one or both of shields 302 and 304 is in electrical contact with the full length of the individual EKG shields as they travel through cable 228, thereby reducing the distance between the EKG shields and a reference plane from being the length of the cable to only the diameter of each individual EKG conductor.
The table below cross references the labelled conductors of FIG. 3 with the type of patient monitoring signal carried thereby. Note that the SPO 2 receive signal actually comprises a coaxial cable wherein the central portion F conducts a low-level signal current and the SPO 2 return signal (labelled E) is carried on an insulated shield which surrounds conductor F.
______________________________________P PULSE SIGNAL FOR SPO.sub.2 RED LEDQ PULSE SIGNAL FOR SPO.sub.2 IR LEDR CALIBRATION SIGNAL SPO.sub.2 RESISTOR LEAD RETURND CALIBRATION SIGNAL SPO.sub.2 RESISTOR LEADA TEMPERATURE - COMMONB TEMPERATURE - TAC TEMPERATURE - TBE RETURN FOR SPO.sub.2 RECEIVEF SPO.sub.2 RECEIVEH EKG ELECTRODE SIGNAL - RLI EKG ELECTRODE SIGNAL - RAK EKG ELECTRODE SIGNAL - LAL EKG ELECTRODE SIGNAL - LLM EKG ELECTRODE SIGNAL - V______________________________________
Thus, what has been shown and described is a novel construction for an economical, flexible, light-weight, multi-parameter cable which fulfills all the objects and advantages sought therefore. Many changes, modifications, variations and other uses and applications of the subject invention will, however, become apparent to those skilled in the art after considering this specification and its accompanying drawings, which disclose preferred embodiments thereof. For example, although inner shield 302 is conductive, shield 302 could comprise merely a non-conductive tubular sheath and conductors P, Q and R could be individually shielded. Alternatively, the remaining conductors could be individually shielded, like the EKG conductors. Additionally, inner shield 302 could be formed by the air hose of a non-invasive blood pressure apparatus. The outside of the air hose could be made conductive in order to facilitate the shielding effect provided by the individual EKG shields. Furthermore, it should be clear that additional "outer" zones could be provided symmetrically spaced about zone 308, each additional outer zone having its own "lay" of signal conductors. Furthermore, one or more "drain" wires (a bare conductor in physical contact with the metallic shield) can be included, as known in the art. It should also be understood that the term signal conductor is intended to include conductors for signals other than electric ones, e.g., fibers for optical signals or even hoses for air-pressure signals as noted above. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by this patent, which is limited only by the claims which follow as interpreted in light of the foregoing description.
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A flexible multi-parameter conductor cable having coaxially symmetric elongated zones for signal carrying conductor placement therein, comprising an electrically conductive inner shield defining an electrically shielded inner longitudinal zone symmetrically disposed along and defining a center of said cable for containing at least one of a first type of signal carrying conductor, and an electrically conductive outer shield spaced a given distance symmetrically around said inner shield so as to define an electrically shielded outer longitudinal zone symmetrically disposed about said inner longitudinal zone for containing a plurality of at least a second type of signal carrying insulated conductor arranged in a single layer adjacent one another in said second longitudinal zone, said second type of conductor having an electrically conductive outer jacket in electrical contact with at least said outer shield.
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BACKGROUND OF THE INVENTION
The operating life of electrical equipment such as transformers depends to a large extent upon the dielectric properties of the transformer wire insulation. When the coating ceases to provide sufficient insulation between the turns of the transformer coil, electrical breakdown can occur between the turns causing the transformer to fail. Long term dielectric failure can be caused by the hydrolysis of the wire insulation at the temperatures incurred during transformer operation. The primary source of water contributing to the hydrolysis reaction is the thermal degradation of the cellulosic composition of the transformer winding insulation paper.
Besides having good thermal aging properties, the insulated wire must be tough and sufficiently flexible to be wound into a transformer coil without cracking in order to maintain its insulating properties. Transformer wire insulation such as those described within U.S. patent applications Ser. Nos. 889,889, and 970,249 are continuously being subjected to improvements in order to obtain better electrical, physical and thermal properties.
In order to provide insulating coating systems which have improved properties, a plurality of different types of catalysts were employed to cure the polyvinyl acetal, phenolic and epoxy resins within the coating composition. The investigation of the effects of various catalysts upon the coated transformer wire properties showed that the catalysts affect the thermal stability of the coated transformer wire when subjected to accelerated thermal aging tests.
The purpose of this disclosure is to provide a wire coating enamel composition having a preferred catalyst for promoting good flexibility and improved hydrolytic stability.
SUMMARY OF THE INVENTION
The invention comprises transformer wire coating compositions containing polyvinyl acetal and phenolic resins either as a two component composition, or as a three component composition containing epoxy resin, which are cured by means of an inner complex salt catalyst. In one embodiment of the invention, the inner complex salt consists of a bidentate chelating agent having one acid and one coordinating group with metals having coordination numbers which are exactly twice their principle valence. Examples of inner complexes which proved effective are acetylacetonates and glycinates.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphic representation of the dissipation factor as a function of time for a plurality of wire coating formulations;
FIG. 2 is a graphic representation of the dissipation factor as a function of time comparing wire coatings catalyzed with zinc octoate to wire coating catalyzed with nickel acetylacetonate and zinc acetylacetonate; and
FIG. 3 is a graphic representation of the dissipation factor as a function of time for wire coating compositions catalyzed by zinc octoate and aluminum acetylacetonate.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In order to provide transformer wire insulating enamel coatings having good flexibility and improved thermal aging properties the following compositions were prepared:
EXAMPLE 1
17 Parts of weight of polyvinylacetal resin was mixed with 8.5 parts of phenolic resin and 0.5 parts of aluminum acetylacetonate catalyst in a solvent consisting of 24.2 parts xylene, 24.2 parts of hydrocarbon, and 51.2 parts cresol. Resin films were cast from their composition and were evaluated for flexibility and electrical properties.
The dissipation factor at 170° C. for the cured wire coating of Example 1 measured from 8 to 10% initially. The percent solids by weight of the enamel was 21%.
EXAMPLE 2
A wire coating enamel having a higher 23.5% solids content was prepared in a manner similar to Example 1 and was evaluated for flexibility and electrical properties. The coating had good flexibility and the dissipation factor of the coating was equal to that of the coating described in Example 1.
EXAMPLE 3
100 Parts of a 23.5% solids polyvinylacetal-phenolic enamel was treated with 0.8 parts aluminum acetylacetonate and 0.7 parts hexamethoxymethylmelamine. This enamel was applied to 0.0403 Cu wire and the finished product had excellent flexibility and electrical properties. The resulting enamel was also evaluated for thermal aging by measuring the dissipation factor initially at 175° C., and determining the dissipation factor at 175° C. as a function of time. For purposes of this disclosure, the "dissipation factor" is defined as one measurement of the electrical losses occurring in the coating. The dissipation factor measurement is obtained by submerging the coated wire with a layer of insulating paper within a container of heated transformer oil. The electrical properties of the wire are continuously monitored relative to a standard over a period of time. The dissipation factor at 175° C. over a period of time in days is an indication of how the transformer wire would operate within a transformer at the lower temperature in the transformer oil over a period of years.
FIG. 1 shows the comparative thermal aging values of a standard polyvinylacetal-phenolic coating at Curve A; a coating from a polyvinylacetal-phenolic enamel which had been treated with zinc octoate and hexamethoxymethylmelamine at Curve B; and a coating from example 3 where the zinc octoate was replaced by the non-ionic inner complex salt, aluminum acetylacetonate at Curve C.
EXAMPLE 4
A wire coating enamel was prepared by dissolving 452 parts of weight polyvinylacetal, 226 parts of a phenolic resin, 18.9 parts hexamethoxymethylmelamine and 19.8 parts zinc acetylacetonate catalyst in a solvent containing 490 parts xylene, 798 parts of a hydrocarbon and 1262 parts cresol. The coating exhibited excellent flexibility and had a dissipation factor of 7% at 170° C. The solids content was 22% by weight.
EXAMPLE 5
452 Parts polyvinylacetal, 226 parts of a phenolic resin, 18.9 parts hexamethoxymethylmelamine and 19.3 parts nickel acetylacetonate catalyst, were dissolved in a solvent containing 490 parts xylene, 798 parts of a hydrocarbon, and 1262 parts cresol. The coating exhibited excellent flexibility and the dissipation factor of the coating was 7% at 170° C.
EXAMPLE 6
A wire coating enamel similar to Example 4 was prepared using copper glycinate catalyst in place of the zinc acetylacetonate. The resultant coating exhibited excellent flexbility and the dissipation factor of the coating was low.
EXAMPLE 7
A wire coating enamel similar to Example 5 was prepared with nickel dimethylglyoxime substituted for nickel acetylacetonate as a catalyst. The resulting coating had excellent flexibility and exhibited a dissaption factor of 14% at 170° C.
EXAMPLE 8
A wire coating enamel was prepared by mixing 4.7 parts polyvinylacetal, 3.1 parts phenolic, 2.0 parts epoxy resin and 0.18 parts aluminum acetylacetonate in a solvent containing 10 parts xylene and 30 parts cresol. The aluminum acetylacetonate comprised 1.9% by weight of the resins. Coatings from this composition exhibited excellent flexibility and dissipation factors below 20% at 170° C.
EXAMPLE 9
A wire coating enamel metal was prepared from the composition given in Example 8 with the following parts by weight of aluminum acetylacetonate catalyst: 0.015, 0.03, 0.06, and 0.10. These correspond to 0.15, 0.31, 0.61 and 1.02 percent by weight of the resins, respectively. Good flexibility and low dissipation factors occurred throughout the entire range of catalyst concentration.
EXAMPLE 10
A wire coating enamel was prepared containing the composition given in Example 8 substituting 0.08 parts of titanium acetylacetonate for aluminum acetylacetonate. Coatings prepared from this composition exhibited excellent flexibility and low dissipation factors.
EXAMPLE 11
An insulating coating with excellent physical and electrical properties was obtained by curing a film applied to the wire from an enamel prepared from 731 parts of a polyvinylacetal-phenolic resin containing approximately 50 parts of a blocked polyisocyanate, 290 parts epoxy resins and 5.2 parts aluminum acetylacetonate. These materials were dissolved in 1650 parts of a cresylic solvent and 550 parts of a hydrocarbon solvent to give an enamel of 26% solids.
EXAMPLE 12
Excellent coatings were prepared from an enamel similar to Example 11, but with 14.6 parts of aluminum acetylacetonate.
The dissipation factor for wire coated with the enamel given in Example 5 employing the non-ionic inner complex salt nickel acetylacetonate as a catalyst is shown at D in FIG. 2 for comparison with the same enamel composition containing the ionic salt zinc octoate catalyst at F and the enamel composition from Example 3 containing the non-ionic inner complex salt zinc acetylacetonate catalyst at E.
FIG. 2 shows that the zinc octoate catalyst has a lower dissipation factor than the nickel acetylacetonate but a higher dissipation factor than the zinc acetylacetonate. FIG. 2 shows further that not only do the inner complex salts affect hydrolytic stability, but also that the particular metal that comprises that salt may also have an effect.
In order to determine whether the lower dissipation factor resulting from the use of the non-ionic inner complex salt catalysts occurs with three component wire enamels containing epoxy, a control composition similar to Example 11 was prepared using the metal organic salt, zinc octoate, for comparison to the non-ionic aluminum acetylacetonate used in Example 11. The results are shown in FIG. 3 with the dissipation factor for the enamel composition catalyzed with zinc octoate shown at G, substantially higher than the same composition catalyzed with aluminum acetylacetonate shown at H.
The improvement in thermal aging and the anticipated extended transformer life by the use of inner complex salts catalysts, in place of metal organic salts in wire coating enamels, is not well understood at this time. It is postulated however, that the catalyst for the enamel resins may remain as an impurity in the coating after the curing process is completed. The inner complex salts, which are non-ionic, whould be less likely to react with moisture to ionize and interfere with the dielectric properties of the coating than the metal organic salts which readily form ions in solution with water.
Although the use of a non-ionic inner complex salt is disclosed as a catalyst for transformer wire insulating enamels, this is by way of example only. The coatings of the instant invention find application wherever insulating enamels may be utilized.
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An electrically insulating wire coating material comprised of the heat cured product of a mixture of polyvinylacetal and phenol-aldehyde resins, or a mixture of these resins with epoxy resins, and a catalyst from the special metal containing group of cyclic organic compounds known as chelates and which can be further defined as being a non-ionic inner complex salt. These materials give insulating coatings with improved flexibility and thermal aging properties.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a national stage of International Application No. PCT/EP2013/067451 filed Aug. 22, 2013, the disclosures of which are incorporated herein by reference in entirety, and which claimed priority to German Patent Application No. 10 2012 016 737.7 filed Aug. 23, 2012, the disclosures of which are incorporated herein by reference in entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a disc brake for a motor vehicle brake system, comprising a brake support which has at least one receiving region; a brake lining arrangement which has a brake lining support and a brake lining which is attached to the brake lining support and which can be brought into interaction with a brake disc in order to achieve a braking effect, wherein the brake lining arrangement is received in the at least one receiving region in a guided manner via a guiding portion formed on the brake lining support; and at least one restoring spring which engages the brake lining arrangement and biases the brake lining arrangement under elastic deformation into a starting position that does not produce a braking effect, wherein the at least one restoring spring can be plastically deformed in order to compensate for brake lining wear.
[0003] Such disc brakes are prior art. In these disc brakes the brake lining support, after a deflection from its starting position that produces a braking effect whereby it moves into frictional contact with a brake disc, has to be moved back into the starting position in order to separate the brake lining from the brake disc. In order to avoid unnecessary wear and reduce consumption, after the brake lining arrangement has been deflected so as to produce a braking effect it is absolutely necessary to prevent any contact from remaining between brake lining and brake disc and any residual sliding moments from arising.
[0004] However, as is likewise generally known, it is necessary to configure the disc brake in such a way that in the event of wear at the brake linings a wear correction may be effected so that, despite the occurrence of lining wear, the behaviour of the disc brake upon actuation remains substantially constant. Such wear correction entails adjusting the restoring spring in accordance with the wear. For this purpose there are solutions, whereby in the receiving region the restoring spring may effect a sliding adjustment in accordance with the actual wear situation. Other solutions provide that the restoring spring deforms, in particular plastically deforms, in the receiving region in accordance with the actual wear. Such a solution is described for example in the document U.S. Pat. No. 7,318,503 B2. Here, the brake lining arrangement is biased into its starting position by means of a loop-shaped restoring spring, wherein the loop-shaped restoring spring is configured so as also to guarantee a lining wear compensation by means of a plastic deformation component.
[0005] It has however been shown that such solutions do not exhibit reliable behaviour during wear compensation. In particular, it is difficult to predict whether a plastic deformation of the spring curve always corresponds precisely to the actual wear state. A consequence of this is that with progressive brake lining wear in practice the restoring behaviour of the restoring spring may also vary. This may lead to the spring being for example overly deformed, with the result that the remaining elastic deformation component no longer provides an adequate restoring movement and residual sliding moments occur. On the other hand it is equally possible for the spring to be insufficiently plastically deformed, with the result that it provides a greater restoring travel than is desired. This leads to a delayed response behaviour of the brake upon renewed actuation.
BRIEF SUMMARY OF THE INVENTION
[0006] In contrast to this it is a feature of the present invention to provide a disc brake of the type described in the introduction, the restoring spring of which provides reliable wear compensation combined with constant restoring behaviour.
[0007] This feature is achieved by a disc brake of the type described in the introduction, in which it is provided that the restoring spring rests against the brake support via a base portion and has at least one limb which is connected to the base portion via a connecting region and which is arranged at an angle relative to said base portion, said angle changing under the effect of plastic deformation as the brake lining wear increases.
[0008] Instead of a harmonically round-shaped spring curve the invention provides that in the connecting region a solid formation portion is provided, in which the plastic deformation for wear correction occurs. This allows the plastic deformation behaviour to be adjusted in a more defined manner.
[0009] A development of the invention provides that the restoring spring is configured with at least two limbs disposed at an angle relative to one another, wherein with increasing lining wear the angle between the two limbs varies for the purpose of wear compensation.
[0010] The wear compensation under the effect of plastic deformation of the restoring spring therefore takes place in the at least one connecting region between base portion and the at least one limb and/or—in the case of at least two limbs—additionally or alternatively in the connecting region between the two adjacent limbs, wherein said connecting regions are clearly defined. Consequently, given a suitable configuration of the connecting regions, a more detailed description of which will be given below, the deformation behaviour of the spring may be adjusted purposefully and reliably for wear compensation.
[0011] In principle it is possible to subject the spring to tensile loading, wherein the at least one limb is deformed with simultaneous reduction of the angle that the limb forms with the base portion. If at least two adjacent limbs are provided, these are spread with simultaneous widening of the angle formed thereby. As an alternative to this, according to the invention it is preferably provided that the restoring spring is disposed in such a way between the brake support and the brake lining arrangement that it is subject to compression loading, wherein with increasing brake lining wear the angle between the at least one limb and the base portion becomes larger under the effect of plastic deformation. If two adjacent limbs are provided, the angle between them becomes smaller under the effect of plastic deformation and the adjacent limbs move closer to one another. This variant of the spring that is elastic under compression has the advantage that the adjacent limbs under the effect of increasing wear compensation move closer to one another and finally, given maximum deformation (plastic and elastic), place themselves against one another. Upon release of the brake, a restoring movement within the scope of the elastic deformation component occurs. The plastic (permanent) deformation component is used for wear compensation.
[0012] A development of the invention provides that the restoring spring in the connecting regions between two adjacent limbs or between the at least one limb and the base portion as well as close to said connecting regions is provided in each case with a recess, wherein the limbs remote from the connecting regions are designed free of recesses. By suitably dimensioning the length and/or breadth of the recess in the connecting regions the deformation behaviour in said connecting regions may be purposefully controlled. Larger recesses provide a greater weakening of the connecting regions and hence a lower deformation limit. By deformation limit in the present context is meant the transition from a state of elastic deformation to a state of plastic deformation. Smaller recesses provide a higher deformation limit, i.e. greater forces are needed to obtain a plastic deformation in a connecting region. The designing of the connecting regions with recesses has the further advantage that it allows a purposeful adjustment of the deformation behaviour to be effected with a low manufacturing outlay. In summary it is therefore possible for the desired deformation limit of a connecting region between elastic and plastic deformation to be determinable by dimensioning the size of the recess in the connecting region.
[0013] As regards the structural design of the restoring spring it may be provided that the connecting region of the limb connected to the base portion has a different deformation limit than the connecting region between adjacent limbs. The limb close to the base portion therefore plastically deforms, so to speak, later than the limb disposed further away from the base portion.
[0014] In this connection it may further be provided that the connecting regions between adjacent limbs with increasing spacing from the base portion are configured with a deformation limit of unequal value, preferably of decreasing value. It is however also possible to provide alternating deformation limits in successive connecting regions.
[0015] As regards the structure of the restoring spring it may further be provided that the at least one connecting region is of a substantially harmonically rounded construction, albeit with a small radius. The harmonic rounding prevents an undesirable fracture of the restoring spring and guarantees a long service life. In addition it may be provided that the limbs are of a substantially rectilinear construction.
[0016] According to the invention it is in principle possible that the restoring spring takes the form of a separate component and is fastenable relative to the brake support, preferably by means of a detent connection or a clip connection. This allows easy manufacture as a bent stamping from a spring steel sheet or the like. It is however also possible for the restoring spring to be attached to a guide clip for guiding the brake lining support, which guide clip is accommodated in the receiving region. In this connection it may be provided that the restoring spring is latched and/or clamped on the guide clip by means of a detent connection, wherein the guide clip for this purpose has a recess. Alternatively it is possible for the restoring spring to be formed integrally on the guide clip. This facilitates the handling of restoring spring and guide clip as a unit during assembly and logistics.
[0017] In this connection it may further be provided according to the invention that the unit of restoring spring and guide clip is manufactured by shaping a flat component, wherein the restoring spring and the guide clip are manufactured in each case by shaping an, in the flat state, substantially elongate portion of the flat component, wherein the respective longitudinal axes of the elongate portions run substantially parallel to one another. As a flat component preferably a metal sheet may be considered, which in the course of cutting- or stamping processes is provided with desired contours and recesses and which is then shaped in the course of bending processes. By virtue of the construction according to the invention of restoring spring and guide clip as elongate portions of the flat component and by virtue of parallel arrangements of the respective longitudinal axes of said portions the dimensions of the flat component may be kept extremely small. This accordingly reduces the surface area of material needed to manufacture the flat component and hence the material scrap that arises, with the result that the cost of manufacture may be markedly reduced.
[0018] The invention further relates to a restoring spring for a disc brake of the previously described type, wherein all of the above features pertaining to the restoring spring and the mounting thereof may be provided individually or in any desired combination thereof.
[0019] Other advantages of this invention will become apparent to those skilled in the art from the following detailed description of the present embodiments, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a three-dimensional view of the disc brake;
[0021] FIG. 2 is a perspective view of a guide clip for guiding the brake lining support;
[0022] FIGS. 3 and 4 are perspective views of the guide clip of FIG. 2 with a restoring spring according to a first embodiment of the invention fastened thereto;
[0023] FIG. 5 is a component drawing of the restoring spring according to the first embodiment;
[0024] FIG. 6 is a sectional view of the restoring spring of FIG. 5 according to the first embodiment;
[0025] FIGS. 7 and 8 are rear and front views of a combination of guide clip and restoring spring according to a second embodiment, wherein the viewing axis corresponds to the axis of motion of the brake lining arrangement;
[0026] FIG. 9 is a perspective view of the combination of guide clip restoring spring according to the second embodiment;
[0027] FIG. 10 is a view of a flat component for the manufacture by shaping of a combination of restoring spring and guide clip according to the second embodiment;
[0028] FIG. 11 is a view of a flat component for the manufacture by shaping of a combination of restoring spring and guide clip according to a third embodiment;
[0029] FIG. 12 is a perspective view of the combination of guide clip and restoring spring according to the third embodiment that is manufactured by shaping the flat component of FIG. 11 ; and
[0030] FIG. 13 is a further perspective view of the representation of FIG. 12 .
DETAILED DESCRIPTION OF THE INVENTION
[0031] In FIG. 1 a disc brake according to the invention is shown and denoted generally by 9 . Here, in a U-shaped brake support 10 a brake lining arrangement 11 is disposed and guided in a displaceable manner in a receiving region 12 in the brake support 10 . Inside the receiving region 12 a restoring spring 13 is disposed. In the illustrated embodiment said spring is provided substantially inside a guide clip 15 , which is disposed in the receiving region 12 . The restoring spring 13 abuts a laterally projecting guiding portion 14 of the brake lining arrangement 11 . In order to build up a braking force the brake lining arrangement 11 is moved by components, which are not represented in detail, in an as such known manner in the receiving region 12 . The restoring spring 13 in this case in accordance with the displacement travel of the brake lining arrangement 11 deforms initially elastically in accordance with the forces acting upon it. After cancelling of the actuating force acting upon the brake lining arrangement 11 , the restoring spring 13 may by means of an elastic spring-back move the brake lining arrangement 11 back into the starting position, hereinafter also referred to as restoring position. In the present case, in the opposite region of the brake support 10 a non-illustrated, identical assembly group comprising a corresponding restoring spring 13 is disposed.
[0032] During the service period of the disc brake 9 a brake lining, which is situated on parts of the surface of the brake lining arrangement 11 facing the restoring spring 13 , is eroded by wear. In order that the response behaviour of the disc brake 9 remains constant, such wear is typically compensated by means of a wear correction corresponding to the actual brake lining wear. In this case the brake lining arrangement 11 is permanently displaced forward in the direction of the restoring spring 13 and/or in actuating direction. The starting position and/or restoring position of the brake lining arrangement 11 is likewise to be adapted by means of a wear correction to the increasing brake lining wear and/or to a compensating forward displacement of the brake lining arrangement 11 . This means that the starting position and/or restoring position is likewise to be changed for the purpose of wear compensation. The restoring spring 13 according to the invention solves this problem of wear compensation in that as a result of the plastic deformation following an increased action of force it shifts its point of application on the brake lining arrangement 11 in the elastically non-deformed state and hence the ensuing restoring position in actuating direction of the brake lining arrangement 11 . There now follows a detailed description of this operation with reference to a first embodiment that is represented in FIGS. 2 to 6 . An increased action of force is achieved for example when, because of the incipient wear, upon a brake actuation a greater movement of the brake lining arrangement 11 occurs and hence the restoring spring 13 is deformed to a greater extent. This deformation comprises a reversible elastic component and a permanent plastic component.
[0033] FIG. 2 shows a guide clip 15 , which is disposed in the receiving regions 12 of the brake lining support 10 . Such guide clips are as such prior art. They are used to guide the brake lining arrangement in a defined manner in the brake support. For the disc brake 9 according to the invention the recess 20 is additionally provided.
[0034] FIGS. 3 and 4 show a first embodiment of the restoring spring 13 , which takes the form of a separate component and is fastened to the guide clip 15 . For this purpose, it engages by means of a detent lug 24 into the recess 20 of the guide clip 15 and embraces a part of the guide clip 15 by means of a clamping portion 21 . In this case the clamping portion 21 interacts in such a way with an adjoining, opposing base portion 22 that said portions are spread elastically upon being pushed onto the retaining region of the guide clip 15 . The restoring spring 13 is therefore clamped firmly on the guide clip 15 . It is alternatively possible for such a fastening of the restoring spring to be effected without a guide clip directly on the brake lining support 10 .
[0035] FIG. 5 shows a detailed view of the restoring spring 13 according to the first embodiment. Here, the restoring spring has the previously described clamping portion 21 , which verges at an angle of approximately 180° into the base portion 22 , so that these two portions run substantially parallel to one another. Provided in the base portion 22 is a recess 23 , from which a detent lug 24 projects in the direction of the clamping portion 21 . Connected to the base portion 22 by a first connecting region 26 is a first limb 28 . This verges via a connecting region 30 into a second limb 32 . The transitions from the base portion 22 to the limb 28 as well as between the limbs 28 and 32 are denoted respectively by angles α and β, which are produced by bending the limbs 28 and 32 out from an initially flat metal sheet in the direction of the side of the base portion 22 remote from the clamping portion 21 . The resulting transitions are in this case deliberately of a harmonic and not, say, sharp-edged design in order to avoid concentrations of stress.
[0036] FIG. 6 shows a sectional view of the restoring spring 13 , wherein the section axis extends parallel to the direction of motion of the brake lining arrangement 11 . The opposing portions 21 and 22 in this case verge in such a way into one another that the spacing between them is smaller than the material thickness of a corresponding counterpart (region of a guide clip 15 or of the brake lining support 10 ). These portions upon being pushed onto the corresponding counterpart are accordingly spread elastically apart and firmly clamp the restoring spring 13 thereon. Opposite the detent lug 24 in the clamping portion 21 a recess 34 is provided so that the detent lug projects through a recess in the counterpart, onto which the restoring spring 13 is pushed, (for example recess 20 of the guide clip 15 ), and hence engages partially into the recess 34 .
[0037] As may be seen in FIGS. 5 and 6 , the transitional regions 26 and 30 are denoted in each case by recesses 34 , 36 . These recesses also project into the immediately adjoining regions of the limbs 28 , 32 and/or of the base portion 22 . Otherwise, however, the limbs 28 , 32 are designed free of recesses and substantially rectilinearly. The recesses 34 , 36 are design features, by means of which the connecting regions 26 , 32 are purposefully weakened. By said means the deformation limits are determined, which for the respective connecting region 26 , 30 define the transition from elastic to plastic deformation in dependence upon the effective forces. The recesses 34 , 36 in the illustrated example are dimensioned in such a way that different deformation limits arise for each connecting region. In the illustrated embodiment the deformation limit of the connecting region 30 is selected so as to be lower than that of the region 26 . It is self-evident that this also means that the degree of elastic deformation in the connecting region 30 is initially greater than that of the connecting region 26 .
[0038] Thus, under the effect of a force F according to the arrow F in FIG. 6 upon actuation of the disc brake 9 , i.e. upon a movement of the brake lining arrangement 11 in the direction of the arrow F, the angle β between the limbs 28 and 32 is reduced. An increase of the force F, and/or a greater deformation of the restoring spring 13 as a result of an increasing lining wear, results in the deformation limit of the connecting region 30 being exceeded. As a result the angle β between the limbs 28 and 32 is permanently reduced as a consequence of the plastic deformation of the restoring spring 13 . The point of application of the limb 32 on the brake lining arrangement 11 is accordingly also shifted in the direction of the arrow F. The restoring position of the brake lining arrangement that arises as a result of an elastic relaxation of the restoring spring 13 therefore likewise shifts in actuating direction in accordance with the plastic deformation, which is determined by the compensated lining wear. This effect is intensified when the deformation limit of the connecting region 26 is also exceeded. In the illustrated example this occurs only after the limb 32 has been plastically deformed towards the limb 28 . There is then a plastic deformation behaviour for wear compensation, in which parallel in time the angle α increases and the angle β decreases until the two limbs 28 and 32 finally position themselves one against the other in the actuating situation. A further plastic deformation as a rule does not occur. At least two defined limits may therefore be provided, at which the restoring spring 13 plastically deforms in order to compensate brake lining wear.
[0039] It should be noted that the restoring spring 13 following such a deformation substantially retains its elastic spring-back capability and so the value of the restoring travel also remains substantially constant. Only the point of application of the restoring spring 13 on the brake lining arrangement 11 and hence the absolute position of the brake lining arrangement 11 after a completed restoring operation vary in a wear-related manner in that they are shifted in actuating direction.
[0040] FIGS. 7 to 9 show a second embodiment of the restoring spring 13 , wherein in comparison to the first embodiment components of an identical type or effect are provided with the same reference characters.
[0041] The essential difference is that the restoring spring 13 is not designed as a separate component but is formed integrally on the guide clip 15 . The fastening mechanisms by means of the detent lug 24 and the clamping portion 21 therefore no longer apply. The elements crucial to the spring response as well as the recesses 34 and 36 defining the deformation limits are however retained. The spring in this case is initially of a two-dimensional construction and is then bent into the base portion 22 and the limbs 28 , 32 .
[0042] In the second embodiment the restoring spring 13 and the guide clip 15 are manufactured by shaping from a common, initially flat component. This flat component is represented on its own in FIG. 10 and denoted by 40 . It is evident that the restoring spring 13 and guide clip 15 initially take the form of substantially elongate portions 44 and 46 of the component 40 . In this case the respective portions 44 and 46 already for the most part have the basic contours and recesses in accordance with the finished combination of restoring spring 13 and guide clip 15 shown in FIGS. 7 to 9 . Thus, for example the previously described recesses 34 and 36 may be seen in the portion 44 .
[0043] To manufacture the unit of restoring spring 13 and guide clip 15 according to the second embodiment the flat component 40 is bent around a plurality of bending axes, the position of which may be gathered from a combined viewing of the finished shaped component shown in FIGS. 7 to 9 . It is self-evident that in this case for example in the course of combined stamping-/bending processes further changes may be made to the contour or further recesses may be introduced.
[0044] In the flat state shown in FIG. 10 it is evident that the portions 44 and 46 , from which the guide clip 15 and restoring spring 13 are subsequently formed, extend along a respective longitudinal axis L 1 and L 2 . In this case the elongate portion 44 and/or the longitudinal axis L 1 thereof extends at right angles to the longitudinal axis L 2 of the elongate portion 46 . During shaping of the component 40 the portion 44 is therefore bent relative to the portion 46 in particular around a bending axis denoted in FIG. 10 by z, which runs at right angles to the longitudinal axis L 1 of the portion 44 . It is further evident that the flat component 40 has two main dimensions y and x, which crucially define a material surface area of sheet metal that is needed to manufacture the component 40 . In this case it may be seen from FIG. 10 that the component 40 takes up only a relatively small proportion of the spread-out material surface area, with the result that the material scrap that arises when the component 40 is cut or stamped out of this surface area is relatively high.
[0045] In comparison to this, FIG. 11 shows an alternative development of a flat component 40 according to a third embodiment of the invention. In this case the elongate portions 44 and 46 as such are of an identical construction to the example in FIG. 10 . In this embodiment, however, the longitudinal axes L 1 and L 2 are aligned parallel to one another. Accordingly the surface area portions 44 and 46 extend substantially in a common direction and the spread-out required material surface area is smaller, particularly in the transverse direction y, than in the previous example of FIG. 10 . The component 40 according to the third embodiment therefore takes up a comparatively high proportion of the spread-out material surface area and the scrap is markedly reduced.
[0046] The bending axis z, around which the surface area portion 44 is bent relative to the portion 46 , extends in this embodiment at an angle α of 45° relative to the longitudinal axis L 1 of the surface area portion 44 . This enables the restoring spring 13 in the third embodiment also to be aligned in the same manner relative to the guide clip 15 and the actuating direction as in the examples discussed above.
[0047] A finished shaped unit according to the third embodiment is shown in FIGS. 12 and 13 . Evident once more are the obliquely extending bending axis z and the portions of the restoring spring 13 that lie adjacent thereto. In order to increase the stiffness of the region bent around the bending axis z and avoid local concentrations of stress, the restoring spring in this region is configured with a curvature 48 , which is likewise produced in the course of the shaping process.
[0048] In accordance with the provisions of the patent statutes, the principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.
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A disc brake for a motor vehicle brake system and a restoring spring arranged therein, the disc brake comprising the following: a brake support which has at least one receiving region; a brake lining arrangement which has a brake lining support and a brake lining which is attached to the brake lining support and which can be brought into interaction with a brake disc in order to achieve a braking effect, wherein the brake lining arrangement is received in the at least one receiving region in a guided manner via a guiding portion formed on the brake lining support; and at least one restoring spring which engages the brake lining arrangement and biases the brake lining arrangement under elastic deformation into a starting position that does not produce a braking effect. The at least one restoring spring can be plastically deformed in order to compensate for brake lining wear. To improve the wear compensation by means of the restoring spring, rests against the brake support via a base portion and has at least one limb which is connected to the base portion via a connecting region and which is arranged at an angle relative to the base portion, the angle changing under the effect of plastic deformation as the brake lining wear increases.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to dobbies and other weaving mechanisms of the negative type and more particularly to the drawing device interposed between each of the members for maneuvring the mechanisms and a corresponding heddle frame mounted on the associated weaving machine.
2. History of the Related Art
It is known that a weaving mechanism of the negative type ensures positive control of the frames only in one direction of their reciprocating stroke, with the result that it is necessary to provide elastic elements which are placed in tension during positive actuation so as to effect the return of each frame as soon as the corresponding maneuvring member of the mechanism ceases its action.
In practice, these elastic elements are spring systems including a plurality of springs maintained between two hooking elements. One of the hooking elements is suitably fastened to the fixed structure of the weaving machine, while the other is secured either with the end of a control cable coupled to each heddle frame, or with a rocking guide lever disposed along path of the cable between the frame and the spring system.
It should be observed that, to allow the weaving machines to operate at very high speeds, there is a tendency, at present, to employ increasingly powerful spring systems, which results in both the springs of the systems and the control cables breaking more frequently. Now, it is difficult to repair these operational failures, as this involves dismantling and subsequent remounting a large number of springs on which a very high tension is exerted.
SUMMARY OF THE INVENTION
It is an object of the present invention to overcome this drawback by providing a drawing device for the actuation of heddle frames of the weaving mechanisms of the negative type, which includes at least one control cable which is laterally fixed to the frame and of which one end is attached to one of the members for maneuvring the mechanism, while the opposite end is associated with a spring system after being guided by a lever mounted to oscillate on a support shaft carried by the fixed structures of the weaving machine. The support shaft is engaged inside guiding slideways with which are associated actuation elements arranged to cause its transverse displacement in the slideways and subsequently the momentary relaxing of tension on the assembly of spring systems and cables so that repair may be made thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more readily understood on reading the following description with reference to the accompanying drawings, in which:
FIG. 1 is a side view of a drawing device according to the present invention.
FIG. 2 is a vertical section along the plane indicated at II--II in FIG. 1.
FIG. 3 illustrates in perspective the arrangement of one of the two flanges ensuring adjustable retention of the shaft which supports the oscillating levers.
FIG. 4 reproduces FIG. 1 in the relaxed position of the spring systems.
FIG. 5 illustrates another embodiment of the slideway.
FIG. 6 shows the application of the invention of weaving mechanisms which are mounted in superstructure above the heddle frames.
FIG. 7 shows a variant of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, reference 1 in FIG. 1 denotes one of the heddle frames mounted on a weaving machine. Each frame 1 is laterally secured to a control cable 2 of which one end is fastened to one of the members for maneuvring the weaving mechanism, while the opposite end is guided over one of a series of rocking levers 3 before being fixed to a spring system 4. Each system 4 conventionally includes a series of vertical springs 5 which are hooked to an upper hooking element 6 secured to the end of the cable 2 below the corresponding lever 3, and to a lower hooking element 7 retained in place by a rack 8 secured to a vertical structure 9 of the weaving machine.
The assembly of the levers 3, in a number equal to that of the heddle frames 1 of the weaving machine, is mounted to oscillate on a horizontal shaft 10 of cross section so that the levers 3, attached to the cables 2 by fastening elements such as 3a, may freely rotate on the shaft.
According to the invention, the shaft 10 is supported by the two vertical structures 9 of the weaving machine via two vertical flanges 11, mounted to the top of the structures in the manner illustrated in FIG. 2. Each flange 11 has an elongated slot 11a cut therein, whose longitudinal axis is oriented obliquely with respect to the vertical axis of the frame 2, as shown in FIG. 3. The slot 11a is of a width such that it forms a slideway for the corresponding end of the shaft 10 which traverses it.
For the displacement of the shaft 10 in the slots or slideways 11a along the longitudinal axis thereof, a screw 12 is employed through each flange 11, which passes through a perforation 11b provided therein and along the axis of the slot 11a, and which is screwed into a tapping 10a made diametrally in each of the ends of the shaft 10, as clearly illustrated in FIG. 3.
When the weaving machine is functioning, the support shaft 10 of the rocking levers 3 is located in the upper position inside the slideways 11a, in the manner shown in FIG. 1. In this position, the upper hooking element 6 is spaced by a distance H from the fixed lower hooking element 7, with the result that the springs 5 of the assembly of spring systems 4 are in tension and therefore perform their function. The lowering of the frames 1 under the effect of the positive control exerted by the cables 2 generates an overtension of the spring systems 4 which resiliently return the frames into their upper position as soon as the members maneuvring the mechanism cease their positive movement.
To replace a broken spring 5, or a worn or cut cable, it suffices for the operator to turn the screws 12 carried by the two flanges 11 so as to push shaft 10 downwardly to the lower position illustrated in FIG. 4. It will be appreciated that the lowering of shaft 10 over a distance h provokes the corresponding lowering of the upper hooking element 6 of all the spring systems 4, so that the springs 5 are relaxed to facilitate repair. Once this has been done, the screws 12 are turned to return the support shaft 10 into the upper position for operation.
It should be observed that, due to the oblique orientation of the longitudinal axis of the slots or slideways 11a, the lowering of the shaft 10 is accompanied by a horizontal displacement of value d, which shifts that portion of cables 2 included between the fastening thereof on the side of the heddle frames 1 and the rocking levers toward the structure 9. The cables 2, therefore move away from the frames 1 to thus facilitate extraction and positioning thereof.
When this systematic horizontal displacement of the cables 2 due to the oblique incline of the slideways 11a risks proving a hindrance, the variation illustrated in FIG. 5 may be employed. In the case shown each flange 111 has a slideway 111a hollowed out therein of substantially triangular configuration, whose base includes two recesses 111b and 111c which are sectioned to receive selectively the corresponding end of the shaft 10 engaged inside the slideway.
The adjustment of the screw 12 simultaneously associated with each flange 111 and the shaft 10 makes it possible to lower the shaft until it is brought into recess 111b. The vertical displacement of shaft 10 ensures relaxation of spring systems 4 and cables 2, without the orientation of these cables being affected. On the contrary, for dismantling the frames 1, the operator transfers each of the ends of the shaft 10 of the two recesses 111b to the two recesses 111c, which has for its effect to space the cables 2 from frames 1.
It goes without saying that, in such a case, the opening made in the top of each flange 111 must be sectioned to allow the change in the orientation of the screw 12.
FIG. 6 illustrates the application of the invention to weaving machines in which the weaving mechanism 13 is supported by a fixed superstructure 14. The two cables 2 associated with each member 13a for moving the mechanism 13 to control the corresponding heddle frame 1, are guided and wound over two levers 103 connected to the frame 1 by connecting rods 15 and to the superstructure 14 by spring systems 4.
As in the embodiment according to FIG. 1, each lateral assembly of levers 103 is carried by the same horizontal shaft 10. The ends of the shaft are engaged in slots or slideways 109a which may be directly made in the vertical structure 109. With each end of the shaft is associated a screw 12 whose head abuts the edge of an opening made in the structure 109.
In the case shown in FIG. 6, that portion of cable 2 included between the corresponding lever 103 and the upper guide pulley 16 is oriented vertically, like the axis of spring system 4. Each slideway 109a is oriented substantially vertically so that the lowering of the shaft 10 and the levers 103 during the manoeuvring of the screws 12 causes the simultaneous relaxing of the springs of systems 4 and of cables 2.
In the embodiment shown in FIG. 7, the axis of the end portion of each cable 2 defines an obtuse angle with the vertical axis of the corresponding spring system 4. In such case, the simultaneous relaxing of the spring systems 4 and of the cables 2 causes the axis of slots or slideways 109a to be oriented along the bisectrix of such angle.
It goes without saying that, in all cases, means other than screws 12 may be imagined for ensuring displacement and immobilization of the support shaft 10 with respect to the spring systems 4 of the drawing device. In particular, small hydraulic jacks may be employed.
Furthermore, it will be observed that the invention may be advantageously applied to dobbies or other weaving mechanisms of the negative type in which the drawing device associated with each heddle frame includes only a single cable arranged so as to cause the actuation of the two rocking levers provided for moving a frame. See, for instance U.S. patent application Ser. No. 07/913,952 filed Jul. 17, 1992 by the present Applicants.
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A drawing device for actuating the heddle frames of a weaving machine of the negative type including rocking levers which guide cables extending from the heddle frame to a return spring system. The rocking levers are mounted on shafts which are shiftable within elongated slots to thereby relax tension on the cables and spring system.
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BACKGROUND OF THE INVENTION
This invention relates to the feeding of molten strands of plastic to a trough where the strands are solidified, and more particularly to a slanted drainage trough which extends under the fall line of stands that emerge from nozzles.
In the use of troughs to collect molten plastic strands, the trough is pivoted into position to receive the strands and is supplied with a coolant, such as water, which is directed to the upper end of the trough and drains along its slanted face.
A representative drainage trough for molten plastic strands is disclosed in German patent No. 2,503,455. The drainage trough of this patent is used with a pivotal flap. The flap is mounted on a perpendicular axle with respect to the trough at its upper end. The flap can be pivoted to occupy one of two positions. In the operating position the flap is pivoted into contact with the drainage trough to catch the strands emerging from the nozzles and conduct them to the coolant water that is applied to the product for solidification of the strands. In the non-operating position, the flap is pivoted away from the trough so that the strands emerging from the nozzles fall between the flap and the trough. During initial operation it is necessary to deflect the material emerging from the nozzles in order to avoid the contamination associated with the initial flow, as well as to allow the composition which is emerging from the nozzles to reach a uniform state. In the deflection of the strands from the trough, they are conducted through a relatively narrow shaft formed between the flap and the reverse side of the trough. Since the initial flow of the contaminated and non-uniform material is through the drainage shaft, it is necessary to clean the shaft from time to time. However, because of the construction of the flap relative to the trough in forming the shaft, cleaning is difficult because the interior of the shaft is relatively inaccessible.
Accordingly, it is an object of the invention to facilitate the feed and cooling of molten strands of plastic. A related object is to avoid the feed of contaminated and non-uniform plastic material to a drainage trough where molten stands are subjected to cooling.
Another object of the invention is to achieve the feed of relatively uniform stands of plastic material to a drainage trough for cooling without requiring the periodic cleaning and removal of contaminated and non-uniform materials that flow during initial operation of the cooling trough.
Still another object of the invention is to avoid the need for pivotal flaps in the operation of cooling troughs and the associated inaccessibility from the standpoint of cleaning and maintenance that is occasioned by the presence of such a flap.
SUMMARY OF THE INVENTION
In accomplishing the foregoing and related objects, the invention provides a drainage trough which is readily accessible to the user in all of its operating positions and substantially eliminates the risk of contamination from the initial flow of plastics material.
In accordance with one aspect of the invention, a drainage trough is provided with an axis of pivot that is displaced from the upper end of the trough and generally lies perpendicular to it. The collection portion of the trough, which is disposed above the axis of pivot, can be moved from its operating position during which the strands are collected to a non-operating position which permits the stands to fall freely behind the entire trough and thus avoid any contamination of the trough by the falling material.
As a consequence of the pivotal arrangement provided by the invention, the back side of the trough is freely accessible, both in the operating position where the strands are being collected on the trough as well as in the non-operating position where no collection takes place. Since the strands fall freely behind the pivotable section, there is no tendency for the material of the strands to adhere to the trough, and the risk of contamination is eliminated. Because of the free accessibility to the back side of the trough any incidental contamination, which would not be generally objectionable in any event, is readily eliminated. The invention also avoids the kind of contamination that can occur when a diverting flap is used since there is contact of the flow with the forward side of the flap during the collection of strands and their conduction to a drainage trough in the operating position.
In accordance with another aspect of the invention, the axis of pivot for the drainage trough can be located at various positions. When the drainage trough is relatively short, the axis is suitable disposed at the lower end, and the entire trough is pivotable. Conversely, when the drainage trough is relatively long, the axis of pivot can be disposed at a approximately the center of the trough or in its upper third. In this case, only the portion of the trough that is above the axis of pivot will become pivoted.
In accordance with a further aspect of the invention, the degree of pivoting is governed by the desired accessibility to the nozzles that supply the molten strands of material. The further that the trough, or a specified part, is pivoted, the greater is the accessibility to the nozzles.
In accordance with yet another aspect of the invention, the pivoting of the drainage trough causes the collection portion to move through the strands from the nozzles, and a separational element can be included with the trough. The separational element provides for separation of the strands and movement of the collection portion takes place through the strands. During this movement the strands can be automatically conducted to the collection trough without any nozzle manipulation.
The separation element desirably takes the form of a rod disposed perpendicular to the strands at the end of the collection trough that moves through the strands, and displaced from them. When the end of the trough moves to the strands, they are first caught by the rod and thus kept away from the collection portion of the trough. The strands then fall away from the rod because of gravity and can easily fall from the rod behind the collection trough. The spacial separation of the rod from the upper end of the collection trough assures that the rod will not be significantly cooled and consequently allows the strands on the rod to remain in molten condition.
In accordance with a still further aspect of the invention, the separational element can take the form of a knife which sweeps past the nozzles during movement of the trough. In this case the strands are separated directly below the nozzles so that the subsequent flow of material from the nozzles falls upon the collection part of the trough when it is pivoted into operating position. The collected strands are then subjected to the desired cooling.
DESCRIPTION OF THE DRAWINGS
Other aspects of the invention will become apparent after considering several illustrative embodiments taken in conjunction with the drawings in which:
FIG. 1 is a schematic view of a drainage trough in accordance with the invention with an axis of pivot disposed at the lower end of the trough;
FIG. 2 is a schematic view of the trough of FIG. 1 in its operating position;
FIG. 3 is a schematic view of an alternative embodiment of the invention with an axis of pivot near the middle of the trough and illustrating the non-operating position of the trough in phantom;
FIG. 4 is a schematic view of a further embodiment of the invention with the axis of pivot in the upper third of the drainage trough;
FIGS. 5A through 5D are partial schematic views showing a separation rod positioned at the upper end of the trough in various operating positions to control the flow of material from a nozzle to the trough; and
FIGS. 6A and 6B and 7A, B are fragmentary schematic views showing a separational element in the form of a knife in both non-operating and operating positions for the associated collection trough.
DETAILED DESCRIPTION
With reference to the drawings, the device shown in FIG. 1 contains a drainage trough 1 at whose lower end there is disposed an axle 2, about which the drainage trough 1 can be pivoted. At its upper end the drainage trough 1 contains the collection part 3, which consists of a water box 4 with a water overflow 5. Cooling water is applied to the water box 4 through a collection element 6 into a feed line 7. Furthermore, several spray nozzles 8 are disposed in front of the drainage trough 1. Cooling water is applied to the spray nozzles 8 through a feed line 9. The spray nozzles 8 are directed towards the drainage trough 1 which is sprayed with cooling water.
FIG. 1 shows the non-operating position of the drainage trough 1. In this position the nozzle arrangement 10 is situated above and laterally with respect to the drainage trough 1. The plastic strands in their molten condition emerge from said nozzle arrangement 10. In the non-operating position a plastic strand 11 flows vertically downward and is collected by the container 12.
The granulator 13 is disposed below the drainage trough 1. The granulator 13 consists of the two pull-in rollers 14 and 15 and the milling unit 16, which interacts with the cutter knife 17. Cooling water is applied to the granulator 13 through a connection 18. The cooling water rises in the cooling water space 19. It is conducted through the nozzle 20 to the floow 21 which runs around the milling unit 16. Here the cooling water which has been fed in this fashion encounters the granules which have been cut by the milling unit 16. The granules are then flushed out of the granulator 13 in the direction of the arrow.
FIG. 2 shows the same device in its operating position. As can be seen in this position the strands emerging from the nozzle arrangement 10 fall vertically downward in the direction of the line 22 until they are collected in the collection portion 3 and are conducted to a drainage trough 1. The strands then enter the region of the pull-in rollers 14 and 15 and are cut into granules by the milling unit 16. As a result of appropriate speed of the rollers 14 and 15, the strands are pulled tight over the drainage trough 1 and occupy the position shown by line 23.
The process described above, in as much as it describes the cooling and granulating of the strands, is known from German patent No. 2,503,455.
In the non-operating position shown in FIG. 1 the strands 11 fall unended from the drainage trough, l and in the collection portion 3, which is a component of the drainage trough 1, vertically into the container 12. This operating phase is used when the device is being started up. In this phase plastic material emerges from the nozzle arrangement 10. Frequently, this plastic material does not yet have the required quality. Such material may not be mixed with granules consisting of full-value material. As can be seen, the region below the nozzle arrangement 10 is freely accessible. There is no risk of contaminating the drainage trough 1. Now, if full-value material emerges from the nozzle arrangement 10, the drainage trough 1, with its collection portion 3, is pivoted about the axle 2 counter the arrow 24 which is shown in FIG. 1. In this operating position the strands emerging from the nozzle arrangement 10 are collected in the collection portion 3. The strands are then processed to granules in well known fashion.
The drainage together with its collection part 3 moves in both directions through the strands 11 or 23 respectively, so that the drainage flow is not interrupted. To prevent the liquid melted strands from adhering at the upper end 24 of the collection part 3 during this pivoting process, the flow of strands is briefly interrupted in well known fashion through the valve (not shown) of the nozzle arrangement 10.
As can be seen the drainage of plastic material of inadequate quality is very simple. This happens by collecting the plastic material aft the drainage trough 1 with its collection part 3, and specifically on the back side of the drainage trough 1, so that the removed plastic materials, that is the strands which are designated 11 in FIG. 1, may be readily observed. If is ascertained that a lot of good quality material is emerging from the nozzle arrangement 10 the drainage trough 1 with its collection part 3 is pivoted into the path of the strands 1 as explained above. For this purpose, the flow of plastic material is briefly stopped. When the plastic material again emerges from the nozzle arrangement 10 the respective strands 23 will encounter the collection part 3 which lies below the nozzle arrangement 10. As the strands above, the strands 23 are conducted from there to the drainage trough 1 and the granulator 13.
The device shown in FIG. 3 involves a modification of the device according to FIGS. 1 and 2. In the device of FIG. 3, only a portion of the drainage trough 1 is pivoted, leaving its upper region 25 with the collection part 3. To pivot the region 25 with the collection part 3 the pivoting axle 26 has been provided, which is situated in the center of the drainage trough 1, which here consists of a lower region 27 and an upper region 25 with the collection part 3.
In FIG. 3 the non-operating position of the upper region 25 is shown with dots and dashes, so that FIG. 3 shows both the operating and non-operating position. With regard to further functioning of the device, reference is made to above discussion in connection with FIGS. 1 and 2.
FIG. 4 shows another variant of the device according to FIGS. 1 through 3. In this variant, the pivoting axle of the pivotable part of the drainage trough 1 lies still higher than in the device of FIG. 3. This is the pivoting axle 27, above which is disposed the collection part 3, which is the only pivotable part in this case. The collection part 3 can here be pivoted (not shown) in a similar position as shown in the dash-dot lines of FIG. 3. Furthermore reference is made to the explanations for FIGS. 1 through 3.
The device shown in FIGS. 5A through 5D involve a similar device as is shown in FIG. 4. However, in FIGS. 5A through 5D only that portion of the device that is of interest is shown, mainly the pivotable collection part 3. The collection part 3 is equipped with a rod 28, which acts as a separation element and which runs perpendicular to the strands 11 or 29 respectively. It here runs parallel to the row of nozzles in the nozzle arrangement 10. The rod 28 is disposed at a distance from the end 24 of the collection part 3 where this end passes through the strands. Thus, it cannot be cooled by the cooling water that is conducted through the water box 4. Because of the rod 28, which acts as a separation element, the collection part 3 can be pivoted without interrupting the flow of plastic material from the nozzle arrangement 10.
FIG. 5A shows the non-operating position of the device, in which the collection part 3 is pivoted away from the strands 11. The strands 11 are of inadequate quality and are intercepted by the container 12.
When the material is of perfect quality, the collection part 3 is pivoted through the strands 11 and specifically into the position shown in FIG. 5B. Here the strands emerging from the nozzle arrangement 10 will first hand up on the rod 28 and fall down on both sides of the rod 28 as shown in FIG. 5C. Since the rod 28 is not cooled, the strands which first adhere to the rod 28 remain in the molten condition and finally tear off under the action of gravity. From this results the operating state shown in FIG. 5D in which the strand material 29 continues to flow from the nozzle arrange 10 and is collected by the collection part 3 and is conducted to the portion of the collection trough (not shown here) which is shown in FIG. 4.
This arrangement achieves the feature that the changeover that does the pivoting from the non-operating position shown in FIG. 5A into the operating position shown in FIGS. 5B through 5D can take place without interrupting the flow of the strands. Thus, the rod 28 which acts as a separation element takes care the changeover of the flow of strands proceeds automatically with the pivoting of the collection part.
In order to prevent even a slow solidification of residue strand material which may possibly adhere to the rod 28, the rod 28 is heated approximately to the melting point of the strand of material being processed, for example by an electrical heating mechanism.
The device shown in FIGS. 6A and 6B is shown in similar fashion to the device of FIGS. 5A through 5D, that is, essentially limited to the collection part 3, so that reference can be made to the explanations concerning FIG. 4 as far as the further functioning of the device is concerned.
In the device of FIGS. 6A and 6B, the knife 30 is provided as a separation element. When the collection part 3 moves from the non-operating position of FIG. 6A into the operating position of FIG. 6B, the knife 30 passes over the surface 31 of the nozzle arrangement 22. To facilitate this process the surface 31 is designed with a slight concave curvature. The knife 30 is attached to the extension arm 33, and specifically over the axle 34, which supports the lever 35 at one of whose ends is fastened the knife 30.
A tension spring 36 is hung in at the other end of the lever 35, and this tension spring 36 is also fastened to the extension arm 33. Due to the action of the tension spring 36, the lever 35 tends to turn clockwise. However, because the knife 30 contacts the surface 31, the lever is prevented from executing this motion.
Starting from a non-operating position in FIG. 6A, one thus obtains the following function: In the non-operating position the strands 11 flow vertically from the nozzle arrangement 32 and are collected by the container 12. If the collection part 3 is now pivoted into the operating position of FIG. 6B the lever 35 and also the knife 30 are moved along the surface 31 of the nozzle arrangement 32, through the action of the extension arm 33. The knife 30 slides over the surface 31 and, in one stroke, passes over all the nozzles of the nozzle arrangement 32, which lie one behind the other. Here the knife 30 passes through the strands 11, so that the flow of strands is interrupted. During this interruption the collection part 3 moves in such a manner that the strands 37 which continue to flow after the interruption (see FIG. 6B) now encounter the collection part 3 which is in its operating position. The collection part 3 may further conduct the strands 37, in the manner described in FIG. 4, to the drainage trough which is situated below, and to the granulator 13.
It should also be pointed out that the knife 30 is supported by arm 35 at each of its two ends so that the free space exists between the arms (in FIG. 6B only the forward arm is visible). The strands 37 can flow down through this free space. The strands are therefore not impeded in their flow by the arms 35.
While various aspects of the invention have been set forth by the drawings and specification, it is to be understood that the foregoing detailed description is for illustration only and that various changes in parts as well as the substitution of equivalent constituents for those shown and described may be made without departing from the spirit and scope of the invention as set forth in the appended claims. In FIGS. 7a and b ab apparatus is shown which corresponds to the apparatus according to FIGS. 6a and b in which however lever 35 is replaced by the telescope 38 being under spring tention.
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Extrusion apparatus for extruding plastic filaments and having a trough for cooling filaments, the trough being pivoted about a horizontal pivot means such that the upper end of the trough can pass from the collecting position through the fall line of the filaments to a position where the filaments fall behind the trough.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to a method for manufacturing a porous silicon component which guarantees reliable contacting of the porous silicon.
2. Description of the Prior Art
Silicon is an indirect semiconductor having a band gap of 1.1 eV. The manufacture of semiconductor structures for light emission in the visible spectral range using silicon has heretofore not been thought possible by those knowledgeable in the art.
The production of porous silicon is known in the art from V. Lehman et al. Appl. Phys. Lett. 58, p. 856 (1991). Porous silicon is formed at the surface of a silicon wafer by anodic etching of single-crystal silicon in a fluoride-containing, acidic electrolyte in which the silicon wafer is connected as anode. Porous silicon comprises pores or canals. The diameter of the canals is dependent on the doping of the silicon wafer. Given a doping of the silicon wafer in the range between 10 15 and 10 18 cm -3 yields canals having diameters from 1-2 nm. Canals having diameters of 10 nm-100 nm arise in silicon with a doping of more than 10 19 cm -3 .
It has been discovered (see v. Lehmann et al., Appl. Phys. Lett. 58, p. 856 (1991)) that porous silicon produced from lightly doped silicon with a dopant concentration between 10 15 and 10 18 cm -3 , and therefore having channels with diameters from 1-2 nm, has a band gap of approximately 1.7 eV and exhibits photoluminescence in the visible spectral range (See L. T. Canham Appl. Phys. Lett. 57, p. 1046 (1990) and N. Koshida et al., Jap. J. Appl. Phys. 30 p. L1221 (1991)).
An optical semiconductor component with porous silicon using a layer of porous silicon with Schottky contacts by vapor-deposition of gold has been proposed (see the press release of the Fraunhofer Inst. IFT. Sueddeutsche Zeitung, No. 199, p. 37, Aug. 29, 1991). The vapor deposition of metal, however, is difficult because of the porosity of the porous silicon.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method for manufacturing a component with porous silicon which guarantees reliable contacting of the porous silicon.
The above object is achieved in accordance with the principles of the present invention in a method wherein two highly doped regions and a lightly doped region disposed therebetween are first formed in a silicon wafer. The dopant concentration is set in a range between 10 15 and 10 18 cm -3 in the lightly doped region. The dopant concentration is set to about 10 19 cm -3 in the highly doped regions. An anodic etching is then conducted in a fluoride-containing, acidic electrolyte with which the silicon wafer is in contact and in which the silicon wafer is connected as the anode, causing the silicon in the lightly doped region to be converted into porous silicon. As a result of the dopant concentration in the lightly doped region, the porous silicon has canal diameters around 1 to 2 nm. The highly doped regions have canals with diameters in the range from 10 nm through 100 nm due to the dopant concentration prevailing therein. The highly doped regions are firmly joined to the porous silicon of the lightly doped region. The highly doped regions are therefore suitable as terminals for electron injection or hole injection into the porous silicon lying therebetween. Contacts are provided for the highly doped regions.
The anodic etching is preferably conducted using diluted hydrofluoric acid having at least 5 weight percent HF. The current density is set in the range from 1 to 1000 mA/cm 2 ; the voltage of a few volts is dependent on the current density that is set. When the lightly doped region is p-doped, it is advantageous to illuminate the silicon wafer from the backside during the anodic etching.
In a preferred embodiment of the invention, a first layer doped with a first conductivity type having a dopant concentration of at least 10 19 cm -3 is produced at the surface of a silicon substrate as a first, highly doped region. A second layer is produced on the first layer by epitaxy; this second layer being doped with a second conductivity type opposite from the first conductivity type and having a dopant concentration in the range between 10 15 and 10 18 cm -3 . The second layer forms a lightly doped region. The second highly doped region forms a third layer that is doped with the second conductivity type and has a dopant concentration of at least 10 19 cm -3 . For anodic etching, the surface of the third layer is brought into contact with the electrolyte. Canals having diameters around 10 nm-100 nm thereby occur in the third layer. In the second layer the canals branch into canals having diameters in the range from 1-2 nm. The second layer is converted into porous silicon in this way. For the connection of the first layer, for example, a deeply extending terminal through the third layer and through the second layer having the first conductivity type is doped on the basis of masked implantation. Insulation of a component from the substrate is achieved by doping the silicon substrate with the second conductivity type.
In a further embodiment of the invention, the highly doped regions are driven into a doped silicon layer with a dopant concentration in the range between 10 15 and 10 18 cm -3 . A first highly doped region is thereby annularly surrounded by a second highly doped region. The part of the doped silicon layer displaced between the first and second highly doped regions thereby forms the lightly doped region. The depth of the first highly doped region is less than the thickness of the doped silicon layer. The depth of the second highly doped region is essentially equal to the thickness of the doped silicon layer. Before the anodic etching, a protective layer that leaves the lightly doped region uncovered is produced at the surface of the highly doped regions. This protective layer prevents an etching attack at the surface of the highly doped regions during the anodic etching. Thus, only the lightly doped region, is converted into porous silicon in this manner. Formation of canals having diameters in the range between 10 nm and 100 nm occurs only at the boundary surfaces between the lightly doped region and the highly doped regions.
Doping the highly doped regions with opposite conductivity types creates a light emitting diode. By contrast, doping the two highly doped regions with the same conductivity type and the lightly doped region with opposite conductivity type, creates components which can be operated as bipolar transistors by applying appropriate contacts.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention shall be set forth in greater detail by way of example with reference to the figures.
FIG. 1 and FIG. 2 show the manufacture of a component with porous silicon in accordance with the principles of the present invention, in which the highly doped regions and the lightly doped regions are displaced in a vertical manner.
FIG. 3 shows the manufacture of a component in accordance with the principles of the present invention, wherein the highly doped regions and the lightly doped regions are displaced in a lateral manner.
FIG. 4 shows the manufacture of a bipolar transistor in accordance with the principles of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the inventive method exemplified in the embodiment of FIGS. 1 and 2, a first layer 12 is produced at the surface of the silicon substrate 11. For example, the silicon substrate 11 is p-doped and has a dopant concentration of 10 15 -10 18 cm -3 . The first layer 12, which forms the first highly doped region, is n + -doped and has a dopant concentration of 10 19 -10 21 cm -3 . This first layer 12, having a thickness of 400 nm-10 μm, is epitaxially formed by implantation or by diffusion out of a deposited layer.
A second layer 13 is epitaxially applied onto the first layer 12. The second layer 13, having a thickness of 100 nm-2 μm, preferably 600 nm, is p-doped and has a dopant concentration of 10 15 -10 18 cm -3 .
A third layer 14 is produced at the surface of the second layer 13 epitaxially by implantation or by occupancy. The third layer 14, has a thickness of 100 nm-600 nm, preferably 400 nm, is p + -doped with a dopant concentration of more than 10 19 cm -3 .
The silicon substrate 11 with the first layer 12, the second layer 13 and the third layer 14 is brought into contact with a fluoride-containing, acidic electrolyte so that the surface of the third layer 14 is completely wetted. The silicon substrate 11 is connected as anode and the electrolyte is connected as cathode. An ensuing anodic etching produces canals with diameters in the range from 10 nm-100 nm resulting in the third layer 14. Due to the lower dopant concentration prevailing in the second layer 13, these canals branch into the second layer 13 to form canals having diameters from 1-2 nm. The anodic etching is implemented until the second layer 13 has been completely converted into porous silicon.
In a preferred embodiment of the invention, a terminal 15 extends through the third layer 14 and the second layer 13 onto the first layer 12 to enable contact with said first layer 12 from the surface of the third layer 13. This terminal 15 along with the respective contact 16 produced at the surface of the third layer 14 is shown in FIG. 2. In a preferred embodiment of the present invention, the contact 16 is produced at the surface of the third layer 14 by vapor deposition of gold, and the terminal 15 is produced by masked implantation, for example.
By applying a positive voltage of approximately 2-10 volts between the contacts 16 shown in FIG. 2, the second layer composed of porous silicon with canals having diameters from 1-2 nm floods with electrons and holes, and light emission occurs as a result.
The silicon substrate 11 and the first layer 12 form a pn-junction that insulates the component from the silicon substrate 11. In applications in which an insulation is of no concern, the silicon substrate 11 can also be n-doped.
As shown in a preferred embodiment in FIG. 3, a buried layer 22 is produced on a substrate 21 of single crystal silicon which is p-doped and has a dopant concentration of 10 15 -10 18 cm -3 . The n + -doped buried layer 22 has a dopant concentration of 10 19 -10 20 cm -3 . This buried layer 22 may be formed epitaxially by implantation or diffusion out of a deposited layer. A p-doped silicon layer 23 having a dopant concentration of 10 15 -10 18 cm -3 is disposed from the buried layer 22 by epitaxy. A first highly doped region 24 is disposed in the doped silicon layer 23 for example, by implantation. This first highly doped region 24 is, for example, p-doped and has a dopant concentration of at least 10 19 cm -3 . A second highly doped region 25 is disposed for example by diffusion, in the doped silicon layer 23. In a preferred embodiment, the second highly doped region 25 annularly surrounds the first highly doped region 24. This second highly doped region 25 is for example n + doped and has a concentration of at least 10 19 cm -3 . The part of the doped silicon layer 23 displaced between the first highly doped region 24 and the second highly doped region 25 forms a lightly doped region 26. A structured protective layer 27 composed of photoresist, for example, is disposed at the surface of the highly doped regions 24, 25. This structured protective layer 27 leaves the surface of the lightly doped region 26 uncovered.
Also, the preferred embodiment of the present invention as shown in FIG. 3, the first highly doped region 24 has a shallower depth than the doped silicon layer 23, so that the first highly doped region 24 is separated from the buried layer 22 by the doped silicon layer 23. Also, the second highly doped region 25 has a depth that essentially corresponds to the thickness of the doped silicon layer 23, so that the second highly doped region 25 is in communication with the buried layer 22.
The surface of the lightly doped region 26 and the protective layer 27 is brought into contact with an acidic, fluoride containing electrolyte. The substrate 21 is connected as anode and the electrolyte is connected as cathode. An ensuing anodic etching converts the lightly doped region 26 into porous silicon having canals with diameters in the range from 1-2 nm. Canals having diameters from 10 nm-100 nm can thereby likewise arise as a result at the boundary surface between the lightly doped region 26 and the highly doped regions 24, 25. The anodic etching is preferably conducted in the preferred embodiment with the following parameters:
Fluoride concentration: 10%
Current density: 30 mA/cm 2
Etching duration: 20 seconds for example, 600 nm
Illumination from the backside: approximately 100 mW/cm 2 (white light).
After the removal of the protective layer 27 (not shown), vapor deposition of aluminum is utilized to produce contacts at the surface of the first highly doped region 24 and at the surface of the second highly doped region 25. The finished component is insulated by n + p-junction at the boundary surface between substrate 21 and the buried layer 22 in the substrate 21.
In a preferred embodiment of the present invention shown in FIG. 4, a buried layer 32 is disposed on a substrate 31 of single-crystal silicon which is p-doped and has a dopant concentration of 10 15 -10 18 cm -3 . The n + -doped buried layer 32 having a dopant concentration of least 10 16 cm -3 is formed for example by epitaxy implantation or occupancy to a thickness of 400 nm-2 μm. A p-doped silicon layer 33 having a dopant concentration in the range between 10 15 -10 18 cm -3 is disposed by epitaxy onto the buried layer 32.
The preferred embodiment of the present invention of FIG. 4 shows a first highly doped region 34 disposed at the surface of the doped silicon layer 33 by diffusion. The n + -doped first highly doped region 34 has a dopant concentration on at least 10 19 cm -3 and a depth that is less than the thickness of the doped silicon layer 33, so that the first highly doped region 34 is separated from the buried layer 32 by the doped silicon layer 33.
A second highly doped region 35 is produced in the doped silicon layer 33 by diffusion. The second highly doped region 35 is n + -doped and has a dopant concentration of at least 10 19 cm -3 and annularly surrounds the first highly doped region. The depth of the second highly doped region 35 essentially corresponds to the thickness of the doped silicon layer 33 and is therefore in communication with the buried layer 32. That portion of the doped silicon layer 33 that is arranged between the first highly doped region 34 and the second highly doped region 35 forms a lightly doped region 36.
A structured protective layer (not shown) of, for example, photoresist is produced at the surface of the first highly doped region 34 and the second highly doped region 35. The protective layer leaves the surface of the lightly doped region 36 uncovered. The surface of the lightly doped region 36 and of the protective layer are brought into contact with a fluoride-containing, acidic electrolyte, whereby the electrolyte is connected as cathode and the substrate 31 is connected as anode. By anodic etching, canals having diameters in the range from 1-2 nm are produced in the lightly doped region 36. Porous silicon results. The structured protective layer prevents an etching attack at the surface of the first highly doped region 34 and of the second highly doped region 35. The formation of canals having diameters in the range from 10-100 nm can thereby occur at the boundary surfaces of the lightly doped region 36 to the first highly doped region 34 and to the second highly doped region 35.
The anodic etching preferably ensues with the following parameters:
Hydrofluoric acid concentration: 10%
Current density: 30 mA/cm 2
Voltage: a few volts dependent on the current density
Etching duration: 20 seconds for, for example, 600 nm
Illumination from the backside: approximately 100 mW/cm 2 .
After the removal of the protective layer, contacts 37 are applied to the surface of the first highly doped region 34, to the surface of the lightly doped region 36 and to the surface of the second highly doped region 35. The contacts 37 are produced, for example, by vapor-deposition of aluminum.
The finished component shown in FIG. 4 can be operated as a bipolar transistor. The first highly doped region 34 thereby acts as collector; the lightly doped region 36 that was converted into porous silicon in the anodic etching acts as base; and the second highly doped region 35 acts as emitter. The contacts on the lightly doped region 36 as well as the contacts on the second highly doped region 35 are connected to one another. The bipolar transistor can be controlled by the base by beaming light in.
Although various minor modifications may be suggested by Those versed in the art, it should be understood that we wish to embody within the patent granted hereon all changes and modifications as reasonably and properly come within the scope of our contribution to the art.
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For manufacturing a component with porous silicon, two highly doped regions with a lightly doped region arranged between them are formed in a silicon wafer. The dopant concentrations are thereby set such that porous silicon arises in the lightly doped region in a subsequent anodic etching. Light-emitting diodes or light-controlled bipolar transistors can be manufactured in this way.
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[0001] The entire disclosure of Japanese Patent Application No. 2006-064010, filed Mar. 9, 2006 is expressly incorporated by reference herein.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates to ferroelectric memory devices having ferroelectric capacitors and methods for manufacturing the same.
[0004] 2. Related Art
[0005] A ferroelectric memory device (FeRAM) is composed with ferroelectric capacitors, and is a nonvolatile memory that is capable of low voltage and high speed operations (see, for example, Japanese laid-open patent application JP-A-2005-277315). In such a ferroelectric memory device, its memory cell can be composed of, for example, one transistor and one capacitor ( 1 T/ 1 C), whereby integration to the level of DRAM is possible. Accordingly, ferroelectric memory devices are highly expected as large capacity nonvolatile memories in recent years.
[0006] For such ferroelectric memory devices, it has become an important issue to prevent deterioration of ferroelectric films in their manufacturing process. In other words, during the process for manufacturing a ferroelectric memory device, after a ferroelectric film is formed, the ferroelectric film may be exposed to a hydrogen atmosphere (i.e., a reducing atmosphere) in the steps of forming an interlayer dielectric film, dry etching and the like. Because the ferroelectric film is generally composed of metal oxide, oxygen that composes the ferroelectric film is reduced when the ferroelectric film is exposed to a reducing atmosphere, such as, for example, hydrogen (H 2 ), water (H 2 O) and the like, and electrical characteristics of the ferroelectric capacitor are considerably deteriorated. As a measure to prevent hydrogen damage, after a capacitor is formed, an insulation film (AlOx film, etc.) having a hydrogen barrier function and covering the capacitor is provided as a hydrogen barrier film.
[0007] Also, a ferroelectric capacitor in such a ferroelectric memory device is formed from a lower electrode, a ferroelectric film and an upper electrode. When the ferroelectric capacitor is formed, normally, a layer composed of a material for the lower electrode, a layer composed of a ferroelectric material, and a layer composed of a material for the upper electrode are successively laminated, and these layers are etched and patterned together.
[0008] When the ferroelectric capacitor is formed through etching, its ferroelectric film may be damaged. In order to remove the damage and recover the characteristics, a so-called recovery annealing is conducted after forming the ferroelectric capacitor, in which the ferroelectric capacitor is heat-treated in an oxygen atmosphere at about 300° C.-500° C. However, such a heat-treatment (recovery annealing) forms hillocks at the upper electrode that is composed of, for example, iridium (Ir). This phenomenon is believed to occur as compressive stress is generated in the upper electrode by the heat treatment, and metal atoms in the material composing the upper electrode diffuse in order to relieve the stress.
[0009] When hillocks are formed on the upper electrode in this manner, when a hydrogen barrier film is formed to cover the ferroelectric capacitor, the hydrogen barrier film cannot be formed well on the upper electrode that has the hillocks formed thereon, and the upper electrode cannot be sufficiently covered by the hydrogen barrier film, such that the ferroelectric capacitor would eventually be deteriorated by hydrogen. In other words, because concave and convex portions are formed by the hillocks, the hydrogen barrier film material would not be deposited particularly in a portion shaded by the convex portion, such that the film would not be formed in such a portion.
[0010] Also, contacts that are connected to the lower electrode and the upper electrode of the ferroelectric capacitor are formed, and the ferroelectric capacitor is driven through these contacts and electrodes. In this structure, in particular, the contact that is connected to the upper electrode is formed with a plug that is embedded in a contact hole formed in an interlayer dielectric film that covers the ferroelectric capacitor. When forming the contact hole by etching to reach the upper electrode, it would be difficult to form the contact hole securely in a manner to reach the upper electrode if the hydrogen barrier film that covers the upper electrode is composed of a material that is difficult to be etched. Accordingly, currently, excessive over-etching is conducted to form a contact hole so as to reach an upper electrode. However, by so doing, the upper electrode may be largely cut in part, which leads to degradation of the characteristics of the ferroelectric capacitor.
SUMMARY
[0011] In accordance with an advantage of some aspects of the invention, it is possible to provide a ferroelectric memory device and a method for manufacturing a ferroelectric memory device, in which deterioration of characteristics of a ferroelectric capacitor due to generation of hillocks can be prevented, and formation of a contact hole to reach an upper electrode is facilitated, thereby further preventing degradation of the characteristics of the ferroelectric capacitor.
[0012] A method for manufacturing a ferroelectric capacitor in accordance with an embodiment of the invention includes the steps of: forming a ferroelectric capacitor having at least a lower electrode, a ferroelectric film and an upper electrode on a base substrate; and applying an anneal treatment to the ferroelectric capacitor in an oxygen atmosphere, wherein, in the step of forming the ferroelectric capacitor, the ferroelectric capacitor is formed to have a structure in which an electrode protection film composed of titanium oxide is provided on the upper electrode.
[0013] According to the method for manufacturing a ferroelectric memory device, the ferroelectric capacitor is formed in a structure in which an electrode protection film composed of titanium oxide is provided on the upper electrode. Therefore, when an anneal treatment is applied later to the ferroelectric capacitor in an oxygen atmosphere, the electrode protection film suppresses generation of hillocks on the surface of the upper electrode, whereby deterioration of characteristics of the ferroelectric capacitor can be prevented. In other words, even when metal atoms in the material composing the upper electrode diffuse at the time of the anneal treatment, the diffusing atoms remain within the electrode protection film because the electrode protection film composed of titanium oxide is provided on the upper electrode, such that generation of hillocks can be prevented.
[0014] Also, the method for manufacturing a ferroelectric memory device may preferably include, after the step of applying an anneal treatment, the step of forming a hydrogen barrier film that covers the ferroelectric capacitor including the electrode protection film.
[0015] Generation of hillocks is suppressed by the electrode protection film, and therefore the top surface of the ferroelectric capacitor forms a flat surface without irregularities, such that, by forming the hydrogen barrier film thereon, the hydrogen barrier film is favorably coated on the upper electrode, in other words, on the electrode protection film. Accordingly, deterioration of characteristics of the ferroelectric capacitor that may be caused by hydrogen and the like can be securely prevented by the hydrogen barrier film.
[0016] Also, the method for manufacturing a ferroelectric memory device may preferably include, after the step of applying an anneal treatment, the steps of forming an interlayer dielectric film that covers the ferroelectric capacitor including the electrode protection film over the base substrate, and forming a contact hole in the interlayer dielectric film by etching which reaches the upper electrode of the ferroelectric capacitor.
[0017] For forming a contact hole that reaches the upper electrode, excessive over-etching may have been needed in the past, for example, when the upper electrode is covered by a hydrogen barrier film composed of a material that is difficult to be etched. In contrast, according to the manufacturing method of the present embodiment, the electrode protection film is provided on the upper electrode. The electrode protection film functions as an etching stopper layer, the etching is substantially slowed down and the etching is apparently almost stopped by the electrode protection film even in excessive etching, whereby the etching is facilitated. Accordingly, thereafter, etching may be conducted for the electrode protection film if necessary, whereby the contact hole can be formed without largely cutting the upper electrode in part. Therefore, deterioration of characteristics of the ferroelectric capacitor can be prevented.
[0018] Furthermore, the method for manufacturing a ferroelectric memory device may preferably include, after the step of forming a contact hole, the step of cleansing inside the contact hole by dry etching or the like.
[0019] By so doing, residues of the electrode protection film and its reactants remaining in the contact hole can be removed, such that electrical conduction between the plug embedded in the contact hole and the upper electrode can be made more secure, and the connection resistance can be lowered.
[0020] Also, in the method for manufacturing a ferroelectric memory device, the step of forming the ferroelectric capacitor above the base substrate may preferably include the steps of: forming at least a lower electrode layer, a ferroelectric layer, an upper electrode layer and a titanium oxide layer on the base substrate; patterning the titanium oxide layer on the upper electrode layer by high-temperature etching between 200° C. and 500° C. into a mask pattern; and etching the upper electrode layer, the ferroelectric layer and the lower electrode layer together by using the mask pattern as a mask, to thereby form a ferroelectric capacitor having a lower electrode, a ferroelectric film, an upper electrode and an electrode protection film composed of the mask pattern.
[0021] Because titanium oxide such as titania (TiO 2 ) is difficult to be etched, and is therefore difficult to be patterned, it was thought that titanium oxide could not be used as a hard mask. However, it has discovered that titanium oxide has a moderate etching rate in high-temperature etching at about 200° C., and can therefore be patterned and used as a hard mask. Accordingly, etching is conducted by using titanium oxide that is difficult to be etched and therefore has great etching resistance as a mask pattern to form the ferroelectric capacitor, whereby the mask pattern composed of titanium oxide can be made relatively thin. Accordingly, the aspect ratio of the mask to be used for forming the ferroelectric capacitor is relatively lowered, and the ferroelectric capacitor can be etched favorably to its bottom side without conducting excessive over-etching. As a consequence, problems as such roughened side wall surfaces of the ferroelectric capacitor that may be caused by excessive over-etching, and the resultant difficulty to obtain good ferroelectric characteristics can be avoided.
[0022] Moreover, the mask pattern is formed by patterning a titanium oxide layer in high-temperature etching between 200° C. and 500° C. Therefore, although titanium oxide is difficult to be etched at room temperature as described above, it can be patterned by etching particularly when it is conducted at 200° C. or higher. Also, since the etching is conducted at 500° C. or below, other components such as a driving transistor for driving the ferroelectric capacitor to be obtained can be prevented from being thermally damaged.
[0023] In the method for manufacturing a ferroelectric memory device, the step of forming the mask pattern on the upper electrode layer may preferably include the steps of: forming a second mask pattern on the titanium oxide layer, and etching the titanium oxide layer in high-temperature etching by using the second mask pattern to thereby form a mask pattern, wherein the step of forming the ferroelectric capacitor may preferably be conducted by etching and patterning, using a laminated mask pattern composed of the mask pattern and the second mask pattern as a mask.
[0024] As a result, etching is conducted by using the laminated mask pattern composed of the mask pattern and the second mask pattern, such that the burden on the mask pattern composed of titanium oxide is reduced, and the film thickness thereof can be made smaller. Accordingly, etching of the titanium oxide layer that is difficult to be etched can be reduced to a necessity minimum.
[0025] In the method for manufacturing a ferroelectric memory device, the step of forming the ferroelectric capacitor over the base substrate may preferably include forming the ferroelectric capacitor in a structure in which an oxygen barrier film is provided between the base substrate and the lower electrode.
[0026] Because the oxygen barrier film is provided between the base substrate and the lower electrode, oxidation of a plug in a contact hole formed in the base substrate and the resultant substantial increase in the resistance in the anneal treatment step conducted in an oxygen atmosphere after forming the ferroelectric capacitor can be prevented. Accordingly, electrical conductivity between the plug and the lower electrode can favorably be secured.
[0027] A ferroelectric memory device in accordance with an embodiment of the invention includes: a base substrate; a lower electrode, a ferroelectric film and an upper electrode provided on a base substrate; an electrode protection film composed of titanium oxide provided on the upper electrode, wherein the lower electrode, the ferroelectric film, the upper electrode and the electrode protection film form a ferroelectric capacitor on the base substrate; and a hydrogen barrier film that covers the ferroelectric capacitor.
[0028] According to the ferroelectric memory device described above, the ferroelectric capacitor is formed with the electrode protection film composed of titanium oxide provided on the upper electrode. Therefore, when an anneal treatment is applied to the formed ferroelectric capacitor in an oxygen atmosphere at the time of manufacturing, the electrode protection film suppresses generation of hillocks on the surface of the upper electrode, whereby deterioration of the characteristic of the ferroelectric capacitor can be prevented. Also, the top surface of the ferroelectric capacitor is in a flat surface without irregularities, such that the hydrogen barrier film is favorably coated on the upper electrode. Accordingly, deterioration of characteristics of the ferroelectric capacitor that may be caused by hydrogen and the like can be securely prevented by the hydrogen barrier film.
[0029] Also, in the ferroelectric memory device, an interlayer dielectric film that covers the hydrogen barrier film may preferably be provided above the base substrate, and a contact hole that is connected to the upper electrode of the ferroelectric capacitor may be formed in the interlayer dielectric film.
[0030] With the structure described above, at the time of manufacturing, when a contact hole that reaches the upper electrode is formed, the electrode protection film, which is provided on the upper electrode, functions as an etching stopper layer, and therefore the etching is substantially slowed down and is apparently almost stopped by the electrode protection film even in excessive etching. Accordingly, thereafter, etching may be conducted for the electrode protection film depending on the necessity, whereby the contact hole can be formed without largely cutting the upper electrode in part. Therefore, deterioration of characteristics of the ferroelectric capacitor can be prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a cross-sectional view in part of a ferroelectric memory device in accordance with an embodiment of the invention.
[0032] FIGS. 2A-2C are views for describing steps of a method for manufacturing the device shown in FIG. 1 .
[0033] FIGS. 3A-3C are views for describing steps of the method for manufacturing the device shown in FIG. 1 .
[0034] FIGS. 4A and 4B are views for describing steps of the method for manufacturing the device shown in FIG. 1 .
[0035] FIGS. 5A and 5B are views for describing steps of the method for manufacturing the device shown in FIG. 1 .
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0036] Examples of preferred embodiments of the invention are described below. First, a ferroelectric memory device in accordance with an embodiment of the invention is described. FIG. 1 is a cross-sectional view in part of a ferroelectric memory device in accordance with an embodiment of the invention. Reference numeral 1 in the figure denotes a ferroelectric memory device. The ferroelectric memory device 1 is of a stacked type having a 1 T/ 1 C memory cell structure, and is equipped with a base substrate 2 , and a plurality of ferroelectric capacitors 3 provided on the base substrate 2 .
[0037] The base substrate 2 is formed from a silicon substrate (i.e., a semiconductor substrate) 4 . Transistors 5 for driving the ferroelectric capacitors 4 are formed on a top surface portion of the silicon substrate 4 , and a base dielectric film 6 that covers the driving transistors 5 is formed above the silicon substrate 4 . Source and drain regions (not shown) and channel regions (not shown) composing the driving transistors 5 are formed in the silicon substrate 4 , and gate dielectric films (not shown) are formed over the channel regions. Further, gate electrodes 5 a are formed on the gate dielectric films, thereby forming the driving transistors 5 , respectively.
[0038] It is noted that the driving transistors 5 corresponding to the respective ferroelectric capacitors 3 are electrically isolated from one another by embedded isolation regions (not shown) formed in the silicon substrate 4 . Further, the base dielectric film 6 may be composed of silicon oxide (SiO 2 ), and planarized by a CMP (chemical mechanical polishing) method or the like.
[0039] Over the base substrate 2 where the driving transistors 5 and the base dielectric film 6 are formed on the silicon substrate 4 , the ferroelectric capacitors 3 are formed on the base dielectric film 6 . Each of the ferroelectric capacitors 3 is composed of an oxygen barrier film 7 formed on the base dielectric film 6 , a lower electrode 8 formed on the oxygen barrier film 7 , a ferroelectric film 9 formed on the lower electrode 8 , an upper electrode 10 formed on the ferroelectric film 9 , and an electrode protection film 17 .
[0040] The oxygen barrier film 7 may be composed of, for example, TiAlN, TiAl, TiSiN, TiN, TaN, TaSiN or the like. Above all, TiAlN including titanium, aluminum and nitrogen is suitable, and the oxygen barrier film 7 is formed from TiAlN in the present example.
[0041] The lower electrode 8 and the upper electrode 10 may be formed from, for example, iridium (Ir), iridium oxide (Ir O x ), platinum (Pt), ruthenium (Ru), ruthenium oxide (RuO x ) or the like. In the present example, the lower electrode 8 and the upper electrode 10 are formed from iridium.
[0042] The ferroelectric film 9 is composed of material having a perovskite crystal structure, which may be expressed by a general formula, ABXO 3 . Concretely, the ferroelectric film 9 is composed of Pb (Zr, Ti)O 3 (PZT), (Pb, La) (Zr, Ti) O 3 (PLZT), or a ferroelectric material in which metal such as niobate (Nb) or the like is added to the foregoing material. In the present embodiment example, the ferroelectric film 9 is formed from PZT.
[0043] The electrode protection film 17 is composed of titanium oxide (TiOx) such as titania (TiO 2 ), and is formed into a thin film of 100 nm or less in thickness.
[0044] A bottom portion of the oxygen barrier film 7 is connected to a contact hole 11 formed in a manner to penetrate the base dielectric film 6 . With this structure, the lower electrode 8 on the oxygen barrier film 7 is conductively connected to a plug 12 formed in the contact hole 11 . The plug 12 is connected to one of the source and drain regions of the driving transistor 5 , whereby the ferroelectric capacitor 3 is operated by the driving transistor 5 , as described above. It is noted that the plug 12 embedded in the contact hole 11 is formed from tungsten (W) in the present example.
[0045] Also, a dielectric hydrogen barrier film 13 that covers the ferroelectric capacitors 3 is formed on the base dielectric film 6 . The hydrogen barrier film 13 exhibits a hydrogen barrier function, thereby protecting the ferroelectric film 9 whose electrical characteristics would likely be lowered, particularly, due to the reducing action of hydrogen. As the dielectric hydrogen barrier film 13 , aluminum oxide such as alumina (AlOx), titanium oxide such as titania (TiOx), zircon oxide such as zirconia (ZrOx) or the like is used, and in particular, alumina (AlOx) is preferably used. Accordingly, in the present example, the hydrogen barrier film 13 is composed of alumina (AlOx).
[0046] An interlayer dielectric film 14 is formed on the hydrogen barrier film 13 . The interlayer dielectric film 14 is formed from silicon oxide (SiO 2 ), like the base dielectric film 6 , and planarized by a CMP (chemical mechanical polishing) method or the like. Contact holes 15 , which penetrate the interlayer dielectric film 14 , further penetrate the hydrogen barrier film 13 and the electrode protection film 17 , and connect to the upper electrodes 10 , are formed in the interlayer dielectric film 14 , and plugs 16 are embedded in the contact holes 15 . The ferroelectric capacitors 3 having such a structure as described above are driven by the driving transistors 5 and conductive sections (not shown) connected to the plugs 16 , respectively. Further, a second interlayer dielectric film (not shown) that covers the conductive sections may be formed on the interlayer dielectric film 14 .
[0047] Next, a method for manufacturing a ferroelectric memory device in accordance with an embodiment of the invention is described based on the method for manufacturing the ferroelectric memory device 1 having the structure described above.
[0048] First, as shown in FIG. 2A , driving transistors 5 are formed in advance on a silicon substrate 4 by a known method. Then, a silicon oxide (SiO 2 ) film is formed by a CVD method or the like, and planarized by a CMP method, thereby forming a base dielectric film 6 .
[0049] Then, a resist pattern (not shown) is formed on the base dielectric film 6 by known resist technique and exposure and development technique, and etching is conducted by using the resist pattern as a mask, thereby forming contact holes 11 , as shown in FIG. 2B .
[0050] Then, tungsten (W) as a plug material is formed into a film by a sputter method or the like, whereby the tungsten is embedded in the contact holes 11 . Then, portion of the tungsten on the base dielectric film 6 is removed by a CMP method or the like, whereby plugs 12 composed of tungsten are embedded in the contact holes 11 . It is noted that, when forming the plugs 12 , prior to embedding tungsten, an adhesion layer composed of TiN (titanium nitride) or the like may preferably be formed in a thin film on inner wall surfaces of the contact holes 11 by a sputter method or the like, and then, tungsten is embedded in the contact holes 11 , as described above.
[0051] Then, for forming ferroelectric capacitors 3 on the base dielectric film 6 , first, a forming material of an oxygen barrier film 13 that covers upper surfaces of the plugs 12 is formed on the base dielectric film 6 . More concretely, a film of TiAlN is formed by a sputter method or the like, thereby forming an oxygen barrier layer 7 a , as shown in FIG. 2C . Then, a film of iridium that is a forming material of a lower electrode 8 is formed on the oxygen barrier layer 7 a by a sputter method or the like, thereby forming a lower electrode layer 8 a.
[0052] Then, a film of PZT that is a forming material of a ferroelectric film 9 is formed on the lower electrode layer 8 a by, for example, a sputter method, a spin-on method, a MOCVD method or the like, thereby forming a ferroelectric layer 9 a . Then, a film of iridium that is a forming material of an upper electrode 10 is formed on the ferroelectric layer 9 a by a sputter method or the like, thereby forming an upper electrode layer 10 a . In this manner, the oxygen barrier layer 7 a , the lower electrode layer 8 a , the ferroelectric layer 9 a and the upper electrode layer 10 a are laminated, whereby a laminated film substantially composing a ferroelectric capacitor layer 3 in accordance with the present embodiment can be obtained.
[0053] Then, as shown in FIG. 3A , a film of titanium oxide (TiOx such as TiO 2 ) is formed on the laminated film, in other words, on the upper electrode layer 10 a , thereby forming a titanium oxide layer 17 a to a thickness of, for example, about 50-100 nm. The titanium oxide layer 17 a functions as a mask pattern, after it is patterned to be described below, and becomes to be an electrode protection film 17 , as described above. Then, a second mask material is formed on the titanium oxide layer 17 a into a film that becomes to be a mask for patterning the titanium oxide layer 17 a , thereby forming a second mask material layer (not shown).
[0054] It is noted that, as the second mask material that forms the second mask material layer, silicon oxide (SiOx such as SiO 2 ) may preferably be used. As a method of forming the second mask material layer composed of silicon oxide (a silicon oxide layer), a chemical vapor deposition (CVD) method using tetraethoxysilane (TEOS) as a raw material is particularly suitable. Accordingly, in accordance with the present embodiment, the second mask material layer (a silicon oxide layer) is formed by a CVD method using TEOS as a raw material. Film formation of the silicon oxide layer (the second mask layer) by a CVD method using TEOS as a raw material is a relatively easy film forming method, and the obtained silicon oxide layer can be readily etched, and thus has good workability, such that a second mask pattern can be readily formed from the silicon oxide layer (the second mask material layer), as described below.
[0055] Then, a resist pattern (not shown) is formed on the second mask material layer by known resist technique and exposure and development technique, and the second mask material layer is etched by using the resist pattern as a mask, whereby a second mask pattern 18 is formed, as shown in FIG. 3B . It is noted that FIG. 3B shows a state in which, after the second mask pattern 18 has been formed, the resist pattern is removed by ashing or the like.
[0056] Then, the titanium oxide layer 17 a is etched by high-temperature etching, using the second mask pattern 18 as a mask, thereby forming a mask pattern 17 b , as shown in FIG. 3C , which becomes to be an electrode protection film 17 , as described above. The high-temperature etching may be conducted in a temperature range between 200° C. and 500° C. in accordance with the present embodiment of the invention, and may preferably be conducted in a temperature range between 350° C. and 450° C. More concretely, the base substrate 2 is set to a retaining section within an etching apparatus (a high-temperature etcher), the base substrate 2 is then heated in the temperature range described above, and etching is conducted. Etching gas may be pre-heated depending on the requirements, and then supplied in the etching apparatus. As the etching method, a reactive ion etching (RIE) method using a single gas of Cl 2 , BCl 3 , CF 4 , C 2 F 6 or C 4 F 8 , or a mixed gas of the aforementioned gas and Ar or He may preferably be used.
[0057] The temperature range in the high-temperature etching is set between 200° C. and 500° C., because titanium oxide such as titania (TiO 2 ) is hardly etched and therefore patterning thereof is substantially difficult at temperatures less than 200° C. However, if the temperature exceeds over 500° C., other components, such as, for example, the driving transistors 5 formed on the base substrate 2 may be thermally damaged, and their characteristics may be negatively affected. In order to prevent the problems described above more securely, and in order to conduct favorable etching without causing thermal damage on the other components, the temperature range is preferably set between 350° C. and 450° C.
[0058] After the mask pattern 17 b has been formed in a manner described above, the second mask pattern 18 used for forming the mask pattern 17 b is left as it is without being removed, and the mask pattern 18 and the mask pattern 17 b are left together as a laminated mask pattern 19 . Then, as shown in FIG. 4A , the laminated film is etched and patterned by using the laminated mask pattern 19 , thereby forming ferroelectric capacitors 3 . It is noted that, in particular, the second mask pattern 18 is removed by dry etching or the like, during or after the patterning. Also, the mask pattern 17 b remains on the upper electrode 10 , and becomes to be an electrode protection film 17 , as described above.
[0059] More concretely, in accordance with the present embodiment of the invention, in particular, when the upper electrode layer 10 a , the ferroelectric layer 9 a and the lower electrode 8 a among the laminated film are etched, the etching is stopped once. Then, only the second mask pattern 18 may be selectively removed, and etching is conducted again by using the remaining mask pattern 17 alone, to thereby form the ferroelectric capacitors 3 . In this case, for example, after the etching is stopped once, the base substrate 2 may be taken out of the etching apparatus (i.e., a high-temperature etcher) and placed in a dry etcher, where the second mask pattern 18 alone is selectively removed. Then, the base substrate 2 is returned to the high-temperature etcher, where etching is conducted again by using the remaining mask pattern 17 alone as a mask to pattern the oxygen barrier layer 7 a , thereby forming the ferroelectric capacitors 3 .
[0060] It is noted that, in particular, etching of the oxygen barrier layer 7 a may be conducted by high-temperature etching, like etching of the titanium oxide layer 17 a , such that the mask pattern 17 can be etched, concurrently with patterning (etching) of the oxygen barrier layer 7 a . In other words, through concurrently etching the mask pattern 17 in this manner, patterning of the oxygen barrier layer 7 a is completed, and when the ferroelectric capacitor 3 is obtained, the mask pattern 17 has been etched to a degree, whereby its film thickness is adjusted to a predetermined thickness. The adjustment of film thickness can be conducted through appropriately setting in advance the thicknesses of the oxygen barrier layer 7 a and the mask pattern 17 to specified values, etching conditions and the like based on experiments and the like.
[0061] In the case of etching that uses the laminated mask pattern 19 as a mask, the total thickness of the laminated mask pattern 19 would become smaller compared with a conventional mask pattern, as the mask pattern 17 composed of titanium oxide is particularly thin, which is about 50-100 nm. As a result, the aspect ratio becomes lower, and etching of the laminated film to the side of its bottom portion (the lower electrode layer 8 a ) can be favorably conducted. Further, in particular, as the oxygen barrier layer 7 a is also patterned by using the mask pattern 17 , the ferroelectric capacitors 3 can be favorably formed without conducting excessive over-etching.
[0062] When the ferroelectric capacitors 3 are formed through patterning in a manner described above, the ferroelectric film 9 is damaged by etching. Accordingly, to remove the damage and recover the characteristics, heat treatment is conducted in an oxygen atmosphere between about 300° C. and about 500° C., and more preferably about 350° C., in other words, so-called recovery annealing is conducted. Because the electrode protection film 17 composed of titanium oxide is provided on the upper electrodes 10 of the ferroelectric capacitors 3 , generation of hillocks at the surface of the upper electrodes 10 is suppressed by the electrode protection film 17 . In other words, even when metal atoms (for example, Ir) in the material composing the upper electrodes 10 diffuse at the time of the anneal treatment, the diffusing atoms remain within the electrode protection film 17 because the electrode protection film 17 is provided on the upper electrodes 10 , such that generation of hillocks can be prevented. Accordingly, the top surface of the ferroelectric capacitors 3 , in other words, the top surface of the electrode protection film 17 , becomes flat, without forming irregularities by hillocks.
[0063] Then, as shown in FIG. 4B , AlOx that covers the obtained ferroelectric capacitors 3 is deposited in a film by a sputter method, a CVD method or the like over the base dielectric film 6 , thereby forming a hydrogen barrier film 13 . As described above, the top surface of the electrode protection film 17 forms a flat surface. Therefore, by forming the hydrogen barrier film 13 thereon, the hydrogen barrier film 13 favorably covers the upper electrodes 10 , in other words, the electrode protection film 17 . Then, a film of silicon oxide (SiO 2 ) is formed on the formed hydrogen barrier film 13 by a CVD method or the like, and further planarized by a CMP method or the like, thereby forming an interlayer dielectric film 14 , as shown in FIG. 5A .
[0064] Next, a resist pattern (not shown) is formed on the interlayer dielectric film 14 by known resist technique and exposure and development technique, and the interlayer dielectric film 14 is etched by using the resist pattern as a mask, thereby forming contact holes 15 that connect to the upper electrodes 10 , as shown in FIG. 5B . In this instance, the hydrogen barrier film 13 is composed of AlOx that is a material difficult to be etched, compared with the interlayer dielectric film 14 that is composed of silicon oxide (SiO 2 ). Therefore, in order to penetrate the hydrogen barrier film 13 by etching, over-etching needs to be conducted with relatively excessive conditions compared to those for etching an apparent thickness.
[0065] In the past, the upper electrode 10 would be largely cut in part by such excessive over-etching, which resulted in deterioration of the characteristics of the ferroelectric capacitor. In contrast, in accordance with the present embodiment of the invention, because the electrode protection film 17 is provided on the upper electrode 10 , the upper electrode 10 is prevented from being largely cut in portion, and deterioration of characteristics of the ferroelectric capacitor 3 can be prevented. In other words, the electrode protection film 17 functions as an etching stopper layer, such that, even when etching is conducted with relatively excessive conditions compared to those that may be required for etching an apparent thickness, the etching is considerably slowed down, and the etching apparently almost stops at the electrode protection film 17 .
[0066] However, as described above, as the electrode protection film 17 is extremely thin, which is, for example, 50 nm-100 nm, it is eventually penetrated after a certain time elapses, though the etching is apparently almost stopping. Accordingly, the time required for the electrode protection film 17 to be penetrated may be obtained in advance by experiments or the like, and the etching time is accordingly controlled, so that etching is set to be finished at the time when the electrode protection film 17 is penetrated and the upper electrode 10 is exposed. It is noted that, as the etching advances considerably slowly at the electrode protection film 17 , a large margin can be taken for etching completion time, and therefore the control of etching time becomes easier.
[0067] Also, at the time of setting the etching time, if the etching time is adjusted such that the etching lasts for a long time after the upper electrode 10 is exposed, there is a possibility that the upper electrode 10 may be largely cut. Therefore, the etching time is preferably adjusted such that the etching is finished before the upper electrode 10 is completely exposed.
[0068] If the upper electrode 10 is not completely exposed in a manner described above, and a portion of the electrode protection film 17 therefore remains within the formed contact hole 15 , the contact hole 15 may preferably be cleansed by a cleansing treatment after forming the contact hole 15 . As the cleansing treatment, etching with Ar (reverse sputter with Ar) gas, which is generally conducted as a pretreatment prior to forming an adhesion layer, or a cleansing treatment by dry etching with another kind of gas may be conducted as it is for both purposes.
[0069] More specifically, after forming a contact hole, and before embedding a plug in the contact hole, an adhesion layer composed of TiN or the like is generally formed in advance. Before forming the adhesion layer, the cleansing treatment described above can be conducted, whereby a conduction section (the upper electrode 10 in this example) is sufficiently exposed within the contact hole. Accordingly, in accordance with the present embodiment, such a cleansing treatment can be conducted, whereby a portion of the electrode protection film 17 remaining within the contact hole 15 is securely removed, and the upper electrode 10 can be sufficiently exposed within the contact hole 15 .
[0070] After conducting the cleansing treatment in this manner, an adhesion layer (not shown) composed of TiN or the like is thinly formed on the inner wall surface of the contact holes 15 , and then, plugs 16 are embedded in the contact holes 15 , as shown in FIG. 1 . Further, conduction sections (not shown) such as wirings that are conductively connected to the plugs 16 are formed, and a second interlayer dielectric film (not shown) that covers the aforementioned layers and wirings is formed, whereby the ferroelectric memory device 1 in accordance with the present embodiment is obtained.
[0071] According to the method for manufacturing the ferroelectric memory device 1 , the ferroelectric capacitor 3 is formed with the electrode protection film 17 composed of titanium oxide provided on the upper electrode 10 . Therefore, when the ferroelectric capacitor 3 is subjected to an anneal treatment in an oxygen atmosphere, the electrode protection film 17 suppresses generation of hillocks on the surface of the upper electrode 10 . Accordingly, the top surface of the ferroelectric capacitor 3 , in other words, the top surface of the electrode protection film 17 has a flat surface without forming irregularities due to hillocks, such that, when the hydrogen barrier film 13 is formed thereon, the hydrogen barrier film 13 favorably covers the upper electrode 10 , in other words, the electrode protection film 17 . Therefore, deterioration of characteristics of the ferroelectric capacitor 3 , which may be caused by hydrogen or the like, can be securely prevented by the hydrogen barrier film 13 .
[0072] Also, because the electrode protection film 17 is provided on the upper electrode 10 , the electrode protection film 17 functions as an etching stopper layer, such that, even when excessive etching is conducted, the etching is considerably slowed down, and the etching apparently almost stops at the electrode protection film 17 , which facilitates the etching process. Accordingly, thereafter, etching for the electrode protection film 17 and cleansing of the inside of the contact hole 15 may be conducted if necessary, whereby the contact hole 15 can be formed without largely cutting the upper electrode 15 in part. Therefore, deterioration of characteristics of the ferroelectric capacitor 3 can be prevented.
[0073] Furthermore, the mask pattern 17 b composed of titanium oxide that is difficult to be etched and thus has large etching resistance is laminated with the second mask pattern 18 to form the laminated mask pattern 19 , and etching is conducted using the laminated mask pattern 19 to pattern the ferroelectric capacitor 3 . As a result, the aspect ratio of the masks at the time of forming the ferroelectric capacitor 3 can be made relatively low, and therefore the ferroelectric capacitor 3 can be favorably etched to the side of its bottom portion. As a consequence, the workability at the time of forming the ferroelectric capacitors 3 can be improved, and excessive over-etching can be made unnecessary, such that side wall surfaces of the ferroelectric capacitors 3 can be prevented from being roughened due to excessive over-etching, and the ferroelectric capacitors 3 with excellent ferroelectric characteristics can be formed.
[0074] Also, etching is conducted by using the laminated mask pattern 19 composed of the mask pattern 17 and the second mask pattern 18 as a mask, such that the burden on the mask pattern 17 b composed of titanium oxide is lessened and the film thickness thereof can be made smaller, and therefore etching for the titanium oxide layer that is difficult to be etched can be suppressed to a necessity minimum.
[0075] Also, in the ferroelectric memory device obtained in a manner described above, the hydrogen barrier film 13 favorably covers the top surface of the ferroelectric capacitor 3 , such that deterioration of characteristics of the ferroelectric capacitor 3 , which may be caused by hydrogen or the like, can be securely prevented by the hydrogen barrier film 13 . Furthermore, the contact hole 15 is formed without largely cutting the upper electrode 10 in part, such that deterioration of characteristics of the ferroelectric capacitor 3 can be prevented.
[0076] It is noted that the ferroelectric memory device 1 is applicable to various electronic devices, such as, for example, cellular phones, personal computers, liquid crystal devices, electronic notebooks, pagers, POS terminals, IC cards, mini-disc players, liquid crystal projectors, engineering workstations (EWS), word processors, televisions, view finder or monitor-direct viewing type video recorders, electronic desk-top calculators, car-navigation systems, devices equipped with touch-panels, clocks, gaming devices, and electrophoretic devices.
[0077] Also, the invention is not limited to the embodiments described above, and many changes can be made without departing from the subject matter of the invention. For example, in the embodiment described above, the laminated film is etched by using the laminated mask pattern 19 composed of the mask pattern 17 b and the second mask pattern 18 as a mask. However, the laminated film may be etched and patterned by using only the mask pattern 17 composed of titanium oxide as a mask.
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A method for manufacturing a ferroelectric capacitor includes the steps of: forming a ferroelectric capacitor having at least a lower electrode, a ferroelectric film and an upper electrode on a base substrate; and applying an anneal treatment to the ferroelectric capacitor in an oxygen atmosphere, wherein the step of forming the ferroelectric capacitor includes forming the ferroelectric capacitor to have a structure in which an electrode protection film composed of titanium oxide is provided on the upper electrode.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a carrier for door drives of lifts.
2. Discussion of the Prior Art
Carriers of the kind which are mounted on the roof of an elevator cage at the door side, serve for the reception of all important components for the door drive, such as, for example, translation gear, belt drive, motor bearer with drive motor, guide rails, etc. In general, in the case of door drives for elevators such as have become known by, for example, U.S. Pat. No. specification 4,149,615 or European patent specification 0, 513,509, the carriers are conceived on each occasion only for a specific door system. In the case of different door systems with different entrance widths, carriers of different lengths matched to the entrance widths are required for the aforesaid door drives, whereby warehousing is more costly and the door drives are more expensive.
SUMMARY OF THE INVENTION
The invention is based on the object of providing a carrier of the kind stated in the introduction, which does not have the above-mentioned disadvantages.
Pursuant to this object, and others which will become apparent hereafter, one aspect of the invention resides in a carrier having consists of a base part and a length adapter, which are connectable together in such a manner that carriers of different lengths can be produced.
The advantages achieved by the invention are to be seen in that one and the same carrier can be used for different door systems with different entrance widths (for example, 600 to 800 millimeters). With the carrier the drive components can be arranged in such a manner that it is possible to reach all important components from the storey. The carrier according to the invention has a geometric form which offers mechanical protection for the belt drive unit, whereby, in particular, a protection against objects, dirt, water, etc., falling down as well as against wanton destruction by elevators users is guaranteed. The carrier is adjustable not only horizontally, but also vertically, so that an adaptation to different cages and compensation for tolerances are possible. Costs can be saved by this carrier and warehousing simplified. The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of the disclosure. For a better understanding of the invention, its operating advantages, and specific objects attained by its use, reference should be had to the drawing and descriptive matter in which there are illustrated and described preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWING
The invention is more closely explained in the following by reference to an example of embodiment in conjunction with the drawings, in which:
FIG. 1 shows an elevation of the carrier according to the invention, with mounted door drive components;
FIG. 2 shows a partially sectioned side elevation of the carrier with door drive components, in a scale enlarged relative to FIG. 1;
FIG. 3 shows an elevation of a base part of the carrier;
FIG. 4 shows a cross-section of the base part according to FIG. 3;
FIG. 5 shows an elevation of a length adapter of the carrier; and
FIG. 6 shows a cross-section of the length adapter according to FIG. 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A cage roof is designated by 2 and the front side of an elevator cage 1 by 3 in FIG. 2 . Two C-section profile rails 4 , 5 , to which two support brackets 6 and 7 are fastened, are arranged on the cage roof 2 . The support brackets 6 , 7 are screw-connected with the C-section profile rails 4 , 5 by means of rotationally fast screws 8 , which are guided in the C-section profile rails, and nuts 9 . A carrier 10 , which consists of a base part 11 and a length adapter 12 and is more closely described in the following by reference to FIGS. 3 to 6 , is fastened to the support brackets 6 , 7 . The carrier 10 is screw-connected with the support, 7 merely by way of the base part 11 , whereas the length adapter 12 is connected with the base part 11 . The most important components of a door drive, by means of which a door, consisting of two door leaves 13 , 14 , of the elevator cage 1 can be opened and closed, are arranged at the carrier 10 . In FIGS. 1 and 2 these components fastened to the carrier 10 are illustrated merely by dotted lines and are briefly described in the following.
An electric motor 15 is screw-connected with the base part 11 of the carrier 10 by way of a motor bracket 16 and drives a belt pulley 18 by way of a belt 17 . The belt pulley 18 is rotatably mounted by means of ball bearings 19 . 1 on a pin 19 fastened to the base part 11 and connected rotationally fast with a toothed belt pulley 20 . A further toothed belt pulley 21 is rotatably mounted on the length adapter 12 , which is screw-connected with the base part 11 , and stands under the effect of a tensioning device, which is not illustrated, so that a toothed belt 22 guided over the toothed belt pulleys 20 and 21 always has a sufficient tension. Guide rails, 23 , 24 are screw-connected with the base part 11 by way of screws 25 and spacers 26 , are. Support rollers 29 are guided on the guide rails 23 , 24 and are rotatably arranged at guide carriages 27 , 28 by way of ball bearings 29 . The guide carriages 27 , 28 are firmly connected with the door leaves 13 , 14 by way of screw bolts 30 .
Door drives of the kind briefly described in the foregoing are known. Reference is therefore made to, for example, European reference EP-A 0 332 841 and EP-B 0 513 509 for further not-illustrated details such as, for example, the movement transmission from the toothed belt 22 to the guide carriages 27 or 28 or the entraining equipment for the cage door and the shaft door.
According to FIGS. 3 and 4, the base part 11 , which consists of, for example, sheet steel, of the carrier 10 has a substantially U-shaped cross-section. In order to better protect the belt drive unit, the one U limb 11 . 1 of the base part 11 is longer than the other U limb 11 . 2 . A prolongation 11 . 3 , which is bent over at right angles and rests on the front side 3 of the lift cage 1 (FIG. 2 ), is provided at the other U limb 11 . 2 . Two rows of first bores 35 and two rows of second bores 36 are provided in the base part 11 . Moreover, the base part 11 similarly has elongate holes 37 , square passages 38 and rectangular passages 39 arranged in rows. A shaped-out portion 11 . 5 of trapezium-shaped cross-section is provided in the region of a lower longitudinal edge 11 . 4 of the prolongation 11 . 3 . The trapezium-shaped shaped-out portion 11 . 5 has a row of threaded holes 40 , which are, for example, reinforced by means of drawn-through elements and are intended for the fastening of the guide rails 23 and 24 . The square passages 38 are provided for the axle of the electric motor 15 and a belt pulley arranged on the axle. The rectangular passages 39 serve as cutouts for an infrared incremental transmitter of the door drive control. The elongate holes 37 are intended for the fastening of the motor bracket 16 and a carrier plate for the door drive electronic unit. The bores 35 and 36 , elongate holes 37 , passages 38 and 39 and threaded holes 40 preferably have a predetermined constant spacing from one another. The most diverse variants of the arrangement of the most important components are possible by the multiplicity of the different holes or passages, so that an optimum adaptation to construction conditions can be achieved.
The length adapter made of, for example, sheet steel has, according to FIGS. 5 and 6, a U-shaped cross-section which is smaller than the U-shaped cross-section of the base part 11 . In order to better protect the belt drive unit, the one U limb 12 . 1 of the length adapter 12 is longer than the other U limb 12 . 2 , wherein the U limbs 12 . 1 and 12 . 2 of the length adapter 12 are approximately equal in length to the U limbs 11 . 1 and 11 . 2 of the base part 11 . Two rows of further bores 41 , which are congruent with the first bores 35 of the base part 11 , are provided in the length adapter 12 . The length adapter 12 is used with greater door widths, wherein it can be adjusted in steps corresponding to the predetermined hole spacings and can be screw-connected with the base part 11 . Rectangular passages, which are necessary for the mounting of the above-mentioned belt tensioning device, are designated by 42 . The invention is not limited by the embodiments described above which are presented as examples only but can be modified in various ways within the scope of protection defined by the appended patent claims.
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A carrier for the reception of all important components of a door drive. The carrier has a base part and a length adapter, which are connectible together in such a manner that carriers of different lengths can be produced so that the carrier can be used in different door systems with different entrance widths.
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REFERENCES CITED
[0001]
[0000]
U.S. Patent Documents
3,817,203
June 1974
Brauer
3,872,820
March 1975
Hess
3,874,322
April 1975
Brauer
4,490,917
January 1985
Pilling
5,297,500
March 1994
Wilson
5,315,953
May 1994
Mullarkey, Jr.
5,832,865
November 1998
Harmel
6,209,478
February 1999
Curtis
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a residential garage incorporating a vehicle parking alignment device that moves in a vertical fashion in conjunction with the opening or closing of a garage door.
[0004] 2. Description of Prior Art
[0005] The action of parking a vehicle inside a garage can be challenging, particularly if the garage is smaller than usual; the garage is also used for storage and available parking area is minimal; the vehicle to be parked is larger than normal; or the driver of the vehicle is relatively inexperienced (teenage driver).
[0006] The idea of utilizing some sort of positioning indicator inside a residential garage has been with us for many years, and many different solutions to assist in parking a vehicle in a garage have been developed. All have their relative benefits and detriments. Most are expensive to construct (complex designs), and some are relatively simple.
[0007] One type of indicator consists of an object that is suspended from a flexible element (cord) and attached to the garage ceiling in a fixed or non-retractable position. When the windshield of a vehicle touches the object, the vehicle is properly positioned in the garage.
[0008] One significant problem with this design is that the object suspended from the garage ceiling can hinder freedom of movement inside the garage when the vehicle is not present.
[0009] To overcome this drawback, the object is suspended in such a manner that it rises to the ceiling as the garage door is closed, and lowers to windshield height when the garage door is opened. This is currently achieved by attaching the flexible element (cord) and pendant to the garage door.
[0010] This design however presents another problem. In some garages, the optimal distance from the driver's line of sight in the vehicle to the garage ceiling is less than the linear distance through which the garage door moves (e.g. 80 inches of garage door linear movement versus 50 inches of optimal travel between a driver's line of sight and the garage ceiling). Therefore, it becomes necessary to compensate in some manner for the difference in travel between the garage door and the position alignment device movement.
[0011] As disclosed in U.S. Pat. No. 6,209,478, one way to compensate for the difference in the distances of travel is to utilize a retraction device with an adjustable diameter coiling mechanism powered in various ways by the garage door mechanical systems. This design is relatively expensive to manufacture and time-consuming to install due to its inherent complexity.
[0012] Another solution to compensate for the object and garage door travel distances was offered in U.S. Pat. No. 5,832,865 by making a part, or the entire flexible element (cord) elastic. One key disadvantage of this design would be that like all elongated, elastic devices, the code would lose its elasticity over time and will eventually break. This makes the approach unreliable, and possibly a safety hazard in that the resulting falling object could strike a person on the head or in the face.
[0013] Yet another approach as specified in U.S. Pat. Nos. 3,874,322 and 3,817,203 to compensate for the difference in the travel distances of the object and garage door describes the use of a reel having two portions of different diameter. Two cords are used with one of the cords attached to the garage door and to the larger diameter portion of the reel. One end of the second cord is attached to the object while the other end is attached to the smaller diameter portion of the reel. When the garage door closes, the travel that occurs by the cord attached to the garage door is used to pull on the larger diameter reel causing rotation of the reel. In turn, the other cord attached to the object is pulled onto and wound around the reel and causes the object to move up toward the garage ceiling. Likewise, when the garage door is opened, the cord attached to the garage door is no longer under tension, and the weight of the object allows the reel to reverse direction and the object to drop.
[0014] This arrangement is also expensive to manufacture, and difficult to install and is cost prohibitive due to its inherent complexity.
SUMMARY OF THE INVENTION
[0015] It is an object of the invention to provide a garage vehicle parking alignment device that allows complexity inherent in previous designs to be substantially reduced.
[0016] Another object of this invention is to provide a garage vehicle parking alignment device that is inexpensive to manufacture.
[0017] A further object of this invention is to provide a garage vehicle parking alignment device that is relatively easy to install, and at the same time possess the ability to quickly and easily compensate for the varying residential garage floor to ceiling heights.
[0018] A further object of this invention is to provide a garage vehicle parking alignment device that presents a pendant that incorporates rotational stability such that the pendant remains in a fixed rotational orientation throughout its linear, vertical travel.
[0019] Another object of this invention is to provide a garage vehicle parking alignment device that provides a means to easily adjust the longitudinal position of the pendant relative to the vehicle being parked so as to compensate for variable distances from the front of the vehicle (grill) to the windshield of various makes and model of vehicle.
[0020] An additional object of this invention is to provide a garage vehicle parking alignment device that is reliable.
[0021] Another object of this invention is to provide a garage vehicle parking alignment device that poses no safety hazard to people in the vicinity of the device.
[0022] The preceding objects, as well as others that will become apparent as the description progresses—are achieved by the invention.
[0023] One aspect of the invention is located in a garage incorporating a garage door that is movable between a closed and open position. The garage further includes the means for indicating a vehicle parking position after the garage door travels to an open position. The indicating means includes an elongated flexible element attached at one end to a pendant and at the other end to the top of the garage door, or to the garage door linear movement means.
[0024] Another aspect of the invention resides in a method of operating a garage door. The method includes the steps of moving the garage door from a closed position to an open position utilizing moving means, and providing an indication of vehicle position in response to the moving step. The method further includes the steps of returning the garage door to the closed position by way of the moving means, and subsequent return of the vehicle positioning pendant toward the garage ceiling facilitating full, unobstructed use of the garage.
[0025] Another aspect of the invention resides in a method of suspending a low mass pendant from the garage ceiling utilizing lightweight, stationary or pivotal hooks (threaded or adhesive backed tape) to facilitate ease of installation and adjustment in conjunction with a readily available, lightweight, high strength, low friction, small diameter flexible element.
[0026] Another aspect of the invention resides in the method of routing and attaching the cord to the pendant so as to provide a fixed rotational position of the pendant relative to the vehicle driver.
[0027] Another aspect of the invention resides in the method of routing and attaching the pendant cord to the ceiling guides and through the pendant so as to achieve a pendant linear, vertical travel distance reduction ratio that is approximately one-half that of the horizontal movement of the garage door (garage door moves 2 inches, pendant moves 1 inch).
[0028] Additional features and advantages of the invention will be forthcoming from the following detailed description of preferred embodiments when read in turn with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIGS. 1 a and 1 b are schematic sectional side views of a garage illustrating the principle of operation of the vehicle parking alignment device according to the invention.
[0030] FIGS. 2 a , 2 b and 2 c are plan views of examples of various styles of guides (non-exclusive) for the flexible element that constitutes part of the vehicle parking alignment device as shown in FIGS. 1 a and 1 b.
[0031] FIG. 3 is a schematic sectional view of a garage illustrating one embodiment of a vehicle parking alignment device in accordance with the invention.
[0032] FIG. 4 is a plan view of the guide attachments for the flexible element and flexible element routing through the guides and pendant that constitute part of the vehicle parking alignment device as shown in FIGS. 1 a and 1 b.
[0033] FIGS. 5 a , 5 b and 5 c are plan and isometric views of various non-exclusive styles of pendants 16 that could be used to provide the desired functional and aesthetic characteristics for this part of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] FIG. 1 a schematically illustrates the principle of operation of a vehicle parking alignment arrangement in accordance with the invention. In FIG. 1 a , the numeral 10 identifies a residential garage. The garage 10 , which has a floor 11 and a ceiling 12 , defines a space 15 serving as a parking area for a motor vehicle 14 and as an auxiliary storage area. The motor vehicle 14 enters and leaves the garage 10 through an entrance and exit opening which can be opened and closed by a conventional garage door 13 . The garage door 13 is movable between a lowered or closed position and a raised or open position by a non-illustrated automatic garage door opener or moving means. In FIG. 1 a the garage door 20 is in a normal closed position. In FIG. 1 b the garage door 13 is in a normal open position, which allows ingress and egress of the motor vehicle 14 .
[0035] A pendant which constitutes a vehicle parking alignment indicator is shown here as a typical pliable, round object 16 such as a ball. The pendant is suspended by a cord or flexible element 18 , one end of which is attached to the ceiling 12 by a guide 17 and subsequently passes through the pendant 16 and returns to and passes over a second ceiling guide 17 and then on to the garage door 13 and attached at the top of the garage door 13 . When the garage door 13 is closed as in FIG. 1 a , the pendant 16 is raised to a position toward the garage ceiling 12 . When the garage door 13 is fully closed, the pendant 16 stops at a resting position at an approximate height of 80 to 100 inches above the garage floor 11 .
[0036] During normal operation, the garage door 13 is opened when a motor vehicle 14 is to be parked in the garage 10 . As the garage door 13 is opened, the pendant 16 falls to a lowered position shown in FIG. 1 b . When the garage door 13 is fully opened, the pendant 16 will stop and come to rest at its lowest position at an approximate height somewhere near the driver's line of sight at the height of the motor vehicle 14 windshield.
[0037] The motor vehicle 14 subsequently enters the garage 10 and moves forward until the windshield touches the pendant 16 . This is illustrated in FIG. 1 b and shows that at this point, the motor vehicle 14 is properly aligned in the garage 10 and is stopped. The garage door 13 is subsequently activated to close and, as the garage door 13 closes, the pendant 16 returns to its fully raised position.
[0038] In FIGS. 2 a , 2 b and 2 c , several variations of cord guide 17 are depicted. FIG. 2 a shows a typical utility hook guide 17 that is comprised of a threaded shank 17 a and hook shaped appendage 17 b and opening 17 c . FIG. 2 b shows another style of utility hook that can be fixed to object utilizing an adhesive backed tape 17 e permanently attached to the body of the hook 17 d . The hook body 17 d can be either plastic metal, and in some cases pivotal 17 f rather than fixed. FIG. 2 c shows yet another style of guide 17 , this time a screw eye design with a treaded shank 17 a and a circular head 17 b that defines an opening 17 c for the cord 18 to pass through.
[0039] Virtually any type of guide 17 can be used so long as it provides a passage over which or through the cord 18 may pass and a means to permanently affix to the garage ceiling 12 and the top of the garage door 13 .
[0040] In FIG. 3 , it is illustrated that the cord 18 is attached at one end to a guide 17 which is fixed to the garage ceiling 12 , and is subsequently routed down to the pendant 16 at which point it passes through a cylindrically shaped passageway 19 through the pendant 16 (entry and exit holes through the pendant 16 one or more inches apart) and back up to another guide 17 fixed to the garage ceiling 12 . The cord 18 then passes over the hook shaped guide 17 and travels along the garage ceiling down to the top of the garage door 13 where the other end of the cord 18 is attached to yet one more guide 17 fixed to the top of the garage door 13 .
[0041] FIG. 4 depicts the routing of the cord 18 from a guide 17 attached to the garage ceiling 12 , then down to the pendant 16 , then passing through the pendant 16 via a hollow channel and tubular insert 19 , and back up to another guide 17 attached to the garage ceiling 12 and on to a final attachment guide 17 positioned on the top of the garage door 13 (not shown in FIG. 4 , refer to FIG. 1 b ).
[0042] Alternately, the two cord guides 17 attached to the garage ceiling 12 could be movable and attached to a track mounted to the garage ceiling 12 allowing for easy adjustment of the guides 17 to compensate for the positioning of various makes and models of motor vehicle.
[0043] Additionally, and again referring to FIG. 4 , the pendant 16 style can be variable in that different shapes and materials of construction could be used so long as the weight of the pendant 16 remains relatively, lightweight and within a range of one to eight ounces. Various other means could be used to achieve the desired two attachment points on the pendant 16 so as to maintain a rotational fixed position. For instance, if the pendant 16 were to be manufactured from a moldable plastic, the two attachment points could be an integral part or component of the pendant 16 . Another possible method for achieving a minimum of two attachment points on the pendant 16 could be to add mechanical hardware after fabrication of the pendant 16 , such as screw eye hooks. The distance between the two or more attachment points on the pendant 16 can be variable, but sufficient to provide the desired rotational stability of the pendant (fixed rotational position).
[0044] FIGS. 5 a , 5 b and 5 c depict several variations of a pendant 16 that can be employed to serve as a visual aid to the driver to determine when the motor vehicle 14 is properly aligned in the optimal parking position. FIG. 5 a shows a plastic wiffle ball that contains many small diameter holes in the hollow structure allowing an entry and exit pathway for the cord 18 to pass through. FIG. 5 b shows another type of spherically shaped pendant 16 suitable for silk-screening a graphic 20 . The pendant 16 can be manufactured from metal, plastic, wood, solid, hollow, rigid, pliable or compressible material—so long as it is reasonably lightweight and provides a suitable surface for silk-screening or embossing a desired graphic 20 . FIG. 5 c shows yet another style of pendant 16 that is “tee” shaped and includes a means for the cord 18 to pass through the top. The construction can be virtually any material and any geometric shape, so long as it remains reasonably lightweight and presents a surface that can accept a graphic 20 by application of a decal, silk-screening, embossing or other means.
[0045] The pendant 16 suspended from the cord 18 may have any shape and may be made of any of a variety of natural or man-made materials. Preferably, the outside layer of the pendant 16 is soft so as to prevent any inadvertent damage to a motor vehicle 14 or injury to people. It may also be desirable for the outside layer of the pendant 16 to be suitable for acceptance of a graphic 20 that can be applied by a decal, painting, printing, or embossing. This will allow the pendant to be colored and/or to be provided with text, logos, graphic designs to provide a means for business advertising, or to make the pendant 16 more aesthetically pleasing to the consumer.
[0046] The pendant 16 can be designed to glow in the dark or may incorporate a means to provide one or more steady or flashing lights of the same of different colors, activated either remotely, or through a motion or impact detection means, among others.
[0047] The pendant 16 could include a sound generation capability activated in a similar manner as described above for lights.
[0048] The cord 18 can be made from a variety of flexible natural or synthetic materials including metal and plastic, such as 10 to 20 pound test nylon fishing line. The cord 18 could be single or multiple-strand, smooth or textured construction. The cord 18 could also employ a means to glow in the dark.
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A residential garage can be either attached or detached from a residence and normally includes a paneled, roll-up door that can be opened and closed either manually or via mechanical means utilizing a motor and drive system. A pendant (soft target) suspended from a cord is movable in a vertical direction from a raised position (garage door closed) to a lowered position (garage door open) via direct linkage and travel reduction of the cord to the top of the garage door, suspended from the garage ceiling with guides. When the garage door is raised and the pendant is lowered, a driver in a vehicle can park in the garage utilizing the pendant to properly and precisely align the vehicle inside the garage by stopping the vehicle at the point when the vehicle windshield first contacts the pendant.
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FIELD OF THE INVENTION
The present invention relates to a cylinder head gasket for an internal combustion engine. More particularly, the invention relates to cylinder head gasket having a self-energizing combustion seal flange.
BACKGROUND OF THE INVENTION
Gaskets 10 are often used to provide a seal between an engine block 12 and a cylinder head 14 of an internal combustion engine. As shown in FIGS. 1-3, known cylinder head gaskets 10 typically include a flange 16 that extends around the periphery 18 of cylinder bores formed in the gasket 10 to provide a combustion seal for maintaining the high temperature gases of combustion within the cylinder bores. A typical combustion flange 16 has a generally semicircular cross-sectional shape with the outmost portion 20 of the flange 16 extending away from the periphery 18 and into the combustion bore.
Referring to FIGS. 1 and 2, during operation of the engine, combustion explosion forces (represented by arrows A) act upon the flange 16 . As can be seen in FIG. 3, the combustion forces A C try to pass between the overlap of the flange 16 and the cylinder head 14 and heel of the flange 16 and the engine block 12 . The tangential forces A T acting on the flange 16 pushes ends 22 of the flange 16 downward and way from the engine block 12 and cylinder head 14 , thereby reducing sealing and promoting combustion leaks between the flange 16 and the hardware 12 and 14 . Accordingly, more durable combustion seals are required to reduce the opportunity for combustion leaks and increase flange life.
SUMMARY OF THE INVENTION
The present invention provides a gasket having a core and a self-energizing seal flange. The core includes at least one gasket plate, wherein the plate has at least first apertures for mating with cylinder bores of an engine block.
In accordance with the invention, the self-energizing seal flange has a generally convex center face that directly addresses a flame front of a combustion bore opening in an otherwise generally concave combustion flange cross-sectional profile. Such a design produces a generally flatter medial profile or face to address the flame front of the combustion zone, thereby minimizing deleterious tangential forces that operate to create gasket leaks and to shorten the life of the flange.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and inventive aspects of the present invention will become more apparent upon reading the following detailed description, claims, and drawings, of which the following is a brief description:
FIGS. 1-3 are cross-sectional views of a prior art gasket.
FIG. 4 is a partial planar view of a gasket in accordance with the present invention.
FIG. 5 is a cross-sectional view of an embodiment of the present invention positioned between mating components taken along line 5 — 5 of FIG. 4 shown with combustion explosion forces acting upon a combustion seal flange.
FIG. 6 is a cross-sectional view of the embodiment of FIG. 5 with the combustion explosion forces broken down into its respective tangential and normal components.
FIG. 7 is another cross-sectional view of the embodiment of FIG. 5 illustrating the effect of normal forces exerted on the combustion seal flange.
FIG. 8 is a cross-sectional view of the embodiment of FIG. 5 in an unloaded condition.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 4-7 illustrate a gasket 100 that is adapted to be positioned between an engine block 102 and a cylinder head 104 of a combustion engine. Gasket 100 has a plurality of bolt holes 106 and first apertures 108 that are adapted to mate with cylinder bores of engine block 102 . Gasket 100 may also provided with second apertures (not shown) that serve as fluid flow openings for engine coolant and the like. Gasket 100 is constructed so as to provide at least one combustion seal around the periphery 110 of each first aperture 108 .
Referring to FIGS. 5-7, gasket 100 includes a core 112 that has at least one gasket plate and a combustion seal flange 114 . Core 110 may be constructed of any suitable material, but is preferably constructed of metal. Combustion seal flange 114 is preferable constructed of metal to resist the high temperatures of combustion gases passing through combustion bores 108 .
In accordance with one aspect of the invention, flange 114 includes a head leg 116 and a block leg 118 . Head leg 116 and block leg 118 are connected together by a bridge segment 120 that extends around periphery 110 of combustion bore opening 108 . Bridge segment 120 has a generally concave cross-sectional profile face. However, unlike known gasket flanges, bridge segment 120 further includes at least one slightly inwardly extending portion that forms a shallow and generally convex-shaped valley 122 between adjacent peaks 124 or a generally flatter profile face than the rounded profile faces of the prior art.
In the preferred embodiment, bridge segment 120 includes only one valley 122 . It is also preferred that valley 122 is positioned at approximately the center of bridge segment 120 . Referring to FIG. 8, in one preferred embodiment, valley 122 has a radius R in the range of about 0.40-0.80 inches and the distance D from an outermost profile face 126 of peaks 124 to the outermost profile face 128 of valley 122 is within the range of about 0.000-0.010 inches.
Referring to FIGS. 5-7, the operation of gasket 100 will be explained in greater detail. As can be seen in FIG. 5, during operation of a combustion engine, combustion explosion forces C F act upon the outer profile face 130 of flange 114 . The combustion explosion forces C F , are shown broken down into their respective tangential components F CT and normal components F CN in FIG. 6 . Due to the inclusion of valley 122 , most of the combustion forces C F are transferred into valley 122 , rather than the corners formed between the cylinder head 104 and flange 114 and the engine block 102 and flange 114 .
Referring to FIG. 7, in accordance with the invention, the normal force component F CN acts perpendicularly to the outer profile face 130 of flange 114 , causing head and block legs 116 , 118 to push against cylinder head 104 and engine block 102 , respectively. Thus, the normal force component F CN contributes to increase the pressure of flange 114 against head and block legs 116 , 118 to reduce the opportunity for combustion leaks, and to increase flange life.
Preferred embodiments of the present invention have been disclosed. A person of ordinary skill in the art would realize, however, that certain modifications would come within the teachings of this invention. Therefore, the following claims should be studied to determine the true scope and content of the invention.
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An improved combustion gasket is disclosed incorporating a self-energizing combustion seal flange. The flange includes at least one valley that serves to redistribute combustion explosion forces acted upon the gasket during operation of the engine to provide improved combustion sealing and to extend flange life.
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[0001] This application is a continuation-in-part of and claims the benefit of priority from PCT application PCT/EP2011/057002 filed May 3, 2011 and German Patent Application DE 10 2010 019 696.7 filed May 7, 2010, the disclosure of each is hereby incorporated by reference in its entirety.
[0002] The present invention relates to a process for melt-spinning, drawing and winding multiple synthetic threads and to an apparatus for carrying out the process.
BACKGROUND
[0003] In the production of synthetic threads in a melt-spinning process, it is usual that in a spinning position side by side, a plurality of threads are extruded, cooled, drawn and wound in parallel to bobbins. After extrusion, the threads are led as a sheet of strands and collectively drawn by godets and collectively wound in multiple winding stations on bobbins. In order to be able to simultaneously pull off the plurality of threads by a godet from the spinnerets, it is also usual to guide the threads in a first transition section to a smaller distance from each other. During the extrusion and the cooling stages, the spinnerets are kept spaced with respect to each other so that the threads are guided within a vertical spinning section at a spinning distance near each other. The collective guidance of the threads on the godets requires a smaller distance godets so that the transition section between the spinning apparatus and the drawing apparatus is used for merging the threads. For this purpose, it is necessary to deflect in particular the threads in the outer regions of the sheet of strands. In addition, there thus result different pull-off ratios of the threads during the extrusion of the thread strands at the spinnerets.
[0004] Such a method and such an apparatus are known, for example, from EP 0 845 550 A1. In this method and apparatus, after drawing and before winding up, the threads are guided through individually driven delivery apparatuses in order to be able to compensate for the differences in tension arising from the different deflection of individual threads before winding up the threads. It is true that a homogenization of differences in tension caused by multiple deflections in the threads of the sheet of strands can be achieved. However, the different thread guiding paths occurring already before and during the drawing remain here ignored and directly affect the individual threads during the drawing of the threads.
[0005] Such disadvantages in the production of multiple synthetic threads parallel side by side can be entirely avoided only if every single thread is separately and independently pulled off, drawn and wound to bobbins. Such a method and such an apparatus are known, for example, from DE 102 36 826 A1. In this method and apparatus, a separate drawing apparatus is provided for each thread, which interacts with a winding apparatus. This permits substantially straight thread runs between the spinning apparatus and the drawing apparatus. However, such methods and apparatuses require much more space, because all devices for pulling-off, drawing, treatment and winding of threads must be present in multiple numbers. To this extent, these methods and apparatuses are preferably used for the production of composite fibers, in which each of the generated partial threads must have the same properties.
[0006] New developments, such as for example those known from DE 10 2009 021 131 A1, are based on an arrangement in which the drawing device is arranged laterally adjacent to the spinning device, wherein between the spinneret and the drawing device deflecting rollers are arranged for each thread. This allows larger deflections in the transition region between the drawing device and the spinning device to be avoided. However, the free thread route between the drawing device and the spinnerets is formed differently in length for each thread. In that regard, differences can also be expected in this method.
SUMMARY
[0007] The technical task of the invention is to propose a method for melt-spinning, drawing and winding multiple synthetic threads and to provide an apparatus for performing the method of the generic type, in which the threads can be produced with as high homogeneity as possible.
[0008] This technical task is inventively achieved by a method such that after extrusion and before the collective drawing the threads can be pulled off each other independently by separate individual godets.
[0009] In the apparatus, this technical task is solved by providing a plurality of juxtaposed individual godets arranged upstream of the drawing device, wherein each individual godet is associated with one of the threads and are formed to be individually drivable for the withdrawal of the respective threads.
[0010] Advantageous developments of the invention are defined by the features and combinations of features of the respective claims.
[0011] The invention is based on the insight that during the extrusion, cooling and drawing, the processes relevant for the determination of the physical properties of the threads occur on the basis of solidifying the amorphous molecular structure and the crystallization. The molecular structure formed in the threads during the drawing thus represents the essential foundation for achieving the desired effects during further treatment. According to the present invention, each thread is associated with an individual godet that determines the respective pull-off of the thread from the spinneret. As a result, each of the threads can be pulled and fed to collective drawing with essentially identical properties, regardless of the number of threads produced per spinning position.
[0012] For this purpose, it is preferred that the threads are pulled off at the individual godets in a straight thread run with equal speeds. This allows high and uniform throughput of the spinnerets to be achieved.
[0013] For the production of threads with larger titers, it has been found that it is effective if the threads are guided on the periphery of each individual godet in multiple wraps. This results in higher extraction forces at each of the individual threads.
[0014] In order for the subsequent treatments of the thread to be performed for all the threads collectively, it is further provided that after being pulled off, the threads are brought together to form a sheet of strands, and that the sheet of strands are drawn by being guided over several godets that are arranged one after the other. Thus a collective drawing of the threads is possible.
[0015] A safe guiding of the threads is required in order to be able to maintain the lowest possible spacing between the individual threads of the sheet of strands. This is achieved by driving the first drawing godet at a peripheral speed that is equal to or greater than the pull-off speed of the individual godet. Preferably a weak drawing is set between the pull-off godets and the drawing godet. Depending on the type of thread and the process, the threads can be tempered directly at the individual godets.
[0016] The inventive method and the apparatus of the invention are particularly suitable for such threads where after the melting-spinning process they are fed directly to a final processing. Optionally, the threads can be crimped in parallel after the drawing and before the winding the threads. Such crimped threads can be advantageously used as carpet threads.
[0017] For realizing a straight thread path during the pull-off of the threads, the inventive apparatus is preferably designed such that the individual godets are associated with the spinnerets at a distance and centered. This allows each thread to be pulled off with high uniformity and, in particular, the filament strands that form the thread from the spinneret have high uniformity.
[0018] To generate higher pull-off forces, overtravel rollers are associated with a respective individual godet to guide the relevant threads. Thus, each of the threads can be led at the individual godet with a multiple wrap.
[0019] Depending on the method and the type of thread, a first tempering of the thread is already made possible in that each of the individual godets comprise a heatable godet shell. Especially with the multiple wraps, preparatory drawing warming can thus be supplied into the thread.
[0020] In order to obtain a low profile of the overall apparatus, on the one hand, and small displacements, on the other hand, according to a particularly advantageous embodiment of the invented apparatus, a first drawing godet of the drawing device is arranged laterally adjacent with or downstream from the series of the individual godets. The inlet of the first drawing godet is associated with the outlet of a multiple thread guide. Thus, the threads can be fed to the drawing godet together as one sheet of strands with a narrow treatment distance from each other.
[0021] The inventive apparatus may also include a crimping device between the drawing device and the winding device. The crimping device has a plurality of texturing means for collectively crimping the threads. This advantageously produces carpet threads that can be directly introduced to a finishing process.
[0022] The inventive method and the inventive apparatus are explained below in more detail with reference to some embodiments shown in the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 schematically shows a front view of a first embodiment of the inventive apparatus for carrying out the method.
[0024] FIG. 2 is a schematic side view of the embodiment of FIG. 1 .
[0025] FIG. 3 schematically shows a plan view of another embodiment the inventive apparatus.
[0026] FIG. 4 is a schematic side view of the embodiment of FIG. 3 .
DETAILED DESCRIPTION
[0027] FIGS. 1 and 2 schematically show in several views a first embodiment of the invention apparatus for carrying out the inventive method. FIG. 1 represents the exemplary embodiment schematically in a front view, and FIG. 2 is a schematic side view. Unless an explicit reference to one of the figures is made, the following description applies to both figures.
[0028] The embodiment shown in FIGS. 1 and 2 has a spinning unit 1 with a total of three adjacent spinnerets 4 . 1 , 4 . 2 , and 4 . 3 . The number of spinnerets in the spinning unit 1 is just by way of example, and can also be significantly higher per spinning position than three threads. The spinnerets 4 . 1 , 4 . 2 , and 4 . 3 are held at the bottom of a heated spinning beam 3 . The spinning beam 3 contains further melt leading parts, not shown here, to feed the thermoplastic melt of a melt source that is supplied through an inlet 2 to the 5 spinnerets 4 . 1 to 4 . 3 . In that regard, at least one or several spinning pumps and distribution lines are disposed in the spinning beam 3 . The spinnerets 4 . 1 to 4 . 3 comprise at their lower sides a plurality of nozzle openings, from which a plurality of strand-like threads is extruded.
[0029] Below the spinning beam 3 is arranged a cooling device 6 that extends with a cooling shaft 7 directly below the spinnerets 4 . 1 to 4 . 3 . The cooling device 6 in this embodiment is designed as cross-flow quenching, in which a cooling air flow is produced by means of a laterally disposed puffer chamber 8 and is directed to the filament strands of the threads 5 . 1 , 5 . 2 , and 5 . 3 .
[0030] To merge the plurality of threads generated per spinneret 4 . 1 to 4 . 3 to a respective thread, a collecting thread guide 9 . 1 , 9 . 2 and 9 . 3 as well as a preparation device 10 . 1 , 10 . 2 and 10 . 3 are arranged in each case at a distance underneath the spinnerets 4 . 1 , 4 . 2 , and 4 . 3 . The collecting thread guides 9 . 1 , 9 . 2 , and 9 . 3 are each held in the middle of the spinnerets 4 . 1 , 4 . 2 , and 4 . 3 . Thus, the collecting thread guide 9 . 1 is held in the middle of spinneret 4 . 1 .
[0031] At this point, it should be specifically noted that the preparation devices 10 . 1 , 10 . 2 , and 10 . 3 as well as the collecting thread guides 9 . 1 , 9 . 2 , and 9 . 3 can also be advantageously combined so that the merging of the filament strands and the preparation of the filament strands is carried out, for example, by a pin oiler.
[0032] In the further course of the thread, each of the spinnerets 4 . 1 , 4 . 2 , and 4 . 3 is associated with one of several individual godets 11 . 1 , 11 . 2 , and 11 . 3 , which in this exemplary embodiment are each combined with an overtravel roller 12 . 1 , 12 . 2 , and 12 . 3 . The individual godets 11 . 1 , 11 . 2 , and 11 . 3 are spaced essentially centrally to the upstream spinnerets 4 . 1 , 4 . 2 , and 4 . 3 . Thus, the threads 5 . 1 , 5 . 2 , and 5 . 3 can be pulled-off from the spinnerets 4 . 1 , 4 . 2 and 4 . 3 respectively vertically in a straight thread run through the individual godets 11 . 1 , 11 . 2 , and 11 . 3 . Thus the individual godet 11 . 1 is associated with the spinneret 4 . 1 , which extrudes the filament strands for the thread 5 . 1 .
[0033] As is apparent from FIG. 2 , the individual godets 11 . 1 to 11 . 3 and the overtravel rollers 12 . 1 to 12 . 3 are supported on a machine frame 25 in a protruding design, wherein each individual godet 11 . 1 to 11 . 3 is associated with a drive 23 . The drives 23 (in FIG. 2 only one of the drives is shown) independently drive the individual godets 11 . 1 , 11 . 2 , and 11 . 3 . The drives 23 can be controlled both by individual control units and by a common control device.
[0034] As is apparent from the illustration in FIG. 1 , the individual godets 11 . 1 to 11 . 3 are arranged in a row next to each other. In the further course of the threads, a first drawing godet 14 . 1 of a drawing device 13 is arranged laterally adjacent to or downstream from the godet 11 . 3 . Between the drawing godet 14 . 1 and the individual godet 11 . 3 is arranged a multiple thread guide 15 , which merges the threads running from the individual godets 11 . 1 to 11 . 3 into a sheet of strands 29 . Within the sheet of strands 29 , the threads 5 . 1 to 5 . 3 have an essentially short treatment distance from each other.
[0035] The drawing device 13 comprises multiple drawing godets 14 . 1 to 14 . 4 for collective drawing of the threads 5 . 1 to 5 . 3 , wherein each of two godets 14 . 1 and 14 . 2 and 14 . 3 and 14 . 4 constitute a godet duo, on which the threads are guided in multiple wrap. The drawing godets 14 . 3 and 14 . 4 are driven at a higher peripheral speed compared to the godets 14 . 1 and 14 . 2 so that the threads are drawn between the godets 14 . 2 and 14 . 3 . For this purpose, each godet 14 . 1 to 14 . 4 is associated with a separate drive. FIG. 2 only shows drives 24 . 1 and 24 . 2 of the first two godets 14 . 1 and 14 . 2 . The drawing godets 14 . 1 to 14 . 4 are preferably equipped with heated godet shells.
[0036] Underneath the drawing device 13 is arranged a winding device 17 that has a plurality of winding stations 18 . 1 , 18 . 2 and 18 . 3 . In each of the winding stations 18 . 1 , 18 . 2 and 18 . 3 , the threads 5 . 1 , 5 . 2 , and 5 . 3 guided as a sheet of strands are wound, side by side in parallel, to bobbins 21 . 1 , 21 . 2 , and 21 . 3 . For this purpose, the winding device 17 has two winding spindles 19 . 1 and 19 . 2 , where in turns the bobbins 21 . 1 , 21 . 2 and 21 . 3 are wound. The winding spindles 19 . 1 and 19 . 2 are arranged on a winding turret 20 as a cantilever, which pivots the winding spindles alternately between an operating region and an exchange region to allow continuous winding.
[0037] The feeding of the sheet of strands 29 to the winding apparatus 17 occurs over a guide roller 16 , which is arranged downstream of the drawing device 13 .
[0038] In the example embodiment shown in FIGS. 1 and 2 , the threads 5 . 1 to 5 . 3 extruded by the spinnerets 4 . 1 to 4 . 3 are pulled off, in each case individually and separately, by the driven individual godets 11 . 1 to 11 . 3 . In this process, the same pull-off speed can be set on each of the threads 5 . 1 to 5 . 2 so that each of the threads of 5 . 1 to 5 . 3 can be extruded, then cooled and pulled off under the same conditions. Only then are the threads 5 . 1 to 5 . 3 combined together into a sheet of strands 29 in order to be collectively drawn in the drawing device 13 and subsequently wound together by the winding apparatus 17 to bobbins. In addition to the constant pull-off conditions, the multiple wrap on the godets, any larger deflections and spreading of the sheet of strands are avoided. To this extent, greater number of threads can thus be advantageously produced with a collective treatment with essentially the same physical characteristics.
[0039] In this respect, the inventive method and the inventive apparatus are particularly advantageous for producing high-quality threads in a melt spinning process, which can be directly used in subsequent processing. Thus, FIGS. 3 and 4 show another preferred embodiment of the invention, in which, after the drawing of the threads, a crimp is generated at the threads. The exemplary embodiment shown in FIGS. 3 and 4 is essentially identical to the aforementioned embodiment so that at this point, only the differences will be explained, and otherwise reference is made to the above description.
[0040] In the example embodiment shown in FIGS. 3 and 4 , a crimping device 26 is arranged between the drawing device 13 and the winding device 17 . The crimping device 26 comprises a plurality of texturing means 27 to texture the drawn threads 5 . 1 to 5 . 3 in parallel side by side as a sheet of strands. The texturing means 27 can be, for example, texturing nozzles that consist of a delivery nozzle and a stuffer box. Thereby each of the threads 5 . 1 to 5 . 3 is reshaped to a thread plug 30 . 1 to 30 . 3 . Such crimping devices are well known so that at this point no further explanation is needed. The crimping device 26 comprises a cooling roller 28 , on whose periphery are provided three thread guide tracks for receiving the thread 30 . 1 to 30 . 3 . At the periphery of the cooling roller 28 , the thread plugs 30 . 1 to 30 . 3 are cooled. The cooling roller 28 is driven by a roller drive 33 .
[0041] As is further apparent from the illustration in FIG. 3 , after crimping, the thread plugs 30 . 1 to 30 . 2 are dissolved into the threads 5 . 1 to 5 . 3 and collectively pulled by a pull-off godet 31 . 1 off the cooling roller 28 . Downstream the pull-off godet 31 . 1 , a further godet 31 . 2 is arranged and is combined with an overtravel roll. A swirling device 32 is located between the pull-off godets 31 . 1 and 31 . 2 . The pull-off godets 31 . 1 and 31 . 2 are independently driven, and FIG. 4 shows only the drive 34 of the godet 31 . 1 . To treat the sheet of strands 29 , the swirling device 32 comprises three separate processing channels, in which each of the threads 5 . 1 , 5 . 2 , and 5 . 3 is individually swirled. So, in addition to crimping, an intensive thread end on the threads 5 . 1 to 5 . 3 is produced, which is subsequently fed to over the pulley 16 into the winding device 17 . In the winding device 17 , the crimped threads 5 . 1 to 5 . 3 are wound parallel side by side to bobbins, as has already been shown in FIG. 2 .
[0042] The method and apparatus of the invention are thus particularly advantageous to allow an individual pull-off of the threads with a subsequent collective treatment and a shared use of the subsequent devices. FIGS. 1 to 4 only show a few exemplary embodiments of the invention. Basically, the threads pulled off the individual godets can also be formed from a plurality of filament bundles. It is essential here that the thread led and treated in the sheet of strands is first individually pulled off during the extrusion and the cooling.
REFERENCE LIST
[0000]
1 Spinning device
2 Inlet
3 Spinning beam
4 . 1 , 4 . 2 , 4 . 3 Spinneret
5 . 1 , 5 . 2 , 5 . 3 Thread
6 Cooling device
7 Cooling shaft
8 Puffer
9 . 1 , 9 . 2 , 9 . 3 Collecting thread guide
10 . 1 , 10 . 2 , 10 . 3 Preparation device
11 . 1 , 11 . 2 , 11 . 3 Individual godet
15 12 . 1 , 12 . 2 , 12 . 3 Overtravel roller
13 Drawing device
14 . 1 , 14 . 2 , 14 . 3 , 14 . 4 Drawing godet
15 Multiple thread guides
16 Deflection pulley
17 Winding device
18 . 1 18 . 2 18 . 3 Winding positions
19 . 1 , 19 . 2 Spindles
20 Spindle turret
21 . 1 , 21 . 2 , 21 . 3 Bobbins
23 Drive of the individual godets
24 . 1 , 24 . 2 Drive of the drawing godets
25 Machine frame
26 Crimping device
27 Texturing means
28 Cooling roller
29 Sheet of strands
Thread plug
31 . 1 , 31 . 2 Pull-off godet
32 Swirling device
33 Roller drive
34 Drive of the pull-off godet
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The invention relates to a process for melt-spinning, drawing and winding multiple synthetic threads and to an apparatus for performing the process. The synthetic threads are spun concurrently side by side through extrusion of fine filamentous strands, cooled down and hauled off to be then collectively drawn as a sheet of threads and wound up on bobbins. To obtain ideally identical physical properties in the collective treatment of the threads, the threads are hauled off independently of each other by separate individual godets after extrusion and before collective drawing. This makes it possible to realize for each thread the same conditions during extrusion, cooling and hauling off. The apparatus includes multiple individual godets arranged side by side, which are arranged upstream of the drawing facility and are each associated with one of the threads. To pull off the threads, the individual godets are configured to be individually driveable.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to a data-conversion device and an information-processing device. The present invention more particularly relates to a data conversion device supplying digital image data processed by an information-processing device to a monitor, and relates to the information-processing device including such data conversion device.
[0003] 2. Description of the Related Art
[0004] [0004]FIG. 1 is a block diagram showing a conventional personal computer. A personal computer 1 includes a processing unit 2 , chipsets 3 and 4 , a memory 5 , a hard-disk drive (HDD) 6 , a video card 7 , a monitor 8 , a peripheral component interconnect (PCI) slot 9 , an industry standard architecture (ISA) slot 10 , a universal serial bus (USB) port 11 , a PCI bus 12 , an ISA bus 13 and a USB 14 . The processing unit 2 includes a central processing unit (CPU), a secondary cache and the like, and processes data. The chipset 3 called a north bridge is connected to the processing unit 2 , the chipset 4 , the memory 5 , the video card 7 and the PCI slot 9 , and exchanges data with each of the above-described units. The chipset 4 called a south bridge is connected to the chipset 3 , the HDD 6 , the PCI slot 9 , the ISA slot 10 and the USB port 11 , and exchanges data with each of the above-described units.
[0005] The memory 5 includes a semiconductor storage device such as a random access memory (RAM) that supplies data read therefrom and stores data written therein. The memory 5 is used as a working area for the processing unit 2 . The HDD 6 stores a program and data therein, and the program. The data stored in the HDD 6 are transferred to the memory 5 when the processing unit 2 uses the data. The video card 7 converts digital image data supplied from the chipset 3 into analog image signals, and supplies the analog image signals to the monitor 8 . The PCI slot 9 is connected to the PCI bus 12 that connects the chipsets 3 and 4 , and accepts a PCI card based on a PCI standard. The ISA slot 10 is connected to the chipset 4 by the ISA bus 13 , and accepts an ISA card based on an ISA standard. The USB port 11 is connected to the chipset 4 by the USB 14 , and accepts a device based on a USB standard.
[0006] The personal computer 1 uses the video card 7 located between the chipset 3 and the monitor 8 to generate a signal that can be processed by the monitor 8 . This video card 7 must include a variety of large-scale integrated circuits (LSI) on a printed circuit board so that a cost of producing the personal computer 1 increases by adding the video card 7 thereto.
[0007] [0007]FIG. 2 is a block diagram showing another conventional personal computer. A personal computer 15 includes a processing unit 2 , a memory 5 , a HDD 6 , a PCI slot 9 , a USB port 11 , chipsets 16 and 17 , a transmitter 18 , a receiver 19 , a digital monitor 20 , a firmware hub 21 and a digital-audio output port 22 . It should be noted that a unit in FIG. 2 having the same number as a unit in FIG. 1 includes the same function as the unit in FIG. 1, and a description of the unit is omitted. The chipset 16 is connected to the processing unit 2 , the memory 5 , the chipset 17 and the transmitter 18 , and exchanges data among the above-described units. The chipset 17 is connected to the HDD 6 , the ISA slot 9 , the USB port 11 , the firmware hub 21 and the digital-audio output port 22 , and exchanges data among the above-described units.
[0008] The chipset 16 can output digital image data therefrom. The digital image data outputted from the chipset 16 is supplied to the transmitter 18 . The transmitter 18 converts a data format of the digital image data supplied from the chipset 16 to a special data format for transmitting to the receiver 19 . The digital data outputted from the transmitter 18 is supplied to the receiver 19 . Subsequently, the receiver 19 outputs the digital data received from the transmitter 18 in a data format requested by the digital monitor 20 . The data format requested by the digital monitor 20 is a data format wherein a data length is 24 bits, and a reference voltage is 3.3 V.
[0009] As shown in FIG. 2, a personal computer whereto a monitor is connected by a data transmission path has the data transmission path that is exposed, and thus uses a special data transmission method that protects data transmitted through the path from electromagnetic waves. An example of such data transmission method is a panel link standard. The panel link standard needs a transmitter and a receiver, and thus the transmitter 18 and the receiver 19 are provided in the personal computer 15 based on the panel link standard. The transmitter 18 converts the digital image data supplied from the chipset 16 into a signal based on the panel link standard, and outputs the signal to the data transmission path. Subsequently, the receiver 19 converts the signal received from the transmitter 18 through the data transmission path into digital data that has a voltage level and a data bit length requested by the digital monitor 20 .
[0010] On the other hand, a personal computer that has a monitor as an integral part thereof does not need to transmit digital image data to a monitor located outside the personal computer through the data transmission path, and distance to transmit the digital image data is shorter than that of the personal computer with the monitor located outside the personal computer. Accordingly, the personal computer that includes the monitor does not need any special data transmission method to transmit the digital image data to the monitor. In such conventional personal computer, however, a voltage level and a data bit length are different between digital image data outputted from a chipset and digital image data requested by a monitor to be inputted, so that the digital image data outputted from the chipset cannot be inputted to the monitor without any data conversion.
[0011] Accordingly, the personal computer that has a monitor integrated therein transmits digital image data to the monitor by use of the panel link standard in the same manner as does the personal computer having a separate monitor. Therefore, the personal computer that includes the monitor needs to include two kinds of extra integrated circuits (IC), i.e., a transmitter and a receiver, which are expensive and are exclusively used for the panel link standard. Consequently, the cost of producing the personal computer that includes the monitor increases by having the transmitter and the receiver therein.
SUMMARY OF THE INVENTION
[0012] Accordingly, it is a general object of the present invention to provide a data conversion device connecting a chipset and a monitor provided in an information-processing device with a structure of the data conversion device being simple. A more particular object of the present invention is to provide a data conversion device converting a voltage level and a bit length of data outputted from a chipset provided in an information-processing device respectively to a desired voltage level and a desired bit length so that the data can be received by a monitor provided in the information-processing device.
[0013] The above-described object of the present invention is achieved by a data conversion device provided in an information-processing device having an image-display device as an integral part thereof, wherein the information-processing device supplies data to the image-display device through the data conversion device, the data conversion device including a voltage-level conversion unit converting a voltage level of input data of the data conversion device inputted from the information-processing device to a desired voltage level, and a bit-length conversion unit converting a bit length of the input data to a desired bit length, wherein the data conversion device is implemented on a single semiconductor chip, and is directly connected to the information-processing device without using a data transmission method of transmitting data for a long distance.
[0014] By use of the data conversion device, the voltage level and the bit length of the input data, that is, the data outputted from the chipset, can be altered to desired values so that the monitor can accept the data.
[0015] Other objects, features and advantages of the present invention will become more apparent from the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 is a block diagram showing a conventional personal computer 1 ;
[0017] [0017]FIG. 2 is a block diagram showing conventional personal computer 15 ;
[0018] [0018]FIG. 3 is a block diagram showing an information-processing device 100 according to an embodiment of the present invention;
[0019] [0019]FIG. 4 is a block diagram showing a data-conversion device 102 according the embodiment of the present invention;
[0020] [0020]FIG. 5 is a graph showing a first mode for storing input data in registers 116 and 117 ;
[0021] [0021]FIG. 6 is a graph showing a second mode for storing the input data in registers 118 and 119 ;
[0022] [0022]FIG. 7 is a graph showing a third mode for storing the input data in registers 120 and 121 ; and
[0023] [0023]FIG. 8 is a graph showing a fourth mode for storing the input data in registers 122 and 123 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] A description will now be given of preferred embodiments of the present invention, with reference to the accompanying drawings.
[0025] [0025]FIG. 3 is a block diagram showing an information-processing device according to an embodiment of the present invention. It should be noted that a unit in FIG. 3 having the same number as a unit in FIG. 2 includes the same function as that unit in FIG. 2, and a description thereof will be omitted.
[0026] An information-processing device 100 shown in FIG. 3 is a personal computer including a computing unit 101 and a digital monitor 20 . The computing unit 101 includes a processing unit 2 , a memory 5 , a HDD 6 , a PCI slot 9 , a USB port 11 , chipsets 16 and 17 , a firmware hub 21 , a digital-audio output port 22 and a data-conversion device 102 . The digital monitor 20 is connected to the computing unit 101 through the data-conversion device 102 . The data-conversion device 102 is on a single semiconductor chip, and converts digital data outputted from the chipset 16 to digital data having a voltage level and a data bit length requested by the digital monitor 20 .
[0027] [0027]FIG. 4 is a block diagram showing a structure of the data-conversion device 102 according to the embodiment of the present invention. The data-conversion device 102 includes a data-input terminal Tin, clock-input terminals TCLKA and TCLKB, a data-output terminal Tout, a clock-output terminal TCLKOUT, a mode-selecting terminal Tmode, a voltage-level conversion unit 103 and a bit-length conversion unit 104 . The voltage-level conversion unit 103 includes buffer amplifiers 105 , 106 and 107 . The bit-length conversion unit 104 includes buffers 108 and 109 , inverting buffers 110 and 111 , switching circuits 112 through 115 , registers (REG) 116 through 123 , a selector (SEL) 124 , an output register (OUT REG) 125 and a configuration register (CONFIG REG) 126 .
[0028] The data-input terminal Tin is connected to the chipset 16 , and is supplied with 12-bit parallel digital data with its reference voltage being set to 1.8V from the chipset 16 . The data-input terminal Tin then outputs the data supplied from the chipset 16 to the buffer amplifier 105 . The clock-input terminal TCLKA is connected to the chipset 16 , and is supplied with a 1-bit clock signal CLKA with its reference voltage being set to 1.8V, that is synchronous to the digital data inputted to the data-input terminal Tin, from the chipset 16 . The clock-input terminal TCLKA then outputs the clock signal CLKA to the buffer amplifier 106 . It should be noted that the 12-bit parallel digital data is supplied from the chipset 16 to the data-input terminal Tin at a rising edge and a falling edge of the clock signal CLKA. The clock-input terminal TCLKB is also connected to the chipset 16 , and is supplied with a 1-bit clock signal CLKB with its reference voltage being set to 1.8V, that is the inverse of the clock signal CLKA. The clock-input terminal TCLKB then outputs the clock signal CLKB to the buffer amplifier 107 .
[0029] The data-output terminal Tout is connected to the digital monitor 20 , and outputs 24-bit parallel digital data with its reference voltage being set to 3.3V to the digital monitor 20 . The clock-output terminal TCLKOUT is connected to the clock-input terminal TCLKA and the digital monitor 20 , and outputs 1-bit digital data, that is, the clock signal CLKA from the clock-input terminal TCLKA to the digital monitor 20 . The mode-selecting terminal Tmode is connected to the chipset 16 and to other control units not shown in FIG. 4, and is supplied with 4-bit serial digital data therefrom.
[0030] A description will now be given of the voltage-level conversion unit 103 .
[0031] The buffer amplifier 105 located in the voltage-level conversion unit 103 is connected to the data-input terminal Tin. The buffer amplifier 105 is supplied with the 12-bit parallel digital data with its reference voltage being set to 1.8V from the data-input terminal Tin, and converts the reference voltage of the 12-bit parallel digital data from 1.8V to 3.3V. Similarly, the buffer amplifier 106 connected to the clock-input terminal TCLKA converts the reference voltage of the clock signal CLKA supplied from the clock-input terminal TCLKA from 1.8V to 3.3V. Additionally, the buffer amplifier 107 connected to the clock-input terminal TCLKB converts the reference voltage of the clock signal CLKB supplied from the clock-input terminal TCLKB from 1.8V to 3.3V. The data from the buffer amplifier 105 , the clock signal CLKA from the buffer amplifier 106 and the clock signal CLKB from the buffer amplifier 107 are supplied to the bit-length conversion unit 104 with their reference voltages being converted from 1.8V to 3.3V.
[0032] A description will now be given of the bit-length conversion unit 104 .
[0033] The buffer 108 receives the clock signal CLKA from the buffer amplifier 106 , amplifies the clock signal CLKA, and then outputs the amplified clock signal CLKA to the switching circuits 112 , 113 and 114 . The buffer 109 receives the clock signal CLKB from the buffer amplifier 107 , amplifies the clock signal CLKB, and then outputs the amplified clock signal CLKB to the switching circuit 114 . The inverting buffer 110 inverts and amplifies the clock signal CLKA received from the buffer amplifier 106 . The inverting buffer 110 then outputs the inverted and amplified clock signal CLKA as a clock signal CLKA_NOT to the switching circuits 112 , 113 and 115 . The inverting buffer 111 inverts and amplifies the clock signal CLKB received from the buffer amplifier 107 . Subsequently, the inverting buffer 111 outputs the inverted and amplified clock signal CLKB as a clock signal CLKB_NOT to the switching circuit 115 .
[0034] The switching circuit 112 connected to the buffer 108 , the inverting buffer 110 and the configuration register 126 receives the clock signal CLKA from the buffer 108 , the clock signal CKLA_NOT from the inverting buffer 110 and a 1-bit signal from the configuration register 126 . The switching circuit 112 is activated and outputs the clock signal CLKA to the register 116 and the clock signal CLKA_NOT to the register 117 if it receives a 1-bit signal set to “1” from the configuration register 126 . If the 1-bit signal supplied from the configuration register 126 is set to “0”, the switching circuit 112 is deactivated and does not output the clock signal CLKA and the clock signal CLKA_NOT respectively to the register 116 and the register 117 .
[0035] The switching circuit 113 connected to the buffer 108 , the inverting buffer 110 and the configuration register 126 receives the clock signal CLKA from the buffer 108 , the clock signal CKLA_NOT from the inverting buffer 110 and a 1-bit signal from the configuration register 126 . The switching circuit 113 is activated and outputs the clock signal CLKA_NOT to the register 118 and the clock signal CLKA to the register 119 if it receives a 1-bit signal set to “1” from the configuration register 126 . If the 1-bit signal supplied from the configuration register 126 is set to “0”, the switching circuit 113 is deactivated and does not output the clock signal CLKA_NOT and the clock signal CLKA respectively to the register 118 and the register 119 .
[0036] The switching circuit 114 connected to the buffer 108 , the buffer 109 and the configuration register 126 receives the clock signal CLKA from the buffer 108 , the clock signal CKLB from the buffer 109 and a 1-bit signal from the configuration register 126 . The switching circuit 114 is activated and outputs the clock signal CLKA to the register 120 and the clock signal CLKB to the register 121 if it receives a 1-bit signal set to “1” from the configuration register 126 . If the 1-bit signal supplied from the configuration register 126 is set to “0”, the switching circuit 114 is deactivated and does not output the clock signal CLKA and the clock signal CLKB respectively to the register 120 and the register 121 .
[0037] The switching circuit 115 connected to the inverting buffer 110 , the inverting buffer 111 and the configuration register 126 receives the clock signal CLKA_NOT from the inverting buffer 110 , the clock signal CKLB_NOT from the inverting buffer 111 and a 1-bit signal from the configuration register 126 . The switching circuit 115 is activated and outputs the clock signal CLKA_NOT to the register 122 and the clock signal CLKB_NOT to the register 123 if it receives a 1-bit signal set to “1” from the configuration register 126 . If the 1-bit signal supplied from the configuration register 126 is set to “0”, the switching circuit 115 is deactivated and does not output the clock signal CLKA_NOT and the clock signal CLKB_NOT respectively to the register 122 and the register 123 .
[0038] The register 116 stores the 12-bit parallel digital data supplied from the buffer amplifier 105 at a rising edge of the clock signal CLKA supplied from the switching circuit 112 . The register 117 stores the 12-bit parallel digital data supplied from the buffer amplifier 105 at a rising edge of the clock signal CLKA_NOT supplied from the switching circuit 112 . The register 118 stores the 12-bit parallel digital data supplied from the buffer amplifier 105 at the rising edge of the clock signal CLKA_NOT supplied from the switching circuit 113 . The register 119 stores the 12-bit parallel digital data supplied from the buffer amplifier 105 at the rising edge of the clock signal CLKA supplied from the switching circuit 113 . The register 120 stores the 12-bit parallel digital data supplied from the buffer amplifier 105 at the rising edge of the clock signal CLKA supplied from the switching circuit 114 . The register 121 stores the 12-bit parallel digital data supplied from the buffer amplifier 105 at a rising edge of the clock signal CLKB supplied from the switching circuit 114 . The register 122 stores the 12-bit parallel digital data supplied from the buffer amplifier 105 at the rising edge of the clock signal CLKA_NOT supplied from the switching circuit 115 . The register 123 stores the 12-bit parallel digital data supplied from the buffer amplifier 105 at a rising edge of the clock signal CLKB_NOT supplied from the switching circuit 115 . It should be noted that the registers 116 through 123 include latch registers.
[0039] The configuration register 126 receives 4-bit serial digital data from the mode-selecting terminal Tmode as a mode-set value. Each of the most significant bit, the second most significant bit, the second least significant bit and the least significant bit in the mode-set value corresponds to the 1-bit signal supplied respectively to the switching circuits 112 , 113 , 114 and 115 .
[0040] Thus, when the mode-set value is “1000”, digital data supplied from the buffer amplifier 105 at the rising edge of the clock signal CLKA is stored in the register 116 at the rising edge of the clock signal CLKA, and digital data supplied from the buffer amplifier 105 at the falling edge of the clock signal CLKA is stored in the register 117 at the rising edge of the clock signal CLKA_NOT, as shown in FIG. 5. When the mode-set value is “0100”, the digital data supplied from the buffer amplifier 105 at the falling edge of the clock signal CLKA is stored in the register 118 at the rising edge of the clock signal CLKA_NOT, and the digital data supplied from the buffer amplifier 105 at the rising edge of the clock signal CLKA is stored in the register 119 at the rising edge of the CLKA, as shown in FIG. 6. When the mode-set value is “0010”, the digital data supplied from the buffer amplifier 105 at the rising edge of the clock signal CLKA is stored in the register 120 at the rising edge of the clock signal CLKA, and the digital data supplied from the buffer amplifier 105 at the falling edge of the clock signal CLKA is stored in the register 121 at the rising edge of the clock signal CLKB, as shown in FIG. 7. Additionally, when the mode-set value is “0001”, the digital data supplied from the buffer amplifier 105 at the falling edge of the clock signal CLKA is stored in the register 122 at the rising edge of the clock signal CLKA_NOT, and the digital data supplied from the buffer amplifier 105 at the rising edge of the clock signal CLKA is stored in the register 123 at the rising edge of the clock signal CLKB_NOT, as shown in FIG. 8.
[0041] The digital data stored in the registers 116 through 123 is supplied to the selector 124 . The selector 124 selects the digital data to be outputted to the output register 125 according to the mode-set value supplied from the configuration register 126 . For instance, the selector 124 outputs the digital data stored in the registers 116 and 117 to the output register 125 if the mode-set value is “1000”. The selector 125 outputs the digital data stored in the registers 118 and 119 to the output register 125 if the mode-set value is “0100”. If the mode-set value is “0010”, the selector 124 outputs the digital data stored in the registers 120 and 121 to the output register 125 . If the mode-set value is “0001”, the selector 124 outputs the digital data stored in the registers 122 and 123 to the output register 125 .
[0042] The output register 125 is supplied with digital data selected by the selector 124 , and the clock signal CLKA from the buffer amplifier 106 . The output register 125 stores digital data with its data length being 24 bits, that is a combination of the 12-bit digital data supplied from two of the registers 116 through 123 . The output register 125 outputs 24-bit digital data to the digital monitor 20 at the rising edge of the clock signal CLKA.
[0043] In order to explain about the digital data stored in the output register 125 , the digital data supplied from the buffer amplifier 105 to one of the registers 116 through 123 at the rising edge of the clock signal CLKA is referred to as data 1. Additionally, the digital data supplied from the buffer amplifier 105 to one of the registers 116 through 123 at the falling edge of the clock signal CLKA is referred to as data 2. When the mode-set value is “1000”, the registers 116 and 117 respectively store the data 1 and the data 2, and thus the output register 125 stores 24-bit data that consists of the data 1 as a higher 12-bit part of the 24-bit data and the data 2 as a lower 12-bit part of the 24-bit data. When the mode-set value is “0100”, the registers 118 and 119 respectively store the data 2 and the data 1, and thus the output register 125 stores 24-bit data that consists of the data 2 as the higher 12-bit part of the 24-bit data and the data 1 as the lower 12-bit part of the 24-bit data. Similarly, when the mode-set value is “0010”, the registers 120 and 121 respectively store the data 1 and the data 2, and thus the output register 125 stores the 24-bit data that includes the data 1 as the higher 12-bit part of the 24-bit data and the data 2 as the lower 12-bit part of the 24-bit data. When the mode-set value is “0001”, the registers 122 and 123 respectively store the data 2 and the data 1, and thus the output register 125 stores the 24-bit data that consists of the data 2 as the higher 12-bit part of the 24-bit data and the data 1 as the lower 12-bit part of the 24-bit data.
[0044] The bit-length conversion unit 104 includes a combination of the registers 116 and 117 , and a combination of the registers 120 and 121 so that one of the combinations can be selected by use of the mode-set value to output correct data to the output register 125 in a case that an error has occurred on data stored in the other combination, the error being caused by, for instance, noises on the clock signals CLKA and CLKB supplied from the chipset 16 , and time lags that occur on the rising edges and the falling edges of the clock signals CLKA and CLKB. Similarly, a combination of the registers 118 and 119 and a combination of the registers 122 and 123 are provided in the bit-length conversion unit 104 .
[0045] As described above, the voltage-level conversion unit 103 provided in the data-conversion unit 102 converts the voltage level of the digital data inputted to the data-conversion unit 102 from 1.8V to 3.3V. Additionally, the bit-length conversion unit 104 provided in the data-conversion unit 102 coverts the bit length of the digital data inputted to the data-conversion unit 102 from 12 bits to 24 bits. Accordingly, the data-conversion unit 102 can obtain digital data with its reference voltage set to 3.3V and its data length set to 24 bits that are requested by the digital monitor 20 .
[0046] According to the present invention, the data-conversion device 102 can connect devices that input and output data in different data lengths with different standard voltage levels by converting their data lengths and standard voltage levels to respectively desired data lengths and desired standard voltage levels. A simply structured bit-length conversion unit 104 and a simply structured voltage-level conversion unit 103 can alter a data length and a reference voltage of digital data inputted to the data-conversion unit 102 , respectively. By including the voltage-level conversion unit 103 and the bit-length conversion unit 104 in the data-conversion unit 102 on a single semiconductor chip, a structure of the data-conversion device 102 can be simplified, and thus the cost of producing the data-conversion device 102 can be reduced. Furthermore, a chipset and a digital monitor can be connected by use of the single semiconductor chip. Accordingly, a personal computer including the digital monitor therein can connect the chipset provided therein and the monitor at a low cost, for instance. By use of clock signals supplied with digital data from the chipset 16 , timing to store the digital data in the registers provided in the data-conversion unit 102 and to output the digital data from the data-conversion unit 102 can be controlled with a simple structure of the data-conversion unit 102 .
[0047] The above description is provided in order to enable any person skilled in the art to make and use the invention and sets forth the best mode contemplated by the inventors of carrying out the invention.
[0048] The present invention is not limited to the specially disclosed embodiments and variations, and modifications may be made without departing from the scope and spirit of the invention.
[0049] The present application is based on Japanese Priority Application No. 11-349453, filed on Dec. 8, 1999, the entire contents of which are hereby incorporated by reference.
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A data conversion device is provided in an information-processing device having an image-display device as an integral part thereof, wherein the information-processing device supplies data to the image-display device through the data conversion device. The data conversion device includes a voltage-level conversion unit converting a voltage level of input data of the data conversion device inputted from the information-processing device to a desired voltage level, and a bit-length conversion unit converting a bit length of the input data to a desired bit length. The data conversion device is implemented on a single semiconductor chip, and is directly connected to the information-processing device without using a data transmission method of transmitting data for a long distance. By use of the data conversion device in an information-processing device that includes a chipset and a monitor, the voltage level and the bit length of the input data, that is, the data outputted from the chipset, can be altered to desired values so that the monitor can accept the data.
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[0001] This application is a Division of Ser. No. 10/958,855, filed Oct. 5, 2004 which is a Division of Ser. No. 09/936,039, filed Sep. 8, 2001, now U.S. Pat. No. 6,866,171.
[0002] This invention relates generally to a method for introducing additives into flowing or fluidized media with specific application for metallurgical, metal/ceramic powder technology processes.
BACKGROUND
[0003] U.S. Pat. No. 4,474,717 describes an injection of a small portion of plastics without introducing inert gas (preloading) followed by sectional introduction of inert gas using frequencies from 4 to 100 cycle per second having a pressure of 300-1500 psi (2 to 10 MPa) into the continuous passing plastic material. The result is a multi-layered internal foamed structure. The present invention expands this method by applying injection technology used in the combustion engine technology and reaching a more intensive penetration by higher pressure (40 to 200 MPa), higher frequency (100 to 1000 hz) and more exact dosing by controlled width of the pulses, frequency of the pulses and regulation of pressure using this technology.
[0004] The pulsing adding of liquid and gas is state of the art in burner systems, airless jet systems and spraying systems (atomizers). The present invention is distinguished from these applications by higher pressure of the liquid than 40 MPa and high energy atomizing. This pressure is not possible with the nozzles used at this time. Only by electrical activated hydraulic servo valves in common rail technology can these pulsations be realized.
SUMMARY OF THE INVENTION
[0005] The basic concept of the method for introducing additives consists of obtaining intensive atomizing, mixing and deep penetrating of additives into the medium stream by using high kinetic energy of the additives and exact timed pulsing and exact pulse width using appropriate injectors.
[0006] The exact dosing of the additives is obtained by regulation of the operation parameters of introduction for instance pressure, frequency, pulsing width, etc.
[0007] The state of the art of combustion engines using the “common rail” injection technology is utilized. The flexibility of this system by modifying the operating parameters is the highlight of this technology in comparison to the present mechanically operated injection methods. The common rail is loaded with fuel being pressurized up to 200 MPa and supplies the injector with this constant pressure. Electronic controller activating solenoid and piezo-operated, electro-hydraulic servo-valves move the nozzle needle by push rods with high precision. According to this technology exact dosing and homogenous distribution will be obtained.
[0008] The application and further development of this injection technology is subject to utilizing this improved technology for further applications as mentioned before. Furthermore, detailed design and configuring of nozzles, nozzle-needles, the arrangement of orifices in position and shape as well as arrangement of injectors are aspects of this invention.
[0009] The spatially predetermined position of the additives in the flowing material, also called fluid bed, is obtained by controlling the pulsating injection. The introduction and exact dosing of additives, that is hardeners, dyes, gas producers and softener for instance, into a liquid metal melt, metal/ceramic powder technology stream or metal stream for instance or the fluid bed of bulk material, such as powder, granules and pellets, is carried out by means of an injector.
[0010] The invention is used in melting units, in hot channel systems, in tools, components of tools and extruders, metal, metal/ceramic powder technology injection moulding, pelletizing, arrangements.
[0011] The nozzle needle of at least one nozzle is variable and highly precisely moved for the introduction by means of a device and in such a way that an additive is dosed exactly in relation to the volume flow of the medium and that a pulsating stream is injected into the medium flowing past the pulsating stream by means of at least one well-aimed nozzle opening. The additives are dosed by means of a pressure that can be variably adjusted such as by pulse width and pulse frequency. The desired homogenous distribution is obtained by the penetrating injection jet during compounding for instance.
[0012] The invention is particularly directed to the following applications:
[0013] i) Introduction into the metal, metal/ceramic powder technology melt stream. The introduction happens after the extruder unit. This is for many processes listed below having advantages noted. Producing material of different properties out of one plasticizing unit is possible.
[0014] ii) For metal, metal/ceramic powder technology Injection moulding systems, predetermined properties like porosity, coloring are possible by one process step through variable introduction. Only multi-component metal, metal/ceramic powder technology injection moulding machines can accomplish this today.
[0015] iii) For extruder systems, profiles can be extruded with different components at predetermined sections which can be foamed by diverting the metal, metal/ceramic powder technology melt stream and introducing gas creators in one side stream by an injector so that this melt stream will expand and joined together with the material of the main stream.
[0016] iv) Metal, metal/ceramic powder technology for sheet and tube extruders can be introduced with dyes, gas processors and softeners after the extruder. Therefore, a fast change of the material properties is possible that leads to economical flexibility in the production process.
[0017] The following application, processes and devices can be economically realized with the invention:
Introducing, dosing and homogenous distribution of additives such as, hardeners, dyes, gas processors, softeners and reactants into the melt stream of metal, metal/ceramic powder technology in:
extrusion systems for sheets, tubes and profiles. compounding systems for production and adaptation of metals, metal/ceramic powder technology metal, metal/ceramic powder technology Injection moulding, forming operation, preform manufacturing systems. auxiliary processing, forming operation, preform manufacturing systems.
Introducing, dosing and homogenous distribution of additives into fluidized material like bulk and powder material (ceramics, metalics), granules, pellets in plants operating fluidized bed and whirl sintering installations.
Method of Introducing Additives.
[0024] Exact dosing and homogenous distribution is utilized. The present invention relates to introducing additives for instance gas processors into the melt stream of low melting metals.
[0025] The advantage of this process is the application of light weight structures at locations of a part where it is demanded. The gas processing substance for expanding the matrix material is introduced in spatially predetermined positions. Various operation modes and combination of these can be obtained firstly by pressure differences between melt and gas processing substances and secondly by the frequency of pulsation and thirdly by the shape of the nozzle reaching into the melt channel.
[0026] i) Creation of Foam:
[0027] Creation of foam is possible using high frequency pulsation and therefore atomizing at high pressure differences and the advantages of counterflow and the subsequent high acceleration of the melt past variable sections of the melt channel. The difference in the speed of melt and additive is selected to be of a high value.
[0028] ii) Macro-Hollow Cavities:
[0029] The introduction happens by drop shaped dosing of the melt flow at low frequency of the pulsation and only small pressure difference in flow direction and essentially laminar streaming conditions of gas processors and melt.
[0030] iii) Continuous Introduction:
[0031] Continuous introduction of a string of gas processors at nearly adequate flow speed of the passing medium. Small pressure difference is an advantage.
[0032] An apparatus for injection molding of compound parts with charger, which are connected to a pump which is compressing a chemical blowing agent has been published in DE1948454 to achieve a spatially predetermined foaming. Because of the insufficient mixing and dosing, the proposed foam quality cannot be reached. The present invention is distinguishes from this apparatus by using injectors (combination of valve and nozzle) and pulsing injection and optionally using a continuously pressurized pipeline “common rail” and hydro-electrical activated valves. Because of the shaping of nozzles and channels according to hydrodynamic principles as well as regulated pressure, the apparatus is different. The solenoid is activated by electrical supply and optionally controlled to generate selected wave forms from an arbitrary wave generator. This leads to operation mode like atomizing, dosage and continuous string. The selection of pressure difference and frequency of pulsation leads to a predetermined introduction of gas processors into the melt. The exact dosing and pressure regulation leads to a targeted dosage of drops into the melt resulting in a subsequent macro hollow cavity expansion.
[0033] The apparatus for introduction of gas creating substances into the highly pressurized melt consists of a nozzle in immediate connection with a servo-valve, or consists of a pump-nozzle system with a non-return-valve combination.
[0034] The injection technology of combustion engineering has reached a high state of art concerning the exact repeatability due to the demands of strict exhaust specifications and is especially applicable to the invention. The state of the art is shown by “fuel-injection valves for internal combustion engines” disclosed in DE2028442. The hydraulic activation of the valve push rod is regulated by a three way valve. An “injection device” with hydroelectric activation is described in FR2145081. The valve is pushed by a continuous hydraulic pressure and released by a controlled pressure loss on the backside of the push rod. In U.S. Pat. No. 3,990,422, the control of the hydro-electric activation has been improved by using a two circuit hydraulic system.
[0035] The present injectors show features which are necessary to comply with the demands of the inventive application and specification thereof. These are pressure regulation, electro-hydraulic activation by a push rod valve and pressure controlled by a sphere valve at the high pressure circuit, which is necessary to reach the high frequency pulsation and have the high pressure available at the nozzle needle immediately at the valve seat by a common rail system. This makes the accuracy independent of pressure and velocity differences between the gas creating substances and the melt.
[0036] The present invention relates to this high pressure technology which is to be adapted for the special condition of the introduction into the melt. The high pressure for injectors in melt introduction processes is needed to overcome the high melt pressure of about 100 to 140 MPa. Pressure of about 200 MPa can be reached by the available injectors with common rail. The continuous supply and the activation of the valves are solved with high reliability today.
[0037] An essential presupposition for running the injectors is the lubrication by the fuel because gas creating substances (water, alcohol, liquid gas) do not have substantial lubrication effect. The basic idea of the present invention is the use of two circuits applied to the standard injectors available in the market for making additional measures.
[0038] The JP 8170569 describes a version of injectors for diesel engines using a high pressurized circuit for injection and a low pressurized circuit for the servo hydraulic system. The inventive injector operates by separation of the hydro-electrical activation of the push rod of the valve which uses standard hydraulic oil and the introduction of gas creating substances that occurs at a slightly lower pressure (different from JP 8170569) because of a non return lock pressure that prevents penetration of the melt into the injector. Only the needle and seat of the valve are in touch with the non-lubrication medium. These parts can be made of sintered highly wear resistant material and are easily changeable. The electro-hydraulic servo circuit is not effected because of the separate circuit.
[0039] Further alternative solutions for the injector are:
[0040] 1) Pump nozzle system with a combination of high pressure piston and spherical valves.
[0041] 2) An electric activated swing system attached to a pump piston.
[0042] 3) Limits for the stroke and positioning of the inlet valve as known for airless spraying systems can be used as well. In some applications, it is an advantage to have a small pressure difference between the introduced material and the melt. For this, the above solution can be used.
[0043] The regulation and control of the introduction process has the following features. Optionally, the hydraulic circuit can be separated from the gas creating substances to be introduced. The pressure p 1 of the medium to be introduced and the pressure p 2 of the hydraulic system are regulated by a pressure limit valve. The controller regulating the pressure depends on the melt p 3 , for the hydraulic system circuit as well as the injection pressure of the introduced medium. The injector is activated by a solenoid or piezo actuator. The regulation is controlled by an “Arbitrary Wave Form Generator”, known to those skilled in the art. Furthermore, the specification of hydraulic, nozzles, injectors and melt channel are described below.
[0044] The hydraulics for continuous production for instance extrusion, continuous casting and for part production by injection moulding and die casting are prescribed. The system for continuous production is used for extruders. Continuous charging and multiple injector assembly is preferred. The system for part production is used in injection moulding and die casting systems. Because of the interruption after the injection, a simple solution using a pressure multiplier double cylinder is offered for injection moulding systems. The hydraulic system of existing machines have usually a pressure of 26 MPa that can be used to produce high pressure by a pressure multiplying system. While plastification metal melting, metal/ceramic powder technology takes place, the pressure multiplier for the hydraulic system as well as for the introducing system is loaded with hydraulic oil and gas creating substance respectively. For the dosage of the melt with concrete size and spatially predetermined position it is necessary to achieve a constant pressure difference while injection takes place. A high pressure difference leads to the destroying of the melt. The ramping of the pressure is shown in FIG. 9 . The injection pressure increases to the nominal pressure during the injection operation. During the injection, the gas creating medium must be introduced by a higher pressure than the melt. The velocity of the melt in the gate of the mould has to be equivalent to the introduction speed of the gas creating medium. For achieving this feature an exact pressure regulation with electrical pressure limit and a precise activation of the hydroelectric valves is necessary. The shaping of the valve, valve seat and the smooth configuration of the melt channel according to hydrodynamic principles is important for repeatable dosage of the melt. The injectors of the “common rail technology” have the capability to fulfill these features.
[0045] The regulation of the solenoid takes place by controlling with “Arbitrary Wave Form Generator”, opening and locking can be optimized by this system. Furthermore the shape of nozzle and melt channel is described.
EXAMPLES OF INTRODUCING ADDITIVES
[0046] The present process relates to the modification of the properties (compounding) of an original extruded material by diversion of the main stream into a side stream and introducing additives into this side stream by dosing, mixing and distribution of the original material. The kind of additives determine the properties of the metallic, metal/ceramic powder technology material of the melt. These additives are for instance additional components such as hardeners, dyes, gas processors, softeners, fillers and reinforcements.
[0047] This process can be applied to inside melt channels of mould for extrusion as well as for injection moulding systems, by means of using at least two diverted streams of melt to reach different properties of the plastic material. Profiles produced by this process have different properties of the material at spatially predetermined positions. This method saves an additional extruder to produce the additional material component. The essential advantage is, that based on the same origin material the waste disposal is not necessary, because based on the same material the recycling results in a unique material. The additives are introduced by nozzle, injector, charging tube, mixing head, porous sinter metal, sliding pump, charger and spraying system. The following concrete application for production of profiles are subsequently shown for instance:
[0048] i) aluminum, Metal/Ceramic Powder Technology Window Profiles.
[0049] Sections of the profile close to the outside or inside can be insulated with the present process by using foam filling at the concerned chambers. The calipers as used for the known multiple chamber systems will be adapted with inside channels and with the present described devices. From the main melt stream, diverted material comes to the channel duct within the caliber in which by means of a metering regulation (as there are valve, throttle) the melt is fed to the device for introduction of the additives. Subsequently devices for mixing and homogenizing are placed in the channel to complete the compounding process. Using aluminum, metal/ceramic powder technology for the window profile the additive will be physical gas creators like water, carbon dioxide, alcohol, glycerin, etc. The pressure ramping in the melt duct is decreasing because the additives provide additional gas volume. For expansion of the material, a conical zone is configured according to the volume increase or the velocity increase and the additional volume comes to an expansion zone (conical increasing outlet) so that the compounded material is fed to the outside as solid aluminum, metal/ceramic powder technology profile shells and can be homogenous and adhesively bound together. The advantage of the profiles with multi components comes by the cost effective production and the better properties of the material for heat and sound insulation (low pressure within the foam cells and therefore lower heat transfer rates) and less cost for recycling of the waste material. As a variation, the additives can be introduced by singular dosage leading to a profile with honeycomb shaped cellular structures of high strength. These structures replace the necessary stiffener profiles.
[0050] ii) Window Profiles Out of Low Melting Metals, Metal/Ceramic Powder Technology.
[0051] This is as described above but using aluminum, metal/ceramic powder technology
[0052] iii) Claddings or Panel Shaped Coverings for Outside or Inside Walls.
[0053] This is simpler than described above. The total extruded profile with foam core and large cell structure can be obtained by one diverted material stream from the main stream to be compounded within the center of the profile. The subsequent process of calibrating and cooling remains the same as before. The so obtained profiles can be used for inside cladding, mobile walls etc. having high stiffness by using large cell striker.
[0054] iv) Tubes From Low Melting Metals, Powder/Ceramic Technology
[0055] Because of suitable introduction of gas creating and/or fillers, or reinforcement to the melt stream into spatially predetermined locations (as there are intermediate layer, outside layers, etc.), a multi component tube can be produced with simple measures. The device for compounding is attached in between the flanges of extruder and mould and is supplied by the channels of the mould to modify the properties of the material. Another production process with excellent mixing of the melt consists of introducing the additives before the cellular pump. Another improvement can be installed by attaching a mixer or dynamic mixing head for homogenous compounding.
[0056] v) Coloring of the Outside Layers of the Profiles.
[0057] The introduction of dyes into the diverted melt channel makes it possible to produce a fast changeable coloring process. The process is most economical, because the expensive dyes are only applied on the outside and no loss of material happens by changing of color because the extruder does not have to be emptied completely. The change of the color comes into force immediately. Further possibilities for cost reduction can be achieved by bringing the coloring to the outside layers only.
[0058] vi) Production of Sheets, Insulation Sheet Material and Compound Sheets.
[0059] For systems having a large working width, the additives can be introduced into the center layer of the extruded sheet, or diverted to a melt channel similar to that described before for the device as implemented into the calipers having the total width of the sheet.
[0060] vii) Apparatus for Adding Up a Extrusion System for Multi Component Process.
[0061] The apparatus will be attached in between the flanges of the extruder and the mould. Following elements are included:
[0062] 1) Inlet cones with diverting device for the melt channels;
[0063] 2) Pressure and volume metering system;
[0064] 3) Device for introduction of the additives optional consisting of nozzle, injector, charging pipe, mixing head, porous sinter metal, sliding pump, charger or spraying system (The mixer consist of static mixer, for instance with shafts, pins, diaphragms, helical zones.), and,
[0065] 4) The expansion zone consists of variable sections, especially for foam components or macro cellular structures in the melt stream.
[0066] viii) Apparatus for Dosage and Mixing of Additives into Liquid Medium by Using Valve Cone Orifice or Pocket Hole Orifice
[0067] The invention relates to a multifunctional mixing and dosing head, consisting of a nozzle cone and a nozzle needle, in which the volume flow is metered or blocking the outside flowing medium by the position of the outside nozzle needle and consisting of a nozzle cone and a nozzle needle, in which the volume flow is metered or blocking the inside flowing medium by the position of the inside nozzle needle.
[0068] This combination of valve, nozzle and injector leads to an economical mixing and dosing directly on the needle top of the concentric double cone. The invention also relates to a hot runner valve, having an injector, for introducing the additives into the outer flowing medium, instead of the valve needle. Several combinations of mixing and dosing heads are mentioned, especially the attachment to plasticizing unit, extruders, melt channel and the subsequent attachment of static mixer systems.
[0069] The economical benefit consists of the spatially predetermined location of the dosage and the excellent mixing and the exact dosing according to the mixing ratio. Applications for this hot runner valve with integrated mixing head includes introducing additives like dyes, hardener, softener, gas processors, etc. directly into the metallic melt and immediately before the gate of the mould. Besides the several known two component hot runner valves, the present suggested solution has the following features:
[0070] The application of the concentric positioned nozzle needles within the nozzle needle of this invention can be compared to EP 0310 914, 1987, where a concentric positioned nozzle needle is shown in FIGS. 6 . 1 to 6 . 5 . The present apparatus is distinguished from the above by using a spatially predetermined dosing of the melt while in EP 0310914 only each of the two media is switched to the mould. The present apparatus can achieve any mixing ratio in between by using the introduction of the additives by pulsation.
[0071] In U.S. Pat. No. 4,657,496, a hot runner valve for two components is presented with concentric positioned charging tube. By the cavities (9) and (6) within the nozzle needle, depending on the position either the one or the other component is blocked or opened respectively. The concentric shaping of the inside located nozzle makes it possible to regulate the dosing by moving the outside nozzle needle which is controlled by the inner or outer nozzle. A mixing or a fast pulsing introduction as shown by the present apparatus is not a subject of U.S. Pat. No. 4,657,496.
[0072] The target of the present invention is not only to introduce at least two media in a concentric manner, but also to achieve a mixing, i.e., to dosage the outer medium with the inner medium.
[0073] In U.S. Pat. No. 5,286,184, a variation of the concentric nozzle is described, which differs from U.S. Pat. No. 4,657,496, in that it discloses the activation of the hollow shaped nozzle needle. Also in this case, there is a concentric introduction, but no mixing or dosage is the target.
[0074] The nozzle needle is activated by a push rod within the boring of the nozzle needle and is regulated by a servo-mechanic. To reach a spatially predetermined position by the dosage and/or dosing and excellent mixing the usage of a valve cone orifice VCO and a CDI injectors, as it is used in combustion engines, is an advantage. The activation of the injector is known by a hydraulic piston but also can use for the servo-mechanics for instance, solenoid, piezo actuator, hydraulic servo, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
[0075] The invention may take form in certain parts and arrangement of parts, preferred embodiments of which will be described in detail and illustrated in the accompanying drawings which form a part hereof and wherein:
[0076] FIG. 1 is a schematic sectioned view of a valve cone orifice nozzle tip in accordance with the invention;
[0077] FIG. 2 is a sectioned view similar to FIG. 1 illustrating a pocket hole orifice;
[0078] FIG. 3 is an elevation schematic view of a dosing and mixing arrangement;
[0079] FIG. 4 is a top view of the schematic arrangement illustrated in FIG. 3 ;
[0080] FIG. 5 is a schematic cross-sectioned view of a tube shown in FIG. 3 ;
[0081] FIG. 6 is a schematically sectioned plan view of a nozzle for producing a cylindrical profile;
[0082] FIG. 7 is an enlarged schematically sectioned view of one of the nozzles illustrated in FIG. 6 ;
[0083] FIG. 8 is a schematic sectioned plan view of an injector fitted to a tube;
[0084] FIG. 9 is an enlarged view of the injection nozzle/tube arrangement illustrated in FIG. 8 showing cascade distribution of the injection;
[0085] FIG. 10 is a schematically sectioned elevation view of an injector in a metal/powder feeding screw in accordance with the invention;
[0086] FIG. 11 is a schematically sectioned elevation view of an injector positioned in a different part of a metal/powder feeding screw from that shown in FIG. 10 in accordance with the invention;
[0087] FIG. 12 is a schematically sectioned elevation view of an injector in a mold gate of a metal/powder feeding screw in accordance with the invention;
[0088] FIGS. 13 and 14 are schematic representations indicating the nozzle flow pattern;
[0089] FIG. 15 is a schematic representation of a dosing and mixing arrangement for a combustion system;
[0090] FIG. 16 a is a schematic representation of a mold for an extruder;
[0091] FIG. 16 b is an orthogonal representation of the mold depicted in FIG. 16 a;
[0092] FIGS. 17 a and 17 b are views similar to FIGS. 16 a and 16 b respectively;
[0093] FIG. 18 is a schematic operating diagram for standard injectors used in the present invention;
[0094] FIG. 19 is a schematic cross-sectional elevation view of a standard conventional injector shown with a pocket hole valve;
[0095] FIG. 20 is a schematic elevation view of a prior art injector;
[0096] FIGS. 21 and 22 are views similar to FIG. 20 showing modifications to the injector in accordance with the invention;
[0097] FIG. 23 is a schematic elevation view showing a pump nozzle configuration;
[0098] FIG. 24 is a view similar to FIG. 23 illustrating an airless spraying system;
[0099] FIG. 25 is a hydraulic circuit representation for a metal injection molding and die casting system;
[0100] FIG. 26 is a graph showing melt pressure traces as a function of time;
[0101] FIGS. 27, 28 and 29 are schematic representations of various flowing media channels used with the invention;
[0102] FIG. 30 is a depiction of several different nozzles designated “a”, “b”, “c”, capable of being used with the invention;
[0103] FIGS. 31, 32 and 33 are also depictions of nozzle configurations with orifice views designated by “b”;
[0104] FIG. 34 is a schematic elevation view depicting the device compounding a flowing stream;
[0105] FIG. 35 is a schematic representation of a plan view of the arrangement shown in FIG. 34 ;
[0106] FIGS. 36 a and 36 be cross-sectioned views of the outlet and inlet, respectively, of the arrangement shown in FIGS. 34 and 35 illustrating the condition of the flowing media therein;
[0107] FIGS. 37 a and 37 b are schematic view of the outlet and inlet, respectively, of the nozzle disclosed in FIG. 33 ;
[0108] FIG. 38 is a schematic elevation view of a flowing media chamber;
[0109] FIG. 39 is a schematic elevation view of a flowing media chamber similar to FIG. 38 ;
[0110] FIGS. 40 a , 40 b , 40 c and 40 d illustrate various aerosol profile shapes capable of being produced by the subject invention;
[0111] FIG. 41 is a schematic elevation view of the flowing media channel similar to that shown, for example, in FIGS. 38 and 39 ;
[0112] FIG. 42 is an enlarged view of the injector used in the flowing media channel shown in FIG. 41 ;
[0113] FIG. 43 is an elevation view of a mixing head valve;
[0114] FIG. 44 is a view of the orifice of the mixing head valve shown in FIG. 43 in greater detail with the nozzle/orifice arrangement of the present invention depicted on the right side of the drawing and prior art injector nozzle arrangement shown on the left side of the drawing;
[0115] FIGS. 45 a , 45 b and 45 c schematically depict, respectively, progressively closing positions of the needle valve used in the subject invention;
[0116] FIGS. 46 a , 46 b and 46 c represent enlarged views of the orifice/needle shown in FIGS. 45 a , 45 b and 45 c , respectively;
[0117] FIGS. 47 and 48 are schematic elevation representations of an injector in the mixing head valve; and
[0118] FIGS. 49 and 50 are elevation schematic cross-sectioned views of the injector applied to specific flowing media channels.
DETAILED DESCRIPTION OF THE INVENTION
[0119] Referring now to the drawings wherein the showings are for the purpose of illustrating preferred embodiments of the invention and not for the purpose of limiting the same, there is shown in FIGS. 1 and 2 nozzles, nozzle needles and nozzle seats. The subsequent FIGS. 3 through 17 show samples for the application of the present method of introduction with exact dosing and homogenous distribution.
[0120] FIG. 1 shows a valve cone orifice, “VCO” nozzle tip wherein the nozzle needle 1 that closes the needle seat 3 is located in the nozzle body 2 . The small volume of the front chamber 5 is the target of the VCO. The orifices 4 are inclined about 80° to the axis as used in combustion engines. Other orifices 6 shown on the right side of the axis have stepwise inclinations of 0° to 75° inclined to the axis.
[0121] In FIG. 2 , a pocket hole orifice is shown. The larger front chamber 8 of the nozzle gives a larger volume of free drops, by means an inexact dosing. The larger chamber gives the possibility of several radial arranged orifices 6 as well as an axial positioned orifice 7 .
[0122] In FIG. 3 , an arrangement of a dosing and mixing arrangement for a flowing medium in a tube 10 is shown with five injectors 11 reaching into the tube. The injectors 11 are connected to a high pressure pipeline 12 containing the additive. The tank 14 , the high pressure pump 9 , the common rail 15 and the leakage pipe 13 are shown.
[0123] In FIG. 4 , an arrangement of FIG. 3 is shown from the top view for a extrusion system. The dosing and mixing unit is positioned in the flow direction between the cellular pump 16 , the mixing tube 10 and mixer 10 and the mould 22 .
[0124] FIG. 5 shows a sectional view of the tube 10 which is enlarged. The five nozzle tips 2 are in a radial 720 pattern arranged. Each nozzle tip has 7 orifices positioned in an angle of 75°, 50°, 25° and 0°, etc. The jet of the injection 18 gives a complete covering of the section of the medium 17 . The length of the jet stream is determined by the diameter of the orifice and is usual between 0.11 mm and 0.14 mm.
[0125] FIG. 6 shows a mould for an extruder producing a cylindrical profile. Two of the several arranged injectors 11 are shown in the section. The additives 18 are introduced according to the velocity of the medium 17 in the flow direction.
[0126] In FIG. 7 , the detail of the nozzle arrangement is shown. The nozzle bodies 2 have at least one orifice 4 in the direction of the melt channel. The jet stream, not the wall sides 10 , is directed to bring the additives into the core 38 of the stream.
[0127] In FIG. 8 , an application for a single injector is arranged which is inclined about 45° to the tube axis 10 . The orifice 4 is inclined in a flat slope angle to the medium flow i.e. the orifice is positioned about 40° out of the axis of the injector. The pulsing introduction is giving a cascade distribution shown in FIG. 9 .
[0128] FIG. 10 gives applications for injection moulding systems. Similar to FIGS. 8 and 9 , two injectors 11 introducing the additive with a slight slope in the direction of the axis of the nozzle tip 21 of the melt feeding unit. The location of the injector is after the screw tip 40 but within the front chamber 20 of the barrel 19 . Further excellent mixing, for example of dyes can be had. This arrangement also can be placed within screw sectors within the melt/powder feeding arrangement.
[0129] For accurate dosing with less mixing, the arrangement of FIG. 11 takes place. The introduction happens in the center orifice of the melt/powder feeding nozzle tip 21 . This is used for application with hardener and softener (minimum leakage).
[0130] In FIG. 12 , the introduction happens by the injector 11 immediately after the mould gate at the inlet of the mould 22 . The advantage of a hot runner system 23 is evident. The mixture of medium and additives does not depend on the melt feeding unit 19 but is determined by the introduction of the additives, i.e., flexible and variable.
[0131] FIG. 13 shows an airless jet stream 25 . The flowing medium 39 is the streaming side air. The additive is dyes 18 . The pulsation determines the coloring conditions.
[0132] The nozzle arrangement is shown in FIG. 14 . At least one orifice 4 in the nozzle body 2 is directed near the axis and determines the spraying structure or pattern 18 .
[0133] FIG. 15 shows the dosing and mixing arrangement for a combustion system. The nozzle body 2 extends into the combustion chamber 27 and is limited by the casing 28 of the burner zone. The combustion air is compressed by a blower 26 in the casing 28 and the atomizing of the fuel uses the standard arrangement of orifices located on a cone. The injection jet stream 18 results in accurate dosing and mixing of the perfect combustion 29 .
[0134] In FIGS. 16 a and 16 b , the application of a mould for an extruder production of profiles—for instance window profiles—is arranged. The dosing and mixing have the purpose of modifying material diverted from the main stream of the melt for example with gas processors. The section shape is shown in FIG. 16 b . The injector 11 extends into the side channel 30 . The different material streams 31 are separated by inlet channels, i.e. calipers 32 . The melt stream 17 is injected with additives 18 to create foam in the side stream which is transported to the chambers 33 and 34 . Chambers with solid calipers creating hollow profile space is usual.
[0135] In FIGS. 17 a and b , the introduction of additives 18 by pulsation into the side channel is shown. The arrangement is also for extrusion systems as in FIG. 16 as well as for pelletizing and continuous casting with mixing zone 10 applicable. FIG. 17 a shows the tube section 30 and the single tube 10 . FIG. 17 b shows the lateral section of the tube 30 / 10 . The nozzle body 2 has seven radially arranged orifices 4 and gives full coverage of the material section 17 by the jet streams 18 for dosing and mixing. A sequence of several jet streams 36 , 37 are introduced in the flow direction as shown in 17 b.
[0136] In FIG. 18 , the total apparatus for injectors of standard design is given in the layout. The utilization of pumps 101 and 105 enable the application to be used in a continuous operation (extrusion). The circuit for the additives 103 is separated from the circuit of the hydraulic oil of the servo 104 . The pressure of the circuits is regulated by an electrically activated presser limit valve 102 , 106 . The valve 112 is released by electro-hydraulic mechanics. The mechanics consists of a solenoid 109 , a spherical valve 108 , and the push rod connected to the high pressure piston 110 . The controller 122 regulates the electro-hydraulic mechanics according to the information 120 given by the operation data as there is injection time/extrusion data 123 according to the pressure sensor in the melt 114 , of the pressure of the additive circuit 102 and the pressure of the hydraulic oil of the servo 106 .
[0137] The arbitrary wave form generator 120 creates the opening current for the electro mechanism 112 . The introduction of the gas processors 117 into the melt stream 114 happens in the interface 116 part after the extruder tip 160 by a nozzle 113 extending into the channel. For heating, a heater band 159 is located around the nozzle 113 .
[0138] FIG. 19 shows a standard injector. This version shows a pocket hole valve 113 with a small front chamber. The valve seat 112 isolates the nozzle from the continuous pressurized circuit.
[0139] The push spring 131 increases the force resulting from the difference of force on the nozzle needle 112 and the hydraulic pressing (bias) 110 . The opening is activated by the solenoid 109 which releases the sphere of the valve 108 and hydraulic oil of the servo is streaming out of the high pressure chamber 110 .
[0140] FIG. 20 shows an injector of the state of art. The essential features can be readily recognized. The version with the electro-hydraulic activation is extended by throttle 129 and anchor 127 and double chamber. Standard Injectors having separate inlets 126 for the servo supply and the injection supply.
[0141] FIG. 21 shows a section of a modification of a standard “common rail injector”. The already available two supply borings are attached to a special fitting.
[0142] FIG. 22 shows the modification of a standard “common rail injector” with a second boring. The supply 132 of the hydraulic servo circuit is blocked by a pin. Additional supply is given by a boring 133 and a second fitting 126 for the servo circuit.
[0143] FIG. 23 shows a pump-nozzle configuration in principle, by means of the high pressure chamber being close to the location of the nozzle. The medium of the additive is supplied through a boring in the push rod 135 and the pressurizing is effected by an inlet valve 137 and an outlet-valve 139 . The penetration of the melt into the injector is prevented by a sphere 137 which is pressed by a non-return-spring 138 into the valve seat. The push rod 135 is activated by a magnetic swing system 127 . By stroke limit 134 the size of the pulsation is determined. The line for leakage 140 returns the overflowing medium.
[0144] FIG. 24 shows the principle of an airless spraying state of the art system, applied to the present application by using a valve sphere 139 within the nozzle. The advantage of a small front chamber can be reached by a overlapping 141 of the sphere valve 134 , 135 , 140 as shown in FIG. 23 .
[0145] FIG. 25 shows a hydraulic system for part production for instance for injection moulding and die casting systems. The operation of the injector is having a twin circuit system. The pressure multiplier is connected to the basic hydraulic system of the machine 142 . While processing the part there is time to load the system for injection. The pressure multiplier cylinder for the additive 143 and for the servo hydraulic oil 144 are pressurized and being regulated by the pressure limit valve 142 during the melt injection having the pressure p 4 . Subsequently the chambers of the cylinders are refilled by pumps 101 for the additive and pumps 105 for the hydraulic oil.
[0146] FIG. 26 shows the features of the pressure ramping y-axis in MPa 145 over the duration for the present processing. The melt pressure p 3 is shown by the curve 148 . The pressure of the additive p 1 is shown by curve 146 , the pressure of the servo hydraulic p 2 shown with the line 147 . The electric potential 153 to activate the electro-hydraulic regulation is shown by the curve 149 . Various wave forms can be produced and are shown by way of example as triangle 154 , half sinus waves 155 at different frequencies and full sinus wave form 156 with different frequencies and phases or full sinus form 157 in different frequency or different phases 158 as well as unsymmetrical wave forms, all being produced by an arbitrary wave form generator.
[0147] FIGS. 27, 28 and 29 show several melt channels. FIG. 27 shows a parallel melt channel 114 with an orifice positioned in the flow direction in an interface part 116 between the mould 162 and nozzle tip 160 of the barrel. This arrangement is applicable for dosage with drops 161 into the melt stream 114 . FIG. 28 shows a radial multiple orifices 163 facing in the flow and counterflow directions for excellent mixing of the additives with the melt in an enlarged melt channel 114 which causes additional mixing by change of velocity. FIG. 29 shows a continuous string introduction 164 into the melt channel. These method is able to process axial hollow cavities for extruded profiles.
[0148] FIGS. 30,31 and 32 show a nozzle with various orifices. FIG. 30 shows state of the art. FIG. 30 a shows a VCO valve cone orifice. FIG. 30 b shows radial multiple orifices. FIG. 30 c shows pocket hole orifices. FIG. 31 shows a nozzle for flow and counterflow introduction. For introduction of additives as drops into the melt, the nozzle is designed according to hydrodynamic principles. In order to prevent atomizing, sharp edges have to be avoided. The channel profile of FIG. 31 has smooth profiles in valve cone 170 and at the nozzle profiles 171 . FIG. 32 shows a nozzle introducing drops sidewise in flow direction. FIG. 33 shows a nozzle for atomizing in the conical seat 172 and plane seat 173 rectangular to the flow direction.
[0149] FIG. 34 shows a detail of the device for compounding a melt stream. This version is implemented in calipers 53 of profile moulds 51 or for array assembly for moulds to produce sheets. The section is showing details of FIGS. 16 a and 16 b . The view shows the material flow from right to left. The caliber 53 at the inlet side is conical 64 shaped. The inlet is provided with a pressure sensor 63 that is connected to the controller 62 to supply data thereto.
[0150] The introduction of additives to the medium may be in the flow direction 55 b or in the counterflow direction 55 a . The advantage of the counterflow is the introduction of individually closed dosages. The introduction may optionally be caused by pulsation. Also, use may be made of chicanes (i.e. obstacles) in the flow of the medium so that the change of velocity leads to shear forces and to additional mixing respectively in the expansion zone 60 .
[0151] FIG. 35 shows the top view of FIG. 34 and the relevant reference characters are the same. Note the narrow section in the melt channel.
[0152] In FIGS. 36 a and 36 b , the section of the inlet and outlet is shown related to the device in FIGS. 34 and 35 FIG. 36 b shows the inlet in a sectional view.
[0153] FIGS. 37 a and 37 b show the version of the invention as it is in FIGS. 33 a and 33 b but for simple foamed profiles as there are claddings with integrated insulation, panels and tubes. Reference numbers are the same as in FIG. 33 .
[0154] FIG. 38 shows a version of melt channel before the distribution chamber of the mould. Two inlet cones 64 , 65 and the center inlets 66 provide a twin chamber to the melt.
[0155] FIG. 39 shows a version of melt channel design with central inlet of the side channel and a concentrically (twin) introduction of additives and subsequent merging of the melt at spatially predetermined locations of the profile. The melt channel is crossing the main channel 67 in the center of the surrounded flow.
[0156] FIG. 40 a shows a rectangular profile. FIG. 40 b shows a circle, tube profile. FIG. 40 c shows an elliptical profile and FIG. 40 d shows a rounded rectangular profile. Several profile shapes with multiple components are shown for instance in FIGS. 33, 38 , 39 and 41 as being produced as simple tubular profiles.
[0157] FIG. 41 illustrates a device with an add on for existing extrusion systems and can be modified for multi-component operation. For reference, the melt channel has a flange 68 and the extruder has a flange 69 between which the interface part 70 for adding on is positioned in the melt channel 71 with through put.
[0158] FIG. 42 shows the interface part 70 of FIG. 41 in detail. The interface part 70 is constructed as a disc 70 that is attached between the flanges 68 and 69 . The disc 70 has injectors for introduction of the additives as well as diaphragms 72 to divert the melt channel. The tube 72 with attached planes for the hollow calipers is shown in principle.
[0159] In FIGS. 43 to 46 , hot runner valves for metal metal/ceramic powder technology, injection moulding systems are shown.
[0160] In FIG. 44 , a device in accordance with the invention is compared to a the state of art device.
[0161] FIGS. 45A to 45 C show the progressive activation of the needle tip and FIGS. 46A to 46 C correspond to FIGS. 45A to 45 C, respectively, and show the needle tip in detail.
[0162] FIG. 47 shows the version of the invention with high frequency pulsing (CDI Injector).
[0163] FIG. 48 shows the integration of CDI Injectors in the hot runner valve.
[0164] FIG. 49 shows the arrangement of a mixing and dosing head for example in the melt channel of the metal/powder feeding unit of an injection moulding machine or an extruder.
[0165] FIG. 50 shows an arrangement of a twin unit in counterflow used for liquid/liquid mixing as well as for extruders with a subsequent static mixer.
[0166] FIG. 43 shows a device for mixing and dosing and dosage. The inner nozzle needle 82 is activated by the adjusting device 93 and is in the shape of the seat 83 for a pocket hole orifice or a valve cone orifice. This insert also is part of the outer nozzle needle and shaped to be attached to the actuator piston 90 The supply of the additive happens by the boring 85 and is again attached to the interface 91 . The viscous medium is supplied by the channel 89 and passes between the outer nozzle 81 and the supply tube 94 , for instance a hot runner valve a plasticizing unit or a melt channel of an extruder to the final destination.
[0167] In FIG. 44 , the nozzle (“Prior Art”) shows the version of a conventional inner nozzle needle as a push rod 84 , as well as the inner nozzle seat, as well as the outer nozzle 94 , or both according to the position of the push rod 84 for opening or locking. The outer nozzle needle is moved and regulated according to the supply of the outer medium. In FIG. 44 the present device is shown and has a nozzle insert 83 shown as a valve cone (VCO). The orifices of the inner nozzle 83 are completely covered when inside needle 82 is locked. The inner substance is supplied between the nozzle needle 82 and the valve cone orifice 83 and is introduced in the inlet to the outer medium 89 . According to the position of the inner nozzle 82 and the pulsation, the atomizing of the introduced substance 85 into the outer medium 89 occurs. The conical shaped outer nozzle needle 83 , being at the same function for the inner nozzle needle is locking the orifices of the nozzle seat of the hot runner 94 of the feeding unit metal/ceramic powder technology unit 95 or of the melt channel of an 97 , and regulates the opening according to the demanded volume flow and the introduction of the two media 92 .
[0168] In FIG. 45A , the open position for introducing the outer medium is shown. The outer nozzle needle 81 is open. The inner nozzle 82 is closed. The substance 85 cannot penetrate. In FIG. 45B , the inner nozzle needle 82 is open and gives space for the valve cone orifices 83 and the inner substance 85 is introduced to the outer medium 92 . In FIG. 45C , the inner nozzle needle ( 82 ), as well as the outer nozzle needle ( 83 ) is closed.
[0169] FIGS. 46A, 46B , 46 C correspond to FIGS. 45A, 45B , 45 C but show enlarged details.
[0170] FIG. 47 shows the combination of a CDI injector 88 in a nozzle seat as cone valve/pocket hole nozzle 87 , having the function of the nozzle needle in the needle seat of the melt channel and closing the valve seat of the hot runner valve 94 . The CDI injector is activated by the position device 93 . The inner nozzle needle is activated by a solenoid/hydraulic or a piezo/hydraulic servo.
[0171] The supply of the substance happens through the fitting 91 . The melt is supplied by the channel 89 .
[0172] FIG. 48 shows details of FIG. 46 and differs by the melt channel 89 attached as a separate insert 87 .
[0173] FIG. 49 shows the arrangement of a mixing and dosing head 95 inside the nozzle tip of the metal and metal/ceramic powder technology feeding unit 96 of an injection moulding system. The insert 87 extends into the mixing head 95 and the outer nozzle 81 and at the same time as the insert 87 regulates the flow of the melt 89 .
[0174] FIG. 50 shows the dosing and mixing head 98 in a tube, for instance in a tube as liquid/liquid mixer of a melt channel of an extrusion system 99 . The inserts 87 a , 87 b reach into the conical nozzle seat of the mixer and modify the outer nozzle needle 81 according to the position of the volume flow of the melt 89 . The supply happens by a charging device 97 directing the melt into the conical valve seat. The additional mixing occurs by arranging the mixing heads in a counter flow to have counter impact on the media flow. Optionally, this arrangement can have four media which can be mixed together. Optionally, a static mixer can be attached subsequent to the mixing and dosing device.
INDEXING OF REFERENCE NUMBERS
[0175]
1.
Nozzle needle precisely moved
2.
Nozzle body
3.
Nozzle needle seat
4.
Plane plurality of orifice
arrangement
5.
Cavity at valve cone orifice
VCO
6.
Radial plurality of orifice
arrangement
7.
Axial boring in nozzle body
8.
Cavity at valve sack orifice
9.
High pressure pump
10.
I Channel of streaming medium
11.
Injector
12.
High pressure piping
13.
Leakage backflow piping
14.
Container of additives
15.
Common rail (communication
system)
16.
Cellular pump
17.
Streaming medium
18.
Injection spray stream
19.
Feeding unit barrel
20.
Dosing chamber of barrel of
injection moulding machines
21.
Nozzle of barrel
22.
Mould
23.
Hot runner nozzle seat
30.
Inner rod (caliber) of extrusion
mould
31.
Section of extruded profile
32.
Inner rod (caliber) for hollow
section
33.
Foamed inner section
34.
Hollow section
35.
Extruded profile
36.
Cascade shaped injection
37.
Radial plurality of orifice
arrangement for extrusion
38.
Core of the mould
39.
Jet streaming combustion air
40.
Screw of plasticizing unit
41.
Expansion zone in the
extrusion mould, preferable
situated in the inner rod of the
mould
51.
Mould for production of
profiles by extrusion
52.
Melt stream, feeding of melt
from extruder to the mould
53.
Caliber inside the melt stream
section, implementation for
the mould to conduct the melt
stream, particular with an
integrated melt channel.
54.
Injector, nozzle for introducing
of additives into the separately
arranged melt channel.
55.
Introduction of additives
55a.
Introduction in flow direction
55b.
Introduction in counter flow
56.
Outlet section of separately
arranged melt channel.
57.
Caliber inner rod for forming a
hollow section and hollow
profile.
58.
Melt channel with original
shaped extruded profile and
the corresponding section.
59.
High pressure pump for
additives.
60.
Zone of expansion for the
introduced gas creating
additives.
61.
Adjustable section for
controlled outflow, chicane for
mixing
621.
Adjustable section for
controlled inflow.
63.
Pressure sensoring cell for the
separately arranged melt
stream as indicator.
64.
Caliber inner rod with melt
channel and inlet opening.
65.
Tubular inlet section for
multiple shell arrangement for
extrusion profiles.
66.
Central inlet opening for the
inner shell of the extrusion
profile.
67.
Intersecting melt duct, passing
through main melt stream.
68.
Flange of the mould
69.
Flange of the extruder
70.
Intermediate add up
equipment
71.
Extension of the melt stream
channel
72.
Intersection through the melt
stream channel
81.
Melt medium nozzle needle
outside
82.
Additive nozzle needle inside
83.
Coaxial conical needle seat
84.
Bolt in boring to activate the
additive nozzle needle
85.
Supply of additives to the
boring
86.
Details of mixing and dosing
device
87.
Valve cone orifice, Pocket
hole orifice
88.
Common rail injector (CDI
injector)
89.
Supply channel for melt
stream
90.
Activator piston by hydraulics
91.
Supply of the additives
92.
Introduction of additives to the
melt
93.
Servo-mechanics for instance
electro/hydraulic,
piezo/hydraulic
94.
Hot runner nozzle seat
95.
Injection Molding nozzle seat
96.
Injection Molding feeding unit
nozzle
97.
Extrusion nozzle seat
98.
Supply device
99.
Melt channel for extruders
100.
Statical mixer
101.
Feeding device for gas
creators
102.
Pressure controller for gas C.
p1
103.
Circuit for gas creator
substance
104.
Hydraulic circuit for activation
105.
Feeding device for hydraulic
circuit
106.
Pressure control for hydraulic
c. p2
107.
Tank for hydraulic oil
108.
Spheres for valve
109.
Solenoid or piezo activator
device
110.
Hydraulic activation of the
valve
111.
Back pressure, seal
112.
Valve for the injector
113.
Nozzle of injector
114.
Gate of the melt stream
115.
Pressure sensor-cell in melt
stream
116.
Adapting device between the
runner
117.
Introduction of additives to the
melt
118.
Heater band of the adapting
device
119.
Pressure control for additives
p3
120.
Arbitrary Wave Form
Generator
121.
Pressure controller for
additives
122.
Controller
123.
Interface to metal injection
machine, extruder, die-casting
124.
Pump-nozzle combination
125.
Leakage piping
126.
Supply piping for hydraulic
127.
Anchor for solenoid activation
128.
Injector
129.
Throttle valve
130.
Valve push rod
131.
Spring for clamping
132.
Feeder piping for gas creator
133.
Additional channel for 2 nd
medium
134.
Stopping device f. stroke
limitation
135.
Pump push rod
136.
Feeding pipeline valve
137.
Feeding pipeline for sphere
valve
138.
Reverse motion spring 18
139.
Backpressure valve on melt
end
140.
Leakage pipeline
141.
Shrinkage of sphere seat
142.
Hydraulic system of basic
machine
143.
Pressure multiplier piston
additive
144.
Pressure multiplier piston
hydraulics
145.
Axis for force in MPa
146.
P1 pressure of additive
147.
P2 pressure of hydraulic
148.
P3 pressure of melt
149.
P5 pressure on control piston
150.
Axis of time
151.
Current supply to solenoid
152.
Center line
153.
Trapezoid wave shape
154.
Triangle wave shape
155.
Half sinus wave
156.
Full sinus wave
157.
Periodic wave form
158.
Unsymmetrical full sinus wave
159.
Heater band for injector
160.
Injector
161.
Introduction in flow direction
162.
Adaptation to the mould
163.
Spraying in melt flow/counter
melt flow
164.
Volume enlargement after
continuous introducing of
additives
165.
Nozzle body
166.
Slot shaped nozzle
167.
Radial shaped nozzle borings
168.
Valve cone orifice
169.
Enlarged Laval channel
170.
Nozzle needle open
171.
Channel of nozzle
171.
Valve cone orifice nozzle
channel
172.
Conical nozzle needle, axial
spray
|
The method introduces additives into a flowing melt or fluidized metallic/ceramic powder media in a pulsed high pressure manner. The nozzle needle of at least one nozzle is variable and highly precisely moved for the introduction by means of a device and in such a way that additive is dosed exactly in relation to the volume flow of the medium. The pulsating additive stream is injected into the flowing medium by at least one well-aimed nozzle opening. The additives are dosed by means of a pressure that can be variably adjusted by pulse width and pulse frequency. The desired homogenous distribution is obtained by the penetrating injection jet.
| 2
|
BACKGROUND OF THE INVENTION
The instant invention relates to an apparatus for handling elongate members, e.g., drill pipe, drill collars, well tubing, etc., at a well drilling site. More particularly, this invention provides a cable transport mechanism which may be used either to deliver pipe to the elevated rig floor well derrick or to lay down pipe from the rig floor to a lower storage area. Hence, the apparatus herein may be employed throughout the drilling operation for pipe handling tasks, but will be especially useful in pipe lay down operations.
At the well site where an oil well is being drilled or reworked, it is necessary that provision be made for handling of the drill pipe, well tubing, well casing, or drill collars which are used in the well. For example, during the drilling operation, it is continually necessary to provide additional lengths of drill pipe or the like to the derrick as the drilling progresses. Similarly, when the drilling operation is concluded or when problems are encountered during drilling, it may be necessary or desirable to remove the drilling string from the borehole. Accordingly, the operators at the well site are constantly confronted with the problem of efficiently handling the various tubular members used during the drilling operation, and of transporting these tubular members between the rig floor and a nearby storage area where the collars and drill pipe are typically maintained on racks in a stand-by position.
It has been customary in handling pipe or other tubular goods at a well site to provide an inclined trough or skidway adjacent the open side of the derrick to facilitate the transfer of the pipe from the drilling rig substructure, called the rig floor, and the pipe rack storage area. However, due to the weight of these tubular members, such relatively uncontrolled handling can result in damage to thread connections, and also because of the inordinate amount of manual handling which is required, can result in injury to workers at the well site.
Considerable attention has been directed toward devising various types of drill pipe handling apparatus in order to facilitate transfer of tubular goods from the pipe storage area to the usually elevated rig floor of the derrick substructure, and subsequently to transfer the same back to the storage area. One approach has been to provide a mechanical device with a pipe holding through which will accept a length of pipe from the storage area and thereafter lift the pipe or incline it in order to "feed" the pipe upwardly toward the rig floor. Illustrative of such devices is U.S. Pat. No. 3,559,821. Alternatively, powered trolleys riding on tracks could be provided to transport the pipe from the rig floor to the storage area or vice versa, as shown in U.S. Pat. No. 3,268,095 and the like.
Another approach has been to use a cable transport system to handle the pipe. A cable system has inherent advantages in that it can be most easily adapted to the conditions at the well site. Unlike purely mechanical systems, cable systems can usually be adapted to deliver pipe from a convenient storage area, which may be in a different position at different well sites to the rig floor, which may vary in elevation depending upon the particular well being drilled. U.S. Pat. Nos. 3,532,229 and 3,368,699 disclose cable systems for handling pipe at a well site. But in these patents, the pipe is secured only at one end to the cable system, and hence, manual attention of the workers is required to prevent damage to the free end of the pipe. Moreover, the systems disclosed in these patents rely to significant extent upon the use of the traditional pipe skidway.
Another approach has been to use transport carriages supported on a cable to handle the pipe. The use of front and rear carriages to support the pipe at the ends remedies the problems associated with a free and unsupported lower end as found in the above-described prior cable systems, but a system of this type does not permit rapid pickup or laydown operation. Also, if a change is made in the size of pipe to be handled, the carriages must be changed to accommodate the new pipe. An example of this approach to pipe handling at a well site is the apparatus disclosed in U.S. Pat. No. 3,825,129.
SUMMARY OF THE INVENTION
In accordance with the present invention, an apparatus for transporting an elongate member such as a section of drill pipe or the like between an elevated area, for example, a rig floor, and a lower storage area is provided which substantially enhances the speed of pipe handling and reduces the possibility of dropping the pipe.
The present invention comprises a cable track having a pair of support cables extending between the elevated rig floor and the lower storage area. A rear bucket is disposed on and movable along the cable track by a control mechanism such as a cable and sheaves arrangement. The rear bucket receives and holds the lower end of a section of drill pipe to provide support and includes a gripping mechanism mounted on the bucket to engage the end of the pipe preventing it from falling out while being transported.
A series of buckets comprising individual support buckets connected one to another by a length of cable or the like is positioned on the support cable track. The support buckets are movable along the cable track with the entire chain being anchored at a point proximate the rig floor. The series of buckets is situated above the rear bucket on the cable track; and when the rear bucket is raised to its uppermost position, the support buckets are pushed together. After the lower end of the pipe section to be transported is placed into the rear bucket and the bucket is begun to be lowered through the action of the control mechanism, the series of support buckets begins to move downwardly. As the rear bucket is being lowered, the series of support buckets extends out along the cable track. When the connection cables between the support buckets are stretched out, downward travel of the support buckets along the cable track is stopped. As the rear bucket is further lowered along the cable track, the lower end of the pipe section is inherently moved radially outward from the well derrick resulting in the pipe section becoming increasingly reclined. After the rear bucket has moved a sufficient distance down the cable track and out from the derrick, the pipe section being transported will recline far enough to be supported along the portion intermediate its ends by the series chain of support buckets which may at this point be fully extended. Each support bucket comprises a roller upon which the pipe section rests while being supported by the bucket; and as the pipe section continues to be transported by lowering of the rear bucket, the pipe section moves along over the rollers. A stop mechanism on the cable track limits the downward travel of the rear bucket along the cable track and consequently stops the travel of the pipe section being transported.
A draw works assembly is provided that receives the lower end of the cable track and equalizes the tension in each of the support cables forming the cable track. The draw works assembly includes a frame suitable for mounting on a skid with first and second fixed sheaves added on the frame. First and second movable sheaves are aligned with first and second fixed sheaves for receiving support cables that alternately pass over the fixed and the movable sheaves. First and second drums for taking in or paying out cable are provided, and a power drive mechanism for moving the first and second movable sheaves with respect to the fixed sheaves to slacken or tension the support cables is included. The first and second movable sheaves are disposed on opposite sides of a pivot point through which the power drive mechanism acts in moving the movable sheaves, to thereby equalize the tension in the support cables.
The draw works assembly slackens the support cables to begin laying down the pipe section supported in the rear bucket and the lower support bucket of the chain of support buckets. As the cables are slackened, the pipe section is reclined further until it is laid down at the storage area. The pipe section can then be removed from the buckets and the cables tensioned in preparation of raising the rear bucket along the cable track to receive another section of pipe. With the chain of support buckets removed, the apparatus can be utilized for pipe section pickup operations also.
Other aspects of the invention include a bucket for receiving a first end of the elongate member to be transported, which bucket comprises a frame having support sheaves mounted thereon to movably support the frame on a cable track. In addition, the bucket includes a gripping mechanism for engaging the elongate member to limit movement of the frame relative to the elongate member.
BRIEF DESCRIPTION OF THE DRAWINGS
The instant invention will be more particularly understood with reference to those particular embodiments of the invention as illustrated in the accompanying drawings.
FIGS. 1 - 5 are elevation views of a pipe handling apparatus in accordance with the present invention in place at the well site, illustrating the sequence of operation of the pipe handling apparatus during a pipe lay-down operation.
FIGS. 6 - 8 are top, front and side views respectively of one of the support buckets employed in the pipe handling apparatus illustrated in FIGS. 1 - 5.
FIGS. 9 - 11 are top, rear and side views of the rear bucket of the apparatus illustrated in FIGS. 1 - 5.
FIG. 12 is a perspective view of a cable draw works assembly which may be used in a pipe handling apparatus in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 - 5, apparatus in accordance with the present invention is shown operationally disposed proximate well drilling derrick 20 which is of a conventional construction and used in drilling operations. Derrick 20 has a rig floor 22 on which there is positioned a standard rotary table (not shown) from which the drilling string is suspended in a conventional manner. The upper portion of the derrick is not shown but includes an upper platform from which there is supported a traveling block having an elevator suspended therefrom. The elevator is a standard oil field tool for the handling of pipe within a derrick and is used to pick up pipe when going into the well, and to deliver pipe for transport to storage by the apparatus of this invention when coming out of the well borehole.
The pipe handling apparatus of this invention is disposed to one side of the derrick and transports pipe and other elongate members between the rig floor 22 and a lower storage area generally denoted by a reference numeral 24. In the storage area 24, a skid assembly 26 is provided atop catwalk 28. The height of skid assembly 26 may be selectively varied in order to facilitate the transfer of pipe between pipe storage rack 30 and the pipe handling section of the skid assembly.
A truck 32, having draw works assembly 34 mounted on the rear thereof, is disposed proximate catwalk 28. Draw works assembly 34 is a hydraulically powered unit for operating the pipe handling apparatus and at the conclusion of the pipe handling operation at one side rendering the entire apparatus readily transportable to another drilling site as needed.
Referring now specifically to FIG. 1, the apparatus of the present invention is shown at the beginning of a pipe lay-down operation. A section of drill pipe 36 is supported from above by the elevator (not shown) with the lower end being supported and held in rear bucket 38. Side-by-side support cables 40 are fixed at their upper end to support stand 42, which is mounted to rig floor 22, and the lower ends of support cables 40 are attached to draw works assembly 34. Support cables 40 form a cable track extending with an inclined attitude between the elevated area of the rig floor and the lower storage area. The cable track, therefore, extends downwardly and outwardly from the derrick 20.
Pull cable 44 connects to rear bucket 38, and after passing through sheave 46 on support stand 42, connects at its other end to draw works assembly 34. Rear bucket 38 is movable along the cable track formed by support cables 40 with pull cable 44 being utilized to apply a force to raise bucket 38 or controllably released to lower rear bucket 38. During the loading of the section of pipe 36 into rear bucket 38, pull cable 44 holds rear bucket 38 in a fixed position along the cable track. Pull cable 44, therefore, serves as a control mechanism for rear bucket 38.
Also mounted on support cables 40 is a series of support buckets generally denoted by reference numeral 48. The series of support buckets comprises preferably four support buckets, each individually movable along the cable track formed by support cables 40. The series of support buckets 48 are disposed ahead of rear bucket 38 with the uppermost support bucket in the series being anchored to support stand 42 by a length of cable, rope, or other similar flexible connecting material.
Referring next to FIG. 2, the section of pipe 36 remains supported at its upper end by the elevator and at its lower end by rear bucket 38. In this view, rear bucket 38 has been lowered along the cable track formed by support cables 40 to place the section of pipe 36 in a more reclining position. To so permit the lowering of rear bucket 38, pull cable 44 is let out from draw works 34. By the lowering of rear bucket 38, the series of buckets 48 is allowed to extend out along the support cables 40. Specifically, movement of rear bucket 38 to a lower position permits support buckets 50, 52 and 54 to also move to a lower position along the cable track. In FIG. 2, rear bucket 38 has been lowered a sufficient distance to fully extend the connecting cable 56 which attaches between support bucket 54 and support bucket 58. In the position shown, connecting cable 60 is only partly stretched out and connecting cable 62 is not stretched at all.
Turning now to FIG. 3, rear bucket 38 is shown in a yet lower position along support cables 40, as pull cable 44 has been let out further from the draw works 34. With rear bucket 38 being further lowered to this position, the series of support buckets 48 is fully extended along the guide track formed by support cables 40. The support buckets 50, 52, 54 and 58 are preferably spaced at regular intervals and maintained in their position by the anchor cable 64 attached between support bucket 58 and support stand 42.
It will be observed that the section of pipe 36 has been released from the elevator and is supported along its length by the support buckets forming the series of buckets 48 and by rear bucket 38. Rear bucket 38 includes a stop plate (see FIG. 10) which prevents the pipe 36 from sliding out of the buckets.
Transportation of pipe 36 continues, as shown in FIG. 4, with rear bucket 38 continuing to be lowered by pull cable 44. In so lowering rear bucket 38, pipe 36 moves along on the support buckets 50, 52, 54 and 58 which maintain their position along support cables 40. Pipe 36 continues to be supported by the support buckets and rear bucket 38 as it is being transported to the storage area. The support buckets are provided with rollers, as illustrated in FIG. 7, to permit pipe 36 to move easily thereover without hangup.
The lowering of pipe 36 continues with rear bucket 38 being permitted to move further down the guide track as controlled by cable 44 until it comes into contact with stopping mechanism 66. As shown, stopping mechanism 66 is carried on support cables 40 and has a chain 68 which attaches to skid 26. Stopping mechanism 66 along with chain 68 limits the downward travel of rear bucket 38.
From FIG. 4, it may be seen that pipe 36 is lowered sufficiently, before rear bucket 38 contacts stopping mechanism 66, to be free from support buckets 54 and 58. As shown, pipe 36 is supported at this point by rear bucket 38, support bucket 50 and support bucket 52. However, pipe 36 is very close to sliding off support bucket 52.
Upon rear bucket 38 and pipe 36 reaching the position shown in FIG. 4, draw works 34 slackens support cables 40 and lets out an additional length of cable 44, permitting rear bucket 38 and pipe 36 to move slightly further back, being restrained by stop mechanism 66 and chain 68. In moving pipe 36 slides from support bucket 52, but remains supported by support bucket 50 disposed at the front end of the pipe. Support cables 40 continue to be slackened by draw works 34 with pipe 36 becoming more inclined until it is finally laid down on skids 26. Support cables 40 are slackened an additional amount to permit removal of the stand of pipe 36 from skids 26 and be placed into storage.
After the stand of pipe 36 has been moved to storage, support cables 40 are drawn in by draw works 34 to again tension them and reestablish the cable track. Cable 44 can be drawn back in causing rear bucket 38 to advance upwardly on the cable track, moving rear bucket 38 toward the rig floor 22. As it is moved upwardly, rear bucket 38 engages the support buckets 50, 52, 54 and 58 along the way, causing them to be pushed together. Rear bucket 38 is moved along support cables 40 until reaching the location shown in FIG. 1, at which time a new section of pipe is placed in the rear bucket and a new pipe lay-down operation is again ready to begin.
In the case of pipe pickup, the series of support buckets 48 is removed and replaced with a single support bucket. The pipe is supported at one end by the rear bucket 38 and at the other end by the single support bucket. Pipe pickup is begun by tensioning the support cables until they assume a taut attitude. The section of pipe is then transported upwardly by the front and rear buckets as a pull cable attached to the rear bucket is drawn in by a draw works assembly. Upon reaching the rig floor, the anterior end of the pipe is gripped in an elevator and the pipe section is raised.
A suitable bucket for use in the series of support buckets 48 for supporting the pipe during its transportation is shown in FIGS. 6, 7 and 8. The bucket illustrated therein is a double sheave bucket having a support sheave mounted on each side for riding on each of the support cables. With particular reference to FIG. 6, bucket 50 includes a frame 70 comprising a first plate 72 and a second plate 74 which extend in a parallel fashion transversely to support cables 40. Attached to the sides of frame 70 is a sheave assembly 76, 78. A roller 80 is disposed centrally of frame 70 and is freely rotatable about axle 82 which is mounted in support plates 84 and 86 (not shown). Roller 80 is formed in the shape of an hourglass to assist in maintaining a section of pipe or other similar elongate member in a central position on support bucket 50.
Additional details of support bucket 50 may be had with reference to FIG. 7. Sheave assembly 76 comprises a pair of pulley plates 88 and 90 which surround a support sheave 92 with a bracket 94 extending between side plate 96 and pulley plate 90 to give support to the sheave assembly. Support sheave 92 is freely rotatable on an axle 98 having a first end carried in side plate 96 and a second end carried in pulley plate 90. Support bucket 50 and sheave assembly 76 are further illustrated in the side view of FIG. 8. In this view, bracket 94 is observed to be of a width equal to that of pulley plate 90 to give uniform support to sheave assembly 76.
Sheave assembly 78 is of a similar construction having pulley plates 100 and 102 surrounding a support sheave 104 that is freely rotatable about an axle 106. A bracket 108 adds support to the sheave assembly and connects between pulley plate 102 and a second end plate (not shown).
Frame 70 has a box-like construction formed by the side plates 96 and 110, the front and rear plates 72 and 74, the top plates 112 and 114, and the support plates 84 and 86. As shown, top plates 112 and 114 of frame 70 are placed in an inclined attitude, sloping toward the center of the bucket. This configuration, along with the configuration of roller 80, together constitute a concaved topside cross-sectional configuration for support bucket 50. This type of configuration, of course, assures that the pipe 36 will not roll to one side or the other, but will instead remain accurately centered on the support bucket.
In the plan view of FIG. 9, rear bucket 38 is shown accommodating the lower end of a section of pipe and is illustrated in position on support cables 40. The stand of pipe is accommodated in a channel 120 extending centrally of rear bucket 38 and butts against stop plate 122. Rearward motion of the section of pipe relative to rear bucket 38 is prevented by stop plate 122, thus preventing pipe that is being transported from sliding out. Channel 120 is formed by support plates 124 and 126 which extend along the entire length of rear bucket 38 with the pipe held within channel 120 resting on a floor plate 128 (FIG. 10).
Rear bucket 38 is similar in basic construction to support bucket 50; however, rear bucket 38 is longer and includes front support sheaves 130, 132 and rear support sheaves 134, 136. Rear bucket 38 is of a box-like construction having a frame comprising floor plate 128, side plates 138, 140, top plates 142, 144, stop plate 122 and front plates 146, 148.
As best illustrated in FIG. 10, top plate 142 extends in an inwardly inclined manner and is attached between support plate 124 and side plate 138. Similarly, top plate 144 connects between side plate 140 and support plate 126 and is also downwardly inclining. Also illustrated in FIG. 10 is stop plate 122, which as viewed from the rear, is observed to extend vertically in height to the top of side plates 138 and 140. Stop plate 122 and its connection to side plates 138, 140 and to floor plate 128 must be sufficiently sturdy to support the heavy weight presented by a near vertically standing section of pipe.
Referring again to FIG. 9, rear bucket 38 is outfitted with a gripper mechanism for maintaining the pipe within the channel 120 and to prevent forward motion of the pipe relative to rear bucket 38. The gripper mechanism comprises first and second spring-loaded lever arms 150, 152 which are pivotally mounted on opposite sides of channel 120. A cut out portion 154 in top plate 142 and side plate 124 is necessary to permit the lever arm 152 to extend from within the bucket frame into the channel 120. A similar cut out 156 is made in top plate 144 and support plate 126 to accommodate lever arm 150. Both lever arm 150 and 152 are spring biased by springs 158 and 160, respectively. A first end of spring 158 connects to a lug 162 attached to support plate 126, and the opposite end of spring 158 connects to lever arm 150 at a point intermediate the ends thereof. Spring 160 connects in a similar manner to a lug 164 attached to support plate 124.
With reference again to FIG. 10, an elevation view of the gripping mechanism of rear bucket 38 is in view with the stop plate 122 being cut-away. Specifically, in this view lever arm 152 is seen to have a collar 166 which receives a pin therethrough to provide lever arm 152 with pivotal movement, permitting various sizes of pipe to be held by the gripping mechanism. Lever arm 152 also has an extended portion 170 that passes through cut out 154 and extends into channel 120. Lever 150 is of a similar construction having a collar and extended portion pivotal around a pin.
FIG. 11 is a simple side view of rear bucket 38 illustrating the positioning of the bucket with respect to the support cables. The support sheaves 130, 132 and 134, 136 (now shown) are positioned vertically on side plates 138 and 140 to provide rear bucket 38 with a relatively low center of gravity with respect to the support cable 40. The positioning of the support sheaves can also be observed from the view in FIG. 10, wherein the support sheave assemblies 134 and 136 are shown in place on side plates 138 and 140. Also, FIG. 10 illustrates the support sheaves in more detail than does FIG. 11. The construction of the support sheaves 130, 132, 134 and 136 is similar to that of sheave assemblies 76 and 78 of support bucket 50 and will therefore not be discussed in detail.
The draw works assembly 34 is shown in detail in FIG. 12. Draw works assembly 34 is provided with a frame 180 suitable for mounting to a skid which can be disposed adjacent the catwalk 28 in some manner and comprises a series of fixed sheaves and movable sheaves. Support sheave 184 is held in position on a shaft 186 that is carried in a mounting plate 188 and support sheave 182 is similarly disposed on the opposite side of frame 180. Additional fixed sheaves are disposed at 188 and 190 for rotation about shaft 192 and shaft 194 (not shown), respectively, which are likewise supported on the frame 180. Moveable sheaves 196 and 198 are carried by a member 200 that is pivotally attached to a shaft 202 of a hydraulic cylinder 204. The hydraulic cylinder 204 and shaft 202 are adapted to vertically move the movable sheaves 196 and 198. Hydraulic cylinder 204 is disposed at a central position near the rear of frame 180 with fixed sheaves 188 and 190 being disposed on each side.
Support cables 40 enter the draw works assembly over the pair of support sheaves 182 and 184. The support cables 40 then extend upwardly to movable sheaves 196 and 198 and alternately travel around fixed sheaves 188, 190 and movable sheaves 196, 198. The support cables then pass through alignment sheaves 206 and 208 (not shown) which are disposed on the inside of frame 180. The ends of the two support cables 40 come off of the alignment sheaves 206 and 208 and are wound on drums 210 and 212. Drums 210 and 212 rotate around a single axle 214 which is carried by mounts 216 and 218 that are affixed to the front portion of frame 180. Another drum 220 is attached to frame 180 by a mount 222. Drum 220 is the take-up spool for pull cable 44 that attaches to rear bucket 38 and can be driven by a hydraulic or electric power source to operate as a winch.
Slackening or tensioning of support cable 40 is accomplished through the raising or lowering of member 200 by hydraulic cylinder 204 and shaft 202. It will be appreciated that it is important to the operation of the pipe handling system of the invention to maintain the support cables under substantially equal tension during the various pipe handling operations. Equal tensioning of the support cables is accomplished by the pivotal connection of member 200 to shaft 202. Specifically, a clevis 224 is mounted on the end of shaft 202 and receives the apex of a triangular shaped member 226 carried on the other underside of member 200. The triangular shaped member 226 pivots in clevis 224 about a pin 228. Accordingly, as the member 200 is being moved by hydraulic cylinder 204 to tension or slacken the support cables 40, the tension of the support cables will be equalized as the member 200 is able to pivot from side-to-side to compensate for any difference in cable tension existing between the two cables.
Numerous variations and modifications may obviously be made in the apparatus herein described without departing from the present invention. Accordingly, it should be clearly understood that the embodiment of the invention herein described and shown in the FIGURES of the accompanying drawings are illustrative only and are not intended to limit the scope of the invention.
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A pipe handling apparatus for transporting pipe, drill collars, or similar elongate members between the elevated drilling floor of a well derrick and a lower storage area is disclosed. The apparatus comprises a pair of support cables forming a cable track extending between the rig floor and the storage area with a rear bucket that receives and holds the lower end of the pipe riding on the support cables. The rear bucket is movable along the cable track by a third cable which controls the transporting of the pipe from the rig to the storage area in a pipe lay-down operation. A series of support buckets is anchored proximate the rig floor and is extendable along the cable track as the pipe is being transported, providing support to the intermediate portion of the pipe. A draw works, typically in the vicinity of the storage area, secures one end of the cable track and is provided with a take-up mechanism for the support cables to enable them to be slackened to permit the pipe to be laid down for unloading from the rear bucket and the chain of buckets in the storage area. The take-up mechanism also enables the cable track to be tensioned to facilitate the transportation of a pipe to the elevated rig floor and includes a mechanism for equalizing the tension in the support cables.
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