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This is a continuation of International Application No. PCT/GB94/02331, with an international filing date of Oct. 21, 1994, claiming priority of GB 9321861.8, filed Oct. 22, 1993 and GB 9400022.1, filed Jan. 4, 1994.
FIELD OF THE INVENTION
This invention relates to platelet-derived growth factor (PDGF) analogues and their use as cell antiproliferative agents.
DESCRIPTION OF THE RELATED ART
Relevant background material is incorporated herein by reference in the text to the listed references in the appended bibliography.
Platelet-derived growth factor (PDGF) is a potent mitogen for connective tissue cells and promotes the proliferation of fibroblasts and smooth muscle cells (SMC) 33!. The growth factor is a 28-31KD dimeric, highly basic (Pi=9.8-10) glycoprotein consisting of two highly homologous (up to 60% sequence homology) polypeptide chains which are the products of distinct genes. The gene products designated A (on chromosome 7) and B (on chromosome 22) are assembled to form either a disulphide-linked heterodimer (PDGF-AB) or a homodimer (PDGF-AA or PDGF-BB). Analysis of the PDGF present in human platelets reveals that it is a mixture of all three dimeric forms with AB being the predominant form (up to 70%) 10;12!. The human prot-oncogene, c-sis, which codes for the PDGF-B chain 21! has been identified as the human homologue of the v-sis oncogene of the transforming retrovirus, simian sarcoma virus. This oncogene codes for the protein p28 v-sis which has been identified as PDGF-BB 5!.
The cloning and amino acid sequencing of the A and B chains of human PDGF have shown that both chains are synthesised as precursor molecules with hydrophobic leader sequences and both chains undergo proteolytic cleavage at the N-termini during maturation. The B chain is also processed at the C-terminal end 21;20!.
The three isoforms of PDGF exert their biological effects by binding with different affinities to two different receptor types, denoted α and β. Ligand binding induces dimerization of receptors; the A-subunit of PDGF binds to α-receptors whereas the B-subunit binds to both α- and β-receptors 2!.
When PDGF dimer is treated with reducing agents, the protein loses its biological activity irreversibly, suggesting that the protein conformation is disturbed by reduction of critical disulphide bonds 16!. PDGF has 8 cysteine residues which are highly conserved between the two chains. Six residues are involved in 3 intramolecular disulphide bonds: Cys-16---Cys-60, Cys-49---Cys-97 and Cys-53---Cys-99. The other two cysteine residues are involved in asymmetrical inter-molecular disulphide bonds, Cys-43---Cys-52 11!.
A systematic analysis of the abilities of different peptides, derived from the PDGF-B chain sequence, to compete with 125 I-PDGF-BB for binding to PDGF β-receptors, has led to the identification of two regions in the B-chain corresponding to amino acid residues 35-40 and 78-83 that seem important for receptor binding. A peptide corresponding to the two sequences (ANFLVW---EIVRKKP) (SEQ ID NOS:12 & 13 respectively) has been found to be effective as an antagonist for PDGF, although detailed analysis has shown the pure peptide to be less active 6!.
Site-directed mutagenesis studies, using deletion and substitution mutants of PDGF-BB or of the homologous v-sis gene as well as PDGF-A/B chimeras, have also identified a number of amino acid residues which are important for the biological activity of PDGF. The region Ile-25---Phe-38 has been identified as a binding domain by site directed mutagenesis of the v-sis gene 9!. Amino acid residue Asn-34 has been found to be essential for the PDGF-B-like transforming efficiency of PDGF-A/B chimera 27!. Using a different functional assay, which selects for mutants with reduced binding to both receptor types, Ile-30 and, to a lesser extent, Arg-27 have been shown to be important 3!. Basic polypeptides such as polylysine and protamine sulphate inhibit PDGF binding to its receptor, suggesting a role for ligand positive charge in the binding interaction. A receptor binding domain has been assigned to a region at the C-terminal end which is rich with basic amino acid, residues Lys-80---Cys-97 39!. This region contains the sequence Val-78---Arg-79---Lys-80---Lys-81---Pro-82 (SEQ ID NO:14), which is conserved in both the A and B chains, and therefore may be involved in the binding of both chains to PDGF α-receptor. A mutant PDGF-A chain in which the cationic sequence Arg-Lys-Lys has been replaced by the sequence Glu-Glu-Glu displays a marked reduction in both binding affinity for PDGF α-receptor and mitogenic activity in fibroblast cells 7!. Initial studies with neutralizing monoclonal antibodies raised to PDGF-BB indicates that the segment between Thr-20 and Cys-43 represents a surface domain of PDGF-BB and contains amino acid residues involved in receptor binding 22!.
Recently, the crystal structure of the homodimeric BB isoform of human recombinant PDGF has been determined 26!. The protein polypeptide chain is folded into two highly twisted anti-parallel pairs of β-strands and contains an unusual knotted arrangement of three intramolecular disulphide bonds. Dimerization leads to the clustering of three surface loops at each end of the elongated dimer, which most probably form the receptor recognition sites. The three loops are: loop I: Ile-25---Leu38, loop II: Cys-53---Val-58 and loop III: Val-78---Lys-81.
Antibodies to PDGF would be extremely useful in the study of PDGF processing and biosynthesis. It has been difficult to make high avidity antibodies against PDGF, maybe because the molecule is conserved between species and only recently have monoclonal antibodies against PDGF become available 22;34;12;38!. Rabbit and goat antisera to PDGF have been made to the two chains using protein purified from human platelets or recombinant protein or synthetic peptides, some showing chain specificity and neutralizing activity 28;17;13;37;30!. None of the antibodies raised to peptides however have been capable of recognising the native molecule or able to neutralize its biological activities.
PDGF has been implicated in many biological systems. Originally, the close similarity between PDGF and the transforming factor involved in SSV transformation led to the concept that over-production of the factor was involved in the development of human malignancies 14!. Examination of many tumour cell lines shows that the A and B chains are commonly expressed in such cell lines 15;24!. In general, aberrant expression of PDGF or of PDGF receptors is likely to be involved in the stimulation of the growth of certain tumours. In addition, over-activity of PDGF could also be part of the development of certain non-malignant disorders involving an excess of cell proliferation. Examples include atherosclerosis, where PDGF-induced stimulation of smooth muscle cell proliferation could contribute to the thickening of the intima of affected vessels 32!, as well as chronic fibrotic processes, where PDGF could be involved in the stimulation of connective tissue cell proliferation. Ferns et al 8! showed that in a rat experimental model of angioplasty, polyclonal antibodies to PDGF administered intravenously inhibited smooth muscle cell accumulation in the intima of injured arteries, while administration of PDGF induced SMC proliferation in the media by 2-3 fold and, more significantly, increased SMC migration from the media to the intima by 20-fold 19!.
However, PDGF does have a normal function. PDGF and PDGF receptors are expressed in embryonic tissues and in the placenta 23;18! which suggests a function for PDGF during development. A role for PDGF in neuronal development has also been proven 25! and PDGF and its receptors are present in the peripheral and central nervous systems 40;36!. PDGF is known to stimulate growth as well as chemotaxis of connective tissue cells and also chemotaxis of inflammatory cells, which suggests a role in wound healing 4;35!. Recently, PDGF has been used in a clinical trial to look at its wound healing capability. Locally applied PDGF stimulates the healing of large bed sores 31!. PDGF β-receptors occur on capillary endothelial cells 29! and PDGF has weak angiogenic activity 29! which may suggest that its stimulatory effect is important in wound healing.
BRIEF SUMMARY OF THE INVENTION
The varied roles of PDGF, both beneficial and adverse, make PDGF agonists and antagonists highly desirable. They can be used as a replacement for PDGF in wound healing or as inhibitors of the adverse effects of PDGF. Antibodies with neutralizing activity, whether to the mitogenic effect of PDGF and/or the chemotactic effect can also be useful as inhibitors of PDGF adverse effects.
Accordingly, in one aspect the present invention provides novel PDGF peptide analogues and compositions consisting of or containing them for use as antiproliferative agents, particularly antiatherosclerotic, antiatherogenetic, anti-inflammatory or antifibrotic agents. The invention also provides such novel PDGF peptide analogues and compositions consisting of or containing them for use as PDGF agonists for use in wound healing.
Particular PDGF analogues according to the present invention are identified in Table 1 hereinbelow (SEQ ID NOS:1-7). Preferably, the PDGF peptide analogues of the invention, as prepared and used in other aspects and embodiments of the invention, are greater than about 90% pure, more preferably greater than about 95% pure, even more preferably greater than about 99% pure.
Pharmaceutical compositions in accordance with the present invention preferably comprise one or more of the PDGF analogues of the invention together with a pharmaceutically acceptable diluent and/or carrier. Suitable carriers/diluents are well known in the art and include saline or other sterile aqueous media, optionally including additional components such as buffer salts and preservatives, or sugars, starches, salts or mixtures thereof.
Peptides according to the present invention may be provided for use in any suitable form appropriate to the protocol of administration and/or the needs of a patient.
Apart from the pharmaceutically acceptable compositions referred to above, the peptides may for example be provided, either singly or in combination, in lyophilized or freeze dried solid forms.
Within the scope of the invention are linked peptides comprising a first analogue selected from the group consisting of GP1 (SEQ ID NO:1), GP2 (SEQ ID NO:1), GP3 (SEQ ID NO:2), GP4 (SEQ ID NO:2), GP9 (SEQ ID NO:3) and GP10 (SEQ ID NO:3) (as identified in Table 1 hereinbelow) and a second peptide analogue selected from the group consisting of GP5 (SEQ ID NO:4), GP6 (SEQ ID NO:4), GP7 (SEQ ID NO:5), GP8 (SEQ ID NO:5), GP21a (SEQ ID NO:6), GP21 (SEQ ID NO:7) and GP22 (SEQ ID NO:7) (as identified in Table 1 hereinbelow).
The invention further provides the novel PDGF peptide analogues for use in assays and kits for assays.
It is to be understood that within the scope of the present invention are peptide analogues as described and identified herein in which one or more amino acids are substituted with other amino acids, or in which there is inserted a spacer, for example a dithiol group or a diamino group or multiples of amino acid residues, e.g. glycine, as shown in Table 2 hereinbelow, peptides GP11 (SEQ ID NO:8), GP12 (SEQ ID NO:8), GP13 (SEQ ID NO:9) and GP14 (SEQ ID NO:9). The spacer may also be a homo- or hetero-bifunctional crosslinker, for example the heterobifunctional crosslinker N-(4-carboxy-cyclohexyl-methyl)-maleimide, as shown in Table 3 hereinbelow, peptides GP20 and GP23 (SEQ ID NOS:10 & 11, respectively), providing generally of course that the essential activity of the peptide remains substantially unchanged.
The invention further provides the synthesis and use of cyclic peptides such as those derived from GP4 (SEQ ID NO:2) and GP8 (SEQ ID NO:5) as shown in Table 4 below, peptides GP24 (SEQ ID NO:1) and GP25 (SEQ ID NO:6).
The invention further provides the novel PDGF peptide analogues for use in assays and kits for assays, either in the free form or linked to a carrier molecule such as a protein or a solid particle, as well as modified peptides with e.g. biotin or fluorescein isothiocyanate, such as those shown in Table 5 hereinbelow, peptides GP15 (SEQ ID NO:1), GP16 (SEQ ID NO:2), GP19 (SEQ ID NO:3), GP17 (SEQ ID NO:4) and GP18 (SEQ ID NO:5).
In a second aspect, the present invention provides a method of inhibiting or stimulating cell proliferation, particularly smooth muscle cell, 3T3-fibroblast cell, connective tissue cell or inflammatory cell proliferation, by use or administration, particularly to a host, of an effective amount of a PDGF peptide analogue as defined above.
The invention further provides a method of inhibiting or stimulating PDGF-induced DNA synthesis comprising use or administration, such as to a host, of an effective amount of a PDGF peptide analogue as defined above.
In a further aspect, the present invention provides PDGF peptide analogues as defined above for use in inhibiting or stimulating growth and/or chemotaxis of cells such as those identified above.
In yet a further aspect, the present invention provides the above-defined PDGF peptide analogues, particularly the linked peptide analogues of the invention, for use as immunogens for the production of polyclonal and monoclonal antibodies to PDGF, especially for diagnostic, prognostic and therapeutic uses. Such methods of production of polyclonal and monoclonal antibodies are also within the scope of the invention.
In yet another aspect of the present invention, the novel PDGF analogues are provided for and used in methods of inhibiting PDGF-induced DNA synthesis, for example by use of or administration of an effective amount of one or more of the above defined PDGF peptide analogues.
Administration of peptides of the invention in any of the methods described herein may be via any suitable protocol. Preferably, administration to a host, especially a human host, is by intravenous injection or infusion, and may be systemic or topical. Such administration of peptides of the invention is in such an amount as to give the desired effective result of the peptide's activity at the intended site. Thus, a quantity which constitutes an "effective" amount may depend upon various parameters, such as body weight of the patient, degree of activity required, intended site of activity, severity of the condition to be treated or prevented, all of which will be well understood and appreciated by persons skilled in the art.
Generally, an amount (or total amount) of peptide will be administered which gives a concentration in plasma of from about 1 to about 100 mg ml -1 , more preferably from about 1 to about 10 mg ml -1 .
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described in further detail, with reference to the accompanying drawings, in which:
FIG. 1 shows relative mitogenic effects of various PDGF related peptides;
FIGS. 2A and 2B show the results of a 125 I-PDGF binding assay, as described further below;
FIGS. 3A and 3B show the results of titrations of, respectively, anti-Tg-GP4 vs.GP4 and anti-Tg-GP8 vs.GP8;
FIGS. 4A and 4B show the results of titrations of, respectively, anti-Tg-GP4 vs.PDGF-BB and anti-Tg-GP4 vs.FGF and EGF;
FIGS. 5A and 5B show the results of titrations of selected poly- and monoclonal antibodies by direct ELISA against PDGF-BB;
FIG. 6 shows the inhibition of radiolabelled PDGF-BB binding to human smooth muscle cells by anti-peptide antibodies; and
FIGS. 7A and 7B, 8A and 8B, and 9A and 9B show the HPLC and mass spectroscopy profiles of peptides GP4, GP8 and GP14, respectively (SEQ ID NOS:2, 5, and 9, respectively).
DETAILED DESCRIPTION OF THE INVENTION
Methods
1) Synthesis of PDGF-BB Peptide Analogues
A series of PDGF-BB related peptides were synthesised, with or without modifications, by solid phase on a Milligen 9050 Pepsynthesizer, using the FMOC-polyamide continuous method, as listed in Table 1 hereinbelow (SEQ ID NOS:1-7).
Acetylation of the N-terminal end of the peptides was performed after the completion of the synthesis. The resin was acetylated on the solid-support with 45% acetic anhydride in dimethylformamide. Deprotection and cleavage of the resin were carried out in the normal manner.
Biotinylation and FITC labelling were carried out while the peptides were still attached to the resin and prior to deprotection. Biotin-caproate-N-hydroxysucccinimide (B-NHS) and fluorescein isothiocaynate were used to label the free N-terminal end of the peptides.
All peptides were purified to at least 95% homogeneity by HPLC and their molecular weights determined by mass spectroscopy. FIGS. 7, 8 and 9 show examples of the HPLC and mass spectroscopy profiles of peptides GP4 (SEQ ID NO:2), GP8 (SEQ ID NO:5) and GP14 (SEQ ID NO:9), respectively.
2) Effect of PDGF Peptides on Fibroblast Cells in Culture
The stimulatory or inhibitory effect of the peptides on the murine fibroblast cell line Swiss 3T3.A31 were investigated using the 3 H!-thymidine uptake assay as described by Raines & Ross 28!.
3) Effect of PDGF Peptides on 125 I-PDGF-BB Binding to 3T3 Cells and Human Smooth Muscle Cells
PDGF-BB binding inhibition assay was performed as described by Engstrom et al 6!. A murine fibroblast cell line 3T3.A31 and human aortic smooth muscle cells were used.
4) Production of Antisera to PDGF-Peptides
Rabbits and mice were immunised with the peptides either in the free form mixed with Freund's adjuvant or conjugated to a carrier protein (Thyroglobulin or keyhole haemocyanin). Antisera were tested for antibody production to the peptides and PDGF using ELISA, dot blot assays and SDS-PAGE followed by Western blotting.
5) Effect of Anti-PDGF peptides antibodies on 125 I-PDGF binding to Human Smooth Muscle cells
The IgGs of the polyclonal anti- PDGF peptides antisera were purified from the antisera by affinity chromatography on a protein G -Sepharose column as described by the manufacturers (Pharmacia, Uppsala, Sweden). The effect of the IgG on the binding of radiolabelled PDGF-BB to human smooth muscle cells was investigated using essentially the same procedure as for the peptides (method 3 above). In the test, peptides were replaced with IgG.
Results
The peptides were tested for their ability to stimulate thymidine uptake in the cells in culture.
FIG. 1 shows an example of the results obtained with some of the peptides. Peptide GP4 (SEQ ID NO:2) showed the highest stimulatory effect acting as an agonist for PDGF-BB. The mitogenic effect of GP4 was almost completely abolished upon reduction and alkylation of the C-terminal end cysteine residue. This strongly suggests that the peptide is acting via the formation of a dimeric form during the incubation with the cells and that it is the dimerisation which produces the increase in the stimulatory activity. This conclusion is also supported by the low stimulatory effect of peptide GP2 (SEQ ID NO:1) which has the same amino acid sequence as GP4 but without the C-terminal cysteine.
Peptide GP8 (SEQ ID NO:5) was not as stimulatory as GP4 (SEQ ID NO:2).
Some of the peptides were tested for their ability to inhibit the binding of radiolabelled PDGF-BB to 3T3 cells. Both GP4 (SEQ ID NO:2) and GP8 (SEQ ID NO:5) showed modest inhibition of binding at the concentrations tested, as illustrated in FIG. 2A. Peptides GP20 and GP14 (SEQ ID NOS:10 & 9, respectively) were potent inhibitors of labelled PDGF binding to human smooth muscle cells, as shown in FIG. 2B.
Rabbits immunised with GP4 and GP8 peptides (SEQ ID NOS:2 & 5, respectively) linked to thyroglobulin produced high titre antibodies to the corresponding immunising peptide as determine by ELISA, as illustrated in FIGS. 3A and 3B.
One of the rabbits immunised with GP4 (SEQ ID NO:2) also produced antibodies reactive with native PDGF-BB, and had no cross reactivity with human recombinant fibroblast growth factor (FGF) and epidermal growth factor (EGF). This is illustrated in FIG. 4.
Tables 6, 7 and 8 hereinbelow summarise the results of immunochemical characterisation of polyclonal and monoclonal antisera raised to PDGF-derived peptides.
Western immunoblot analysis of polyclonal antisera reactivity with native and reduced PDGF-BB (Table 6) shows that peptides GP4 and GP21a (SEQ ID NOS:2 & 6, respectively) produced antibodies that reacted with the native PDGF. The competitive ELISA data are shown in Table 7. 15 monoclonal antibody hybridomas raised to peptide GP4 (SEQ ID NO:2) coupled to thyroglobulin were immunochemically characterised as shown in Table 8. FIGS. 5A and 5B show typical titration curves for polyclonal and monoclonal antisera against PDGF-BB.
The IgG fraction from rabbits immunised with peptides GP4 and GP21a (SEQ ID NOS:2 & 6, respectively) were effective in inhibiting the binding of radio-labelled PDGF-BB to human smooth muscle cells in culture, as shown in FIG. 6.
TABLE 1______________________________________PDGF-B CHAIN PEPTIDES______________________________________LOOP I .sup.25 I-S-R-R-L-I-D-R-T-N-A-N-F-L.sup.38 GP1Ac-.sup.25 I-S-R-R-L-I-D-R-T-N-A-N-F-L.sup.38 GP2 .sup.25 I-S-R-R-L-I-D-R-T-N-A-N-F-L.sup.38 -C GP3Ac-.sup.25 I-S-R-R-L-I-D-R-T-N-A-N-F-L.sup.38 C GP4 .sup.25 I-S-R-R-L-I-D-R-T-N-A-N-F-L-V-W-P-P-C.sup.43 GP9Ac-.sup.25 I-S-R-R-L-I-D-R-T-N-A-N-F-L-V-W-P-P-C.sup.43 GP10LOOP III .sup.73 R-K-I-E-I-V-R-K-K.sup.81 GP5Ac-.sup.73 R-K-I-E-I-V-R-K-K.sup.81 GP6 .sup.73 R-K-I-E-I-V-R-K-K.sup.81 -C GP7Ac-.sup.73 R-K-I-E-I-V-R-K-K.sup.81 -C GP8 .sup.73 R-K-I-E-I-V-R-K-K-P-I-F-K-K-A-T-V.sup.89 GP21a .sup.73 R-K-I-E-I-V-R-K-K-P-I-F-K-K-A-T-V.sup.89 -C GP21Ac-.sup.73 R-K-I-E-I-V-R-K-K-P-I-F-K-K-A-T-V.sup.89 -C GP22______________________________________
TABLE 2__________________________________________________________________________PDGF-B CHAIN PEPTIDES(LOOP I & LOOP III using Glycyl spacers)__________________________________________________________________________ .sup.25 I-S-R-R-L-I-D-R-T-N-A-N-F-L.sup.38 -(G-G-G-G)- GP11 .sup.73 R-K-I-E-I-V-R-K-K.sup.81 -CAc-.sup.25 I-S-R-R-L-I-D-R-T-N-A-N-F-L.sup.38 -(G-G-G-G)- GP12 .sup.73 R-K-I-E-I-V-R-K-K.sup.81 -C .sup.25 I-S-R-R-L-I-D-R-T-N-A-N-F-L.sup.38 -(G-G-G-G-G-G)- GP13 .sup.73 R-K-I-E-I-V-R-K-K.sup.81 -CAc-.sup.25 I-S-R-R-L-I-D-R-T-N-A-N-F-L.sup.38 -(G-G-G-G-G-G)- GP14 .sup.73 R-K-I-E-I-V-R-K-K.sup.81 -C__________________________________________________________________________
TABLE 3__________________________________________________________________________CROSS-LINKED PDGF LOOP I & LOOP III PEPTIDES__________________________________________________________________________Ac-.sup.25 I-S-R-R-L-I-D-R-T-N-A-N-F-L-V-W-P-P-C.sup.43 -(SMCC)- GP20 .sup.73 R-K-I-E-I-V-R-K-K.sup.81 -CAc-.sup.25 I-S-R-R-L-I-D-R-T-N-A-N-F-L.sup.38 -C-(SMCC)- GP23 .sup.73 R-K-I-E-I-V-R-K-K.sup.81 -C__________________________________________________________________________ {SMCC:N-(4-carboxy-cyclohexyl-methyl)-maleimide OR any heterobifunctional crosslinker
TABLE 4______________________________________CYCLIC PDGF-B CHAIN PEPTIDES______________________________________LOOP I1 #STR1##LOOP III2 #STR2##______________________________________ (Xa = bridging spacer arm) aa1 = amino acid/acids of Cterminus aa2 = amino acid/acids of Nterminus
TABLE 5______________________________________AFFINITY-LABELLED PDGF-B CHAIN PEPTIDES______________________________________LOOP IX-.sup.25 I-S-R-R-L-I-D-R-T-N-A-N-F-L.sup.38 GP15X-.sup.25 I-S-R-R-L-I-D-R-T-N-A-N-F-L.sup.38 -C GP16X-.sup.25 I-S-R-R-L-I-D-R-T-N-A-N-F-L-V-W-P-P-C.sup.43 GP19LOOP IIIX-.sup.73 R-K-I-E-I-V-R-K-K.sup.81 GP17X-.sup.73 R-K-I-E-I-V-R-K-K.sup.81 -C GP18______________________________________ (X = Biotin or FITC)
TABLE 6__________________________________________________________________________Polyclonal anti-PDGF peptides antisera analysis by western Blot. vs PDGF vs PDGF vs PDGF vs RED-PDGF vs RED-PDGFAntibodyImmunogen Ser-1/100 Ser-1/1000 Ser-1/10000 Ser-1/100 Ser-1/10000__________________________________________________________________________Rb 86GP4 - - - ++ -Rb 65Tg-GP4 ++++ +++ - +++++ +++++Rb 66Tg-GP4 +++ - - +++++ +++Rb 109GP10 - - - ++ -Rb 37GP10 - - - +++ ++Rb 38Tg-GP10 - - - ++++ +++Rb 39Tg-GP10 - - - +++++ ++++Rb 112Tg-GP10 - - - +++ +Rb 67Tg-GP8 - - - ++++ ++Rb 68Tg-GP8 + - - ++ -Rb 78GP21a +++++ +++++ + +++++ -Rb 91GP21a - - - +++ (1/200) + (1/20,000)Rb 113Tg-GP4 - (1/200) - - - (11200) - (1/20,000)Rb 114Tg-GP4 ++ (1/200) - - ++++ (1/200) + (1/20,000)__________________________________________________________________________ +++++ Very strong ++++ Strong +++ Medium ++ Weak + Very weak - Negative
TABLE 7__________________________________________________________________________Competitive ELISA analysis of polyclonal anti-PDGF-BB peptides antisera GP4 GP10 GP21a GP8 PDGFAntibodyImmunogen titre IC50 IC50 IC50 IC50 IC50__________________________________________________________________________Rb 86GP4Rb 65Tg-GP4 1/243,000 3 nM 3 nM NONE >6000 nM 180 nMRb 66Tg-GP4 1/27,000 <2 nM <2 nM NONE NONE NONERb 109GP10 1/10,000 2 nM 4 nM NONE NONE NONERb 37GP10 1/21,000 20 nM 10 nM NONE NONE NONERb 38Tg-GP10 1/27,000 156 nM 74 nM NONE NONE NONERb 39Tg-GP10 1/100,000 2 nM 2 nM NONE NONE NONERb 112Tg-GP10 1/243,000 2 nM 3 nM NONE NONE NONERb 61Tg-GP8 1/243,000 Not Sig Not Sig Not Sig 2 nM 200 nMRb 68Tg-GP8 1/243,000 Not Sig Not Sig Not Sig <2 nM 30 nMRb 78GP21a 1/15,000 NONE NONE 100 nM NONE NONERb 91GP21a ND ND ND ND ND NDRb 113Tg-GP4 1/100,000Rb 114Tg-GP4 1/2,000__________________________________________________________________________ Peptides tried up to 6000 nM, PDGF up to 200 nM
TABLE 8__________________________________________________________________________Reactivities of monoclonal antibodies sub-class, ELISA, CELIA and Westernblot analysis ELISA ELISA BLOT BLOT CELIA CELIA CELIA CELIA CELIAANTIBODY Sub-class TITRE PDGF* RED PDGF PDGF GP4 GP10 GP21a GP8 PDGF**__________________________________________________________________________1DMB IgG1 ND -ve + - - - - - -2DMB IgG1 ND -ve + - 2 uM 2 uM - - -3DMB IgG1 ND -ve + - - - - - -4DMB IgG1 ND -ve +++ - 150 nM 150 nM - - -9DB-1 EgG1 1/10 -ve - - 1 uM 1.2 uM - - +10%?10DB-1 EgG1 1/243 10% +++++ - 400 nM >6 uM - - +10%?11DB-1 IgM 1/2 30% ++ - - - - - +175%?12DB-1 IgG1 1/243 -ve +++++ - 2 uM - - - -13DB-1 IgG1 1/10 -ve - - 200 nM 400 nM - - -15DB-1 IgM 1/9 31% ++ - - - - - +356%?17DR-1 IgG1 1/81 30% +++++ - 180 nM 3 uM - - +25%?19DB-1 IgG1 1/1000 -ve - - 18 nM 18 nM - - +10%?21DB-1 IgG1 1/1000 -ve - - 18 nM 30 nM - - -22Da-1 IgG1 1/1000 -ve - - 20 nM 25 nM - - -__________________________________________________________________________ *Expressed as a percentage of OD given by 500 ng/ml Rb anitPDGF (Bochem) **An Increase in signal may be caused by crosslinking In CELIAS, peptides tried up to 6000 nM, PDGF up to 200 nM
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__________________________________________________________________________# SEQUENCE LISTING- (1) GENERAL INFORMATION:- (iii) NUMBER OF SEQUENCES: 14- (2) INFORMATION FOR SEQ ID NO: 1:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 14 amino (B) TYPE: amino acid (C) STRANDEDNESS: single (D) TOPOLOGY: both- (ii) MOLECULE TYPE: peptide- (ix) FEATURE: (A) NAME/KEY: Modified-sit - #e (B) LOCATION: 1#/note= "Ile may be acetylated":- (ix) FEATURE: (A) NAME/KEY: Cross-links (B) LOCATION: 1#/note= "A cyclic peptide may be formed by - # linking Ile 1 with Leu 14 via a bridging spacer ar - #m"- (ix) FEATURE: (A) NAME/KEY: Binding-site (B) LOCATION: 1#/note= "Ile may be bound to biotin or FITC"#1: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Ile Ser Arg Arg Leu Ile Asp Arg Thr Asn Al - #a Asn Phe Leu# 10- (2) INFORMATION FOR SEQ ID NO: 2:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 15 amino (B) TYPE: amino acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (ix) FEATURE: (A) NAME/KEY: Modified-sit - #e (B) LOCATION: 1#/note= "Ile may be acetylated":- (ix) FEATURE: (A) NAME/KEY: Binding-site (B) LOCATION: 1#/note= "Ile may be bound to biotin or FITC"#2: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Ile Ser Arg Arg Leu Ile Asp Arg Thr Asn Al - #a Asn Phe Leu Cys# 15- (2) INFORMATION FOR SEQ ID NO: 3:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 19 amino (B) TYPE: amino acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (ix) FEATURE: (A) NAME/KEY: Modified-sit - #e (B) LOCATION: 1#/note= "Ile may be acetylated":- (ix) FEATURE: (A) NAME/KEY: Binding-site (B) LOCATION: 1#/note= "Ile may be bound to biotin or FITC"#3: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Ile Ser Arg Arg Leu Ile Asp Arg Thr Asn Al - #a Asn Phe Leu Val Trp# 15- Pro Pro Cys- (2) INFORMATION FOR SEQ ID NO: 4:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 9 amino (B) TYPE: amino acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (ix) FEATURE: (A) NAME/KEY: Modified-sit - #e (B) LOCATION: 1#/note= "Arg may be acetylated":- (ix) FEATURE: (A) NAME/KEY: Binding-site (B) LOCATION: 1#/note= "Arg may be bound to biotin or FITC"#4: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Arg Lys Ile Glu Ile Val Arg Lys Lys1 5- (2) INFORMATION FOR SEQ ID NO: 5:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 10 amino (B) TYPE: amino acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (ix) FEATURE: (A) NAME/KEY: Modified-sit - #e (B) LOCATION: 1#/note= "Arg may be acetylated":- (ix) FEATURE: (A) NAME/KEY: Binding-site (B) LOCATION: 1#/note= "Arg may be bound to biotin or FITC"#5: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Arg Lys Ile Glu Ile Val Arg Lys Lys Cys# 10- (2) INFORMATION FOR SEQ ID NO: 6:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 17 amino (B) TYPE: amino acid (C) STRANDEDNESS: single (D) TOPOLOGY: both- (ii) MOLECULE TYPE: peptide- (ix) FEATURE: (A) NAME/KEY: Cross-links (B) LOCATION: 1#/note= "A cyclic peptide may be formed by - # linking Arg 1 with Val 17 via a bridging spacer ar - #m"#6: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Arg Lys Ile Glu Ile Val Arg Lys Lys Pro Il - #e Phe Lys Lys Ala Thr# 15- Val- (2) INFORMATION FOR SEQ ID NO: 7:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 18 amino (B) TYPE: amino acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (ix) FEATURE: (A) NAME/KEY: Modified-sit - #e (B) LOCATION: 1#/note= "Arg may be acetylated":#7: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Arg Lys Ile Glu Ile Val Arg Lys Lys Pro Il - #e Phe Lys Lys Ala Thr# 15- Val Cys- (2) INFORMATION FOR SEQ ID NO: 8:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 28 amino (B) TYPE: amino acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (ix) FEATURE: (A) NAME/KEY: Modified-sit - #e (B) LOCATION: 1#/note= "Ile may be acetylated":#8: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Ile Ser Arg Arg Leu Ile Asp Arg Thr Asn Al - #a Asn Phe Leu Gly Gly# 15- Gly Gly Arg Lys Ile Glu Ile Val Arg Lys Ly - #s Cys# 25- (2) INFORMATION FOR SEQ ID NO: 9:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 30 amino (B) TYPE: amino acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (ix) FEATURE: (A) NAME/KEY: Modified-sit - #e (B) LOCATION: 1#/note= "Ile may be acetylated":#9: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Ile Ser Arg Arg Leu Ile Asp Arg Thr Asn Al - #a Asn Phe Leu Gly Gly# 15- Gly Gly Gly Gly Arg Lys Ile Glu Ile Val Ar - #g Lys Lys Cys# 30- (2) INFORMATION FOR SEQ ID NO: 10:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 29 amino (B) TYPE: amino acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (ix) FEATURE: (A) NAME/KEY: Cross-links (B) LOCATION: 19..20#/note= "Cross-linker may beION: N-(4-carboxy - #-cyclohexyl-methyl)-maleimide or any other het - #erobifunctional cross-linker."- (ix) FEATURE: (A) NAME/KEY: Modified-sit - #e (B) LOCATION: 1#/note= "Ile may be acetylated":#10: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Ile Ser Arg Arg Leu Ile Asp Arg Thr Asn Al - #a Asn Phe Leu Val Trp# 15- Pro Pro Cys Arg Lys Ile Glu Ile Val Arg Ly - #s Lys Cys# 25- (2) INFORMATION FOR SEQ ID NO: 11:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 25 amino (B) TYPE: amino acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (ix) FEATURE: (A) NAME/KEY: Cross-links (B) LOCATION: 15..16#/note= "Cross-linker may beION: N-(4-carboxy - #-cyclohexyl-methyl)-maleimide or any other het - #erobifunctional cross-linker."- (ix) FEATURE: (A) NAME/KEY: Modified-sit - #e (B) LOCATION: 1#/note= "Ile may be acetylated":#11: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Ile Ser Arg Arg Leu Ile Asp Arg Thr Asn Al - #a Asn Phe Leu Cys Arg# 15- Lys Ile Glu Ile Val Arg Lys Lys Cys# 25- (2) INFORMATION FOR SEQ ID NO: 12:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 6 amino (B) TYPE: amino acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide#12: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Ala Asn Phe Leu Val Trp1 5- (2) INFORMATION FOR SEQ ID NO: 13:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 7 amino (B) TYPE: amino acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide#13: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Glu Ile Val Arg Lys Lys Pro1 5- (2) INFORMATION FOR SEQ ID NO: 14:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 5 amino (B) TYPE: amino acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide#14: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Val Arg Lys Lys Pro1 5__________________________________________________________________________
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Novel peptide analogues of platelet-derived growth factor, for use in inhibiting or stimulating growth and/or chemotaxis of cells, e.g., smooth muscle cells, are provided. Also provided are compositions of matter comprising those peptide analogues.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of PPA Ser. No. 60/883,001, filed Dec. 31, 2006 by the present inventor.
FEDERALLY SPONSORED RESEARCH
Not Applicable
SEQUENCE LISTING OR PROGRAM
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to the identification and retrieval of digital data by a computing device.
2. Prior Art
A method for the discovery of digital data, such as images, that are organized for point-wise two dimensional presentation (2DDDs), that are similar to a target 2DDD is invented here. Formulae from algebraic topology [Spanier] are used to compute signatures that characterize equivalence classes of 2DDDs. The method leverages these “equivalence signatures” to find 2DDDs that are similar to target 2DDDs and, separately and alternatively, find 2DDDs that are dissimilar from the target 2DDDs. The most important examples of 2DDD are images, video frames and rasterized graphics data. In this invention, we will refer to such 2DDD simply as images.
The definition of “similarity”, and thus the features and method used to compute it, is idiosyncratic to the retrieval application [O'Connor]. In the case of image retrieval [Gonzalez], methods using entropy, moments, etc. as signatures, have been invented [5,933,823; 5,442,716]. Work in computer graphics has advanced these analytical methods by using an elementary result from topology, the Euler number of polyhedra, as a descriptor of boundary polygons of graphics objects [Foley]. Recently, a method for computing the Euler numbers of binary images using a chip design has been invented [7,027,649]. Another invention [7,246,314], uses closeness to a Gaussian model as a similarity measure for identifying similar videos.
The cost of implementing these methods is typically proportional to the product of the number of 2DDDs in the database with the cost of computing the distance between the target 2DDD and another 2DDD. The latter often [Raghavan] involves the computation of the projection angle between two vectors that represent the features (e.g., histogram of the text elements) of the 2DDDs. For large databases, this process can be both resource and time expensive. A two step method is required wherein, during the retrieval phase, the number of candidates for similarity is significantly reduced in a computationally inexpensive first step and then the traditional features can be applied to the reduced set of candidates.
Intuitively, if two 2DDDs are similar, then they should be deformable into each other without having to remove or glue together portions of 2DDDs. For example, if two images are rescalings and/or rotations of each other, then the images are similar. The field of topology provides a foundation for solving this problem. In particular, we appeal to homotopy invariants that characterize equivalence classes of maps between topological spaces [Bott].
We interpret each 2DDD as a sampling of maps from a two-dimensional presentation space to a n-dimensional topological space and seek homotopy equivalence classes of such maps. Mapping of the Cartesian subspace onto the two-dimensional sphere can be done by a number of methods. Here, we will ascribe the azimuthal and zenith angles (θ 1 ,θ 2 ) of the sphere, S 2 , as the horizontal and vertical coordinates, (x 1 , x 2 ), on the image, or vice versa:
θ i ≡ 2 πx i L t ,
where the L i (i=1,2) are the lengths of the respective dimensions. In another embodiment, an embedding into three dimensional Euclidean space is first performed.
We work with 2DDDs that have at least two data planes, {tilde over (σ)} A (θ 1 ,θ 2 ), with maximum and minimum values, {tilde over (σ)} max A and {tilde over (σ)} min A , respectively. The maximum and minimum values of each of the two planes are used to normalize their data to new minimum and maximum values, σ max A and σ min A respectively, through the expressions:
σ
A
(
θ
1
,
θ
2
)
=
[
σ
max
A
-
σ
min
A
σ
~
max
A
-
σ
~
min
A
]
[
σ
~
A
(
θ
1
,
θ
2
)
-
σ
~
max
A
]
+
σ
max
A
Eqn
.
1
Additional normalizations of the 2DDD, such as scaling to a fixed width and height and the like, may also be performed.
To leverage the equivalence classes of the Second Homotopy Group [Bott], π 2 (S 2 )=Z, we select pairs of the normalized planes of the 2DDD and interpret them as the maps from the world sphere onto the target sphere:
σ:S 2 →S 2
(θ 1 ,θ 2 )→(σ 1 (θ 1 ,θ 2 ),σ 2 (θ 1 ,θ 2 )) Eqn. 2
An example of such a choice is the two planes of chroma pixel data in a YCC color space representation of images. If objects have been segmented from the 2DDD then the data for these objects are themselves 2DDDs. We refer to each segmented portion of each pair of normalized planes henceforth as a “2DDD section” with its own map, σ. With the definition that two 2DDDs are similar if one can be continuously deformed into the other, the well-established results on equivalence classes of homotopic maps lead to the conclusions: If two 2DDD sections do not have the same value of π 2 (S 2 ), then they are not similar. If none of the 2DDD sections from parent 2DDDs are similar to each other, then those parent 2DDDs are not similar to each other.
The equivalence signature, ξ[σ], of a 2DDD section is given by the value of π 2 (S 2 ) for the section computed as [Schwarz]
ξ
[
σ
]
≡
π
2
[
σ
]
=
-
1
4
π
∫
ⅆ
2
θsinσ
2
[
∂
σ
1
∂
θ
1
∂
σ
2
∂
θ
2
-
∂
σ
1
∂
θ
2
∂
σ
2
∂
θ
1
]
Eqn
.
3
Consider two 2DDD sections, σ and σ′ such that, at each point, the difference between the values of the maps is infinitesimal:
σ′ A (θ 1 ,θ 2 )−σ A (θ 1 ,θ 2 )=ε A (θ 1 ,θ 2 )
An example of such a difference is the constant resealing and shifts of the data values at each point
σ′ A (θ 1 ,θ 2 )−σ A (θ 1 ,θ 2 )=α A σ A (θ 1 ,θ 2 )+β A Eqn. 5
for some fixed, small, real constants α A and β A . The difference in the values of the equivalence signatures for the two 2DDD sections, in term of the first one, σ, is
Δξ[σ;ε]≡ξ[σ+ε]−ξ[σ] Eqn. 6
Given a choice for the functions ε A , a limit on the difference of the values of the equivalence signatures for two 2DDD sections can be set so that the 2DDD sections are still regarded as similar. For example, suppose we are interested in finding images whose color planes differ by no more than p percent at each pixel, then that values α A =p and β A =0 are used in the computation of Δξ[σ;ε]. Retrieval of similarity candidates then proceeds by finding those images with values of ξ[σ], denoted as ξ[σ similar ], for which the following inequalities hold:
|ξ[σ target ]−ξ[σ similar ]|≦|Δξ[σ target ;ε]| Eqn. 7
As an example for the reduction factor for the number of CPU cycles and other resources required to find similar sections of 2DDDs in a corpus, assume for simplicity that and that the equivalences signatures of the 2DDDs in the corpus are uniformly distributed in [ξ max ,ξ min ]. If for a target 2DDD section, the choice of ε A leads to a value for Δξ[σ;ε], the reduction in the number of secondary features to be compared is
f
r
=
(
2
Δ
ξ
[
σ
;
ɛ
]
+
1
)
(
ξ
max
-
ξ
min
+
1
)
Eqn
.
8
In state of the art information retrieval methodologies, the feature vector which is used for each 2DDD would have to be compared to all NA feature vectors computed for the 2DDDs in the corpus. Upon employing the method invented here as a precursor to the feature vector comparison, the number of feature vectors to be compared would be reduced to f r N c .
OBJECTS AND ADVANTAGES
The objects of the current invention include the:
1. computation of an equivalence signature for each 2DDD section such that 22DDD sections that do not have the same equivalence signatures will not be similar, 2. population of a database with the equivalence signatures, secondary features and other meta data about the 2DDD, 3. use of the equivalence signatures for the identification of those 2DDDs that are not similar to a target 2DDD, 4. use of equivalence signatures for the identification of those candidate 2DDDs that may be similar to a target 2DDD, 5. use of the secondary features and other meta data for the candidate similar 2DDDs in further analysis, such as feature comparison, to determine the final set of similar 2DDDs, and 6. retrieval of the files containing the similar 2DDDs by means of the meta data stored in the database.
The advantages of the current invention include:
1. a method for computing these signatures for data, such as images and video frames, that have segmented components realized in a two-dimensional plane with each point in the plane having a plurality of values, 2. a quantifiable means for measuring similarity, and 3. the computational and resource expense of using feature comparison methods to determine the similarity of 2DDDs is reduced to a fraction given by a function of the percentage change allowed between similar data.
SUMMARY
In accordance with the present invention, a method for determining the similarity of sets of data uses the Second Homotopy Group to compute an equivalence signature for each segmented component or section of two-dimensional digital data (2DDD), and further uses the differences of the equivalence signatures of any two sections of 2DDD as the measure of the similarity distance between said 2DDD sections. The output from this method can be used to significantly reduce the computational expense, time and resources required by a subsequent secondary feature comparison.
DRAWINGS
Figures
In the drawings, closely related figures have the same numerically close numbers.
FIG. 1 is a block diagram of a computing device for calculating the equivalence signatures of a plurality of 2DDDs (targets) and finding previously analyzed 2DDDs that are similar to (or separately and alternatively not similar to) the target(s), according to one embodiment.
FIG. 2 is a block diagram of the modules and their interconnections, executed by the processing unit of the computing device in FIG. 1 , in computing the equivalence signature of and determining the similarity of a plurality of 2DDDs to other 2DDDs, according to one embodiment.
FIG. 3 is a flow diagram illustrating the steps taken by the modules, in FIG. 2 , to compute equivalence signatures of 2DDDs and adding them to a database, according to one embodiment.
FIG. 4 is a flow diagram illustrating the steps taken by the modules, in FIG. 2 , to find other 2DDDs that are similar to a target 2DDD, according to one embodiment.
DETAILED DESCRIPTION
Preferred Embodiment
FIGS. 1 - 4
A preferred embodiment of the method of the present invention is illustrated in FIGS. 1-4 .
A 2DDD is represented as a set of integers (realized in a computing device as a set number of bits). Each 2DDD may be realized as the addition of layers of 2DDD sections. The entire 2DDD, or the resultant from the point-wise addition of all the layers of the 2DDD, is also taken to be a section. Each two-dimensional point in said sections may have a plurality of integer values. For example, some images are composed of a set of layers of segmented objects with each pixel having three color values or one luminance and two color values.
To determine the similarity, or separately and alternatively non-similarity, of one or a plurality of 2DDDs with a plurality of 2DDDs, each 2DDD may be numerically characterized. For example, each section of the 2DDDs of a corpus of 2DDDs may be assigned an equivalence signature that has the property that small changes to the section of the 2DDD, which maintain similarity with the original section of the 2DDD, will not significantly change the equivalence signature.
As specified by Eqn. 3, the equivalence signature for each section of a 2DDD is given by the functional representation of the Second Homotopy Group computed over the data of the 2DDD's section interpreted as a mapping between two, two dimensional spheres. Once an equivalence signature is assigned to a section of a 2DDD, then a plurality of 2DDDs that are deformations of the former 2DDD will have equivalence signatures that are within a bounded range of the equivalence signature of the former 2DDD as given by Eqn. 7. That range is computed based on configurable similarity threshold parameters that specify the maximum shift and ratio of the values of the data at a point in two similar sections of 2DDDs. Consequently, 2DDD sections that are candidates for similarity with a section of a target 2DDD can be identified, in a database, by requiring that the absolute value of the difference between the values of their equivalence signatures and that of the target's section be no more than the maximum allowed difference computed in terms of the target's data and the similarity threshold parameters. If a target 2DDD has N S (T) sections of which N S (T) (X) are similar to the sections of another 2DDD, X, then the degree of similarity of X to the target 2DDD is
N s ( T ) ( X ) N s ( T ) .
The closer the degree of similarity to one, the more similar X is to the target 2DDD. 2DDDs in a database that are not similar to a target 2DDD will have a similarity degree of zero.
Operation—Preferred Embodiment— FIGS. 1-4
In FIG. 1 , an illustration of a typical computing device 1000 is configured according to the preferred embodiment of the present invention. This diagram is just an example, which should not unduly limit the scope of the claims of this invention. Anyone skilled in the art could recognize many other variations, modifications, and alternatives. Computing device 1000 typically consists of a number of components including Main Memory 1100 , zero or more external audio and/or video interfaces 1200 , one or more interfaces 1300 to one or more storage devices, a bus 1400 , a processing unit 1500 , one or more network interfaces 1600 , a human interface subsystem 1700 enabling a human operator to interact with the computing device, and the like.
The Main Memory 1100 typically consists of random access memory (RAM) embodied as integrated circuit chips and is used for temporarily storing the 2DDDs, configuration data, database records and intermediate and final results processed and produced by the instructions implementing the method invented here as well as the instructions implementing the method, the operating system and the functions of other components in the computing device 1000 .
Zero or more external audio and/or video interfaces 1200 convert digital and/or analog A/V signals from external A/V sources into digital formats that can be reduced to PCM/YUV values and the like. Video frames of YUV values at each two-dimensional point in the frame are 2DDDs.
Storage sub-system interface 1300 manages the exchange of data between the computing device 1000 and one or more internal and/or one or more external storage devices such as hard drives which function as tangible media for storage of the data processed by the instructions embodying the method of this invention as well as the computer program files containing those instructions, and the instructions of other computer programs directly or indirectly executed by the instructions, embodying the method of this invention.
The bus 1400 embodies a channel over which data is communicated between the components of the computing device 1000 .
The processing unit 1500 is typically one or more chips such as a CPU or ASICs, that execute instructions including those instructions embodying the method of this invention.
The network interface 1600 typically consists of one or more wired or wireless hardware devices and software drivers such as NIC cards, 802.11x cards, Bluetooth interfaces and the like, for communication over a network to other computing devices.
The human interface subsystem 1700 typically consists of a graphical input device, a monitor and a keyboard allowing the user to select files that contain 2DDDs that are to be analyzed by the method.
In FIG. 2 , an illustration is given of the modules executing the method of the present invention on the processing unit 1500 .
An equivalence signature is computed as in, 1500 , for a 2DDD under the control of the Analysis Manager. First, the Analysis Manager 1550 instructs the Data Reader 1510 to read the 2DDD and return control to the Analysis Manager 1550 upon completion. Secondly, when control is returned by the Data Reader 1510 , the Analysis Manager 1550 instructs the Data Preprocessor 1520 to process the output from the Data Reader 1510 and return control to the Analysis Manager 1550 upon completion. Third, when control is returned by the Data Preprocessor 1520 , the Analysis Manager 1550 instructs the Signature Generator 1530 to process the output from the Data Preprocessor 1520 and return control to the Analysis Manager 1550 upon completion. Fourth, when control is returned by the Signature Generator 1530 , the Analysis Manager instructs the Signature Database 1560 to record the output from the Signature Generator 1530 , said Signature Database may write the output to a file by means of calls to the Operating System 1570 , and return control to the Analysis Manager 1550 upon completion. The Analysis Manager 1550 then waits for the next request.
The Data Reader module 1510 reads the 2DDD from its storage medium such as a file on a hard drive interfaced to the bus of the computing device or from a networked storage device or server using TCP/IP or UDP/IP based protocols, and the like.
The Data Preprocessor module 1520 finds the start and end of each section in the 2DDD by finding the start layer markers in the data stream of the 2DDD.
In FIG. 3 , a request to compute the equivalence signatures of a 2DDD is received 100 by the Signature Generator 1530 which then reads the configured maximum and minimum values to which to normalize the data in subsequent steps. Secondly, it pre-processes 102 the first section from the 2DDD by executing the following steps in sequence:
1) first, allocates a section buffer in main memory and partitions it into planes that are offset from each other by the product of the width and height of each plane, 2) second, breaks each section into color planes where each world-point of the data of the section is in one-to-one correspondence with the world-point in each plane, 3) third if there are N p color planes in the section then for each of the
(
N
p
2
)
pairs of color planes, allocating buffers for two new color planes and populating these buffers as follows,
a) looping over the values of y from y=0 to y=(H−1) incrementing by one at each roll of the loop, where H is the height of the two-dimensional data, and for each y, looping over the values of x from x=0 to x=(W−1) incrementing by one at each roll of the loop, where W is the width of the two-dimensional data, b) at each roll of the latter x loop,
i) adding the values of the data in the first and second planes and then diving the sum by the square root of two and assign the quotient as the value of the data at the point (x,y)y in the new second plane, ii) subtracting the value of the data in the second plane from the value of the data in the first plane and then diving the difference by the square root of two and assign the quotient as the value of the data at the point (x,y)y in the new first plane,
c) processing then processed with these new color planes,
4) fourth, for each color plane, sets the maximum value and minimum value to the value of the data at the first point in the plane and then sequentially reads the value of the data at each subsequent point in the plane to see if that value is
a) larger than the current maximum value for the plane, in which case it updates the current maximum value for the plane to the value of the data at the current point, or b) smaller than the current minimum value for the plane, in which case it updates the current minimum value for the plane to the value of the data at the current point,
5) fifth, for each color plane, normalizes each data value read by
a) subtracting the configured maximum value for the plane from said data value, b) multiplying the result from by the ratio of the differences between the configured maximum and minimum values for the plane and the difference between the maximum and minimum values computed for the plane in step, and c) adding the maximum value to form the normalized value, d) said normalized value is then written to the section buffer,
6) sixth 104 , if there are N p color planes in the section then for each of the
(
N
p
2
)
pairs of color planes, the equivalence signature is calculated as follows:
a) introducing and setting a variable, ES, to zero, b) processing loops over the values of y from y=0 to y=(H−1) incrementing by one at each roll of the loop, where H is the height of the two-dimensional data, c) for each y, loops over the values of x from x=0 to x=(W−1) incrementing by one at each roll of the loop, where W is the width of the two-dimensional data, d) for each x and y,
i) reading the data values at (x,y), (x+1,y), (x,y+1) and (x+1,y+1) from the first plane and assigning it as the values of the variables with names such as σ x,y 1 , σ x+1,y 1 , σ x,y+1 1 , σ x+1,y+1 1 , respectively, ii) reading the data values at (x,y), (x+1,y), (x,y+1) and (x+1,y+1) from the second plane and assigning it as the values of the variables with names such as σ x,y 2 , σ x+1,y 2 , σ x,y+1 2 , σ x+1,y+1 2 , respectively, iii) computing the difference of σ x+1,y 1 minus σ x,y 1 and assigning the result to a variable with name such as d x σ x,y 1 , iv) computing the difference of σ x,y+1 1 minus σ x,y 1 and assigning the result to a variable with name such as d y σ x,y 1 , v) computing the difference of σ x+1,y 2 minus σ x,y 2 and assigning the result to a variable with name such as d x σ x,y 2 , vi) computing the difference of σ x,y+1 2 minus σ x,y 2 and assigning the result to a variable with name such as d y σ x,y 2 , vii) computing the product of the sin σ x,y 2 and the difference of
(1) the products of the values of the variables d y σ x,y 1 and d x σ x,y 2 , (2) the products of the values of the variables d x σ x,y 1 and d y σ x,y 2 and
e) adding the result from the latter step to the value of the variables ES and setting the value of ES to the sum,
7) seventh, upon completion of both loops, dividing the value of ES by the product of four times the value of π and setting the value of ES to the result,
8) eighth 106 , a new record is added to the Signature Database 1560
a) with the most significant half (MSH) of the key equal to the value the variable ES, and the least significant half (LSH) of the key set to one plus the value of the largest LSH of the other keys in the database which have a MSH equal to value of ES, and b) other fields containing the meta data about the section of the 2DDD that was provided in the request at 100 ; such meta data may include other signatures or features of the section of the 2DDD, and the like.
The calculations of 102 - 108 are performed while looping over the remaining sections. When no more sections remain 110 , a new record is added to the Signature Database 1560 with fields containing the keys of the record of each section of the 2DDD, as added in the latter step, the meta data about the 2DDD including the path or URL to the file containing the 2DDD, the data and time that the 2DDD was last written, a text description of the data in the 2DDD, the name of the source or author for the 2DDD, the policy for the use of the 2DDD, other signatures or features of the 2DDD, and the like.
In FIG. 4 , a target 2DDD is provided in a request 200 to the Analysis Manager 1550 to find 2DDDs, that were previously analyzed and whose equivalence signatures are stored in records of the Signature Database 1560 that are candidates for similarity with the target. To with, the Analysis Manager 1550 instructs the Data Reader 1510 , Data Preprocessor 1520 and Signature Generator 1530 in series as follows:
1) a dictionary, the dictionary of candidate similar 2DDDs, ordered as the doublet (key of a 2DDD meta data record, count of appearance of similar pairs of planes with said key of a 2DDD meta data record) is initiated with all counts set to zero, 2) a loop over each section in the target 2DDD is performed 202
a) a loop over each pair of planes in the current section in the outer loop, is performed
i) the equivalence signatures for the pair of planes in the loop is computed 204 as described by FIG. 3 , with each equivalence signatures so computed then stored as the value of the variable, ES, ii) a second equivalence signature is computed 206 as described by FIG. 3 and then stored as the value of the variable, ESPrime, except that the value of the data at each point is replaced by the sum of
(1) the similarity shift value for the plane, and (2) the product of
(a) the sum of the percentage scale factor for that plane and one, and (b) the value of the data at the point,
iii) the minimum equivalence signature for a similar pair of planes is computed 208 as the minimum of
(1) ESPrime, and (2) twice the value of the variable ES minus the value of ESPrime, and the value of said minimum equivalence signature is assigned to the variable ESMin,
iv) the maximum equivalence signature for a similar pair of planes is computed 208 as the maximum of
(1) ESPrime, and (2) twice the value of the variable ES minus the value of ESPrime, and the value of said maximum equivalence signature is assigned to the variable ESMax,
v) a loop is performed over the signature records in the Signature Database 1560 for which the MSH of keys of the records is equal to or greater than the ESMin and less than or equal to ESMax, from each of the signature records found, the key for the meta data record of the 2DDD associated with the signature record is extracted and the count of the corresponding entry in the dictionary of candidate similar 2DDDs is incremented, vi) processing passes to the next pair of planes in the current section
b) processing passes to the next section in the target 2DDD
3) the keys of the 2DDD meta data records appearing in the dictionary of candidate similar 2DDDs are ordered by their appearance counts from highest count to lowest, 4) the meta data from each field in each record whose key is in the dictionary of candidate similar 2DDDs is returned, by the Analysis Manager 1550 , ordered from most similar to less similar according to the ordering in step.
Operation—Additional Embodiments— FIG. 2
In a second embodiment, an equivalence signature is computed for a 2DDD as in 1500 through the pipelined steps: Data Reader 1510 →Data Preprocessor 1520 →Signature Generator 1530 →Signature Database 1560 with the Data Reader 1510 , Data Preprocessor 1520 , Signature Generator 1530 , and Signature Database 1560 performing the same function as in the preferred embodiment except that each module calls the succeeded module in the pipeline upon completion of their computation. In this second embodiment, the Analysis Manager is not invoked.
CONCLUSION, RAMIFICATIONS, AND SCOPE
Accordingly, the reader will see that the method invented here introduces novel features of an equivalence signature including that
1. it is computationally inexpensive to compute; 2. it can be directly used to reduce by a factor, the set of candidate 2DDDs that are to be further analyzed for similarity by more computationally intensive feature comparison techniques such as [7,031,980; 5,933,823; 5,442,716] and a similar reduction in the computing cycles and resources needed to find 2DDDs can be obtained; 3. the difference between the equivalence signatures of two non-homotopically equivalent 2DDDs is bounded; 4. 2DDDs with subsequences in the same homotopy classes will have the same value for the equivalence signature; 5. it is an integer by virtue of the fact [Bott] that π 2 (S 2 )=Z.
The present invention has been described by a limited number of embodiments. However, anyone skilled in the art will recognize numerous modifications of the embodiments. It is the intention that the following claims include all modifications that fall within the spirit and scope of the present invention.
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A method for finding sets of two-dimensional data (S2DDs), which are similar to a target S2DD, is invented. The method leverages a new category of signatures, called equivalence signatures, to characterize the S2DDs. These signatures have the salient feature that, at worst, they change in a bounded manner when changes are made to the S2DD and when used to find S2DDs that are similar to a target S2DDs, they allow for a significant reduction in the number of SDDs to be compared with the target. This is an improvement over the state of the art wherein the computational expensive process of performing a complete search against the entire corpus must be applied.
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FIELD OF THE INVENTION
[0001] This invention relates to a socket caddy holding sockets and socket ratchets for use by mechanics.
BACKGROUND OF THE INVENTION
[0002] Sockets and socket ratchets are widely used in various repairs, particularly in auto repairs. An auto mechanic would position himself under a vehicle and then reach for a toolbox in order to retrieve a socket ratchet or a socket to perform the repairs. This often has to be done “on the fly”, while using only one hand and while the hand is greasy. After use, a particular socket needs to be placed back for storage or replaced with a different socket, also “on the fly”, while using only one hand and while the hand is greasy. Most mechanics lack time or discipline to return a socket to a particular predetermined location and tend to just drop it into a tool box. Accordingly, there is a need to have a socket caddy providing easy and convenient access to sockets and socket ratchets, permitting removing and replacing sockets with one hand, quickly and with minimal effort. Further, an open view storage allows the user to determine whether there are any missing sockets at a glance.
SUMMARY OF THE INVENTION
[0003] The socket caddy according to this invention satisfies this need. According to the first embodiment of this invention, a tent-shaped structure atop a base comprising storage is provided with pins extending at a substantially forty five degree angle to the base. Sockets are hung on the pins by way of the force of gravity without friction with the pins and thus can be easily removed and replaced with one hand. The second embodiment of this invention provides a vertical panel is atop a base comprising storage with pins extending at a substantially forty five degree angle to the base. As in the first embodiment, sockets are hung on the pins without the use of the force of friction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 shows perspective and elevational views of the socket caddy according to the first embodiment of this invention.
[0005] FIG. 2 shows perspective and elevational views of the socket caddy according to the second embodiment of this invention.
[0006] FIG. 3 shows an alternative embodiment of this invention.
DETAILED DESCRIPTION
[0007] This invention will be better understood with the reference to the drawing figures FIG. 1 through 3 . The same numerals refer to the same elements in all drawing figures.
[0008] Viewing FIG. 1 , numeral 10 indicates a base. Base 10 comprises a rectangular bottom panel with unequal dimensions and a longitudinal axis. In the preferred embodiment described in reference to FIG. 1 (as well as the embodiment described in reference to FIG. 2 , as will be shown later), base 10 further comprises base walls indicated by numeral 80 . Base walls 80 and the rectangular bottom panel of base 10 form a shallow box for storing socket ratchets and socket ratchet extensions indicated by numeral 90 .
[0009] A first and second panels, indicated respectively by numerals 20 and 30 , extend from base 10 and meet at a crest indicated by numeral 40 . In the preferred embodiment shown in FIG. 1 , first panel 20 and second panel 30 extend from tops of base walls 80 , base walls 80 being a part of base 10 . In different embodiments, first panel 20 and second panel 30 may extend directly from the rectangular bottom panel of base 10 .
[0010] First panel 20 and second panel 30 form a tent having a conventional tent shape with a cross section, is in a plane perpendicular to crest 40 , in the form of an inverted “V”. Crest 40 is parallel to the longitudinal axis of base 10 . In the preferred embodiment shown in FIG. 1 , a handle indicated by numeral 100 is disposed on crest 40 . Handle 100 is for carrying the socket caddy according to this invention.
[0011] Numeral 50 indicates pins. A plurality of pins 50 extends from first panel 20 and second panel 30 at a predetermined angle indicated by numeral 60 .
[0012] Numeral 70 indicates sockets. Pins 50 slidably and removably retain sockets 70 in a frictionless hanging arrangement by way of the force of gravity, permitting sockets 70 to be removed with one hand. To accomplish such frictionless hanging arrangement of pins 50 , angle 60 must be between zero and ninety degrees with respect to the rectangular bottom panel of base 10 . The objective of this invention is to provide effortless and quick removal and replacement of sockets 70 with one hand. Angles 60 smaller than zero degrees would cause sockets 70 to fall off of pins 50 . Angles 60 larger than ninety degrees would make removal and replacement of sockets 70 difficult. The preferred embodiment described in reference to FIG. 1 shows angle 60 of forty five-degrees.
[0013] In the preferred embodiment described in reference to FIG. 1 , base 10 , first panel 20 , second panel 30 and pins 50 are fabricated from a durable plastic material by way of injection molding. In other embodiments, base 10 , first panel 20 , second panel 30 and pins 50 may be fabricated from rigid metal, such as steel or aluminum, or wood. Numeral 110 indicates an indicia selected from the group consisting of standard and metric. Indicia 110 is disposed on first panel 20 and second panel 30 , such that if first panel 20 comprises indicia “METRIC”, as shown in FIG. 1 , second panel 30 would comprise indicia “STANDARD”. Standard and metric sockets are placed on either first panel 20 or second panel 30 accordingly. Indicia 110 can be applied either by injection molding or by way of an adhesive tape label.
[0014] Viewing now FIG. 2 , numeral 120 indicates a vertical panel. Vertical panel 120 is fixedly attached to the rectangular bottom panel of base 10 along the longitudinal axis. Vertical panel 120 comprises a first and second faces indicated, respectively, by numerals 120 a and 120 b . Pins 50 extend from first face 120 a and second face 120 b at angle 60 . As in the embodiment shown in FIG. 1 , angle 60 is shown to be forty-five degrees with respect to the rectangular bottom panel of base 10 . Similarly, in other embodiments, angle 60 must be between zero and ninety degrees with respect to the rectangular bottom panel of base 10 .
[0015] In the preferred embodiment shown in FIG. 2 , handle 100 is disposed on a top portion of vertical panel 120 .
[0016] In the preferred embodiment described in reference to FIG. 2 , base 10 , vertical panel 120 and pins 50 are fabricated from a durable plastic material by way of injection molding. In other embodiments, base 10 , vertical panel 120 and pins 50 may be fabricated from rigid metal, such as steel or aluminum, or wood.
[0017] Indicia 110 is disposed on first face 120 a and second face 120 b , such that if first face 120 a comprises indicia “STANDARD”, as shown in FIG. 2 , second face 120 b would comprise indicia “METRIC”. Standard and metric sockets are placed on either first face 120 a or second face 120 b accordingly.
[0018] In the embodiments described in reference to FIGS. 1 and 2 , pins 50 are not removable but are fabricated from a unitary piece of material with either first and second panels 20 and 30 or vertical panel 120 . This can be accomplished, for example, by injection molding. It may be desirable to reduce manufacturing cost of the socket caddy according to this invention by having pins 50 removable, such that the user assembles the socket caddy himself by inserting pins 50 into either first and second panels 20 and 30 or vertical panel 120 . FIG. 3 describes such removable pins 50 inserted into first and second panels 20 and 30 . Removable pins 50 inserted into vertical panel 120 (not shown) work the same way.
[0019] Specifically, first and second panels 20 and 30 (as well as vertical panel 120 ) further comprise a plurality of openings indicated by numeral 50 b . Openings 50 b receive and removably retain pins 50 . Pins 50 are frictionally press fit into openings 50 b by the end user. This can be accomplished by way of a hammer.
[0020] The embodiment described in reference to FIG. 3 shows pin 50 as having a taper indicated by numeral 50 a . Taper 50 a is disposed on the end of pin 50 inserted into opening 50 b . In this case, the diameter of opening 50 b is slightly larger than the diameter of pin 50 , allowing for press fitting of taper 50 a into opening 50 b . In other embodiments, pins 50 do not have tapers 50 a , in which case openings 50 b have diameters slightly larger than that of pins 50 for press fitting pins 50 into openings 50 b.
[0021] While the present invention has been described and defined by references to the preferred embodiments of the invention, such references do not imply limitations on the invention, and no such limitations are to be inferred. The invention is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those ordinarily skilled and knowledgeable in the pertinent arts. The depicted and described preferred embodiments of the invention are exemplary only, and are not exhaustive of the scope of the invention. Consequently, the invention is intended to be limited only by the spirit and scope of the appended claims, giving full cognizance to equivalents in all respects.
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A tent-shaped socket caddy with pins holding sockets by way of the force of gravity, substantially without friction with the pins. A base with a shallow storage box provides storage for socket ratchets and socket ratchet extensions.
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RELATED APPLICATIONS
The present application is related to and claims the priority benefit of each of the following U.S. Patent Applications: U.S. application Ser. No. 10/837,525, filed Apr. 29, 2004 (now U.S. Pat. No. 7,279,451), which in turn is a continuation-in-part of each of U.S. application Nos. 10/694,273 (now U.S. Pat. No. 7,534,366) and 10/694,272 (now U.S. Pat. No. 7,230,463), each of which was filed Oct. 27, 2003, and each of which in turn is related to and claims the priority benefit of U.S. Provisional Application Nos. 60/421,263, and 60/421,435, each of which was filed on Oct. 25, 2002.
FIELD OF THE INVENTION
This invention relates to compositions having utility in numerous applications, including particularly refrigeration systems, and to methods and systems utilizing such compositions. In preferred aspects, the present invention is directed to refrigerant compositions comprising at least one multi-fluorinated olefin of the present invention.
BACKGROUND OF THE INVENTION
Fluorocarbon based fluids have found widespread use in many commercial and industrial applications. For example, fluorocarbon based fluids are frequently used as a working fluid in systems such as air conditioning, heat pump and refrigeration applications. The vapor compression cycle is one of the most commonly used type methods to accomplish cooling or heating in a refrigeration system. The vapor compression cycle usually involves the phase change of the refrigerant from the liquid to the vapor phase through heat absorption at a relatively low pressure and then from the vapor to the liquid phase through heat removal at a relatively low pressure and temperature, compressing the vapor to a relatively elevated pressure, condensing the vapor to the liquid phase through heat removal at this relatively elevated pressure and temperature, and then reducing the pressure to start the cycle over again.
While the primary purpose of refrigeration is to remove heat from an object or other fluid at a relatively low temperature, the primary purpose of a heat pump is to add heat at a higher temperature relative to the environment.
Certain fluorocarbons have been a preferred component in many heat exchange fluids, such as refrigerants, for many years in many applications. For, example, fluoroalkanes, such as chlorofluoromethane and chlorofluoroethane derivatives, have gained widespread use as refrigerants in applications including air conditioning and heat pump applications owing to their unique combination of chemical and physical properties. Many of the refrigerants commonly utilized in vapor compression systems are either single components fluids or azeotropic mixtures.
Concern has increased in recent years about potential damage to the earth's atmosphere and climate, and certain chlorine-based compounds have been identified as particularly problematic in this regard. The use of chlorine-containing compositions (such as chlorofluorocarbons (CFCs), hydrochlorofluorocarbons (HCFCs) and the like) as refrigerants in air-conditioning and refrigeration systems has become disfavored because of the ozone-depleting properties associated with many of such compounds. There has thus been an increasing need for new fluorocarbon and hydrofluorocarbon compounds and compositions that offer alternatives for refrigeration and heat pump applications. For example, it has become desirable to retrofit chlorine-containing refrigeration systems by replacing chlorine-containing refrigerants with non-chlorine-containing refrigerant compounds that will not deplete the ozone layer, such as hydrofluorocarbons (HFCs).
It is generally considered important, however, that any potential substitute refrigerant must also possess those properties present in many of the most widely used fluids, such as excellent heat transfer properties, chemical stability, low- or no-toxicity, non-flammability and lubricant compatibility, among others.
Applicants have come to appreciate that lubricant compatibility is of particular importance in many of applications. More particularly, it is highly desirably for refrigeration fluids to be compatible with the lubricant utilized in the compressor unit, used in most refrigeration systems. Unfortunately, many non-chlorine-containing refrigeration fluids, including HFCs, are relatively insoluble and/or immiscible in the types of lubricants used traditionally with CFC's and HFCs, including, for example, mineral oils, alkylbenzenes or poly(alpha-olefins). In order for a refrigeration fluid-lubricant combination to work at a desirable level of efficiently within a compression refrigeration, air-conditioning and/or heat pump system, the lubricant should be sufficiently soluble in the refrigeration liquid over a wide range of operating temperatures. Such solubility lowers the viscosity of the lubricant and allows it to flow more easily throughout the system. In the absence of such solubility, lubricants tend to become lodged in the coils of the evaporator of the refrigeration, air-conditioning or heat pump system, as well as other parts of the system, and thus reduce the system efficiency.
With regard to efficiency in use, it is important to note that a loss in refrigerant thermodynamic performance or energy efficiency may have secondary environmental impacts through increased fossil fuel usage arising from an increased demand for electrical energy.
Furthermore, it is generally considered desirably for CFC refrigerant substitutes to be effective without major engineering changes to conventional vapor compression technology currently used with CFC refrigerants.
Flammability is another important property for many applications. That is, it is considered either important or essential in many applications, including particularly in heat transfer applications, to use compositions, which are non-flammable. Thus, it is frequently beneficial to use in such compositions compounds, which are nonflammable. As used herein, the term “nonflammable” refers to compounds or compositions, which are determined to be nonflammable as determined in accordance with ASTM standard E-681, dated 2002, which is incorporated herein by reference. Unfortunately, many HFCs, which might otherwise be desirable for used in refrigerant compositions are not nonflammable. For example, the fluoroalkane difluoroethane (HFC-152a) and the fluoroalkene 1,1,1-trifluoropropene (HFO-1243zf) are each flammable and therefore not viable for use in many applications.
Higher fluoroalkenes, that is fluorine-substituted alkenes having at least five carbon atoms, have been suggested for use as refrigerants. U.S. Pat. No. 4,788,352—Smutny is directed to production of fluorinated C 5 to C 8 compounds having at least some degree of unsaturation. The Smutny patent identifies such higher olefins as being known to have utility as refrigerants, pesticides, dielectric fluids, heat transfer fluids, solvents, and intermediates in various chemical reactions. (See column 1, lines 11-22).
While the fluorinated olefins described in Smutny may have some level of effectiveness in heat transfer applications, it is believed that such compounds may also have certain disadvantages. For example, some of these compounds may tend to attack substrates, particularly general-purpose plastics such as acrylic resins and ABS resins. Furthermore, the higher olefinic compounds described in Smutny may also be undesirable in certain applications because of the potential level of toxicity of such compounds which may arise as a result of pesticide activity noted in Smutny. Also, such compounds may have a boiling point, which is too high to make them useful as a refrigerant in certain applications.
Bromofluoromethane and bromochlorofluoromethane derivatives, particularly bromotrifluoromethane (Halon 1301) and bromochlorodifluoromethane (Halon 1211) have gained widespread use as fire extinguishing agents in enclosed areas such as airplane cabins and computer rooms. However, the use of various halons is being phased out due to their high ozone depletion. Moreover, as halons are frequently used in areas where humans are present, suitable replacements must also be safe to humans at concentrations necessary to suppress or extinguish fire.
Applicants have thus come to appreciate a need for compositions, and particularly heat transfer compositions, fire extinguishing/suppression compositions, blowing agents, solvent compositions, and compatabilizing agents, that are potentially useful in numerous applications, including vapor compression heating and cooling systems and methods, while avoiding one or more of the disadvantages noted above.
SUMMARY
Applicants have found that the above-noted need, and other needs, can be satisfied by compositions comprising one or more C3 or C4 fluoroalkenes, preferably compounds having Formula I as follows:
XCF z R 3-z (I)
where X is a C 2 or a C 3 unsaturated, substituted or unsubstituted, alkyl radical, each R is independently Cl, F, Br, I or H, and z is 1 to 3. Highly preferred among the compounds of Formula I are the cis- and trans-isomers of 1,3,3,3-tetrafluoropropene (HFO-1234ze)
The present invention provides also methods and systems which utilize the compositions of the present invention, including methods and systems for heat transfer, foam blowing, solvating, flavor and fragrance extraction and/or delivery, and aerosol generation.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The Compositions
The present invention is directed to compositions comprising at least one fluoroalkene containing from 3 to 4 carbon atoms, preferably three carbon atoms, and at least one carbon-carbon double bond. The fluoroalkene compounds of the present invention are sometimes referred to herein for the purpose of convenience as hydrofluoro-olefins or “HFOs” if they contain at least one hydrogen. Although it is contemplated that the HFOs of the present invention may contain two carbon—carbon double bonds, such compounds at the present time are not considered to be preferred.
As mentioned above, the present compositions comprise one or more compounds in accordance with Formula I. In preferred embodiments, the compositions include compounds of Formula II below:
where each R is independently Cl, F, Br, I or H
R′ is (CR 2 ) n Y,
Y is CRF 2
and n is 0 or 1.
In highly preferred embodiments, Y is CF 3 , n is 0 and at least one of the remaining Rs is F.
Applicants believe that, in general, the compounds of the above identified Formulas I and II are generally effective and exhibit utility in refrigerant compositions, blowing agent compositions, compatibilizers, aerosols, propellants, fragrances, flavor formulations, and solvent compositions of the present invention. However, applicants have surprisingly and unexpectedly found that certain of the compounds having a structure in accordance with the formulas described above exhibit a highly desirable low level of toxicity compared to other of such compounds. As can be readily appreciated, this discovery is of potentially enormous advantage and benefit for the formulation of not only refrigerant compositions, but also any and all compositions, which would otherwise contain relatively toxic compounds satisfying the formulas described above. More particularly, applicants believe that a relatively low toxicity level is associated with compounds of Formula II, preferably wherein Y is CF 3 , wherein at least one R on the unsaturated terminal carbon is H, and at least one of the remaining Rs is F. Applicants believe also that all structural, geometric and stereoisomers of such compounds are effective and of beneficially low toxicity.
In highly preferred embodiments, especially embodiments comprising the low toxicity compounds described above, n is zero. In certain highly preferred embodiments the compositions of the present invention comprise one or more tetrafluoropropenes. The term “HFO-1234” is used herein to refer to all tetrafluoropropenes. Among the tetrafluoropropenes, both cis- and trans-1,3,3,3-tetrafluoropropene (HFO-1234ze) are particularly preferred. The term HFO-1234ze is used herein generically to refer to 1,3,3,3-tetrafluoropropene, independent of whether it is the cis- or trans-form. The terms “cisHFO-1234ze” and “transHFO-1234ze” are used herein to describe the cis- and trans-forms of 1,3,3,3-tetrafluoropropene respectively. The term “HFO-1234ze” therefore includes within its scope cisHFO-1234ze, transHFO-1234ze, and all combinations and mixtures of these.
Although the properties of cisHFO-1234ze and transHFO-1234ze differ in at least some respects, it is contemplated that each of these compounds is adaptable for use, either alone or together with other compounds including its stereoisomer, in connection with each of the applications, methods and systems described herein. For example, while transHFO-1234ze may be preferred for use in certain refrigeration systems because of its relatively low boiling point (−19° C.), it is nevertheless contemplated that cisHFO-1234ze, with a boiling point of +9° C., also has utility in certain refrigeration systems of the present invention. Accordingly, it is to be understood that the terms “HFO-1234ze” and 1,3,3,3-tetrafluoropropene refer to both stereo isomers, and the use of this term is intended to indicate that each of the cis-and trans-forms applies and/or is useful for the stated purpose unless otherwise indicated.
HFO-1234 compounds are known materials and are listed in Chemical Abstracts databases. The production of fluoropropenes such as CF 3 CH═CH 2 by catalytic vapor phase fluorination of various saturated and unsaturated halogen-containing C 3 compounds is described in U.S. Pat. Nos. 2,889,379; 4,798,818 and 4,465,786, each of which is incorporated herein by reference. EP 974,571, also incorporated herein by reference, discloses the preparation of 1,1,1,3-tetrafluoropropene by contacting 1,1,1,3,3-pentafluoropropane (HFC-245fa) in the vapor phase with a chromium-based catalyst at elevated temperature, or in the liquid phase with an alcoholic solution of KOH, NaOH, Ca(OH) 2 or Mg(OH) 2 . In addition, methods for producing compounds in accordance with the present invention are described generally in connection with pending United States patent application entitled “Process for Producing Fluoropropenes” bearing attorney docket number (H0003789 (26267)), which is also incorporated herein by reference.
The present compositions, particularly those comprising HFO-1234ze, are believed to possess properties that are advantageous for a number of important reasons. For example, applicants believe, based at least in part on mathematical modeling, that the fluoroolefins of the present invention will not have a substantial negative affect on atmospheric chemistry, being negligible contributors to ozone depletion in comparison to some other halogenated species. The preferred compositions of the present invention thus have the advantage of not contributing substantially to ozone depletion. The preferred compositions also do not contribute substantially to global warming compared to many of the hydrofluoroalkanes presently in use.
In certain preferred forms, compositions of the present invention have a Global Warming Potential (GWP) of not greater than about 1000, more preferably not greater than about 500, and even more preferably not greater than about 150. In certain embodiments, the GWP of the present compositions is not greater than about 100 and even more preferably not greater than about 75. As used herein, “GWP” is measured relative to that of carbon dioxide and over a 100-year time horizon, as defined in “The Scientific Assessment of Ozone Depletion, 2002, a report of the World Meteorological Association's Global Ozone Research and Monitoring Project,” which is incorporated herein by reference.
In certain preferred forms, the present compositions also preferably have an Ozone Depletion Potential (ODP) of not greater than 0.05, more preferably not greater than 0.02 and even more preferably about zero. As used herein, “ODP” is as defined in “The Scientific Assessment of Ozone Depletion, 2002, A report of the World Meteorological Association's Global Ozone Research and Monitoring Project,” which is incorporated herein by reference.
The amount of the Formula I compounds, particularly HFO-1234, contained in the present compositions can vary widely, depending the particular application, and compositions containing more than trace amounts and less than 100% of the compound are within broad the scope of the present invention. Moreover, the compositions of the present invention can be azeotropic, azeotrope-like or non-azeotropic. In preferred embodiments, the present compositions comprise HFO-1234, preferably HFO-1234ze, in amounts from about 5% by weight to about 99% by weight, and even more preferably from about 5% to about 95%. Many additional compounds may be included in the present compositions, and the presence of all such compounds is within the broad scope of the invention. In certain preferred embodiments, the present compositions include, in addition to HFO-1234ze, one or more of the following:
Difluoromethane (HFC-32)
Pentafluoroethane (HFC-125)
1,1,2,2-tetrafluoroethane (HFC-134)
1,1,1,2-Tetrafluoroethane (HFC-134a)
Difluoroethane (HFC-152a)
1,1,1,2,3,3,3-Heptafluoropropane (HFC-227ea)
1,1,1,3,3,3-hexafluoropropane (HFC-236fa)
1,1,1,3,3-pentafluoropropane (HFC-245fa)
1,1,1,3,3-pentafluorobutane (HFC-365mfc)
water
CO 2
The relative amount of any of the above noted components, as well as any additional components which may be included in present compositions, can vary widely within the general broad scope of the present invention according to the particular application for the composition, and all such relative amounts are considered to be within the scope hereof.
Heat Transfer Compositions
Although it is contemplated that the compositions of the present invention may include the compounds of the present invention in widely ranging amounts, it is generally preferred that refrigerant compositions of the present invention comprise compound(s) in accordance with Formula I, more preferably in accordance with Formula II, and even more preferably HFO-1234ze, in an amount that is at least about 50% by weight, and even more preferably at least about 70% by weight, of the composition. In many embodiments, it is preferred that the heat transfer compositions of the present invention comprise transHFO-1234ze. In certain preferred embodiments, the heat transfer compositions of the present invention comprise a combination of cisHFO-1234ze and transHFO1234ze in a cis:trans weight ratio of from about 1:99 to about 10:99, more preferably from about 1:99 to about 5:95, and even more preferably from about 1:99 to about 3:97.
The compositions of the present invention may include other components for the purpose of enhancing or providing certain functionality to the composition, or in some cases to reduce the cost of the composition. For example, refrigerant compositions according to the present invention, especially those used in vapor compression systems, include a lubricant, generally in amounts of from about 30 to about 50 percent by weight of the composition. Furthermore, the present compositions may also include a compatibilizer, such as propane, for the purpose of aiding compatibility and/or solubility of the lubricant. Such compatibilizers, including propane, butanes and pentanes, are preferably present in amounts of from about 0.5 to about 5 percent by weight of the composition. Combinations of surfactants and solubilizing agents may also be added to the present compositions to aid oil solubility, as disclosed by U.S. Pat. No. 6,516,837, the disclosure of which is incorporated by reference. Commonly used refrigeration lubricants such as Polyol Esters (POEs) and Poly Alkylene Glycols (PAGs), silicone oil, mineral oil, alkyl benzenes (ABs) and poly(alpha-olefin) (PAO) that are used in refrigeration machinery with hydrofluorocarbon (HFC) refrigerants may be used with the refrigerant compositions of the present invention.
Many existing refrigeration systems are currently adapted for use in connection with existing refrigerants, and the compositions of the present invention are believed to be adaptable for use in many of such systems, either with or without system modification. In many applications the compositions of the present invention may provide an advantage as a replacement in systems, which are currently based on refrigerants having a relatively high capacity. Furthermore, in embodiments where it is desired to use a lower capacity refrigerant composition of the present invention, for reasons of cost for example, to replace a refrigerant of higher capacity, such embodiments of the present compositions provide a potential advantage. Thus, It is preferred in certain embodiments to use compositions of the present invention, particularly compositions comprising a substantial proportion of, and in some embodiments consisting essentially of transHFO-1234ze, as a replacement for existing refrigerants, such as HFC-134a. In certain applications, the refrigerants of the present invention potentially permit the beneficial use of larger displacement compressors, thereby resulting in better energy efficiency than other refrigerants, such as HFC-134a. Therefore the refrigerant compositions of the present invention, particularly compositions comprising transHFP-1234ze, provide the possibility of achieving a competitive advantage on an energy basis for refrigerant replacement applications.
It is contemplated that the compositions of the present, including particularly those comprising HFO-1234ze, also have advantage (either in original systems or when used as a replacement for refrigerants such as R-12 and R-500), in chillers typically used in connection with commercial air conditioning systems. In certain of such embodiments it is preferred to including in the present HFO-1234ze compositions from about 0.5 to about 5% of a flammability suppressant, such as CF3I.
The present methods, systems and compositions are thus adaptable for use in connection with automotive air conditioning systems and devices, commercial refrigeration systems and devices, chillers, residential refrigerator and freezers, general air conditioning systems, heat pumps, and the like.
Blowing Agents, Foams and Foamable Compositions
Blowing agents may also comprise or constitute one or more of the present compositions. As mentioned above, the compositions of the present invention may include the compounds of the present invention in widely ranging amounts. It is generally preferred, however, that for preferred compositions for use as blowing agents in accordance with the present invention, compound(s) in accordance with Formula I, and even more preferably Formula II, are present in an amount that is at least about 5% by weight, and even more preferably at least about 15% by weight, of the composition. In certain preferred embodiments, the blowing agent compositions of the present invention and include, in addition to HFO-1234 (preferably HFO-1234ze) one or more of the following components as a co-blowing agent, filler, vapor pressure modifier, or for any other purpose:
Difluoromethane (HFC-32)
Pentafluoroethane (HFC-125)
1,1,2,2-tetrafluoroethane (HFC-134)
1,1,1,2-Tetrafluoroethane (HFC-134a)
Difluoroethane (HFC-152a)
1,1,1,2,3,3,3-Heptafluoropropane (HFC-227ea)
1,1,1,3,3,3-hexafluoropropane (HFC-236fa)
1,1,1,3,3-pentafluoropropane (HFC-245fa)
1,1,1,3,3-pentafluorobutane (HFC-365mfc)
water
CO 2
it is contemplated that the blowing agent compositions of the present invention may comprise cisHFO-1234ze, transHFO1234ze or combinations thereof. In certain preferred embodiments, the blowing agent composition of the present invention comprise his a combination of cisHFO-1234ze and transHFO1234ze in a cis:trans weight ratio of from about 1:99 to about 10:99, and even more preferably from about 1:99 to about 5:95.
In other embodiments, the invention provides foamable compositions, and preferably polyurethane, polyisocyanurate and extruded thermoplastic foam compositions, prepared using the compositions of the present invention. In such foam embodiments, one or more of the present compositions are included as or part of a blowing agent in a foamable composition, which composition preferably includes one or more additional components capable of reacting and/or foaming under the proper conditions to form a foam or cellular structure, as is well known in the art. The invention also relates to foam, and preferably closed cell foam, prepared from a polymer foam formulation containing a blowing agent comprising the compositions of the invention. In yet other embodiments, the invention provides foamable compositions comprising thermoplastic or polyolefin foams, such as polystyrene (PS), polyethylene (PE), polypropylene (PP) and polyethyleneterpthalate (PET) foams, preferably low-density foams.
In certain preferred embodiments, dispersing agents, cell stabilizers, surfactants and other additives may also be incorporated into the blowing agent compositions of the present invention. Surfactants are optionally but preferably added to serve as cell stabilizers. Some representative materials are sold under the names of DC-193, B-8404, and L-5340 which are, generally, polysiloxane polyoxyalkylene block co-polymers such as those disclosed in U.S. Pat. Nos. 2,834,748, 2,917,480, and 2,846,458, each of which is incorporated herein by reference. Other optional additives for the blowing agent mixture may include flame retardants such as tri(2-chloroethyl)phosphate, tri(2-chloropropyl)phosphate, tri(2,3-dibromopropyl)-phosphate, tri(1,3-dichloropropyl) phosphate, diammonium phosphate, various halogenated aromatic compounds, antimony oxide, aluminum trihydrate, polyvinyl chloride, and the like.
Propellant and Aerosol Compositions
In another aspect, the present invention provides propellant compositions comprising or consisting essentially of a composition of the present invention, such propellant composition preferably being a sprayable composition. The propellant compositions of the present invention preferably comprise a material to be sprayed and a propellant comprising, consisting essentially of, or consisting of a composition in accordance with the present invention. Inert ingredients, solvents, and other materials may also be present in the sprayable mixture. Preferably, the sprayable composition is an aerosol. Suitable materials to be sprayed include, without limitation, cosmetic materials such as deodorants, perfumes, hair sprays, cleansers, and polishing agents as well as medicinal materials such as anti-asthma components, anti-halitosis components and any other medication or the like, including preferably any other medicament or agent intended to be inhaled. The medicament or other therapeutic agent is preferably present in the composition in a therapeutic amount, with a substantial portion of the balance of the composition comprising a compound of Formula I of the present invention, preferably HFO-1234, and even more preferably HFO-1234ze.
Aerosol products for industrial, consumer or medical use typically contain one or more propellants along with one or more active ingredients, inert ingredients or solvents. The propellant provides the force that expels the product in aerosolized form. While some aerosol products are propelled with compressed gases like carbon dioxide, nitrogen, nitrous oxide and even air, most commercial aerosols use liquefied gas propellants. The most commonly used liquefied gas propellants are hydrocarbons such as butane, isobutane, and propane. Dimethyl ether and HFC-152a (1,1-difluoroethane) are also used, either alone or in blends with the hydrocarbon propellants. Unfortunately, all of these liquefied gas propellants are highly flammable and their incorporation into aerosol formulations will often result in flammable aerosol products.
Applicants have come to appreciate the continuing need for nonflammable, liquefied gas propellants with which to formulate aerosol products. The present invention provides compositions of the present invention, particularly and preferably compositions comprising HFO-1234, and even more preferably HFO-1234ze, for use in certain industrial aerosol products, including for example spray cleaners, lubricants, and the like, and in medicinal aerosols, including for example to deliver medications to the lungs or mucosal membranes. Examples of this includes metered dose inhalers (MDIs) for the treatment of asthma and other chronic obstructive pulmonary diseases and for delivery of medicaments to accessible mucous membranes or intranasally. The present invention thus includes methods for treating ailments, diseases and similar health related problems of an organism (such as a human or animal) comprising applying a composition of the present invention containing a medicament or other therapeutic component to the organism in need of treatment. In certain preferred embodiments, the step of applying the present composition comprises providing a MDI containing the composition of the present invention (for example, introducing the composition into the MDI) and then discharging the present composition from the MDI.
The compositions of the present invention, particularly compositions comprising or consisting essentially of HFO-1234ze, are capable of providing nonflammable, liquefied gas propellant and aerosols that do not contribute substantially to global warming. The present compositions can be used to formulate a variety of industrial aerosols or other sprayable compositions such as contact cleaners, dusters, lubricant sprays, and the like, and consumer aerosols such as personal care products, household products and automotive products. HFO-1234ze is particularly preferred for use as an important component of propellant compositions for in medicinal aerosols such as metered dose inhalers. The medicinal aerosol and/or propellant and/or sprayable compositions of the present invention in many applications include, in addition to compound of formula (I) or (II) (preferably HFO-1234ze), a medicament such as a beta-agonist, a corticosteroid or other medicament, and, optionally, other ingredients, such as surfactants, solvents, other propellants, flavorants and other excipients. The compositions of the present invention, unlike many compositions previously used in these applications, have good environmental properties and are not considered to be potential contributors to global warming. The present compositions therefore provide in certain preferred embodiments substantially nonflammable, liquefied gas propellants having very low Global Warming potentials.
Flavorants and Fragrances
The compositions of the present invention also provide advantage when used as part of, and in particular as a carrier for, flavor formulations and fragrance formulations. The suitability of the present compositions for this purpose is demonstrated by a test procedure in which 0.39 grams of Jasmone were put into a heavy walled glass tube. 1.73 grams of R-1234ze were added to the glass tube. The tube was then frozen and sealed. Upon thawing the tube, it was found that the mixture had one liquid phase. The solution contained 20 wt. % Jasome and 80 wt. % R-1234ze, thus establishing its favorable use as a carrier or part of delivery system for flavor formulations, in aerosol and other formulations. It also establishes its potential as an extractant of fragrances, including from plant matter.
Methods and Systems
The compositions of the present invention are useful in connection with numerous methods and systems, including as heat transfer fluids in methods and systems for transferring heat, such as refrigerants used in refrigeration, air conditioning and heat pump systems. The present compositions are also advantageous for in use in systems and methods of generating aerosols, preferably comprising or consisting of the aerosol propellant in such systems and methods. Methods of forming foams and methods of extinguishing and suppressing fire are also included in certain aspects of the present invention. The present invention also provides in certain aspects methods of removing residue from articles in which the present compositions are used as solvent compositions in such methods and systems.
Heat Transfer Methods
The preferred heat transfer methods generally comprise providing a composition of the present invention and causing heat to be transferred to or from the composition changing the phase of the composition. For example, the present methods provide cooling by absorbing heat from a fluid or article, preferably by evaporating the present refrigerant composition in the vicinity of the body or fluid to be cooled to produce vapor comprising the present composition. Preferably the methods include the further step of compressing the refrigerant vapor, usually with a compressor or similar equipment to produce vapor of the present composition at a relatively elevated pressure. Generally, the step of compressing the vapor results in the addition of heat to the vapor, thus causing an increase in the temperature of the relatively high-pressure vapor. Preferably, the present methods include removing from this relatively high temperature, high pressure vapor at least a portion of the heat added by the evaporation and compression steps. The heat removal step preferably includes condensing the high temperature, high-pressure vapor while the vapor is in a relatively high-pressure condition to produce a relatively high-pressure liquid comprising a composition of the present invention. This relatively high-pressure liquid preferably then undergoes a nominally isoenthalpic reduction in pressure to produce a relatively low temperature, low-pressure liquid. In such embodiments, it is this reduced temperature refrigerant liquid which is then vaporized by heat transferred from the body or fluid to be cooled.
In another process embodiment of the invention, the compositions of the invention may be used in a method for producing heating which comprises condensing a refrigerant comprising the compositions in the vicinity of a liquid or body to be heated. Such methods, as mentioned hereinbefore, frequently are reverse cycles to the refrigeration cycle described above.
Foam Blowing Methods
One embodiment of the present invention relates to methods of forming foams, and preferably polyurethane and polyisocyanurate foams. The methods generally comprise providing a blowing agent composition of the present inventions, adding (directly or indirectly) the blowing agent composition to a foamable composition, and reacting the foamable composition under the conditions effective to form a foam or cellular structure, as is well known in the art. Any of the methods well known in the art, such as those described in “Polyurethanes Chemistry and Technology,” Volumes I and II, Saunders and Frisch, 1962, John Wiley and Sons, New York, N.Y., which is incorporated herein by reference, may be used or adapted for use in accordance with the foam embodiments of the present invention. In general, such preferred methods comprise preparing polyurethane or polyisocyanurate foams by combining an isocyanate, a polyol or mixture of polyols, a blowing agent or mixture of blowing agents comprising one or more of the present compositions, and other materials such as catalysts, surfactants, and optionally, flame retardants, colorants, or other additives.
It is convenient in many applications to provide the components for polyurethane or polyisocyanurate foams in pre-blended formulations. Most typically, the foam formulation is pre-blended into two components. The isocyanate and optionally certain surfactants and blowing agents comprise the first component, commonly referred to as the “A” component. The polyol or polyol mixture, surfactant, catalysts, blowing agents, flame retardant, and other isocyanate reactive components comprise the second component, commonly referred to as the “B” component. Accordingly, polyurethane or polyisocyanurate foams are readily prepared by bringing together the A and B side components either by hand mix for small preparations and, preferably, machine mix techniques to form blocks, slabs, laminates, pour-in-place panels and other items, spray applied foams, froths, and the like. Optionally, other ingredients such as fire retardants, colorants, auxiliary blowing agents, and even other polyols can be added as a third stream to the mix head or reaction site. Most preferably, however, they are all incorporated into one B-component as described above.
It is also possible to produce thermoplastic foams using the compositions of the invention. For example, conventional polystyrene and polyethylene formulations may be combined with the compositions in a conventional manner to produce rigid foams.
Cleaning Methods
The present invention also provides methods of removing containments from a product, part, component, substrate, or any other article or portion thereof by applying to the article a composition of the present invention. For the purposes of convenience, the term “article” is used herein to refer to all such products, parts, components, substrates, and the like and is further intended to refer to any surface or portion thereof. Furthermore, the term “contaminant” is intended to refer to any unwanted material or substance present on the article, even if such substance is placed on the article intentionally. For example, in the manufacture of semiconductor devices it is common to deposit a photoresist material onto a substrate to form a mask for the etching operation and to subsequently remove the photoresist material from the substrate. The term “contaminant” as used herein is intended to cover and encompass such a photo resist material.
Preferred methods of the present invention comprise applying the present composition to the article. Although it is contemplated that numerous and varied cleaning techniques can employ the compositions of the present invention to good advantage, it is considered to be particularly advantageous to use the present compositions in connection with supercritical cleaning techniques. Supercritical cleaning is disclosed in U.S. Pat. No. 6,589,355, which is assigned to the assignee of the present invention and incorporated herein by reference. For supercritical cleaning applications, is preferred in certain embodiments to include in the present cleaning compositions, in addition to the HFO-1234 (preferably HFO-1234ze), one or more additional components, such as CO 2 and other additional components known for use in connection with supercritical cleaning applications. It may also be possible and desirable in certain embodiments to use the present cleaning compositions in connection with particular vapor degreasing and solvent cleaning methods.
Flammability Reduction Methods
According to certain other preferred embodiments, the present invention provides methods for reducing the flammability of fluids, said methods comprising adding a compound or composition of the present invention to said fluid. The flammability associated with any of a wide range of otherwise flammable fluids may be reduced according to the present invention. For example, the flammability associated with fluids such as ethylene oxide, flammable hydrofluorocarbons and hydrocarbons, including: HFC-152a, 1,1,1-trifluoroethane (HFC-143a), difluoromethane (HFC-32), propane, hexane, octane, and the like can be reduced according to the present invention. For the purposes of the present invention, a flammable fluid may be any fluid exhibiting flammability ranges in air as measured via any standard conventional test method, such as ASTM E-681, and the like.
Any suitable amounts of the present compounds or compositions may be added to reduce flammability of a fluid according to the present invention. As will be recognized by those of skill in the art, the amount added will depend, at least in part, on the degree to which the subject fluid is flammable and the degree to which it is desired to reduce the flammability thereof. In certain preferred embodiments, the amount of compound or composition added to the flammable fluid is effective to render the resulting fluid substantially non-flammable.
Flame Suppression Methods
The present invention further provides methods of suppressing a flame, said methods comprising contacting a flame with a fluid comprising a compound or composition of the present invention. Any suitable methods for contacting the flame with the present composition may be used. For example, a composition of the present invention may be sprayed, poured, and the like onto the flame, or at least a portion of the flame may be immersed in the composition. In light of the teachings herein, those of skill in the art will be readily able to adapt a variety of conventional apparatus and methods of flame suppression for use in the present invention.
Sterilization Methods
Many articles, devices and materials, particularly for use in the medical field, must be sterilized prior to use for the health and safety reasons, such as the health and safety of patients and hospital staff. The present invention provides methods of sterilizing comprising contacting the articles, devices or material to be sterilized with a compound or composition of the present invention comprising a compound of Formula I, preferably HFO-1234, and even more preferably HFO-1234ze, in combination with one or more sterilizing agents. While many sterilizing agents are known in the art and are considered to be adaptable for use in connection with the present invention, in certain preferred embodiments sterilizing agent comprises ethylene oxide, formaldehyde, hydrogen peroxide, chlorine dioxide, ozone and combinations of these. In certain embodiments, ethylene oxide is the preferred sterilizing agent. Those skilled in the art, in view of the teachings contained herein, will be able to readily determine the relative proportions of sterilizing agent and the present compound(s) to be used in connection with the present sterilizing compositions and methods, and all such ranges are within the broad scope hereof. As is known to those skilled in the art, certain sterilizing agents, such as ethylene oxide, are relatively flammable components, and the compound(s) in accordance with the present invention are included in the present compositions in amounts effective, together with other components present in the composition, to reduce the flammability of the sterilizing composition to acceptable levels.
The sterilization methods of the present invention may be either high or low-temperature sterilization of the present invention involves the use of a compound or composition of the present invention at a temperature of from about 250° F. to about 270° F., preferably in a substantially sealed chamber. The process can be completed usually in less than about 2 hours. However, some articles, such as plastic articles and electrical components, cannot withstand such high temperatures and require low-temperature sterilization. In low temperature sterilization methods, the article to be sterilized is exposed to a fluid comprising a composition of the present invention at a temperature of from about room temperature to about 200° F., more preferably at a temperature of from about room temperature to about 100° F.
The low-temperature sterilization of the present invention is preferably at least a two-step process performed in a substantially sealed, preferably air tight, chamber. In the first step (the sterilization step), the articles having been cleaned and wrapped in gas permeable bags are placed in the chamber. Air is then evacuated from the chamber by pulling a vacuum and perhaps by displacing the air with steam. In certain embodiments, it is preferable to inject steam into the chamber to achieve a relative humidity that ranges preferably from about 30% to about 70%. Such humidities may maximize the sterilizing effectiveness of the sterilant, which is introduced into the chamber after the desired relative humidity is achieved. After a period of time sufficient for the sterilant to permeate the wrapping and reach the interstices of the article, the sterilant and steam are evacuated from the chamber.
In the preferred second step of the process (the aeration step), the articles are aerated to remove sterilant residues. Removing such residues is particularly important in the case of toxic sterilants, although it is optional in those cases in which the substantially non-toxic compounds of the present invention are used. Typical aeration processes include air washes, continuous aeration, and a combination of the two. An air wash is a batch process and usually comprises evacuating the chamber for a relatively short period, for example, 12 minutes, and then introducing air at atmospheric pressure or higher into the chamber. This cycle is repeated any number of times until the desired removal of sterilant is achieved. Continuous aeration typically involves introducing air through an inlet at one side of the chamber and then drawing it out through an outlet on the other side of the chamber by applying a slight vacuum to the outlet. Frequently, the two approaches are combined. For example, a common approach involves performing air washes and then an aeration cycle.
EXAMPLES
The following examples are provided for the purpose of illustrating the present invention but without limiting the scope thereof.
Example 1
The coefficient of performance (COP) is a universally accepted measure of refrigerant performance, especially useful in representing the relative thermodynamic efficiency of a refrigerant in a specific heating or cooling cycle involving evaporation or condensation of the refrigerant. In refrigeration engineering, this term expresses the ratio of useful refrigeration to the energy applied by the compressor in compressing the vapor. The capacity of a refrigerant represents the amount of cooling or heating it provides and provides some measure of the capability of a compressor to pump quantities of heat for a given volumetric flow rate of refrigerant. In other words, given a specific compressor, a refrigerant with a higher capacity will deliver more cooling or heating power. One means for estimating COP of a refrigerant at specific operating conditions is from the thermodynamic properties of the refrigerant using standard refrigeration cycle analysis techniques (see for example, R. C. Downing, FLUOROCARBON REFRIGERANTS HANDBOOK, Chapter 3, Prentice-Hall, 1988).
A refrigeration/air conditioning cycle system is provided where the condenser temperature is about 150° F. and the evaporator temperature is about −35° F. under nominally isentropic compression with a compressor inlet temperature of about 50° F. COP is determined for several compositions of the present invention over a range of condenser and evaporator temperatures and reported in Table I below, based upon HFC-134a having a COP value of 1.00, a capacity value of 1.00 and a discharge temperature of 175° F.
TABLE I
DISCHARGE
REFRIGERANT
Relative
TEMPERATURE
COMPOSITION
Relative COP
CAPACITY
(° F.)
HFO 1225ye
1.02
0.76
158
HFO trans-1234ze
1.04
0.70
165
HFO cis-1234ze
1.13
0.36
155
HFO 1234yf
0.98
1.10
168
This example shows that certain of the preferred compounds for use with the present compositions each have a better energy efficiency than HFC-134a (1.02, 1.04 and 1.13 compared to 1.00) and the compressor using the present refrigerant compositions will produce discharge temperatures (158, 165 and 155 compared to 175), which is advantageous since such result will likely leading to reduced maintenance problems.
Example 2
The miscibility of HFO-1225ye and HFO-1234ze with various refrigeration lubricants is tested. The lubricants tested are mineral oil (C3), alkyl benzene (Zerol 150), ester oil (Mobil EAL 22 cc and Solest 120), polyalkylene glycol (PAG) oil (Goodwrench Refrigeration Oil for 134a systems), and a poly(alpha-olefin) oil (CP-6005-100). For each refrigerant/oil combination, three compositions are tested, namely 5, 20 and 50 weight percent of lubricant, with the balance of each being the compound of the present invention being tested
The lubricant compositions are placed in heavy-walled glass tubes. The tubes are evacuated, the refrigerant compound in accordance with the present invention is added, and the tubes are then sealed. The tubes are then put into an air bath environmental chamber, the temperature of which is varied from about −50° C. to 70° C. At roughly 10° C. intervals, visual observations of the tube contents are made for the existence of one or more liquid phases. In a case where more than one liquid phase is observed, the mixture is reported to be immiscible. In a case where there is only one liquid phase observed, the mixture is reported to be miscible. In those cases where two liquid phases were observed, but with one of the liquid phases occupying only a very small volume, the mixture is reported to be partially miscible.
The polyalkylene glycol and ester oil lubricants were judged to be miscible in all tested proportions over the entire temperature range, except that for the HFO-1225ye mixtures with polyalkylene glycol, the refrigerant mixture was found to be immiscible over the temperature range of −50° C. to −30° C. and to be partially miscible over from −20 to 50° C. At 50 weight percent concentration of the PAG in refrigerant and at 60°, the refrigerant/PAG mixture was miscible. At 70° C., it was miscible from 5 weight percent lubricant in refrigerant to 50 weight percent lubricant in refrigerant.
Example 3
The compatibility of the refrigerant compounds and compositions of the present invention with PAG lubricating oils while in contact with metals used in refrigeration and air conditioning systems is tested at 350° C., representing conditions much more severe than are found in many refrigeration and air conditioning applications.
Aluminum, copper and steel coupons are added to heavy walled glass tubes. Two grams of oil are added to the tubes. The tubes are then evacuated and one gram of refrigerant is added. The tubes are put into an oven at 350° F. for one week and visual observations are made. At the end of the exposure period, the tubes are removed.
This procedure was done for the following combinations of oil and the compound of the present invention:
a) HFO-1234ze and GM Goodwrench PAG oil
b) HFO1243 zf and GM Goodwrench oil PAG oil
c) HFO-1234ze and MOPAR-56 PAG oil
d) HFO-1243 zf and MOPAR-56 PAG oil
e) HFO-1225 ye and MOPAR-56 PAG oil.
In all cases, there is minimal change in the appearance of the contents of the tube. This indicates that the refrigerant compounds and compositions of the present invention are stable in contact with aluminum, steel and copper found in refrigeration and air conditioning systems, and the types of lubricating oils that are likely to be included in such compositions or used with such compositions in these types of systems.
Comparative Example
Aluminum, copper and steel coupons are added to a heavy walled glass tube with mineral oil and CFC-12 and heated for one week at 350° C., as in Example 3. At the end of the exposure period, the tube is removed and visual observations are made. The liquid contents are observed to turn black, indicating there is severe decomposition of the contents of the tube.
CFC-12 and mineral oil have heretofore been the combination of choice in many refrigerant systems and methods. Thus, the refrigerant compounds and compositions of the present invention possess significantly better stability with many commonly used lubricating oils than the widely used prior art refrigerant-lubricating oil combination.
Example 4
Polyol Foam
This example illustrates the use of blowing agent in accordance with one of the preferred embodiments of the present invention, namely the use of HFO-1234ze, and the production of polyol foams in accordance with the present invention. The components of a polyol foam formulation are prepared in accordance with the following table:
PBW Polyol Component * Voranol 490 50 Voranol 391 50 Water 0.5 B-8462 (surfactant) 2.0 Polycat 8 0.3 Polycat 41 3.0 HFO-1234ze 35 Total 140.8 Isocyanate M-20S 123.8 Index 1.10 * Voranol 490 is a sucrose-based polyol and Voranol 391 is a toluene diamine based polyol, and each are from Dow Chemical. B-8462 is a surfactant available from Degussa-Goldschmidt. Polycat catalysts are tertiary amine based and are available from Air Products. Isocyanate M-20S is a product of Bayer LLC.
The foam is prepared by first mixing the ingredients thereof, but without the addition of blowing agent. Two Fisher-Porter tubes are each filled with about 52.6 grams of the polyol mixture (without blowing agent) and sealed and placed in a refrigerator to cool and form a slight vacuum. Using gas burets, about 17.4 grams of HFO-1234ze are added to each tube, and the tubes are then placed in an ultrasound bath in warm water and allowed to sit for 30 minutes. The solution produced is hazy, a vapor pressure measurement at room temperature indicates a vapor pressure of about 70 psig, indicating that the blowing agent is not in solution. The tubes are then placed in a freezer at 27° F. for 2 hours. The vapor pressure was again measured and found to be 14-psig. The isocyanate mixture, about 87.9 grams, is placed into a metal container and placed in a refrigerator and allowed to cool to about 50° F. The polyol tubes were then opened and weighed into a metal mixing container (about 100 grams of polyol blend are used). The isocyanate from the cooled metal container is then immediately poured into the polyol and mixed with an air mixer with double propellers at 3000 RPM's for 10 seconds. The blend immediately begins to froth with the agitation and is then poured into an 8×8×4 inch box and allowed to foam. Because of the froth, a cream time cannot be measured. The foam has a 4-minute gel time and a 5-minute tack free time. The foam is then allowed to cure for two days at room temperature.
The foam is then cut to samples suitable for measuring physical properties and is found to have a density of 2.14 pcf. K-factors are measured and found to be as follows:
Temperature
K, BTU In/Ft 2 h ° F.
40° F.
.1464
75° F.
.1640
110°
.1808
Example 5
Polystyrene Foam
This example illustrates the use of blowing agent in accordance with two preferred embodiments of the present invention, namely the use of HFO-1234ze and HFO-1234-yf, and the production of polystyrene foam. A testing apparatus and protocol has been established as an aid to determining whether a specific blowing agent and polymer are capable of producing a foam and the quality of the foam. Ground polymer (Dow Polystyrene 685D) and blowing agent consisting essentially of HFO-1234ze are combined in a vessel. A sketch of the vessel is illustrated below. The vessel volume is 200 cm 3 and it is made from two pipe flanges and a section of 2-inch diameter schedule 40 stainless steel pipe 4 inches long (see FIG. 1). The vessel is placed in an oven, with temperature set at from about 190° F. to about 285° F., preferably for polystyrene at 265° F., and remains there until temperature equilibrium is reached.
The pressure in the vessel is then released, quickly producing a foamed polymer. The blowing agent plasticizes the polymer as it dissolves into it. The resulting density of the two foams thus produced using this method are given in Table 1 and graphed in FIG. 1 as the density of the foams produced using trans-HFO-1234ze and HFO-1234yf. The data show that foam polystyrene is obtainable in accordance with the present invention. The die temperature for R1234ze with polystyrene is about 250° F.
TABLE 1
Dow polystyrene 685D
Foam density (lb/ft 3 )
T ° F.
transHFO-1234ze
HFO-1234yf
275
55.15
260
22.14
14.27
250
7.28
24.17
240
16.93
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Disclosed are the use of fluorine substituted olefins, including tetra- and penta-fluoropropenes, in a variety of applications, including connection with blowing agents, foams, foamable compositions, foaming methods, heat transfer compositions and methods, propellants, and solvating methods.
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TECHNICAL FIELD
The present invention relates generally to communications and in particular to methods, devices and systems involving presence technologies.
BACKGROUND
During the past years, the interest in using mobile and landline/wireline computing devices in day-to-day communications has increased. Desktop computers, workstations, and other wireline computers currently allow users to communicate, for example, via e-mail, video conferencing, and instant messaging (IM). Mobile devices, for example, mobile telephones, handheld computers, personal digital assistants (PDAs), etc., also allow the users to communicate via e-mail, video conferencing, IM, and the like. Mobile telephones have conventionally served as voice communication devices, but through technological advancements they have recently proved to be effective devices for communicating data, graphics, etc. Wireless and landline technologies continue to merge into a more unified communication system, as user demand for seamless communications across different platforms increases.
Many communication applications allow for real-time or near real-time communication that falls outside of the traditional voice communication associated with wireline and wireless telephone communications. Chat session, instant messaging, Short Message Service (SMS), video conferencing, are a few such communication vehicles. Many of these types of communications are expected to become increasingly popular, particularly in view of the proliferation of wireless devices and continual technological breakthroughs in this area.
One method for facilitating the above mentioned communication vehicles is the so-called “presence” technology Presence technology can be used to determine the location, willingness to communicate, publishing information, and other parameters relating to real-time or near real-time communications. The presence technology generally refers to applications and services that facilitate location and identification of one or more endpoints to such communication links. For example, if a first user of a wireless, handheld device intends to initiate an IM session with a second IM user, presence services may be used to present the second user's willingness to receive IM messages. Presence services are an integral part of third generation (3G) wireless networks, and are intended to be employed across a wide variety of communication devices, as well as next generation wireless communication systems.
Presence information may be created at a presence server or an associated system. Presence information may be a status indicator that conveys the ability and willingness of a potential user to communicate with other users. The presence server may provide the presence information for distribution to other users (called watchers) to convey the availability of the user for communication. Presence information is used in many communication services, such as IM, and recent implementations of voice over IP (VoIP) communications.
A user client may publish a presence state to indicate its current communication status. This published state informs others that wish to contact the user of his or her availability and willingness to communicate. One use of presence is to display an indicator icon on IM clients, for example a choice of a graphic symbol with an easy-to-convey meaning, and a list of corresponding text descriptions of each of the states. This is similar to the “on-hook” or “off-hook” state of a fixed phone. Common states regarding the user's availability are “free for chat”, “busy”, etc. Such states exist in many variations across different modern IM clients. However, the standards support a rich choice of additional presence attributes that may be used for presence information, such as user mood, location or free text status.
Different protocols can be used over communications networks which use presence technology to support different presence aspects. For example, in an Internet Protocol Multimedia Subsystem (IMS), Session Initiation Protocol (SIP) can be used to support presence features. More specifically, the SIP Publish mechanism can be used to upload presence information to a presence server. The SIP Publish is normally performed by the “presentity”, i.e., the entity owning the data to be published, however in some cases other entities on behalf of the presentity may desire to have the data published. In another example, the Open Mobility Alliance—Presence and Availability Working Group 2.0 (OMA-PAG) allows for the creation of rules for publishers, where the presentity may set rules for who is allowed to publish what data on behalf of the presentity. However, these different systems do not address all features and communication methods that may be desirable for use in these growing networks, e.g., how to publish information based on content or how to deal with unauthorized, third party requests to publish presence data.
Accordingly, systems and methods for the improvement of publishing methods in the context of presence technology are desirable.
SUMMARY
Exemplary embodiments relate to methods for handling publication requests to, e.g., a presence server, especially requests which are currently unauthorized, i.e., for which the presence server has no instructions from the relevant presentity to permit the requested publication at the time the request is received. A number of signaling variations are contemplated to resolve the unauthorized publication request, which signaling variations may require more or less interaction from the requesting publishing entity and/or from the presentity itself. Some potential advantages associated with exemplary embodiments described herein include the provision of a capability, via various methods, for determining which third party (or third parties) are allowed to publish what information on behalf of another user or application.
According to an exemplary embodiment, a method for handling unauthorized requests to publish information associated with a first entity is described. A request is received from a second entity to publish information associated with the first entity. This request is compared to stored authorization information to determine that the request is currently unauthorized. A first authorization response is transmitted toward the second entity, which indicates that the request to publish information is currently unauthorized.
According to another exemplary embodiment, a communications node for handling unauthorized requests to publish information associated with a first entity is described. The communications node includes at least one memory for storing authorization information associated with publication and a communications interface for transmitting and receiving messages. Such messages include a request from a second entity to publish information associated with the first entity. The communications nodes also includes a processor, wherein the processor uses information stored in the memory to execute instructions in response to received messages and is configured to compare the request to the stored authorization information to determine that the request is currently unauthorized. Then, the communications interface also transmits a first authorization response toward the second entity which indicates that the request to publish information is currently unauthorized.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate exemplary embodiments, wherein:
FIG. 1 depicts a communication system that uses presence data according to exemplary embodiments;
FIGS. 2( a )- 2 ( e ) show signalling diagrams for various use cases when a publisher desires to publish information associated with a presentity according to exemplary embodiments;
FIGS. 3( a )- 3 ( c ) illustrate signalling diagrams for various use cases when a publisher desires to publish information associated with a presentity and subscribes to publication information at a presence server according to exemplary embodiments;
FIG. 4 illustrates a signalling diagram using a SIP Refer message for notifying a third party regarding publication authorization according to exemplary embodiments;
FIG. 5 depicts a representative mobile communication computing system according to exemplary embodiments;
FIG. 6 shows a representative computing system according to exemplary embodiments; and
FIG. 7 is a method flowchart according to exemplary embodiments.
DETAILED DESCRIPTION
The following detailed description of the exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. Also, the following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims.
As telecommunications systems expand and are upgraded, presence information is expected to become more useful in support of an increasing number of applications, which should lead to improvements in presence technologies and to the increased popularity of presence mechanisms with users of such systems becoming more desirable. Prior to discussing the exemplary embodiments below, a purely illustrative communication system in which presence data may be used will now be described with respect to FIG. 1 to provide some context for this discussion.
According to exemplary embodiments, a communication system that uses presence data may include a presentity 10 , a publisher 12 and a presence server 18 which includes both a publication information/state information function 14 and a presence eXtensible Markup Language (XML) Data Management System (XDMS) function 16 . The presence server 18 can include these two functions, however they may also be implemented as separate servers located at separate physical locations. The presentity 10 can be an agent or function associated with a device, e.g., a mobile phone or computer, which provides presence information, e.g., publishing and subscription rules for information associated with itself. Publisher 12 could be a function associated with another device, e.g., a mobile phone, communications server, etc., which desires to publish information associated with presentity 10 . The presence server 18 receives and stores presence information for use by other communication nodes. More specifically, the publication information/state information function 14 stores publishing information and state information for any presentities 10 (or other applicable communication nodes) with which the presence server 18 is in communication. Additionally, the presence XDMS function 16 represents a logical function, e.g., a presence publication authorization (PPA) XDMS function, capable of implementing the set of presence authorization rules, e.g., authentication rules. The presence authorization rules may be stored in the presence XDMS 16 or stored elsewhere as desired, particularly in the cases where protocols other than XML Configuration Access Protocol (XCAP) are used to provide this authorization information. Communications by the presentity 10 and the publisher 12 with the presence server 18 may be wireline or wireless. As used herein (and in the associated Figures), the presence server 18 represents both the publication information/state information function 14 and the presence XDMS function 16 for simplicity, except where expressly stated otherwise and recognizing that these functions may or may not be co-located with one another.
Using the system shown in FIG. 1 , various protocols, e.g., Session Initiation Protocol (SIP), can be used to upload presence information to a presence server 18 in various architectures, e.g., Internet Protocol (IP) Multimedia Subsystem. However, this method of publication, by itself, does not address the issues of how to determine in real-time or near real-time what entity(s) are allowed to publish information on behalf of another user, as well as what presence attributes such an entity may publish. Other challenges addressed below by the various exemplary embodiments allow for real-time and near real-time publishing using presence technology to inform the presentity 10 that a user, e.g., publisher 12 , is trying to publish information on behalf of the presentity 10 , enabling the presentity 10 to allow, block or modify the publishing attempt, and selectively allowing or denying each publication request based upon the content of the publication via instructions to the presence server 18 .
As described in the various exemplary embodiments herein, the terms “publishing”, “publication” and the like are used generally to describe the act of presenting information, for viewing or use by others, associated with an entity or created by an entity. For example, the publishing of information can include the creation or publication of a Presence Information Data Format (PIDF) document which is used by a presence server to enables others (watchers) to view or be provided with presence information associated with an entity, e.g., whether a cell phone is open for calling. A PIDF document stored by a presence server 18 can, for example, be a composition of multiple PIDF documents which the presence server 18 receives from multiple sources. For example, if a particular presentity 10 is associated with multiple client devices (e.g., a person's home computer, that person's mobile phone and/or that person's work computer), the presence server 18 could receive information from each client which it could combine into a single PIDF document for the presentity 10 for handling presence information for that presentity 10 . Additionally, third parties may desire to add data to that presentity 10 's PIDF document. Other non-limiting examples of types of data that a third party might wish to publish include location information, blog data, service availability, etc. Also, other formats than PIDF can be used for the viewing of the to be published information.
Thus, according to exemplary embodiments, using the communications system shown in FIG. 1 , the presence server 18 can query the presentity 10 in real time, or near real time, to publish information on behalf of the presentity 10 , e.g., a reactive authorization for publication of data requested by a third party. The publisher 12 may already be authorized to publish data on behalf of presentity 10 , or may be unauthorized. An “unauthorized request” to publish, as used herein, describes a currently unauthorized request to publish due to at least one the following reasons: (1) identity of requesting entity is unknown/unauthorized; (2) the type of content/data to be published is unknown/unauthorized; and/or (3) due to other desired reasons. Exemplary embodiments discussed herein are particularly focused on the handling of publication requests by as-yet unauthorized publishers 12 , but are not limited thereto.
For example, there can be an authorization mechanism for publications such that when a publisher 12 (which is not currently listed in the publication authorization document within presence server 18 ) sends a publication request on behalf of a presentity 10 , the presence server 18 can send an authorization request to the presentity 10 to ask for instructions regarding the publisher 12 and/or its publication request. This authorization can include a blanket authorization, a onetime authorization, a partial authorization, an authorization based upon content, a denial or some combination thereof. In addition to the real time and near real time authorization opportunities, authorization instructions can be stored, if applicable, in the presence server 18 for future use.
As described above, there may be times when there are no previously stored authorization rules at a presence server 18 with respect to publishing information associated with a presentity 10 by a third party, or at least with respect to a particular third party which has not previously requested to publish information associated with presentity 10 . Various exemplary combinations for solving this problem, as well as their associated signalling, are described in more detail below. In these exemplary embodiments, the presence server 18 receives various type of signals, e.g. SIP signalling, XML data, Hypertext Transport Protocol signalling, etc., and these various types of signals and data are routed within the presence server 18 , e.g., to the publication rules/state information function 14 and the XDMS presence function 16 , as will be described in more detail herein.
According to exemplary embodiments, signalling and logic used between presentity 10 , presence server 18 and publisher 12 to allow real time or near real time response to publishing requests will now be described with respect to the exemplary signalling diagrams shown in FIGS. 2( a )- 2 ( e ). In these figures (and the associated text herein) User A and the publisher 12 are considered to refer to the same entity (e.g., a second entity), and User B and the presentity 10 are also considered to refer to the same entity (e.g., a first entity), such that these terms may be used interchangeably or together below. Initially, presentity 10 subscribes to pub-rules information and, optionally, submits publication information, as shown by SIP Subscribe message 202 to the presence server 18 . Message 202 instructs presence server 18 to notify presentity 10 when a publish request is received by the presence server 18 that is outside of the currently existing publishing rules, i.e., such that the presentity 10 is informed when an unauthorized publisher desires to publish data for that presentity 10 or when a previously approved publisher requests to publish data that it is not yet allowed to publish by that presentity 10 . At some future point in time, publisher 12 sends a SIP Publish message 204 , which includes information about User B and data X, Y, which message 204 requests publishing of data X and Y on behalf of User B. Data X and Y can represent different content and/or presence parameters, associated with presentity 10 , that publisher 12 desires to publish (or have published). Presence server 18 then reviews its publishing/authorization rules and determines, in this case, that no authorization rule(s) exist for User A publisher 12 . Accordingly, a 202 Accepted message 206 , including a temporary Entity tag (Etag) which indicates that the request has been accepted but not yet been authorized, is transmitted to publisher 12 . Additionally, a retry-after notification may be included in message 206 , as a part of the Etag, to inform the publisher 12 that it can retry the publication attempt at a later time. A potential, but purely illustrative, retry time could be five minutes. However, depending upon the type of service, shorter or longer time retry time frames such as one minute, twenty four hours or others could be used.
Additionally, at the same time or about the same time, a SIP Notify message 208 which includes publication notification information is sent to the presentity 10 regarding the publication attempt by User A. In this purely illustrative example, the User B presentity 10 decides to allow the User A publisher 12 to publish only data Y, and sends an XCAP PUT message 210 to the presence server 18 with this information for its use/storage. At some point in the future, based upon when publisher 12 decides to perform a publish retry, publisher 12 transmits another SIP Publish message 212 to the presence server 18 . Message 212 can, for example, be sent at a time based upon the retry-after notification received from the presence server 18 in message 206 (if any), at a predetermined time after receipt of message 206 or at another time. Alternatively, message 212 can be a shorter message with an eTag for the publishing request as compared to resubmitting all of the data to be published. Upon receipt of message 212 , presence server 18 checks its stored instructions, finds a match between the request and its stored instructions and transmits a 200 OK message 214 back to the publisher 12 which includes the allowed data to be published, in this case, data Y.
According to another exemplary embodiment, an initially unauthorized publisher 12 can publish information from presentity 10 without sending multiple SIP Publish requests to the presence server 18 as shown in FIG. 2( b ). As in the previous example, presentity 10 first subscribes to publication information and potentially submits publication information, as shown by SIP Subscribe message 202 , from presentity 10 to the presence server 18 . Message 202 provides the presence server 18 with that presentity's authorized publication information and, optionally, with its preferred mechanism for handling unauthorized publishers. At some future point in time, publisher 12 sends a SIP Publish message 204 , which includes information about the presentity 10 and data X, Y, requesting publication of data X and Y on behalf of User B. Data X and Y can represent different content, associated with presentity 10 , that publisher 12 desires to publish (or have published). Presence server 18 then reviews its publishing/authorization rules and determines, in this case, that no authorization rule(s) exist for User A 12 and a 202 Accepted message 206 , including a temporary Entity tag (Etag) which indicates that the request has not yet been authorized, is transmitted to the publisher 12 .
Additionally, at or around this time a SIP Notify message 208 which includes publication rules notification information is sent to the presentity 10 regarding the publication attempt. The User B presentity 10 decides to allow the User A publisher 12 to publish only data Y and sends an XCAP PUT message 210 to the presence server 18 with this information for its use/storage. Presence server 18 checks its stored information, and determines that User A publisher 12 is interested in publishing the data that presentity User B 10 has now indicated as allowed to be published by User A publisher 12 and transmits a 200 OK message 214 back to the publisher 12 which includes the allowed data to be published, in this case, data Y.
According to another exemplary embodiment, publisher 12 can publish information from presentity 10 without sending multiple SIP Publish requests to the presence server 18 as shown in FIG. 2( c ). Moreover, no additional response is sent from the presence server 18 to the publisher 12 to indicate that publication of the previously requested data is now permitted. Initially, presentity 10 subscribes to pub-rules information and potentially submits publication information, as shown by SIP Subscribe message 202 from presentity 10 to the presence server 18 , to get information when an unauthorized publisher desires to publish data or when a previously approved publisher publishes data that it is not yet allowed to publish, i.e., this informs presence server 18 to notify presentity 10 when a publish request occurs that is outside of the currently existing publishing rules. At some future point in time, publisher 12 sends a SIP Publish message 204 , which includes information about the presentity 10 and data X, Y, to publish data X and Y on behalf of User B. Data X and Y can represent different content, associated with presentity 10 , that publisher 12 desires to publish (or have published). Presence server 18 then reviews its publishing/authorization rules and determines, in this case, that no authorization rule(s) exist for publisher User A 12 and a 202 Accepted message 206 , including a temporary Entity tag (Etag) which indicates that the request has not yet been authorized is transmitted to publisher 12 . Additionally, at this (or another) time a SIP Notify message 208 which includes publication rules notification information is sent to the presentity 10 regarding the publication attempt. The presentity (User B) 10 decides to allow the publisher (User A) 12 to publish only data Y and sends an XCAP PUT message 210 to the presence server 18 with this information for its use/storage. For this exemplary embodiment, the information can be published in various ways. For example, the publication can be automatically activated after the presentity 10 has authorized it, or alternatively, the presence server 18 can wait for another SIP Publish request from the publisher 12 before publishing the information.
According to another exemplary use case, FIG. 2( d ) shows the signalling for the case where the presentity User B 10 fails to respond to a request for publication rules from the presence server 18 with respect to the publish request from the publisher User A 12 . Initially, presentity 10 subscribes to publication information and potentially submits publication information, as shown by SIP Subscribe message 202 from presentity 10 to the presence server 18 . At some future point in time, publisher 12 sends a SIP Publish message 204 , which includes information about the presentity 10 and data X, Y, to publish data X and Y on behalf of User B. Data X and Y can represent different content, associated with presentity 10 , that publisher 12 desires to publish (or have published). Presence server 18 then reviews its publishing/authorization rules and determines, in this case, that no authorization rule(s) exist for publisher User A 12 . A 202 Accepted message 206 , including a temporary Entity tag (Etag) which indicates that the request has not yet been authorized, is then transmitted to publisher 12 . Additionally, a retry-after notification may be included in message 206 to inform the publisher 12 that it can retry the publication at a later time. The retry-after notification also serves to notify the publisher 12 to not publish until the stated time has elapsed. Also, according to exemplary embodiments, an eTag can be added, in a separate header, for cases where the publisher 12 has multiple publications to differentiate the publications. In the case of just a single publication associated with publisher 12 , the eTag can be omitted.
At (or around) this time a SIP Notify message 208 , which includes publication notification information, is sent to the presentity 10 regarding the publication attempt. In this exemplary embodiment, no response is received back at the presence server 18 in a timely fashion. At some time in the future, based upon when publisher 12 decides to perform a publish retry, publisher 12 transmits another SIP Publish message 212 to the presence server 18 . Presence server 18 checks its stored instructions, and still does not find a match between the request and its stored rules since the presentity 10 has not yet provided updated publication authorization information. A second 202 Accepted message 216 (potentially with another Etag) is transmitted back to the publisher 12 . At this point, the presence server 18 can optionally transmit another message SIP Notify message to the presentity 10 , and the publisher 12 can continue to retry and publish via the use of SIP Publish messages to the presence server 18 until authorization or rejection occurs.
According to another exemplary use case, FIG. 2( e ) shows signalling for the case where the presentity User B 10 rejects a request for publication from the presence server 18 with respect to the publish request from the publisher User A 12 . Initially, presentity 10 subscribes to publication information and potentially submits publication information, as shown by SIP Subscribe message 202 from presentity 10 to the presence server 18 . At some future point in time, publisher 12 sends a SIP Publish message 204 , which includes information about the presentity 10 and data X, Y, to publish data X and Y on behalf of User B. Data X and Y can represent different content, associated with presentity 10 , that publisher 12 desires to publish (or have published). Presence server 18 then reviews its publishing/authorization rules and determines, in this case, that no authorization rule(s) exist for publisher User A 12 and a 202 Accepted message 206 , including a temporary Entity tag (Etag) which indicates that the request has not yet been authorized, is transmitted to publisher 12 . Additionally, a retry-after notification may be included in message 206 , as a part of the Etag, to inform the publisher 12 that it can retry the publication at a later time.
At (or around) this time a SIP Notify message 208 which includes publication rules notification information is sent to the presentity 10 regarding the publication attempt. The presentity User B 10 decides to block the publisher User A 12 from publishing any data and sends an XCAP PUT message 218 to the presence server 18 with these instructions for its use/storage. At some point in the future, based upon when publisher 12 decides to perform a publish retry, publisher 12 transmits another SIP Publish message 212 to the presence server 18 . Presence server 18 checks its stored instructions, finds a match between the request and its stored instructions and transmits a 403 Response (or a 603 Declined response) message back to the publisher 12 which informs the publisher 12 of the block or refusal to allow publisher User A 12 to publish data X and Y.
According to exemplary embodiments, alternative signalling and logic used between presentity 10 , presence server 18 and publisher 12 wherein the User A Publisher 12 subscribes to pubinfo to allow real-time or near real-time responses to publishing requests will now be described with respect to the exemplary signalling diagrams shown in FIGS. 3( a )- 3 ( c ). According to exemplary embodiments, a publisher 12 subscribes to the pubinfo event package to obtain information relating to authorization decisions of the presentity 10 as shown in FIG. 3( a ).
Initially, presentity 10 subscribes to publication information and potentially submits publication information, as shown by SIP Subscribe message 302 , from presentity 10 to the presence server 18 . At some future point in time, publisher 12 sends a SIP Publish message 304 , which includes information about the presentity 10 and data X, Y, to publish data X and Y on behalf of User B. Data X and Y can represent different content, associated with presentity 10 , that publisher 12 desires to publish (or have published). Presence server 18 then reviews its publishing/authorization rules and determines, in this case, that no authorization rule(s) exist for publisher User A 12 and a message returning a form of a negative response, e.g., 488 Not Accepted message 306 , is transmitted back to the publisher 12 . It is expected that other types of negative response messages could be used here as desired. Additionally, at (or around) this time a SIP Notify message 308 , which includes information associated with pubinfo and User A is transmitted from the presence server 18 to the User B presentity 10 .
After receipt of the 488 Not Accepted message 306 , the User A publisher 12 transmits a SIP Subscribe message 310 for subscription to the pubinfo stored at the presence server 18 , e.g., publication information/state information 14 within the presence server 18 , associated with the presentity User B 10 . The presence server 18 then transmits a SIP Notify message 312 which includes a publish pending decision to the publisher 12 . At some later point in time, the User B presentity 10 transmits an XCAP PUT message 314 which updates the publication rules for User A and the associated request. The presence server 18 can then transmit another SIP Notify message 316 to the publisher 12 which includes information associated with the publication information/state update of presentity 10 . The publisher 12 then transmits another SIP Publish message 318 , which the presence server 18 compares to its stored publication rules, and responds to the publisher 12 with a 200 OK message 320 with the allowed publication result, in this case, the authorization to publish data Y on behalf of the presentity 10 .
According to other exemplary embodiments, a publisher 12 subscribes to a pub-rule document stored in the Presence XDMS function 16 in the presence server 18 to obtain knowledge of the authorization decision(s) of the presentity 10 as shown in FIG. 3( b ). Initially, presentity 10 subscribes to publication information and potentially submits publication information, as shown by SIP Subscribe message 302 from presentity 10 to the presence server 18 . At some future point in time, publisher 12 sends a SIP Publish message 304 , which includes information about the presentity 10 and data X, Y, to publish data X and Y on behalf of User B. Data X and Y can represent different content, associated with presentity 10 , that publisher 12 desires to publish (or have published). Presence server 18 then reviews its publishing/authorization rules and determines, in this case, that no authorization rule(s) exist for publisher User A 12 and a message returning a form of a negative response, e.g., 488 Not Accepted message 306 , is transmitted back to the publisher 12 . It is expected that other types of negative response messages could be used here as desired. Additionally, at (or around) this time a SIP Notify message 308 , which includes information associated with pubinfo and User A is transmitted from the presence server 18 to the User B presentity 10 .
After receipt of the 488 Not Accepted message 306 , the User A publisher 12 transmits a SIP Subscribe message 322 to the presence server 18 for subscription to XCAP changes of interest, e.g., changes in publishing rules from User B 10 . In response to this message 322 , the presence server 18 transmits a SIP Notify message 324 which informs the publisher 10 that publication authorization is pending. At some subsequent point in time, the presence server 18 receives an XCAP PUT message 314 which updates the publication rules for User A 12 . The presence server 18 can then transmit another SIP Notify message 326 to the publisher 12 which includes notification of a publication rules update. The publisher 12 then transmits another SIP Publish message 318 , which the presence server 18 compares to its stored publication rules, and responds to the publisher 12 with a 200 OK message 320 with the allowed publication result, in this case, the authorization to publish data Y on behalf of the presentity 10 .
According to other exemplary embodiments, a publisher 12 subscribes to the pub-rule document stored in the Presence XDMS function 16 in the presence server 18 to obtain knowledge of the authorization decision(s) of the presentity 10 as well as obtaining a link to the pub-rule document as shown in FIG. 3( c ). This exemplary embodiment is similar to that described above for FIG. 3( b ). The difference between the signalling embodiments of FIG. 3( b ) and FIG. 3( c ) is in the 488 Not Accepted message 306 . In this case, attached to this message 306 (in FIG. 3( c )) is a link to the pub-rule document stored in the presence XDMS 16 within the presence server 18 as an alternative (or additional) method for enabling the publisher 12 to obtain knowledge of the authorization decision by presentity 10 . This link can also be sent via other channels or SIP messages.
According to still further exemplary embodiments, a SIP Refer message can be used in the signalling process for notifying a third party that it is authorized to publish on behalf of another as shown in FIG. 4 . Initially, presentity 10 subscribes to publication information and potentially submits publication information, as shown by SIP Subscribe message 402 from presentity 10 to the presence server 18 . At some future point in time, publisher 12 sends a SIP Publish message 404 , which includes information about User B presentity 10 and data X, Y, to publish data X and Y on behalf of User A, as well as, a Global Routable User Agent identifying the address of publisher User A 12 . Data X and Y can represent different content, associated with presentity 10 , that publisher 12 desires to publish (or have published). Presence server 18 then reviews its publishing/authorization rules and determines, in this case, that no authorization rule(s) exist for publisher 12 and a 488 Not Accepted message 406 is transmitted back to the publisher 12 . Additionally, at this time a SIP Notify message 408 , which includes information associated with pubinfo and User A is transmitted from the presence server 18 to the User B presentity 10 .
After receipt of the SIP Notify message 408 , the presentity 10 transmits an XCAP PUT message 410 which updates the publication rules for User A 12 , e.g., allow data Y for publishing. The presence server 18 can then transmit a SIP Refer message 412 to the SIP user agent (UA) associated with publisher User A 12 , indicating permission for publisher 12 to publish data associated with presentity User B 10 . The publisher 12 then transmits another SIP Publish message 414 , which the presence server 18 compares to its stored publication rules, and responds to the publisher 12 with a 200 OK message 416 with the allowed publication result, in this case, the authorization to publish data Y on behalf of the presentity 10 .
Using the above described exemplary signalling diagrams a presentity 10 can determine and transmit publication rules regarding third party publishing, e.g., User A publisher 12 , to a presence server 18 . These publication rules can be expanded to include publishing rules for a plurality of third parties, publishing rules base upon content, publishing rules that require consent by the presentity per publishing request, publishing rules based upon content and various combinations of these potential publishing rules.
Additionally, according to exemplary embodiments, the concepts described by these signalling diagrams, e.g., FIGS. 2( a )- 2 ( e ), 3 ( a )- 3 ( c ) and FIG. 4 , can be used for other concepts and protocols. For example, in an XCAP environment, the above described exemplary embodiments could be used to handle authorization of users that are allowed to change XCAP documents as well as other XCAP access rights. Additionally, these exemplary embodiments could be used to determine and control the publication of other presence attributes, as well as other parameters (both presence and non-presence related) such as the maximum number of publications allowed by a third party, the publication rate, size, etc.
According to exemplary embodiments, variations to the above described signalling diagrams can be made. For example, in certain cases a SIP Invite or a SIP Subscribe message can be used in place of the SIP Publish message to transmit the data stored by the presence server 18 . Additionally, other types of signals can be used. For example, longer lived HTTP transactions can be used instead of the SIP Publish mechanism. This allows for an open HTTP session in which the presence server 18 will return the decision when the authorization has been decided. This alternative exemplary embodiment would remove the need for the publisher 12 to iteratively send SIP Publish messages to the presence server 18 . Additionally, or alternatively, the presence server 18 could withhold its signaling toward the publisher 12 until after the presentity 10 has responded to an inquiry from the presence server regarding the publication request. According to alternative exemplary embodiments, if desired, the HTTP signalling can also be used in a manner similar to that of SIP signalling whereby a new request message does need to be transmitted.
According to exemplary embodiments, as described above, it is possible to determine which user(s), application(s), etc., are authorized to publish what information on behalf of another user and/or application. This allows for the increased usability for so called “content buddies” and groups where server users may publish to a single instance. Additionally, this can allow a moderator for a group to decide what data can and cannot be published in a real-time or near real-time environment.
Communication nodes that may act as a presentity, publisher, or an XDMS presence function/server in connection with the exemplary embodiments described above, may be desktop/personal computers, workstations, large-scale computing terminals, wireless terminals, or any other computing device capable of executing presence functions, e.g., awareness, publication and the like. The wireless terminals capable of publishing or having presence information which may be published, may include devices such as wireless/cellular telephones, personal digital assistants (PDAs), or other wireless handsets, as well as portable computing devices. The mobile terminals may utilize computing components to control and manage the conventional device activity as well as the functionality provided by the exemplary embodiments. Hardware, firmware, software or a combination thereof may be used to perform the various methods and techniques described herein.
For purposes of illustration and not of limitation, an example of a representative mobile communication computing system, e.g., a mobile communication unit acting as either a publisher 12 or a presentity 10 , capable of carrying out operations in accordance with the exemplary embodiments is illustrated in FIG. 5 . It should be recognized, however, that the principles of the exemplary embodiments described above are equally applicable to standard computing systems.
The exemplary mobile computing arrangement 500 may include a processing/control unit 502 , such as a microprocessor, reduced instruction set computer (RISC), or other central processing module. The processing unit 502 need not be a single device, and may include one or more processors. For example, the processing unit 502 may include a master processor and associated slave processors coupled to communicate with the master processor.
The processing unit 502 may control the basic functions of the mobile terminal as dictated by programs available in the storage/memory 504 . Thus the processing unit 502 may execute the functions described above with respect to the exemplary embodiments. More particularly, the storage/memory 504 may include an operating system and program modules for carrying out functions and applications on the mobile terminal (or other computing devices). For example, the program storage may include one or more of read-only memory (ROM), flash ROM, programmable and/or erasable ROM, random access memory (RAM), subscriber interface module (SIM), wireless interface module (WIM), smart card, or other removable memory device, etc. The program modules and associated features may also be transmitted to the mobile computing arrangement 500 via data signals, such as those downloaded electronically via a network, e.g., the Internet.
One of the programs that may be stored in the storage/memory 504 is a specific application program 506 . As previously described, the specific program 506 may interact with presence functions to support search request, authorization decisions and the like. The program 506 and associated features may be implemented in software and/or firmware operable by way of the processor 502 . The program storage/memory may also be used to store data 508 , such as various publication rules, or other data associated with the above described exemplary embodiments. In one exemplary embodiment, the programs 506 and data 508 are stored in non-volatile electrically erasable, programmable ROM (EEPROM), flash ROM, etc., so that the information is not lost upon power down of the mobile terminal.
The processor 502 may also be coupled to user interface 510 elements associated with the mobile terminal. The user interface 510 of the mobile terminal may include, for example, a display 512 such as a liquid crystal display, a keypad 514 , speaker 516 , and a microphone 518 . These and other user interface components are coupled to the processor 502 as is known in the art. The keypad 514 may include alpha-numeric keys for performing a variety of functions, including dialing numbers and executing operations assigned to one or more keys. Alternatively, other user interface mechanisms may be employed, such as, voice commands, switches, touch pad/screen, graphical user interface using a pointing device, trackball, joystick, or any other user interface mechanism.
The mobile computing arrangement 500 may also include a digital signal processor (DSP) 520 . The DSP 520 may perform a variety of functions, including analog-to-digital (A/D) conversion, digital-to-analog (D/A) conversion, speech coding/decoding, encryption/decryption, error detection and correction, bit stream translation, filtering, etc. The transceiver 522 , generally coupled to an antenna 524 , may transmit and received the radio signals associated with a wireless device.
The mobile computing arrangement 500 of FIG. 5 is provided as a representative example of a computing environment in which the principles of the exemplary embodiments described herein may be applied. From the description provided herein, those skilled in the art will appreciate that the present invention is equally applicable in a variety of other currently known and future mobile and fixed computing environments. For example, the specific application 506 and associated features, and data 508 , may be stored in a variety of manners, may be operable on a variety of processing devices and may be operable in mobile devices having additional, fewer, or different supporting circuitry and user interface mechanisms. It is noted that the principles of the exemplary embodiments are equally applicable to non-mobile terminals, i.e., landline computing systems.
The presence, publishing and/or presence XDMS servers or other systems for providing presence and publishing/authorizing information in connection with the above described embodiments, may be any type of computing device capable of processing and communicating presence information. An example of a representative computing system capable of carrying out operations in accordance with the servers of the exemplary embodiments is illustrated in FIG. 6 . Hardware, firmware, software or a combination thereof may be used to perform the various steps and operations described herein. The computing structure 600 of FIG. 6 is an exemplary computing structure that may be used in connection with such a system.
The exemplary computing arrangement 600 suitable for performing the activities described in the exemplary embodiments may be a presence server or a publishing server or an XDMS server 601 . Such a server 601 may include a central processor (CPU 602 ) coupled to a random access memory (RAM) 604 and to a read-only memory (ROM) 606 . The ROM 606 may also be other types of storage media to store programs, such as programmable ROM (PROM), erasable PROM (EPROM), etc. The processor 602 may communicate with other internal and external components through input/output (I/O) circuitry 608 and bussing 610 , i.e., collectively or individually a “communications interface”, to provide control signals and the like. The processor 602 carries out a variety of functions as is known in the art, as dictated by software and/or firmware instructions.
The server 601 may also include one or more data storage devices, including hard and floppy disk drives 612 , CD-ROM drives 614 , and other hardware capable of reading and/or storing information such as DVD, etc. In one embodiment, software for carrying out the above discussed steps may be stored and distributed on a CD-ROM 616 , diskette 618 or other form of media capable of portably storing information. These media may be inserted into, and read by, devices such as CD-ROM drive 614 , the disk drive 612 , etc. The server 601 may be coupled to a display 620 , which may be any type of known display or presentation screen, such as LCD displays, plasma displays, cathode ray tubes (CRTs), etc. A user input interface 622 is provided, including one or more user interface mechanisms such as a mouse, keyboard, microphone, touch pad, touch screen, voice-recognition system, etc.
The server 601 may be coupled to other computing devices, such as the landline and/or wireless terminals and associated publishing requests/applications, via a network. The server may also be part of a larger network configuration as in a global area network (GAN) such as the Internet 628 , which allows ultimate connection to the various landline and/or mobile client devices. Alternatively, the server 601 could be part of a single operator's communication network and be reserved for the use of its subscribers.
Utilizing the above-described exemplary embodiments, an exemplary method for handling unauthorized requests to publish information is shown in the flowchart of FIG. 7 . Initially a method for handling unauthorized requests to publish information associated with a first entity includes: receiving a request from a second entity to publish information associated with the first entity in step 702 ; comparing the request to stored authorization information to determine that the request is currently unauthorized in step 704 ; and transmitting a first authorization response toward the second entity which indicates that the request to publish information is currently unauthorized in step 706 .
The above-described exemplary embodiments are intended to be illustrative in all respects, rather than restrictive, of the present invention. Thus the present invention is capable of many variations in detailed implementation that can be derived from the description contained herein by a person skilled in the art. All such variations and modifications are considered to be within the scope and spirit of the present invention as defined by the following claims. No element, act, or instruction used in the description of the present application should be construed as critical or essential to the invention unless explicitly described as such. Also, as used herein, the article “a” is intended to include one or more items.
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Systems and methods for reactively authorizing publication of information by a third party are coordinated through the use of a presence server. The presence server communicates with other communication nodes/devices to determine and relay publication information. Publication requests that are initially unauthorized, from the perspective of the presence server, are resolved.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] The present application is a continuation of co-pending U.S. application Ser. No. 10/235,168 filed Sep. 5, 2002, the contents of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a refrigerator and/or freezer with an appliance body and a door for closing an opening of the appliance body, wherein a pivot bearing is provided which pivotably supports the door relative to the appliance body about a pivot axis.
[0003] Refrigerators and freezers generally have on their door an elastic gasket with an integrated magnet which has the function of pulling the door-side gasket bead against the sealing contact surface on the appliance body. Due to the geometric properties of such pivot doors, however, the desired optimal sealing interface is often not achieved, especially in the region of the door adjacent the pivot axis, despite obliquely positioned magnets present in the gasket profile. The magnet prematurely attracts the gasket against the appliance body such that the gasket does not seat in optimal fashion and may flex as the door continues to pivot closed. Both problems result in an unsatisfactory seal which may cause increased frost formation in the freezer space, and more generally, premature wear of the gasket.
[0004] FIG. 11 shows a refrigerator of the known type in the region of the sealing interface between pivotable door and appliance body, the door being shown in the closed position with the gasket optimally seated. The appliance body 1 has an essentially flat sealing contact surface 2 on which rests the gasket 3 attached to the door 6 . As FIG. 11 shows, gasket 3 is designed as an elastic sealing bead in which a magnet 4 is integrated. This magnet pulls gasket 3 against the metal sealing contact surface 2 of appliance body 1 . The optimum sealing interface shown in FIG. 11 for gasket 3 is often not achieved, however:
[0005] When door 6 is pivoted in the closing direction around the essentially vertical pivot axis 5 from the pivoted-open position, the magnet 4 first contacts sealing contact surface 2 of appliance body 1 , as shown in FIG. 12 . This situation also occurs if magnet 4 is positioned at an oblique angle. When door 6 continues to be pivoted in the closing direction from the position of FIG. 12 , it may happen that door magnet 4 contacts appliance body 1 during the closing process due to the attractive force and cannot be moved into the optimum position during the continuing closing process by gasket 3 . This sealing interface is of variable size, depending on the tolerances present. Magnet 4 seemingly prematurely attaches itself in fixed position by suction—with the result the gasket 3 flexes. FIG. 13 shows an unreliably deformed gasket 3 of this type which can only create an insufficient seal. In addition, the above-mentioned flexure of gasket 3 results in premature wear of the gasket.
SUMMARY OF THE INVENTION
[0006] The object of the invention is therefore to create an improved refrigerator or freezer of the type mentioned in the introduction in which the disadvantages of prior-art technology may be avoided and in which this technology may be further modified in an advantageous manner. Specifically, the goal is to achieve an improved opening and closing of the door with the most optimum seal possible.
[0007] This object is achieved according to the invention by a refrigerator and/or freezer described herein. Advantageous embodiments of the invention are also described herein.
[0008] According to the invention, an additional axis of motion perpendicular to the pivot axis is thus provided for the door. The door may be movably mounted relative to the pivot axis, and/or the pivot axis may be movably mounted relative to the appliance body, in the direction perpendicular to the pivot axis. The pivot bearing is thus designed such that in addition to the rotational pivot motion of the door about the pivot axis, in the region of the pivot axis the door may be moved roughly perpendicular to the sealing interface of the appliance body away from or onto said body. This capability of translational motion transverse to the pivot axis prevents flexure of the gasket. This gasket may essentially be mounted vertically onto the opposite sealing contact surface such that it is always seated in the intended position and provides the optimum seal. Similarly, flexure is prevented when the door is opened since the additional pivot axis of the door perpendicular to the sealing contact surface allows the gasket to be pulled vertically away from the opposite sealing interface.
[0009] In a further modification of the invention, the motion of the door is controlled perpendicular to the pivot axis as a function of the pivot position of the door. A corresponding motion-control device may specifically be designed such that at the beginning of a pivot-opening process the door is initially moved essentially perpendicular to the pivot axis and thus vertically away from the appliance body; while conversely, toward the end of each pivot-closing process, the door is moved essentially perpendicular to the pivot axis, and thus perpendicular to the appliance body or its sealing contact surface and onto the latter. The translational motion superimposed on the pivot motion is thus provided in the pivot region adjoining the completely closed position of the door such that in this region the door is moved translationally essentially perpendicular to the appliance body. The conventional pure pivot motion may then be again provided in the subsequent open pivot region of the door.
[0010] Preferably, a cam device is provided perpendicular to the pivot axis, specifically in the region of the pivot axis between the appliance body and the door, to control the door motion, said cam device determining the door's distance from the appliance body as a function of the pivot position of the door. A cam may be provided with a first curve section which allows for a door position close to the appliance body, and with a second curve section adjoining the first curve section which results in a distant door position removed from the appliance body. When the door is opened, the cam presses the door in the region of the pivot axis away from the sealing interface of the appliance body. When closed, the door snaps in or falls vertically onto the sealing interface at the end of the pivot-closing process. In principle, the cam may be provided on the door or on the appliance body and rest against the opposite sliding surface. In a preferred embodiment of the invention, the cam is rigidly connected to the door so that it slides or rolls off, along with its curve control surface, on a support surface fixedly attached on the appliance body side when the door is pivoted open or closed.
[0011] Preferably, a pretensioning device, specifically a spring device, is provided to pretension the door relative to the pivot axis, or the pivot axis relative to the appliance body, in the direction of the additional axis of motion. The spring device presses the pivot axis relative to the door or relative to the appliance body into its initial position from which it is pressed out by the above-mentioned cam against the spring tension given the appropriate pivot position of the door. The pretensioning device is oriented such that when the door is closed the door is under tension toward the appliance body. The pretensioning device is appropriately dimensioned such that its pretensioning force is greater than the sealing forces in effect between door and appliance body, i.e., such that sealing forces already in effect between door and appliance body do not cause any displacement of the pivot axis, or the door to be pressed open.
[0012] The cam device and pretensioning device advantageously act together so as to effect an automatic closing of the door in the final section of the door's pivot motion. Cam device and pretensioning device together form a kind of automatic closing device. The last segment automatically swings the door shut in response to the pretensioning force and its translation by the cam device.
[0013] The additional axis of motion of the door perpendicular to the sealing contact surface of the appliance body is preferably achieved by movably mounting the door relative to the pivot axis fixed to the appliance body, and specifically in the direction transverse to the longitudinal direction of the pivot axis. In principle, is also possible, based on an approach employing a kinematic reversal, to mount the door in the conventional fashion as nondisplaceable and only rotationally movable on the pivot axis and then to arrange the latter movably relative to the appliance body in the direction perpendicular to the sealing interface of the appliance body. The preferred approach is the previously mentioned design with the pivot axis rigidly fixed on appliance body. Specifically in this regard, elongated holes may be provided on the door side in the form of bearing slots for the pivot axis, in which holes the pivot axis runs or by which the door sits on the pivot axis. The elongated-hole-shaped bearing slots extend perpendicular to the front and rear sides of the door, thereby achieving the desired motion perpendicular to the sealing interface of the appliance body.
[0014] Preferably, door arresters may be provided which sit essentially free of play and rotationally on the pivot axis, and which are pretensioned by a spring relative to the door in the direction of the door side facing away from the appliance body. The above-mentioned door arresters cause the pivot axis to be pressed preferably toward one end of the elongated-hole-shaped bearing slots of the door such that a defined position of the door relative to the pivot axis is provided whenever the cam device does not press the axis in another direction.
[0015] Door arrester and cam device preferably form one assembly unit. In one advantageous embodiment of the invention, provision may be made that one cam each is rigidly fixed to the door along with a control curve surface facing the appliance body and has a guide for one door arrester each in which the respective door arrester located on the pivot axis is displaceably routed perpendicular to the front and rear sides of the door. The pretensioning device, preferably in the form of a spring, may also be integrated into the cam. The cam may have a spring slot to accommodate the pretensioning spring.
[0016] In an alternative preferred embodiment of the invention, the cam may be rigidly fixed on the door along with a control curve surface facing the appliance body and be of an integrated one-piece design with the door arrester sitting on the pivot axis, wherein a spring section is provided between the curve control surface and the door arrester—this being achieved, for example, by having the curve control surface section and the door arrester section together define an approximately U-shaped contour. The one leg defining the door arrester may be deflected by spring action relative to the other leg of the U-shaped body which forms the rigid cam or the rigid curve control surface.
[0017] In a further modification of the invention, the pivot axis or the hinge pins are rigidly fixed to hinge plates projecting from the appliance body. The hinge plates may be attached in the conventional fashion to the appliance body or housing. Supports, specifically support pins parallel to the hinge pins, may be provided on the hinge plates on which the door-side-attached cam rests. The cam is preferably of plastic. It is useful to employ a slidable lubricating material such as polyamide. The support pins interacting with the cams at the hinge plates may be steel pins.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The following discussion explains the invention based on preferred embodiments and associated drawings. The drawings are as follows:
[0019] FIG. 1 is a perspective view of a refrigerator and freezer with a refrigerator door and a freezer door which are each pivotably mounted on the appliance body about a vertical pivot axis.
[0020] FIG. 2 is a perspective view of a top bearing of the refrigerator door of FIG. 1 in a sectional view from above based on a preferred embodiment of the invention.
[0021] FIG. 3 is a perspective view of a door bearing from FIG. 2 as seen obliquely from below.
[0022] FIG. 4 is an exploded plan view of a door bearing from the previous figures wherein first the door is shown with a movable guide for the pivot axis as well as a door-side-located cam, and secondly a hinge plate provided on the appliance body side is shown with the pivot axis and a support pin for the door-side cam.
[0023] FIG. 5 shows a horizontal section through the refrigerator and freezer of FIG. 1 in the region of the seal between appliance body and door wherein the door is shown in a completely closed position.
[0024] FIG. 6 . shows a section through the refrigerator and freezer similar to FIG. 5 wherein the door is shown in a position which is slightly pivoted open and raised vertically from the appliance body.
[0025] FIG. 7 shows a horizontal section through the refrigerator and freezer similar to FIGS. 5 and 6 wherein the door is shown in a position pivoted further open.
[0026] FIG. 8 shows a longitudinal section through a top bearing of the door of the refrigerator and freezer of FIG. 1 based on another preferred embodiment of the invention, specifically along line A-A in FIG. 9 .
[0027] FIG. 9 is a plan view of the top bearing of FIG. 8 , specifically along line B-B of FIG. 8 .
[0028] FIG. 10 is a plan view of a top door bearing of the refrigerator and freezer of FIG. 1 based on another preferred embodiment of the invention.
[0029] FIG. 11 shows a horizontal section through a refrigerator in the region of the seal between door and appliance body based on prior art in which a fixed pivot axis is provided.
[0030] FIG. 12 shows a horizontal section through a refrigerator of prior art similar to FIG. 11 wherein the door is shown in a slightly opened position.
[0031] FIG. 13 shows a horizontal section through a refrigerator of prior art similar to FIGS. 11 and 12 wherein the gasket is shown in a flexed, displaced contact position.
[0032] FIG. 14 is a perspective view of a top bearing of a refrigerator door, similar to FIG. 2 , of another preferred embodiment of the present invention and illustrating an embodiment where the pivot axis is movable relative to the appliance body.
[0033] FIG. 15 shows a horizontal section through the refrigerator and freezer in the region of the seal between the appliance body and door in completely closed position, similar to FIG. 5 , and illustrating the embodiment where the pivot axis is movable relative to the appliance body.
[0034] FIG. 16 shows a section through the refrigerator and freezer similar to FIG. 15 wherein the door is shown in a position which is slightly pivoted open and raised vertically from the appliance body.
[0035] FIG. 17 is a perspective view of a door bearing from FIG. 14 as seen obliquely from below.
[0036] FIG. 18 is an exploded plan view of a door bearing from FIGS. 14-17 wherein first the appliance body is shown with a movable guide for the pivot axis as well as an appliance-side-located cam, and secondly a hinge plate provided on the door side is shown with the pivot axis and a support pin for the appliance-side cam.
[0037] FIG. 19 shows a horizontal section through the refrigerator and freezer similar to FIGS. 15 and 16 wherein the door is shown in a position pivoted further open in the direction of the arrow.
[0038] FIG. 20 shows a longitudinal section through a top bearing of the appliance body of the refrigerator and freezer of FIGS. 14-19 based on another preferred embodiment of the invention, specifically along line A-A in FIG. 21 infra.
[0039] FIG. 21 is a plan view of the top bearing of FIG. 20 , specifically, along line B-B of FIG. 20 .
[0040] FIG. 22 is a plan view of a top door bearing of the refrigerator and freezer of FIGS. 14-19 based on another preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] FIG. 1 shows a standing refrigerator and freezer which has a cubic appliance body 1 , the front side of which has a refrigerator opening and a freezer compartment opening. The top-located smaller freezer compartment opening is closed by a freezer compartment door 7 , while the bottom large refrigerator opening is closed by the refrigerator door 6 . Both doors 6 and 7 and are pivotable about a vertical pivot axis which is located on the right side of the refrigerator and freezer as shown in FIG. 1 .
[0042] Both doors here have a top bearing and a bottom bearing which together define the pivot axis 5 . The top and bottom bearing of each door 6 and 7 may be designed analogously, and consequently the following discussion describes only the top bearing of refrigerator door 6 .
[0043] FIGS. 2 and 3 provide a perspective view of the top bearing of refrigerator door 6 . A bearing bracket 8 in the form of a hinge plate 9 projects from the appliance housing or body 1 , the bracket overlapping door 6 on its top side. A hinge pin 10 projecting downward is rigidly fixed to hinge plate 9 , the hinge plate along with the corresponding hinge pin of the lower bearing of door 6 defining pivot axis 5 . Hinge pin 10 may be fastened by screws or welded on to hinge plate 9 , or attached by an analogous method.
[0044] An essentially plate-type door arrester 11 with an essentially U-shaped contour is fastened to the top side of door 6 . Specifically, door arrester 11 along with its one leg is rigidly connected to the top side of door 6 , specifically screwed to it, while the other leg of door arrester 11 does not have a fixed connection to the surface of the door. Door arrester 11 is composed of an elastic material, specifically a flexible plastic, so that the free door arrester leg 12 may move flexibly relative to the door. Door arrester 11 is arranged such that the recess between legs 12 and 13 runs parallel to the front and rear sides of the door. As a result, free door arrester 12 is able to move or function elastically essentially perpendicular to the front and rear side of door 6 .
[0045] As FIG. 2 shows, hinge pin 10 of bearing bracket 8 engages the elastic or movable leg of door arrester 11 . Door arrester 11 has a hinge pin slot 14 on door arrester leg 12 , which slot accepts hinge pin 10 (see FIG. 4 ). Hinge pin 10 passes through door arrester 11 and then passes within an elongated-hole-type bearing slot 15 provided on the top side of door 6 . The elongated hole 15 extends along its longitudinal axis essentially perpendicular to the front and rear sides of the door such that door 6 is able to move perpendicular to its front and rear sides relative to pivot axis 5 . To explain it from the reverse point of view, hinge pin 10 can be moved back and forth within elongated hole 15 , where each door arrester leg 12 moves elastically in tandem. Door arrester leg 12 is arranged such that hinge pin 10 is pressed into that end of elongated slot 15 which lies toward the outside of door 6 . The mobility of the door relative to the hinge pin, and visa versa, is indicated in FIG. 4 by the arrow 16 . Door arrester 11 thus simultaneously forms a pretensioning or spring-like device which pretensions pivot axis 5 and door 6 in a predefined position relative to each other.
[0046] In an alternative inventive design, not shown separately, it would also be possible to dispense with the elongated-hole design 15 and to guide hinge pin 10 exclusively with door arrester leg 12 . In this case, hinge pin slot 14 in door arrester 11 would sit essentially free of play and concentrically on hinge pin 10 . Mobility would then not be provided by elongated hole 15 but by the elastic motion of door arrester leg 12 . Stops may be used to limit the maximum deflection of door arrester leg 12 in the direction of arrow 16 .
[0047] As FIGS. 2 and 4 show, the door arrester section 13 rigidly fixed to the top side of the door forms a cam 17 projecting toward the door interior or appliance body 1 , which cam has a curve control surface 18 on its side facing appliance body 1 . Curve control surface 18 essentially consists of a first section in the form of a sink 19 and a second section contiguous with it in the form of a convex camber 20 projecting with the door closed toward appliance body 1 , which camber forms a door opening section or functions as a door opener.
[0048] Interacting with cam 17 is a support pin 21 which is rigidly fixed and projects parallel to hinge pin 10 on bearing bracket 8 (see FIG. 3 ). The peripheral surface of support pin 21 forms a sliding surface on which curve control surface 18 of cam 17 is able to slide.
[0049] Curve control surface 18 of cam 17 , and support pin 21 are arranged and dimensioned relative to one another such that with the door completely closed, support pin 21 contacts sink 19 of cam 17 with a snug fit. This configuration is shown in FIG. 5 , specifically in segment a). With door 6 in the completely closed position, a seal extending circumferentially around the interior side of the door in the form of an elastic gasket bead 3 contacts the sealing contact surface 2 facing the door of appliance body 1 . As FIG. 5 shows, gasket 3 may include a magnet 4 in the conventional manner which attracts the metallic appliance housing surface or exterior side of body 1 , thus effecting a secure tight contact between sealing contact surface 2 and gasket 3 .
[0050] When door 6 is pivoted open from the closed position, curve control surface 18 of cam 17 with its camber 20 projecting toward sealing contact surface 2 must move over support pin 21 . FIG. 6 shows this specifically in segment a). Since cam 17 is rigidly connected to door 6 , this bumping of cam 20 against support pin 21 presses door 6 essentially vertically away from sealing contact surface 2 . In the process, gasket 3 is lifted essentially deflection-free from sealing contact surface 2 . The hinge axis or hinge pin 14 then moves within elongated hole 15 , as FIG. 6 shows, against the spring resistance of the pretensioning device. Door arrester leg 12 here is flexed toward the fixed door arrester leg 13 .
[0051] As the door is opened further, curve control surface 18 moves further along support pin 21 . Camber 20 retracts so that the spring pretensioning device of elastic door arrester 11 is able to press door 6 back into its initial position relative to hinge pin 14 . This is shown in FIG. 7 . As soon as pivot axis 5 again assumes its initial position relative to the door, the superimposition of the translational motion of the door perpendicular to pivot axis 5 has ended. When the door is pivoted further open, the door again undergoes a purely rotary motion of the conventional type. When pivoted back to the closed position, the door undergoes a correspondingly reverse motion. Specifically, gasket 3 along with its magnet 4 does not remain prematurely caught on sealing contact surface 2 ; instead gasket 3 moves essentially vertically onto sealing contact surface 2 only toward the end of the closing motion, and specifically when cam 17 along with its sink 19 snaps onto support pin 21 . In the process, an automatic closing motion occurs effected by the spring pretensioning of elastic door arrester 11 , which motion pulls the door completely shut. The spring pretensioning device attempts to press support pin 21 into sink 19 in order to obtain a lower energy level for the system.
[0052] Other embodiments are also possible in place of the integrated one-piece and elastic spring-action design of door arrester 11 .
[0053] FIGS. 8 and 9 show another embodiment of this type. Here again the hinge pin 10 is routed within an elongated-hole-shaped bearing slot 15 in the top side of door 6 . Elongated-hole-shaped bearing slot 15 also extends perpendicular to the door interior and exterior sides, thereby achieving the corresponding motion already described. Here, however, door arrester 22 is of a multi-part design. A first door arrester section 23 , the side of which facing the appliance body is designed as cam 17 , is rigidly fixed on the top side of door 6 . First section 23 , essentially of a plate-like design, has on its side facing the door exterior a drawer-like slot 26 in which the second door arrester section 24 is displaceably mounted and is located. Slot 26 extends along its longitudinal axis parallel to elongated-hole-shaped slot 15 within the top side of door 6 such that second door arrester section 24 is reciprocally slidable within first door arrester section 23 transversely relative to hinge pin 10 , or with the door closed, essentially perpendicular to sealing contact surface 2 . A spring 25 presses second door arrester section 24 toward the outside of door 6 . Here a stop, which may be formed by a stage of slot 26 , defines an end position of second door arrester section 24 in which this section is pretensioned.
[0054] A circular hinge pin slot 14 is provided in second door arrester section 24 , with which slot second door arrester section 24 sits on hinge pin 10 ( FIG. 8 ).
[0055] In order to move the door perpendicular to pivot axis 5 , spring 25 is deformed accordingly, specifically compressed as in FIG. 9 . Here second door arrester section 24 moves deeper into drawer-like slot 26 within first door arrester section 23 . Pivot axis 5 moves toward the interior side of the door. In this design too, the motion between pivot axis 5 and door 6 is controlled transversely relative to the pivot axis as a function of the pivot position of the door. Cam 17 acts in analogous fashion, and so reference is made here to the previous description.
[0056] Another embodiment of the door arrester is shown in FIG. 10 which essentially corresponds to the embodiment of FIGS. 8 and 9 . The door arrester 27 here is also of a two-part design. The first door arrester section 28 is rigidly connected with door 6 , specifically as in the embodiments described previously on the top side of the door. Its side facing appliance body 1 with the door closed is designed analogously as cam 17 . In place of the previously described drawer-like slot 26 , door arrester 27 has a longitudinal groove 29 open on the top side in which the second door arrester section 30 sits longitudinally with precise fit and is arranged to be longitudinally displaceable ( FIG. 10 ). A spring 32 located in a first spring receptacle compartment 31 of door arrester section 28 pretensions second door arrester section 30 toward the exterior of the door. As in the embodiments described previously, hinge pin 10 is able to pass through door arrester 27 and engage elongated hole 15 within the top side of door 6 . Otherwise the function of door arrester 27 matches the previously described embodiment.
[0057] The additional axis of motion of the door perpendicular to pivot axis 5 and, with the door closed, perpendicular to sealing interface 2 in connection with the cam device prevents any flexure of gasket 3 . Gasket 3 always meets, and is lifted from, sealing contact surface 2 of body 1 essentially vertically. Defective sealing is prevented and the life considerably lengthened due to the flexure-free closing and opening processes.
[0058] FIGS. 14-16 and 19 illustrate an embodiment according to the present invention, in which the pivot axis 5 is fixed to the door 6 and movable with respect to the appliance body 1 , notably in a direction perpendicular to the sealing interface 2 of door 6 . The various components in this embodiment are mounted upon the respective door 6 and appliance body 1 in exactly opposite fashion to the mounting of the analogous components upon the door 6 and appliance body 1 illustrated, e.g., in FIGS. 2 and 5 - 7 .
[0059] More specifically, a bearing bracket 8 in the form of a hinge plate 9 projects from the door 6 , the bracket 8 overlapping the appliance body 1 on its top side. A hinge pin 10 projecting downwardly is rigidly fixed to the hinge plate 9 which, together with the corresponding hinge pin of the lower bearing of the appliance body 1 , defines pivot axis 5 . Hinge pin 10 may be fastened by screws or welded onto the hinge plate 9 .
[0060] An essentially plate-type door arrester 11 with an essentially U-shaped contour is fastened to the top side of appliance body 1 . Specifically, door arrester 11 along with its one leg is rigidly connected to the top side of appliance body 1 , specifically screwed to it, while the other leg of door arrester 11 does not have a fixed connection to the surface of the appliance body 1 . Door arrester 11 is composed of an elastic material so that free door arrester leg 12 may flexibly move relative to the appliance body 1 . Door arrester 11 is arranged such that the recess between legs 12 and 13 run parallel to the front and rear sides of the appliance body 1 . As a result, free door arrester leg 12 is able to move or function elastically essentially perpendicular to the front and rear side of appliance body 1 .
[0061] As FIG. 14 illustrates, hinge pin 10 of bearing bracket 8 engages the elastic or movable leg 12 of door arrester 11 which also has a hinge pin slot 14 to accept hinge pin 10 ( FIG. 18 ), passing through door arrester 11 and then within an elongated-hole-type bearing slot 15 provided on the top side of appliance body 1 . The elongated hole 15 extends along its longitudinal axis essentially perpendicular to front and rear sides of the appliance body 1 such that the door 6 and pivot axis 5 are able to move perpendicular to the front and rear sides of appliance body 1 . In other words, hinge pin 10 can be moved back and forth within elongated hole 15 , with each door arrester leg 12 moving elastically in tandem. Door arrester leg 12 is arranged such that hinge pin 10 is pressed into an end of elongated slot 15 which lies toward the inside of the appliance body 1 . The mobility of the door 6 and hinge pin 10 relative to appliance body 1 is illustrated in FIG. 18 by arrow 16 . Door arrester 11 thus simultaneously forms a pre-tensioning or spring-like device which pretensions pivot axis 5 and door 6 in predefined position.
[0062] In an alternative design not shown separately, it would also be possible to dispense with the elongated-hole design 15 and guide hinge pin 10 exclusively with door arrester leg 12 . In this situation, hinge pin slot 14 in door arrester 11 would sit essentially free of play and concentrically on hinge pin 10 . Mobility would then not be provided by elongated hole 15 but by the elastic motion of door arrester leg 12 . Stops may be used to limit the maximum deflection of door arrester leg 12 in the direction of arrow 16 .
[0063] As FIGS. 14 and 18 show, the door arrester section 13 rigidly fixed to the top side of the appliance body 1 forms a cam 17 projecting toward the door 6 and having a curved control surface 18 on a side facing the door 6 and which is essentially constituted by a first section in the form of a sink 19 and a second section contiguous with it in the form of a convex camber 20 projecting towards the door 6 when closed. This camber 20 forms a door opening section.
[0064] Interacting with cam 17 is a support pin 21 which is rigidly fixed and projects parallel to hinge pin 10 on bearing bracket 8 ( FIG. 17 ). The peripheral surface of support pin 21 forms a sliding surface on which curved control surface 18 of cam 17 can slide.
[0065] Curved control surface 18 of cam 17 and support pin 21 are arranged and dimensioned relative to one another such that with the door 6 completely closed, support pin 21 contacts sink 19 of cam 17 with a snug fit. This configuration is shown in FIG. 15 , specifically in segment a). With door 6 in completely closed position, a seal extending circumferentially around the interior side of the appliance body 1 in the form of an elastic gasket bead 3 contacts the sealing surface 2 of the door 6 . As FIG. 15 shows, gasket 3 may include a magnet 4 in the conventional manner which attracts the metallic door surface or exterior side of door 6 , thus effecting a secure, tight contact between sealing contact surface 2 and gasket 3 .
[0066] When door 6 is pivoted open from the closed position, curve control surface 18 of cam 17 with its camber 20 projecting toward sealing contact surface 2 must move over support pin 21 . FIG. 16 shows this specifically in segment a). Since cam 17 is rigidly connected to appliance body 1 , this bumping of cam 20 against support pin 21 presses door 6 essentially vertically away from gasket 3 . The hinge axis or hinge pin 10 then moves within elongated hole 15 , as FIG. 16 shows, against the spring resistance of the pre-tensioning device. Door arrester leg 12 here is flexed toward the fixed door arrester leg 13 .
[0067] As the door 6 is further opened, curve control surface 18 moves further along support pin 21 , camber 20 retracts so that the spring pre-tensioning device of elastic door arrester 11 is able to press door 6 back into its initial position relative to elongated hole 15 , i.e., appliance body 1 . This is shown in FIG. 19 . As soon as pivot axis 5 again assumes its initial position relative to the appliance body 1 , the superimposition of the translational motion of the door 6 perpendicular to slot 15 defined on appliance body 1 , has ended. When the door 6 is pivoted further open, the door 6 again undergoes a purely rotary motion of the conventional type. When pivoted back to the closed position, the door 6 undergoes a correspondingly reverse motion. Specifically, gasket 3 along with its magnet 4 does not remain prematurely caught on sealing contact surface 2 ; instead, contact surface 2 moves essentially vertically onto gasket 3 only toward the end of the closing motion, and specifically when cam 17 along with its sink 19 snaps onto support pin 21 .
[0068] In this process, an automatic closing motion occurs effected by the spring pre-tensioning of elastic door arrester 11 , which motion pulls the door 6 completely shut. The spring pre-tensioning device attempts to press support pin 21 into sink 19 in order to obtain a lower energy level for the system.
[0069] Other embodiments are also possible in place of the integrated one-piece and elastic spring-action of door arrester 11 mounted upon appliance body 1 . For example, FIGS. 20 and 21 illustrate hinge pin 10 routed within an elongated-hole-shaped bearing slot 15 in the top side of appliance body 1 and which also extends perpendicular to exterior and interior sides of the appliance body 1 , to achieve the corresponding motion described above. In FIGS. 20 and 21 , the door arrester 22 is of a multi-part design. A first door arrester section 23 , the side of which facing the door 6 is designed as cam 17 , is rigidly fixed on the top side of appliance body 1 . First section 23 , essentially of a plate-like design, has on its side facing the appliance body exterior a drawer-like slot 26 in which the second door arrester section 24 is displaceably mounted and located. Slot 26 extends along its longitudinal axis parallel to elongated-hole-shaped slot 15 within the top side of appliance body 1 such that second door arrester section 24 is reciprocally slidable within first door arrester section 23 essentially perpendicular to sealing contact surface 2 (with the door 6 closed). A spring 25 presses second door arrester section 24 toward the outside of appliance body 1 . Here a stop, which may be formed by a stage of slot 26 , defines an end position of second door arrester section 24 in which this section is pre-tensioned.
[0070] A circular hinge pin slot 14 is provided in second door arrester section 24 , through which the second door arrester section 24 sits on hinge pin 10 ( FIG. 20 ). In order to move the door 6 with pivot axis 5 perpendicular to sealing contact surface 2 , spring 25 is deformed, i.e., compressed as shown in FIG. 21 . Here, second door arrester section 24 moves deeper into drawer-like slot 26 within first door arrester section 23 . Pivot axis 5 moves toward the interior side of the appliance body 1 . In this design too, the motion between pivot axis 5 and appliance body 1 is controlled transversely relative to the pivot axis 5 as a function of the pivot position of the door 6 . Cam 17 acts in analogous fashion as the preceding description.
[0071] Another embodiment of the door arrester is shown in FIG. 22 which essentially corresponds to the embodiment of FIGS. 20 and 21 . The door arrester 27 here is also of a two-part design. The first door arrester section 28 is rigidly connected with appliance body 1 , specifically as in the embodiments described previously on the top side of the appliance body 1 . Its side facing door 6 when closed is designed analogously as cam 17 . In place of the previously-described drawer-like slot 26 , door arrester 27 has a longitudinal groove 29 open on the top side in which the second door arrester section 30 longitudinally with precise fit and is arranged to be longitudinally displaceable ( FIG. 22 ). A spring 32 located in a first spring receptacle compartment 31 of door arrester section 28 pre-tensions second door arrester section 30 toward the exterior of the appliance body 1 . As in the embodiments described previously, hinge pin 10 is able to pass through door arrester 27 and engage elongated hole 15 within the top side of appliance body 1 . Otherwise, the function of door arrester 27 matches the previously-described embodiment.
[0072] The additional axis of motion of the door 6 and pivot axis 5 perpendicular to face of the sealing interface 2 (with the door 6 closed) in connection with the cam device, prevents any flexure of gasket 3 which always meets, and is lifted from, sealing contact surface 2 of door 6 essentially vertically.
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The invention relates to a refrigerator and/or freezer with an appliance body and a door for closing an opening of the appliance body, wherein a pivot bearing is provided which pivotably supports the door relative to the appliance body about a pivot axis. According to the invention, the refrigerator and/or freezer is characterized in that the door relative to the pivot axis and/or the pivot axis relative to the appliance body are movably mounted in the direction perpendicular to the pivot axis.
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FIELD OF THE INVENTION
[0001] This invention relates to hand-wear for wearers of helmets having face-enclosing visors and for wearers of goggles. The invention has particular, although not exclusive, application to motorcyclists and snow skiers.
BACKGROUND OF THE INVENTION
[0002] An inherent problem with wearing goggles or a face-covering visor on a helmet at the same time as wearing gloves is the removal of items from the surface of the goggles or visor that impair vision.
[0003] This problem is commonly found among motorcyclists in conditions where mud, dust, tar particles, insects, water from rain and the like lodge on the visor and impair the vision of the helmet wearer. Snow skiers have a similar problem with snow and ice that lodges on ski goggles or other forms of eye-wear. In both cases, wearing gloves reduces a user's ability to remove the vision impairing items. Removing the gloves to wipe the items clear of the visor or goggles is a nuisance because the motorcyclist may be travelling on a highway or in traffic and because the skier may not be in a position to stop on a slope or may be out in very cold conditions.
[0004] One solution used in motorcycle and open-car racing is the use of tear-off visor strips applied to the surface of a visor. Vision impairing items lodged on a strip are removed when the strip is torn-off to reveal a clean underlying strip.
[0005] Another simpler and less expensive option involves using a rag to wipe the vision impairing items from the visor or goggles. However, retrieving a rag from a closed pocket can be difficult for a motorcycle rider and skier because both hands are required to control the motorcycle or to stay upright on the skis. The act of retrieving the rag and placing it back inside a pocket is complicated by the reduced dexterity of the motorcyclist or skier due to wearing gloves
[0006] It is an object of the invention to alleviate the above problem by providing an improved means for removing vision impairing debris from a visor or goggles.
SUMMARY OF THE INVENTION
[0007] According to a first aspect of the invention there is provided a glove for use by wearers of eye shields, such as goggles and face-covering visors in helmets, the glove having:
[0008] a body for at least partially covering the hand and fingers of a wearer;
[0009] means for wiping the eye shield to remove debris;
[0010] wherein the at least one wiping means is located on the glove to enable wiping of the eye shield with natural hand movements.
[0011] The location of the wiping means is important for improving the ease of use of the wiping means. Using natural hand movements to apply the means to the eye shield improves accuracy so specific spots of debris can be targeted and, more importantly, improves comfort and ease of use. The ease of use is improved by virtue of the user avoiding having to contort their arm and hand to apply the wiping means to the eye shield with sufficient force and control to effectively remove debris.
[0012] The term “debris” is taken to include water, snow, ice, mud, insects and road grime such as dust and tar particles.
[0013] The wiping means is formed as a flexible wiping strip or squeegee such as a rubber strip.
[0014] The wiping strips may be located on fingers or a thumb of the glove, and are preferably located on the glove such that when the glove is fitted to a wearer the wiping strips coincide with one or more of the following locations:
[0015] along the side of the little finger that is opposite to the ring finger;
[0016] along the side of the index finger that is opposite to the middle finger; or
[0017] along the side of the thumb that is opposite to the index finger.
[0018] The glove has at least one surface scrubbing portion for scrubbing the eye shield to loosen debris so that subsequent wiping of the eye shield with the wiping means removes the loosened debris.
[0019] In the preferred embodiment, the glove is formed from two or more pieces of fabric or leather and fabric lining that are sewn together to form a glove and the wiping means is located to coincide with a seam of the glove. In this embodiment, the at least one wiping strip is sewn into the glove at the seams of those locations.
[0020] The at least one scrubbing portion is located on the body to coincide with the fingers of the wearer and more preferably to coincide with the palm-side of the fingers. In such location the wearer has optimum dexterity for applying and varying pressure through the scrubbing portions onto the eye shield and for moving the scrubbing portions over the eye shield.
[0021] In an alternative embodiment, scrubbing portions are located on either or both sides of a wiping strip to enable the wearer to scrub and wipe in the same hand, finger or thumb action. In such an alternative embodiment, the scrubbing portions are located in abutment with either or both sides of the wiping means.
[0022] In a second aspect of the invention there is provided a wiper for removing debris from an eye shield, the wiper comprising:
[0023] a sleeve for slipping over the finger or thumb of a glove;
[0024] means formed on the exterior of the sleeve for wiping over the eye shield to remove debris.
[0025] The wiper includes at least one scrubbing portion formed on the exterior of the sleeve for scrubbing the eye shield to loosen debris so that subsequent wiping of the eye shield with a wiping strip removes the loosened debris.
[0026] The at least one scrubbing portion is formed on the sleeve relative to the wiping means such that, when slipped over the finger or thumb of the glove, the at least one scrubbing portion coincides with the palm-side of a wearer's finger or thumb and the wiping means coincides with the side of the wearer's finger or thumb.
[0027] Alternatively, the wiper includes scrubbing portions on either or both sides of the wiping means to enable the wearer to scrub and wipe in the same hand, finger or thumb action. In such an alternative embodiment, the scrubbing portions are preferably located in abutment with either or both sides of the wiping means.
[0028] Referring to the first aspect, the invention provides, in other words, a glove for use by wearers of eye shields, the glove comprising:
(a) a body shaped to receive and at least partially cover the hand and fingers of a wearer; and (b) a wiper adapted to remove debris from an eye shield upon wiping the wiper across the eye shield; and wherein the wiper is located on the glove at a position that enables wiping of the eye shield with natural hand movements.
[0031] Referring to the second aspect, the invention provides, in other words, a wiper for removing debris from an eye shield, the wiper comprising:
(a) a sleeve for slipping over a finger or a thumb of a glove; and (b) at least one wiper element on the exterior of the sleeve for wiping over the eye shield to remove the debris.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0035] FIG. 1 is an isometric view of an embodiment of the present invention as typically used to wipe a visor.
[0036] FIG. 2 is a plan view of the palm of a glove formed in accordance with the first aspect of the invention.
[0037] FIG. 3A is a section view along the line 2 - 2 of the thumb of the glove in FIG. 1 .
[0038] FIG. 3B is a section along the line 2 - 2 of the thumb of the glove in FIG. 1 with an alternative arrangement of the rubber strip and abrasive portions.
[0039] FIG. 3C is a section along the line 2 - 2 of the thumb of the glove in FIG. 1 showing the wiping strip sewn into a seam of the glove.
[0040] FIG. 4 is a perspective view of a wiper formed in accordance with the second aspect of the invention.
DESCRIPTION OF PREFERRED EMBODIMENT
[0041] A glove 10 formed in accordance with an embodiment of the first aspect of the invention is shown in FIG. 1 as typically used by a wearer to wipe rain 6 from a visor 5 of, for example, a motorcycle helmet 7 .
[0042] Although the glove 10 is described in reference to a glove for motorcycling applications, gloves formed in accordance with the invention may be utilised in motor sport, emergency services by, for example, fire fighters and in a broad range of industrial applications, including oil drilling applications.
[0043] The glove 10 , as seen from the palm-side ( FIG. 2 ), includes index, middle, ring and little finger portions 12 , 14 , 16 and 18 respectively and are formed, or in other words, shaped to receive the fingers of a wearer of the glove 10 . The glove 10 also includes a thumb portion 20 for receiving the thumb of a wearer of the glove 10 .
[0044] Each finger portion 12 , 14 , 16 , and 18 includes an scrubbing portion in the form of a scrubbing strip 26 . Each scrubbing strip 26 has a raised profile. The profile may comprise intersecting lines of ridges or an array of raised dots. The raised profile enables a wearer of the glove to rub the scrubbing strips 26 over debris that has lodged on the surface of a motorcycle helmet visor, ski goggles or similar eye shields to loosen the debris that has lodged on and stuck to the visor, goggles or eye shields.
[0045] The material from which the scrubbing strip 26 is formed may be any suitable material that is flexible and durable, such as rubber, Teflon or both. In some applications, such as fire fighting and motor sport, the gloves are exposed to high temperatures. Accordingly, the scrubbing strip 26 of such gloves must have the additional property of heat resistance. In this circumstance, the scrubbing strip 26 is formed of a silicon rubber or compound or any other material that has the required properties of flexibility, durability and heat resistance.
[0046] The scrubbing strips 26 are located on the palm-side of the finger portions 12 , 14 , 16 and 18 to apply the scrubbing strips 26 to the eye shield in a natural hand and arm movement. The term “natural” refers to the comfort and ease with which a user can perform the hand and/or arm movement. For example, positioning of the scrubbing strips 26 at locations that require a wearer to contort the hand or arm or to strain the hand or arm to place the scrubbing strips 26 on a visor or goggles and then perform a wiping action is an unnatural movement.
[0047] Such placement of the scrubbing strips 26 provides the glove wearer with greater dexterity and thereby enables greater accuracy and comfort in moving the scrubbing strips 26 over an eye shield.
[0048] Once the debris is loosened, it may be removed by dragging a wiping means across the eye shield to displace the loose debris from the eye shield. The wiping means are formed as wiping strips 30 from natural, synthetic or wiper blade rubber to have a squeegee effect.
[0049] In a more general sense, however, the wiping strips 30 are made of the same materials described above in relation to scrubbing strips 26 , particularly in relation to high temperature applications.
[0050] Wiping strips 30 are located along a side of the little finger portion 18 that is opposite to the ring finger portion 16 , along a side of the index finger portion 12 that is opposite to the middle finger portion 14 and along the side of the thumb portion 20 that is opposite to the index finger portion 12 . These locations are selected to enable the glove wearer to drag the wiping strips 30 across an eye shield with the most natural hand and arm movements and, at the same time, to avoid the wiping strips 30 interfering with the normal use of the glove. The term “natural” defined above, with reference to the scrubbing strips, has the same definition in respect of the hand and/or arm movements used to wipe the wiping strips 30 across an eye shield.
[0051] It will be appreciated, however, that any number of wiping strips may be incorporated into the glove and on any finger or thumb portion 12 , 14 , 16 , 18 or 20 such that the wiping strip 30 can be dragged across an eye shield using natural and comfortable hand and arm movements.
[0052] The wiping strips 30 have a rectangular profile raised above the surface of the glove and a flattened base portion 22 to prevent the wiping strip 30 being pulled from the glove ( FIGS. 3A and 3B ). In an alternative embodiment, the portion of the wiping strip 30 raised above the surface of the glove 10 may have a triangular profile or other profile that is effective to wipe loose debris from the surface of an eye shield.
[0053] To facilitate ease of use of the glove, the scrubbing strips 26 may be located on one or both sides of a given wiping strip 30 such that scrubbing and wiping of the debris from an eye shield occurs in a single hand and arm movement.
[0054] The wiping strips 30 are preferably added to the glove during manufacture and, ideally, are sewn into the seams 22 of the glove 10 ( FIG. 3C ) whereby the material forming the glove 10 extends to a short distance along the side of the wiping strip 30 to form part of the seam 22 .
[0055] The wiping strips 30 can also be attached to the glove 10 by gluing, bonding, fusing or other conventional attachment method.
[0056] Similarly, the scrubbing strips 26 are added during manufacture of the glove by a suitable attachment method, including any of the methods mentioned above in respect of attaching the wiping strips 30 to the glove 10 .
[0057] Wiping strips 30 and scrubbing strips 26 may be retrofitted to an existing glove by virtue of wiper 40 ( FIG. 4 ). The wiper 40 comprises a cylindrical sleeve 42 shaped to snugly fit over a finger or thumb portion 12 , 14 , 16 , 18 or 20 of a glove. The wiper 40 includes a scrubbing strip 26 and a wiping strip 30 for respectively loosening and removing debris from an eye shield when the wiper 40 is fitted to a finger or thumb portion of a glove.
[0058] The snug fitting of the sleeve 42 over the finger or thumb portions 12 , 14 , 16 , 18 or 20 ensures that the wiper stays securely in position during the scrubbing and wiping movements of the wiper 40 over an eye shield.
[0059] The sleeve 42 and wiping strip 30 may be extruded as a unitary construction either in cylindrical or sheet form. In sheet form, the sleeve is formed by heat welding or crimping the sheet to form the desired sleeve shape for snugly fitting over a finger or thumb portion 12 , 14 , 16 , 18 or 20 of a glove.
[0060] The scrubbing strip 26 is attached to the sleeve 42 by gluing, bonding, welding or other conventional attachment method.
[0061] The scrubbing strip 26 is located on the sleeve at a position relative to the wiping strips 30 to coincide with the palm-side of a wearers finger or thumb when the wiping strip 30 coincides with the side of the wearer's finger or thumb. These respective locations enable the wiper 40 to be fitted to a glove such that the scrubbing strip 26 and wiping strip 30 are in the same relative locations as the scrubbing strips 26 and wiping strips 30 on the glove 10 in FIG. 2 . These relative locations enable use of the wiper 40 with natural hand and arm movements to facilitate comfort and ease of use.
[0062] In an alternative form, the scrubbing strips 26 on the wiper 40 may be located on one or both sides of the wiping strip 30 in the same manner as exemplified in FIG. 3B .
[0063] Since modifications within the spirit and scope of the invention may readily be effected by persons skilled within the art, it is to be understood that this invention is not limited to the particular embodiment described by way of example hereinabove.
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This invention relates to gloves ( 10 ) and wipers fitted to gloves that enable wearers of the gloves to wipe debris from eye shields, such as goggles and face-coverings, visors ( 5 ) in helmets. More specifically, the invention relates to a glove ( 10 ) that comprises a covering for the hand and fingers of a wearer and means for wiping the eye shield to remove debris. The wiping means ( 30 ) is located on the glove to enable wiping of the eye shield with natural hand movements.
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CROSS-REFERENCE
The invention described and claimed hereinbelow is also described in PCT/EP2008/004990, filed on Jun. 20, 2008 and DE 10 2007 029 358.7, filed on Jun. 26, 2007. This German Patent Application, whose subject matter is incorporated here by reference, provides the basis for a claim of priority of invention under 35 U.S.C. 119 (a)-(d).
BACKGROUND OF THE INVENTION
The invention relates to a method for actuating a hydraulic consumer and a hydraulic control system for supplying pressure medium to the consumer.
U.S. Pat. No. 5,138,883 A has disclosed a hydraulic control system in which a consumer such as a differential cylinder can be supplied via a valve device—which is equipped with two continuously adjustable directional control valves—with pressure fluid that is furnished by a pump. The supply to the consumer and the return from it each contain a respective continuously adjustable directional control valve. In their neutral positions, the directional control valves are prestressed into a closed position and, by means of pressure reduction valves, can each be moved in one direction in which the pump is connected to the associated pressure chamber and in another direction in which the respective associated pressure chamber is connected to the tank. In this known control system, through suitable triggering of the two directional control valves, the consumer can be operated with a so-called regeneration circuit. For example, when a cylinder travels outward, the contracting annular chamber is connected via the associated directional control valve to the pressure fluid inlet of the expanding annular chamber so that the cylinder is extended in a rapid movement. A disadvantage of the regeneration/differential circuit, however, is that due to the restraining of the consumer (effective area corresponds approximately to the piston rod area), the consumer cannot be operated with the maximum output.
If a control system of this kind is used in a mobile piece of equipment such as a backhoe loader, a mini- or compact excavator, or a telehandler, then the available digging power in the regeneration mode is too low due to the restraining of the consumer. Preferably, the regeneration mode is correspondingly used when lowering the machine component of the mobile piece of equipment. In order to operate the consumer with a high power, for example when digging or when lifting a load, a switch into the normal mode is executed, in which the expanding pressure chamber is connected to the pump and the contracting pressure chamber is connected to the tank.
In order to prevent the occurrence of cavitation in the pressure fluid supply with a pulling load, a load lowering valve can be provided in the return from the consumer, as is known, for example, from DE 196 08 801 C2 or from the data sheet VPSO-SEC-42; 04.52.12-X-99-Z from the company Oil Control, a subsidiary of the applicant.
The directional control valves are moved by means of a piloting device, which is equipped with pressure reduction valves and is actuated by a joystick; the operator decides when to switch from regeneration mode into normal mode.
In this case, it is often difficult to determine the correct moment to make the switch, as a result of which the consumer remains too long in the regeneration mode with reduced power or the switch to the normal mode is made prematurely even though it would be advantageous to operate the consumer at a high speed.
By contrast, the object underlying the present invention is to optimize the switching from regeneration mode to normal mode with regard to the energy savings entailed by the regeneration mode and the power available at the consumer.
SUMMARY OF THE INVENTION
According to the invention, in order to actuate the consumer, a pressure chamber on the supply side and a pressure chamber on the return side of a hydraulic consumer are connected to a pump or a tank via a valve device that can be actuated by means of a control unit. To move the consumer rapidly, the valve device is moved into a regeneration mode in which the pressure fluid emerging from the return-side pressure chamber is added to the delivery rate of the pump so that the pump can be set to a lower delivery rate or the consumer executes its extending movement at a higher speed. The pressure fluid requirement is set by means of an actuator such as a joystick. According to the invention, the pump is set in accordance with a pressure regulation. In this case, a switch to the normal mode is automatically executed when the pump regulation reduces the pump delivery rate with no change in the set pressure fluid requirement (setting of the actuator), so that the consumer slows down or remains immobile. In other words, the pressure of the variable displacement pump is monitored. If it reaches its maximum pressure in the regeneration mode because of a rise in the resistance working against the consumer, then the swivel angle of the pump is reset in accordance with the characteristic curves of the pump control so that the volumetric flow of pressure fluid supplied by the pump no longer corresponds to the pressure fluid requirement preset for the actuator. According to the invention, a comparison of the pump flow rate to the pressure fluid requirement set by means of the actuator is used to decide when to switch to the normal mode. As a result, the optimum switching time is no longer decided based on the subjective assessment of the operator, thus permitting the consumer to be operated with greater operational reliability and improved effectiveness.
For example, the actual pump flow rate can be determined based on the swivel angle of the pump, which is embodied in the form of a variable displacement pump, and on the pump speed at a predetermined pump pressure.
The variable displacement pump is preferably embodied with an electroproportional swivel angle control; preferably, an actuating signal of a pressure control loop is then proportional to the swivel angle of the pump.
For this purpose, the actual pump pressure can be detected and compared to a setpoint pump pressure preset by means of the actuator. The pressure difference is then transmitted as an input signal to a controller, for example a PI controller or a PID controller, whose output signal is a measure for the swivel angle and constitutes the input signal of the pump controller.
The actuation of the consumer is further optimized if the regeneration mode is preset as a starting situation in certain movement directions of the consumer, for example when lowering an excavating component. In other words, as soon as the actuator (joystick) is moved in the lowering direction, a switch into the regeneration mode is automatically executed. This mode is maintained until the operator moves the joystick back into the zero position or beyond this zero position. The switch into the normal mode then occurs in the above-described fashion.
The switch between the regeneration mode and the normal mode preferably occurs by means of a ramp; the pressure fluid connection between the variable displacement pump and the expanding pressure chamber remains open and the pressure fluid connection of the contracting pressure chamber is opened in accordance with the curve of the ramp.
With a suitable embodiment, the swivel angle control of the variable displacement pump also permits a power control.
The apparatus complexity of the control system can be reduced if the supply and return of each consumer contains a continuously adjustable directional control valve, which has two switching positions, and a load lowering valve, thus permitting the supply and return to be actuated independently of each other.
The directional control valves, which are electrically or electrohydraulically adjustable, are preferably open to the tank in their neutral position.
The operational reliability of the control system is improved if the load lowering valves are embodied with a secondary pressure limiting function.
Other advantageous modifications of the invention are the subject of the remaining dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, a preferred exemplary embodiment of the invention will be explained in greater detail in conjunction with schematic drawings.
FIG. 1 is a schematic circuit diagram of a control system according to the invention for actuating two consumers,
FIG. 2 is an enlarged depiction of a variable displacement pump of the control system from FIG. 1 ,
FIG. 3 is a partial depiction of a directional control valve section of the control system from FIG. 1 ,
FIGS. 4 through 6 show different load situations in the regeneration mode or in the normal mode of the control system and
FIG. 7 is a simplified embodiment of the directional control valve section from FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a hydraulic control system 1 for supplying pressure fluid to two consumers 2 , 4 of a piece of mobile equipment such as an excavator, a backhoe loader, a mini- or compact excavator, or a telehandler. It is a so-called
EFM system (electronic flow management) in which the valve elements that determine the volumetric flow of pressure fluid and the flow direction of the pressure fluid are electrically or electrohydraulically triggered as a function of characteristic curve families stored in a control unit 6 . In this case, the setpoint values are input by means of a joystick 8 that is actuated by the operator in order to control the speed and position of the machine components (e.g. booms, shovels) of the piece of equipment.
In the exemplary embodiment shown, the two consumers 2 , 4 are each embodied in the form of a differential cylinder with a pressure chamber 10 or 12 at the bottom and an annular chamber 14 or 16 around the piston rod. These pressure chambers 10 , 14 ; 12 , 16 can be respectively connected via a directional control valve section 18 , 20 to a variable displacement pump 22 or a tank 24 in order to retract or extend the cylinder. The variable displacement pump 22 is pressure-controlled by means of a pump controller 26 , which, once the predetermined pressure has been reached, adjusts the delivery rate of the pump so that the pressure in the system remains constant independent of the delivery rate. A change in the volumetric flow of the pressure fluid should result in practically no change in pressure.
The variable displacement pump 22 is moved by means of a pump controller 25 , whose design is explained below in conjunction with the enlarged depiction in FIG. 2 . By means of an electroproportional swivel angle control, the pump controller 25 permits an infinitely variable and reproducible adjustment of the displacement volume of the variable displacement pump, directly controlled by means of a swiveling swashplate of the pump. Pump controllers of this kind are known, for example, from the data sheet RD 92 708—in particular, see the variants EP and EK, so that only those features of the pump controller 25 required for comprehension of the invention are described in the present application.
A pump controller 25 of this kind has a pump control valve 26 that is embodied with three connections and is prestressed by a control spring 27 in the direction of a neutral position in which the three connections of the pump control valve 26 are closed. The control spring 27 is supported against the actuating piston 28 of an actuating cylinder 29 by means of which it is possible to swivel the swiveling swashplate of the variable displacement pump 22 . The actuating piston 28 is prestressed by a spring into a home position in which the swivel angle of the variable displacement pump 22 is at a maximum. The valve slider of the pump control valve 26 is actuated by means of a proportional magnet 30 that can be supplied with current via a signal line 51 connected to the control unit 6 .
This proportional magnet 30 is used to exert the control force on the control piston of the pump control valve 26 ; the movement occurs in proportion to the power of the current. An input connection of the pump control valve 26 is connected via a control line 31 to a pump line 38 connected to the pressure connection of the variable displacement pump 22 . An output connection of the pump control valve 26 is connected via a conduit 32 to a control surface of the control piston that acts in the direction of the neutral position. This control surface delimits a spring chamber of the control spring 27 . The pressure in the conduit 32 also impinges on a control surface that acts in the movement direction of the pump control valve 26 so that the pressure at the outlet of the pump control valve impinges on both sides of the control piston.
The conduit 32 is connected via a nozzle 33 to a connecting conduit 34 that contains two pressure limiting valves 35 , 36 connected in series. The outlet of the downstream pressure limiting valve 36 in FIG. 2 is connected to the tank 24 via a tank control conduit 37 .
The two pressure limiting valves 35 , 36 are prestressed in the direction of their depicted home position in which the pressure fluid connection to the tank control conduit 37 is open.
The pressure in the control line 31 , which is tapped via a pressure limiting line 39 , acts on both of the pressure limiting valves 35 , 36 in the switching direction. This pressure limiting line 39 also leads to the respective third connection of both pressure limiting valves 35 , 36 . The region of the connecting conduit 34 situated between the pressure limiting valve 35 and the nozzle 33 is connected to the spring chamber of the control spring 27 via a branch line 40 and a check valve that opens in the direction toward the pressure limiting valve 35 . A connecting line also branches off from the pressure fluid flow path between the nozzle 33 and the pressure limiting valve 35 and is connected to the tank control conduit 37 via two additional nozzles 41 , 42 . An angle conduit 43 branches off between the two nozzles 41 , 42 and feeds into the pressure fluid flow path between the two pressure balances 35 , 36 . Control surfaces that act in the direction of the spring-prestressed home position of the pressure limiting valves 35 , 36 are also connected to the tank control conduit 37 via pilot lines 44 , 45 .
The two pressure limiting valves 35 , 36 are set to different pressures. When the respective pressure is reached, the relevant pressure limiting valve 35 , 36 is moved out of its depicted home position, thus opening a control oil flow path from the pump line 38 to the spring chamber of the control spring via the control line 31 , the pressure limiting line 39 , the relevant pressure limiting valve 35 , 36 , the connecting conduit 34 , and the branch line 40 so that a pressure approximately equivalent to the pump pressure prevails in this spring chamber. Consequently, the actuating piston 28 is then moved toward the left in the depiction according to FIG. 2 in opposition to the force of the return spring and the swivel angle is reset to zero so that the volumetric displacement is correspondingly minimal or equal to zero.
In the normal mode of the variable displacement pump, the two pressure limiting valves 35 , 36 are prestressed into their depicted home position. Adjusting the swivel angle of the pump requires a predetermined standby pressure of 20 bar, for example; only then is it possible to overcome the force of the return spring.
In the depicted home position—as mentioned above—the swivel angle of the variable displacement pump 22 is set to its maximum value. When the proportional magnet 30 is supplied with current, the control piston of the pump control valve 26 in the depiction according to FIG. 2 is moved to the left so that the control line 31 is connected to the conduit 32 and a pressure corresponding to the pump pressure prevails in the spring chamber of the control spring 27 . This pressure then moves the return piston 28 in opposition to the force of its return spring in the direction toward a minimization of the swivel angle so that the pump delivery rate approaches zero. As the pump control valve 26 is moved farther toward the left, the pressure fluid connection between the control line 31 and the conduit 32 is closed and the spring chamber of the control spring 27 is connected via the branch line 40 to the connecting conduit 34 and therefore to the tank control conduit 37 so that the control oil can flow out of the spring chamber into the tank 24 and the force of the return spring correspondingly moves the actuating piston 28 in the direction of an increase of the swivel angle. Correspondingly, the pump delivery rate increases in proportion to the power of the current in the proportional magnet 30 . In the event of the cable break or a loss of the control signal, the depicted variable displacement pump 22 swivels back into its home position in which the maximum swivel angle is set.
For further details relating to the design of the pump controller 26 , the reader is referred to the above-mentioned data sheet RD 92 708.
As can also be inferred from the depiction in FIG. 1 , the pressure in the pump line 38 is detected by a pressure sensor 48 and reported to the control unit 6 via a signal line 46 . This pressure signal corresponding to the actual pump pressure is compared to the setpoint pressure preset by means of the joystick 8 and the output signal is sent to an electronic PI controller or PID controller 47 . By means of software in the control unit 6 , the output signal of this controller is then taken into account in the triggering of the directional control valve sections 18 , 20 . The output signal is also transmitted to the proportional magnet 30 via a signal amplifier 49 and a signal line 51 in order to move the control piston of the pump control valve 26 ; in the control position of the control piston, an equilibrium is reached between the force exerted by the proportional magnet 30 and the force exerted on the control piston in the opposite direction by the control spring 27 and the actuating piston 28 .
The suction connection of the variable displacement pump 22 is connected to the tank 24 via a suction line 50 and a filter. The pressure fluid supplied by the variable displacement pump 22 flows to the consumers 2 , 4 via the pump line 38 and the two directional control valve sections 18 , 20 , whose design is explained below in conjunction with FIG. 2 . On the return side, the pressure fluid flows from the consumers 2 , 4 to the tank 24 via the associated directional control valve sections 18 , 20 and a tank line 52 ; in the end section of the tank line 52 , an additional filter is provided, which can be bypassed via a pressure limiting valve that opens when the filter becomes clogged and the pressure loss induced by the filter rises as a result.
The temperature of the pressure fluid contained in the tank 24 is detected by a temperature sensor 54 and reported to the control unit 6 via a signal line. In order to prevent an overheating of the pressure fluid, a purge valve 57 is provided between the tank line 52 and the pump line 38 . This purge valve 57 also has a pressure limiting function that makes it possible to limit the pressure in the pump line 38 to a maximum pressure. When the purge valve 57 is opened, the pressure fluid used to actuate the consumer, particularly in the regeneration circuit, can be exchanged for “fresh” pressure fluid from the tank 24 . The opening of the purge valve 57 is likewise executed electrically as a function of a signal from the control unit 6 .
FIG. 3 shows the basic design of the two directional control valve sections 18 , 20 ; the directional control valve segment 18 is shown by way of example and the variable displacement pump 22 and tank 24 are schematically depicted.
According to FIG. 3 , the directional control valve section 18 has two pressure connections P that are each connected to the pump line 38 via a respective inlet line 56 , 58 . Two tank connections T of the directional control valve section 18 are connected to the tank line 52 via outlet lines 60 , 62 . Each connection pair P, T of the directional control valve section 18 is associated with a respective working connection A or B, each of which is connected via a respective supply line 64 or return line 66 to the pressure chamber 10 or annular chamber 14 of the consumer 2 . The pressure fluid flow paths between the connections P, T and the associated working connections A, B each contain a respective continuously adjustable 3-port directional control valve 68 , 70 , which has two switching positions and three connections, and a respective load lowering valve 72 , 74 . Each directional control valve 68 , 70 is prestressed by a control spring into its depicted neutral position in which a pressure fluid connection is open between the outlet line 60 , 62 and a connecting conduit 76 , 78 that respectively extends to the adjacent load lowering valve 72 , 74 .
Each directional control valve 68 , 70 is adjusted by means of a respective pilot valve 81 , 83 with a proportional magnet 80 , 82 that can be supplied with current by the central control unit 6 via signal lines in order, by adjusting the pilot valves 81 , 83 , for example of pressure reduction valves, to move the directional control valve 68 , 70 independently of each other in the direction of their position shown in FIG. 3 in which the pressure fluid connections are opened between the inlet lines 56 , 58 and the connecting conduits 78 , 76 . Consequently, the two directional control valves 68 , 70 , with their neutral position that is open in relation to the tank 24 , have an extremely simple design in which by contrast with the prior art described at the beginning, only one pilot valve and one proportional magnet 80 , 82 are required to execute the movement, whereas in the known embodiments with a closed neutral position, it is necessary to use two expensive proportional magnets. In principle, the directional control valves 68 , 70 can also be triggered directly by means of the proportional magnets.
The two load lowering valves 72 , 74 have an intrinsically known design of the kind described, for example, in DE 196 08 801 C2, which was mentioned at the beginning, or in the above-mentioned publication from the company Oil Control. Load lowering valves of this kind permit the controlled lowering of a load and simultaneously function as a secondary pressure limiting valve. To that end, the load lowering valves are prestressed into a closed position by means of an adjustable prestressing spring 84 , 86 . As shown in FIG. 2 , the spring chambers of the two prestressing springs 84 , 86 are vented toward the atmosphere. The respective pressure at the associated working connection A, B, which is tapped by means of a respective pressure limiting control line 88 , 90 , acts in the opening direction. The pressure in the respective other connecting conduit 76 , 78 , the so-called “cross-over”, which is tapped by means of opening lines 92 , 94 , also acts in the opening direction. Furthermore, the two load lowering valves 72 , 74 can also provide leakage-free support to the load acting on the consumer 2 . The supply of pressure fluid from the directional control valve 68 , 70 to the respective pressure chamber of the consumer 2 takes place via a respective bypass conduit 96 , 98 that connects the connecting conduit 76 , 78 to the respective supply line 64 , 66 ; each bypass conduit 96 , 98 contains a check valve 100 , 102 that opens in the direction toward the consumer 2 .
In the neutral positions—depicted in FIGS. 1 and 3 —of the two directional control valves 68 , 70 , the two pressure chambers of each consumer 2 , 4 are connected to the tank 24 . The load F acting on the consumer 2 is supported in a leakage-free fashion by the load lowering valve 72 , 74 , which is embodied in the form of a seat valve. In this case, the load F can be in the form of a pulling or pushing load. The pressure limiting function of the two load lowering valves 72 , 74 ensures that a maximum pressure cannot be exceeded in the lines 64 , 66 .
Several load situations will be explained below to better illustrate the invention.
Let us first assume that a pulling load F is acting on the cylinder 2 and that according to the depiction in FIG. 4 , the cylinder is to be extended (movement toward the right). This extending motion should occur at a maximum speed (rapid movement). For this purpose, the two directional control valves 68 , 70 are moved in the direction toward the position shown in FIG. 4 in which a regeneration occurs. In other words, the consumer 2 is triggered by means of a differential circuit in which both the annular chamber 14 and the bottom pressure chamber 10 are connected to the pump 22 . To accomplish this, the two proportional magnets 80 , 82 move the directional control valves from the neutral position ( FIG. 3 ) toward the left so that both pressure connections P of the directional control valve section 18 are connected to the connecting conduits 76 , 78 . The pump 22 supplies the pressure fluid into the expanding bottom pressure chamber 10 via the pressure connection P, the directional control valve 68 , the connecting line 76 , the bypass conduit 96 , the check valve 100 , and the supply line 64 . The pressure fluid displaced from the annular chamber 14 flows via the return line 66 , the load lowering valve 74 that the pressure in the connecting conduit 76 has completely opened in the pressure limiting function, the connecting conduit 78 , and the directional control valve 70 , to the inlet line 56 and from there, into the pump line 38 so that the volumetric flow of pressure fluid emerging from the consumer is added to the volumetric flow of pressure fluid delivered by the pump 22 .
In the bottom pressure chamber 10 , a pressure is present, which after the slider is set, lies between the maximum pump pressure (for example 250 bar) and 0 bar (slider in the neutral position). If one assumes that the pressure in the annular chamber 14 is approximately 250 bar (slider of the directional control valve 70 completely open, pump set to 250 bar) and that the pulling load corresponds to a pressure of 50 bar, then the bottom pressure chamber 10 must contain a pressure that equals the difference of the pressure in the annular chamber 14 minus the load, divided by the area ratio of the differential cylinder (for example 2) so that 250 bar in the annular chamber 14 and a load of 50 bar results in a pressure of approximately 100 bar in the pressure chamber 10 .
With a pushing load, an equivalent function occurs in which the pressure in the supply-side supply line 64 is limited by the pressure limiting function of the load lowering valve 72 .
In regeneration mode, the consumer is moved at maximum speed; the force exerted by the consumer, however, is comparatively slight because the effective area of the consumer corresponds to the piston rod area. In order to trigger the maximum output of the consumer 2 , the control system is switched from regeneration mode to the normal operating mode shown in FIG. 5 by moving the directional control valve 70 in the direction of its neutral position so that the pressure fluid flows out of the annular chamber 14 to the tank 24 via the return line 66 , the open load lowering valve 74 , the connecting conduit 78 , and via the directional control valve 70 and the outlet line 60 . With a pulling load ( FIG. 5 ), cavitations in the vicinity of the supply line 64 are reliably prevented by means of the load lowering valve 74 since this valve, by restraining the consumer 2 , prevents an uncontrolled, excessively rapid extending motion of the consumer 2 as a result of the pulling load. In this case, the maximum pressure in the return line 66 is limited by the secondary pressure limiting function of the load lowering valve 74 . The pressure in the pressure fluid supply is in turn determined by means of the opening cross section established by the slider of the directional control valve 68 and consequently lies between 0 bar and the maximum pump pressure (for example 250 bar).
With a pushing load and an extending cylinder 2 ( FIG. 5 ), depending upon the slider position of the directional control valve 68 and the triggering of the variable displacement pump 22 , a pressure occurs in the bottom pressure chamber 10 that lies between the load pressure and the maximum pump pressure (consumer against stop). The load lowering valve 74 situated in the return is opened completely by the pressure in the inlet (tapped via the opening line 94 ) so that the pressure fluid can flow out of the annular chamber 14 and into the tank 24 . In this load situation, no regeneration mode is provided and there is no danger of cavitations.
With a retracting cylinder and a pulling or pushing load, the directional control valve section 18 is switched into the position shown in FIG. 6 in which the directional control valve 68 opens the pressure fluid connection to the tank 24 and the pump 22 conveys pressure fluid into the annular chamber 14 via the directional control valve 70 . The pressure in the inlet to the annular chamber 14 then depends on the load, the opening cross section of the directional control valve 70 , and the set pump pressure. The pressure fluid is conveyed via the bypass conduit 98 and the opening check valve 102 and via the return line 66 into the annular chamber 14 and flows out of the contracting pressure chamber 10 and into the tank 24 via the supply line 64 , the load lowering valve 72 that has been opened by the pressure in the inlet (connecting conduit 78 ), the directional control valve 68 that has been moved in the direction of its neutral position, and the outlet line 62 . In this case, the load lowering valve 72 limits the pressure level in the outlet. Depending on the load direction, the pressure level in the inlet lies between the maximum pump pressure and 0 bar (pushing load, minimum retraction speed).
According to the invention, it is preferable if the regeneration mode is activated by default in a certain movement direction of the consumer 2 , 4 . This can be the case, for example, when lowering the machine component of an excavator, for example a boom with a shovel. If the resistance to the movement of the working equipment subsequently rises, then the pump pressure of the variable displacement pump 22 is increased and is limited to a maximum value by the pump controller. As described at the beginning, when this maximum value is reached, the swivel angle of the variable displacement pump 22 —and therefore also the actuating signal for the swivel angle—is limited so that the volumetric flow of pressure fluid supplied by the pump no longer corresponds to the pressure fluid requirement preset by means of the joystick 8 . According to the invention, the relevant directional control valve section 18 , 20 is switched into the above-described normal mode without intervention by the operator so that the maximum digging power is available, for example. The variable displacement pump 22 can be embodied with a swivel angle sensor for determining the swivel angle.
FIG. 7 shows a simplified exemplary embodiment of the control system 1 according to FIG. 2 . The sole difference between it and the above-described exemplary embodiment according to FIG. 2 lies in the fact that the line that is connected to the consumer 2 and is referred to as the return line 66 contains neither a load lowering valve nor an associated directional control valve equipped with two so-called “switching positions,” but is instead provided with a single continuously adjustable directional control valve 104 , which is prestressed into a home position (0) by a centering spring arrangement 105 and can be moved in the direction of the positions (a) and (b) shown in FIG. 7 through actuation of two pilot valves 108 , 83 . The two pilot valves 83 , 108 —as in the above-described exemplary embodiment—are embodied as pressure reduction valves that can each be triggered by means of a respective proportional magnet 82 , 106 . The design of the valves embodied in the supply line 64 —with the load lowering valve 72 , the check valve 100 , and the directional control valve 68 prestressed into an open position, which can only be moved in one direction by means of a single pilot valve 81 —and the pressure fluid supply correspond to those of the above-described exemplary embodiment, rendering explanations of them unnecessary. For the sake of simplicity, the hydraulic components that correspond to one another have been provided with the same reference numerals as in the exemplary embodiment described at the beginning and the reader is referred to the description given with regard to them.
In the depicted home position (0) of the continuously adjustable directional control valve 104 , the pressure fluid connection between the outlet line 60 , the inlet line 56 , and the return line 66 is closed. When the proportional magnet 106 is supplied with current, the pressure reducing valve 108 can be used to set a control pressure so that the valve slider of the directional control valve 104 is moved toward the right in the direction of the position labeled (a) in which the connection between the return line 66 and the outlet line 60 is opened. The pressure fluid connection to the inlet line 56 remains closed. When the pilot valve 83 is triggered, the valve slider of the directional control valve 104 is moved in the direction of position (b) so that the pressure fluid connection between the inlet line 56 and the return line 66 , which is then functioning as a supply line, is correspondingly opened; the pressure fluid connection between the return line 66 and the outlet line 60 is closed.
The actuation of the load lowering valve 72 situated in the supply line 64 is carried out—as in the exemplary embodiment described at the beginning—by means of the pressure in the return line 66 .
Naturally, the directional control valve 104 can also be integrated into the supply line 64 so that the load lowering valve 74 and the directional control valve 70 from FIG. 3 remain situated in the return line 66 .
In order to retract the hydraulic cylinder (consumer 2), the directional control valve 104 is moved in the direction of its position of its positions (b) (sic) so that the variable displacement pump 22 conveys pressure fluid to the annular chamber 14 of the consumer via the pump line 38 , the inlet line 56 , the directional control valve 104 , and the return line 66 , which is then functioning as an inlet line. The directional control valve 104 is then used to correspondingly set the volumetric flow of pressure fluid and also the effective pressure in the annular chamber 14 . The pressure in the return line 66 is used to move the load lowering valve 72 into its open position so that for example with a pushing load, cavitations are prevented since the consumer 2 remains restrained. With a pulling load, the load lowering valve 72 is completely or almost completely opened by the pressure in the supply, which pressure is tapped via the opening line 92 , thus allowing the pressure fluid to flow out into the tank 24 via the load lowering valve 72 and the correspondingly set directional control valve 68 .
During the extending movement of the consumer (hydraulic cylinder 2 ), the control system can also be operated once again in the regeneration mode; then the pilot valve 81 is used to switch the directional control valve 68 and the pilot valve 83 is used to move the directional control valve 104 toward its position (b) so that the pressure fluid flows out of the annular chamber 14 via the directional control valve 104 , into the inlet line 58 and from there, via the directional control valve 68 and the check valve 100 , the bypass conduit 96 , and the supply line 64 to the pressure chamber 10 so that the consumer 2 is extended at a high speed. To exert a greater force, the directional control valve 104 is moved toward its position (a) so that the pressure fluid flows out of the annular chamber 14 into the tank 24 . For further details about the various operating modes, please refer to the preceding explanations.
The present application has disclosed a hydraulic control system and a method for triggering a hydraulic consumer, which has a pressure chamber on the supply side and a pressure chamber on the return side that are connectable to a pump or a tank via a valve device. The valve device is actuated by means of a control unit that can move the valve device into a regeneration mode in which both of the pressure chambers are connected to the pump. According to the invention, the pump is pressure-regulated; in the regeneration mode, a switch to a normal mode—in which the inlet-side pressure chamber is connected to the pump and the return-side pressure chamber is connected to the tank—is automatically executed when the pump delivery rate falls below the pressure fluid requirement.
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The invention relates to a hydraulic control arrangement and to a method for controlling a hydraulic consumer that comprises a pressure chamber on the input side and on the return side, said pressure chamber being connected to an adjusting pump or a tank via a valve device. The valve device is controlled by means of a control unit via which it can be adjusted in a regeneration mode, in which both pressure chambers are connected to the adjusting pump. According to the invention, the adjusting pump is pressure controlled, whereby in the regeneration mode, it is automatically switched to the normal operation in which the supply side of the pressure chamber is connected to the adjusting pump and the return side of the pressure chamber is connected to the tank when the pumping rate falls below the demand for the pressure medium.
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CROSS REFERENCE TO RELATED APPLICATION
This application is related to the following copending applications:
1. U.S. patent application Ser. No. 08/757,978 entitled "Circuitry and Method for Translating Voltages" filed by International Business Machines Corporation on Nov. 27, 1996, now U.S. Pat. No. 5,777,490, issued Jul. 7, 1998; and
2. U.S. patent application Ser. No. 08/851,261, entitled "A Static Pulsed Cross-Coupled Level Shifter and Method Therefor", filed on May 5, 1997, invented by Joshua Siegel, Hector Sanchez, and Chai-Chin Chao and assigned to the assignee hereof.
FIELD OF THE INVENTION
This invention relates to electrical circuits, and more particularly, to digital output buffer circuits.
BACKGROUND OF THE INVENTION
Semiconductor technologies continuously evolve such that leading edge semiconductors have decreased geometries of transistor sizes and decreased voltages for voltage supplies. The smaller transistors are now manufactured with very thin gate oxide material. As a result, the dielectric breakdown voltage for such transistors in the leading edge semiconductor products has decreased. Thus, a decreased voltage supply is both desirable in order to reduce power consumption and necessary in order to avoid damaging the very thin gate oxide material. Meanwhile, other semiconductor products coupled to the leading edge semiconductor products still have much higher breakdown voltage devices, and utilize higher supply voltages.
For many years, semiconductor designers have dealt with the problem of translating between various levels of supply voltages. For example, when technology transferred between TTL (Transistor to Transistor Logic) to MOS (Metal Oxide Silicon) technology there was a need for voltage level shifting to be performed between the TTL and MOS technologies. Additionally, as supply voltages gradually decreased from 15 volts to 5 volts to 3 volts, designers created interface circuits which could operate between different voltage systems. However, most of those designs were focused on the issue of being able to just interface between one system operating at one voltage and a second system operating at a different voltage. Such systems typically did not have the problem of coping with breakdown voltages of transistors being threatened by the higher voltage system.
There are many chips and integrated circuits such as memories, memory controllers, and other peripherals that work with leading edge microprocessors. However, such peripherals and memories have not changed their supply voltages or reduced their voltage levels nearly as quickly as microprocessors have. In being able to interface between a peripheral circuit that has a much higher voltage than a leading edge integrated circuit, such as a microprocessor, designers often use a well biasing technique to try to minimize the impact in an integrated circuit of receiving a voltage signal much higher than the supply voltage intended for that integrated circuit. The well bias technique which is used eliminates a charge drain from the output node to an output stage power supply within the circuit. Prior circuits typically dealt with receiving higher voltage levels and using those voltage levels in a system operating at a lower voltage level. However, such systems did not typically worry about or have to compensate for transistor damage due to thin gate oxides. As technologies have evolved, the maximum voltage permitted across a transistor has decreased much faster than the decrease of supply voltages for the output bus. As a result, a need exists for a circuit and method which is able to guarantee the integrity of transistors and transistor gate oxides when interfacing with very high supply voltages at the output bus.
A known circuit for dealing with protecting gate oxides when coupling to an output bus having a higher supply voltage than the circuit supply voltage is illustrated in FIG. 1. An output buffer 10 has an input portion 11, an intermediate portion 12, and an output portion 13. In input portion 11, a P-channel transistor 15 has a source connected to a first (higher voltage) supply voltage V DDH , a gate connected to a node 24, and a drain connected to a node 17. A P-channel transistor 18 has a source connected to the supply voltage V DDH , and a gate connected a drain thereof at node 17. An N-channel transistor 20 has a drain connected to node 17, a gate connected to a second (lower voltage) supply voltage V DDL , and a source connected to a drain of an N-channel transistor 21. The gate of transistor 21 is connected to the DATA INPUT terminal, and a source of transistor 21 is connected to a ground terminal. Intermediate portion 12 includes an inverter 23 and an inverter 26 connected via a node 24 which is also connected to the gate of P-channel transistor 15. Inverters 23 and 26 are connected between the first supply voltage V DDH and the second supply voltage V DDL . The output portion 13 comprises P-channel transistors 28 and 29 and N-channel transistors 31 and 32. P-channel transistor 28 has a source connected to the first supply voltage V DDH , a gate connected to the output of inverter 26, and a drain connected to a source of transistor 29. P-channel transistor 29 has a gate connected to supply voltage V DDL , and a drain connected to a chip output terminal. N-channel transistor 31 has a drain connected to the chip output terminal, a gate connected to supply voltage V DDL , and a source connected to a drain of N-channel transistor 32. N-channel transistor 32 has a gate connected to the complement of the "DATA INPUT" signal, and has a source connected to the ground terminal.
In operation, circuit 10 is an output buffer with an input portion 11 which consumes DC power. Input portion 11 functions as a level shift stage. When the input data has a logic high level, node 17 is driven low by the input portion 11. However, node 17 does not assume a ground level potential, but rather node 17 is at a level which is driven below V DDL . Once node 17 is driven below V DDL , the first inverter 23 drives node 24 to the V DDH supply level. As a result, inverter 26 transitions the gate of transistor 28 to V DDL so that transistor 28 is made conductive. As a result, the chip output terminal is driven to the V DDH value. In the illustrated form, V DDL is a lower voltage magnitude than V DDH , and V DDH exceeds the maximum permitted voltage of the gate-to-source voltage, V GS , of each of the transistors of buffer 10. However, the difference between the V DDH voltage level and the V DDL voltage level is less than the maximum gate-to-source/drain voltage allowed in the technology in which buffer 10 is implemented.
When the DATA INPUT signal is at a logic low level, N-channel transistor 21 isolates node 17 from the ground terminal, and node 17 transitions to the V DDH potential. As a result, inverter 23 transitions node 24 to supply voltage V DDL and inverter 26 transitions the gate of transistor 28 to V DDH which makes transistor 28 non-conductive. Furthermore, transistor 32 is conductive and thus the chip output signal transitions to the ground terminal potential. Note in summary that output buffer 10 operates to consume power in the input portion 11 when the DATA INPUT signal is at logic high state. When the DATA INPUT signal is at a logic low state, power is not consumed. Although the power consumption of output buffer 10 is a potential problem for many applications, output buffer 10 functions to allow the circuit to interface with a system having a higher supply voltage. Additionally, output buffer 10 does not permit a voltage between the gate to source electrodes of each transistor which would destroy the gate oxide of that transistor.
Additionally output buffer 10 suffers from various limitations. If the two voltages are equal: V DDH =V DDL , output buffer 10 is not functional. The reason is that level shifted inverters do not work. It is common practice for a manufacturer of an Integrated Circuit to set voltage V DDH to V DDL during the debug phase of a design as well as for simplicity of test equipment during stress testing, such as is done in "bum-in" testing. Furthermore, the propagation delays of output buffer 10 do not track well as process technology, temperature, and voltage change, since transistors 28 and 32 are decoupled and are not driven from the same source. Part of this problem arises because the high and low output propagation paths differ significantly in circuit topology. Also note that output stage 13 tends to consume more active power than desired due to increased "crowbar" or short-circuit current due to different switching times through the two propagation paths since transistors 28 and 32 are decoupled.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying Figures. where like numerals refer to like and corresponding parts and in which:
FIG. 1 illustrates in schematic form a known output buffer for interfacing between two supply voltages of differing magnitude.
FIG. 2 illustrates in partial schematic and partial block diagram form an output buffer in accordance with one embodiment of the present invention.
FIG. 3 illustrates in partial schematic and partial block diagram form an output buffer in accordance with a second embodiment of the present invention.
FIG. 4 illustrates in schematic form one embodiment of the voltage dropping elements of FIGS. 2 and 3.
FIG. 5 illustrates in schematic form a second embodiment of the voltage dropping elements of FIGS. 2 and 3.
FIG. 6 illustrates in schematic form one embodiment of a bias circuit for use with the output buffers of FIGS. 2 and 3.
FIG. 7 illustrates in schematic form a second embodiment of a bias circuit for use with the output buffers of FIGS. 2 and 3.
DETAILED DESCRIPTION
The output buffers presented herein operate correctly even if voltages V DDH =V DDL . Propagation delays high to low and low to high track over process technology, temperature, and voltage changes since the output stage is driven from a common signal. Crowbar or short-circuit current is minimized as well since both high and low propagation paths switch together. Also importantly, transistors are biased as closely as possible to a given technology's maximum gate to source voltage to provide higher performance and smaller resulting circuit. The propagation delays of the output buffers disclosed herein are strictly a function of the V DDH level, and are not dependent upon the difference in voltage between V DDH and V DDL as in output buffer 10 in FIG. 1.
FIG. 2 is a block diagram that illustrates one version of a digital output buffer for multiple voltage system 36. Three stages or parts are shown: a first dual output voltage limiting inverter 40, a second dual output voltage limiting inverter 50, and an output stage 60. Both the first dual output voltage limiting inverter 40 and the second dual output voltage limiting inverter 50 have nearly identical structure and functionality.
The first dual output voltage limiting inverter 40 contains a first bias circuit 46 coupled in series between a first terminal 47 of a voltage drop circuit 44 and ground. Also coupled to the first terminal 47 of the voltage drop circuit 44 is a switch 48 to ground controlled by the DATA INPUT signal 64. The first terminal of the voltage drop circuit 44 provides a first output. Coupled between a second terminal 45 of the voltage drop circuit 44 and a output voltage V DDH is a second bias circuit 42. Also coupled to the second terminal 45 of the voltage drop circuit 44 is a switch 43 to V DDH . The second terminal of the voltage drop circuit 44 provides a second output.
The second dual output voltage limiting inverter 50 contains a first bias circuit 56 coupled in series between a first terminal 57 of a voltage drop circuit 54 and ground. Also coupled to the first terminal 57 of the voltage drop circuit 54 is a switch 58 to ground controlled by an inverted 62 DATA INPUT 64 signal. The first terminal 57 of the voltage drop circuit 54 provides a first output signal 68. Coupled between a second terminal 55 of the voltage drop circuit 54 and the output voltage V DDH is a second bias circuit 52. Also coupled to the second terminal 55 of the voltage drop circuit 54 is a switch 53 to V DDH . The second terminal 55 of the voltage drop circuit 54 provides a second output signal 66. The second switch 43 of the first dual output voltage limiting inverter 40 is controlled by the second terminal 55 of the dual output voltage limiting inverter 50, and the second switch 53 of the second dual output voltage limiting inverter 50 is controlled by the second terminal 45 from the first dual output voltage limiting inverter 40.
BIAS1 and BIAS2 are chosen such that the potential across voltage drop 44, 54 allows the voltages across the dielectrics of switches 43, 48, 53, 58 to reach but not exceed the maximum dielectric voltage permitted in the technology. The voltage drop circuits 44, 54 provide a constant voltage drop. Though a resistor is one possible implementation, it is far from optimum. Two preferred embodiments are further disclosed hereinbelow in FIGS. 4 and 5.
The output stage 70 consists of four transistors in series between V DDH and ground. A first P-channel transistor 72 controlled by the second output signal 66 from the second dual output voltage limiting inverter 50 has its source coupled to V DDH and its drain coupled to the source of a second P-channel transistor 74. The first N-channel transistor 78 controlled by the first output signal 68 from the second dual output voltage limiting inverter 50 has its source coupled to ground and its drain coupled to a source of a second N-channel transistor 76. The drains of the second P-channel transistor 74 and the second N-channel transistor 76 are coupled together to provide a CHIP OUTPUT signal 79 and are both controlled by BIASP and BIASN, respectively.
FIG. 3 is a block diagram that illustrates one version of a digital output buffer for multiple voltage system. Three stages or parts are shown: a first dual output voltage limiting inverter 80, a second dual output voltage limiting inverter 90, and an output stage 60. Both the first dual output voltage limiting inverter 80 and the second dual output voltage limiting inverter 90 have nearly identical structure and functionality.
The first dual output voltage limiting inverter 80 contains a first bias circuit 86 coupled in series between a first terminal 87 of a voltage drop circuit 84 and ground. Also coupled to the first terminal 87 of the voltage drop circuit 84 is a switch 88 to ground controlled by output 106 from a pulse generator. The pulse generator receives its input from the DATA INPUT signal 100 and comprises an odd number of inverters 102 in series as one input to an AND gate 104. The second input to the AND gate 104 is the DATA INPUT signal 100. The width of the pulse is the time it takes for a pulse to transit the number of inverters 102 in the pulse generator. The output 106 of the AND gate 104 is the output of the pulse generator that controls the switch 88 to ground. The first terminal of the voltage drop circuit 84 provides a first output. Coupled between a second terminal 85 of the voltage drop circuit 84 and a output voltage V DDH is a second bias circuit 82. The second terminal of the voltage drop circuit 84 provides a second output.
The second dual output voltage limiting inverter 90 contains a first bias circuit 96 coupled in series between a first terminal 97 of a voltage drop circuit 94 and ground. Also coupled to the first terminal 97 of the voltage drop circuit 94 is a switch 98 to ground controlled by an inverted 108 DATA INPUT 100 signal. The first terminal 97 of the voltage drop circuit 94 provides a first output signal 68. Coupled between a second terminal 95 of the voltage drop circuit 94 and the output voltage V DDH is a second bias circuit 92. Also coupled to the second terminal 95 of the voltage drop circuit 94 is a switch 93 to V DDH . The second terminal 95 of the voltage drop circuit 54 provides a second output signal 66. The second switch 93 of the second dual output voltage limiting inverter 90 is controlled by the second terminal 85 from the first dual output voltage limiting inverter 80.
The output stage 70 consists of four transistors in series between V DDH and ground. A first P-channel transistor 72 controlled by the second output signal 66 from the second dual output voltage limiting inverter 90 has its source coupled to the first supply voltage V DDH and its drain coupled to the source of a second P-channel transistor 74. The gate of a first N-channel transistor 78 is controlled by the first output signal 68 from the second dual output voltage limiting inverter 90, and its source is coupled to ground and its drain is coupled to a source of a second N-channel transistor 76. The drains of the second P-channel transistor 74 and the second N-channel transistor 74 are coupled together to provide a CHIP OUTPUT signal 79 and are both controlled by bias voltages BIASP and BIASN.
Note that the pulse generator output 106 essentially replaces the need for the first switch 43 to V DDH in FIG. 2. This embodiment allows a much larger second bias circuit 82 to be used, since the time in which it is enabled is substantially shortened due to the pulse generated by the ANDing of the output of the inverters 102 with the DATA INPUT signal 100. Furthermore, this embodiment allows a substantially faster propagation through the output buffer.
A blownup schematic of the inverters 62, 102, 108 illustrated in FIGS. 2 and 3 is also shown. It is a standard inverter comprised of one N-channel transistor and one P-channel transistor. Note though that the drain of the P-channel transistor as well as its well bias are both tied to the second supply voltage (V DDL ). This second supply voltage (V DDL ) is usually the reference voltage of the interior of the integrated circuit, whereas the first reference voltage (V DDH ) is used on the exterior of the integrated circuit. The AND gate 104 is similarly constructed to contain transistors connected to V DDL .
FIG. 4 illustrates in schematic form one embodiment of the voltage dropping elements of FIGS. 2 and 3. Voltage dropping element 110 includes a first PNP transistor 112 and a second PNP transistor 114. Transistor 112 has an emitter providing the first terminal of voltage dropping element 110, a base, and a collector connected to ground. Transistor 114 has an emitter connected to the base of transistor 112, a base forming the second terminal of voltage dropping element 110 and a collector connected to ground.
In operation, voltage dropping element 110 provides a voltage drop which is equal to two (2) diode voltage drops formed by the emitter-base junction of collector 112 in series with the emitter-base junction of transistor 114. In processes where vertical PNP transistors such as transistors 112 and 114 are available, voltage dropping element 110 provides an exponential current voltage characteristic. This is desirable because the current through the PNP transistor increases exponentially as its voltage increases, which is faster than a linear or quadratic increase. Thus, voltage dropping element 110 is preferable to other types of voltage dropping elements such as resistors, diode connected MOS transistors and the like. In particular, voltage dropping element 110 may be advantageously implemented using a conventional CMOS process. In such a case, the emitter of transistors 112 and 114 are formed by a P+ diffusion in an N-well, the base being formed by the N-well and the collector by the P-substrate and thus transistors 112 and 114 represent the parasitic bipolar transistors formed in P-substrate N-well CMOS integrated circuits.
FIG. 5 illustrates in schematic form a second embodiment 120 of the voltage dropping elements of FIGS. 2 and 3. Voltage dropping element 120 represents a voltage dropping element formed in a CMOS process and further including disabling circuitry to reduce steady state or DC current consumption. Voltage dropping element 120 includes N-channel transistors 122 and 124, a CMOS transmission gate 128, a P-channel transistor 130, an N-channel transistor 132, and a P-channel transistor 126. Transistor 122 has a drain forming the first terminal of voltage dropping element 120, a gate for receiving a signal label "SHIFT OE" and a source. Transistor 124 has a drain connected to the source of transistor 122, a gate connected to the drain thereof, and a source. Transistor 126 has a source connected to the source of transistor 124, a gate and a drain, and a bulk electrode connected to the source thereof and a drain electrode forming the second terminal of voltage dropping element 120. Transmission gate 128 has a first terminal connected to the gate of transistor 126 and a second terminal connected to the drain of transistor 126. Transmission gate 128 is a conventional CMOS transmission gate formed of a P-channel transistor and an N-channel transistor connected in parallel. Thus, for controlling the conductivity of transmission gate 128, the N-channel transistor receives a signal labeled "OE" on its gate and the P-channel transistor receives a compliment of signal OE labeled "OE" on its gate.
Transistor 130 has a source connected to the first supply voltage V DDL , a gate for receiving signal OE and a drain and a bulk connected to the source thereof. Transistor 132 has a drain connected to the drain of transistor 130, a gate for receiving a signal labeled "SHIFT OE" and a source connected to the gate of transistor 126. In operation, voltage dropping element 120 includes a series combination of two diode connected transistors 124 and 126 in conjunction with enabling circuitry. The enabling circuitry includes transistor 122 which prevents current from flowing through transistors 124 and 126 when signal OE is at a logic low state and transmission gate 128 which selectively couples the gate of transistor 126 to the drain thereof thereby forming the diode connection and the series combination of transistors 130 and 132 which act to pull the gate of transistor 126 to the logic high level of signal SHIFT OE minus the threshold voltage of transistor 132. While voltage dropping element 120 provides a less ideal voltage dropping characteristic due to the quadratic current voltage characteristic of MOS transistors it is useful, however, for lower power applications because it can be easily disabled.
FIG. 6 illustrates in schematic form one embodiment 140 of a bias circuit for use with the output buffers of FIGS. 2 and 3. The bias circuit illustrated in FIG. 6 uses voltage dropping element 110 of FIG. 4 and is used to provide the bias voltages for P-channel transistors 74 and 76 as previously illustrated in FIGS. 2 and 3. Bias circuit 140 includes a P-channel transistor 141, bipolar transistors 112 and 114, an N-channel transistor 144, all of which are used in conjunction with output stage 70. Transistor 141 has a source connected to V DDH , a gate, a drain connected to the gate thereof for providing a signal labeled "BIAS2" and a bulk connected to the source thereof. Transistor 112 has an emitter connected to the drain of transistor 141, a base, and a collector connected to ground. Transistor 114 has an emitter connected to the base of transistor 112, a base and a collector connected to ground. Transistor 144 has a drain connected to the base of transistor 114, a gate connected to the drain thereof, and a source connected to ground. The drain of transistor 144 provides a signal labeled "BIAS1". Driver stage 70 is connected as previously shown in FIGS. 2 and 3 except that transistor 74 receives signal BIAS1 on the gate thereof and transistor 76 receives signal BIAS2 on the gate thereof. Note that bias circuit 140 provides voltages on the gates of transistors 74 and 76 which are intermediate to power supplies V DDH and ground and thereby prevent the dielectrics of transistors 74 and 76 from exposure to voltage potentials greater than the dielectric breakdown voltage for the technology.
It is important to note that by connecting BIAS2 to the gate of transistor 76 and using a signal NDRIVE generated from BIAS1, the series combination of transistors 76 and 78 provide a roughly constant current drive as temperature varies. As temperature increases, transistor 78 increases in current drive, while transistor 76 proportionately decreases in current drive, thus limiting the current drive of the series combination. As temperature decreases, the current drive of transistor 78 decreases, while the current drive of transistor 76 increases proportionately, thus maintaining approximately the same current drive for the series combination of transistors 76 and 78. So, this technique allows the current drive characteristics of the series combination of transistors 76 and 78 to remain fairly constant across temperature changes. Furthermore, connecting the gate of transistor 74 to BIAS1 and using the signal PDRIVE generated from BIAS2, the same temperature compensation is achieved for the P-channel series combination.
FIG. 7 illustrates in schematic form a second embodiment 150 of a bias circuit for use with the output buffers of FIGS. 2 and 3 and output stage 70. Bias circuit 150 includes P-channel transistors 151, 152 and 154, an N-channel transistor 155, a P-channel transistor 156, and N-channel transistors 160 and 162 used in conjunction with voltage dropping element 120. Transistor 151 has a source connected to V DDH , a gate for receiving an input signal which is opposite in polarity to the signal on the gate of transistor 160, a drain, and a bulk connected to the source thereof. Transistor 152 has a source connected to V DDH , a drain connected to the drain of transistor 151 and a bulk connected to the source thereof. Voltage dropping element 120 has a first terminal connected to the drains of transistors 151 and 152 and a second terminal. Transistors 152 and 162 operate as BIAS2 and BIAS1, respectively. Transistor 154 has a source connected to V DDL , a gate for receiving signal OE and a drain. Transistor 155 has a drain connected to the drain of transistor 154, a gate for receiving signal OE, and a source connected to transistor 74. Transistor 156 has a source connected to the drain of transistor 154, a gate for receiving signal OE, and a drain connected to the gate of transistor 74. Transistor 160 has a drain connected to the second terminal of voltage dropping element 120, a gate for receiving an input signal which is opposite in polarity to the signal on the gate of transistor 151, and a source connected to ground. Transistor 162 has a drain connected to the second terminal voltage dropping element 120, a gate connected to the drain thereof and a source connected to ground. The gate of transistor 76 is also connected to the source of transistor 155, the drain of transistor 156, the gate of transistor 74, and the drain of transistor 124. Note that the drain of transistor 124 in voltage dropping element 120 is used as a further output terminal to bias transistors 74 and 76. When output enable signal is inactive, transistors the gates of transistors 74 and 76 are biased to V DDL .
Those skilled in the art will recognize that modifications and variations can be made without departing from the spirit of the invention. Therefore, it is intended that this invention encompass all such variations and modifications as fall within the scope of the appended claims.
Claim elements and steps herein have been numbered and/or lettered solely as an aid in readability and understanding. As such, the numbering and/or lettering in itself is not intended to and should not be taken to indicate the ordering of elements and/or steps in the claims.
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An output buffer translates digital input signals which toggle between ground and V DDL to signals which toggle between ground and V DDH . The technology dielectric breakdown voltage limit is less than the magnitude of V DDH , such that use of a traditional output stage would subject transistors' dielectrics to voltages which exceed their dielectric breakdown limit, and would thus be damaged. Predrive circuits (40, 50) control output stage (70) transistors' (72, 78) gates, and voltage dropping circuits control output stage (70) transistors (74, 76). These control signals are generated specifically to maximize output stage transistor drive strengths, thereby minimizing output stage size. Output buffer functions when V DDL =V DDH , and its performance is V DDL independent. Temperature compensation is incorporated into the output buffer by deliberately offsetting temperature effects on output stage transistor drive strengths. Desired performance and temperature compensation are accomplished without subjecting any dielectrics to voltages which exceed the technology dielectric breakdown limit.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to heat exchangers, and more particularly to heat exchangers featuring anti-freeze protection of the condensate draining path.
2. Brief Description of the Prior Art
Although freeze protection is an important criteria in designing an air-cooled steam condenser, the systems of the prior art, after more than two decades of development, still present complex and costly solutions to that problem and/or are unable to prevent freezing under certain operating conditions.
A typical solution to reduce the risk of freezing in the tubes of a steam condenser is to use a bundle of more than one row of tubes successively traversed by the air flow. The first row is struck by the coldest air flow but only a portion of the steam supplied to the tubes can be condensed. The outlet of the first row is connected to the inlet of the next row which converts a further amount of steam into condensate but is contacted by preheated air. Hence, although the steam could be totally reduced to cooled condensate at that stage, freezing is prevented because of the higher temperature of the air flow striking that row.
Larinoff in U.S. Pat. No. 5,787,970 issued on Aug. 4, 1998 presents an improved solution based on that concept characterized by a mixed flow vertical tube bundle design, in which some of the tube rows conduct counterflow steam and condensate while others have parallel flow. The condensate is drained at the bottom of the bundle from a header connecting a parallel flow row to a successive counterflow row in the protected warm air zone and non-condensable gases are collected at the outlet header of the counterflow rows.
The main drawback of the above type of systems lies in their lower efficiency/cost ratio as the second pass tube rows provide less heat exchange than the others for a comparable size and manufacturing cost. Also, some risks of freezing in the condensate drain piping and in tubes next to the edges of the bundle are still present. Moreover, circulation of steam and condensate in counterflow may result in interaction between the two fluids that disrupts normal flow and heat transfer. U.S. Pat. No. 5,056,592 (Larinoff) issued on Oct. 15, 1991 offers a solution to that problem by providing baffling inside some of the tubes to channel and separate the upward bulk flow of steam and the downward flow of condensate.
Another approach based on a similar principle is to use two rows of U-shaped tubes connected to a common steam supply as described in U.S. Pat. No. 3,705,621 (Schoonman) issued on Dec. 12, 1972. The tubes are so disposed that the air flow is successively striking the hottest legs of the first and second rows and then the coldest legs of the second and first tube rows.
Similarly, U.S. Pat. No. 4,926,931 (Larinoff) issued on May 22, 1990 presents a system in which the tubes are so arranged that steam flows from the input headers to the exposed legs of the inner and outer tube rows, and returns as condensate through the tube legs located in the protected warm air region in the middle of the tube bundle. The air flow thus successively strikes the hottest legs of the outer tube row, the coldest legs of the same row, the coldest legs of the second tube row and finally the hottest legs of that second row. Such an arrangement provides better protection to the exposed tubes especially at the top and bottom faces of the bundle. Moreover, the condensate drain headers extending in the protected region parallel and next to the steam supply headers provide some protection against freezing of the condensate by radiation heating. However, this system has drawbacks similar to the above concepts, as to the efficiency/cost ratio and still offers limited freezing protection especially in the U-shaped portions connecting the two legs of the finned tubes.
Another solution of comparable efficiency is described in U.S. Pat. No. 5,765,629 delivered to Goldsmith on Jun. 16, 1998 and uses a second stage vent condenser disposed in the same plane as a first stage condenser, both comprising bundles of vertically oriented tubes. The first stage operates at a higher steam pressure and consequently is easily drained from condensate and non-condensable gases into a lower header with excess steam. This header is connected to the upper header of the second stage condenser and to a hydraulically balanced common drain pot below the lower header. Non-condensable gases from the second stage flow counter-currently to be vented near the upper header. In this arrangement, freezing is controlled by continuous purging of the tube rows to avoid steam back-flow in the tube rows thereby eliminating trapping of condensate and non-condensable gases. However, this system is maintaining a constant level of condensate in the drain headers and the drain pot which are subject to freezing, particularly on the second stage condenser side.
Some solutions of the prior art have been specifically addressing potential freeze-up of the condensate drain lines. For instance, U.S. Pat. No. 3,968,836 (Larinoff) issued on Jul. 13, 1976 discloses a heat exchanger wherein leg seals connecting with outlets from individual condensate outlet headers are enclosed within a drain pot which is heated by uncondensed vapor from one of the outlet headers. In U.S. Pat. No. 4,240,502 issued on Dec. 23, 1980, Larinoff brings some improvements to the latter system, including a small hole in the drain pipe to purge the drain pot when the steam condensing system is shut down and applying some insulating material on the portion of the outlet header extending outside of the heated drain pot.
In U.S. Pat. No. 5,145,000, (Kluppel) issued on Sep. 8, 1992, a steam condensing system similar to the above has a tank receiving the condensate drain line from the drain pot. A steam line from the source of steam which also feeds the condenser, is connected to the upper end of the tank section receiving the drain line for supplying steam above the condensate level in the tank section. The steam heats the condensate drain line in the tank section to avoid freezing of the condensate.
In U.S. Pat. No. 5,355,943 (Gonano) issued on Oct. 18, 1994, steam from the source supplying the condenser is again connected to the upper end of a tank section receiving a condensate overflow drain duct from a drain vessel. Condensate is rain-like spread falling in the duct while the steam supplied to the tank goes up along the duct in countercurrent with the condensate, thus heating it on its passage to finally be sucked with non-condensable gases through the top portion of the drain vessel.
Although the latter vapor condensing system arrangements of the prior art significantly contribute to prevent freeze-up of the heat exchanger tube bundles or condensate drain lines, considerable drawbacks still limit their use on the market. Principally, their relative complexity significantly increases the system manufacturing and maintenance costs, while some efficiency of the heat transfer is lost and most of these systems still present risks of freezing especially if they are operated outside of their optimal vapour pressure conditions.
There is thus a need for an improved air-cooled vapor condensing system providing freeze protection over a wide range of operating conditions as required in applications such as heating of buildings.
OBJECT OF THE INVENTION
The main object of the present invention is therefore to provide a freeze-protected heat exchanger which overcomes the limitations and drawbacks of the above described prior art.
SUMMARY OF THE INVENTION
More specifically, in accordance with the invention as broadly claimed, there is provided a freeze-protected heat exchanger comprising:
a fluid supply member for connection to a source of condensable heated fluid;
a drain chamber coextending with the fluid supply member, and comprising a drain outlet;
a plurality of heat exchanger tubes extending from the fluid supply member and drain chamber, each heat exchanger tube comprising:
a first pipe having a heat-conductive wall, and a proximal end in fluid communication with the drain chamber;
a second pipe coextending with the first pipe, and having a proximal end in fluid communication with the fluid supply member; and
at least one first orifice through which the first pipe is in fluid communication with the second pipe; and
at least one second orifice through which the drain chamber is in fluid communication with the fluid supply member.
In operation, heated fluid is supplied from the fluid supply member to the second pipes, heated fluid from the second pipes is transferred to the respective first pipes through the first orifices, heat from the heated fluid in the first pipes is transferred to the outside of the first pipes through the heat-conductive walls, cooled fluid from the first pipes is collected and drained through the drain chamber and drain outlet, and the second orifice produces a jet of heated fluid in the drain chamber to prevent the formation of ice in the drain chamber.
In accordance with preferred embodiments of the invention:
the second orifice opens in the drain chamber in the area of the drain outlet;
the first pipe comprises an outer pipe having the heat-conductive wall and a distal closed end, the second pipe comprises an inner pipe having an inner pipe wall and disposed within the outer pipe with a space between the inner and outer pipes, and the first orifice extends through the inner pipe wall;
the fluid supply member and the drain chamber are substantially elongated and coaxial to each other, and the heat exchanger tubes extend substantially radially from the fluid supply member and drain chamber.
the heat exchanger tubes are generally horizontal with a slight slope toward the fluid supply member and drain chamber to enable draining of the cooled fluid from the first pipes toward the drain chamber by gravity;
each outer pipe comprises at least one outer heat-conductive fin to enhance heat transfer from the heat-conductive wall of the outer pipe to the outside, this fin comprising a helical extruded fin integral with the outer pipe to further prevent dilatation of the outer pipe and thus prevent formation of ice in the outer pipe;
the coextending fluid supply member and drain chamber are elongated, the heat exchanger tubes are arranged in bundles distributed along the length of the fluid supply member and drain chamber, each bundle of heat exchanger tubes comprise a plurality of rows of heat exchanger tubes, the heat exchanger tubes comprise first and second sets of heat exchanger tubes, and these first and second sets are diametrically opposite to each other about the fluid supply member and drain chamber;
the coextending fluid supply member and the drain chamber are substantially elongated and vertical;
the drain chamber comprises a bottom end provided with the drain outlet through which cooled fluid collected by the drain chamber from the first pipes is drained; and
the fluid supply member comprises a header with a closed lower end proximate to the drain outlet, the lower end of the header being provided with the second orifice to produce the jet of heated fluid in view of preventing formation of ice in the region of the drain outlet of the bottom end of the drain chamber;
the fluid supply member comprises a heat-conductive wall located at least in part in the drain chamber to provide for transfer of heat from the heated fluid to the drain chamber in view of preventing formation of ice in the drain chamber;
each inner pipe has a distal end short of the distal closed end of the corresponding outer pipe, and the distal end of the inner pipe is open through at least one first orifice to transfer heated fluid from the inner pipe to the area of the outer pipe proximate to the distal closed end of the outer pipe; and
a plurality of first orifices are distributed along the first and second pipes of each heat exchanger tubes, and the fluid supply member comprises a header provided with a plurality of heated fluid inlets distributed along the header.
The present invention also relates to a freeze-protected heat exchanger comprising:
a fluid supply member for connection to a source of condensable heated fluid, the fluid supply member having a first heat-conductive wall;
a drain chamber comprising a drain outlet and enclosing at least a portion of the fluid supply member, the fluid supply member and the drain chamber being substantially elongated, and the fluid supply member extending longitudinally within the drain chamber; and
a plurality of heat exchanger tubes extending from the fluid supply member and drain chamber, each heat exchanger tube comprising:
a first pipe having a second heat-conductive wall, and a proximal end in fluid communication with the drain chamber;
a second pipe coextending with the first pipe, and having a proximal end in fluid communication with the fluid supply member; and
at least one orifice through which the first pipe is in fluid communication with the second pipe;
In operation, heated fluid is supplied from the fluid supply member to the second pipes, heated fluid from the second pipes is transferred to the respective first pipes through the orifices, heat from the heated fluid in the first pipes is transferred to the outside of the first pipes through the second heat-conductive walls, cooled fluid from the first pipes is collected and drained through the drain chamber and drain outlet, and heat from the heated fluid in the fluid supply member is transferred to the drain chamber through the first heat-conductive wall in view of preventing formation of ice in the drain chamber.
Preferably, the fluid supply member and the drain chamber are substantially coaxial to each other.
The present invention further relates to a face and by-pass heat exchanger unit comprising the above described freeze-protected heat exchanger.
Freezing is prevented by direct contact of heated fluid, for example steam, and cooled fluid, for example condensate in the first pipes and by heating of the drain chamber by radiation, conduction and/or convection provided by the fluid supply member, and by heated fluid jet(s) directed toward the lower end of the drain chamber to prevent formation of ice near the drain outlet of the drain chamber.
The present invention presents, amongst others, the following advantages:
freezing is prevented in the heat exchanger tubes as well as in the drain chamber and corresponding draining path;
the freeze-protected heat exchanger complies with face and by-pass system arrangements for building heating applications as well as in any other type of heat exchanger and can be easily retrofitted into a wide range of existing conventional system units of different types, capacities and sizes;
the freeze-protected heat exchanger is automatically drained from cooled fluid when shut-off;
the freeze-protected heat exchanger presents a good overall energetic efficiency and an improved capacity/size ratio;
the freeze-protected heat exchanger is economical to produce and maintain;
the freeze-protected heat exchanger featuring generally horizontally oriented heat exchanging finned tubes connected to a substantially vertical steam supply header;
the freeze-protected heat exchanger is functional with a single row of tubes or multiple parallel rows of tubes supplied by a common steam source through a common or separate headers; and
the freeze-protected heat exchanger is not subject to disturbance of the steam flow by countercurrent condensate flow.
The objects, advantages and other features of the present invention will become more apparent upon reading of the following non restrictive description of a preferred embodiment thereof, given by way of example only with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the appended drawings:
FIG. 1 a is an isometric front view of a face and by-pass heat exchanger heating unit incorporating a freeze-protected heat exchanger according to the present invention;
FIG. 1 b is an isometric rear view of the face and by-pass heat exchanger unit of FIG. 1 a;
FIG. 2 a is an isomeric front view of a freeze-protected heat exchanger according to the present invention, in which fins of the outer tubes are not shown;
FIG. 2 b is a front elevation view of the freeze-protected heat exchanger of FIG. 2 a;
FIG. 2 c is a top view of the freeze-protected heat exchanger of FIG. 2 a;
FIG. 3 is a perspective, partly cross sectional view of an upper portion of the freeze-protected heat exchanger of FIGS. 2 a , 2 b and 2 c , showing steam distribution and condensate return paths;
FIG. 4 is a perspective, partly cross sectional view of a lower portion of the freeze-protected heat exchanger of FIGS. 2 a , 2 b and 2 c , showing condensate drain path and the heating steam jets;
FIG. 5 a is a side elevational view of a preferred embodiment of coextending steam supply header and drain chamber forming part of the freeze-protected heat exchanger according to the invention;
FIG. 5 b is an elevational, end view of the coextending steam supply header and drain chamber of FIG. 5 a ; and
FIG. 5 c is a top plan view of the coextending steam supply header and drain chamber of FIGS. 5 a and 5 b.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the appended drawings, similar reference numerals refer to similar parts throughout the various figures.
The preferred embodiment of the freeze-protected steam operated heat exchanger according to the present invention will now be described in detail referring to the appended drawings.
A face and by-pass heat exchanger unit 100 is illustrated in FIG. 1 . This face and by-pass heat exchanger unit incorporates the preferred embodiment of the freeze-protected heat exchanger 1 (FIG. 2 ). In this preferred embodiment, the freeze-protected heat exchanger 1 is steam operated. Of course, use of any other type of condensable heated fluid could be contemplated. The face and by-pass heat exchanger unit (FIG. 1) comprises a housing 10 in which the freeze-protected heat exchanger 1 (FIG. 2) is installed.
Referring to FIG. 1, housing 10 defines a pair of airflow passages 31 and 32 each provided with a remotely adjustable front set of air deflectors 11 (FIG. 1 a ) for:
directing a predetermined portion of the incoming air flow (see arrow 25 ) through bundles 5 of heat exchanger tubes 7 forming part of the freeze-protected heat exchanger 1 (better shown in FIGS. 2 a , 2 b and 2 c ; and
directing the remaining portion of the incoming air flow 25 toward by-pass zones such as 27 located between the bundles 5 of heat exchanger tubes 7 ;
and a remotely adjustable rear set of air deflectors 23 (FIG. 1 b ) for:
blocking passage of air through the by-pass zones; or
blocking passage of air through the bundles 5 of heat exchanger tubes by blocking the exit downstream these bundles 5 .
Each bundle 5 comprises at least one vertical row of generally horizontal heat exchanger tubes 7 connected at one end to generally vertical steam supply header 3 and condensate drain chamber 4 .
As better shown in FIGS. 2 a and 3 , the steam supply header 3 is substantially cylindrical and extends substantially vertically and coaxially in the box-like condensate drain chamber 4 . The steam supply header 3 comprises an upper, threaded steam inlet connector 2 . Referring to FIG. 1 a , the steam supply header 3 and the box-like condensate drain chamber 4 are installed in a substantially central closed housing portion 12 of the face and by-pass heat exchanger unit 100 .
In FIGS. 1 a , 1 b , 2 a , 2 b and 2 c diametrically opposite sets of superposed and substantially radially extending bundles 5 of heat exchanger tubes 7 are illustrated. However, it shall be deemed that in smaller units having less heating capacity, the housing portion 12 and the enclosed steam supply header 3 and drain chamber 4 may be located at one end of the unit 100 comprising a single set of superposed bundles 5 of heat exchanger tubes 7 extending substantially radially from supply header 3 . In this case, to improve distribution of the steam into the inner pipes 13 (FIG. 3) of the superposed bundles 5 , a plurality of steam inlets (not shown) can be provided in the side wall of supply header 3 . Preferably, these steam inlets will be distributed along the length of the header 3 and disposed diametrically opposite to the single set of superposed bundles 5 of heat exchanger tubes 7 . As described hereinafter and as illustrated in FIG. 3, each heat exchanger tube 7 is formed of an heat-conductive outer pipe 26 and an inner pipe 13 .
In this type of application, a substantially constant steam flow is established through the steam inlet connector 2 while the temperature of the air emerging downstream of the heat exchanger unit 100 is modulated according to the position of the cooperating series of air deflectors 11 and 23 . Both series of air deflectors 11 and 23 are connected together through connecting rods such as 24 and actuated through an external actuator such as an electric motor (not shown) to operate as follows:
in a face mode, the defectors 11 direct the incoming air flow toward the bundles 5 of heat exchanger tubes 7 , while the deflectors 23 block the by-pass zones; and
in a by-pass mode, the deflectors 11 direct the incoming air toward the by-pass zones, while the deflectors 23 block the exit downstream the bundles 5 of heat exchanger tubes 7 .
Intermediate positions of the deflectors 11 and 23 may be adopted by the face and by-pass heat exchanger unit 100 under the control of the external actuator so as to modulate the proportion of air flowing through the bundles 5 of heat exchanger tubes 7 and being heated by the heat exchanger 1 , thus controlling the average temperature of the air flow downstream the face and by-pass heat exchanger unit 100 .
The housing portion 12 provides some protection of the condensate drain chamber 4 against contact by incoming cold air and can be filled with insulating material to further improve insulating properties. FIGS. 2 a and 2 b illustrate a generally vertical condensate drain pipe 8 extending from the bottom of the condensate drain chamber 4 . FIGS. 2 a and 2 b also illustrate a threaded condensate outlet connector 9 of the condensate drain pipe 8 .
FIG. 3 illustrates the upper portion of the freeze-protected heat exchanger 1 showing the structure of the steam distribution and condensate return paths. Steam is supplied through the inlet connector 2 of the steam supply header 3 . The inner pipes 13 of the heat exchanger tubes 7 are each provided with two diametrically opposite series of orifices 14 distributed therealong. The inner pipes 13 extend generally horizontally and radially from the steam supply header 3 and are in fluid communication therewith (see openings such as 28 ). Each inner pipe 13 therefore extends through a wall of the condensate drain chamber 4 and is mounted in a corresponding outer pipe 26 coaxially therewith with an annular spacing between the inner 13 and outer 26 pipes. On the other hand, each outer pipe 26 is heat-conductive and provided with a rigid heat-conductive integral helical extruded fin 15 to enhance heat transfer from the heat-conductive wall of the output pipe 26 to the airflow 25 . Also, each outer pipe 26 has a distal closed free end 29 and a proximal end 30 opening in the condensate drain chamber 4 . More specifically, the proximal end 30 of each outer pipe 26 is connected to and extends through a side wall of the condensate drain chamber 4 , in fluid communication therewith. As illustrated, the inner pipes 13 extend into the respective outer pipes 26 up to a few inches short from the distal closed free ends 29 . These inner pipes 13 preferably comprise respective axial end orifices 21 to produce axial steam jets 22 toward the closed free ends of the respective outer pipes 26 . All the inner 13 and outer 26 pipes are slightly sloping downwardly toward the condensate drain chamber 4 to assure proper draining of the condensate 19 from the outer pipes 26 in the chamber 4 by gravity. A slope of the order of 2% fulfills this purpose.
Those of ordinary skill in the art will appreciate that the steam supplied by a steam source (not shown) through inlet connector 2 to the steam supply header 3 is distributed in the inner pipes 13 and subsequently transferred to the outer pipes 26 through the orifices 14 and 21 . Again, it shall be noted that in large units comprising many superposed bundles 5 of heat exchanger tubes 7 , more than one steam inlet can be provided along steam supply header 3 to better balance the distribution of steam into the inner pipes 13 . Upon contact with the inner side of the air-cooled wall of finned outer pipes 26 , heat from the steam is transferred to the airflow 25 through the finned outer pipes 26 and the steam condenses and flows by gravity as condensate 19 toward the drain chamber 4 , rain-like spread falling along the walls thereof toward the bottom 20 (FIG. 4) of that chamber. Each row of heat exchanger tubes 7 in such an arrangement provides about twice the heat-transfer capacity of a conventional U-shaped tube design, thus reducing the size and cost for a face and by-pass heat exchanger unit 100 of given capacity.
The internal volume and the walls of the condensate drain chamber 4 are submitted to some heating from the steam supply header 3 , thus preventing sub-cooling of the condensate and formation of ice in the chamber 4 or at the outlet (proximal ends 30 ) of the outer pipes 26 . Moreover, the rigid extruded fins 15 provide the outer tubes 26 with a high resistance to dilatation which contribute to further prevent formation of ice. Although integral, extruded fins 15 are preferred, use of some other fin configuration such as flat or corrugated plates, or flat or corrugated rectangular individual fins of an overlapped or footed “L” design could be contemplated with acceptable results.
FIG. 4 illustrates the lower portion of the freeze-protected heat exchanger 1 to show the structure of the condensate drain path. The condensate 19 dripping along the internal walls of drain chamber 4 hits the bottom 20 and flows through an inlet 18 of the condensate drain pipe 8 and is returned to the steam trap and remaining components of the system (not shown) via the threaded condensate outlet connector 9 . Two jets of steam 16 a and 16 b are respectively escaping from two small orifices 17 a and 17 b of diameter depending on the pressure of the steam supply, preferably provided in the bottom wall 31 of the steam supply header 3 and so positioned as to direct these steam jets 16 a and 16 b preferably toward the front (cold air side) corners of the bottom 20 of the condensate drain chamber 4 thus avoiding any build-up of ice at the bottom 20 and at the inlet 18 of the condensate drain pipe 8 . The orifices 17 a and 17 b also serve to drain the condensed steam from the steam supply header 3 when the steam-producing heating device (not shown) is shut-off and the steam flow 32 is interrupted at the steam inlet connector 2 .
Alternatively, more than two orifices such as 17 a and 17 b can be provided to produce more than two corresponding jets of steam such as 16 a and 16 b.
In the case of the two orifices 17 a and 17 b , these orifices can be positioned at a higher level on the vertical and cylindrical wall of the header 3 to both heat and prevent build-up of ice throughout the entire drain chamber 4 . In the case of a number of orifices larger than 2, the orifices can be distributed vertically on the vertical, cylindrical wall of the header 3 again to both heat and prevent build-up of ice throughout the entire drain chamber 4 .
Furthermore, a closure member (not shown) can be provided for manually or automatically controlling the opening and closing of the orifices as a function of different operating conditions such as external air temperature.
FIGS. 5 a , 5 b , and 5 c illustrate an alternative embodiment 50 of the freeze-protected heat exchanger 1 showing the structure of the steam distribution and condensate return paths.
The embodiment 50 of FIGS. 5 a , 5 b and 5 c comprises a steam supply header 52 and a condensate drain chamber 53 formed of a vertical tube 55 with a closed top end 56 . A central vertical flat, heat-conductive wall 57 separates the vertical tube 55 into two halves of which one forms the header 52 and the other the drain chamber 53 . The steam supply header 52 has closed top and bottom ends, while the drain chamber 53 has a closed top end but a bottom end 54 open to form a drain outlet 58 .
Steam is supplied through an inlet connector 51 of the steam supply header 52 . As illustrated, inlet connector 51 is threaded for connection to a steam source (not shown). The inner pipes 13 of the heat exchanger tubes 7 are still provided with the two diametrically opposite series of orifices 14 (see FIGS. 5 c ) distributed therealong. The inner pipes 13 extend generally horizontally and radially from the steam supply header 52 and are in fluid communication therewith (see portions of inner pipes 13 extending through the drain chamber 53 ). Each inner pipe 13 therefore extends through a wall of the condensate drain chamber 53 and is mounted in a corresponding outer pipe 26 coaxially therewith with an annular spacing between the inner 13 and outer 26 pipes. On the other hand, each outer pipe 26 is heat-conductive and provided with a rigid heat-conductive integral helical extruded fin 15 to enhance heat transfer from the heat-conductive wall of the output pipe 26 to the airflow 25 . Also, each outer pipe 26 has a distal closed free end 29 and a proximal end 30 opening in the condensate drain chamber 53 . More specifically, the proximal end 30 of each outer pipe 26 is connected to and extends through a side wall of the condensate drain chamber 53 , in fluid communication therewith. As illustrated in FIG. 5 c , the inner pipes 13 extend into the respective outer pipes 26 up to a few inches short from the distal closed free ends 29 . These inner pipes 13 preferably comprise respective axial end orifices 21 to produce axial steam jets 22 toward the closed free ends of the respective outer pipes 26 . All the inner 13 and outer 26 pipes are slightly sloping downwardly toward the condensate drain chamber 53 to assure proper draining of the condensate from the outer pipes 26 in the chamber 53 by gravity. A slope of the order of 2% fulfills this purpose.
Those of ordinary skill in the art will appreciate that the steam supplied by a steam source (not shown) through the inlet connector 51 to the steam supply header 52 is distributed in the inner pipes 13 and subsequently transferred to the outer pipes 26 through the orifices 14 and 21 . Again, it shall be noted that in large units comprising many superposed bundles 5 of heat exchanger tubes 7 , more than one steam inlet such as 51 can be provided along steam supply header 52 to better balance the distribution of steam into the inner pipes 13 . Upon contact with the inner side of the air-cooled wall of finned outer pipes 26 , heat from the steam is transferred to the airflow 25 through the finned outer pipes 26 and the steam condenses and flows by gravity as condensate toward the drain chamber 53 , rain-like spread falling along the walls thereof toward the bottom end 54 and drain outlet 58 (FIG. 5 a ) of that chamber. Each row of heat exchanger tubes 7 in such an arrangement provides about twice the heat-transfer capacity of a conventional U-shaped tube design, thus reducing the size and cost for a face and by-pass heat exchanger unit 100 of given capacity.
The internal volume and the walls of the condensate drain chamber 53 are submitted to some heating through the heat-conductive wall 57 from the steam supply header 52 , thus preventing sub-cooling of the condensate and formation of ice in the chamber 53 or at the outlet (proximal ends 30 ) of the outer pipes 26 . Moreover, the rigid extruded fins 15 provide the outer tubes 26 with a high resistance to dilatation which contribute to further prevent formation of ice. Although integral, extruded fins 15 are preferred, use of some other fin configuration such as flat or corrugated plates, or flat or corrugated rectangular individual fins of an overlapped or footed “L” design could be contemplated with acceptable results.
The condensate dripping along the internal walls of drain chamber 53 hits the bottom 54 and flows through the drain outlet 58 and is returned to the steam trap or remaining components of the system (not shown) via this drain outlet 58 . Drain outlet 58 is threaded for connection to the steam trap or remaining components of the system. At least one jet of steam 59 escapes from a small orifice 60 of a diameter depending on the pressure of the steam supply, preferably provided in the lower portion of wall 57 of the steam supply header 52 and so positioned as to direct this steam jet 59 preferably toward a cold air side corner 61 of the bottom 54 of the condensate drain chamber 53 thus avoiding any build-up of ice at the bottom 54 and at the drain outlet 58 . The orifice 60 also serves to drain the condensed steam from the steam supply header 52 when the steam source (not shown) is shut-off and the steam flow is interrupted at the steam inlet 51 .
Alternatively, a plurality of orifices such as 60 can be provided to produce a plurality of corresponding jets of steam such as 59 .
In the case of the single orifice 60 , this orifice can be positioned at a higher level on the wall 57 to both heat and prevent build-up of ice throughout the entire drain chamber 53 . In the case of a plurality of orifices such as 60 , the orifices can be distributed vertically on the wall 57 again to both heat and prevent build-up of ice throughout the entire drain chamber 53 .
Furthermore, a closure member (not shown) can be provided for manually or automatically controlling the opening and closing of the single or plurality of orifices such as 60 , as a function of different operating conditions such as external air temperature.
Therefore, it will be apparent to those of ordinary skill in the art that the freeze-protected heat exchanger 1 of the present invention can be advantageously used for efficiently transferring heat from a steam flow 32 to an air flow 25 potentially below the freezing point of water, without causing damages or malfunctions due to freezing of steam condensate, thus overcoming the drawbacks of the prior art devices.
Although the present invention has been described hereinabove by way of a preferred embodiment thereof, this embodiment can be modified at will, within the scope of the appended claims, without departing from the spirit and nature of the subject invention.
For instance, it would be obvious for one of ordinary skill in the art to use the freeze-protected heat exchanger of the present invention with a different arrangement of bundles and rows of tubes, in a wide range of sizes and power capacities and/or to use two units forming a A-shaped condenser for condensing steam or other condensable heated fluid at the outlet of turbines in power plants. Moreover, the heat exchanger can be retrofitted into many types of existing units.
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The freeze-protected heat exchanger comprises a fluid supply header for receiving a pressurized heated fluid and a drain chamber coextending with the fluid supply header for collecting and draining cooled fluid. A plurality of heat exchanger tubes extends radially from the fluid supply header and drain chamber, and each comprise outer and inner pipes. The outer pipe has a heat-conductive wall, a proximal end in fluid communication with the drain chamber and a distal closed end. The inner pipe is disposed coaxially within the outer pipe, has a proximal end in fluid communication with the fluid supply header and comprises a plurality of first orifices through which the inner pipe is in fluid communication with the outer pipe. At least one second orifice through which the drain chamber is in fluid communication with the fluid supply header opens in the drain chamber. In freeze-protected operation, heated fluid from the fluid supply header is supplied to the inner pipes, heated fluid from the inner pipes is transferred to the respective outer pipes through the first orifices, heat from the heated fluid in the outer pipes is transferred to the outside, for example to a flow of air, through the heat-conductive walls of the outer pipes, cooled fluid from the outer pipes is collected and drained through the drain chamber, the second orifice produces a jet of heated fluid in the drain chamber to prevent the formation of ice preferably in the area of the drain outlet, and heat from the fluid supply member is also transferred to the drain chamber by conduction and radiation. The invention also relates to a face and by-pass heat exchanger unit including the above described freeze-protected heat exchanger.
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FIELD
[0001] Embodiments usable within the scope of the present disclosure relate, generally, to apparatus and methods usable for controlling vibrations within a drill string and applying a downhole force to a drill bit, and more specifically, to devices and methods for maintaining weight-on-bit during drilling operations while preventing vibrational forces from a drill string from interfering with operation of the drill bit.
BACKGROUND
[0002] When drilling a wellbore, the drill bit and drill string, as well as other associated equipment, are subject to various forces. For example, during drilling, the drill bit is subject to a counterforce in the uphole direction applied by the formation, rotational force from the motive source being used to drill, excess torque from the drill string, vibrational forces from the drill string and/or other equipment located uphole from the drill bit, and/or other similar forces. These and other types of forces can briefly lift the drill bit from the bottom of a wellbore (e.g., creating “bit whirl”), and/or cause the drill bit to be subjected to undesirable lateral forces, which can result in the drill bit and/or drill string becoming stuck, an undesired deviation of the direction in which the wellbore is drilled, and other losses in drilling efficiency, as well as possible wear and/or damage to equipment. Further, in addition to lifting and/or deviating the drill bit, vibration of the drill string can cause the drill string, itself, and/or other components associated therewith, to contact the borehole wall, becoming stuck, damaged, and/or reducing drilling efficiency.
[0003] As such, during drilling operations, it is important to maintain an adequate “weight-on-bit” to counteract the tendency of the drill bit to be lifted from the bottom of the wellbore and/or to deviate from the desired direction of drilling. During vertical drilling operations, the weight of the drill string, itself, as well as the weight of one or multiple drill collars, stabilizers, and/or other components, placed just above the drill bit in a bottomhole assembly, provides significant weight to the drill bit, which not only maintains contact between the bit and the formation to reduce deviation, but also improves the rate of drilling. However, during horizontal drilling and/or drilling in any other non-vertical direction, the weight of the drill string, bottomhole assembly, and/or other components associated with the drill string provides significantly less benefit, and in many cases, may hinder directional drilling operations through undesired contact between the drill string and/or any tools or components therealong and the borehole wall, especially when passing through curved/bent portions of the wellbore.
[0004] Conventionally, during horizontal drilling operations, a thruster, tractor, and/or shock absorber can be installed, proximate to the drill bit. A typical thruster will use hydraulic elements (e.g., pistons and cylinders) to apply a constant force to the drill bit to maintain the bit on the bottom of the wellbore. A tractor will use hydraulic elements to pull and/or push on the drill string or drill bit. A shock absorber will include resilient and/or similar elements designed to cushion all components on one side of the shock absorber from forces received from components on the opposing side. Each of these types of tools, used singularly or in combination, provides some effectiveness when attempting to improve drilling efficiency, maintain a drill bit on the bottom of a wellbore, and reduce the effect of drill string vibration on a drill bit. However, a need exists for devices specifically designed to apply an uphole force in the direction of the drill string to reduce the inefficiencies and difficulties caused by drill string vibration on the drill string itself, not simply the drill bit. A need also exists for devices and methods for simultaneously applying a downhole force to maintain an acceptable weight-on-bit, and an uphole force usable to control drill string vibrations.
SUMMARY
[0005] Embodiments usable within the scope of the present disclosure include apparatus for controlling drill string vibrations and applying a force to a drill bit. Such an apparatus can include a body with an uphole end and a downhole end, having a first piston (e.g., a mandrel, rod, etc.) positioned at the uphole end and a second piston positioned at the downhole end. A first biasing member (e.g., one or more Bellville springs or similar members) can be operatively associated with the first piston, and the first biasing member can be configured to urge the first piston outwardly from the body to provide a first force in an uphole direction to a drill string, which can be engaged with the uphole end of the body. A second biasing member can be operatively associated with the second piston and configured to urge the second piston outwardly from the body to provide a second force in a downhole direction to a drill bit, which can be engaged with the downhole end of the body. Vibrations from the drill string can thereby compress the first biasing member (e.g., through contact between the drill string and the first piston), while the first force resists the vibration and maintains the body and drill bit in a generally constant orientation relative to the drill string. Uphole forces from the drill string and/or the drill bit can compress the second biasing member, while the second force prevents movement of the drill bit in an uphole direction (e.g., maintaining weight-on-bit.)
[0006] A specific embodiment can include a tubular housing having an axial bore with a first end and a second end, a first mandrel positioned within the first end and movable in an axial direction relative to the housing, and a second mandrel positioned within the second end and movable in an axial direction relative to the housing. A spring mandrel can be positioned within the axial bore between the ends thereof. At least one first biasing member can thereby be positioned between the spring mandrel and the first mandrel, while at least one second biasing member can be positioned between the spring mandrel and the second mandrel. A vibrational force from the drill string can move the first mandrel into the axial bore, thereby compressing the one or more first biasing members, which apply a vibrational counterforce that resists the vibration. An uphole force from the drill bit can move the second mandrel into the axial bore, thereby compressing the one or more second biasing members, which apply a downhole counterforce that prevents movement of the drill bit in an uphole direction.
[0007] In use, an apparatus can be provided into a wellbore, the apparatus having a first end adapted to contact and apply a force to a drill bit and a second end adapted to contact and apply a force to a drill string. The drill bit can be used to bore through a formation, such that the formation can apply an uphole force to the drill bit that compresses a first biasing member associated with the first end. The first biasing member can thereby apply a downhole counterforce to the bit to prevent movement of the drill bit in an uphole direction. The drill string can be extended into the wellbore, which can apply a vibrational force to the apparatus, which can thereby compress a second biasing member associated with the second end of the apparatus. The second biasing member can thereby apply an uphole counterforce to the drill string to resist the vibrational force and maintain the drill bit and apparatus in a generally consistent orientation relative to the drill string.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] In the detailed description of various embodiments usable within the scope of the present disclosure, presented below, reference is made to the accompanying drawings, in which:
[0009] FIG. 1 depicts a diagrammatic side view showing an embodiment of an apparatus usable within the scope of the present disclosure.
[0010] FIG. 2A depicts a diagrammatic side view showing an embodiment of an apparatus usable within the scope of the present disclosure positioned within a wellbore.
[0011] FIG. 2B depicts a diagrammatic side view showing the apparatus of FIG. 2A operatively associated with a drill string and a drill bit.
[0012] One or more embodiments are described below with reference to the listed Figures.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0013] Before describing selected embodiments of the present disclosure in detail, it is to be understood that the present invention is not limited to the particular embodiments described herein. The disclosure and description herein is illustrative and explanatory of one or more presently preferred embodiments and variations thereof, and it will be appreciated by those skilled in the art that various changes in the design, organization, means of operation, structures and location, methodology, and use of mechanical equivalents may be made without departing from the spirit of the invention.
[0014] As well, it should be understood that the drawings are intended to illustrate and plainly disclose presently preferred embodiments to one of skill in the art, but are not intended to be manufacturing level drawings or renditions of final products and may include simplified conceptual views to facilitate understanding or explanation. As well, the relative size and arrangement of the components may differ from that shown and still operate within the spirit of the invention.
[0015] Moreover, it will be understood that various directions such as “upper”, “lower”, “bottom”, “top”, “left”, “right”, and so forth are made only with respect to explanation in conjunction with the drawings, and that components may be oriented differently, for instance, during transportation and manufacturing as well as operation. Because many varying and different embodiments may be made within the scope of the concept(s) herein taught, and because many modifications may be made in the embodiments described herein, it is to be understood that the details herein are to be interpreted as illustrative and non-limiting.
[0016] Referring now to FIG. 1 , a diagrammatic side view of an embodiment of an apparatus ( 10 ) usable within the scope of the present disclosure is shown. While in operation, the depicted portions of the apparatus ( 10 ) can be provided within a tubular housing (not shown), which can be engaged with adjacent joints and/or components within a drill string at each end (e.g., via threaded connections), FIG. 1 depicts the apparatus ( 10 ) without an outer housing to promote visibility of the interior portions thereof.
[0017] A first piston or mandrel ( 12 ) is shown positioned at a first end of the apparatus ( 10 ), attached via a splined connection ( 24 ) and left handed threads ( 25 ), such that the first mandrel ( 12 ) can move axially relative to other portions of the apparatus ( 10 ) (e.g., inward and outward parallel to the longitudinal axis of the apparatus ( 10 )). A second piston/mandrel ( 14 ) is shown positioned at a second end of the apparatus ( 10 ), similarly attached via a splined connection ( 26 ) and left handed threads ( 27 ) such that the second mandrel ( 14 ) can be movable in an axial direction relative to other portions of the apparatus ( 10 ). While FIG. 1 depicts each mandrel ( 12 , 14 ) being substantially identical, in an embodiment, the mandrels ( 12 , 14 ) could have differing dimensions, shapes, and/or materials, depending on the nature of the drill bit, drill string, and/or other components. Further, while FIG. 1 depicts use of splined connections ( 24 , 26 ) and left handed threads ( 25 , 27 ), it should be understood that any means of connection and/or association between the mandrels ( 12 , 14 ) and the remainder of the apparatus ( 10 ) can be used without departing from the scope of the present disclosure.
[0018] A spring mandrel ( 16 ) is shown generally centrally located within the apparatus ( 10 ) (e.g., between the ends thereof, and between the first and second mandrels ( 12 , 14 )), the spring mandrel ( 16 ) engaging and/or directly/indirectly contacting the other portions of the apparatus ( 10 ).
[0019] A first spring housing ( 18 ) is depicted between the spring mandrel ( 16 ) and the first mandrel ( 12 ). The spring housing ( 18 ) can, in an embodiment, include a generally tubular body about which a plurality of Bellville springs or similar biasing members can be positioned, of which two exemplary springs ( 20 A, 20 B) are depicted. As such, the first mandrel ( 12 ) can be placed in association with a drill string (not shown) located uphole from the apparatus ( 10 ), such that vibrations and/or other forces from the drill string can impart a downhole force to the first mandrel ( 12 ), which can cause axial movement of the first mandrel ( 12 ) relative to other portions of the apparatus ( 10 ), by compressing the biasing members ( 20 A, 20 B) along the first spring housing ( 18 ). The compression of the biasing members ( 20 A, 20 B) and movement of the first mandrel ( 12 ) can be limited by, for example, use of a stop nut ( 32 ), which is shown engaged with the spring mandrel ( 16 ) via a cap and/or associated section of wash pipe ( 34 ). Other configurations and/or stop members can also be used without departing from the scope of the present disclosure. For example, a shoulder and/or similar protruding feature of the first mandrel ( 12 ) could be used to limit the movement thereof, through contact with a corresponding feature located elsewhere along the apparatus ( 10 ) and/or the housing thereof. A sub ( 36 ) (e.g., a crossover sub usable to connect components of differing diameters and/or dimensions) can be positioned between the stop nut ( 32 ) and the first mandrel ( 12 ) to provide a desired spacing therebetween. In an embodiment, the first mandrel ( 12 ) can have a stroke length (e.g., a maximum compression distance) of approximately two feet. The biasing members ( 20 A, 20 B) can be configured to urge the first mandrel ( 12 ) outwardly from the apparatus ( 10 ) (e.g., in an uphole direction), such that compression of the biasing members applies a counterforce to the drill string, thereby minimizing the effect of any downhole and/or vibrational force on the apparatus ( 10 ) and on the drill bit below.
[0020] A second spring housing ( 22 ) is shown between the spring mandrel ( 16 ) and the second mandrel ( 14 ). The second spring housing ( 22 ) can similarly include a tubular body about which biasing members (e.g., Bellville springs or similar members) are positioned. The second mandrel ( 14 ) can be placed in association with a drill bit (not shown) located downhole from the apparatus ( 10 ), such that an uphole force from the drill bit (e.g., a force that has the tendency to lift the drill bit from the bottom of the wellbore) will be applied to the second mandrel ( 14 ), which can cause axial movement of the second mandrel ( 14 ), relative to other portions of the apparatus ( 10 ), by compressing the biasing members positioned along the second spring housing ( 22 ). Compression of the biasing members and movement of the second mandrel ( 14 ) can be limited by using a stop nut ( 28 ), which is shown engaged with the spring mandrel ( 16 ) via a cap and/or associated section of wash pipe ( 30 ), though other configurations and/or stop members can be used without departing from the scope of the present disclosure, as described above. A sub ( 38 ) (e.g., a crossover sub) can be positioned between the stop nut ( 28 ) and the second mandrel ( 14 ) to provide a desired spacing therebetween. In an embodiment, the second mandrel ( 14 ) can have a stroke length (e.g., a maximum compression distance) of approximately two feet. The biasing members along the spring housing ( 22 ) can be configured to urge the second mandrel ( 14 ) outwardly from the apparatus ( 10 ) (e.g., in a downhole direction), such that compression of the biasing members, e.g., by an associated drill bit, can cause a counterforce to be applied to the drill bit, thereby maintaining contact between the drill bit and the bottom of the wellbore.
[0021] In an embodiment, a piston sub ( 40 ) or similar member can be positioned within the interior of the apparatus ( 10 ) (e.g., within a hollow spring mandrel). For example,. the piston sub ( 40 ) can engage the first and second mandrels ( 12 , 14 ) (e.g., via the splined connections ( 24 , 26 )), while the spring mandrel ( 16 ) can engage the subs ( 36 , 38 ) and spring housings ( 18 , 22 ). In an alternative embodiment, the piston sub ( 40 ) could be positioned external to the spring mandrel ( 16 ) and/or other portions of the apparatus.
[0022] Referring now to FIG. 2A , an embodiment of an apparatus ( 10 ) usable within the scope of the present disclosure is shown positioned within a directional wellbore ( 50 ). As known in the art, the wellbore ( 50 ) is shown having a drill string ( 42 ) therein having a drill bit ( 44 ) at the distal end thereof. The drill bit ( 44 ) can be used to extend the wellbore ( 50 ) by boring into the downhole end ( 46 ) thereof. It should be understood that the diagram shown in FIG. 2A is simplified, to show the general position of the apparatus ( 10 ) relative to the drill string ( 42 ) and drill bit ( 44 ), and that various other components (e.g., a mud motor, a measurement-while-drilling device, and/or other components) not specifically depicted, but well known in the art, can also be present. The apparatus ( 10 ) is shown having an outer housing ( 48 ) within which the remainder thereof is positioned, and from within which the first and second mandrels ( 12 , 14 ) extend. The first mandrel ( 12 ) is shown in association with the drill string ( 42 ), while the second mandrel ( 14 ) is shown in association with the drill bit ( 44 ).
[0023] FIG. 2B depicts the apparatus ( 10 ) of FIG. 2A during a drilling operation. The drill string ( 42 , labeled in FIG. 2A ) is shown imparting a vibrational force (F 1 ) to the first mandrel ( 12 ) in a downhole direction, which compresses biasing members (shown in FIG. 1 ) associated with the first mandrel ( 12 ), such that the first mandrel ( 12 ) retracts a first distance (D 1 ) into the housing ( 48 ). The biasing members exert an equal and opposite counterforce (CF 1 ) in an uphole direction, which reduces and/or eliminates the effect of the vibrational force (F 1 ) on the remainder of the apparatus ( 10 ) and on the drill bit ( 44 ) and any other components located downhole from the apparatus ( 10 ).
[0024] The drill bit ( 44 ) is shown imparting an uphole force (F 2 ) (e.g., a force that would tend to lift the drill bit ( 44 ) from the downhole end ( 46 ) of the wellbore ( 50 , labeled in FIG. 2A )) to the second mandrel ( 14 ), which compresses biasing members associated with the second mandrel ( 14 ), such that the second mandrel ( 14 ) retracts a second distance (D 2 ) into the housing. The biasing members associated therewith exert an equal and opposite counterforce (CF 2 ) in a downhole direction, which reduces and/or eliminates the effect of the uphole force (F 2 ) on the remainder of the apparatus ( 10 ) and on the drill string ( 42 ) and other components associated therewith, while also urging the drill bit ( 44 ) into contact with the downhole end ( 46 ) of the wellbore ( 50 ).
[0025] While FIG. 2B depicts the uphole force (F 2 ) having a greater magnitude than the vibrational force (F 1 ), such that the second counterforce (CF 2 ) and second distance (D 2 ) are greater than the first counterforce (CF 1 ) and first distance (D 1 ), it should be understood that the forces illustrated in FIG. 2B are merely exemplary of one possible set of circumstances that may be encountered within a wellbore, and that embodiments of the present apparatus ( 10 ) can be used to compensate for any magnitude of force.
[0026] While various embodiments usable within the scope of the present disclosure have been described with emphasis, it should be understood that within the scope of the appended claims, the present invention can be practiced other than as specifically described herein.
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Apparatus and methods for controlling drill string vibrations and applying a force to a drill bit include a body having a first piston at an uphole end in association with a drill string and a second piston at a downhole end in association with a drill bit. A first biasing member urges the first piston outward to provide a first force in an uphole direction to the drill string. A second biasing member urges the second piston outward to provide a second force in a downhole direction to the drill bit. When vibration from the drill string compresses the first biasing member, the first force resists the vibration and maintains the apparatus and drill bit in a consistent orientation. When an uphole force from the drill string or the drill bit compresses the second biasing member, the second force prevents movement of the drill bit in an uphole direction.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 11/640,475, filed Dec. 15, 2006, claiming the benefit of European Patent Application 05 027 634.4, filed Dec. 16, 2005, herein incorporated by reference.
FIELD OF THE INVENTION
The invention relates to a method for treating a flue gas catalyst base (substrate/carrier), including reactivating a catalyst base.
BACKGROUND OF THE INVENTION
In order to catalytically accelerate chemical reactions in fluid streams, one uses catalysts that are applied on or contained in catalyst bases. Usually, such bases comprise at least one contact area of a porous material. The surface that is made of and enlarged by the porous material includes active centers favoring a reaction of the reactants carried by the fluid stream. The contact area is understood as a macroscopic boundary of the base material adjacent to the fluid stream. That contact area is to be distinguished from the pore wall areas that have smaller, sometimes microscopic dimensions and are formed by areas defining the boundaries of the pore spaces/volumes. The pore wall areas of such pores leading into an opening in the contact area form one surface with the contact area and enlarge the surface that is accessible by the fluid stream.
The streaming fluid and the reactants (within the fluid) enter (diffuse) into the pore system that is formed by the pores; they come into contact with the active centers located at the pore wall areas and there they are adsorbed. In this process, the reactants react and the reaction products are released by desorption and diffuse out of the pore system back into the fluid stream. Such catalyst bases are in particular used in processes, if exhaust gases are to be cleaned from undesired substances carried within the gases, e.g. when cleaning the flue gas of combustion power plants.
Burning fossil fuels (or waste and/or biomass) produces air pollutants. It is desirable to remove the air pollutants because of their negative effect on the environment. Apart from the dusts that can be removed from flue gas streams by dust removing devices, sulfur compounds are removed by desulfurization plants. However, fossil fuels contain in particular nitrogen compounds that are transformed to nitrogen oxides in the flue gas. Furthermore, a portion of the nitrogen of the combustion air is changed to nitrogen oxide under combustion conditions. Accordingly, in respect of the production of nitrogen oxides, a distinction is made between thermal formation, prompt (direct) nitrogen oxide formation and nitrogen oxide formation from fuel nitrogen. For environmental reasons, the portion of nitrogen oxides (NO x ) in exhaust gases should be reduced.
Apart from reducing the formation of nitrogen oxide by primary measures, i.e. measures affecting the fueling, it is becoming more and more common for power plants to also use secondary measures, i.e. removing NO x compounds from the flue gases.
Apart from other methods (e.g. selective non-catalytic reduction), catalytic reduction methods are in particular relevant due to their large-scale applicability.
The so-called selective catalytic reduction methods (SCR) are used for the NO x reduction on a large industrial scale. When those methods are used, NO x is transformed to water and nitrogen using NH 3 (ammonia). In the presence of catalysts, the reaction runs faster and/or at a lower temperature and therefore it is also suitable for high flue gas stream velocities. The used catalysts usually consist of catalyst bases (substrates/carriers) of ceramic base materials, in which active metal compounds have been homogeneously introduced or on whose surfaces active metal compounds that combine with the base material have been applied (usually a simple coating cannot be used because of the mechanical stress in the flue gas stream). Frequently, the main component for the catalyst base is titanium dioxide; active centers are formed by adding vanadium, tungsten, molybdenum, copper and/or iron compounds. Zeolites can also be used as catalyst bases.
It is problematic when catalysts are used to reduce nitrogen oxides, as there are competing reactions, which are also favored by the active centers and which can in particular result in the undesired oxidization of sulfur dioxide to sulfur trioxide.
Furthermore, the activity of the catalyst (the desired nitrogen oxide reduction) as well as (due to a decrease in competition) the proportion between the desired catalytic effect and the undesired catalytic effect decreases the longer the catalyst is used. This is the reason that catalyst bases must be reactivated after a certain period of time, i.e. the catalyst base is cleaned, reaction products are removed and the base material is covered/doped with new active centers. For this purpose, a catalytically relevant substance is introduced into pores of the catalyst base using a transport fluid. The introduction is carried out through openings in the contact area, into which the pores lead (pores that do not have any fluid contact to openings in the contact area are irrelevant, since flue gas cannot enter such pores during operation). After removal of the transport fluid, the catalytically relevant substance remains on the pore wall areas of the pores and there it forms active centers.
Usually, catalysts that have been reactivated in such a way have a similar activity to newly manufactured catalysts. However, it can happen that the proportion between activity (catalysis of the nitrogen oxide reduction) and undesired reactions changes for the worse.
This is the starting point of the invention.
The purpose of the invention is to provide a method for treating a catalyst base, wherein the method can be used for the first manufacturing of catalysts as well as for their reactivation, and wherein the method makes a high activity of the catalyst possible without increasing the undesired side reactions.
SUMMARY OF THE INVENTION
According to the invention, this problem is solved by a method wherein the catalyst base, which comprises at least one contact area of a porous material, is treated by introducing at least one catalytically relevant substance into pores of the catalyst base (which lead into the contact area) by use of a transport fluid, wherein the catalytically relevant substance remains on pore wall areas after removal of the transport fluid. A catalytically relevant substance is a substance that is catalytically active or that can form a catalytically active substance, e.g. by temperature treatment (calcining). The transport fluid may be a fluid or gas or any mixture, e.g. an aerosol or foam. The catalytically relevant substance may be dissolved in the fluid or distributed as superfine particles, e.g. a component of aerosol droplets. According to the invention, the catalytically relevant substance is introduced into the pores in a way that—at least in a plurality of the pores—the catalytically relevant substance's surface amount (i.e. the amount relative to the surface) that remains on the pore wall areas depends on the place within each pore in such a way that the surface amount of the catalytically relevant substance decreases within the pore beyond a certain pore depth, i.e. if a certain pore depth is exceeded.
The invention is based on the knowledge that most of the desired catalytic reactions take place in the pores' regions close to the contact area and that there—due to competition—the undesired reactions are suppressed, whereas the undesired reactions prevail in the deeper pore regions; therefore the catalytically active centers should be reduced there.
Accordingly, the catalytically relevant substance is unequally introduced into the pore system of the catalyst base. The catalytically relevant substance does not cover the whole pore system uniformly (as suggested by the state of the art). The introduced substance amount that covers the pore wall areas (pore surfaces), i.e. the transport fluid amount that fills the pore spaces, depends on the location/position of the place of the respective pore wall areas or pore spaces within the pore. A different amount of the catalytically relevant substance remains, depending on the pore depth of the respective pore wall area, i.e. depending on the distance the flue gas components must travel from the pore's opening to the place of the pore wall area. Pore depth is understood as the distance from the opening through the pore to a place in the pore. The maximum distance is the complete extension of the pore into the material, i.e. the total pore depth. According to the invention, the surface amount of the catalytically relevant substance decreases after exceeding a specific pore depth. The “specific pore depth” could be the same for all pores leading into the contact area irrespective of the diameter and the form of the pore. However, it is preferred that the specific pore depth, beyond which the amount of the catalytically relevant substance decreases (in proportion to the covered area), depends on the form of the pore, e.g. that it is greater for a pore having a greater diameter than for a narrow pore. It is preferred that the specific pore depth corresponds to an entering depth that is reached by a given fluid in a predetermined time. The decrease of the coverage beyond the specific pore depth may be a sudden or continuous decrease. The statement that the wall coverage decreases after reaching a specific pore depth does not exclude that there may be a minor decrease in wall coverage even before reaching the specific pore depth; before reaching the specific pore depth, the wall coverage may increase, remain constant, decrease to a minor degree and/or vary. This is supposed to mean that there is a qualitative jump (step) in the degree and/or kind of decrease after reaching the specific pore depth; the decrease increases either suddenly or continuously. When the pore walls are covered by the catalytically relevant substance in such a way it is ensured that the competing reactions that occur in the deeper pore regions are less supported. By contrast, according to the treatment methods known from the state of the art, the surface coverage often increases with increasing pore depth, since the pore system is flooded with a transport fluid and subsequently the catalyst base is dried. Usually, the substance carried in the transport fluid concentrates in the rear pore spaces (which is not desired.)
According to the invention, a great amount of the transport fluid with the substance enters regions having a low pore depth (pore regions close to the contact area). Less substance is introduced into pore regions that can only be reached by the flue gas stream if it covers a greater distance (greater pore depth).
The method of the invention provides an activated catalyst base, which has a lot of active centers in the pore regions that can easily be reached by the flue gas stream together with further substances (e.g. ammonia) and which has less active centers in the regions, where undesired side reactions are more likely to occur. In this respect, the outer design of the catalyst base is of no importance. For instance, the method can be equally used for honeycomb or plate catalysts.
Any fluid that can carry a catalytically relevant substance (e.g. by dissolving the substance) may be used as transport fluid. In particular gases, liquids or aerosols may be used as transport fluids. A catalytically relevant substance is understood to be any substance that has a catalytic effect or that can be transformed to a catalytically effective compound during or after application to the base material (e.g. by subsequent physical and/or chemical treatment).
Catalysts that have been activated according to the method of the invention produce less undesired side reaction products, like e.g. sulfur trioxide, at a similar performance level (activity). Accordingly, the impairment of subsequent components of the installation caused by side reaction products (sulfur trioxide leads e.g. to corrosion) is reduced, and their life time and the operational safety of the whole installation are increased. Costs for additional maintenance, repairs and loss of production are avoided and the risk of malfunctioning is reduced. Visible exhaust gas plumes are reduced. An otherwise necessary sulfur trioxide elimination may not be necessary anymore.
According to the preferred embodiment of the method of the invention, the introduction is carried out in a way that at least in a plurality of the pores, the catalytically relevant substance's surface amount remaining on the pore wall areas within each pore depends on the pore depth in a way that the surface amount increases, remains essentially constant or at most decreases only to a minor degree up to the specific pore depth and suddenly starts decreasing after exceeding the specific pore depth or that the increase of the surface amount suddenly starts decreasing after exceeding the specific pore depth.
In proximity to the pore's opening to the contact area, i.e. in the region of a low pore depth, the pore wall coverage does not decrease substantially, wherein the coverage in this region may decrease or increase in dependence on the used method. Beyond a pore depth t i , the surface coverage (i.e. the amount of coverage relative to the surface) substantially decreases in the direction of an increasing pore depth so that regions of a pore depth>t i are covered to a lesser degree. The transition may be sudden over a short distance in the sense that the coverage decreases over a short distance to a substantially lower coverage. But it is also possible that the coverage decreases uniformly (e.g. linearly, quadratically or exponentially) beyond a pore depth>t i . The expression that is used herein that the amount or its increase should “suddenly start decreasing” should be understood as a change of the functional dependence of the area coverage on the pore depth, wherein a very steep decrease takes place in the function or one of its derivatives and wherein the function—not taking into account any superimposed fluctuations—continuously decreases.
The catalytically relevant substance may be introduced into the pores of the contact area of the catalyst base in different ways to ensure that the substance is introduced in dependence on the pore depth. According to the invention, some introduction methods make use of the natural thermodynamic processes. (During the treatment) the transport fluid with the catalytically relevant substance usually needs more time to enter the pore regions that are also more slowly entered by flue gas components during operation (great pore depth). In any case this is true for all substances that are introduced (diffused) into the pores, using the thermodynamic behavior.
On the other hand, more time or energy is necessary to remove substances from pore regions in greater pore depths. Accordingly, the substances are removed from the pore system in dependence on the pore depth during the process of removing substances from the catalyst base (e.g. by vaporization or washing out), namely the substances are more thoroughly removed from the regions of a lower pore depth than from the regions of a greater pore depth.
However, in respect of a catalytically relevant substance or transport fluid in which a catalytically relevant substance is dissolved, this causes a situation or coverage of the pore system that is contrary to the desired situation (more substance in regions close to the contact area).
According to an embodiment of the invention's method, it is therefore preferred that firstly a blocking fluid is introduced into the pores in such a way that the pores in regions remote from the contact area beyond the specific pore depth are filled with the blocking fluid.
Subsequently, the transport fluid is introduced into the pores of the material, wherein the transport fluid contains the catalytically relevant substance. At least part of the blocking fluid and the transport fluid is removed from the pores so that at least a part of the catalytically relevant substance remains on the pore wall areas.
The accessible pores are partially filled after introducing the blocking fluid so that deeper pore regions are blocked by the blocking fluid when the transport fluid is introduced. Accordingly, when the transport fluid is subsequently introduced, in particular the pore regions (close to the surface) that have a smaller distance to the contact area of the catalyst base are filled. The catalytically relevant substance is dissolved in the transport fluid (or it is transported in any other way by the fluid).
Ideally, all accessible pores are completely filled with the blocking and transport fluids after introducing the first and second fluids. Since the catalytically relevant substance is transported in the transport fluid. only the pore wall areas (close to the surface) that are adjacent to the transport fluid come into contact with the catalytically relevant substance. Although the catalytically relevant substance may diffuse into the blocking fluid at the phase boundary between the blocking fluid and the transport fluid, such a diffusion (in view of the usual residence time of the fluids in the pores) does not change the fact that the amount of the introduced catalytically relevant substance is by far greater in regions of a low pore depth than in regions of a greater pore depth.
After removal of the blocking fluid and the transport fluid from the pores, catalytically relevant substance remains in the pores.
According to the above-described method, the blocking fluid is preferably introduced into a plurality of the pores in such a way that the plurality of the pores are filled at least partially with the first fluid in a first filling step and subsequently the introduced blocking fluid is partially removed from the pores in a removing step.
In practice, introducing the blocking fluid in a filling step and a subsequent removing step is in particular convenient, since such a method makes use of the natural characteristics of the pore system and the thermodynamic processes in the catalyst base. In particular, a fluid can be introduced into a pore system by common methods in a way that it is filled in the best possible way. On the other hand, removing the fluid from the regions of a low pore depth is simpler than from the regions that are located closer to the inside.
In the filling step, the accessible pore system is first nearly completely filled and then, in the removing step, the blocking fluid is removed from the regions of the pores that are located in a low pore depth. This ensures that most of the fluid remains in the regions located deeper in the inside so that the required distribution of the blocking fluid is certain to block those regions to the transport fluid.
According to the method described above it is in particular advantageous, if the catalyst base is soaked in the blocking fluid during the filling step.
Soaking the catalyst base in the blocking fluid ensures an equal distribution of the fluid in the pore system, in particular, if known supporting means (e.g. ultrasonic sound, heating) are used. Such soaking is used e.g. in known and indiscriminate methods for reactivating cleaned catalyst bases; there is sufficient corresponding experience. However, those known methods have the indicated disadvantages of an equal (indiscriminate) distribution of the catalytically relevant substance. According to the invention's method, only the blocking fluid is equally distributed. The desired unequal distribution of the blocking fluid and, indirectly, the distribution of the catalytically relevant substance are not achieved by the filling step, but the removing step (partial removal of the blocking fluid). It is preferred to partially remove the blocking fluid from the pore system of the catalyst base by drying.
If e.g. the catalyst base material is soaked in the blocking fluid and if the accessible pore system is nearly completely filled with the blocking fluid, then it is a matter of course that a subsequent drying step removes fluid first from the pore system's regions that are close to the contact area. This ensures that the blocking fluid is distributed as required by the invention. It is advantageous and economical to carry out drying—at least part of the time—under low pressure so that the drying step is carried out economically and fast.
Any substance that can be transported by the transport fluid may be used as a catalytically relevant substance. However, it is in particular advantageous, if the transport fluid contains at least one metal compound as catalytically relevant substance. All substances may be used, if they may be transformed into catalytically active substances, in particular e.g. tungsten oxide, vanadium pentoxide or molybdenum, copper and iron oxides. In the fluid, those substances are usually present in the form of ions.
According to the above-described method—if the transport fluid and the blocking fluid are miscible liquids—it is in particular advantageous if the blocking fluid contains catalytically neutral ions. The catalytically neutral ions in the blocking fluid slow down the diffusion of the catalytically relevant substance, which is introduced with the transport fluid and which partially diffuses into blocking fluid regions at the phase boundaries between the blocking fluid and transport fluid. It is in particular advantageous if the blocking fluid contains such catalytically neutral ions that can react in a neutralizing way with the catalytically relevant substance. The ions react with each other at the boundary areas between the fluids, preventing the catalytically relevant/active substance from entering deeper into the pore regions filled with the blocking fluid. In those regions, the substance is at least no longer present in a catalytically effective form. Another possibility of reducing the mixing of the transport fluid and the blocking fluid is to lower the temperature.
Gases and liquids may both be used as blocking and transport fluids, wherein in practice most often use is made of substances that are in liquid form under the conditions under which the invention's method is carried out.
It is preferred to choose blocking and transport fluids that do not mix with each other or that mix with each other only to a minor degree. This significantly reduces the mixing of the two fluids and the diffusion of the catalytically relevant substance from the transport fluid into the blocking fluid regions.
Another possibility to introduce the catalytically relevant substance mostly into the pore system's regions that are close to the contact area is first to cool the catalyst base and then soak it with a fluid, wherein the fluid contains at least one dissolved catalytically relevant substance. Since a heat exchange takes place between the catalyst base and the fluid when the fluid enters the pore system, the fluid is cooled the deeper it enters into the pore system. The fluid regions close to the contact area, i.e. the regions of a low pore depth, are warmer than those that are deeper inside the material. By cooling the catalyst base it can be achieved—if there is sufficient heat exchange between the fluid and the catalyst base—that the fluid solidifies (or freezes) so that it will not enter deeper pore regions; accordingly, distributing the catalytically relevant substance is limited to the regions that are close to the contact area.
On the other hand, at a lower fluid temperature, the solubility of the catalytically relevant substance in the cooled fluid can be reduced. Accordingly, before the fluid enters regions that are more remote from the contact area, a part of the substance precipitates out of the fluid on the pore wall. Preferably, the catalytically relevant substance is dissolved in the fluid at a concentration that is close to the saturation limit.
In this case, it is in particular effective to carry out the above-mentioned cooling. since reducing the temperature results in higher precipitation.
Another possibility to introduce the catalytically relevant substance into the pore system comprises the steps of soaking the catalyst base for a first predetermined period of time in transport fluid. wherein the first period of time is selected in a way that the transport fluid essentially reaches the specific pore depth. Subsequently, the transport fluid is removed from the catalyst base in a way that the catalytically relevant substance, which is transported in the transport fluid, remains in the pores.
As already described, the regions of a lower pore depth are to be filled faster with the fluid than the pore spaces that are deeper inside. It takes more time for the fluid to enter the regions of a greater pore depth. This time dependence of the distribution can be used according to the invention. If the supply of the transport fluid to the catalyst base is interrupted at the right time, then the fluid with the catalytically relevant substance has entered only the pore regions that are close to the contact area, but not the pore system's spaces that lie more on the inside. When the catalyst base is dried immediately thereafter, then the fluid can be removed from the pores before it can enter any deeper. The catalytically relevant substance settles on the pore wall areas and there it forms catalytically active centers or the substance combines with the pore wall areas forming catalytic centers.
According to the latter method, it is preferred that the fluid is chosen to have a higher viscosity than water. The viscosity of the transport fluid may be adjusted using known methods, e.g. by adding cellulose. If viscosity is increased, then the fluid enters the pore system at a lower velocity so that observing the first period of time is not that critical or the catalyst base may be longer soaked in the fluid without the fluid filling the complete pore system.
Another possibility to introduce the catalytically relevant substance into the pore system includes the steps of immersing the catalyst base into a transport fluid immersion bath until the catalyst base is soaked, and adding the catalytically relevant substance to the fluid immersion bath, wherein the substance is dissolved in the fluid. The catalyst base remains in the immersion bath for a predetermined period of time so that the substance diffuses into pore regions that are close to the surface. Subsequently, the catalyst base is dried, i.e, the transport fluid is removed.
The described method makes use of the natural process of diffusion of the substance in a fluid. The catalytically relevant substance is added to the fluid, when the catalyst base is already in the fluid and soaked with it. Accordingly, the pore system already contains the transport fluid, but initially without the catalytically relevant substance. When, subsequently, the catalytically relevant substance is dissolved in the fluid, the substance enters the pore system by diffusion processes, wherein diffusion starts at the contact area, i.e. at the point of entry into the pore system. According to the invention, the distribution in the pore system takes place unequally (higher diffusion of catalytically relevant substance into the pore system's regions that are close to the contact area). In addition, the diffusion processes may be accelerated by mechanical support or heating the fluid so that convection processes may also be used to transport the substance. The period of time is selected in a way that the catalytically relevant substance has already entered the pore system's regions of a lower pore depth, but has almost not entered the more inner regions of the pore system having a greater pore depth. After the period of time has expired the catalyst base is taken out of the fluid and dried.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be explained in more detail on the basis of the enclosed drawings showing steps of a preferred embodiment of the method.
The drawings show the following:
FIG. 1 : schematic representation of an arrangement of a plurality of channel catalyst base elements in a frame.
FIG. 2 : schematic perspective representation of the arrangement of the channel catalyst base elements according to FIG. 1 .
FIG. 3 : schematic representation of a boundary area between a catalyst base and a flue gas stream.
FIG. 4 : the boundary area of FIG. 3 when a first filling step according to an embodiment of the invention is carried out.
FIG. 5 : the boundary area of FIG. 4 , after a first removing step according to an embodiment of the invention has been carried out.
FIG. 6 : the boundary area of FIG. 5 , when a second filling step according to an embodiment of the invention is carried out.
FIG. 7 : the boundary area of FIG. 6 , after a second removing step according to an embodiment of the invention has been carried out.
DETAILED DESCRIPTION OF INVENTION
According to the represented embodiment, catalyst bases are used, wherein the catalyst bases have a honeycomb structure with rectangular honeycombs. Reference number 1 in FIG. 1 designates such a catalyst base element. Catalyst base 1 has a surrounding wall 2 forming a quadratic boundary. Between opposing, parallel wall portions, partition walls 3 having a vertical direction and partition walls 4 having a horizontal direction are located, the walls dividing up the space within the surrounding wall 2 to form equally formed honeycombs. Flue gases can stream through the plurality of the honeycombs formed by walls 3 and 4 (perpendicular to the plane of the sheet). For instance, walls 3 and 4 form the boundary of a flue gas channel 6 having a honeycomb form. The catalyst base material that forms walls 3 and 4 as well as the thicker, surrounding wall 2 consists of a porous ceramic so that walls 3 and 4 have significantly increased surfaces.
In a metal frame 5 , a plurality of such catalyst bases 1 are arranged side by side and on top of each other to form a greater cross section for the flue gas to stream through.
FIG. 2 shows the arrangement of the catalyst bases of FIG. 1 in perspective representation. In frame 5 , base elements 1 are arranged horizontally and vertically side by side. The porous material of the catalyst bases comprises active centers accelerating reactions of substances carried by the flue gas stream. Due to the honeycomb structure and a plurality of base elements being connected in series, an intensive contact between the active centers and the flue gas is ensured.
The following figures show a wall area section of the catalyst base.
FIG. 3 shows a schematic and enlarged cross section through a region close to the surface of wall 3 of catalyst base 1 . Contact area 11 forms a boundary area between the material of the catalyst base, i.e. wall 3 , and flue gas channel 6 . In flue gas channel 6 , flue gas 12 streams through the streaming region of the open honeycomb space.
In the material of wall 3 , there are a plurality of pores 15 , 16 , 17 , 18 , and 19 . Pores 15 , 16 , 17 , and 19 are connected to stream channel 6 through openings in contact area 11 . Pore 18 has the form of a bubble and is not connected to flue gas channel 6 .
The flue gas streams from flue gas channel 6 through the openings of the pores in contact area 11 into accessible pores 15 , 16 , 17 , and 19 , while flue gas that is present in there streams out again. The more the distance from an opening in the contact area is covered by the flue gas within a pore and the deeper the flue gas enters into the pore system in the inside of the material, the longer is the flue gas' residence time in the pore system. The undesired side reactions take place mostly in the regions having a greater distance from contact area 11 .
The boundary areas between the pore spaces and the material of the catalyst base are pore wall areas 15 a , 16 a , 17 a , 18 a , and 19 a . The pore wall areas are to be covered with active centers, where the pollutants carried in the flue gas stream, in particular nitrogen oxides, are reduced with ammonia added to the flue gas stream. In pores 15 and 17 , whose pore spaces do not extend deeply from the contact area into the inside of the catalyst base material, such a reaction is favored. Pores 16 and 19 , however, have a larger pore wall area, and they extend more into the catalyst base material with increasing pore depth, and they have a complex structure. Accordingly, the flue gas must cover a longer diffusion way from the openings in the contact area to the spaces that are located deeper in the material.
FIGS. 4 , 5 , 6 , and 7 schematically show the pore system of FIG. 3 during or after carrying out the invention's method for treating a catalyst base.
FIG. 4 shows wall 3 of the catalyst base, when it is immersed in a first fluid 20 . Contact area 11 is covered with fluid 20 and accessible pores 15 , 16 , 17 , and 19 are completely filled with the fluid. Filling the pores with the fluid can be achieved by supporting the soaking/immersing process by ultrasonic sound and rotating/shaking the catalyst base. Bubble-like pore 18 is not filled with fluid 20 , since the pore is not connected to stream channel 6 .
In the simplest case, water is used as fluid 20 , wherein the water does not contain any catalytically relevant substances. After soaking the catalyst base, it is taken out of the water, drained, and—in a drying step—fluid 20 is partially removed from the pore system. In order to accelerate the process, the drying step may be carried out under increased temperature or low pressure.
FIG. 5 shows the surface section of FIG. 4 after the drying step.
Pores 16 , 17 , and 19 are still partially filled with the residue of the fluid 21 , 22 , and 23 , since—according to the invention—the drying step is stopped before the fluid has been completely removed from the pores. For thermodynamic reasons, fluid 20 remains in particular in pore regions that are more remote from the outer openings in contact area 11 , i.e. that are located in a greater pore depth. In those regions, the effect of the drying process is smaller. In addition, the residue of the fluid can only be removed from those regions, after the fluid closer to the pore opening has been removed through the pore opening in contact area 11 .
In another filling step, the catalyst base is soaked with a second fluid 30 (e.g. by immersion). FIG. 6 shows the surface section of FIG. 5 after the second filling step.
The catalytically relevant substance is dissolved in second fluid 30 . As fluid 20 before, fluid 30 also enters the pore system, but it enters only the accessible regions, which are not blocked by first fluid 20 . Accordingly, second fluid 30 (with catalytically relevant substance) is contained in particular in the regions that are easily accessible by the flue gas during operation, whereas the deeper branches and pore spaces contain fluid 20 (without catalytically relevant substance). Accordingly, the pore wall areas that are in contact with fluid 30 also have contact with the catalytically relevant substance. The pore wall areas that are in contact with fluid 20 , however, do not have any contact to the catalytically relevant substance.
In a final drying step both, fluid 20 and fluid 30 are removed from the pore system, e.g. by heating the catalyst base under low pressure. FIG. 7 shows the surface section of FIG. 6 after the final drying step.
The catalytically relevant substance remains partially on the pore wall areas with which it has been in contact. Contact area 11 as well as portions of pore wall areas 15 a , 16 a , 17 a , and 19 a are covered with catalytically active centers 40 . Those regions of pores 16 , 17 , and 19 that have a greater distance to contact area 11 and which are therefore not easily accessed by the flue gas during the catalytic operation of the catalyst base do not contain any (or almost no) catalytically active centers. On the other hand, the pore regions that have a short distance to the contact area are densely covered with active centers. Accordingly, the distribution of the active centers after having carried out the method according to the invention is not uniform as it is when the material is soaked in a fluid with a catalytically relevant substance according to the state of the art. Rather, the treatment or doping differs in a way that different regions of the pore wall areas comprise a different amount of active centers depending on the pore depth or the accessibility to the flue gas.
If water or a watery solution is used as transport fluid, the catalytically relevant substance may be a water soluble metal compound that may be transformed to a catalytically active substance after drying and a tempering step. For example, ammonia metavanadate or vanadyloxalate (or the salt of another organic acid) may be used to form vanadium pentoxide. Preferred is the use of soluble substances that, under heat treatment, form volatile compounds (ammonia, water, CO 2 ) and the desired metal oxides (V 2 O 5 , for instance).
A lot of modifications are possible within the limits of the invention. Some of the possibilities for carrying out the method according to the invention have been described, but there are other ways to carry out the method within the limits of the invention.
The specification incorporates by reference the disclosure of European priority document 05 027 634.4 filed Dec. 16, 2005.
The present invention is, of course, in no way restricted to the specific disclosure of the specification and drawings, but also encompasses any modifications within the scope of the appended claims.
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A method for treating a catalyst base that comprises a contact area of porous material. A fluid, such as a flue gas stream, can be conducted along the contact area. A catalytically relevant substance is introduced into pores of the catalyst base using a transport fluid and remains on pore wall areas after removal of the transport fluid. The introduction is carried out such that an amount of the catalytically relevant substance relative to the surface remains on the pore wall areas as a function of location within the pore and decreases within the pore after exceeding a specific pore depth. A blocking fluid can first be introduced into pore regions beyond the specific pore depth, thus blocking these regions when transport fluid containing the catalytically relevant substance is introduced.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to methods for medical diagnosis and treatment, and more particularly to methods for diagnosis and treatment of specific psychiatric, neurological and neuroendocrine conditions using a Focused Ultrasonic Pulse (FUP) delivered to different points of neuronal circuits within the brain using existing focused ultrasound devices. The treatment is performed under the guidance of the existing brain-imaging devices, such as functional magnetic resonance imaging (fMRI).
[0003] 2. Brief Description of the Prior Art
[0004] With advances in brain imaging techniques, the pathophysiology of psychiatric and medical disorders began to be more and more related to the specific neuronal circuits. Neuronal circuits are specific brain centers functionally and anatomically connected with each other. Usually a circuit involves sub-cortical neuronal centers connected with cortex. It is not totally clear how the circuits operate. However, it is clear that they play a major role in multiple psychiatric, neurological and medical conditions. For example, Obsessive Compulsive Disorder (OCD) and OCD Spectrum Disorders including Impulse Control Disorders appear to be related to abnormality in Orbito-Fronto-Talamic-Striatum circuit. Panic Disorder, Social Anxiety Disorder and panic spectrum disorders seem to be associated with the abnormal functioning of circuit involving Orbital-Frontal cortex, Amygdala, Cingulum and Hippocampus. Post-Traumatic Stress Disorders seem to associate with Prefrontal Cortex, Amydgala and Hippocampus abnormalities. Psychotic disorders seem to have an association with Prefrontal Cortex-Talamic-Striatum and Occipital Cortex Circuits. Circuits involved in neurological conditions have also been identified. For example, Parkinsonian Disease, Huntington Chorea, La Touretts and tick syndromes seem to have abnormalities in Cortico-Talamic-Straitum Circuit. Chronic pain has association with cortico-thalamic circuits. Insomnia has association with temporal cortex-lymbic-cingulum circuit. Medical conditions seem to have connection with specific neurocircuitry. For example, obesity and stress are associated with temporal-hypothalamic circuit. For a simple review and description of the above circuits, see Clark, D. L. and Boutros, N. N., Brain and Behavior (1999) and Rauch, S. L. et al., “Clinical Neuroimaging in Psychiatry” in Harvard Review of Psychiatry (1995), Vol. 2, no. 6, pp. 297-312.
[0005] Neuroimaging techniques exist that permit assessment of rapid changes in activity of the brain. Functional Nuclear Magnetic Resonance (fMRI), Vector Electroencephalagraphy (V-EEG) and Positron Emission Tomography (PET) are the most promising. These techniques, specifically fMRI, are capable of producing real time 3-dimensional maps of brain activity. These techniques merit scientists to study the neuronal circuits involved in pathology of different psychiatric or neurological conditions. However, the study process has been slowed by the absence of reliable activation of these circuits.
[0006] Recently, a few novel methods of the treatment of mental and neurological disorders directed at neuronal circuits have been introduced. These include deep brain stimulation by implanted electrodes, successfully used in OCD, Parkinson's disease and epilepsy, and brain surgery used in the treatment of OCD and depression. See New England Journal of Medicine (Sep. 27, 2001), pp. 656-63; R. M. Roth, et al., Current Psychiatry Report (October 2001), Vol. 3, no. 5, pp. 366-72. Because of the invasiveness and possible complications, these methods are reserved for the treatment resistant conditions where other treatments fail. However, the success of these treatments underlines the importance of specific neurocircuits in the pathophysiology of mental and neurological disorders. Furthermore, it underlines the importance of developing noninvasive methods of intervention at the neuronal circuit level. In addition, the studies using deep brain stimulation techniques determined that low frequency (2-150 Hz) signals inhibit the neuronal tissue and that high frequency (1-3 MHz) signals stimulate neuronal circuits.
[0007] Recently it has been proposed that neuronal circuits can be assessed and modified non-invasively using Transcranial Magnetic Stimulation (TMS). The signal from the brain after the TMS stimulation can be read using MRI. That method has been described in U.S. Pat. No. 6,198,956, incorporated herein by reference, which described using the method for therapeutic purposes. The method and device proposed by that patent are currently being implemented in psychiatry and neurology for diagnostic and therapeutic purposes. See M. S. George, et al., Journal of Neurophsychiatry and Clinical Neuroscience (Fall 1996), Vol. 8, no. 4, pp. 373-382. The method, however, has several problems. For example, TMS does not stimulate deep brain centers, because it is incapable of penetrating brain tissue deeper than 1-2 cm. Also, TMS has a large area of focus, 1 cubic cm or more, which does not permit focused activation of a specific neuronal circuit. Also, there is a problem in using TMS together with fMRI, because TMS produces a magnetic signal that interferes with the magnetic field and consequently with the fMRI image.
[0008] Focused ultrasound has been used to stimulate tissue, including neuronal tissue. This has been done by a combined application of a magnetic field and an ultrasonic field to neuronal and other tissue in the body. The prior art proposes that stimulation of the neurons will come from the interaction of the two fields. For example, U.S. Pat. No. 4,343,301 describes generating high energy by intersecting two ultrasound beams within any single fixed point of the body, including the skull. While it is not proven that such an application of ultrasound would do anything except heat or destroy tissue, there is recent evidence that application of focused ultrasound to brain slices, subjected to simultaneous electrical stimulation, can change the electrical currents in the slices. However, because two ultrasound beams cannot be focused within the skull, because of the complexity of bone density and bone structure, it is not possible to focus such a two-beam device in the brain tissue.
[0009] Some companies have produced ultrasonic devices that use multiple beams. See G. T. Clement, et al., Physics in Medicine and Biology (December 2000), Vol. 45, no. 12, pp. 3707-3719. By coordinating the amplitude and the phase of the ultrasound beams generated by multiple sources via computer multi-beam devices, algorithms can be developed to adjust the bone dispersion of the beam and focus the ultrasound within the brain tissue. These devices are to be used as ultrasonic knives within the brain for the destruction of tumors, for example. However, they cannot be used to modify the electrical and electromagnetic currents within the brain circuits without harming the surrounding tissue.
SUMMARY OF THE INVENTION
[0010] It is an object of the invention to provide methods for the stimulating neurons within the brain of a mammal, preferably of a human, by modifying electrical currents in a live neuronal circuit. The modification is accomplished by applying a focused ultrasound pulse (FUP) under the guidance of a brain-imaging system such as a functional magnetic resonance imaging (fMRI) system, a video-electroencephalograph (V-EEG), or a positron emission tomograph (PET), preferably fMRI. The application of FUP is generally via multiple ultrasound transducers that are housed in a cap worn by a patient. It is simultaneous with the use of the brain-imaging system. The application of different frequencies and phases of FUP to the brain circuits will generate a signal that will be captured by fMRI. At that time, changes in circuits will be assessed. This will permit adjustment of the focus of the FUP and of the location of the FUP, or the use of multiple focuses, to achieve the maximum modification of the circuit. The changes in the circuit are useful for research, diagnosis and treatment.
[0011] It is a further object of the methods to diagnose and treat specific psychiatric, neurological, and neuroendocrine conditions. Examples of such conditions include, but are not limited to, Obsessive Compulsive Disorder and its spectrum, Post Traumatic Stress Disorder, Depression, Bipolar Disorder, Social Anxiety Disorder, Psychotic Disorders, Panic Disorder, Ticks, Chronic Pain Syndrome, Insomnia, Chronic Fatigue Syndrome, Insomnia, Stress and Obesity, and other conditions apparent to one of ordinary skill in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] A detailed description of embodiments of the invention will be made with reference to the accompanying drawings, wherein numerals designate corresponding parts in the several figures.
[0013] [0013]FIG. 1 illustrates an FUP device according to one embodiment of the invention. Show is a modified multi-transducer cap, capable of focusing ultrasound in the skull and delivering the FUP signal to a specific target in the brain.
[0014] [0014]FIG. 2 illustrates how the cap of FIG. 1 can be placed on the head of a human subject.
[0015] [0015]FIG. 3 illustrates a system in accordance with the present invention in which the FUP device is being used in conjunction with the brain imaging system, here shown as fMRI.
[0016] [0016]FIG. 4 illustrates a perspective of the right side of the system shown in FIG. 3, looking down on the head of the human subject.
DETAILED DESCRIPTION
[0017] [0017]FIG. 1 illustrates a preferred embodiment of a focused ultrasound pulse (FUP) device. A cap 1 houses multiple ultrasound transducers 2 , preferably 300-1000 transducers. The FUP device is preferably a multi-beam ultrasonic device, which is coordinated via computer with conventional brain-imaging system, such as a focused magnetic resonance imaging (fMRI) system, a video-electroencephalograph (V-EEG) or a positron emission tomograph (PET), preferably an fMRI system. An example of a preferable multi-beam ultrasonic devices is an ultrasound knife. The transducers are regulated via a computer capable of focusing the ultrasound waves into a specific point 3 . The cap and transducers are preferably made from a non-ferromagnetic material, a material that has a very low permeability and residual magnetism and hysterisis, such as copper. The use of a non-ferromagnetic material reduces fMRI field distortion and thereby reduces distortion of the image, permitting the application of FUP concurrently with the use of fMRI. By concurrent, it is meant that one applies an FUP within 1 millisecond to 10 seconds before or after using the fMRI system to image the brain.
[0018] [0018]FIG. 2 illustrates how the cap can be placed on the head of a human subject. A computer, which is coupled to the FUP device, controls the parameters of the FUP, including focus, frequency, phase and amplitude. Through user interaction with the computer, the FUP device is capable of producing a focused ultrasound pulse in a specific point within the brain. The FUP's focus is preferably 2 or more centimeters deep and 0.5-1000 mm in diameter, and more preferably 2-12 cm deep and 0.5-2 mm in diameter. The specific point is determined by a conventional brain-imaging system, preferably an fMRI system, which provides information about brain form and density. FUP software is preferably coordinated with fMRI software for precise positioning and coordination of the focused signal. The changes in activity within the neuronal circuits are determined by monitoring the changes in the brain image produced by the fMRI before the application of FUP and during and after the application of FUP. These changes are used to determine exactly where the FUP focus was in the brain and the functional connectivity between the focus and surrounding brain centers. The specific point may be confirmed using the addition of a computed tomography (CT) scan, which provides information about bone density and structure of the skull and brain. The focus of the FUP may then be modified to direct it into a different point of the brain.
[0019] A single FUP may be applied to a single live neuronal circuit. Muliple FUPs may be applied to the same live neuronal circuit. Additionally, a single FUP may be applied to multiple live neuronal circuits, and multiple FUPs may be applied to multiple live neuronal circuits.
[0020] FUP given in different frequency, phase and amplitude will produce different effects on neuronal circuits and centers. Low frequencies, below 300 Hz, will decrease the firing of the centers and inhibit or disrupt the neuronal circuits. High frequencies, 500 Hz to 5 MHz, will produce activation of firing of neuronal centers and activation of the circuits. In either case, the FUP will modify physiological properties in the circuits. This will happen both when the FUP is applied to the centers and when the FUP is applied to the white matter.
[0021] Repeated application of the FUP to neuronal circuits will cause long-term or permanent changes to the circuits. The modification of the circuits using FUP will be used for the treatment of psychiatric, neurological and neuroendocrine disorders. Exampes of such diseases include, but are not limited to, Obsessive Compulsive Disorder (and its spectrum), Post Traumatic Stress Disorder, Depression, Bipolar Disorder, Social Anxiety Disorder, Psychotic Disorders, Panic Disorder, Ticks, Chronic Pain Syndrome, Insomnia, Chronic Fatigue Syndrome, Insomnia, Stress, Obesity, and other conditions apparent to one of ordinary skill in the art. This will be done by repeated assessment and modification of changes in neuronal flow or field activity under the guidance of specific brain imaging techniques, such as fMRI, V-EEG, or PET.
[0022] [0022]FIG. 3 illustrates the FUP being used in conjunction with a fMRI system. The fMRI system is preferably a typical GE build cylindrical magnet 4 . The patient 5 preferably lies on a sliding platform 6 inside of the magnetic cavity 7 . The imaging coil 8 , which has been placed over the head of the patient, detects the magnetic resonance field generated by rotation of the magnet 4 . The field signals detected by the imaging coil are preferably transmitted to the processing electronics outside the magnet. As a result of the fMRI system's computer analysis, a functional image of the brain is generated.
[0023] [0023]FIG. 4 illustrates a cross-sectional view of FIG. 3, from a perspective looking down on the head of the patient. The cap 1 containing the FUP transducers 2 is preferably on the head of the patient. The imaging coil 8 is preferably placed above the FUP cap. A cable 9 connects the FUP cap with the transducers to the computer, which is kept outside of the room, controlling the FUP. The FUP device is also connected to MRI processing electronics. The FUP device generates FUP pulses that cause activation or deactivation of specific neuronal centers or circuits. The fMRI signal is modified in specific locations. This modification is captured and used to adjust the FUP transducers to achieve better focus, different position, or different influence on the neuronal circuit by modification of the frequency of the waves, frequency of the pulse, intensity of the pulse, or the phase of the waves.
[0024] The use of FUP in combination with fMRI or other imaging devices can provide a variety of diagnostic, research and therapeutic benefits. The invention can be used to create a functional map of the brain in response to modification of the neuronal circuits. It can also allow one to observe the functional connectivity within the brain of normal subjects as well as in the brain of the subjects suffering from various neurological conditions (such as the ones identified above). The invention can also be used treat these conditions, and may be used concurrently with the pharmaceutical agents commonly prescribed for them.
[0025] Development of the functional brain maps can significantly improve our understanding of the operation of the brain in normal subjects and in different diseased states. Unlike the use of transcranial magnetic stimulation (TMS), which can only read a brain tissue depth of 1-2 cm, the FUP is able to reach brain tissue much deeper, 2 or more centimeters into the brain, for example 2-12 cm. The FUP can also produce a focus of energy that will be only 0.5-2 mm. in diameter, as opposed to 2-3 cm. attainable by TMS.
[0026] The invention can be used for evaluation of the outcome of a variety of treatments. For example, the functional maps of the brain, such as those mapping functions of different areas of the brain after application of the FUP, could be constructed using fMRI before and after a particular treatment. If after the treatment the functional reactivity of a certain neuronal circuit becomes similar to that of normal controls that may be an indicator of the efficacy of a treatment. In the same way, the invention can be used to determine when the activity of the certain neuronal areas reaches a specific level. Also, the repeated application of FUP may modify the circuits in such a way that their functionality becomes the same as in normal subjects. Repeated application together with continuous fMRI monitoring may help us to determine the most efficient, reliable and fast ways to achieve the normalization of neuronal structure and neuronal circuits' function. Thus, the invention may make the FUP more efficient by determining the best phase, intensity and frequency of the pulse, as well as the best position of the focus or multiple focuses for diagnosis and treatment of the above-mentioned conditions.
[0027] The invention can be used for the development of pharmaceuticals. For example, the functional maps of the brain could be created using fMRI before, during, and after a particular pharmaceutical is administered to a patient. If, after adminstration of the pharmaceutical, the functional reactivity of a certain neuronal circuit becomes similar to that of normal controls, that may be an indicator of the efficacy of the medication.
[0028] While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention.
[0029] The presently disclosed embodiments are therefore to be considered in all respects illustrative and not restrictive, the scope of the invention being indicated by the appended claims, rather than the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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Disclosed herein are methods for stimulating neurons within the brain by modifying electrical currents in brain circuits through the simultaneous use of focused ultrasound pulse (FUP) and an existing brain-imaging system, such as a functional magnetic resonance imaging (fMRI) system. The methods are used for research, treatment and diagnosis of psychiatric, neurological, and neuroendocrine disorders whose biological mechanisms include brain circuits. The methods include the simultaneous steps of applying FUP to a live neuronal circuit within a brain and monitoring a brain image produced by a brain imaging system during the application of FUP.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a temperature detector circuit and an oscillation frequency compensation device using it, and more particularly to a MOS-transistor-based temperature detector circuit which has stable output characteristics and an oscillation frequency compensation device including such temperature detector circuit.
[0003] 2. Discussion of the Background
[0004] FIG. 1 illustrates an example of a background temperature detector circuit using a bipolar transistor with commonly connected base and collector. FIG. 2 illustrates an example of a background temperature detector circuit using a Darlington connection of bipolar transistors.
[0005] The background temperature detector circuit of FIG. 1 drives the bipolar transistor by a constant current to use a temperature dependency of forward direction voltage for temperature detection. This is of the same kind as a method of using a temperature dependency of forward direction voltage in a so-called PN junction diode. Further, a series connection of two or more of this circuit in FIG. 1 is also known.
[0006] In FIG. 2 , this circuit has a configuration of Darlington connection with two or more bipolar transistors in order to raise its output sensitivity. This circuit realizes a high sensitivity temperature sensor having two or more Darlington connections and a constant current power supply to the sensor. This kind of circuit may be formed on a one substrate by using a CMOS (complementary metal oxide semiconductor) manufacture process.
[0007] FIG. 3 illustrates an example of a background temperature detector circuit having MOS (metal oxide semiconductor) transistors with commonly connected gate and drain in a state of diode connection. The background temperature detector circuit of FIG. 3 uses a temperature dependency of a MOS-transistor threshold for temperature detection. The background temperature detection circuit drives the MOS transistors by a constant current and uses a voltage between the gate and a sauce for temperature detection.
[0008] The temperature dependency of voltage between a gate and a sauce of a MOS transistor having diode connection is known to change with values of the driving constant current. Specifically, the temperature dependency of threshold is dominantly effective in a minute current domain, resulting in a negative temperature inclination of voltage between the gate and the sauce. However, the temperature dependency of electron mobility is dominantly effective in a domain above a certain current, resulting in a positive temperature inclination of the voltage.
[0009] As illustrated in FIG. 3 , the background temperature detection circuit includes a temperature detection section 81 , a constant voltage generating section 82 , a constant current circuit 832 , and a P-type MOS transistor 831 . In the temperature detection section 81 , a MOS transistor 811 has the diode connection and is driven in a minute current domain to make the temperature dependency of threshold dominantly effective. To increase output sensitivity, the temperature detection section 81 is provided with a plurality of series-connected MOS transistors 812 1 - 812 m which have diode connection.
[0010] FIG. 4 illustrates an example of a background semiconductor integrated circuit for temperature detection. This circuit includes a circuit block 97 and a circuit block 98 . The circuit block 97 generates a reference voltage without temperature dependency. The circuit block 98 generates an output voltage which has a temperature dependency with a similar configuration to the circuit block 98 . An output Vs 1 of the circuit block 97 and an output Vs 2 of the circuit block 98 may be compared in this circuit. In the circuit block 97 , MOS transistors 912 and 914 having different thresholds form a current mirror circuit which outputs a voltage determined based on a difference between the thresholds of these MOS transistors 912 and 914 . In the circuit block 97 , a channel conductance of the MOS transistor 912 and a MOS transistor 913 is made equivalent to a channel conductance of the transistor 914 and a MOS transistor 915 . On the other hand, in the circuit block 98 , a channel conductance of MOS transistors 916 and 917 is intentionally made different from a channel conductance of MOS transistors 918 and 919 .
[0011] Since the output Vs 2 of the circuit block 98 may be a reference voltage with temperature dependency, it can be used as a temperature sensing element. This reference voltage Vs 2 is divided so that it can be detected at a predetermined temperature by using resistances 920 and 921 and an operational amplifier 99 that outputs an output voltage Vs 3 . A comparator 910 compares Vs 1 and Vs 3 to detect a predetermined temperature, and an output buffer 911 outputs a resultant signal.
SUMMARY OF THE INVENTION
[0012] A novel temperature detector circuit and a novel oscillation frequency compensation device using a MOS transistor capable of reducing manufacture variation of a mobility and realizing stable output characteristics which are not affected by temperature dependency is offered. In one example, the temperature detector circuit includes a pair of depression type transistors to output a voltage which is proportional to temperature from a connecting point of a sauce of a first transistor and a drain of a second transistor. The transistors are the same conducted type of current and are formed in different channel size, which are connected between power supplies in series, and have a configuration in which first transistor's gate and sauce are connected each other and a first transistor's drain is connected with a second power supply and second transistor's gate and drain are connected each other and a second transistor's sauce is connected with a first power supply.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] A more complete appreciation of the disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0014] FIG. 1 illustrates an example of a background temperature detector circuit using a bipolar transistor;
[0015] FIG. 2 illustrates an example of a background temperature detector circuit using bipolar transistors with a Darlington connection;
[0016] FIG. 3 illustrates an example of a conventional temperature detector circuit including a MOS transistor;
[0017] FIG. 4 illustrates an example of a background semiconductor integrated circuit for temperature detection;
[0018] FIG. 5 illustrates an example configuration of a temperature detector circuit according to an example embodiment of the present invention;
[0019] FIG. 6A illustrates an example configuration of a temperature detector circuit according to another example embodiment of the present invention;
[0020] FIG. 6B illustrates an example configuration of a temperature detector circuit including a Wilson current mirror circuit according to another example embodiment of the present invention;
[0021] FIG. 6C illustrates an example configuration of a temperature detector circuit including a cascode current mirror circuit according to another example embodiment of the present invention;
[0022] FIG. 6D illustrates an example configuration of a temperature detector circuit including a cascode current mirror circuit corresponding to a low-voltage operation according to another example embodiment of the present invention;
[0023] FIG. 7 illustrates an example configuration of a temperature detector circuit according to another example embodiment of the present invention;
[0024] FIG. 8A illustrates an example configuration of a temperature detector circuit according to another example embodiment of the present invention;
[0025] FIG. 8B illustrates an example configuration of a temperature detector circuit according to another example embodiment of the present invention; and
[0026] FIG. 9 illustrates a configuration of a clock generator or a real-time clock which includes the temperature detector circuit of FIGS. 8A and 8B .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0027] In describing preferred embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this patent specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner. Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, particularly to FIG. 5 , an illustration showing a configuration of an embodiment of the present invention as a temperature detector circuit.
[0028] FIG. 5 illustrates an example configuration of a temperature detector circuit according to an embodiment of the present invention. Depression type N channel transistors M 1 and M 2 are connected in series between the second power supply terminal Vdd and the first power supply terminal Vss. A drain of the transistor M 1 is connected to the high-voltage terminal Vdd, and a sauce of the transistor M 2 is connected to the low-voltage terminal Vss. The gate and the sauce of the transistor M 1 and the gate and the drain of the transistor M 2 have a common connection to output voltage Va. In the above-mentioned configuration, when power supply voltage is high enough, the transistor M 1 may operate in a satiety region, and the transistor M 2 may operate in a variable resistor domain.
[0029] To the voltage Va, currents I 1 and I 2 which penetrates the transistors M 1 and M 2 , respectively, are sought by the following formulas:
I 1 = 1 2 μ n C ox A 1 V t 1 2 ;
and
I 2 = μ n C ox A 2 { ( V a - V t 2 ) V a - V a 2 2 }
, where μ n is a surface mobility of electron, C ox is a gate capacity per unit area, A 1 and A 2 are channel width W/channel length L (i.e., an aspect ratio) of the transistors M 1 and M 2 , V t1 and V t2 are threshold of the transistors M 1 and M 2 . If the formula explaining the output of the temperature sensor include the mobility μ n or the gate capacity C ox , a calculated value may change with the variations of μ n or C ox , or output characteristics may be influenced by the change of the mobility μ n due to temperature change. It is desirable to eliminate these, if possible, and it is preferable to reduce influences by variations in a process.
[0030] In the above-mentioned formulas, a value calculated by multiplying by the mobility μ n , the gate capacity C ox per unit area, and the aspect ratios A 1 and A 2 of a channel is generally called a channel conductance. If the same type transistors are formed in adjacent area on a semiconductor board in same physical and electric conditions, their element values, such as the mobility μ n , the gate capacity C ox , and the threshold may be substantially equal in each transistors on the same type element values. Where I 1 =I 2 , V t2 =−651 V t1 |=V td , a next formula holds:
V a = ( 1 - A 2 2 + A 1 A 2 A 2 ) V td
, where Vtd is a threshold of a depression type transistor. A 1 and A 2 are channel width W/channel length L (i.e., an aspect ratio) of the transistors M 1 and M 2 . An inclination of the A 1 and A 2 may be controlled by adjusting the size. The temperature inclination of Va may be given by a following formula:
ⅆ V a ⅆ t = ( 1 - A 2 2 + A 1 A 2 A 2 ) ⅆ V td ⅆ t
[0031] An absolute value of output voltage Va and the conditional expression of a temperature inclination are determined only by a threshold and an aspect ratio of a channel of a depression type transistor, and may not be affected by a mobility.
[0032] It is known generally that a temperature inclination of a mobility is nonlinear, and that a temperature inclination of a threshold may be linear of about −1 to −2 mV/° C. As a realistic value, if the aspect ratio of M 1 and M 2 is 1:8, then the value of output voltage Va may be |2×V td | and a temperature inclination may be given by −2 times of the temperature inclination of a same threshold.
[0033] It is greatly effective that an output characteristic may be simply set up using the aspect ratio. For example, an output sensitivity may be secured by the Darlington connection etc. using a bipolar transistor in conventional technology, the detection means of this example embodiment simply need to change the aspect ratio of both transistors to secure the output sensitivity. Further, it is not necessary to verify a current domain where a transistor operates at this time.
[0034] Thus, in the circuit of this embodiment, since the temperature detector circuit is composed of one kind of depression type transistor, a mobility may not intervenes when determining an output voltage and output characteristics, just a threshold of the depression type transistor and an accuracy of the ratio may determine the output voltage and the output characteristics. For this reason, there are few elements changed with manufacture variation, and a stable output is obtained. It is not necessary to limit the range of the current value which penetrates the inside of a detector circuit to a specific domain, and a temperature detection means which has high design flexibility may be offered.
[0035] FIG. 6A to 6 D illustrate another example configuration of a temperature detector circuit according to an embodiment of the present invention. As for the above-mentioned embodiment, it is ideally desirable for a back gate of the transistor M 1 to be Va potential. However, in a CMOS process using P base, it generally becomes Vss potential in the example, and errors may be produced in output voltage due to a base bias effect of the transistor M 1 . In such a case, it may be a configuration that includes current which penetrates the transistor M 1 as a current mirror to the transistor M 2 .
[0036] A circuit in FIG. 6A has a configuration including a series connection of a depression type N channel transistor M 1 and a P channel transistor M 3 between power supplies, a series connection of a depression type N channel transistor M 2 and a P channel transistor between power supplies, a gate and a sauce of the transistor M 1 and a sauce of the M 2 to a low power supply terminal Vss, a sauce of the transistors M 3 and M 4 which constitute a current mirror to a high power supply terminal Vdd, a gate of the transistors M 3 and M 4 to a drain of the M 3 and M 1 , and a gate and a drain of the transistor M 2 and a drain of the transistor M 4 to an output terminal a.
[0037] In this example, using a current ratio of a current mirror enable to set up an output voltage and a temperature inclination other than a technique using an aspect ratio of a channel like the former example.
[0038] For example, if aspect ratios of the transistors M 1 and M 2 are in equal and a current ratio is 1:α, then next formula about an output voltage Va holds:
V a =(1−√{square root over (1+α)})V td
[0039] Further, a temperature inclination of Va is given by a following formula:
ⅆ V a ⅆ t = ( 1 - 1 + α ) ⅆ V td ⅆ t
[0040] An output voltage Va and output characteristics are determined only by a threshold and an aspect ratio of a channel of a depression type transistor, and may not be affected by a mobility.
[0041] According to this example, although the numbers of elements and current paths of a detection means increase in number, it may respond even if a base bias effect influences, and it enable to set up an output voltage and output characteristics using a ratio of a current mirror or an aspect ratio of a channel.
[0042] In this example, a function of the current mirror is produced by only using the transistors M 3 and M 4 . In the circuit in FIG. 6A , the voltage between sauce-drains of both transistors is not in agreement in many power-supply-voltage conditions, and there is a problem that a current ratio of the current mirror is not reproduced correctly. In this case, output voltage may separate from a theoretical formula, or may include power-supply-voltage dependability. When using this example embodiment in a wide power-supply-voltage range, it is effective to change the configuration of a current mirror into circuits in FIGS. 6B to 6 D.
[0043] FIG. 6B illustrates a configuration of a temperature detector circuit which includes a Wilson current mirror circuit. It is realizable only by adding one P channel transistor M 5 to the circuit in FIG. 6A . A threshold of the transistor M 5 may cause a little gap to remain in the voltage between sauce-drains of transistors M 3 and M 4 , a slight error may occur in output voltage, and the minimum operation voltage may rise by the threshold of the P channel transistor.
[0044] FIG. 6C illustrates a configuration of a temperature detector circuit which includes a cascode current mirror circuit. In this circuit, a P channel transistors M 6 is connected between a transistor M 3 and a high power supply terminal Vdd, and a P channel transistors M 7 is connected between a transistor M 4 and the high power supply terminal Vdd, and a common connection of a gate of M 6 and M 7 is connected with a sauce terminal of the transistor M 3 . According to this circuit, since the voltage between sauce-drains in the transistor pair of right and left of a current mirror circuit is kept in high accuracy, a current ratio may be reproduced correctly and the accuracy of output voltage may improve. However, the rise of the minimum operation voltage is the same level in FIG. 6B .
[0045] FIG. 6D illustrates a configuration of a temperature detector circuit which includes a cascode current mirror circuit corresponding to low-voltage operation. A common connection of a gate of transistors M 6 and M 7 is connected with a drain terminal of a transistor M 3 . A constant voltage generated in another circuit such as a circuit 20 shown in this FIG. 6D is input into gates of transistors M 3 and M 4 . According to this example, a current ratio may be kept in high accuracy in a wide power-supply-voltage range, and a rise of the minimum operation voltage may also be controlled.
[0046] FIG. 7 illustrates another example configuration of a temperature detector circuit according to an embodiment of the present invention. This example amplifies an output signal of the temperature detection means in former examples using an amplification circuit 31 which includes resistances R 31 and R 32 and an operation amplifier 30 so as to raise an output sensitivity to temperature. In former examples, since the temperature detection means may set up output sensitivity by using an aspect ratio of a channel, arbitrary sensitivity setup may be possible theoretically. However, a setup of an extreme aspect ratio may cause the influence of a processing accuracy in a manufacturing process to be imbalanced between transistors, and an assumed characteristic may not be acquired.
[0047] In such a case, an out output sensitivity at the rate of amplification set up by resistance may be realized by using the circuit of this example which set up the aspect ratio of a temperature detection means as a suitable value.
[0048] For example, if a large aspect ratio of the channel is taken as 1:100 in former examples in FIG. 6A to 6 D, sensitivity may increase about 9 times as converted value as a threshold, but accuracy may fall. For this reason, using the circuit in FIG. 7 , controlling the rate of amplification of the temperature detection means as twice (i.e. 1:8 as an aspect ratio), the amplification circuit 31 may amplify 4.5 times.
[0049] It may has a configuration which adopts a variable resistor or a trimming means as a part of resistance, and adjusts the rate of amplification.
[0050] Otherwise, it is also possible to change the connection place of R 32 in giving DC-offset as fixed potential other than Vss or in combining the known addition circuit.
[0051] FIG. 8A illustrates another example configuration of a temperature detector circuit according to an embodiment of the present invention. FIG. 8B also illustrates another example configuration of a temperature detector circuit as an application of the example in FIG. 8A . The example in FIG. 8A is the temperature detector circuit including the temperature detection means of former example which has output voltage Va′ and the reference voltage Vref prepared independently, comparing both outputs Va′ and Vref through an A/D converter 41 , and outputting the comparing result as digital data. In this example, the input reference voltage Vref may be, for example, voltage generated using a well-known reference voltage generating circuit, or a fixed potential provided physically. Further, when the reference voltage has a little temperature dependency, it may increase the rate of amplification of the circuit means which includes a configuration of former example in FIG. 7 according to the accuracy of the reference voltage, and errors due to the temperature dependency of the reference voltage Vref may be set as the level which does not cause a problem substantially.
[0052] For example, when using a depression type transistor which has a condition that V td =−0.3 V and the temperature dependency of a threshold is −1.2 mV/° C. setting about 4 times of output sensitivity, an output value Va′ may be about 1.2 V, and a temperature inclination may be 4.8 mV/° C.=4000 ppm/° C. in normal temperature. When comparing the reference voltage which has a range of ±100 ppm/° C. fluctuation with this, it may be a calculation which changes from normal temperature to ±40° C. with an error of 1° C.
[0053] Further, when having a configuration in FIG. 8B , a next formula holds:
V a ′ = R 31 + R 32 R 32 V a - R 31 R 32 V bias
[0054] Therefore, it may be possible to increase only a temperature inclination without changing an output value in normal temperature, for example, it may also be possible for ±80° C. change with an error of 1° C. at 8000 ppm/° C. Although Vbias in FIG. 8B may be a form of a buffer output here, it also may be given with a regulator output or a fixed power supply, and it may be used together with other addition circuits.
[0055] FIG. 9 illustrates a configuration of a clock generator or a real-time clock which includes a temperature detector circuit of a former example in FIGS. 8A and 8B . This example is a clock generator or a real-time clock equipped with a means which compensates oscillation frequency using a digital output of the temperature detector circuit in FIGS. 8A and 8B . It is known that oscillation frequency of a clock generator or a real-time clock using a piezoelectric vibrator may be fluctuated based on temperature.
[0056] As a general method of rectifying this oscillation frequency, there is a method in which oscillation capacity is changed according to acquired temperature information with a temperature detector circuit, in addition, there is another method in which time information is compensated with adjusting frequency divider. In a real-time clock, since it may be driven full-time in a equipment, it is important that it has low consumption current. The temperature detector circuit in FIGS. 8A and 8B uses MOS transistors which run in low consumption current. Thus, when using a configuration of this embodiment in a real-time clock and a clock generator equipped with a correction means for temperature, whole consumption current may be controlled in low.
[0057] Numerous additional modifications and variations are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the disclosure of this patent specification may be practiced otherwise than as specifically described herein.
[0058] This patent specification is based on Japanese patent application, No. JPAP2005-206581 filed on Jul. 15, 2005 in the Japan Patent Office, the entire contents of which are incorporated by reference herein.
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A temperature detector circuit using a MOS transistor capable of reducing manufacture variation of a mobility and realizing stable output characteristics which are not affected by temperature dependency may be offered. In one example, the temperature detector circuit includes a pair of depression type transistors to output a voltage which is proportional to temperature from a connecting point of a source of a first transistor and a drain of a second transistor. The transistors are the same conducted type of current and are formed in different channel size, which are connected between power supplies in series, and have a configuration in which first transistor's gate and source are connected each other and a first transistor's drain is connected with a second power supply and second transistor's gate and drain are connected each other and a second transistor's source is connected with a first power supply.
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BACKGROUND OF INVENTION
1. FIELD OF INVENTION: The present invention relates to acoustic well logging.
2. DESCRIPTION OF PRIOR ART: In acoustic well logging, acoustic waves are emitted from a wave transmitter or source in a well borehole into subsurface formations to obtain information about the formations. This is done by detecting the acoustic waves after their travel through the formations to a receiver/transducer spaced from the source. The manner in which the transmitted waves are modified during travel through the formation gives indications of the nature of the formation. One area of interest is detection of fractures in the formations. However, polarized acoustic shear waves or S-waves were necessary for this purpose.
It has been known to use piezoelectric crystals or magnetostrictive materials to form pressure waves in borehole fluid to form acoustic signals. A portion of the pressure wave energy was then coupled into the earth formations surrounding the borehole. Such a technique was often effective in an open or uncased borehole. However, in a cased borehole almost all of the signal energy remained trapped in the casing.
SUMMARY OF INVENTION
Briefly, the present invention provides a new and improved method of acoustic well logging. It is particularly adapted for investigating subsurface formations adjacent a cased well borehole. Electromagnetic energy is emitted from an electromagnetic source in the cased well borehole. The emitted electromagnetic energy displaces the well borehole casing, forming acoustic waves which travel through the subsurface formations. The acoustic waves are then sensed after their travel through the subsurface formations at a transducer spaced from the electromagnetic source.
The electromagnetic source may take several forms. For example, it may be an electromagnet having its magnetic poles spaced from each other along a longitudinal axis transverse the well borehole axis. Such a source displaces the generally circular cross-section well borehole casing into an elliptical cross-section, causing the casing to contract. When the electromagnetic is periodically activated by electrical current, pressure waves or P-waves, which travel along an axis parallel to the longitudinal axis of the electromagnet are formed.
Alternatively, the electromagnetic source may be one or more sets of electromagnets aligned along the longitudinal axis of the well borehole. When one set of aligned electromagnets is used, the uppermost pole of the upper electromagnet and the lowermost pole of the lower electromagnet face opposite sides of the borehole casing. When two sets are used, corresponding poles of the second set face portions of the borehole casing at right angles to the portion of the borehole casing faced by those of the first set. When the set, or sets, of electromagnets is periodically activated by electric current, a bending moment is exerted on the borehole casing, forming shear waves or S-waves which travel vertically in the formation parallel to the well borehole axis.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view, taken partly in cross-section, of an electromagnetically induced acoustic well logging tool according to the present invention in a well borehole.
FIG. 2 is an elevation view, taken partly in cross-section, of a portion of the tool of FIG. 1.
FIG. 3 is an elevation view, taken partly in cross-section, of another electromagnetically induced acoustic well logging tool according to the present invention.
FIG. 4 is an isometric view of an addition to the well logging tool of FIG. 3.
FIG. 5 is an elevation view, taken partly in cross-section of another electromagnetically induced acoustic well logging tool according to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENT
In the drawings, the letter T (FIG. 1) designates generally an electromagnetically induced acoustic well logging tool in a wellbore 10. The well logging tool T includes an electromagnetic source E mounted in a sonde 12 which is supported by an armored well logging cable or wireline 14 in the well borehole 10.
The tool T is moved in the well borehole 10 to a depth of interest adjacent a subsurface earth formation 16. The well borehole 10 is lined with a steel casing 18 at the depths of interest and a lining of cement 20 has been introduced into an annular space between the casing 18 and the subsurface earth formation 16. The sonde 12 is stabilized at depths of interest by a suitable number of conventional stabilizer springs 22.
The electromagnetic source E includes a cylindrically wound inductor or coil 24 having a longitudinal axis 26 displaced perpendicular to a longitudinal axis 28 of the well borehole 10. A ferromagnetic core 30 is mounted within the coil 24 along its longitudinal axis 26, having opposite magnetic poles at end portions 30a and 30b.
The coil 24 receives operating electrical power from an electrical current source 32 driven by electrical power and control signals provided by the well logging cable 14 from the surface. The electrical current source 32 may be a pulsed source, providing high energy, short duration pulses of suitable length. A typical time duration, for example, would be on the order of from about one hundred to five hundred microseconds. Alternatively, the electrical current source may be a swept frequency source which periodically activates the source E with swept frequency signals, typically sinusoids. A suitable swept frequency range would be, for example, about one thousand hertz to about five thousand hertz.
An acoustic wave detector/transducer 34 is mounted in the sonde 12 at a spaced position from, either above or below, the source E. The detector/transducer 34 forms electrical signals in response to acoustic waves or vibrations sensed. The electrical signals from the transducer 34 are transmitted via the wireline 14 to a computer 36 and a data display or plotter 38 at the surface for recording and analysis. Typically, signals formed in the transducer 34 are digitized and amplified before transmission over the well logging cable 14.
As is conventional, a sheave wheel 40 is mounted at the surface to form a record of the depth of sonde 12 in the well borehole 10 while recordings are being made of the electrical signals formed by the transducer 34. The record of depth formed by the sheave wheel 40 is also furnished to the computer 36 for recording and processing.
In the operation of the well logging tool T, the coil 24 is periodically activated by the current source 32, causing the coil 24 to generate electromagnetic lines of force along the longitudinal axis 26 which are enhanced by the ferromagnetic core 30. The electromagnetic lines of force from the source E act through the sonde 10 on the steel casing 18, causing it to repeatedly expand and contract slightly from its generally circular vertical cross-section into a slightly elliptical cross-section. This causes contraction and expansion of the casing 18 during the periodic activation of the coil 24 by the source 32, causing acoustic pressure waves or P-waves which travel along axes 42 parallel to the longitudinal axis 26 of the electromagnetic source E.
The response of the subsurface formation 16 to the pressure waves or P-waves is then sensed by the detector/transducer 34. The responses of the transducer 34 are transferred via the wireline 14 to the computer 36 for processing and analysis.
An alternate electromagnetically induced well logging tool T-1 (FIG. 3) has an electromagnetic source E-1 having an uppermost electromagnetic coil 50 and a lowermost electromagnetic coil 52 mounted in a sonde 12 in the well borehole 10. Other like structure of the tool T-1 to that of the tool T performing like functions bears like reference numerals. The coils 50 and 52 have ferromagnetic cores 54 and 56, respectively, disposed along a longitudinal axis 58 corresponding to the longitudinal axis 28 of the well borehole 10.
The uppermost ferromagnetic core 54 has opposed magnetic poles at upper and lower ends 54a and 54b, respectively. The lowermost ferromagnetic core has opposed magnetic poles at its upper and lower ends 56a and 56b, respectively. The uppermost magnetic pole 56a of the core 56 and the lowermost magnetic pole 54b of the uppermost core 54 are of like magnetic polarity, as are the uppermost magnetic pole 54a of the core 54 and the lowermost magnetic pole 56b of the core 56. Accordingly, when coils 50 and 52 are periodically activated by the source 32, electromagnetic lines of force are exerted on casing 18 as indicated by arrows 60, introducing a bending moment into the casing 18. The bending moment on the casing 18 causes formation of acoustic shear waves or S-waves which travel in the formation 16 along lines indicated by arrows 62 parallel to the longitudinal axis 28 of the well borehole 10. The acoustic shear or S-waves once detected in transducer/detector 34 can be analyzed after processing in the computer 36 for information indicative of conditions in the earth, such as possible fractures in the formation 16.
In another alternate electromagnetically induced well logging tool T-2 (FIG. 4), a sonde 112 has been elongated in order to accommodate another pair of electromagnetic coils, comprising an uppermost coil 150 and a lowermost coil 152 mounted beneath a coil set of like construction and function to that of the electromagnetic source E-1 of FIG. 3. The structure of the source E-1 is shown only as a block diagram in FIG. 4, since elements are shown in FIG. 3. The coils 50 and 52 of the first coil set comprising the electromagnetic source E-1 cause lines of force to be exerted on the casing 18 as indicated by the arrows 60 (FIGS. 3 and 4). It can be seen that the arrows 60 align in a common vertical plane parallel to the longitudinal axis 28 of the well borehole 10.
A second electromagnetic source E-2 has an uppermost coil 150 and a lowermost coil 152 mounted in the sonde 112 below the electromagnetic source E-1. The coils 150 and 152 have ferromagnetic core 154 and 156, respectively, disposed along a longitudinal axis 158 of the electromagnetic source E-1 corresponding to the longitudinal axis 28 of the well borehole 10. However, the uppermost ferromagnetic core 154 and lowermost core 156 of the source E-2 have their magnetic poles disposed at a 90° angle (as indicated in FIG. 4) from the poles of the electromagnetic source E-1 in a horizontal plane transverse the longitudinal axis 28 of the well borehole 10.
Accordingly, when the coils 150 and 152 are periodically activated by the source 32, electromagnetic lines of force are exerted on the casing 18 at perpendicular locations in the horizontal plane from the lines of force 60 (FIG. 4), again introducing vertically travelling shear waves which are, however, oriented in a perpendicular direction in the horizontal plane from the shear waves formed by the electromagnetic source E-1. The second set of vertically travelling shear waves formed by the source E-2 are particularly adapted for use in detecting shear wave anisotropy as an aid in identifying formation fractures.
Another alternative electromagnetically induced acoustic well logging tool T-2 (FIG. 5) according to the present invention has an electromagnetic source E-3 mounted in the sonde 12. Other like structure to that of the embodiments set forth above bears like reference numerals. The source E-3 has a ferromagnetic core 200 about which is wound an electromagnetic coil 202. The electromagnetic coil 202 is activated in a like manner to the coil 24 to cause the casing 18 to expand and contract, so that the transducer 34 may form electrical signals in response to the acoustic waves or vibrations sensed. As has been set forth, the electrical signals are transmitted via wireline 14 to computer 36 and data display or plotter 38 for processing and analysis.
The sonde 12 is again pushed toward the casing 18 by a suitable number of conventional stabilizer springs 22. The sonde 12 does not contact the casing 18 along any appreciable portion of its length. Rather, an upper node or contact 204 and a lower node or contact 206, between which is located the electromagnetic source E-3, serve as the points of contact between the sonde 12 and the casing 18. Otherwise, a small clearance indicated by reference numeral 208 exists between the casing wall 18 and the sonde 12.
Having described the invention above, various modifications of the techniques, procedures, material and equipment will be apparent to those in the art. It is intended that all such variations within the scope and spirit of the appended claims be embraced thereby.
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An electromagnetic source or sources in a sonde in a well bore is caused to emit electromagnetic forces into the well casing. The electromagnetic forces cause displacement of the casing, inducing acoustic waves. The acoustic waves may be either P-waves or S-waves, depending on the type of electromagnetic source used. The response of earth formations to the acoustic waves, once detected, is used to detect fractures in the formations.
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This application is a continuation of U.S. application Ser. No. 08/289,696 filed Aug. 12, 1994, now abandoned, of BILL J. POPE for PROSTHETIC JOINT WITH DIAMOND COATED INTERFACES.
BACKGROUND OF INVENTION
The present invention relates to a prosthetic joint, and in particular to a prosthetic joint having diamond-coated load-bearing surfaces to thereby reduce friction and increase the useful life of the joint.
The use of prosthetic joints to replace joints which have either been worn out or damaged in an accident has become commonplace. The use of prosthetic joints has allowed many people with severe joint problems to return to activity, and enjoy a relatively normal lifestyle. While prosthetic joints have been used in numerous applications, the most common are those used to replace knees and hips which have either worn out, been fractured, or otherwise been damaged.
The primary problem with prosthetic joints is that the joints eventually erode and must be replaced. This erosion is caused, in large part, by the forces of impact and friction routinely encountered by the load-bearing surfaces of the prosthetic joint. As the joint is repeatedly used, the ball and socket (in the case of a hip prosthesis) wear against each other. The impact and friction forces eventually cause pieces of the load-bearing surfaces to spall and float about the joint. This debris initiates a hystiocytic reaction in which the body's immune system is activated and releases enzymes to dissolve the particles. However, because the debris is usually relatively hard material, such as metal or polycarbon compounds, the enzymes usually fail to dissolve the debris, or take a considerable amount of time to do so. To further complicate matters, the enzymes react with the bone supporting the prosthetic joint. The enzymes weaken or dissolve the bone. This condition causes osteolysis or weakening of the bone, therefor weakening attachment to the bone and making it difficult to replace the prosthetic joint when the bearing surfaces have eroded to such a point that the joint should be replaced. Osteolysis decreases the lifetime of the replacement prosthetic joint, and eventually renders the bone unusable.
Thus, there is a need for a prosthetic joint that will function the remainder of the life of the recipient without osteolysis. The present invention accomplishes this by introducing long wearing, low friction, diamond-coated bearing surfaces, thereby decreasing the amount of debris eroded into the joint, so as to extend the life of the joint.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a prosthetic joint for replacement of faulty natural joints which significantly decreases load-bearing surface erosion and debris.
It is an additional object of the present invention to provide a prosthetic joint which has load-bearing surfaces of sufficient strength to obviate the need for repetitive replacement of the joint.
It is yet another object of the present invention to provide a prosthetic joint which has a low coefficient of friction between its load-bearing surfaces.
The above and other objects of the invention are realized in a prosthetic joint having a thin layer of diamond bonded to at least one of the bearing surfaces of the joint. The diamond compact is affixed to the bearing surfaces and processed in such a way as to give the diamond coating a high luster and a low coefficient of friction.
In accordance with one aspect of the invention, the diamond layer is formed from polycrystalline diamond compact having a diamond particle diameter of between one nanometers and ten microns, to thereby further reduce the coefficient of friction between the bearing surfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
The above, and other objects, features and advantages of the invention, will become apparent from the following detailed description presented in conjunction with the accompanying drawings, in which:
FIG. 1 shows a side cross-sectional view of a prosthetic hip joint such as those commonly mounted in the hip of a human body.
FIG. 2 shows an enlarged side cross-sectional view of one embodiment of a prosthetic hip joint made in accordance with the principles of the present invention.
FIG. 2A shows a blow-up of the diamond layers disposed on the ball and socket of the present invention.
DETAILED DESCRIPTION
Reference will now be made to the drawings in which the various elements of the present invention will be discussed using the human prosthetic hip joint as an example, using numeral designations so as to enable one skilled in the art to make and use the invention for other types of prosthetic joints. Referring to FIG. 1 there is shown a prosthetic hip joint, generally indicated at 4. The prosthetic hip joint 4 consists of a ball 8 which is connected by a stem 12 to an anchor 16. Typically, the ball 8 is metal and is mounted to a metal stem 12 by a Morse taper. However, the ball 8 may be made of a durable, biocompatible material. Additionally, the ball may be attached to the stem 12 by a variety of means.
The anchor 16 is held in place in the femur by bone adhesive, such as bone cement using a cement mantle 24, friction or a threaded mechanism which extends down into the center of the femur. Recently, there has been increased use of porous surfaces along the outside of the anchor 16 which allows the bone to grow into the exterior surface of the anchor, thereby holding the anchor in place.
A cup shaped socket 30 is anchored in the pelvis 34 by a knurled or threaded exterior 38. The ball 8 is positioned adjacent the concave load-bearing surface 36 of the socket 30 so as to permit rotation, simulating the movement of the natural hip joint. As shown in FIG. 1, a high molecular weight polymer liner 42 is disposed within the socket 30 so as to decrease friction between the ball 8 and the socket 30, thereby increasing the life of the joint 4. The outer surface of the ball 8 is generally referred to as the load-bearing area 46 of the ball, as this area interfaces with the load-bearing surface 36 of the socket 30 and allows the joint 4 to rotate.
As was discussed in the background section, in such an arrangement wear during use produces small debris fragments as the load-bearing surfaces of the ball 8 and the socket 30 or liner 42 rub against each other. Eventually the enzymes activated to dissolve the debris will weaken the bones (20 and 34) housing the anchor 16 and the socket 30, making it difficult to replace the prosthetic joint.
FIGS. 2 and 2A illustrate one embodiment of the present invention. FIG. 2 shows diamond-coated load-bearing surfaces forming a joint 104. The joint 104 shown includes a ball 108, stem 112, a fragmented view of the anchor 116 and a socket 130 similar to those shown in FIG. 1. In accordance with the principles of the present invention, the socket 130 and the ball 108 may still be made of durable metal. For example, the ball 108 and socket 130 could be made of titanium, cobalt-chrome alloys, or stainless steel. Such materials are well known in the prosthetic joint art, and have long been considered safe for such purposes. Those skilled in the art will also be able to apply the principles of the present invention to other hard materials such as polycarbon compounds, which may be used in prosthetic joints.
In accordance with the present invention it has been found that forming thin layers of polished diamond 150 and 158 on the load-bearing areas 146 and 136, both reduces debris, and significantly increases the life of the prosthetic joint. A blown-up view of the load-bearing surfaces 136 and 146 and the diamond layers 150 and 158 is shown in FIG. 2A. (In FIGS. 2 and 2A, the thickness of the diamond layers are exaggerated to make them visible. The actual thickness is between less than 1000 microns, and may be less than 1 micron). These polished diamond layers, 150 and 158, have a very low coefficient of friction, and are very hard, thereby effectively eliminating debris from interfering with the joint. While a conventional prosthetic joint has a typical life of approximately 10 years, by placing a diamond coating on the load bearing surfaces, the life of the joint can be increased significantly. For many joints it may altogether obviate the necessity of periodically replacing the joint.
The diamond layers 150 and 158 are typically formed by bonding diamond compact to the load-bearing surface (146 or 136) by sintering at high temperature and high pressure, high temperature laser application, electroplating, chemical vapor deposition, forming a matrix with high molecular weight polyethylene or by other methods which are known in the art. Once the diamond layers 150 and 158 have been applied to the ball 108 and/or socket 130, the diamond surface is polished to a Ra value between 0.10 and 0.01 microns. The friction, and consequently the wear between surface layers 150 and 158, is extremely low, thereby increasing the life of the diamond--diamond joint 104 beyond that of the present art.
While shown in FIG. 2 as having diamond layers on both the ball 108 and socket 130, a single diamond layer, either the ball 108, or the socket 130 may have the diamond layer. However, the preferred embodiment is with diamond layers on each load-bearing surface of the joint 104. The two diamond layers 150 and 158 decrease the coefficient of friction between the two load-bearing surfaces 146 and 136 and decrease the likelihood of debris generated by movement of the joint 104.
Typically, polycrystalline diamond compact is formed using particles of diamond having a diameter of approximately one to one hundred microns. Use of such compact results in a prosthetic joint 104 which is more durable and less likely to erode. However, it has been found that a preferred layer 150 or 158 is formed by using polycrystalline diamond compact having a diamond particle diameter between one nanometer and one micron. The use of smaller diameter diamond particles increases the life of the prosthetic joint 104. This is so because the smaller diameter of the diamond particles makes them easier to polish to a fine surface, resulting in a lower coefficient of friction. Thus, there is a decrease in the amount of erosion debris, decreasing the risk of hystiocytic reactions and increasing the useful life of the joint.
As will be apparent to those skilled in the art, the polycrystalline diamond layer could be bonded to one of the load-bearing surfaces by any satisfactory method, and to an opposing load-bearing surface by some other method. Those skilled in the art will recognize that other methods and materials may be used to form the joint.
It has long been known that polycrystalline materials can be bonded to substrates, such as cemented tungsten carbide and used on rock bits for oil and natural gas. The polycrystalline material is typically bonded to the substrate at pressures in excess of 50,000 atmospheres and temperatures in excess of 1,300° C. For more detailed descriptions of methods of applying polycrystalline compacts to a substrate, see U.S. Pat. Nos. 3,745,623; 3,767,371; 3,871,840; 3,841,852; 3,913,280; and 4,311,490.
Once the polycrystalline diamond compact has been applied to the load-bearing surfaces 146 and 136 of the prosthetic joint 48, it is polished to an Ra value of 0.1 to 0.01 microns by the use of concave and convex spherical diamond laps. The thin diamond layers 150 and 158, now disposed on the load-bearing surfaces 146 and 136, respectively, of the prosthetic joint 104, create a joint with surfaces which are resistant to high-impact loads and which have a low coefficient of friction. Thus, impacting the surfaces together and interaction between the surfaces by rotation of the ball 108 within the socket 130 will not lead to wear of the surfaces and generation of debris as has been the case with prior prosthetic joints.
In the manner described, a prosthetic joint with diamond-coated interfaces is provided. The joint utilizes a thin diamond layer on at least one of the load-bearing surfaces of the joint to decrease friction within the joint and decrease debris caused by erosion of the load-bearing surface. It is to be understood that the above-described arrangements are only illustrative of the application of the principals of the present invention. Numerous modifications and alternate arrangements may be devised by those skilled in the art without departing from the spirit and scope of the invention. The appended claims are intended to cover such modifications and arrangements.
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A prosthetic joint with polycrystalline diamond compact coated interfaces and a method for making the same are disclosed. The prosthetic joint has a diamond layer formed on at least one of the interacting, load-bearing surfaces of the joint. The diamond layer adds resistance to damage from impacts and, when polished, gives the joint a low coefficient of friction, thereby increasing the life of the joint. In accordance with one aspect of the invention, the diamond layer is formed of polycrystalline diamond compact having a common diamond particle diameter of less than 1 micron to further reduce friction.
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This application is a continuation of application Ser. No. 108,921 filed on Oct. 15, 1987, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a disposable CO 2 gas generator which utilizes chemical reactants to generate the CO 2 gas. Conventional CO 2 gas cylinders are heavy, relatively expensive and available only as returnable, refillable packages. Since such cylinders are under very high pressure, handling requires appropriate care.
With the trend toward mini-sized and home-dispensers for soft-drinks, where the syrup-packaging is generally one-way, it is logistically attractive to make one-way CO 2 -packaging also available. Moreover, certain conventional distribution channels, such as super-market stores, could only be effectively exploited if one-way packaging were available. An additional factor is that lay dispenser-users are understandably nervous of handling high-pressure gas cylinders. High-pressure CO 2 -capsules, generally containing about 8 g CO 2 , are already available, but these are expensive and restricted in practical capacity to a limit of around 16-20 g. They do not, therefore, represent a solution, since such quantities are barely sufficient for carbonating 2 liters of beverage without reckoning the considerable additional CO 2 quantities needed for propulsion of the beverage in the dispenser.
Inexpensive, light-weight, unpressurized or moderately pressurized CO 2 -packaging can therefore provide a whole scope of new business opportunities with respect to small-sized dispensers designed for non-professional users.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide a device, which enables the generation of gas at a predetermined pressure, by automatically mixing the necessary reagents to the required degree.
It is another object of the present invention to provide a fully automatic gas generator which is also portable and easily deliverable.
It is yet another object of the present invention to provide a disposable gas generator which is at or near user pressure.
It is still another object of the present invention to provide a non-pressurized device which can be combined with an outside reference pressure source to generate gas automatically by mixing the necessary reagents to the degree required to maintain the reference pressure.
It is a further object of the present invention to provide a device, which can maintain a predetermined pressure in the head-space of a beverage bottle during use.
It is yet a further object of the present invention to provide a device, which can maintain a predetermined pressure in a liquid container and also propell the liquid through a simple dispensing head.
It is still a further object of the present invention to provide a dispensing head for a container of a simple disposable construction.
It is another object of the present invention to provide a gas generator capsule construction suitable for use in an aerosol container for maintaining head space pressure.
The solution of the present invention involves the use of a substance, such as sodium bicarbonate, which in contact with a liquid acid, such as phosphoric acid, generates CO 2 . Alternatively, a powdered mixture of bicarbonate and a solid acid, such as citric acid, may be employed and then only water is needed to release the CO 2 gas. The chemicals used can be types normally found in beverages, so that their use in a beverage dispensing system, or other food application, need not arouse concern. Since the chemicals only generate a gas pressure when they are mixed in the aqueous state, their packaging can be relatively simple.
Chemical generation of CO 2 gas is well-known but has so far had limited application, since a convenient, simple method enabling CO 2 -gas generation at a controlled user pressure of the order, say, of 1-8 Bar has not been available. According to the present invention, devices are provided which package the chemicals within a system, which releases CO 2 at a predetermined pressure. It allows the chemicals to be consumed only as and when CO 2 -gas is drawn off, whereby the chemicals react just sufficiently to maintain the required user pressure. The net result is that the chemical mixture can either be supplied as a liquid system or as a liquid-solid system or finally as a solid system, depending on application. It can be contained in relatively simple plastic packaging, capable of withstanding only moderate pressures, or depending on the system employed by the user, even in non-pressurized dry solid form. This involves relatively inexpensive packaging and the system as a whole can provide the user with simplicity and convenience.
Furthermore, a convenient CO 2 gas-generation package has uses in many household applications associated with beverages and other products, aside from direct use in beverage dispensers. Examples of these are:
Capsules inserted in large carbonated beverage bottles, which release CO 2 once the closure is applied, and thus maintain a CO 2 pressure in the head-space of the package until the product is consumed. In this way, the freshness of the beverage can be maintained throughout the period of consumption, providing improved quality with larger packages. Such a device would be pencil-like in shape, inserted within the bottle during the bottling process prior to capping and additionally ensure a high shelf-life without requiring exceptional barrier properties in the package itself.
Inclusion of gas-generator in simple dispensing heads, thus maintaining a head-space pressure in extra-large beverage bottles and bottles of other products, so that the user may dispense the liquid by simply pressing the dispensing head. This will improve the convenience of large liquid packages. In the case of carbonated beverages, it will enable the sale of ready-for-use "premix" dispensers comprising a large bottle, a simple dispensing head and a CO 2 -gas generator.
Inclusion of gas-generator in devices requiring a propellant gas, such as aerosols. Here the availability of a controlled, low-pressure source of CO 2 within the aerosol will resolve a continuing industry problem. Current propellants for aerosols are liquids with low boiling points, which additionally must be non-inflammable and have harmless vapours. While presently used halogenated hydrocarbons are variously suspect on health, environmental, and other grounds, CO 2 is both non-flammable and completely harmless both to the environment and to humans.
It is proposed to describe herein the principles of the CO 2 -gas generator of the present invention in some of its various possible forms and also to describe its embodiment with reference to the various applications described above.
A laboratory gas-generator, generally referred to as "Kipps Apparatus" is well-known, but this produces gas at pressures barely above atmospheric and cannot be transported. Other systems currently available using acid/bicarbonate chemicals involve the user in inconvenient manipulation. The system of the present invention can provide medium pressure gas, in transportable and convenient form.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIGS. 1A to 1C are diagrammatic views in side elevation illustrating the basic principles of the gas generators of the present invention;
FIGS. 2A to 2H are diagrammatic views illustrating variations of the basic principles of the gas generators of the present invention;
FIG. 3A is an elevational sectional view of one embodiment of a gas generator of the present invention;
FIG. 3B is an enlarged cross-sectional view of the CO 2 -valve (V) of FIG. 3A;
FIG. 3C is a cross-sectional view illustrating an alternative arrangement for outputting CO 2 gas from the gas generator;
FIG. 3D is an elevational cross-sectional view of another embodiment of the present invention
FIG. 3E is an enlarged view showing detail "A" of FIG. 3D;
FIG. 3F is an enlarged view showing details of valve V 1 of FIG. 3E;
FIG. 3G shows an alternative construction to the valve V 1 of FIG. 3E;
FIG. 3H shows still another alternative construction for the valve assembly V 1 of FIG. 3E;
FIG. 3I shows an embodiment of the present invention with the valving arrangements illustrated in FIGS. 3G and 3H;
FIGS. 3J and 3K are further embodiments of the present invention;
FIG. 3L is an embodiment of the invention employing only liquid reagents;
FIG. 3M shows an embodiment of the present invention utilizing an external reference pressure source;
FIGS. 4A to 4C show a gas generator capsule of the present invention inserted in a beverage bottle; FIG. 4A being a sectional view of the capsule, FIG. 4B a partial sectional view of the capsule in a bottle, and FIG. 4C a diagrammatic view illustrating the relative proportions of the capsule and the bottle;
FIGS. 5A to 5C illustrate the use of the gas generator of the present invention in a beverage bottle equipped with a manually actuable dispensing head; and
FIGS. 6A and 6B illustrate the use of a gas generator capsule of the present invention in an aerosol container for maintaining the required gas head-space pressure therein.
DETAILED DESCRIPTION OF THE INVENTION
Basic Principles
The basic principles are shown in FIG. 1A to 1C. Firstly, in FIG. 1A, a pre-pressurized gas chamber G a presses a reagent R a through a small orifice SO. As reagent R a contacts reagent R b in the lower chamber G b , CO 2 gas is released. Reagent R a continues to flow through to the chamber G b , until the gas pressure in chamber G b is equal to that of chamber G a . Flow stops due to the surface tension of liquid R a . When gas is drawn off by opening valve V, more reagent R a flows into chamber G b so as to equalize pressures again. The pre-set pressure in chamber G a acts as a reference and controls the product gas-pressure accordingly. It acts in effect as a pre-set pressure memory. As a result, the gas content of reagents R a and R b is released only as it is used and the total pressure of the system does not exceed that of the pre-set reference G a , which in effect is the user-pressure, i.e. the lowest system-pressure possible. The system is automatic in response and once pre-packaged delivers gas at the pre-arranged pressure until the reagents are exhausted. The user only needs to open valve V. Simple materials can be used for packaging the system, since relatively low pressures are involved.
Regarding the reagents, many options are available. Reagent R a can be simply water, whereby R b would then be a solid mixture of alkali and acid (e.g. sodium bicarbonate and citric acid). Alternatively, R a could be an acid solution (e.g. phosphoric acid) and R b an alkali such as sodium bicarbonate, enabling quicker system responses to pressure change. For rapid system response to pressure change, both R a and R b could be aqueous solutions, as indicated in FIG. 1B.
The pressure memory provided by gas chamber G a can be replaced by a mechanical system, such as a spring, if this is more convenient to a particular application (see FIG. 1C). In such a case the gas chamber G a is replaced by the spring S p and a piston or membrane P, or by similar devices. All devices must have the effect of providing a constant and desired pressure at the orifice SO.
Depending on application, other variations of the basic principle are possible and some of these are shown in FIGS. 2A to 2H.
For example, the reagents R a and R b may be allowed to achieve a balance, whereby reagent R a is pushed back into chamber G a once gas: pressures in G a and G b have equalized. This feature can be used, where precise control of the equilibrium is desirable. In FIG. 2A, reagent R a flows into reagent R b until the gas pressure is in equilibrium with G a . At that point, the reagent R a is pushed back by the pressure away from R b , stopping the reaction.
In FIG. 2B, the same effect is achieved using a spring S p or similar mechanical pressure exerting device, with a piston or membrane, instead of a pre-set gas pressure. In FIG. 2C the gas is ducted internally to the top of the device, which may be important in certain applications.
For applications where the gas outlet is better placed at the top of the system, FIGS. 2E and 2F illustrate the same principles as FIGS. 2A, 2B and 2C but here the position of the reagents is reversed.
During transportation, the reagent R a ducts in FIG. 2A, 2B, 2C, 2E and 2F would have to be capped and opened at the time of use. Otherwise inadvertent mixing of reagents could occur. This can be achieved by a simple valve arrangement, which is opened when the gas-generator is finally connected for use. An example of this valving (V 1 ) is given in FIG. 2D.
Alternatively, the reagent R b can be suspended and located centrally between two fine sieves as illustrated by FIG. 2G. The reagent R a does not reach R b even if the container is placed in a horizontal or vertical position and cannot run out of the gas outlet because of the configuration of the gas outlet tube C. Pressure chamber G a acts through a membrane or piston and this gas cannot mix with the gas in G b . This container can be transported without disturbing the system and is always ready for use once valve V is opened. A variation of the same system would be to use a spring as shown in FIG. 2F.
Another variation of a transportable system, as shown in 2H, would be to suspend the reagent R b between 2 fine screens and to supply reagent R a through a small orifice. All previously described methods of pressuring R a to a predetermined level can be used or alternatively a pre-pressurized flexible pouch, dead-weighted so that it sinks to the bottom of the container. The pouch FP expands to maintain pressure G b . Once G b is in equilibrium with the pressure in FP, the reagent R a is pushed back into its own chamber and gas generation stops. Surface tension forces prevent leakage of reagent R a onto R b once pressures in FP and G b are equalized, even if the device is inverted or placed in a horizontal position.
The above variations are intended to indicate only a part of the range of options available, using the same basic principles. All may have application depending on the type of user-system employed.
Pre-pressuring of gas-space G a or pouch FP can be achieved by using coated reagent R b pellets together with reagent R a . Thus the space (or pouch) can be sealed in an unpressurized state and the pre-determined pressure (dependent entirely on the quantity of reagents used) is generated some time after packing. The slowly-dissolving coating could, for example, be sugar or some other slowly-dissolving medium in water.
As a further option, the pressurized pouch can contain a liquid whose boiling point is chosen to provide a constant pressure at the operating temperature. Such an arrangement would be more compact, since a pre-pressurized pouch or chamber, using gas only, must have a volume which is relatively large compared with unacceptable pressure variations.
Physical Construction
Gas Generator
One embodiment of the gas-generator, based on the principles already described, and constructed from moulded plastic parts, is shown in FIG. 3A. The base section contains a 12 with a dead-weight 14 flexible plastic pouch therein. In the manner already described, this pouch has been filled with coated reagent R b pellets and liquid reagent R a in correct proportions so as to generate the desired pressure, once the coating has been dissolved some time after sealing. The liquid reagent R a is also filled into this base section 10 around pouch 12. Since the flexible pouch 12 first expands at a later state, the base section 10 is only partly filled and presents no handling problems in assembly. The middle section 16, also moulded plastic, comprises a small orifice 18 in its base. A circular filter paper 20 is laid over the orifice 18, covering the entire base and the reagent R b is poured in pellet or powder form on top of the filter. A fine retention screen 22 is laid over the reagent R b . The top section 24, also moulded plastic, is then applied and holds down the reagent retention screen 22. The joints of the three sections are welded by appropriate means. Some time after assembly, the coated pellets in the flexible pouch 12 dissolve and the pouch expands pushing reagent R a through the orifice 18 and onto reagent R b . As soon as the gas pressure in the gas-space G b rises up to the predetermined pressure within the pouch, the reagent R a is expelled into the lower compartment and the pouch is forced to contract appropriately. Thereafter, the pouch re-expands to bring reagent R a in contact with R b , whenever the gas-space pressure falls, and thus maintains the required gas supply pressure.
G a s is drawn-off through a simple valve such as illustrated in FIG. 3B. Alternatively, a simple tapping device may be used as shown in FIG. 3C. Here, the dome 26 of the device is punctured at a pre-determined break-point 27 by an external tool 28 which at the same time seals against the entry duct. The same break-point 27 serves as the pressure safety disc of the device.
The system is transportable once the gas-space has achieved equilibrium pressure (shortly after assembly) since surface tension forces at the orifice will not permit liquid to enter the reagent R b space.
Similar embodiments involving the other basic systems described in 2A to 2H above are also possible by employing the principles outlined. A further embodiment is illustrated by 3D. Here the pre-determined pressure is provided by gas space G a and reagent R a is pushed up a tube 32 to R b . When pressure G a and G b have equalized, R a returns down to the tube 32 to its own space and the reaction stops. For transportation a simple valve V 1 at base of central tube 32, can be used. Alternatively, as shown in FIG. 3G, the central tube 32 can be sealed at the base and have a pre-determined break-point 34, which is broken by pressing in the base prior to use. The appropriate pressure can be applied by rotating an external cap 36 including a pressure applying pin 38. A further variation of the same principle is shown in 3H, whereby the central tube 32 has a foil seal 39 which is punctured by pressing in the base. This is done by pressing the cylinder against an external protrusion 40. (For example, a protrusion in the CO.sub. 2 -compartment base in a dispenser.) FIG. 3I shows an embodiment of 3D with the valving arrangements described in FIGS. 3G and 3H.
FIGS. 3J and 3K are further embodiments of the principles described, which may prove easier to manufacture in a high-speed line. FIG. 3L is an embodiment of a system employing only liquid reagents for R a and R b . Here the flow of reagent R a stops, once pressure-equilibrium between G a and G b has been reached, due to the action of surface tension forces in the orifices at the base of chamber G a . The reagent R a is released at the time of use by pressing in the base, which in turn raises the puncturing tube 42 to break the foil seal 44 at the base of chamber G a .
Provided the device is to be used in a dispenser, which can be designed to provide the necessary pressure on reagent R a externally, a non-pressurized generator, with all the attendant production and transportation advantages, is possible. An embodiment of this is shown in FIG. 3M. Now there is no in-built pressure memory, and in its place, a simple bellows 46 or membrane or piston is used. The reference pressure is applied from an external source, within the equipment employing the generator, and this presses the bellows 46. Thereafter, the generator operates as already described.
Beverage Refresher
The gas generator can be constructed as a capsule which is inserted in a beverage bottle and releases gas only when the closure is applied. An embodiment of this is shown in FIGS. 4A and 4B. The gas generator itself employs one of the principles explained above, but many of the other principles could also be adapted to this application.
The capsule is pencil-shaped so that it can be passed through the normal finish of a bottle (see FIG. 4C). The capsule of FIG. 4A comprises the same 4 basic components already outlined above for the gas generator: a base-section containing reagent R a , a pre-pressurized pouch, a middle-section containing reagent R b , a top-section (which in this case locates in the mouth of the bottle) and finally a gas-valve, which in this case is opened by the pressure of the applied closure. The middle-section has an orifice which protrudes above the surface of the reagent R b . The fine screen or sieve, retaining the reagent R b is pressed over the lips of the orifice and located by protrusions on the outside of the orifice tube. Reagent R a flows onto R b until the gas space achieves equilibrium with the pressure of the flexible pouch. A simple moulded plastic valve V 2 , which is actuated by the downward pressure of the closure is welded to the top-section. The embodiment of this valve is illustrated in FIG. 4B, together with the method of location of the capsule in the mouth of the beverage bottle. The valve consists of 2 moulded plastic parts: the valve housing and the valve spindle. The valve spindle locates in the ga exit tube and is moulded with a series of fingers, which act as springs. Assisted by the gas pressure, the springs help to seat the valve, whenever the downward pressure of the closure is removed. Thus, no gas escapes while the bottle is open.
When the closure is reapplied, gas is generated and fills the bottle head-space until this is at equilibrium with the pressure in the flexible pouch.
During transportation of the bottle, the gas valve is open. It is, in fact, open at all times after the bottle is first capped. However, no reagents can pass into the beverage since the reagent immediately below the gas valve is powder, the gas exit tube is constructed so as to prevent liquids/solids escaping, and the gas pressure helps to keep the liquid in the lower space. Moreover since beverage-type components are used as reagents, a leakage of the capsule would not affect the safe consumption of the beverage.
Finished Beverage Dispenser
The gas-generator may be used to maintain a gas pressure in the head-space of a beverage bottle (or other liquid container) and thus enable the beverage (or other liquid) to be dispensed through a dip-tube by opening a valve at the head of the dip-tube. An embodiment of this is shown in FIG. 5A, 5B and 5C.
The gas-generator capsule is shown in FIG. 5A. It consists of a base section containing reagent R a and including a pre-pressurized flexible plastic pouch, a middle section containing reagent R b and including an orifice, filter-paper and retention screen; and a top-section which holds down the screen and includes the gas outlet. The gas-outlet is sealed when the gas generator is assembled and the tube is cut to initiate gas release immediately prior to cap application after filling. The gas is generated, in the mode already described, to maintain a head-space gas-pressure in the bottle.
The gas-generator is cradled in moulded support hoops on the dispensing dip-tube, as shown in FIG. 5C.
A dispensing head embodiment is shown in FIG. 5B. It consists of five parts: a capping section, which screws onto the threads of the bottle-finish and connects to the dip-tube, a valve-spindle, a transportation sealing lock-ring, a spring and a press-down-head. The capping-section includes a spout. The valve spindle seats against a shoulder on the base of the capping section and opens the flow when depressed downwards. A series of membranes, moulded onto the valve spindle, seal against the bore of the top of the capping section to prevent liquid leakage. The spring presses the valve spindle upwards so as to close the valve. In this it is assisted by the head-space pressure within the bottle. When the spring is compressed by a downward pressure on the dispenser head, the valve opens and liquid flows, propelled by the gas-pressure in the head-space. For safe transportation, the sealing lock-ring presses the dispensing head upwards ensuring that the dispensing valve remains closed. The user breaks the seal of this ring by screwing it downwards to a stop. This frees the dispensing head and enables it to be used. All 5 dispenser-head parts described are constructed of moulded plastic.
Aerosol Application
The capsule described above for the finished beverage dispenser can be also used to maintain a required gas head-space pressure in an aerosol. Two examples of such an assembly are shown in FIGS. 6A and 6B. This employs the principles already described. The release of gas can be initiated by cutting the gas outlet tube shortly before the aerosol is sealed or by employing a simple valve, as shown in principle in FIG. 4B, which opens on application of the container lid.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims:
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A gas generator chemically generates a gas from a chemical reaction between two reagents contained within a common container. The reagents are normally separated by a gas generation chamber into different regions of the container in the absence of gas generation therein. A reference pressure source of a predetermined pressure forces the two reagents into contact with each other when the pressure of gas in the gas generation chamber is less than the predetermined pressure. A valve in fluid communication with the gas generation chamber is provided to withdraw the generated gas from the chamber when OPEN. As the gas flows through the valve from the chamber the gas pressure in the chamber drops permitting more mixing of the reagents. When the chamber pressure becomes equal to or higher than the predetermined pressure applied by the reference pressure source, the reagents become separated again and gas generation ceases.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Continuation-in-Part of U.S. Non-Provisional Application Ser. No. 12/093,625, filed May 14, 2008, which claims priority to International application Ser. No. PCT/ZA07/00015 filed Feb. 14, 2007, which claims priority to foreign Application Ser. No. ZAP2006/1350 filed on Feb. 15, 2006.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to liquid applicators in general and more particularly to a roller applicator having a removable applicator surface.
2. Discussion of the Related Art
Paints and other liquid or semi-liquid substances have been developed over the years for multitudes of purposes. Paints are used to provide a protective and decorative coating to interior and exterior building walls. Liquid glues are utilized to bond two surfaces in permanent or semi-permanent contact. Various brushes were developed to assist in applying these substances in a controlled and regulated manner in order to spread the substance over the application surface and to provide a relatively uniform coating thickness. Most commonly, the surface to which the substance is to be applied is relatively large and flat, such as the wall of a room or a building exterior, and the use of a brush becomes a very time consuming effort.
In order to more efficiently apply these coatings, an apparatus was developed that facilitated covering a larger area in a shorter period of time while simultaneously applying a more uniform coat of the substance. The apparatus that was developed has become widely known and used, and is commonly known as a ‘paint roller.’ The roller, which usually has a “T” shaped frame wherein the stem of the “T” includes a grip to serve as a handle for the user. The top bar of the “T” generally has a structure resembling a wire cage that freely rotates about the axis of the top bar, and a cylindrical sleeve that is telescopically received over the structure. The cylindrical sleeve is typically rigid for durability and support and has a fibrous or porous outer layer. In use, the outer layer of the cylinder is introduced to the coating substance contained in an appropriately sized reservoir such that the entire fibrous or porous outer surface absorbs a portion of the substance. The roller is then transferred to the surface on which the substance is intended to coat and maneuvered to distribute the substance in the manner desired by the user.
Upon completion of the coating process, the user is faced with the task of cleaning the roller. While the sleeve is removable from the frame allowing the frame to be readily cleaned, the task is much more difficult for the cleaning the sleeve. Since the outer surface of the sleeve is porous or fibrous, it typically retains a significant amount of the coating substance within the pores or fibers. The coating substance must be removed if the sleeve is desired to be reused for a subsequent task. The removal of the substance from the fibrous or porous material generally involves utilizing a rigid edge of some kind to squeegee out the majority of the coating substance and then to thoroughly rinse the cylinder in an appropriate solvent to remove the remaining coating substance. Since the fibrous or porous material is permanently fixed to the rigid sleeve, this task is awkward at best and can be very difficult to almost impossible at worst when the knap of the fibrous material is relatively deep. Often, when a roller sleeve is attempted to be cleaned not all of the coating substance is removed and subsequently dries leaving an inferior surface for its subsequent reuse. Although sleeves are generally sufficiently sturdy for reuse, many users become frustrated with the process of cleaning the sleeve and treat them as one-time use items and then discard the sleeves upon completion of the coating task. This is an inefficient use of resources and can result in considerable expense when compared to cleaning and reusing sleeves.
Thus what is desired is an application roller wherein the fibrous or porous layer on the roller is readily removable and can be easily cleaned for reuse.
SUMMARY OF THE INVENTION
The present invention is directed to an application roller that satisfies the need for an easily removable and cleanable application layer. The application roller for applying liquid or semi-liquid substances on surfaces comprises a frame having a shaft including a handle thereon for grasping by a user and a cross axle oriented at a right angle to the shaft. A cylinder having first and second ends rotatably mounted on the cross axle defines an outer surface having a first portion of an attachment system thereon. A cover wrap dimensioned to circumferentially encompass the cylinder has a liquid absorbent outer surface and an inner surface including a second portion of the attachment system. The first and second portions of the attachment system cooperate to permit selective removal and reattachment of the cover wrap on the cylinder.
Another aspect of the present invention is an applicator cover sleeve for a standard or pre-existing paint roller frame that has a freely rotating structure for receiving an applicator sleeve thereon. The applicator cover sleeve is constructed of a cylindrical sleeve having first and second ends and defines an outer surface having a first portion of an attachment system thereon. A cover wrap is dimensioned to circumferentially encompass the cylindrical sleeve and has a liquid absorbent outer surface for absorbing and releasing the coating substance. An inner surface of the cover wrap includes a second portion of the attachment system such that the first and second portions of the attachment system cooperate to permit selective removal and reattachment of the cover wrap on the cylindrical sleeve.
Yet another aspect of the present invention is a method for attaching a cover wrap for an application roller to a cylinder of the application roller, the method includes the steps of placing a cover wrap to be attached to an application roller on a flat surface such that the inner surface of the cover wrap faces up. The rotational axis of the application roller cylinder is aligned so that the axis is parallel to a line connecting two alignment marks on the inside surface of the cover wrap. The cylinder is registered over the cover wrap so that the cylinder is substantially centered between opposing edges of the cover wrap marked with the alignment marks. The cylinder is pressed against the inner surface of the cover wrap, and the roller is then translated in a first direction substantially perpendicular to the line connecting the two alignment marks until a first end of the cover wrap is affixed to the cylinder. Upon completion of the first translation the roller is then translated in a second direction opposite from the first direction until a second end of the cover wrap is affixed to the cylinder.
Still another aspect of the invention is an application roller including a shaft having a handle connected thereto. A circular cylinder has ends wherein each end forms a hub rotatable about the shaft. An outer layer covers the cylinder wherein the outer layer includes a plurality of small hooks extending radially outward therefrom. A non-rectangular parallelogram shaped fabric cover is dimensioned to fit on the cylinder when wrapped therearound. The cover has a fibrous surface on an inner side and has a dimension between a first pair of opposite sides equaling the length of the cylinder and a dimension between a second pair of opposite sides equaling the circumference of the cylinder.
These and other features, aspects, and advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature of the present invention, reference should be made to the accompanying drawings in which:
FIG. 1 is an exploded perspective view of an application roller embodying the present invention, wherein the wrap is removed from the sleeve;
FIG. 2 is a plan view of the wrap lying on a planar surface;
FIG. 3 is a perspective view of an alternate embodiment applicator cover sleeve for use with pre-existing roller assemblies;
FIG. 4 is a plan view of the roller and wrap positioned to affix the wrap to the roller sleeve;
FIG. 5 is a plan view of the roller and wrap combination with the wrap partially encircling the roller sleeve;
FIG. 6 is a plan view of the roller and wrap with the wrap almost fully engaged on the roller sleeve.
Like reference numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
For purposes of description herein, the terms “upper”, “lower”, “left”, “rear”, “right”, “front”, “vertical”, “horizontal”, and derivatives thereof shall relate to the invention as oriented in FIG. 1 . However, one will understand that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. Therefore, the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
Turning to the drawings, FIG. 1 illustrates an application roller 20 which is one of the preferred embodiments of the present invention and illustrates its various components. Application roller 20 includes a roller assembly 22 and a removable cover wrap 50 . Roller assembly 22 has a frame 24 that includes a shaft 26 on which a handle 28 is secured for comfortable grasping by the user. Frame 22 further includes a cross axle 30 which may be an integrally formed part of and extension of shaft 26 . Cross axle 30 is generally oriented at right angles to shaft 26 thereby orienting frame 24 in a generally T-shaped configuration. Those skilled in the art will readily recognize that other orientations and configurations of frame 24 are possible and, although not shown herein, are intended to be within the scope of the disclosure.
A cylinder 32 is supported on cross axle 30 in a freely rotating manner about an axis ‘A’ by hubs 34 at each of cylinder ends 36 , 38 . Cylinder 32 has a length bounded by ends 36 , 38 and a circumference defining an outer surface 42 . Surface 42 has attached thereto an attachment system layer 40 which substantially covers the entirety of cylinder surface 42 . Layer 40 is a portion of an attachment system such as a well known hook and loop system. In the most preferred embodiment, the hook portion of the hook and loop system comprises layer 40 . FIG. 1 illustrates layer 40 as being a separately formed layer which is subsequently permanently bonded to surface 42 . However, cylinder 32 can be formed of a molded resin in such a manner as to integrally form the hook portion of the hook and loop fastening system as part of surface 42 without the necessity of bonding a separate hook layer to cylinder 32 . Other fastening systems that permit repeated removals and reattachments are also contemplated to be within the scope of this disclosure.
A cover wrap 50 is sized to circumferentially encompass cylinder 32 and includes a liquid absorbent outer layer 62 . Cover wrap 50 is typically constructed as a woven fabric wherein outer layer 62 is a fibrous pile interwoven into the fabric and is of a desired depth for absorbing a coating substance from a reservoir and then releasing the coating substance on the surface to be coated. The depth of the pile can vary depending on the resulting surface texture the user desires. Outer layer 62 can alternatively be a porous layer for yet a different type of texture. Cover wrap 50 also has an inner surface or layer 52 that comprises a second portion of the attachment system. In the most preferred embodiment, inner layer 52 comprises the loop portion of the hook and loop fastening system. Inner layer 52 can be separately formed and then permanently bonded to the woven fabric constructing cover wrap 50 . Alternatively, the woven fabric of cover wrap 50 can be formed in such a manner that the loop portion of the hook and loop fastening system is integrally formed or woven with the woven fabric and outer layer pile.
Referring to FIG. 2 , in a most preferred embodiment, cover wrap 50 is formed as a parallelogram and most preferably as a non-rectangular parallelogram. The parallelogram describing cover wrap 50 includes a first pair of parallel edges 54 , 56 spaced one from the other by a distance substantially equal to the length of cylinder 32 . Edges 58 , 60 define a second pair of parallel edges of the parallelogram and are spaced apart by a distance substantially equal to the circumference of cylinder 32 . The geometry of the non-rectangular parallelogram is further defined by angle ‘B’ in FIG. 2 . Angle ‘B’ is typically within the range of 65 to 85 degrees, and is most preferably 75 degrees. Inner surface 52 also carries a pair of alignment marks 64 . One alignment mark 64 is present at each of edges 54 , 56 . The marks are positioned substantially on a line 66 that is perpendicular to edges 54 , 56 wherein line 66 represents the length dimension of cylinder 32 .
Referring now to FIGS. 4-6 , cover wrap 50 is affixed to cylinder 32 in the following manner. Cover wrap 50 is placed on a flat surface with outer layer 62 facing against the flat surface and inner surface 52 with alignment marks 64 visible to the user. Roller assembly 22 is oriented such that rotational axis ‘A’ of cylinder 32 is parallel to line 66 defined by alignment marks 64 . Cylinder 32 can then be registered over cover wrap 50 such that cylinder 32 is centered between opposing edges 54 , 56 . Once cylinder 32 has been centered and aligned with marks 64 , cylinder 32 is then firmly pressed onto inner surface 52 of cover wrap 50 thereby initially engaging hooked layer 40 of cylinder 32 with the loops of inner surface 52 . With a firm grip by the user on handle 28 , roller assembly 22 is then translated in a first direction ‘C’ ( FIG. 5 ) toward edge 60 until edge 60 is affixed to cylinder 32 . The user then translates roller assembly 22 in an opposite direction ‘D’ ( FIG. 6 ) toward edge 58 until edge 58 is also affixed to cylinder 32 . Since the distance between edges 58 and 60 dimensionally define the circumference of roller 32 , upon cover wrap 50 being completely affixed to roller 32 , edges 58 , 60 should be in a substantially abutting relationship on roller 32 thereby completing application roller 20 .
Application roller 20 is then utilized in the same manner as previously known application rollers wherein the outer surface 62 is introduced to a reservoir of liquid coating substance in a manner sufficient to saturate the entire surface 62 . Application roller 20 is then transferred to the surface to be coated and repeatedly translated thereacross until the pile of outer surface 62 requires resaturation. This procedure is repeated until the desired surface is adequately coated. To clean cover wrap 50 , any corner at the intersections of edges 54 , 56 with edges 58 , 60 can be grasped by the user and pulled to disengage the hook and loop fastening system. Cover wrap 50 can then be place on a substantially flat surface with outer surface 62 exposed. Excess coating substance can be squeegeed out from the pile utilizing a straight-edged object if desired. Cover wrap 50 can then be placed in a washing machine and laundered as a typical cloth object and thereby resulting in a clean cover wrap 50 for reuse at a later time.
The purpose of wrap 50 being other than a rectangular parallelogram is to orient the abutment of edges 58 , 60 to be other than parallel to axis of rotation ‘A’. In this manner, only a single point of the abutment line of edges 58 and 60 is in tangential contact with the surface to be coated at any one time. If cover wrap were configured as a rectangle, the entire abutment line would simultaneously contact the surface at one time and thus potentially leave an undesirable visible aberration in the coating layer.
Referring now to FIG. 3 , an alternative embodiment employing an application cover sleeve 132 is illustrated wherein cover sleeve 132 is intended for use with pre-existing rollers. The preexisting rollers are typically configured with a rotating cage (not shown) that accepts a standard sleeve thereover. Applicator cover sleeve 132 includes a cylindrical sleeve 133 having a length bounded by ends 136 , 138 and a circumference defining an outer surface 142 . Sleeve 133 further defines a hollow interior 144 sized to snuggly fit over the rotating cage of a standard pre-existing roller assembly. Surface 142 has affixed thereto an attachment system layer 140 which substantially covers the entirety of sleeve outer surface 142 . Layer 140 is one portion of an attachment system, such as hook layer 40 shown in FIG. 1 . FIG. 3 illustrates layer 140 as being a separately formed layer which is subsequently bonded permanently to surface 142 . However, cylindrical sleeve 133 can be formed of a molded resin in such a manner as to integrally form the hook portion of the hook and loop fastening system as part of surface 142 without the requirement of bonding a separate hook layer to cylindrical sleeve 133 . In use, applicator cover roller 132 is sleeved over the rotating cage of a pre-existing roller assembly. A cover wrap 50 can then be selectively attached to and removed therefrom in the same manner as described above.
The above description is considered that of the preferred embodiments only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and are not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the doctrine of equivalents.
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An application roller for applying liquid or semi-liquid substances on surfaces comprises a frame having a shaft including a handle thereon for grasping by a user and a cross axle oriented at a right angle to the shaft. A cylinder having first and second ends rotatably mounted on the cross axle defines an outer surface having a first portion of an attachment system thereon. A cover wrap dimensioned to circumferentially encompass the cylinder has a liquid absorbent outer surface and an inner surface including a second portion of the attachment system. The first and second portions of the attachment system cooperate to permit selective removal and reattachment of the cover wrap on the cylinder.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for driving roller shutter doors to a closed or open state. More specifically, the present invention relates to a controller for applying motive power to a roller shutter door of the type used to retard passage in the event of fire, smoke or similar conditions, or, of doors simply used to prevent egress or entrance based on the time of day or the opening or closing of the facility to which the door is a portal.
2. Description of the Related Art
Roller shutter doors have been known for some time and are used in a variety of applications. They include such categories as: rolling grille; storm doors; fire and smoke doors; air-leakage doors, counter shutters; and, the like. What they have in common is a construction that allows them to be rolled up onto a drum or tube when in the open position; or, to be unreeled from the drum when the door is being lowered. Theses doors are typically used in commercial establishments to seal or close off large doorways, or bays, and can be operated electrically, manually, or both.
The methods and systems for driving the doors into an upward or downward position, during normal or emergency operation, have evolved over time from simple pull down doors of a kind used in residential garages, to more technologically advanced electric drive systems with timers, manual over-rides, and diverse safety features.
Generally, commercial or large capacity fire doors were driven by electric motors to open or close the door. However, when a fire occurred, these mechanisms would disengage the motor from the fire door and allow the door to close under the pressure exerted by an auxiliary spring activated by mechanical means or from a counterbalance. These mechanical means included pendulums, oscillating governors, friction discs, ratchets, etc. These mechanical devices tended to be unreliable because of jamming or other malfunctions caused by the motion of the door. One early mechanism that attempted to address this problem was described in U.S. Pat. No. 5,203,392 for a Mechanism For Controlling The Raising And Lowering Of A Door, issued Apr. 20, 1993 to Shea (hereinafter referred to as “Shea”).
In Shea, there is disclosed a mechanism for controlling the opening and closing of a door such as a fire door. The mechanism controls the speed of the door when it drops under the force of gravity; and, can be electrically, or manually, operated. The problem that Shea was attempting to address was the need for a fire door mechanism that regulates the raising and lowering of the door while effectively controlling the door's movement without the need of springs or similar mechanical means. The speed of the door's drop was under control of a centrifugal governor employing brake shoes.
Other prior art has addressed the need for testing the speed and effects of the door's drop during non-emergency uses. U.S. Pat. No. 5,482,103 for a Door Apparatus With Release Assembly, issued Jan. 9, 1996 to Burgess et al. (hereinafter referred to as “Burgess”) teaches the use of a counterweight to offset the weight of the roller door and a reducing weight to reduce the weight of the counterweight. The assembly of the door allows the use of a standard governor to control downward speed. This use of reduced weight and the resultant reduced stress on the door allows the mechanism to use parts that are reduced in size and weight.
After the disclosures of Shea and Burgess, came the teachings of U.S. Pat. No. 5,924,949 for an Apparatus For Driving A Roller Shutter Door, issued Jul. 20, 1999 to Fan (hereinafter referred to as “Fan”). Fan teaches a driving mechanism for roller shutter doors that can be adjusted from outside of the apparatus so as to accommodate doors of different heights. The advantage of Fan is that the mechanism, if either moved from a door of one height to a door of a differing height, or if the door is not of the height for which the factory settings apply, does not have to be disassembled for adjustments. Rather, the adjustable control means is disposed within the stationary housing of the apparatus, and extends from within the apparatus to a point outside where it can be manipulated or adjusted as required. And, while Fan addresses a legitimate need, it still leaves unanswered the need to allow the door to move freely into an open position while under control of a governor.
Further improvements to the drive mechanism are taught in U.S. Pat. No. 6,530,863 for a Door Operator Unit, issued Mar. 11, 2003 to Balli et al. (hereinafter referred to as “Balli”). In Balli, an improved power transmission mechanism which works between the drive motor and the operator output shaft is disclosed. The operator unit is adapted to reverse the positions of a manual operator drive and a release mechanism. The advantage provided by Balli is the ability to interchange the operator unit components depending upon the door configuration or application. Thus, the drive mechanism can be established as either a right side or a left side mount. Balli still leaves the question of door control after rebounding, or the issue of timer adjusted openings and closings to be addressed.
The evolution of the rollup door and its drivers and safety mechanisms has continued with the disclosures of U.S. Pat. No. 7,261,139 for a Manual Operating Mechanism For Upward Acting Door, issued Aug. 28, 2007 to Varley et al. Varley teaches a mechanism that addresses the difficulty of operating a roll-up door manually in those cases where the drive motor is mounted in an assembly that is beyond the easy reach of the user. The mechanism of Varley includes a manual brake release that is foot actuated by a person using an elongated crank handle to manually move the door from an open to closed position or vice versa. A problem left unanswered by Varley is how an operator, under the stress of an emergency, can efficiently disengage the motor drive.
What is not appreciated by the prior art is the need to provide a method and apparatus for controlling the drop of the door (or curtain as the case may be) that incorporates each of the successes of the prior art while minimizing the problems. One important issue not addressed by the prior art, is that the drop of the door should be controlled by a mechanical centrifugal governor such that the door does not “bounce” after it arrives in the full open position. While in a closed position, the curtain or door must be able to maintain its locked position unless the door or curtain is manually released through the use of a manual lever and/or an electrical switch. The use of a timer to allow the door to re-open at least part-way, and then close after a specific time interval during an emergency, would provide a safety that is currently lacking in the art.
Accordingly, there is a need for an improved method and apparatus that will supply multiple safety features in the event of an emergency while providing for more efficient operation of the door during normal use.
OBJECTS AND SUMMARY OF THE INVENTION
An object of the present invention is to provide a mechanism for driving a roller-shutter door that can be operated in an emergency by hand push-up, manual chain drive, or by motor power.
Another aspect of the present invention is to provide a mechanism for driving a roller-shutter door in response to elevated, unsafe or emergency levels of wind, smoke or fire that are communicated to the mechanism through a sensor coupled to an electrical control mechanism.
An object of the present invention is to provide a mechanism for driving a roller-shutter door that can be operated simply as an egress mechanism when utilized with non fire-rated door applications, thus allowing for emergency egress on standard doors.
The present invention relates to a method and apparatus for driving a roller-shutter door having a drive mechanism. The method comprises the activation of a circuit in response to any one of several external stimuli (such as a smoke detector alarm) to a switch for activating the door's drive mechanism and/or directional movement. This, in turn, actuates a timer and raises a timer arm. A cable passes across the timing arm and is connected to the switch on one end, and to a solenoid on a second end. The cable passes through a top portion of a rocker arm assembly having a one-way bearing. The solenoid is actuated as a result of the raising of the timing arm; and, activates the one-way bearing to cause the door to be raised to a pre-set position for a pre-set period of time. To reverse the door, the timer arm is dropped after the lapse of the pre-set period of time. The solenoid is re-activated and reverses the one-way bearing.
According to an embodiment of the present invention, there is provided a method and apparatus for driving a roller-shutter door having a drive mechanism. The method of the present invention comprises a number of steps beginning with the activation of a circuit in response to an external stimulus (such as a smoke detector alarm) to a switch. The switch can be located in any one of several of locations depending upon design choice or specific environmental requirements. For instance, it can be located on an outer wall of a building supporting the roller shutter door; and wherein the switch is within a break-glass station.
The external stimuli is the closing of a circuit linked to a sensor for measuring an anomaly, such as: an elevated smoke level, excessive heat (caused by a fire or the like), or simply the passage of time as determined by a real time clock.
The activation of the circuit actuates a timer and which in turn raises a timing arm of the timer. A cable passes across a top portion of the timing arm and is connected to the switch on one end and to a solenoid on a second end. The cable passes through a top portion of a rocker arm assembly disposed between the timer and the solenoid; and, wherein the rocker arm assembly comprises a one-way bearing. The solenoid is actuated as a result of the raising of the timing arm; and activates the one-way bearing to cause the door to be raised to a pre-set position for a pre-set period of time under control of the timer and as driven by the drive mechanism.
In reversing the movement of the door, the method further comprises utilizing the timer for a pre-set period of time; and, wherein the timer bar is dropped after the lapse of the pre-set period of time. The solenoid is re-activated in response to the dropping of the timer bar, and reverses the one-way bearing in response to the actuation of the solenoid. The door is then dropped to a closed position in response to the reversing of the one-way bearing. The dropping of the door is caused by gravity; and, the speed of the dropping of the door is under control of a centrifugal speed governor.
The drive mechanism itself for opening or closing the roller-shutter door comprises a number of key elements. The elements include a drive plate having a centrally located hub, and wherein the hub has a geared portion located on the outside surface thereof. There is also a drive gearset having a geared hub mounted coaxially about the central hub of the drive plate; and, a second gear having a geared hub and mounted coaxially about the geared hub of the drive gearset. In addition, there is a stationary housing adapted to accommodate the drive gearset and the drive plate. A motor located externally to the stationary housing for driving the second gear, and control means disposed within the stationary housing and in meshed contact with the central hub for controlling actuation of the motor in response to an external stimuli, and whereby the roller shutter door can be moved to a predetermined limit position are also provided. The drive mechanism also an adjustable gearset that is accessible from outside the stationary housing. Additionally, the drive mechanism comprises the rocker arm assembly and centrifugal speed governor previously noted.
In an alternative embodiment of the present invention, a stepper motor is used in place of the solenoid. When using the solenoid, the method comprises the activation of a circuit in response to any one of several external stimuli (such as a smoke detector alarm) to a switch for activating the door's drive mechanism and/or directional movement. This, in turn, actuates a timer and raises a timer arm. A cable passes across the timing arm and is connected to the switch on one end, and to a stepper on a second end. The cable passes through a top portion of a rocker arm assembly having a one-way bearing. The stepper is actuated as a result of the raising of the timing arm; and, rotates its shaft to cause the door to be raised to a pre-set position for a pre-set period of time. To reverse the door, the timer arm is dropped after the lapse of the pre-set period of time. The stepper motor is re-activated and completes a turn of the shaft to reverse the one-way bearing.
In another embodiment of the present invention, the doors are driven horizontally (relative to the door's threshold) from opposing directions so that they meet in the middle of the threshold. The drive mechanism is the same as that provided for the vertical (up or down) movement of the door, except that the drive is biased horizontally instead of laterally.
The above, and other objects, features and advantages of the present invention will become apparent from the following description read in conduction with the accompanying drawings, in which like reference numerals designate the same elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a curtain or roller door having a hand chain drive, shown when the door is in the open position.
FIG. 2 is an elevation view of a hand chain drive embodiment of the present invention showing the top of the drive chain housing.
FIG. 3 is an isometric view of the hand chain drive embodiment of the present invention showing the timer, solenoid, rocker arm assembly, and governor.
FIG. 4 is an isometric view of a curtain or roller door having a motorized chain drive, shown when the door is in the open position.
FIG. 5 is an elevation view of the chain drive embodiment of the present invention showing the top of the motor mount housing.
FIG. 6 is an isometric view of a motorized chain drive embodiment of the present invention showing the timer, solenoid, rocker arm assembly, and governor.
FIG. 7 is an isometric view of a curtain or roller door having a 24 v motor drive wherein the door is in the open position.
FIG. 8 an elevation view of the 24 volt motor drive embodiment of the present invention showing the side of the motor mount housing.
FIG. 9 is an isometric view of the 24 volt motor embodiment of the present invention showing the timer, solenoid, rocker arm assembly, and governor.
FIG. 10A is an exploded view of the rocker arm components of the rocker arm.
FIG. 10B is an exploded view of the centrifugal governor components of the governor.
FIG. 11 is an elevation view of the embodiment of the interior of the gear box of the present invention.
FIG. 12 is an exploded view of the embodiment of the interior of the gear box of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to several embodiments of the invention that are illustrated in the accompanying drawings. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps. The drawings are in simplified form and are not to precise scale. For purposes of convenience and clarity only, directional terms, such as top, bottom, up, down, over, above, and below may be used with respect to the drawings. These and similar directional terms should not be construed to limit the scope of the invention in any manner. The words “connect,” “couple,” and similar terms with their inflectional morphemes do not necessarily denote direct and immediate connections, but also include connections through mediate elements or devices.
FIGS. 1-9 are general overviews of the present invention which illustrate the placement of the mechanism relative to the roll-up door to be driven. It is within the scope and teachings of the present invention that the placement of the mechanism can be either on the right side or the left side, of the housing for the roller drum of the door. Indeed, the mechanism is designed in such a way as to provide easy left or right side adjustment.
Turning to FIG. 1 , there is shown an isometric view of the system 50 of the claimed invention having a curtain or rolling door 9 having a hand chain drive 13 wherein the rolling door 9 is in the open position relative to the doorway of wall section 5 . When rolled up under the control of the hand chain drive 13 of the mechanism 11 , the rolling door 9 is wrapped around a drum (not shown) that runs the length of a housing 7 .
The rolling door 9 is lowered or raised, as the case may be, by a user pulling on chain 13 . The movement of the various components is described in more detail with respect to FIG. 3 . The advantage of the current design is the ability to retrofit any of the primary embodiments to existing door drive systems or to upgrade from one embodiment to another. Further, the mechanism allows for driving a rolling door that can be operated simply as an egress mechanism when utilized with non fire-rated door applications, thus allowing for emergency egress on standard doors.
For a depth perspective, as to placement and fitting of components, we turn to FIG. 2 where there is shown an elevation view of the hand chain drive embodiment of the present invention showing the side wall of the drive chain housing.
Hand chain drive 19 is shown wherein pulling of the chain turns a shaft (view blocked by the pulley and shaft housing wall) which in turn rotates a gear (not shown in this perspective). The gear moves chain 29 which is connected to a gear on the main gear shaft 31 . A chain 21 links main gear shaft 31 with adjusting post 33 and is covered by a plate 17 . The main gear shafts 31 , 33 drive the interior mechanism of the gearbox 35 (described in more detail with respect to FIGS. 11 and 12 ), rotating drive gear 27 , that causes the rolling door 9 to be rolled up or down. The speed of the roll up is governed by the governor not shown, and measured by the rocker arm 23 through the rotation of rocker arm gear 15 . Actuation of the rocker arm 23 for upward or downward movement of the rolling door 9 comes from the in or out action of solenoid 25 under control of the timing switch (not shown).
FIG. 3 is an isometric view of the hand chain drive embodiment of the present invention showing the timer 114 , solenoid 118 , rocker arm assembly 122 , and the speed governor 125 .
The hand drive embodiment receives its drive power from the chain 100 being pulled by a mechanism user. The chain rotates pulley 101 which turns gear 102 . In turn, gear 102 causes chain 104 to move which drives main gear shaft 108 . Main gear shaft 108 supports one end of a chain (not shown) which is covered and protected by plate 106 . The other end of the protected chain drives main gear shaft 110 . The movement of the main gear shafts causes the inner workings (as shown and described in FIGS. 11 and 12 ) of the gearbox 111 to rotate drive gear 124 . Drive gear 124 rotates an inner shaft which causes the shaft to take up or release door 9 which is wound or unwound from a drum in housing 7 . The directionality of the rotation up or down is controlled by the one-way bearing of the rocker arm assembly 122 .
There is shown the rocker arm components of the rocker arm 122 as secured just past the 12:00 o'clock position relative to the top of the drive gear 124 . Gear 120 is secured to rocker arm body 122 with a one-way bearing (not shown) disposed therebetween. Bracket attachment assembly 123 is used to secure the lower portion of rocker arm body 122 while allowing it to pivot when activated so as to engage the gear 120 with the drive gear 124 to control speed under the directional control of the pivoting one-way bearings. Cable holder 116 is secured between the upper portions of the swing bodies 117 so as to hold the cable 113 which links the solenoid 118 and timer switch 114 . The cable is under direction of an emergency back up which causes the timer switch 112 to be set so as to position arm 114 in such a way as to elevate the chain 113 causing the solenoid 118 to be activated which pivots the rocker arm 122 to engage opposite directional, one-way bearing 200 . As the timer reaches its “timed out” position, the arm 114 is dropped, causing the solenoid to open, which in turn pivots rocker arm 122 to engage the one-way bearing 200 so that the rolling door 9 will close.
Alternatively, a stepper motor is used in place of the solenoid 118 . When using the stepper motor, the motor is activated which pivots the rocker arm 122 to engage opposite directional, one way bearing 200 . As the timer reaches its “timed out” position, the timer switch 114 is dropped, causing the stepper motor to turn “a step”, which in turn pivots rocker arm 122 to engage the one-way bearing 200 so that the rolling door 9 will close. To reverse the door, the timer switch 114 is dropped after the lapse of the pre-set period of time. The stepper motor is re-activated and completes a turn of the shaft to reverse the one-way bearing.
Alternatively, the doors are driven horizontally (relative to the door's threshold) from opposing directions so that they meet in the middle of the threshold. The drive mechanism is the same as that provided for the vertical (up or down) movement of the door, except that the drive is biased horizontally instead of laterally.
The speed of the door's descent is extremely important in that too great a speed will cause the door to hit the full down position and bounce and be in the wrong position, or cause strain on the mechanism. To avoid these problems, the mechanism utilizes a centrifugal speed governor.
A view of the centrifugal speed governor 125 , and its components, is shown wherein the governor 125 is shown as secured between the 10:00 and 11:00 o'clock position relative to the top of the drive gear 124 (its position could change if the mechanism becomes “right-handed”). Clutch weights 126 , 126 are slot mounted on the upper portion of the rotor body assembly cap 128 . Clutch pad 130 for braking is secured between the rotor body assembly cap 128 and the fixed rotor 140 . Cap 128 , clutch pad 130 , and fixed rotor 140 are combined to form the rotor body assembly.
The rotor body assembly is transected in the center by shaft 132 which supports the rotor body assembly on one end and the governor gear 142 on the opposite end. The gear 142 is in mated contact with the system's main drive gear 124 so as to control the speed of the door 9 . The gear 142 bisects the supports 134 which are perpendicular (90 degrees) to each other and welded to the bracket 201 .
When activated, the governor 125 rotates to a certain speed, when that speed is increased beyond the threshold speed, slot mounted weights 126 are pulled apart by centrifugal force which causes pressure on the clutch pad 130 , causing the governor 125 to brake the speed of the door's descent.
FIG. 4 is an isometric view of a curtain or rolling door 9 having a chain drive wherein the door is in the open position.
Turning to FIG. 4 , there is shown an isometric view of the system 250 of the claimed invention having a curtain or rolling door 9 and having a motorized chain drive 211 wherein the door 9 is in the open position relative to the doorway of wall section 205 . When rolled up under the control of the chain drive of the mechanism 211 , the rolling door 9 is wrapped around a drum (not shown) that runs the length of housing 207 .
The rolling door 9 is lowered or raised, as the case may be, by the electrical activation of a motor which drives the chain. The movement of the various components is described in more detail with respect to FIG. 6 . The advantage of the current design is the ability to retrofit any of the primary embodiments to existing door drive systems or to upgrade from one embodiment to another.
FIG. 5 is an elevation view of the chain drive embodiment of the present invention showing the top of the motor mount housing.
Chain drive 319 is shown where the chain drive 319 under control of a motor, contained within the chain drive housing 319 , rotates a shaft which in turn rotates a gear (not shown in this perspective). The gear moves chain 321 which is connected to the main gear shafts which are connected with a chain therebetween (not shown). The main gear shafts, in turn, drive the interior mechanism of the gearbox 335 (described in more detail with respect to FIGS. 11 and 12 ), rotating drive gear 327 , that causes the door 9 to be rolled up or down. The speed of the roll up is governed by the governor not shown, and measured by the rocker arm 323 through the rotation of rocker arm gear 315 . Actuation of the rocker arm 323 for upward or downward movement of the rolling door 9 comes from the in or out action of solenoid 325 under control of the timing switch (not shown).
FIG. 6 is an isometric view of the chain drive embodiment of the present invention showing the timer 412 , solenoid 418 , rocker arm assembly 422 , and the centrifugal speed governor 425 .
The chain drive embodiment receives its drive power from the motor driven chain 401 being driven by motor 400 which is preferably a 24 volt DC motor which can be battery backed if necessary or desired. The mechanism and operator drive can be separated, where the mechanism will work in conjunction with external operators for larger size doors that require higher voltage units, where the operator needs a minimum of 110 volt, thru 575 volts. The motor turns gear 404 which moves chain 406 . In turn, gear 404 causes chain 406 to move which drives main gear shaft 408 . Main gear shaft 408 supports one end of a chain (not shown) which is covered and protected by plate 407 . The other end of the protected chain drives main gear shaft 410 . The movement of the main gear shafts 408 , 410 causes the inner workings (as shown and described in FIGS. 11 and 12 ) of the gearbox 411 to rotate drive gear 424 . Drive gear 424 rotates an inner shaft which causes the shaft to take up or release door 9 which is wound or unwound from a drum in housing 7 . The directionality of the rotation up or down is controlled by the pivoting of the one-way bearing of the rocker arm assembly.
There is shown the rocker arm components of the rocker arm 422 as secured just past the 12:00 o'clock position relative to the top of the drive gear 424 . Gear 420 is secured to rocker arm body 422 with a one-way bearing (not shown) disposed therebetween. Bracket attachment assembly 423 is used to secure the lower portion of rocker arm body 422 while allowing it to pivot between one way bearing gear 200 when activated so as to engage the gear 420 with the drive gear 424 to control speed under the directional control of the one-way bearings 200 , 420 . Cable holder 416 is secured between the upper portions of the swing bodies 417 so as to hold the cable 413 which links the solenoid 418 and timer switch 414 . The cable is under direction of an emergency back up which causes the timer switch 412 to be set so as to position timer switch 414 in such a way as to elevate the cable 413 causing the solenoid 418 to be activated which pivots the one-way bearing 420 of the rocker arm to the other one way bearing 200 . As the timer reaches its “timed out” position, the rocker arm 422 is dropped, causing the solenoid 418 to open which in turn pivots to the other one-way bearing so that the door 9 will close.
Alternatively, a stepper motor is used in place of the solenoid 418 . When using the stepper motor, the motor is activated which pivots the rocker arm 422 to engage opposite directional, one-way bearing 200 . As the timer reaches its “timed out” position, the timer switch 414 is dropped, causing the stepper motor to turn “a step”, which in turn pivots rocker arm 422 to engage the one-way bearing 200 so that the rolling door 9 will close. To reverse the door, the timer arm is dropped after the lapse of the pre-set period of time. The stepper motor is re-activated and completes a turn of the shaft to reverse the one-way bearing.
Alternatively, the doors are driven horizontally (relative to the door's threshold) from opposing directions so that they meet in the middle of the threshold. The drive mechanism is the same as that provided for the vertical (up or down) movement of the door, except that the drive is biased horizontally instead of laterally.
The speed of the door's descent is extremely important in that too great a speed will cause the door to hit the full down position and bounce and be in the wrong position, or cause strain on the mechanism. To avoid these problems, the mechanism utilizes a centrifugal speed governor.
A view of the centrifugal speed governor 425 , and its components, is shown wherein the governor 425 is shown as secured between the 10:00 and 11:00 o'clock positions relative to the top of the drive gear 424 (its position will be opposite if the mechanism becomes “right-handed”). Clutch weights 426 , 426 are slot mounted on the upper portion of the rotor body assembly cap 428 . Clutch pad 430 for braking is secured between the rotor body assembly cap 428 and the fixed rotor 440 . Cap 428 , clutch pad 430 , and fixed rotor 440 are combined to form the rotor body assembly.
The rotor body assembly is transected in the center by shaft 432 which supports the rotor body assembly on one end and the governor gear 442 on the opposite end. The gear 442 is in mated contact with the system's main drive gear 424 so as to control the speed of the door 9 . The gear 442 bisects the supports 434 which are perpendicular to each other and welded to the bracket 201 .
When activated, the governor 425 rotates to a certain speed, when that speed is increased beyond the threshold speed, slot mounted weights 426 are pulled apart by centrifugal force which causes pressure on the clutch pad 430 , causing the governor 425 to brake the speed of the door's descent.
FIG. 7 is an isometric view of a curtain or rolling door having a 24 v motor drive wherein the door is in the open position.
Turning to FIG. 7 , there is shown an isometric view of the system 550 of the claimed invention having a curtain or roller door 9 and having a motor drive wherein the door 9 is in the open position relative to the doorway of wall section 505 . When rolled up under the control of the motor drive of the mechanism 511 , the door 9 is wrapped around a drum 515 that runs the length of the interior of housing 207 .
The door 9 is lowered or raised, as the case may be, by the electrical activation of a motor which directly drives the inner workings of the gear box to drive the drive gear. The movement of the various components is described in more detail with respect to FIG. 9 . The advantage of the current design is the ability to retrofit any of the primary embodiments to existing door drive systems or to upgrade from one embodiment to another.
FIG. 8 an elevation view of the 24 volt motor drive embodiment of the present invention showing the side of the motor mount housing.
Motor drive 519 is shown to drive a gear and worm gear assembly 521 , contained within the motor drive housing 519 , rotates a shaft which in turn rotates a gear (not shown in this perspective). The gear moves drives the drive gear 523 in accordance with the description of FIGS. 11 and 12 herein. The rotating drive gear 523 causes the door 9 to be rolled up or down. The speed of the roll up is governed by the governor not shown, and measured by the rocker arm 525 through the rotation of rocker arm gear 527 . Actuation of the rocker arm 525 for upward or downward movement of the door 9 comes from the in or out action of solenoid 529 under control of the timing switch (not shown).
FIG. 9 is an isometric view of the 24 volt motor embodiment of the present invention showing the timer 578 , solenoid 586 , rocker arm assembly 592 , and the centrifugal speed governor 565 .
The motor embodiment receives its drive power from the motor 560 mounted directly until the gearbox 595 . The motor 560 is preferably a 24 volt DC motor which can be battery backed if necessary, or desired; however, for driving heavier loads or peripheral features, a 100 volt motor may be advantageous. Its only drawbacks will be weight and the ineffectiveness of using battery back-up for the high power draw device.
The motor 560 turns the inner workings (as shown and described in FIGS. 11 and 12 ) of the gearbox 595 to rotate drive gear 597 . Drive gear 597 rotates an inner shaft which causes the shaft to take up or release door 9 which is wound or unwound from a drum in housing 7 . The directionality of the rotation up or down is controlled by the pivoting of the one way bearings of the rocker arm assembly. Adjusting posts 562 allow for system adjustment of the timing of the internal gears of the gearbox without having to remove the mechanism from the doorway, or to open up the gearbox for simple adjustments.
There is shown the rocker arm components of the rocker arm 592 as secured just past the 12:00 o'clock position relative to the top of the drive gear 597 . Gears 590 , 200 are secured to rocker arm body 592 with a one-way bearing (not shown) disposed therebetween. Bracket attachment assembly 588 is used to secure the lower portion of rocker arm body 592 while allowing it to pivot when activated so as to engage the gear 590 , or the gear 200 , with the drive gear 597 to control speed under the directional control of the one-way bearings. Cable holder 582 is secured between the upper portions of the swing bodies 584 so as to hold the cable 577 which links the solenoid 586 and timer switch 578 . The cable 577 is under direction of an emergency back up which causes the timer switch 578 to be set so as to position timer switch 580 in such a way as to elevate the cable 577 causing the solenoid 586 to be activated which pivots the rocker arm from one one-way bearing to the other one-way bearing. As the timer reaches its “timed out” position, the timer switch 580 is dropped, causing the solenoid 586 to open which in turn pivots the rocker arm 592 from one one-way bearing to the other one-way bearing so that the door 9 will close.
Alternatively, a stepper motor is used in place of the solenoid 586 . When using the stepper motor, the motor is activated which pivots the rocker arm 422 to engage opposite directional, one-way bearing 200 . As the timer reaches its “timed out” position, the timer switch 580 is dropped, causing the stepper motor to turn “a step”, which in turn pivots rocker arm 592 to engage the one-way bearing 200 so that the rolling door 9 will close. To reverse the door, the timer switch 580 is dropped after the lapse of the pre-set period of time. The stepper motor is re-activated and completes a turn of the shaft to reverse the one-way bearing.
Alternatively, the doors are driven horizontally (relative to the door's threshold) from opposing directions so that they meet in the middle of the threshold. The drive mechanism is the same as that provided for the vertical (up or down) movement of the door, except that the drive is biased horizontally instead of laterally.
The speed of the door's descent is extremely important in that too great a speed will cause the door to hit the full down position and bounce and be in the wrong position, or cause strain on the mechanism. To avoid these problems, the mechanism utilizes a centrifugal speed governor.
A view of the centrifugal speed governor 565 , and its components, is shown wherein the governor 565 is shown as secured between the 2:00 and 3:00 o'clock position relative to the top of the drive gear 597 (its position could change if the mechanism becomes “right-handed”). Clutch weights 566 , 566 are slot mounted on the upper portion of the rotor body assembly cap 568 . Clutch pad 570 for braking is secured between the rotor body assembly cap 568 and the fixed rotor 572 . Cap 568 , clutch pad 570 , and fixed rotor 572 are combined to form the rotor body assembly.
The rotor body assembly is transected in the center by shaft 576 which supports the rotor body assembly on one end and the governor gear 574 on the opposite end. The gear 574 is in mated contact with the system's main drive gear 597 so as to control the speed of the door 9 . The gear 574 bisects the supports 575 , 575 which are perpendicular (90 degrees) to each other and welded to the bracket 201 .
When activated, the governor 565 rotates to a certain speed, when that speed is increased beyond the threshold speed, slot mounted weights 566 are pulled apart by centrifugal force which causes pressure on the clutch pad 570 , causing the governor 565 to brake the speed of the door's descent.
FIG. 10A is an exploded view of the rocker arm components of the rocker arm 620 as secured just past the 12:00 o'clock position relative to the top of the drive gear as is shown in FIG. 9 . Gear 600 , 600 is secured to rocker arm body 603 with one-way bearings 601 , 601 disposed therebetween. Bracket attachment assembly 602 is used to secure the lower portion of rocker arm body 603 while allowing it to pivot when activated so as to pivot between directional bearings gears and the drive gear to control speed under the directional control of the one-way bearings 601 , 601 . Brass washers 604 provide spacing for the fixed shaft 605 which joins brass swing bodies 607 to the rocker arm body 602 on opposite sides of the upper portion of the rocker arm body 608 , which allows the upper portion of the rocker arm body 608 to pivot so as to engage either one of the directional bearing gears. Cable holder 606 is secured between the upper portions of the brass swing bodies 607 so as to hold the cable which links the solenoid and timer switch (see FIG. 3 ).
Turning next to FIG. 10B , there is shown an exploded view of the centrifugal governor components of the governor 650 as secured between the 2:00 and 3:00 o'clock positions relative to the top of the drive gear as is shown in FIG. 9 . Clutch weights 625 are slot mounted on the upper portion of the rotor body assembly cap 626 . Clutch pad 627 for braking is secured between the rotor body assembly cap 626 and the fixed rotor 628 . Cap 626 , clutch pad 627 , and fixed rotor 628 are combined to form the rotor body assembly.
The rotor body assembly is transected in the center by shaft 630 which supports the rotor body assembly on one end and the governor gear 633 on the opposite end. The gear 633 is in mated contact with the system's main drive gear so as to control the speed of the door. The gear bisects the supports 634 which are perpendicular (90 degrees) to each other and welded to the bracket of the surface mount. A set of top bearings 631 and bottom bearings 632 are supported by the bearing cover sleeves 629 , 629 respectively which are in turn supported by the shaft and located on opposite sides of the gear 633 .
When activated, the governor 650 rotates to a certain speed, when that speed is increased beyond the threshold speed, slot mounted weights 625 are pulled apart by centrifugal force which causes pressure on the clutch pad 627 , causing the governor 650 to brake the speed of the door's descent.
The internal workings of the system are best understood by reference to FIG. 11 and FIG. 12 .
FIG. 11 is a plan view of the embodiment of the interior of the present invention; and, FIG. 12 is an exploded view of the embodiment of the interior of the gear box of the present invention. Together, the two FIGs. describe the gearbox for the present invention.
As is shown in FIG. 11 , two adjustable control means, each of which includes a timing gearset 760 , an adjusting gearset 770 and a micro-switch 754 , are mounted in the stationary housing 750 . The timing gearset 760 includes a first timing gear 761 and a second timing gear 762 as are shown in FIG. 12 . The first timing gear 761 has a first recessed surface 811 defined thereon. The second timing gear 762 has a second recessed surface 821 defined thereon. The first timing gear 761 and the second timing gear 762 have a same pitch number (diametral pitch) and a same pitch diameter, but have different tooth numbers.
The first timing gear 761 and the second timing gear 762 are coaxially mounted in the stationary housing 750 . The first recessed surface 811 of the first timing gear 761 is arranged to face the second recessed surface 821 of the second timing gear 762 and the two recessed surfaces 811 and 821 are offset by a predetermined angle in the beginning. Since the tooth number of the first timing gear 761 is different from the tooth number of the second timing gear 762 , the first recessed surface 811 of the first timing gear 761 and the second recessed surface 821 of the second timing gear 762 can coincide with each other when the first timing gear 761 and the second timing gear 762 are rotated, which depends on the difference of the tooth number between the two timing gears.
The adjusting gearset 770 (as shown in FIG. 11 ) includes a first adjusting gear 771 , a second adjusting gear 772 , an adjusting knob 773 , and a connecting rod 774 . The first adjusting gear 771 is mounted in the stationary housing 750 to mesh with the geared portion 721 of the central hub 720 of the driving plate 710 . The second adjusting gear 772 is coaxially mounted with the first adjusting gear 771 . The second adjusting gear 772 is disposed to mesh with the first timing gear 761 and the second timing gear 762 .
As is shown in FIG. 12 , the first adjusting gear 771 has a hub 810 formed at the center thereof. The second adjusting gear 772 is formed as a geared axle in which a circular cross-sectional recess (not shown) and a non-circular cross-sectional recess (not shown) are defined. The circular cross-sectional recess is matched with the non-circular cross-sectional recess. The circular cross-sectional recess is capable of receiving the hub 810 ( FIG. 12 ) of the first adjusting gear 71 . The non-circular cross-sectional recess is capable of receiving the adjusting knob 773 which has a through hole 831 defined therein. It is to be noted that the adjusting knob 773 and part of the second adjusting gear 772 are disposed outside of the stationary housing 750 to conduct an adjustment without dis-assembling the stationary housing 750 . The connecting rod 774 can be inserted in the through hole 831 of the adjusting knob 773 and the central hub 810 of the first adjusting gear 771 to be threadedly engaged with the nut (not shown) provided in the hub 810 to have the second adjusting gear 772 frictionally engaged with the first adjusting gear 771 , so that the second adjusting gear 772 can be integrally rotated with the first adjusting gear 771 . In such an arrangement, when the sun gear 730 is driven to rotate by a motor, the first timing gear 761 and the second timing gear 762 can be rotated via the adjusting gearset 770 .
As can be seen in FIG. 12 , the connecting rod 774 is preferably provided with a wing-like head 775 for facilitating manual adjustment. By means of the wing-like head 775 , the engagement or disengagement between the first adjusting gear 771 and the second adjusting gear 772 can be easily rendered.
As is shown in FIG. 11 , each micro-switch 754 has an actuating lever 840 which is placed in contact with a corresponding timing gearset 760 , which includes the first timing gear 761 and the second timing gear 762 . In such an arrangement, when the motor drives the sun gear 730 in one direction to rotate the driving plate 710 to raise the roller-shutter door, the actuating lever 840 of one micro-switch 754 (first) can extend into the recess which is formed by the coincidence of the first recessed surface 811 ( FIG. 12 ) and the second recessed surface 821 , so that the first micro-switch 754 can be de-actuated to stop the motor. At this time, the roller-shutter door is moved to an upper predetermined limit position.
When the motor drives the sun gear 730 in an opposite direction to rotate the driving plate 710 to lower the roller-shutter door, the actuating lever 840 of the other micro-switch 754 (second) can extend into the recess which is formed by the coincidence of the first recessed surface 811 and the second recessed surface 821 , so that the second micro-switch 754 can be de-actuated to stop the motor. At this time, the roller-shutter door is moved to a lower predetermined limit position. When the aforementioned “upper predetermined limit position” or the aforementioned “lower predetermined limit position” need to be changed to be adaptable for a roller-shutter door of a different height, a corresponding connecting rod 774 can be threadedly unfastened from a corresponding nut (not shown) to allow a corresponding second adjusting gear 772 to disengage from a corresponding first adjusting gear 771 . Therefore, the corresponding second adjusting gear 772 can be turned relative to the corresponding first adjusting gear 771 to change the position of the recessed surface 811 of the first timing gear 761 relative to the recessed surface 821 of the second timing gear 762 , thereby controlling the time at which the motor can be stopped to allow a roller-shutter door to be moved to another limit position.
In the claims, means or step-plus-function clauses are intended to cover the structures described or suggested herein as performing the recited function and not only structural equivalents but also equivalent structures. Thus, for example, although a nail, a screw, and a bolt may not be structural equivalents in that a nail relies on friction between a wooden part and a cylindrical surface, a screw's helical surface positively engages the wooden part, and a bolt's head and nut compress opposite sides of a wooden part, in the environment of fastening wooden parts, a nail, a screw, and a bolt may be readily understood by those skilled in the art as equivalent structures.
Having described at least one of the preferred embodiments of the present 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, modifications, and adaptations may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.
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The present invention is a method and apparatus for driving a roller-shutter door having a drive mechanism. The method comprises the activation of a circuit in response to an external stimuli to a switch. This actuates a timer and raises a timing bar. A cable passes across the timing bar and is connected to the switch on one end and to a solenoid on a second end. The cable passes through a top portion of a rocker arm assembly having a one-way bearing. The solenoid is actuated as a result of the raising of the timing bar; and activates the one-way bearing to cause the door to be raised to a pre-set position for a pre-set period of time. To reverse the door, the timer bar is dropped after the lapse of the pre-set period of time. The solenoid is re-activated and reverses the one-way bearing.
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FIELD OF THE INVENTION
This invention pertains to a type of Reed Solomon decoder that decodes Reed Solomon encoded signals used for error correction in recording media and in digital transmission.
BACKGROUND OF THE INVENTION
The Reed Solomon code (referred to as RS code hereinafter) has a high coding efficiency and a good adaptivity to error bursts, and is hence used mainly as the external code for recording media and in digital transmission.
For example, the error correction code adopted for compact discs is called CIRC correction code (Cross Interleaved Reed Solomon code), and it is a product of two RS codes combined with the interleave technique. It adopts RS ( 28 , 24 ) as its external code, and RS ( 32 , 28 ) as its internal code. They are called the C 2 code and C 1 code, respectively. For all of these codes, each RS code symbol is constructed of 1 byte, and each RS code block contains a 4-byte parity check string.
Usually, for the RS code, correction of t symbol can be performed with a check string of 2t symbols. For correction of t symbols, it is necessary to know t error positions and t error values corresponding to these errors, respectively. For the RS code, when t errors are generated, by performing the syndrome operation on the decoder side, 2t independent linear equations are obtained. When these equations are solved, there are 2t unknown parameters, and it is possible to derive the aforementioned t error positions and the aforementioned t error values corresponding to said error positions, respectively.
On the other hand, as the configuration of the product code, such as CIRC code, is handled, by adding the erasure flag to the RS-encoded block that cannot be corrected and the relatively high RS-encoded block that can be corrected in the internal RS decoding for the internal code, it is possible to correct the erasure error in the external RS decoding corresponding to the external code. The erasure symbol of the internal code with the erasure flag added to it is distributed to plural outer RS-encoded blocks by means of de-interleaving. In the erasure error correction, it is assumed that errors exist in the aforementioned erasure symbol, and the simultaneous equations obtained by the syndrome operation are solved. In solving the equations with the error positions taken as known, it is possible to derive up to 2t error values. That is, for the RS code having a check string of 2t symbols, it is possible to perform correction for errors of up to 2t symbols by executing the erasure error correction.
In the following, explanation will be made on the erasure error correction method with reference to the CIRC code as an example.
In the case of CIRC code, by adding the erasure flag to the RS decoding (C 1 decoding) of the C 1 code as the internal code, it is possible to perform the erasure error correction through the RS decoding (C 2 decoding) of the C 2 code as the external code. As both C 1 code and C 2 code have t=2, the C 1 decoding allows up to 2 bytes of correction, and the erasure error correction of the C 2 decoding allows up to 4 bytes of correction. Syndromes s 0 -s 3 in the C 2 decoding and error values e 1 -e 4 are derived as follows.
Formula (1) below shows the code-generating polynomial Ge(x) of the CIRC code. [ Mathematical Formula 1 ] Ge ( x ) = ∏ j = o 3 ( x + α j ) ( 1 )
Here, α represents the primitive element of the Galois field. In this case, s 0 -s 3 obtained through the syndrome operation from the input series are related to said x 1 -x 4 and e 1 -e 4 by following Formula 2. [ Mathematical Formula 2 ] s0 = e1 + e2 + e3 + e4 s1 = x1 · e1 + x2 · e2 + x3 · e3 + x4 · e4 s2 = x1 2 · e1 + x2 2 · e2 + x3 2 · e3 + x4 2 · e4 s3 = x1 3 · e1 + x2 3 · e2 + x3 3 · o3 + x4 3 · e4 ( 2 )
Here, symbol “·” represents multiplication over the Galois field, and symbol “+” represents addition over the Galois field. In the following, the mathematical operations of the elements of certain Galois fields will be shown.
Simultaneous Formulas 2 listed above are solved, and error values e 1 -e 4 are derived as follows as the unknown values.
First of all, e 4 is obtained as represented by following Formula 3. [ Mathematical Formula 3 ] e4 ← s3 + ( x1 + x2 + x3 ) · s2 + ( x1 · x2 + x2 · x3 + x3 · x1 ) · s1 + x1 · x2 · x3 · s0 ( x4 + x1 ) · ( x4 + x2 ) · ( x4 + x3 ) ( 3 )
e 4 obtained here is substituted into said Formula 2 to reconstruct the simultaneous formulas made of three formulas. That is, by noticing the fact that addition and subtraction are the same for the Galois field used in the CIRC code, correction is performed as shown in following Formula 4, and said Formula 2 as simultaneous equations are transformed to following Formula 5.
[Mathematical Formula 4]
s 0 ←s 0 +e 4
s 1 ←s 1 +x 4 ·e 4
s 2 ←s 2 +x 4 2 ·e 4 (4)
[
Mathematical
Formula
5
]
s0
=
e1
+
e2
+
e3
s1
=
x1
·
e1
+
x2
·
e2
+
x3
·
e3
s2
=
x1
2
·
e1
+
x2
2
·
e2
+
x3
2
·
e3
(
5
)
Solution of the simultaneous formulas is the method often adopted when the sequence is derived by manual calculation. Then, Formulas 5, as simultaneous equations, are solved to derive e3, obtaining following Formula 6. [ Mathematical Formula 6 ] e3 ← s2 + ( x1 + x2 ) · s1 + x1 · x2 · s0 ( x3 + x1 ) · ( x3 + x2 ) ( 6 )
By performing the same correction, said Formulas 5 as simultaneous equations are transformed to following Formulas 7 and 8.
[Mathematical Formula 7]
s 0 ←s 0 +e 3
s 1 ←s 1 +x 3 ·o 3 (7)
[
Mathematical
Formula
8
]
s0
=
e1
+
e2
s1
=
x1
·
e1
+
x2
·
e2
(
8
)
Also, Formulas 8 as simultaneous equations are solved to give e 2 , and following Formula 9 is obtained. [ Mathematical Formula 9 ] e2 ← s1 + x1 · s0 x2 + x1 ( 9 )
Then, the obtained e 2 is substituted into said Formulas 8, giving the following Formula 10.
[Mathematical Formula 10]
e 1 ←s 0 +e 2 (10)
In this way, errors e 1 -e 4 are derived in sequence.
In the aforementioned method, in order to distinguish the original information and the operation performed during the applied decoding operation, symbols “=” and “←” are used to indicate the difference. That is, Formulas 3, 4, 6, 7, 9 and 10 correspond to the applied decoding operation, which requires at least 23 rounds of addition, 17 rounds of multiplication, and 3 rounds of division over the Galois field.
On the other hand, when the erasure error correction is not carried out, it is possible to perform correction up to 2 bytes in the C 2 decoding (double error correction). In this case, error values e 1 and e 2 and error positions x′ 1 and x′ 2 are derived from syndromes s 0 -s 3 .
The aforementioned is the processing procedure of the decoding operation in the case of quadruple erasure error correction, that is, when the number of the erasure positions is 4.
In the following, a conventional Reed Solomon decoder will be explained.
FIG. 9 is a diagram illustrating the configuration of conventional Reed Solomon decoder 1 .
As shown in FIG. 9, Reed Solomon decoder 1 has memory block 2 , bus I/F block 3 , and decoding operation processing unit 4 .
Memory block 2 has cache memories 5 , 6 and switches 7 and 8 .
Switch 7 outputs the input data selectively to cache memories 5 and 6 . Switch 8 outputs the content stored in cache memory 5 to correction operation executor 12 .
Bus I/F block 3 has input parameter operator 9 , register B OUT 10 , binary counter 11 , correction operation executor 12 and register B IN 13 .
Decoding operation processing unit 4 has switch 14 , register G IN 15 , register G OUT 16 , and decoding operator 17 .
FIG. 10 is a diagram illustrating the time sequence of the data and structural elements in the operation of Reed Solomon decoder 1 . (A) represents the input data; (B) represents the output data; (C) represents the memory state of register B OUT 10 ; (D) represents the memory state of register B IN 13 ; (E) represents the memory state of register G OUT 16 ; (F) represents the memory state of register G IN 15 ; and (G) represents the processing state of decoding operator 17 .
As shown in FIG. 10, in cache memory 5 of memory block 2 , when the input data pertaining to the C 1 code are input/output, for the input data pertaining to the C 1 code, bus I/F block 3 calculates the decoding operation input parameter in input parameter operator 9 , and the correction operation is performed in correction operation executor 12 . Also, in this case, in decoding operation processor 4 , C 2 decoding processing is performed for the input data pertaining to the C 2 code.
Also, when input/output of the input data pertaining to the C 2 code are performed in cache memory 6 , bus I/F block 3 calculates the decoding operation input parameter in input parameter operator 9 for the input data pertaining to the C 2 code, and correction operation is performed in correction operation executor 12 . Also, in this case, in decoding operation processing unit 4 , C 1 decoding processing is performed for the input data pertaining to the C 1 code.
Here, specific decoding operation input parameters include syndrome (S) and erasure position (I).
Syndrome (S) is operated by a combination of input parameter operator 9 and register B OUT 10 .
FIG. 11 is a diagram illustrating the structure of input parameter operator 9 and register B OUT 10 , illustrated in FIG. 9 .
As can be seen from FIG. 11, input parameter operator 9 has multipliers 24 - 27 , adders 20 - 23 , erasure flag detector 28 , and distributor 29 .
Also, register B OUT 10 has registers 30 - 33 and registers 34 - 37 .
Multipliers 24 - 27 are multipliers of the Galois field with a fixed value of the multiplication coefficient, and they perform multiplications of xα 0 , xα 1 , xα 2 , xα 3 respectively.
Erasure flag detector 28 detects whether or not the erasure flag contained in the input data is “1”.
Distributor 29 outputs the output of binary counter 11 which operates corresponding to the various RS symbol positions contained in the input data to one of registers 34 - 37 of register B OUT 10 .
The memory result of registers 34 - 37 is represented by erasure position (I).
By means of the converter to be explained later, erasure position (I) is converted to the representation of the Galois field, that is, from “i” to “α i ,” in decoding operator 17 shown in FIG. 9 .
More specifically, conversion is made from I={i 1 , i 2 , i e , i 4 } to X={x 1 , x 2 , x 3 , x 4 }.
When the quadruple dropping error correction is performed, the decoding operation corresponding to said Formulas 3, 4, 6, 7, and 10 is performed in decoding operation processing unit 4 , decoding operation input parameters S={s 0 , s 1 , s 2 , s 3 } and I={i 1 , i 2 , i 3 , i 4 } from register B OUT 10 are converted to obtain X={x 1 , x 2 , x 3 , x 4 }, which is used to obtain decoding operation output parameters E={e 1 , e 2 , e 3 , e 4 } and X′=X={x 1 , x 2 , x 3 , x 4 }. When the dropping error correction is performed, in the aforementioned double error correction, decoding operation input parameter S={s 0 , s 1 , s 2 , s 3 } is used to obtain decoding operation output parameters E={e 1 , e 2 } and X′={x′ 1 , x′ 2 }.
In decoding operation processing unit 4 , error position X or X′ is converted to the exponential value, that is, from α i to i by a converter to be explained later. More specifically, conversion is performed from X′=X={x 1 , x 2 , x 3 , x 4 } to I={i 1 , i 2 , i 3 , i 4 }, and from X′={x′ 1 , x′ 2 } to I′={i′ 1 , i′ 2 }.
FIG. 12 is a diagram illustrating the configuration of correction operation executor 12 and register B IN 13 .
As shown in FIG. 12, correction operation executor 12 has comparator 40 , adder 45 , and logic gate 46 .
Also, register B IN 13 has registers 41 - 44 and registers 47 - 50 .
Bus I/F block 3 executes the correction operation using error value (E) and error position (I′) input from register G OUT 16 .
Binary counter 11 performs operation corresponding to a switch of the output from cache memories 5 and 6 by means of switches 7 and 8 . When the binary count value of binary counter 11 is in agreement with one of the structural elements (i′ n ) of error position (I′), error value en corresponding to logic gate 46 is output to adder 45 . Subsequently, in adder 45 , for error value e n and the data output of memory block from switch 8 , addition over the Galois field is carried out, and the addition result becomes the output data.
In the following, the decoding operation processing unit 4 will be explained.
FIG. 13 is a diagram illustrating the structure of decoding operation processing unit 4 .
As shown in FIG. 13, decoding operation processing unit 4 has microcode ROM 50 , sequencer 51 , destination control 52 , working register 53 , GLU (Global Logic Unit) 54 , and port selector 55 .
For a CIRC code with a t of 4 or smaller, when the solution is derived directly from the simultaneous formulas, and it is acceptable to have a relatively low processing speed, RISC (Reduced Instruction Set Computer) type processing is used as decoding operation processing unit 4 .
In decoding operation processing unit 4 , the various operations are carried out sequentially, and the operation sets are timeshared at GLU 54 . Also, the series of operations are microcoded, stored as instrument codes in microcode ROM 50 , and, by means of the ROM address from sequencer 51 , the processing routine (memory readout routine) is controlled.
Also, the operation results are temporarily stored in plural working registers 53 prepared beforehand. However, the specific working registers 53 for storing are described in the destination control code in the instruction code.
This method, although there is a restriction on the processing speed, is able to reduce the size of the device by means of the time sharing of GLU 54 , and, at the same time, the microcode form of the operation processing can improve the freedom of the design.
For example, the addition of the elements of two Galois fields is equivalent to each bit of an exclusive OR logic operation, and it can be executed in one step in decoding operation processing unit 4 . That is, GLU 54 contains the function of an exclusive OR logic operation for each bit. However, multiplication of the Galois field is much more complicated than addition, and when it is performed using ROM, 1 byte of output is obtained for an input of address of 2 bytes. The scale becomes very large.
The configuration of GLU 54 will now be explained.
FIG. 14 is a diagram illustrating the structure of GLU 54 .
As shown in FIG. 14, GLU 54 has operation logic 60 , 61 , converters 62 , 63 , and operation selector 64 .
In GLU 54 , the elements of input data (a) and (b) of the Galois field are converted to the corresponding exponent of the original element, that is, conversion from α i to i in converter 62 , and addition of the exponents is carried out. Then, the obtained addition result is converted to the element of the corresponding Galois field in converter 63 , that is, i is converted to α i .
For example, when multiplication of α v and α w is executed to obtain α v+w , in GLU 54 , the four operations shown by following Formula 11 are needed, and at least four steps are necessary. [Formula 1-1] 1: v ← α v 2: w ← α w 3: v + w ← v , w 4: α w + w ← v + w ( 11 )
In the same way, division is also performed by performing subtraction of the exponent portion in place of addition of the exponent portion in the case of multiplication.
Consequently, in the aforementioned method, when error values e 1 -e 4 are derived, in said Formulas 3, 4, 6, 7, 9, and 10, multiplication and division are performed in 20 rounds, and in this step alone, 80 or more rounds are needed. In addition, 23 rounds of addition are performed, and a total of 103 or more steps are needed. Consequently, there is no way to meet the demand for high-speed processing.
Also, when t is larger than 4, solving the simultaneous Formulas as shown in said Formula 2 is unrealistic. Consequently, the Euclidian decoding method or another repeating algorithm is adopted.
However, for both multiplication and division of the Galois field, 4 steps are needed, and it is hard to realize high-speed processing.
On the other hand, the demand for speed in the data reproduction of the CD-ROM is now as high as X 2 to X 12 , and the restriction imposed by the processing step number of the error correction becomes more and more severe. In addition, as the reading error of the output system is naturally large, and there is a high demand for strengthening the correction power by means of the aforementioned erasure error correction. That is, it is necessary to realize a higher function in fewer steps.
In order to realize the C 1 decoding and C 2 decoding corresponding to the X 12 reproduction speed, for example, suppose one step of the operation is completed in one clock cycle of 16 MHz, it is necessary to execute each round of decoding of C 1 and C 2 within 192 steps. Since this condition includes branching processing and other peripheral processing, it is necessary to perform processing of the core of the C 2 decoding in less then ¼ the steps.
However, in the conventional constitution, for example, when the dropping error correction is performed in C 2 decoding, by performing the correction core processing, 103 or more steps are needed, and it is thus impossible to meet the demand for the high-speed processing.
The purpose of this invention is to solve the aforementioned problems of the conventional technology by providing a type of Reed Solomon decoder which can perform high-speed decoding operation without significantly increasing the circuit scale.
SUMMARY OF THE INVENTION
In order to realize the aforementioned purpose to solve the aforementioned problems, this invention provides a type of Reed Solomon decoder characterized by the following facts: the Reed Solomon decoder has the following means: an input parameter operation means which generates a syndrome and disappearing data for a data sequence, a decoding operation means which performs the decoding operation using the aforementioned syndrome and disappearing data based on the command code indicating the prescribed decoding operation, and which generates the error data and error position data, and a correction operation means which performs the correction operation using the aforementioned error data and error position data; in this Reed Solomon decoder, the aforementioned decoding operation means has an operation processing unit for executing the product and sum operations in a single step for a Galois field.
For the Reed Solomon decoder of this invention, the aforementioned decoding operation means has the following parts: at least a first input port, second input port, and third input port, a multiplier performing multiplication operation for the data input from the aforementioned first input port and the aforementioned second input port, and an adder performing addition for the output data of the aforementioned multiplier and the data input from the aforementioned third input port.
In the Reed Solomon decoder of this invention, data are input to the first input port, second input port, and third input port of the aforementioned decoding operation means; in a multiplier, multiplication operation for the data input from the aforementioned first input port and the aforementioned second input port is performed; then, addition is performed for the output data of the aforementioned multiplier and the data input from the aforementioned third input port in a single step of operation.
Also, for the Reed Solomon decoder of this invention, it is preferred that the aforementioned decoding operation means have the following parts: a first memory means which stores the aforementioned command codes, a sequencer which controls the order of execution of the aforementioned command codes, a second memory means which has plural operation registers for temporary storage of the results of operation of the aforementioned operation processing unit, and a port selecting means which outputs the contents of the aforementioned plural operation registers to the aforementioned first through third input ports of the aforementioned decoding operation means.
Also, for the Reed Solomon decoder of this invention, it is preferred that the aforementioned second memory means store the operation result from the aforementioned operation processing unit in the aforementioned operation register determined corresponding to the aforementioned command code, and the contents stored in the aforementioned plural operation registers be output to any of said first through third input ports by means of the aforementioned port selecting means, respectively.
For the Reed Solomon decoder of this invention, it is preferred that the aforementioned second memory means we shift registers as the aforementioned operation registers and initially store the operation result obtained from the aforementioned operation processing unit in a prescribed operation register. The contents in the aforementioned operation registers can be output to any of the aforementioned first through third input ports by the aforementioned port selecting means, respectively.
Also, for the Reed Solomon decoder of this invention, it is preferred that the aforementioned command code have an operation field and a field which assigns the input port among said first through third input ports of the aforementioned decoding operation means for output of the content stored in the aforementioned plural operation registers.
Also, for the Reed Solomon decoder of this invention, it is preferred the aforementioned decoding operation means have i multipliers, which are multipliers for performing multiplication of the first element α w (A w,i−1 ,A w,i−2 ,A w,i−3 , . . . , A w,3 , A w,2 ,A w,1 ,A w,0 ) T and the second element α v (A v,i−1 ,A v,i−2 ,A v,i−3 , . . . , A v,3 ,A v,2 ,A v,1 ,A v,0 ) T of Galois field GF ( 2 i ) and which performs in parallel the multiplier operations for the aforementioned first element and α 0 , α 1 , α 2 , α 3 , . . . , α i−3 , α i−2 , α i−1 of the primitive element α of the aforementioned Galois field, respectively; an AND operation unit which performs in parallel the AND operations for the results of multiplication of said i units of multiplier and said A v,0 ,A v,1 ,A v,2 ,A v,3 , . . . , A v,i−3 ,A v,i−2 ,A v,i−1 ; and an adder which performs addition for the results of operation of said i AND operation units.
In addition, for the Reed Solomon decoder of this invention, it is preferred for the aforementioned decoding operation means to have the following parts: i AND operation units which are multipliers that perform multiplication for the first element
α w (A w,i−1 ,A w,i−2 ,A w,i−3 , . . . ,A w,3 ,A w,2 ,A w,1 ,A w,0 ) T
and the second element
α v (A v,i−1 ,A v,i−2 ,A v,i−3 , . . . ,A v,3 ,A v,2 ,A v,1 ,A v,0 ) T
of said Galois field GF ( 2 i ), and which performs in parallel the AND operations for said first element and said
A v,0 ,A v,1 A v,2 ,A v,3 , . . . ,A v,i−3 ,A v,i−2 ,A v,i−1
respectively; i multipliers which perform in parallel the multiplier operations for the results of operation of the aforementioned AND operation units and
α 0 ,α 1 ,α 2 ,α 3 , . . . ,α i−3 ,α i−2 ,α i−1
of primitive element α of said Galois field.
BRIEF DESCRIPTION OF THE DRAWINGS
[FIG. 1 ]
FIG. 1 is a diagram illustrating the configuration of the multiplier of the Galois field in an embodiment of this invention.
[FIG. 2 ]
FIG. 2 is a diagram illustrating the configuration of another multiplier of the Galois field in an embodiment of this invention.
[FIG. 3 ]
FIG. 3 is a diagram illustrating the configuration of the decoding operation processing unit of the Reed Solomon decoder in an embodiment of this invention.
[FIG. 4 ]
FIG. 4 is a diagram illustrating the configuration of the GLU shown in FIG. 3 .
[FIG. 5 ]
FIG. 5 is a diagram illustrating the configuration of the GF product/sum operation logic and the working register.
[FIG. 6 ]
FIG. 6 is a diagram illustrating the format of the instruction code shown in FIG. 3 .
[FIG. 7 ]
FIG. 7 is a diagram illustrating another configuration of the working register shown in FIG. 4 .
[FIG. 8 ]
FIG. 8 is a diagram illustrating another format of the instruction code shown in FIG. 3 .
[FIG. 9 ]
FIG. 9 is a diagram illustrating the conventional Reed Solomon decoder.
[FIG. 10 ]
FIG. 10 illustrates the time sequence states of the data and structural elements in the operation of the Reed Solomon decoder. FIG. 10 (A) shows the input data; (B) shows the output data; (C) shows the memory state of register B OUT ; (D) shows the memory state of register B IN ; (E) shows the memory state of register G OUT ; (F) shows the memory storage of register G IN ; and (G) shows the processing state of the decoding operator.
[FIG. 11 ]
FIG. 11 is a diagram illustrating the configuration of the input parameter operator and the register shown in FIG. 9 .
[FIG. 12 ]
FIG. 12 is a diagram illustrating the configuration of the correction operation executor and register shown in FIG. 9 .
[FIG. 13 ]
FIG. 13 is a diagram illustrating the configuration of the decoding operation processing unit.
[FIG. 14 ]
FIG. 14 is a diagram illustrating the configuration of the GLU shown in FIG. 13 .
REFERENCE NUMERALS AS USED IN THE DRAWINGS
104 represents a decoding operation processing unit, 150 a microcode, 151 a sequencer, 152 , a destination controller, 153 a working register, 154 a GLU, 155 a port selector, 160 , 161 operation logic, 162 , a GF inversion ROM, 163 a GF product-and-sum operation logic, 164 an operation selector.
DESCRIPTION OF EMBODIMENTS
In the following, the Reed Solomon decoder pertaining to an embodiment of this invention will be explained.
As a direct method for realizing high-speed processing, multiplication and division of the Galois field are realized in a single step. Although it can be realized by ROM, the size of the ROM is very large (a capacity of 64 KB) as pointed out in the above. However, for multiplication, its uniformity is exploited to realize a high-speed multiplier by about 300 gates.
As an example, the case of a Galois field GF( 2 i ) with i=8 is shown.
First of all, the original element of Galois field ( 2 8 ) is taken as α. The element α v can be represented by the following Formulas 12 and 13. α v - ∑ i = U 7 Av , i α i ( 12 ) (α v )=(Av,7Av,6. . . Av,1Av,0) T (13)
Here,
A v,i =0
or 1, and v represents any integer. Also, (α v ) represents the row vector expression of element α v , and
( . . . ) T
represents the transposed matrix.
Here, the multiplication of any elements α v and α w of the aforementioned Galois field. From said Formula 13, following Formula 14 is established. α v + w - α v · α w = { ∑ i = 0 7 Av · i α i } · α w = ∑ i = 0 7 Av · i α i · α w ( 14 )
As said Formula 14 is represented by the row vector, the following Formula 15 is obtained. ( α v + w ) = ∑ i = 0 7 Av · i [ x α i ] ( α w ) ( 15 )
Here, [Xα i ] is an 8×8 matrix corresponding to multiplication of α i . That is, following Formula 16 is established.
[ xα i ](α w )=(α i+w ) (16)
More specifically, from the field-generating polynomial represented by the following Formula 17 of the Galois field of the CIRC code, following Formulas 18 and 19 are established.
Gp( x )= x 8 +x 4 +x 3 +x 2 +1 (17)
[ x α ] = ( 0 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 1 0 0 0 0 1 0 0 0 1 0 0 0 1 0 0 0 0 1 0 0 1 0 0 0 0 0 1 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 ) ( 18 ) [ xα i ]=[xα] i (19)
From said Formula 15, the multiplier of the Galois field has the following configuration as shown in FIG. 1 . One of two inputs (α w , α v ) is multiplied with α 0 -α 7 by multipliers 111 - 118 , respectively. The other input is gated by AND gates 121 - 128 to obtain eight 8-byte outputs. They are added (exclusive OR logic operation for each bit) by GF adder 129 .
According to said Formulas 18 and 19, the coefficient multipliers corresponding to [xα 0 ]˜[α 7 ], respectively, can be realized through 3-21 exclusive OR logic operation gates, and the overall multipliers of the Galois field can be realized with about 300 gates. The coefficient multipliers are multipliers with a fixed value.
The delay amount of each multiplier is, say, 10 nsec or less, and it well allows processing in one clock cycle of 16 MHz.
Also, said Formula 15 can be modified to the following Formula 20. ( α v + w ) = ∑ i = 0 7 Av , i [ x α i ] ( α w ) = ∑ i = 0 7 [ x α i ] ( Av , i ( α w ) ) ( 20 )
Corresponding to this, the multipliers of the Galois field can have AND gates set on the input side as shown in FIG. 2 . That is, the AND for two inputs (α w , α v ) is derived by means of AND gates 131 - 138 , and the results are multiplied with α 0 -α 7 by multipliers 141 - 148 , respectively, followed by addition by GF adder 129 .
For division of the Galois field, first of all, the inverse element of the divisor is derived, and it is then multiplied with the element of the dividend by the aforementioned multiplier. That is, it requires two steps. When the aforementioned inverse element is derived, it is acceptable to obtain 8-bit output with respect to the 8-bit input. Consequently, it can be realized by means of a ROM having a capacity of 256 bytes. This corresponds to 500 gates, and this has little impact on the circuit scale.
As explained above, by means of an 800-gate circuit, it is possible to perform multiplication of the Galois field in 1 step, and to perform division in 2 steps. In this way, for said Formulas 3, 4, 6, 7, 9, and 10, the 17 rounds of multiplication can be realized in 17 steps, and the 3 rounds of division can be realized in 6 steps. With the 23 rounds (23 steps) of addition included, it is possible to realize the operation in a total of 46 steps.
Although this number of steps is half that of the conventional case, response to the multifunctional request is still insufficient. For example, when it is necessary to make plural uses, such as in the case of no erasure error in audio reproduction and erasure error correction in the case of data reproduction, in order to prevent an increase in the microcodes (the set of instruction codes) stored in the memory, it is necessary for the microcodes to be shared only to enable the formation of subroutines for the common processing. Also, the operation performed by said Formulas 3, 4, 6, 7, 9, and 10 corresponds to the case of quadruple erasure error correction. However, it is also possible to perform triple erasure error correction depending on the number of the erasure symbols. However, the amount of branch processing and other peripheral processings increases, and the number of the steps that can be used in the various correction core processing is limited.
In order to cut the number of steps, the following efforts have been made.
The item of the numerator in said Formula (3) is modified Equation 21 as follows. e4 ← s3 + ( x1 + x2 + x3 ) · s2 + ( x1 · x2 + x2 · x3 + x3 - x1 ) · s1 + x1 · x2 · x3 · s0 ( x4 + x1 ) · ( x4 + x2 ) · ( x4 + x3 ) s3 + x2 · s2 + x1 · ( s2 + x2 · s1 ) + x3 · ( s2 + x2 · s1 + x1 - ( s1 + x2 · s0 ) ) ( x4 + x1 ) · ( x4 + x2 ) · ( x4 + x3 ) ( 21 )
Then, by correction of the syndrome, e 3 is obtained using said Formula 6, and as shown by the following Formulas 22 and 23, transformation is performed to have the same product/sum operation form.
s 0 ←s 0 +e 4
s 1 ←s 1 +x 4 ·e 4
s 2 ←s 2 +x 4·( x 4 ·e 4) (22)
e3
←
s2
+
(
x1
+
x2
)
·
s1
+
x1
·
x2
·
s0
(
x3
+
x1
)
·
(
x3
+
x2
)
=
s2
+
x2
·
s1
+
x1
·
(
s1
+
x2
·
s0
)
(
x3
+
x1
)
·
(
x3
+
x2
)
(
23
)
The remaining is unchanged and is represented by the following Formulas 24, 25 and 26.
s 0 ←s 0 +e 3
s 1 ←s 1 +x 3 ·e 3 (24)
e2 ← s1 + x1 · s0 x2 + x1 ( 25 ) e 1 ←s 0 +e 2 (26)
According to said Formulas 21-26, many product-and-sum operations appear. However, as shown in FIG. 3, by using the global logic unit (GLU) as the 3-input product-and-sum operation unit, it is possible to realize each product-and-sum operation in one step. In this case, decoding operation processing unit 104 is shown in FIG. 3, and GLU peripheral structural diagram is shown in FIG. 4 (yet containing the signal indicated by the broken line).
In the following, the constitution of Reed Solomon decoder 101 of this embodiment will be explained in detail.
The overall constitution of Reed Solomon decoder 101 is basically identical to the conventional Reed Solomon decoder 1 shown in FIG. 9 . However, the decoding operation processing unit of Reed Solomon decoder 101 differs from decoding operation processing unit 4 .
FIG. 3 is a diagram illustrating the constitution of decoding operation processing unit 104 of Reed Solomon decoder 101 .
As shown in FIG. 3, decoding operation processing unit 104 has microcode ROM 150 , sequencer 151 , destination controller 152 , working register 153 , GLU (Global Logic Unit) 154 , port selector 155 .
For example, an RISC type decoding operation processor may be used as decoding operation processing unit 104 .
In decoding operation processing unit 104 , the various operations are carried out sequentially, and the operation set is time shared at GLU 154 . Also, a series of operation processing is represented by microcodes, which are stored as instruction codes in microcode ROM 150 . By means of the ROM address, sequencer 151 , the processing order (the order of readout from the memory) is controlled.
Also, the results of midway operation are temporarily stored in plural working register 153 . Assignment of the specific working register among working registers 153 a , 153 b , 153 c for storing is described in the destination control code input through destination controller 152 .
FIG. 4 is a diagram illustrating the constitution of GLU 154 .
As can be seen from FIG. 4, GLU 154 has the following parts: operation logic 160 , 161 , GF inversion ROM 162 , GF product-and-sum logic 163 , and operation selector 164 .
Here, GF inversion ROM 162 outputs the inverse element of the Galois field of the input (input: α 1 →output: α −1 ).
FIG. 5 is a diagram illustrating the constitution of GF product-and-sum logic 163 and working register 153 of GLU 154 .
As shown in FIG. 5, GF product-and-sum logic 163 has multiplier 163 a and adder 163 b . As multiplier 163 a , multiplier 110 shown in FIG. 1 or multiplier 130 shown in FIG. 2 is used, and multiplication of Galois field ( 2 8 ) is realized in a single step.
Also, in working register 153 , there are registers 153 a , 53 b , and 153 c .
In each step, operation of the numerator of said Formula 21 is modified as the following Formula 27. 1: A ( s1 + x2 · s0 ) ← s1 , x2 , s0 2: B ( s2 + x2 · s1 ) ← s2 , x2 , s1 3: C ( s2 + x2 · s1 + x1 · ( s1 + x2 · s0 ) ) ← B ( s2 + x2 · s1 ) ) x1 , A ( s1 + x2 · s0 ) 4: A ( s3 + x2 · s2 ) ← s3 , x2 , s2 5: A ( s3 + x2 · s2 + x1 · ( s2 + x2 · s1 ) ) ← A ( s3 + x2 · s2 ) , x1 B ( s2 + x2 · s1 ) 6: A ( s3 + x2 · s2 + x1 · ( s2 + x2 · s1 ) + ← A ( s3 + x2 · s2 + x1 · ( s2 + x2 · s1 ) ) x3 , C ( s2 + x2 · s1 + x1 · ( s1 + x2 · s0 ) ) x3 · ( s2 + x2 · s1 + x1 · ( s1 + x2 · s0 ) ) ( 27 )
Here, A-C represent registers 153 a , 153 b , and 153 c in working register 153 , and A(z) represents that the content of register 153 a is “z.” Also, the time on the input side on the right on the time of the 1 step prior to the output side on the left. The three values on the right in each step are the input signals of ports c, b and a of GLU 154 . For example, in first step (1:), “s 1 ” is input to port c, “x 2 ” is input to port b, and “s 0 ” is input to port a.
Based on the destination control code, destination controller 152 controls which registers 153 a , 153 b , and 153 c in working register 153 is assigned for storing GLU data S 154 from GLU 154 . For example, in first step (1:) of said Formula 27,
“ s 1 +x 2 ·s 0 ”
as GLU data S 154 are stored in register 153 a.
In this way, the operation of the numerator in said Formula 21 can be executed by 6 rounds of product-and-sum operation, and the remaining is subjected to 3 rounds of addition, 2 rounds of multiplication, and 1 round of division to derive said error value e 4 .
Also, correction of the syndrome of said Formula 22 also can be executed by 2 rounds of the product-and-sum operation, 1 round of addition, and 1 round of multiplication.
Similarly, the operation of said Formula 23 is executed by 3 rounds of the product-and-sum operation, 2 rounds of addition, 1 round of multiplication, and 1 round of division. Then, correction of the syndrome of said Formula 24 is performed by 1 round of the product-and-sum operation and 1 round of addition.
In addition, for said Formula 25, 1 round of the product-and-sum operation, 1 round of addition, and 1 round of division are executed. Then, for said Formula 26, 1 round of addition is performed.
In this way, the quadruple dropping error correction of the C 2 code is executed by 13 rounds of product-and-sum operation, 9 rounds of addition, 4 rounds of multiplication, and 3 rounds of division. That is, the total number of steps is 13+9+4+3×2=32. That is, the operation can be realized in less than ⅓ steps of the conventional method.
In the following, instruction code S 150 shown in FIG. 3 will be explained.
FIG. 6 is a diagram illustrating the format of instruction code S 150 .
For multiplication, addition, and division (or multiplication after deriving the inverse element), there are two or less inputs. Consequently, instruction code S 150 is made of 4 fields (solid line in FIG. 6 . That is, instruction code S 150 contains in each field the following codes: operation code S 150 a which assigns the specific type of operation GLU 154 is to execute, port a select code S 150 b and port b select code S 150 c which assign the signals to be input to the two input ports (port a and port b in this example), and destination control code S 150 d which assigns the register of working register 153 for input of GLU data S 154 . For example, suppose each of said four fields comprises 4 bits, it is able to assign up to 16 operations, 16 input elements and 16 output elements, respectively.
In GLU 154 containing GF product-and-sum logic 163 shown in FIG. 5, it is necessary to select three inputs, and there are three input select fields only for the product-and-sum operation. As indicated by the broken line in FIG. 6, four more bits are needed to assign the third input port (taken as port c) as indicated by the broken line shown in FIG. 6 ), so that there are in all 20 bits in 5 fields for instruction code S 150 . However, since the input select field of port c is used only in the product-and-sum operation, there is a waste and the result is not economical.
Destination controller 252 and working register 253 shown in FIG. 7 are for improving the aforementioned economy. When the operation code assigns the product-and-sum operation, destination controller 252 controls working register 253 so that GLU data S 154 from GLU 154 are stored and fixed in register 253 a . In this way, there is no need to control the output destination of data S 154 of GLU 154 . Consequently, there is no need to have the destination control code. In this way, as shown in FIG. 8, it is possible to set port c select code in place of the destination control code only in the case of the product-and-sum operation. That is, as shown in FIG. 8, it is possible to allocate in a time division form the destination control code and port c select code. As a result, it is possible to prepare instruction code S 150 only for 4 fields, and there is no increase in the bit number of the instruction code. Consequently, it is possible to prevent the scale of the circuit from becoming larger.
Also, when an operation other than the product-and-sum operation is assigned, if registers 253 a , 253 b , and 253 c of working register 253 are controlled by the destination control code, it is possible to use registers 253 a , 253 b , and 253 c as the conventional working registers.
In this case, as shown in FIG. 3, decoding operation processing unit 104 includes control by the signal indicated by the broken line, that is, control of destination controller 152 by operation code S 150 a.
In addition, as shown in FIG. 7, in consideration of the fact that the product-and-sum operation may be continued, registers 253 a , 253 b and 253 c are made of shift registers.
In the following, for use of the constitution shown in FIG.s 7 and 8 , the specific signal flow will be explained with respect to the operation of the numerator of said Formula 21.
In this case, the signal flow is represented by the following Formula 28. [Formula 2-8] 1: A ( s1 + x2 · s0 ) ← s1 , x2 , s0 B ( . ) ← A ( . ) C ( . ) ← B ( . ) 2: A ( s2 + x2 · s1 ) ← s2 , x2 , s1 B ( s1 + x2 · s0 ) ← A ( s1 + 2 · s0 ) C ( . ) ← B ( . ) 3: A ( s2 + x2 · s1 + x1 · ( s1 + x2 · s0 ) ) ← A ( s2 + x2 · s1 ) , x1 , B ( s1 + x2 · s0 ) B ( s2 + x2 · s1 ) ← A ( s2 + x2 · s1 ) C ( s1 + x2 · s0 ) ← B ( s1 + x2 · s0 ) 4: A ( s3 + x2 · s2 ) ← s3 , x2 , s2 B ( s2 + x2 · s1 + x1 · ( s1 + x2 · s0 ) ) ← A ( s2 + x2 · s1 + x1 · ( s1 + x2 · s0 ) ) C ( s2 + x2 · s1 ) ← B ( s2 + x2 · s1 ) 5: A ( s3 + x2 · s2 + x1 · ( s2 + x2 · s1 ) ) ← A ( s3 + x2 · s2 ) , x1 , C ( s2 + x2 · s1 ) B ( s3 + x2 · s2 ) ← A ( s3 + x2 · s2 ) C ( s2 + x2 · s1 + x1 · ( s1 + x2 · s0 ) ) ← B ( s2 + x2 · s1 + x1 · ( s1 + x2 · s0 ) ) 6: A ( s3 + x2 · s2 + x1 · ( s2 + x2 · s1 ) + ← A ( s3 + x2 · s2 + x1 · ( s2 + x2 · s1 ) ) x3 , C ( s2 + x2 · s1 + x1 · ( s1 + x2 · s0 ) ) x3 · ( s2 + x2 · s1 + x1 · ( s1 + x2 · s0 ) ) B ( . ) ← A ( s3 + x2 · s2 + x1 · ( s2 + x2 · s1 ) ) C ( . ) ← B ( s3 + x2 · s2 ) ( 28 )
Here, (·) indicates that the content is omitted. In each step, three treatments are performed at the same time, and the time system on the right is the time 1 step ahead of that on the output side the left. Also, the three values on the right of the initial row in each step are the port input signals of ports c, b and a of GLU 154 , respectively.
In this way, the operation of the numerator of said Formula 21 can be executed in 6 steps in this embodiment, and it is possible to realize the aforementioned quadruple erasure error correction in a total number of steps of 32.
Various modifications are allowed for this embodiment. More specifically, it is believed that there are various modifications that can be made for said Formula 20. For example, modification allows that shown in the following Formula 29. [ Formula 29 ] e4 = s3 + ( x1 + x2 + x3 ) · s2 + ( x1 · x2 + x2 · x3 + x3 · x1 ) · s1 + x1 · x2 · x3 · s0 ( x4 + x1 ) · ( x4 + x2 ) · ( x4 + x3 ) = s3 + x1 · s2 + x2 · ( s2 + x1 · s1 ) + x3 · ( s2 + x1 · s1 + x2 · ( s1 + x1 · s0 ) ) ( x4 + x1 ) · ( x4 + x2 ) · ( x4 + x3 ) ( 29 )
In this case also, the same product-and-sum operation circuit may be adopted. Also, in the present embodiment, derivation from e 4 is performed. However, it is also possible to obtain from the other error values in order. In addition, as shown in FIG. 3, the inverse element operation of the Galois field is performed in ROM. However, it is also possible to use a logic circuit to construct it.
Also, this invention is not limited to CIRC code. It is not limited to erasure error correction, and can be used in the general RS decoders containing the product-and-sum operation.
As explained in the above, by means of Reed Solomon decoder 101 , the product-and-sum operation can be performed in a single step, and it is possible to use ROM 150 on a relatively small scale with correction processing carried out in a shorter time.
Also, for Reed Solomon decoder 101 , by adopting the configuration shown in FIG. 7 and the format of instruction code S 150 shown in FIG. 8, it is possible to reduce the number of bits of instruction code S 150 , and this can effectively increase the scale of the circuit.
As explained in the above, the Reed Solomon decoder of this invention can perform high-speed decoding operation without significantly increasing the circuit scale.
|
A Reed Solomon decoder which can perform high-speed decoding operation without significantly increasing the circuit scale. The Reed Solomon decoder includes the following: input parameter operator 309 which generates syndrome and erasure data for a data sequence, decoding operation processing unit 304 which performs the decoding operation using the aforementioned syndrome and erasure data based on the command code indicating the prescribed decoding operation, and which generates the error data and error position data, and correction operation executor 312 which performs the correction operation using the aforementioned error data and error position data. The decoding operation processing unit 304 has an multiplier and an adder which execute the product and sum operation of the Galois field in one step.
| 6
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention provides a file folder, box and panel designed with pre-perforated holes, grooves and slots in which file panels and file clips are separately designed. The file clips are selective depending what the type of file folders are used. The separation of file folders from the file clips renders easy environmental recycling and resource reusing in later time.
2. Description of the Related Art
The prior art of most file folder panels and file clips are permanently fixed, impermissible for disassembly and replacement. It offers a si with limited function.
When the file folder panel and the file clip are holding a plurality of paper, and while the file folder is horizontally placed, it usually happens in this way that the document paper will be inclined on the account of gravity, and eventually get loose.
In most cases, the file folder panels are of plastic material, and the file clips, the metal material. Once the file folder panel becomes obsolete, since the file folder panel and the file clip are bound permanently together, will create an environmental problem because it is hard to recycle.
BRIEF SUMMARY OF THE INVENTION
The file folder panel can be designed in the term of single, double, treble or multi-panel, with a plurality of holes, grooves, slots pre-perforated on the panel, the indentations on the panel edge and a flap extended on the panel top border. The pre-perforated holes, grooves and slots are capable of being fixed by many kinds of file clips (such as D clamp, German clip, Spring clip, go-through clip, hole clip, etc.) The pre-perforated holes and slot on the file panel allows binding and winding with elastic trap, the groove for the clamp band to go through. The edge flap, after erected properly, provides pre-perforated holes and groove as a passage for the file clips to hold the paper documents.
The invention realizes the following achievements:
(1) The file shell and the file clip are a separate design, where the shell (the file folder panel) permits being flatly piled up to save much of space in storage and transportation. The users will buy the file clips for self-erection at an adequate quantity without an excessive stock. When the file folder panel is worn out, the file clip can be reused on the new file folder panel. The worn shell and document paper can be recycled for regeneration.
(2) The holes, grooves, slots and indentations pre-perforated on the file folder panel offer the user a wide range of selecting the file clips, convenient to erect and easy to adjust the file folder.
(3) The file folder panel furnishes easy relocation of the file clips, suitable both for Chinese and Western document patterns.
(4) single file folder panel, erected with a plurality of file clips, conducive to holding different sizes of document paper.
(5) Besides the file folder, it can work as handwriting board and drawing board, suitable for carrying along on the outdoor work.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 shows the extension diagram of the file folder panel ( 1 ) of the invention.
FIG. 2 illustrates the fold up diagram of the file folder panel ( 1 ) of the invention.
FIG. 3 displays the file folder panel ( 1 ) of the invention mounted with file clip.
FIG. 4 shows the extension diagram of the file folder panel ( 2 ) of the invention.
FIG. 5 illustrates the fold up diagram of the file folder panel ( 2 ) of the invention.
FIG. 6 displays the file folder panel ( 2 ) of the invention mounted with file clip.
FIG. 7 shows the snap with stud and socket of the invention
FIG. 8 displays the stereo diagram of the staple of the invention.
FIG. 9 shows the file folder panel ( 1 ) mounted with elastic band
FIG. 10 displays the document paper is held by the elastic and on the file folder panel ( 1 ).
FIG. 11 demonstrates another embodiment of the file folder panel ( 1 ).
FIG. 12 shows the file folder panel ( 3 ) mounted with elastic band
FIG. 13 shows the extension diagram of the file folder panel ( 4 ) of the invention.
FIGS. 14 15 and 17 show the file folder panel ( 4 ) mounted with different file clips.
FIG. 16 is the section of FIG. 15, the file folder panel ( 4 ) mounted with file clip.
FIGS. 18 and 19 display the method of binding elastic band on the file folder panel ( 4 )
FIG. 20 shows the file folder panel ( 4 ) mounted with double file clips.
FIG. 21 displays the file folder panel ( 4 ) is in the vertical hanging position.
FIG. 22 shows the file folder panel ( 4 ) with the central crease mounted with the strong clip.
FIG. 23 shows an A-frame converted from the file folder panel ( 4 ) of the invention.
FIG. 24 exhibits the photo frame or painting frame in flat position converted from the file folder panel ( 4 ) of the invention.
FIG. 25 displays the hanging photo frame or painting frame from the file folder panel ( 4 ) of the invention.
FIG. 26 shows a restaurant menu from the file folder panel ( 4 ) of the invention.
FIG. 27 illustrates the month calendar from the file folder panel ( 4 ) of the invention.
FIG. 28 displays a memo pad from the file folder panel ( 4 ) of the invention.
FIG. 29 shows a loose leaf pad from the file folder panel ( 5 ) of the invention.
FIG. 30 displays the file folder panel is laminated with two thin paper on its front and back.
FIG. 31 illustrates a diagram of the file folder panel in FIG. 30 mounted with different clips.
FIG. 32 displays the visual observation over the unused holes, grooves, slots and indentations on the file folder panel.
FIG. 33 shows the form of file folder panel mounted with two kind of clip suitable for holding Western and Chinese documents.
FIG. 34 shows the extension diagram of the file folder panel ( 6 ) of the invention.
FIG. 35 illustrates the fold up diagram of the file folder panel ( 6 ) of the invention.
FIG. 36 shows the extension diagram of the file folder panel ( 7 ) of the invention.
FIG. 37 illustrates the diagram of the single file folder panel ( 7 ) of the invention.
FIG. 38 shows diagram of box from the file folder panel ( 7 ) of the invention.
FIG. 39 illustrates the diagram of box from the file folder panel ( 8 ) of the invention.
FIG. 40 shows the CD pocket cabinet from the file folder panel ( 9 ) of the invention.
FIG. 41 displays the file folder panel ( 9 ) shown in FIG. 40 mounted with elastic band.
DETAILED DESCRIPTION OF THE INVENTION
The invention is exemplified in greater detail with the aid of the drawing as described below.
FIG. 1 is an extended drawing of the file folder panel of this invention, where the file folder can be in single, double, treble and multiple panels. For easy understanding, the file folder panel 10 is composed of three main panels, 11 , 12 , 13 and a small size panel which goes between the panels 11 and 12 and serves as a spine. These three panels 11 , 12 , and 13 are outfitted an extended flap 15 on the top border. The figure only illustrates a flap on the border of panel 11 . Of three panels 11 through 13 are the file clip boards, and the flap 15 forms a file clip region. The purpose of the file clip boards and the file clip region is to accommodate all kind of file clips.
Please refer to FIG. 4 where the file folder board 10 consists of two main panels 11 , 12 , a spine 14 interposed between two main panels and two flaps 15 on the top border of two main panel. It also permits to outfit a third flap 15 there (not shown in the Figure.) Two panels form the file clip board and the flap serves as the clip region.
Ass shown in FIGS. 1 and 4, the flap provides a plurality of pre-perforated holes 16 , slots 17 , grooves 18 and edge indentations 19 at unspecified places, suitable to fit many forms of clips in different sizes, (such as go-through clips, loose leaf clip, German clip, strong clip and etc.).The more the holes, grooves, slots and openings perforated on the panel, it is easier to contain any size of different clips. However, when the holes, grooves, slots and openings are too numerous, it will hurt the strength of the file folder panel 10 . An adequate quantity of holes, grooves and slots set up on panels benefits the file folder panel 10 . The flap 15 also provides a plurality of holes 20 on the crease. The number of holes, grooves, slots and openings are punched as desired to fit the optional positions of the file clips.
FIG. 5 shows a fold-up diagram of the file folder panel 10 from FIG. 4 . Where four pieces of flap are folded back onto the panels 11 and 12 . The holes, grooves slots and indentations punched on the panel are suitable for installing any form of clips.
FIG. 3 illustrates the file folder panel 10 as shown in FIG. 2 along with file clips installed. Where panel 13 , hole 16 or slot 17 are installed with loose leaf clips, fixed in place with fixing element such as bolt 41 and nut 42 on the panel 13 . There are many kind of fixing element available. The commonest fixing elements as shown in FIG. 7 are plastic snap consisting of stud 43 and socket 44 , or the metal staple 45 . In addition, the panel 13 and the slot 18 as shown in FIG. 3 provides for installing strong clip 22 with clip band 221 pressed and fixed in place under the spring rod 222 . The pre-perforated hole 16 on the flap 15 offers for mounting two legs 231 of the go-through clip 23 , and the legs 231 are pressed in place by the presser 232 . As shown in FIG. 10, the slot 17 is for mounting the band slip 48 with serrated teeth band to hold the document paper firmly. The slot can be cut in one section or multiple sections, it is preferably to have two sections and three section cut. As shown in FIGS. 1, 2 and 3 , the slot 18 forms in three sections, in which the side sections are longer than the central section. The central section is for mounting small sized strong clip 22 (about 10 cm long.) If the larger sized strong clip 22 (about 15 cm long) is used, the art knife is employed to cut three section into one long slot. When the small-sized file clip is applied for the clip board and clip region, no art knife is required to cut the sections into a long slot. To ensure the inherent strength of the clip board and the clip region. Viewing from the aforementioned statement, it is fully understood that the file folder panel of this invention is suitable for mounting any kind of file clip as the user desires, the file clip is optional for change, addition, deletion and interchange. Even on the same file, several file clips can be used together.
Please refer to FIG. 9 where the file folder panel 10 from FIG. 3 combines with file clip and paper 38 to form a closed data folder. The file folder holds the paper together, never getting loose by binding an elastic band 24 which passes through the indentation 19 and the hole 20 . The elastic band effects the shrinking force to hold the file folder panel 10 and paper 38 together.
To prevent the gravity inclination taking place on the paper 38 when the file folder panel 10 is placed horizontally, as shown in FIG. 10, a band knot 241 of the elastic band will be confined in the central hole 19 , both ends of the elastic band extend diagonally to the border indentation to form a triangle to hold the paper 38 in place without movement and loosen. Alternatively, two file clips are employed on the upside or downside to keep the paper gravity in balance.
FIG. 11 demonstrates another fold-up of file folder panel 10 , in which the panel 11 is inwardly folded and the panel 13 is folded on the top of the panel 11 , the paper 38 is held by the strong clip 22 , serving as copy board and writing board, easy to operate.
FIG. 12 illustrates an embodiment of a single file panel, similar to the main file panel 13 as aforementioned, it has a pre-perforated hole 16 , several slots 19 and an elastic band 24 to hold the paper 38 in place.
The file folder panel 10 as shown in FIG. 13 comprises two main file panels 11 and 12 . Besides the pre-punched holes, grooves, slots and indentations, the specific feature is two section vertical slots 18 ′ at the crease between the file panels 11 and 12 . Certainly, the slot 18 ′ can be made in a single section or multiple sections, but two sections slot is preferable. In the normal application, the two panels are foldable. In case the strong clip 22 is mounted as shown in FIG. 14, the two section slot must be cut to form a long slot for the insertion of clip strip 221 of the strong clip 22 . The file panel 10 no longer permits to be folded, uniquely used as a large size single file panel.
FIG. 15 is a continuation of FIG. 13 where the file folder panel 10 is folded to form a single file panel convenient for hand carrying. The clip strip 221 of the strong clip 22 is mounted in the slot 18 for holding the paper in place. There are two pre-perforated holes 16 for mounting the loose leaf file clip 21 (as shown in FIG. 17 ;) four pre-perforated holes 16 for the German clip 28 (as shown in FIG. 18 ), two perforated holes 16 for the go-through clip 23 (as shown in FIG. 19 ;) and four indentations 19 combined with the elastic band 24 to hold down the paper 38 . Another embodiment has one hole 16 , four indentations 19 and an elastic band 24 to hold down the paper 38 as shown in FIG. 20 . The band knot is fixed in the hole 16 .
FIG. 21 is a continuation from the above figures. The file folder panel 10 is widely extended, the slot 18 is mounted with strong clip 22 on one panel, and two holes are mounted with the go-through clip 23 to hold down the paper 38 on the other panel. FIG. 22 shows the file folder panel with a loose leaf clip 23 holding down the paper 38 on one panel and an elastic band 24 holding down the paper 38 on the other panel, having a hanging nail 39 to hang the file panel on the wall through the hole 16 .
FIG. 23 demonstrates that the file folder panel 10 is arranged in A-frame with an elastic band 24 binding through the hole 16 and the slot 19 to hold down the paper which serves as the message memo. Both ends of the elastic band are sleeved with a short segment of tube 29 to brace and separate the main panels 11 and 12 apart, so the file folder panel 10 forms a set message memo pad.
FIG. 24 continues the embodiment of FIG. 23, a piece of decoration board 30 (for example, a corrugated board) in diverse color, shape or pattern is posted on the face of the file folder panel 10 , held by a elastic band 24 . A picture may be interposed between the decoration board 30 and the file folder panel 10 and a proper viewing window 301 is cut on the decoration board 30 to display the picture. That is to say it forms a photo frame or and painting frame.
FIGS. 25 and 26 show the disassembly and assembled photo frame or painting frame in which the inverted T-shape hanger 40 is inserted through the slot 18 to facilitate the file folder panel 10 being hanged on the wall. The picture 31 is therefore posted on the file panel 12 by glue, adhesive tape, or transparent cover 49 .
FIG. 27 shows a restaurant menu converting the file folder panel 10 into triangular frame with a triangular block support 31 on the back of the file panel 11 . The pre-perforated holes 16 are mounted with a loose leaf clip to hold down the menu paper 38 . It can be set on the dinning table convenient for the customers to read over.
FIG. 28 illustrates a month calendar frame, the month calendar 33 is held by a elastic band 24 on the file panel 12 . The month calendar is further clamped by the strong clip 22 , which serves as a ball pen holder 27 .
FIG. 29 shows a memo pad, in which the go-through clip 23 is mounted on the file panel 12 and holds down the scrap paper 38 in place. The elastic band is to reinforce the holding force to prevent the paper from being blown off.
FIG. 30 is a loose leaf pad formed by three pieces of file panel. the file folder panel 10 is folded up into triangle by the file panels 11 and 12 . The file panel 12 serves the bottom and the go-through clip 23 is mounted on the file panel 11 to hold down the paper 38 . The file panel 13 supports the go-through clip 23 on its back.
As shown on the file folder panel 10 , there are many holes, grooves, slots and indentations are used up, many of them remain unused, giving the viewers a bad feeling. To remove such bad feeling, as shown in FIG. 31, both the front and the back of the file folder panel 30 is laminated a layer of thin paper 34 and 35 in similar size, large enough to cover the face of file folder panel 10 . Upon the completion of lamination, as shown in FIG. 32, all unused holes, grooves, slots and indentations are hidden up, it presents good looking. In addition, the size of the thin paper can be set larger than the area of the file folder panel 10 , there is enough margin to wrap up the borders of the file panels 11 , 12 , and 14 (not shown in the figure) to produce beauty for the panel borders.
FIG. 33 is the section of FIG. 32 . When it is put under the lamp or sunlight, the unused holes, grooves, slots and indentations are still visible through the thin papers 34 and 35 . Using a ballpoint pen to pierce through the holes, groove, slots and indentations, they reemerge, you can use the clip, the elastic band and other fixing element to change the application of the file folder panel 10 as you wish.
The file folder panels 10 shown in FIG. 34 comprise four main file panels, 11 , 12 , 13 , 15 and a spine panel 14 which is set in the center. The file panels 11 and 15 are inward folded onto the file panels 12 and 13 as shown in FIG. 35 . Then insert two staples 45 through the holes 16 to hold two file panels firmly together. Other file clips and elastic bands can be added to suit the application as is desired.
The file folder panel 10 illustrated in FIG. 36 consists of two main file panels 11 and 12 , and three spine panels 14 , 14 ′ and 14 ″. Besides the application mentioned in the previous paragraphs, it can form a box for storing single panel 13 as shown in FIG. 37. A strong clip 22 is inserted through the slot 18 to hold the file panel 13 in the box. The box 46 is further mounted with a go-through slip to form a hand carrying brief case.
FIG. 40 shows a file folder panel 10 comprising three main file panels 11 , 12 , 13 and a spine panel 14 . The spine panel is interposed between the file panels 11 and 12 . The file panel 13 is mounted with a loose leaf clip which holds a plurality of CD pockets 47 for storing CD 37 to serves as CD bank. In addition, it is necessary to reinforce the holding force by an elastic band 24 as shown in FIG. 41 .
Viewing from the aforementioned statement, it is clear understood that the file folder panel of the invention consists of a single piece of file panel, or more than one file panel and spine panel. The holes, grooves, slots and indentations punched on the file panel, combined with different clips of varying size and elastic band, can accomplish many useful applications.
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A novel file folder, box and panel designed with pre-perforated holes, grooves and slots where the file folder at least comprises two pieces of panel, on which a plurality of holes, grooves, slots, and border indentations are pre-perforated. The file folder panel has at least a flap on its periphery. The pre-perforated holes, grooves and slots are fit for installing a variety of file clips. The pre-perforated holes and slots also permit fixing and winding the elastic trap. The flap, after being erected up in place, allows the file clip and elastic trap to band together. The invention provides a separate design of file folder panels and file clips to form varying combinations, functions and economical benefits as the end-user desires.
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RELATED APPLICATION DATA
[0001] This application is a divisional application of U.S. application Ser. No. 09/611,109.
TECHNICAL FIELD OF THE INVENTION
[0002] This invention relates to novel processes for preparing new aryl-and heteroaryl-substituted urea compounds of formula (I):
[0003] wherein Ar 1 , Ar 2 , X, L and Q are defined below, which are useful for treating diseases and pathological conditions involving inflammation such as chronic inflammatory disease.
BACKGROUND OF THE INVENTION
[0004] Aryl- and heteroaryl-substituted ureas have been described as inhibitors of cytokine production. Examples of such compounds are reported in WO 99/23091 and in WO 98/52558. These inhibitors are described as effective therapeutics in cytokine-mediated diseases, including inflammatory and autoimmune diseases.
[0005] A key step in the synthesis of these compounds is the formation of the urea bond. Various methods have been reported to accomplish this. For example, as reported in the above references, an aromatic or heteroaromatic amine, II, may be reacted with an aromatic or heteroaromatic isocyanate III to generate the urea IV (Scheme I)
[0006] If not commercially available, one may prepare the isocyanate III by reaction of an aryl or heteroaryl amine Ar 2 NH 2 with phosgene or a phosgene equivalent, such as bis(trichloromethyl) carbonate (triphosgene) (P. Majer and R. S. Randad, J. Org. Chem. 1994, 59, 1937) or trichloromethyl chloroformate (diphosgene). K. Kurita, T. Matsumura and Y. Iwakura, J. Org. Chem. 1976, 41, 2070) to form the isocyanate III, followed by reaction with Ar 1 NH 2 to provide the urea. Other approaches to forming the urea known in the chemical literature are to form a carbamate, as shown in Scheme II below, by reaction of an amine with a chloroformate derivative, such as phenyl chloroformate (B. Thavonekham, Synthesis, 1997, 1189), chloromethyl chloroformate (T. Patonay, E. Patonay-Peli, L Zolnai and F. Mogyorodi, Synthetic Communications, 1996, 26, 4253), p-nitrophenyl chloroformate (J. Gante, Chem. Ber. 1965, 98, 3334), or 2,4,5-trichlorophenyl chloroformate (A. W. Lipkowski, S. W. Tam and P. S. Portoghese, J. Med. Chem. 1986, 29, 1222) to form a carbamate V. This may then be reacted with an aryl or heteroaryl amine (II) to provide urea IV (Scheme II- reaction with phenyl chloroformate shown). The synthesis of ureas through (phenoxycarbonyl)tetrazole (R. W. Adamiak, J. Stawinski, Tetrahedron Lett. 1977, 1935) or 1,1′-carbonylbisbenzotriazole (A. R. Katritzky, D. P. M. Pleynet and B. Yang, J. Org. Chem. 1997, 62, 4155) has been reported. In addition, preparation of ureas by catalytic carbonation of amines with carbon monoxide or carbon dioxide has been documented in the literature (N. Sonoda, T. Yasuhara, K. Kondo, T. Ikeda and S. Tsutsumi, J. Am. Chem. Soc. 1971, 93, 691; Y. Morimoto, Y. Fujiwara, H. Taniguchi, Y. Hori and Y.
[0007] Nagano, Tetrahedron Lett. 1986, 27, 1809). In each of these cases, Ar 1 and Ar 2 may be modified before and/or after the urea formation to produce desired compounds.
[0008] Each of the methods described above suffer from one or more disadvantages. For example, phosgene and phosgene equivalents are hazardous and dangerous to use, particularly in large-scale applications. In addition the isocyanate intermediate III is not stable and may undergo decomposition during preparation and storage. The urea formation may be done using a phenyl carbamate, as illustrated in Scheme II and U.S. application Ser. No. 09/484,638. However, the by-product phenol formed in the urea synthesis does not have sufficient water solubility to be easily removed by water washing especially at large scale. Thus it may require multiple washing and several crystallizations to obtain highly pure product. For these reasons these methods are not well-suited for industrial-scale production.
[0009] U.S. application Ser. No. 09/484,638 also discloses the synthesis of substituted naphthyl amino intermediates for use in making aryl-and heteroaryl-substituted urea compounds of the formula(I) as described therein. This synthesis begins with 4-aminonapthol which is protected with a Boc (tert-butoxycarbonyl) group on the amine prior to alkylation and deprotection. This procedure is also not amenable to industrial-scale production. The starting 4-aminonaphthol is very expensive and not available in large quantity. In addition the protection and deprotection steps are tedious and add to the expense.
[0010] Disclosed herein are novel processes for making the aryl-and heteroaryl-substituted urea compounds of the formula(I) including those disclosed in U.S. application Ser. No. 09/484,638 and novel intermediates useful in such processes.
BRIEF SUMMARY OF THE INVENTION
[0011] It is therefore an object of this invention to provide a general and cost-effective process for the preparation of the aryl- and heteroaryl-substituted urea compounds of the formula(I) shown below:
[0012] comprising the steps of:
[0013] reacting of intermediate of formula (II) with intermediate of formula (IV) to produce the product compound of formula (I):
[0014] wherein Ar 1 , Ar 2 , L, Q, X and Ra are as described below.
[0015] In addition, this invention provides efficient methods for preparing intermediates used in the preparation of preferred cytokine-inhibiting aryl-and heteroaryl-substituted ureas. These processes are especially well-suited for preparation of these compounds on an industrial scale.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The present invention is directed to the synthesis of compounds having formula (I):
[0017] wherein:
[0018] Ar 1 is a heterocyclic group selected from the group consisting of phenyl, pyridine, pyridone, pyrrole, pyrrolidine, pyrazole, imidazole, oxazole, thiazole, furan and thiophene; wherein Ar 1 is optionally substituted by one or more R 1 , R 2 or R 3 ;
[0019] Ar 2 is:
[0020] phenyl, naphthyl, quinoline, isoquinoline, tetrahydronaphthyl, tetrahydroquinoline, tetrahydroisoquinoline, benzimidazole, benzofuran, indanyl, indenyl or indole each being optionally substituted with one to three R 2 groups;
[0021] L, a linking group, is:
[0022] C 1-10 saturated or unsaturated branched or unbranched carbon chain;
[0023] wherein one or more methylene groups are optionally independently replaced by O,N or S; and
[0024] wherein said linking group is optionally substituted with 0-2 oxo groups and one or more C 1-4 branched or unbranched alkyl optionally substituted by one or more halogen atoms;
[0025] or L is a cyclic group which is:
[0026] a) a C 5-8 cycloalkyl or cycloalkenyl optionally substituted with 1-2 oxo groups, 1-3 C 1-4 branched or unbranched alkyl, C 1-4 alkoxy or C 1-4 alkylamino chains;
[0027] b) phenyl, furan, thiophene, pyrrole, imidazolyl, pyridine, pyrimidine, pyridinone, dihydropyridinone, maleimide, dihydromaleimide, piperdine, piperazine or pyrazine each being optionally independently substituted with 1-3 C 1-4 branched or unbranched alkyl, C 1-4 alkoxy, hydroxy, cyano, mono- or di-(C 1-3 alkyl)amino, C 1-6 alkyl-S(O) q , or halogen;
[0028] wherein said cyclic group is optionally attached to a C 1-4 saturated or unsaturated branched or unbranched carbon chain wherein said carbon chain is in turn covalently attached to Q, said carbon chain is optionally partially or fully halogenated and wherein one or more methylene groups are optionally replaced by O, NH, S(O), S(O) 2 or S, wherein said methylene groups are further optionally independently substituted with 1-2 oxo groups and one or more C 1-4 branched or unbranched alkyl optionally substituted by one or more halogen atoms;
[0029] Q is selected from the group consisting of:
[0030] a) phenyl, naphthyl, pyridine, pyrimidine, pyridazine, imidazole, benzimidazole, furan, thiophene, pyran, naphthyridine, oxazo[4,5-b]pyridine and imidazo[4,5-b]pyridine, which are optionally substituted with one to three groups selected from the group consisting of halogen, C 1-6 alkyl, C 1-6 alkoxy, hydroxy, mono- or di-(C 1-3 alkyl)amino, C 1-6 alkyl-S(O) m and phenylamino wherein the phenyl ring is optionally substituted with one to two groups selected from the group consisting of halogen, C 1-6 alkyl and C 1-6 alkoxy;
[0031] b) tetrahydropyran, tetrahydrofuran, 1,3-dioxolanone, 1,3-dioxanone, 1,4-dioxane, morpholine, thiomorpholine, thiomorpholine sulfoxide, thiomorpholine sulfone, piperidine, piperidinone, tetrahydropyrimidone, cyclohexanone, cyclohexanol, pentamethylene sulfide, pentamethylene sulfoxide, pentamethylene sulfone, tetramethylene sulfide, tetramethylene sulfoxide and tetramethylene sulfone which are optionally substituted with one to three groups selected from the group consisting of C 1-6 alkyl, C 1-6 alkoxy, hydroxy, mono- or di-(C 1-3 alkyl)amino-C 1-3 alkyl, phenylamino-C 1-3 alkyl and C 1-3 alkoxy-C 1-3 alkyl;
[0032] c) C 1-6 alkoxy, secondary or tertiary amine wherein the amino nitrogen is covalently bonded to groups selected from the group consisting of C 1-3 alkyl and C 1-5 alkoxyalkyl and phenyl wherein the phenyl ring is optionally substituted with one to two groups selected from the group consisting of halogen, C 1-6 alkoxy, hydroxy or mono- or di-(C 1-3 alkyl)amino, C 1-6 alkyl-S(O) r and phenyl-S(O) r , wherein the phenyl ring is optionally substituted with one to two groups consisting of halogen, C 1-6 alkoxy, hydroxy and mono- or di-(C 1-3 alkyl)amino;
[0033] R 1 is selected from the group consisting of:
[0034] (a) C 3-10 branched or unbranched alkyl, which may optionally be partially or fully halogenated, and optionally substituted with one to three phenyl, naphthyl or heterocyclic groups selected from the group consisting of pyridinyl, pyrimidinyl, pyrazinyl, pyridazinyl, pyrrolyl, imidazolyl, pyrazolyl, thienyl, furyl, isoxazolyl and isothiazolyl; each such phenyl, naphthyl or heterocycle selected from the group hereinabove described, being substituted with 0 to 5 groups selected from the group consisting of halogen, C 1-6 branched or unbranched alkyl which is optionally partially or fully halogenated, C 3-8 cycloalkyl, C 5-8 cycloalkenyl, hydroxy, cyano, C 1-3 alkyloxy which is optionally partially or fully halogenated, NH 2 C(O) and di(C 1-3 )alkylaminocarbonyl;
[0035] (b) C 3-7 cycloalkyl selected from the group consisting of cyclopropyl, cyclobutyl, cyclopentanyl, cyclohexanyl, cycloheptanyl, bicyclopentanyl, bicyclohexanyl and bicycloheptanyl, which are optionally partially or fully halogenated and optionally substituted with one to three C 1-3 alkyl groups, or an analog of such cycloalkyl group wherein one to three ring methylene groups are replaced by groups independently selected from O, S, CHOH, >C═O, >C═S and NH;
[0036] (c) C 3-10 branched alkenyl optionally partially or fully halogenated, and optionally substituted with one to three C 1-5 branched or unbranched alkyl, phenyl, naphthyl or heterocyclic groups, with each such heterocyclic group being independently selected from the group consisting of pyridinyl, pyrimidinyl, pyrazinyl, pyridazinyl, pyrrolyl, imidazolyl, pyrazolyl, thienyl, furyl, isoxazolyl and isothiazolyl, and each such phenyl, naphthyl or heterocyclic group being substituted with 0 to 5 groups selected from halogen, C 1-6 branched or unbranched alkyl which is optionally partially or fully halogenated, cyclopropyl, cyclobutyl, cyclopentanyl, cyclohexanyl, cycloheptanyl, bicyclopentanyl, bicyclohexanyl, bicycloheptanyl, hydroxy, cyano, C 1-3 alkyloxy which is optionally partially or fully halogenated, NH 2 C(O) and mono- or di(C 1-3 )alkylaminocarbonyl;
[0037] (d) C 5-7 cycloalkenyl selected from the group consisting of cyclopentenyl, cyclohexenyl, cyclohexadienyl, cycloheptenyl, cycloheptadienyl, bicyclohexenyl and bicycloheptenyl, wherein such cycloalkenyl group is optionally substituted with one to three C 1-3 alkyl groups;
[0038] (e) cyano; and,
[0039] (f) methoxycarbonyl, ethoxycarbonyl and propoxycarbonyl;
[0040] R 2 is selected from the group consisting of:
[0041] a C 1-6 branched or unbranched alkyl optionally partially or fully halogenated, acetyl, aroyl, C 1-4 branched or unbranched alkoxy optionally partially or fully halogenated, halogen, methoxycarbonyl and phenylsulfonyl;
[0042] R 3 is selected from the group consisting of:
[0043] a) a phenyl, naphthyl or heterocyclic group selected from the group consisting of pyridinyl, pyrimidinyl, pyrazinyl, pyridazinyl, pyrrolyl, imidazolyl, pyrazolyl, thienyl, furyl, tetrahydrofuryl, isoxazolyl, isothiazolyl, quinolinyl, isoquinolinyl, indolyl, benzimidazolyl, benzofuranyl, benzoxazolyl, benzisoxazolyl, benzpyrazolyl, benzothiofuranyl, cinnolinyl, pterindinyl, phthalazinyl, naphthypyridinyl, quinoxalinyl, quinazolinyl, purinyl and indazolyl wherein such phenyl, naphthyl or heterocyclic group is optionally substituted with one to five groups selected from the group consisting of a C 1-6 branched or unbranched alkyl, phenyl, naphthyl, heterocycle selected from the group hereinabove described, C 1-6 branched or unbranched alkyl which is optionally partially or fully halogenated, cyclopropyl, cyclobutyl, cyclopentanyl, cyclohexanyl, cycloheptanyl, bicyclopentanyl, bicyclohexanyl, bicycloheptanyl, phenyl C 1-5 alkyl, naphthyl C 1-5 alkyl, halo, hydroxy, cyano, C 1-3 alkyloxy which may optionally be partially or fully halogenated, phenyloxy, naphthyloxy, heteraryloxy wherein the heterocyclic moiety is selected from the group hereinabove described, nitro, amino, mono- or di-(C 1-3 )alkylamino, phenylamino, naphthylamino, heterocyclylamino wherein the heterocyclyl moiety is selected from the group hereinabove described, NH 2 C(O), a mono- or di-(C 1-3 )alkyl aminocarbonyl, C 1-5 alkyl-C(O)—C 1-4 alkyl, amino-C 1-5 alkyl, mono- or di-(C 1-3 ) alkylamino-C 1-5 alkyl, amino-S(O) 2 , di-(C 1-3 )alkylamino-S(O) 2 , R 4 —C 1-5 alkyl, R 5 —C 1-5 alkoxy, R 6 —C(O)—C 1-5 alkyl and R 7 —C 1-5 alkyl-N(R 8 )—;
[0044] b) a fused aryl selected from the group consisting of benzocyclobutanyl, indanyl, indenyl, dihydronaphthyl, tetrahydronaphthyl, benzocycloheptanyl and benzocycloheptenyl, or a fused heterocyclyl selected from cyclopentenopyridine, cyclohexanopyridine, cyclopentanopyrimidine, cyclohexanopyrimidine, cyclopentanopyrazine, cyclohexanopyrazine, cyclopentanopyridazine, cyclohexanopyridazine, cyclopentanoquinoline, cyclohexanoquinoline, cyclopentanoisoquinoline, cyclohexanoisoquinoline, cyclopentanoindole, cyclohexanoindole, cyclopentanobenzimidazole, cyclohexanobenzimidazole, cyclopentanobenzoxazole, cyclohexanobenzoxazole, cyclopentanoimidazole, cyclohexanoimidazole, cyclopentanothiophene and cyclohexanothiophene; wherein the fused aryl or fused heterocyclyl ring is substituted with 0 to 3 groups independently selected from phenyl, naphthyl, heterocyclyl selected from the group consisting of pyridinyl, pyrimidinyl, pyrazinyl, pyridazinyl, pyrrolyl, imidazolyl, pyrazolyl, thienyl, furyl, isoxazolyl, and isothiazolyl, C 1-6 branched or unbranched alkyl which is optionally partially or fully halogenated, halo, cyano, C 1-3 alkyloxy which is optionally partially or fully halogenated, phenyloxy, naphthyloxy, heterocyclyloxy wherein the heterocyclyl moiety is selected from the group hereinabove described, nitro, amino, mono- or di-(C 1-3 )alkylamino, phenylamino, naphthylamino, heterocyclylamino wherein the heterocyclyl moiety is selected from the group hereinabove described, NH 2 C(O), a mono- or di-(C 1-3 )alkyl aminocarbonyl, C 1-4 alkyl-OC(O), C 1-5 alkyl-C(O)—C 1-4 branched or unbranched alkyl, an amino-C 1- 5 alkyl, mono- or di-(C 1-3 )alkylamino-C 1-5 alkyl, R 9 —C 1-5 alkyl, R 10 —C 1-5 alkoxy, R 11 —C (O)—C 1-5 alkyl and R 12 —C 1-5 alkyl-N(R 13 )—;
[0045] c) cycloalkyl selected from the group consisting of cyclopentanyl, cyclohexanyl, cycloheptanyl, bicyclopentanyl, bicyclohexanyl and bicycloheptanyl, wherein the cycloalkyl is optionally partially or fully halogenated and optionally substituted with one to three C 1-3 alkyl groups;
[0046] d) C 5-7 cycloalkenyl, selected from the group consisting of cyclopentenyl, cyclohexenyl, cyclohexadienyl, cycloheptenyl, cycloheptadienyl, bicyclohexenyl and bicycloheptenyl, wherein such cycloalkenyl group is optionally substituted with one to three C 1-3 alkyl groups;
[0047] e) acetyl, aroyl, alkoxycarbonylalkyl and phenylsulfonyl; and
[0048] f) C 1-6 branched or unbranched alkyl optionally partially or fully halogenated;
[0049] R 1 and R 2 taken together optionally form a fused phenyl or pyridinyl ring;
[0050] each R 8 or R 13 is independently selected from the group consisting of:
[0051] hydrogen and C 1-4 branched or unbranched alkyl optionally partially or fully halogenated;
[0052] each R 4 , R 5 , R 6 , R 7 , R 9 , R 10 , R 11 and R 12 is independently selected from the group consisting of:
[0053] morpholine, piperidine, piperazine, imidazole and tetrazole;
[0054] m is 0, 1 or 2;
[0055] q is 0, 1 or 2;
[0056] r is 0, 1 or 2;
[0057] t is 0, 1 or 2; and
[0058] X is O or S.
[0059] The compounds of the invention may be prepared as physiologically and pharmaceutically acceptable salts, as may seem appropriate to one of ordinary skill in the art.
[0060] The compounds produced by the novel process of the invention are only those which are contemplated to be ‘chemically stable’ as will be appreciated by those skilled in the art. For example, a compound which would have a ‘dangling valency’, or a ‘carbanion’ are not compounds contemplated to be made by the novel process.
[0061] All terms as used herein in this specification, unless otherwise stated, shall be understood in their ordinary meaning as known in the art. For example, “C 1-4 alkoxy” is a C 1-4 alkyl with a terminal oxygen, such as methoxy, ethoxy, propoxy, pentoxy and hexoxy. All alkyl, alkenyl and alkynyl groups shall be understood as being branched or unbranched where structurally possible and unless otherwise specified. Other more specific definitions are as follows:
[0062] The term “aroyl” as used in the present specification shall be understood to mean “benzoyl” or “naphthoyl”.
[0063] NMP: 1-methyl-2-pyrrolidinone;
[0064] THF: tetrahydrofuran;
[0065] DMF: N,N′-dimethylformamide;
[0066] DMAC: N-N′-dimethylacetamide;
[0067] DMSO: dimethylsulfoxide;
[0068] DMAP: 4-dimethylaminopyridine;
[0069] DBU: 1,8-diazabicyclo[5.4.0]undec-7-ene;
Process for Making Compounds of the Formula (I)
[0070] The Novel Process Comprises:
[0071] STEP 1:
[0072] Reacting in a suitable solvent an amino-heterocycle NH 2 —Ar 1 with a haloformate RaOC(X)Ha, wherein Ra represents C 2-3 halocarbon, preferably 2,2,2-trichloroethyl, and Ha represents halogen, preferably chloro, X is as defined above, in the presence of a suitable base, to produce carbamate of the formula (II):
[0073] Preferable formate RaOC(X)Ha are those, which upon hydrolysis of the formula(II) intermediates, will form a water soluble byproduct which is easily removed by aqueous washing, such byproduct would be, for example, 2,2,2-trichloroethanol. Examples of preferred RaOCOHa are trichloroethyl chloroformate or trichloroethyl chlorothioformate. Accordingly, a preferred compound of the formula(II) is:
[0074] Synthesis of amino-heterocycle NH 2 —Ar 1 has been illustrated in U.S. patent application Ser. No. 09/484,638, incorporated herein by reference. A particularly preferred compound of the formula(II) is where Ar 1 is 1-tolyl-3-t-butyl-pyrazole-5-yl.
[0075] Reaction conditions such as the selection of a suitable solvent and temperature is within the skill of the ordinary artisan depending on the particular compounds desired. Typically, the reaction of step 1 is in a non-aqueous or an aqueous solvent, preferably THF or ethyl acetate, in the presence of a suitable base such as tertiary amine for example triethylamine, diisopropylethylamine, N-methylpyrrolidine, DBU(1,8-diazabicyclo[5.4.0]undec-7-ene), DMAP(4-dimethylaminopyridine), N-methylmorpholine, pyridine, methyl pyridine or inorganic bases such as sodium hydroxide, sodium carbonate, sodium bicarbonate, potassium hydroxide, potassium carbonate and potassium bicarbonate. Preferred suitable bases for step 1 are diisopropylethylamine, NaOH or N-methylpyrrolidine. The reaction occurs at a temperature of about 0-100° C., preferably 5-15° C., for about 0.5-24 hrs, preferably 3-4 hrs.
[0076] STEP 2
[0077] For certain preferred embodiments, Step 2 proceeds as follows. Reacting a Z—Ar 2 —MH, where Z is a nitro or nitroso group, M is O, S, or NH, and Ar 2 is as defined hereinabove, with a Y—J—Q moiety in a suitable solvent to produce the intermediate of formula (III)
[0078] wherein L and Q are as defined hereinabove , Y is a leaving group such as a halogen and M—J constitutes L;
[0079] A suitable solvent for the above reaction would be a polar non-protic organic solvent, such as acetonitrile, DMF (N,N′-dimethylformamide), DMAC (N-N′-dimethylacetamide), DMSO (dimethylsulfoxide) and NMP (1-methyl-2-pyrrolidinone), preferably NMP, at a temperature of about 50-100° C., preferably between 75-95° C., for about 0.5-24 hrs, preferably 3-4 hrs.
[0080] For other embodiments of L, analogous methods can be found in U.S. patent application Ser. Nos. 09/484,638 and 09/505,582 incorporated in their entirety by reference.
[0081] STEP 3
[0082] Reducing compound of formula (III) with catalytic hydrogenation or non-catalytic reduction to produce the intermediate of formula (IV):
[0083] Catalytic hydrogenation is preferred, a preferred catalyst is Pd/C. Reaction conditions such as the selection of a suitable solvent and temperature is within the skill of the ordinary artisan. The catalytic hydrogenation with respect to H 2 pressure and time can be varied, a preferable hydrogenation occurs under about 30 psi for about 1 hr-24 hours.
[0084] STEP 4
[0085] Reacting the intermediate of formula (II) with the intermediate of formula (IV) with or without base, preferably with a base. A suitable base will be one such as tertiary amine for example triethylamine, diisopropylethylamine, N-methylpyrrolidine, DBU, DMAP, N-methylmorpholine, pyridine, methyl pyridine or an inorganic base such as sodium hydroxide, sodium carbonate, sodium bicarbonate, potassium hydroxide, potassium carbonate and potassium bicarbonate. Preferred bases are diisopropylethylamine or N-methylpyrrolidine. The reaction takes place in the presence of suitable solvent to produce the product of formula (I):
[0086] Reaction conditions such as the selection of a suitable solvent, base and temperature can be varied according to the specific compound of the formula(I) that is desired. The reaction can be run in a suitable polar, or a suitable non-polar solvent such as methylene chloride or chloroform or in heptane, hexane, cyclohexane, ethyl acetate, benzene, toluene, xylene, tetrahydropfuran, dioxane, ethyl ether, methyl butyl ether or in a biphasic aqueous/organic mixture. Preferably the solvent will be a polar non-protic organic solvent such as NMP(1-methyl-2-pyrrolidinone), acetonitrile, DMF(N,N-dimethylformamide), DMAC(N,N-dimethylacetamide) or DMSO, more preferably DMSO or NMP, which is heated to an appropriate temperature, preferably about 55-60° C. for about 1.5 hours. Particular separation methods depending on the compound desired will be apparent to those of ordinary skill in the art. A preferred method is shown in Example 1 in the present specification.
[0087] A preferred subgeneric aspect of the invention comprises a process of producing compounds of the formula(I) wherein Ar 2 is naphthyl, tetrahydronaphthyl, indanyl or indenyl.
[0088] A more preferred subgeneric aspect of the invention comprises a process of producing compounds of the formula(I) wherein Ar 2 is naphthyl.
[0089] A yet more preferred subgeneric aspect of the invention comprises a process of producing compounds of the formula (I), as described in the immediate previous paragraph, wherein:
[0090] Ar 1 is thiophene or pyrazole;
[0091] Ar 2 is 1-naphthyl;
[0092] L is C 1-6 saturated or unsaturated branched or unbranched carbon chain wherein
[0093] one or more methylene groups are optionally independently replaced by O, N or S; and wherein said linking group is optionally substituted with 0-2 oxo groups and one or more C 1-4 branched or unbranched alkyl optionally substituted by one or more halogen atoms;
[0094] or L is cyclopentenyl, cyclohexenyl, cycloheptenyl, each optionally substituted with an oxo group or 1-3 C 1-4 branched or unbranched alkyl, C 1-4 alkoxy or C 1-4 alkylamino; or L is phenyl, pyridine, furan or thiophene each being optionally independently substituted with 1-3 C 1-4 branched or unbranched alkyl, C 1-4 alkoxy, hydroxy, cyano, mono- or di-(C 1-3 alkyl)amino, C 1-6 alkyl-S(O) q or halogen;
[0095] wherein said cyclic group is optionally attached to a C 1-4 saturated or unsaturated branched or unbranched carbon chain wherein said carbon chain is in turn covalently attached to Q, said carbon chain is optionally partially or fully halogenated and wherein one or more methylene groups are optionally replaced by O, NH, S(O), S(O) 2 or S, wherein said methylene groups are further optionally independently substituted with 1-2 oxo groups and one or more C 1-4 branched or unbranched alkyl optionally substituted by one or more halogen atoms;
[0096] R 1 is C 3-4 alkyl branched or unbranched, cyclopropyl or cyclohexanyl optionally partially or fully halogenated and optionally substituted with one to three C 1-3 alkyl groups;
[0097] R 3 is selected from the group consisting of C 1-4 alkyl branched or unbranched optionally partially or fully halogenated, cyclopentanyl optionally partially or fully halogenated and optionally substituted with one to three C 1-3 alkyl groups,
[0098] phenyl, pyridinyl each being optionally substituted with one to five groups selected from the group consisting of a C 1-6 branched or unbranched alkyl, phenyl, naphthyl, pyridinyl, C 1-6 branched or unbranched alkyl which is optionally partially or fully halogenated, cyclopropyl, cyclobutyl, cyclopentanyl, cyclohexanyl, cycloheptanyl, bicyclopentanyl, bicyclohexanyl, bicycloheptanyl, phenyl C 1-5 alkyl, naphthyl C 1-5 alkyl, halo, hydroxy, cyano, C 1-3 alkyloxy which may optionally be partially or fully halogenated, phenyloxy, naphthyloxy, pyridinyloxy, nitro, amino, mono- or di-(C 1-3 )alkylamino, phenylamino, naphthylamino, pyridinylamino, NH 2 C(O), a mono- or di-(C 1-3 )alkyl aminocarbonyl, C 1-5 alkyl-C(O)—C 1-4 alkyl, amino-C 1-5 alkyl, mono- or di-(C 1-3 )alkylamino-C 1-5 alkyl, amino-S(O) 2 , di-(C 1-3 )alkylamino-S(O) 2 , R 4 —C 1-5 alkyl, R 5 -alkoxy, R6—C(O)—C 1-5 alkyl and R 7 —C 1-5 alkyl—N(R 8 )—; and R 3 is alkoxycarbonylalkyl;
[0099] A yet further preferred subgeneric aspect of the invention comprises a process of producing compounds of the formula (I), as described in the immediate previous paragraph, wherein Ar 1 is pyrazole.
[0100] A still yet further preferred subgeneric aspect of the invention comprises a process of producing compounds of the formula (I), as described in the immediate previous paragraph, wherein L is C 1-5 saturated carbon chain wherein one or more methylene groups are optionally independently replaced by O, N or S; and wherein said linking group is optionally substituted with 0-2 oxo groups and one or more C 1-4 branched or unbranched alkyl optionally substituted by one or more halogen atoms;
[0101] More particularly preferred embodiments of the process of the invention is where L is propoxy, ethoxy, methoxy, methyl, propyl, C 3-5 acetylene or methylamino each being optionally substituted as described herein and Q is morpholine.
[0102] A even more particularly preferred embodiment of L is ethoxy optionally substituted, the base is diisopropylethylamine and the polar non-protic organic solvent is DMSO.
[0103] In order that this invention be more fully understood, the following examples are set forth. These examples are for the purpose of illustrating preferred embodiments of this invention, and are not to be construed as limiting the scope of the invention in any way.
SYNTHETIC EXAMPLES
Example 1
1-[3-tert-Butyl-1-p-tolyl-1H-pyrazol-5-yl]-3-[4-(2-morpholin-4-yl-ethoxy)naphthalen-1-yl]-urea
[0104] [0104]
[0105] 5-Amino-3-t-butyl-1-p-tolylpyrazole Hydrochloride:
[0106] A solution of pivaloylacetonitrile (750 g, 6.0 mol) and p-tolylhydrazine hydrochloride (660 g, 4.2 mol) in methanol (2.8 L) was refluxed for 3 h. Heptane was added, and methanol was removed by distillation. The product was crystallized from the solution, collected by filtration and dried in vacuum oven to constant weight. Yield: 1.05 kg, 94%. 1 H NMR δ (CDCl 3 ) 7.50 (d, 2H), 7.30 (d, 2H), 5.60 (s, 1H), 2.45 (s, 3H), 1.40 (s, 9H). MS (CI) m/z 229 (M + +H).
[0107] 5-(2,2,2-Trichloroethoxycarbonyl)amino-3-t-butyl-1-p-tolylpyrazole:
[0108] A mixture of 5-amino-3-t-butyl-1-p-tolylpyrazole hydrochloride (300 g, 1.13 mol), water (0.9 L), EtOAc (2.1 L) and NaOH (117 g, 2.84 mol) was stirred between 5-15° C. for 30 min. To this mixture, 2,2,2-trichloroethyl chloroformate (342 g, 1.58 mol) was added over 1 h between 5-15° C. The mixture was stirred at room temperature for 2 h, and then the aqueous layer was separated from the EtOAc layer. The EtOAc layer was washed with brine (2×0.9 L) and dried over MgSO 4 (60 g). The EtOAc layer was collected by filtration. To this solution, heptane was added. A part of the solution was removed by distillation. The product was crystallized from the solution, collected by filtration and dried in vacuum oven to constant weight. Yield: 409 g, 90%. 1 H NMR (CDCl 3 ) δ 7.40 (d, 2H), 7.30 (d, 2H), 6.40 (s, 1H), 4.80 (s, 2H), 2.40 (s, 3H), 1.40 (s, 9H). MS (EI) m/z 404 (M + ).
[0109] 4-Nitro-1-(2-morpholinethoxy)naphthalene:
[0110] A mixture of 4-nitro-1-hydroxynaphthalene (194 g, 1.0 mol), 4-(2-chloroethyl)morpholine hydrochloride (264 g, 1.4 mol), NaOH (58 g, 1.4 mol), K 2 CO 3 (339 g, 2.4 mol) and 1-methyl-2-pyrrolidinone (1.0 L) was heated to 90-100° C. and held for 1-2 h. The mixture was cooled to 40° C. and water was slowly added. The mixture was cooled to 5° C. and held for 4 h. The product was collected by filtration, washed with water, cyclohexane and dried in vacuum to constant weight. Yield: 227 g, 75%. 1 H NMR (CDCl 3 ) δ 8.76 (d, 1H), 8.38 (m, 2H), 7.74 (dd, 1H), 7.58 (dd, 1H), 6.79 (d, 1 H), 4.38 (dd, 2H), 3.74 (d, 4H), 2.98 (dd, 2H), 2.65 (d, 4H). MS (EI) m/z 303 (M +1).
[0111] 4-Amino-1-(2-Morpholinethoxy)naphthalene Hydrochloride:
[0112] A mixture of 4-nitro-1-(2-morpholinethoxy)naphthalene (40 g, 0.13 mol), MeOH (280 mL) and Pd/C (50% water, 1.2 g) was hydrogenated under 30 psi for 24 h. The catalyst was filtered through a layer of diatomaceous earth under nitrogen. To this filtrate 20 mL of HCl (37%) and cyclohexane (200 mL) were added. The solvent was removed under reduced pressure and the product collected by filtration. The product was dried in vacuum to constant weight. Yield: 33 g, 82%. 1 H NMR (DMSO) δ 8.38 (d, 1H), 8.00 (d, 1H), 7.72 (dd, 1H), 7.64 (m, 2H), 7.05 (d, 1H), 4.62 (s, 2H), 4.00 (b, 4H), 3.88 (s, 2H), 3.40 (b m/z 273 (M + ).
[0113] 1-[3-tert-butyl-1-p-tolyl-1H-pyrazol-5-yl]-3-[4-(2-morpholin-4-yl-ethoxy)naphthalen-1-yl]-urea:
[0114] A solution of 5-(2,2,2-trichloroethoxycarbonyl)amino-3-t-butyl-1-p-tolylpyrazole (10.6 g, 26 mmol), 4-amino-1-(2-morpholinethoxy)naphthalene (free base from HCl salt above, 7.16 g, 26 mmol), diisopropylethylamine (3.2 g, 25 mmol) and DMSO (75 mL) was heated to 55-60° C. and held for 1.5 h. To this solution, ethyl acetate (100 mL) was added. The organic layer was washed with brine (4×50 mL), and dried over MgSO 4 . The solvent was removed under reduced pressure, and residue was crystallized from acetonitrile (50 mL) at 0° C. The product was collected by filtration, recrystallized from isopropanol and dried in vacuum to constant weight, m.p.: 151-152° C. Yield: 11.4g, 87%. 1 H NMR (DMSO) δ 8.75 (s, 1H), 8.51 (s, 1H), 8.21 (d, 1H), 7.85 (d, 1H), 7.65 (d, 1H), 7.55 (m, 2H), 7.49 (dd, 1H), 7.35 (dd, 1H), 6.95 (d, 1H, 6.38 (s, 1H), 4.26 (dd, 2H), 3.60 (dd, 4H), 2.81 (dd, 2H), 2.55 (dd, 4H), 2.38 (s, 3H), 1.29 (s, 9H). MS (CI) m/z 528 (M + +1).
[0115] The following additional non-limiting examples can be made using the novel process of the invention:
Example 2
[-3-tert-Butyl-1-p-tolyl-1H-pyrazol-5-yl]-3-{4-[5-(morpholin4-ylmethyl)fur-2-yl]naphthalen-1-yl}urea
[0116] [0116]
[0117] A solution of 5-(2,2,2-trichloroethoxycarbonyl)amino-3-t-butyl-1-p-tolylpyrazole (26 mmol), 1 -amino-4-[5-(morpholin-4-ylmethyl)fur-2-yl]naphthalene (26 mmol), diisopropylethylamine (25 mmol) and DMSO (75 mL) is heated to 55-90° C. and held for 2-8 h. To this solution, ethyl acetate (100 mL) is added. The organic layer is washed with brine (4×50 mL), and dried over MgSO 4 . The solvent is removed under reduced pressure, and residue is crystallized from a suitable solvent such as acetonitrile (50 mL) at 0° C. The product is collected by filtration and recrystallized from a suitable solvent such as isopropanol and dried in vacuum to constant weight.
Example 3
1-[3-tert-Butyl-1-p-tolyl-1H-pyrazol-5-yl]-3-{4-[6-(morpholin-4-ylmethyl)pyridin-3-yl]naphthalen-1-yl}urea
[0118] [0118]
[0119] A solution of 5-(2,2,2-trichloroethoxycarbonyl)amino-3-t-butyl-1-p-tolylpyrazole (26 mmol), 1-amino-4-[6-(morpholin-4-ylmethyl)pyridin-3-yl]naphthalene (26 mmol), duisopropylethylamine (25 mmol) and DMSO (75 mL) is heated to 55-90° C. and held for 2-8 h. To this solution, ethyl acetate (100 mL) is added. The organic layer is washed with brine (4×50 mL), and dried over MgSO 4 . The solvent is removed under reduced pressure, and residue is crystallized from a suitable solvent such as acetonitrile (50 mL) at 0° C. The product is collected by filtration and recrystallized from a suitable solvent such as isopropanol and dried in vacuum to constant weight.
Example 4
1-[3-tert-Butyl-1-p-tolyl-1H-pyrazol-5-yl]-3-(4-{6-[(3-methoxypropyl) methylamino]pyridin-3-yl}naphthalen-1-yl)urea
[0120] [0120]
[0121] A solution of 5-(2,2,2-trichloroethoxycarbonyl)amino-3-t-butyl-1-p-tolylpyrazole (26 mmol), 1 -amino-4-{6-[(3-methoxypropyl)methylamino]pyridin-3-yl}naphthalene (26 mmol), diisopropylethylamine (25 mmol) and DMSO (75 mL) is heated to 55-90° C. and held for 2-8 h. To this solution, ethyl acetate (100 mL) is added. The organic layer is washed with brine (4×50 mL), and dried over MgSO 4 . The solvent is removed under reduced pressure, and residue is crystallized from a suitable solvent such as acetonitrile (50 mL) at 0° C. The product is collected by filtration and recrystallized from a suitable solvent such as isopropanol and dried in vacuum to constant weight.
Example 5
1-[3-tert-Butyl-1-p-tolyl-1H-pyrazol-5-yl]-3-[4-(3-pyridin-4-yl-propox)naphthalen-1-yl]-urea
[0122] [0122]
[0123] A solution of 5-(2,2,2-trichloroethoxycarbonyl)amino-3-t-butyl-1-p-tolylpyrazole (26 mmol), 1 -amino-4-(3-pyridin-4-ylpropoxy)naphthalene (26 mmol), diisopropylethylamine (25 mmol) and DMSO (75 mL) is heated to 55-90° C. and held for 2-8 h. To this solution, ethyl acetate (100 mL) is added. The organic layer is washed with brine (4×50 mL), and dried over MgSO 4 . The solvent is removed under reduced pressure, and residue is crystallized from a suitable solvent such as acetonitrile (50 mL) at 0° C. The product is collected by filtration and recrystallized from a suitable solvent such as isopropanol and dried in vacuum to constant weight.
Example 6
1-[3-tert-Butyl-1-(2-methylpyridin-5-yl)-1H-pyrazol-5-yl]-3-[4-(pyridin-4-yl-methoxy)naphthalen-1-yl]-urea
[0124] [0124]
[0125] A solution of 5-(2,2,2-trichloroethoxycarbonyl)amino-3-t-butyl-1-(2-methylpyridin-5-yl)pyrazole (26 mmol), 1-amino-4-(pyridin-4-ylmethoxy)naphthalene (26 mmol), diisopropylethylamine (25 mmol) and DMSO (75 mL) is heated to 55-90° C. and held for 2-8 h. To this solution, ethyl acetate (100 mL) is added. The organic layer is washed with brine (4×50 mL), and dried over MgSO 4 . The solvent is removed under reduced pressure, and residue is crystallized from a suitable solvent such as acetonitrile (50 mL) at 0° C. The product is collected by filtration and recrystallized from a suitable solvent such as isopropanol and dried in vacuum to constant weight.
Example 7
1-[3-tert-Butyl-1-p-tolyl-1H-pyrazol-5-yl]-3-[4-(2-pyridin-4-yl-ethenyl)naphthalen-1-yl]-urea
[0126] [0126]
[0127] A solution of 5-(2,2,2-trichloroethoxycarbonyl)amino-3-t-butyl-1-p-tolylpyrazole (26 mmol), 1-amino-4-(2-pyridin-4-yl-ethenyl)naphthalene (26 mmol), diisopropylethylamine (3.2 g, 25 mmol) and DMSO (75 mL) is heated to 55-90° C. and held for 2-8 h. To this solution, ethyl acetate (100 mL) is added. The organic layer is washed with brine (4×50 mL), and dried over MgSO 4 . The solvent is removed under reduced pressure, and residue is crystallized from a suitable solvent such as acetonitrile (50 mL) at 0° C. The product is collected by filtration and recrystallized from a suitable solvent such as isopropanol and dried in vacuum to constant weight.
Example 8
1-(5-tert-Butyl-2-methyphenyl)-3-[4-(6-morpholin-4-ylmethyl-pyridin-3-yl)-naphthalen-1-yl]urea
[0128] [0128]
[0129] A solution of 5-t-butyl-2-methyl-1-(2,2,2-trichloroethoxycarbonyl)aminobenzene (26 mmol), 1-amino-4-[6-(morpholin-4-ylmethyl)pyridin-3-yl]naphthalene (26 mmol), diisopropylethylamine (3.2 g, 25 mmol) and DMSO (75 mL) is heated to 55-60° C. and held for 1.5 h. To this solution, ethyl acetate (100 mL) is added. The organic layer is washed with brine (4×50 mL), and dried over MgSO 4 . The solvent is removed under reduced pressure, and residue is crystallized from a suitable solvent such as acetonitrile (50 mL) at 0° C. The product is collected by filtration and recrystallized from a suitable solvent such as isopropanol and dried in vacuum to constant weight.
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Disclosed are novel processes and novel intermediate compounds for preparing aryl-and heteroaryl-substituted urea compounds of the formula(I) wherein Ar 1 , Ar 2 , L, Q and X are described herein. The product compounds are useful in pharmaceutic compositions for treating diseases or pathological conditions involving inflammation such as chronic inflammatory diseases.
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BACKGROUND
This invention relates to reciprocating pumping units, and more particularly, a pumping unit having variable output without using a transmission between the pump and the prime mover therefor.
Reciprocating pumping units are well known, and such units have been used extensively in oil field applications, such as for pumping water into and out of the wells. Reciprocating pumps are known as fixed or positive displacement pumps.
Prime mover power sources for these pumps are typically diesel engines, but other devices may be used. Multi-ratio automatic transmissions are typically used to drive the pumps to achieve a finite selection of flow rates or pumping rates. Minor flow rate “rangeability” is enabled within any given gear in the transmission by varying the engine speed, but this often requires the engine to operate at less than its maximum horsepower capability which is obviously inefficient. Further, such pumping unit configurations cannot begin pumping at full engine speed, because they are not capable of withstanding the sudden stress on engaging the transmission at full engine speed. Instead, the transmission is shifted into the selected gear while the engine is at low speed, and the pump is at rest. The gear range is selected based on the desired initial pump discharge rate. After engaging the transmission, the engine speed is increased, thus transferring power through the torque converter in the transmission. Only then can the engine speed be increased to the engine's maximum horsepower rating. Once pumping has thus commenced, the transmissions may be shifted “on-the-fly” to achieve various discharge flow rates in an attempt to keep the engine operating near its peak power speed.
Such pumping unit designs do not provide infinitely variable discharge rates at full horsepower, and there is a need for a pumping unit which does provide this feature. A further problem with the prior art pumping units is that, as power requirements increase, the reliability of existing transmissions has proven to decrease to an unacceptable level.
The present invention solves these problems by providing a variable displacement pumping machine consisting of a multiple-crankshaft pump driven by a rotational power source which is enabled to operate at a constant speed if desired and thus take full advantage of the full power of the power source at any given discharge flow rate.
SUMMARY
The transmissionless variable output pumping unit of the present invention comprises a multiple crankshaft pump and a rotational prime mover or power source to drive the pump. The pumping unit can operate at a constant speed so that it can take advantage of the full power output of the prime mover at any particular discharge flow rate selected for the pump. The prime mover may be operated at various speeds depending on the desire output horsepower.
Rotational power is transmitted from the prime mover or movers through a synchronizing mechanism, and individual drive trains are coupled to each pump crankshaft. The individual drive systems are configured to cause the pump crankshafts to rotate at the same speed either in the same or opposite directions. The drive systems are positively synchronized in at least one position along the drive train. One or more of the individual drive trains comprises at least one planetary speed reducer. At least one of these planetary speed reducers is mounted such that it allows the traditionally stationary portion of its gearing to be rotated via a positioning mechanism to impart a phase lead or lag in its associated drive train. The traditionally stationary portion of the gear is typically the outer ring gear, but the invention is not intended to be so limited. The phase difference is used to alter the rotational relationship of the crankshafts in such a fashion as to increase or decrease the effective displacement of the pump.
The invention may be described as a pumping apparatus comprising a first cylinder, a second cylinder, a first plunger reciprocably disposed in the first cylinder and adapted for pumping fluid from the first cylinder, a second plunger reciprocably disposed in the second cylinder and adapted for pumping fluid from the second cylinder, a first crankshaft connectable to a prime mover and connected to the first plunger, a second crankshaft connectable to the prime mover and connected to the second plunger, and an adjustment mechanism connected to at least one of the first and second crankshafts such that a phase angle between the first and second crankshafts may be adjusted.
The phase angle may be adjusted between minimum and maximum phase angles corresponding to minimum and maximum pumping rates for the first and second plungers. Preferably, the phase angle may be infinitely adjusted between the minimum and maximum phase angles. The minimum phase angle is zero, and the maximum phase angle may be 180 degrees.
In one embodiment of the invention, the first and second cylinders are coaxial and have substantially the same diameter. In another embodiment, the first and second cylinders are angularly disposed to one another, such as at 90 degrees.
The apparatus further comprises a drive train connecting the first and second crankshafts to the prime mover. In a preferred embodiment, this drive train comprises a first drive shaft driven by the prime mover, a second drive shaft driven by the prime mover, a first gear train connected between the first drive shaft and the first crankshaft, and a second gear train connected between the second drive shaft and the second crankshaft. The first gear train is a planetary gear train having a fixed first outer housing, the second gear train is a planetary gear train having a second outer housing, and the adjustment mechanism further comprises an angular adjustment for the second outer housing corresponding to the phase angle.
One embodiment of the adjustment mechanism comprises a lever extending from the first outer housing. In another, the second outer housing has an outer geared surface, and the adjustment mechanism comprises a spur gear engaged with the outer geared surface. In a different drive train, the second outer housing has an outer geared surface, and the adjustment mechanism comprises a worm gear engaged with the outer geared surface.
Numerous objects and advantages of the invention will become apparent when the following detailed description of the preferred embodiments is read in conjunction with the drawings illustrating such embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a first embodiment of a transmissionless variable output pumping unit of the present invention having coaxial plungers in a maximum discharge configuration.
FIG. 2 shows the first embodiment in a zero discharge configuration.
FIG. 3 illustrates a second embodiment of the invention having plungers that are angularly disposed to one another.
FIG. 4 shows a third embodiment of the invention having plungers that are angularly disposed and have a crossover position.
FIG. 5 shows details of gear trains used to adjust the phase angle between crankshafts in any of the embodiments of the invention, including a manual adjustment mechanism.
FIG. 6 is a detailed view of an adjustment mechanism having a spur gear drive.
FIG. 7 is a detailed view of an adjustment mechanism having a worm gear drive.
FIG. 8 shows details of one of the gear trains including a planet carrier.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
Referring now to the drawings, and more particularly to FIGS. 1 and 2 , a first embodiment of a transmissionless variable output pumping unit of the present invention is shown and generally designated by the numeral 10 . First embodiment pumping unit 10 comprises a first pumping section 12 and a second pumping section 14 . First and second pumping sections 12 and 14 are synchronized and driven by a gear train which will be subsequently described herein. First and second pumping sections 12 and 14 are positive displacement types. It should be understood that any of the pumping units described herein could have additional pumping sections, and the invention is not intended to be limited to those with two.
First and second pumping sections 12 and 14 operatively engage a pump housing 16 having a first cylinder bore 18 and a second cylinder bore 20 therein. It will be seen that first and second cylinder bores 18 and 20 are coaxial in first embodiment pumping unit 10 and in communication with one another. First and second cylinder bores 18 and 20 form portions of a pumping chamber 22 within pump housing 16 . First and second cylinder bores 18 and 20 are also illustrated as having substantially the same diameter.
Pump housing 16 has an inlet or suction port 24 and an outlet or discharge port 26 therein. An inlet or suction valve 28 is disposed in pump housing 16 such that it allows fluid to flow from inlet port 24 into pumping chamber 22 while preventing reverse flow. An outlet or discharge valve 30 is also disposed in pump housing 16 , and the discharge valve 30 allows fluid to flow from pumping chamber 22 into discharge port 26 while preventing reverse flow. Inlet valve 28 and discharge valve 30 are of a kind generally known in the art and allow fluid flow therethrough in only one direction. This flow of fluid through first embodiment pumping unit 10 will be further described herein.
First pumping section 12 comprises a first piston or plunger 32 reciprocably disposed in first cylinder bore 18 . First plunger 32 is attached to a first connecting rod 34 which is in turn attached to a first crankshaft 36 . First crankshaft 36 is rotatably disposed in a first crankcase 38 which is attached to pump housing 16 adjacent to first cylinder bore 18 . The rotational mounting of first crankshaft 36 in first crankcase 38 is substantially known in the art.
Similarly, second pumping section 14 comprises a second piston or plunger 40 reciprocably disposed in second cylinder bore 20 . Second plunger 40 is attached to a second connecting rod 42 which is in turn attached to a second crankshaft 44 . Second crankshaft 44 is rotatably disposed in a second crankcase 46 which is attached to pump housing 16 adjacent to second cylinder bore 20 . The rotational mounting of second crankshaft 44 in second crankcase 46 is substantially known in the art.
Each of crankshafts 36 and 44 can have multiple plungers mounted thereon, not just the single ones illustrated. Also, crankshafts 36 and 44 can be rotated in opposite directions if desired.
FIG. 1 illustrates first embodiment pumping unit 10 in a maximum pumping configuration wherein first and second pumping sections 12 and 14 operate in phase with one another. That is, in this maximum pumping configuration, first and second plungers 32 and 40 always move in opposite directions to one another. During a suction or intake cycle, first and second plungers 32 and 40 both move outwardly from pumping chamber 22 , and during a pumping or discharge cycle, the first and second plungers 32 and 40 both move inwardly toward the pumping chamber 22 . If first crankshaft 36 is rotated at an angle, Ø, from bottom dead center and second crankshaft 44 is rotated at an angle, β, from bottom dead center, then:
Ø=β
With first embodiment pumping unit 10 in this maximum pumping configuration, fluid enters pumping chamber 22 through inlet valve 28 . When the pressure of fluid in pumping chamber 22 is less than the pressure in inlet port 24 less the pressure necessary to overcome the force of the springs in inlet valve 28 , inlet valve 28 will open and fluid will flow inwardly therethrough. Fluid will not flow backward through discharge valve 30 . When first and second plungers 32 and 40 reach the end of the suction stroke in which they are the maximum distance away from one another, they reverse direction and move toward each other to form the pumping cycle. When the pressure of fluid in pumping chamber 22 is greater than the pressure in discharge port 26 plus the pressure necessary to overcome the force of the springs in discharge valve 30 , discharge valve 30 will open and fluid will flow outwardly therethrough. Fluid will not flow backward through inlet valve 28 . It will be seen by those skilled in the art that this operation of first and second pumping sections 12 and 14 in phase with one another will produce the maximum flow of fluid through first embodiment pumping unit 10 .
It should be noted that, while inlet valve 28 and discharge valve 30 are illustrated as spring-loaded plate valves, other types of known pump valves could be used. For example, reed valves could be incorporated. The invention is not intended to be limited to any particular valve construction.
Referring now to FIG. 2 , a zero discharge configuration of first embodiment pumping unit 10 is illustrated. In this zero pumping configuration, first and second pumping sections 12 and 14 operate 180 degrees out of phase with one another. That is, in this zero pumping configuration, first and second plungers 32 and 40 always move in the same direction as one another. During a first cycle, first and second plungers 32 and 40 both move to the right with respect to pumping chamber 22 , and during another pumping cycle, first and second plungers 32 and 40 both move to the left with respect to pumping chamber 22 . If first crankshaft 36 is rotated at an angle, Ø, from bottom dead center and second crankshaft 44 is rotated at an angle, β, from bottom dead center, then:
Ø=β−180°
With first embodiment pumping unit 10 in this zero pumping configuration, substantially no fluid enters pumping chamber 22 through inlet valve 28 or is discharged therefrom through discharge valve 30 . It will be seen by those skilled in the art that the total volume of pumping chamber 22 does not change. The fluid in it is simply moved back and forth so that nothing changes and no fluid is pumped in or out. This assumes that any heating of the fluid by this movement and any related change in density of the fluid is insignificant.
Second Embodiment
Referring now to FIG. 3 , a second embodiment of the transmissionless variable output pumping unit of the present invention is shown and generally designated by the numeral 100 . Second embodiment pumping unit 100 comprises a first pumping section 112 and a second pumping section 114 . First and second pumping sections 112 and 114 are synchronized and driven by a gear train which will be subsequently described herein. First and second pumping sections 112 and 114 are positive displacement types.
First and second pumping sections 112 and 114 operatively engage a pump housing 116 having a first cylinder bore 118 and a second cylinder bore 120 therein. In this second embodiment pumping unit 100 , first and second cylinder bores 118 and 120 are angularly disposed from one another and are in communication with one another. FIG. 3 illustrates this to be an angle of approximately 90 degrees, but the invention is not intended to be limited to any particular angle. First and second cylinder bores 118 and 120 form portions of a pumping chamber 122 within pump housing 116 . First and second cylinder bores 118 and 120 are also illustrated as having substantially the same diameter.
Pump housing 116 has an inlet or suction port 124 and an outlet or discharge port 126 therein. An inlet or suction valve 128 is disposed in pump housing 116 such that it allows fluid to flow from inlet port 124 into pumping chamber 122 while preventing reverse flow. An outlet or discharge valve 130 is also disposed in pump housing 116 , and discharge valve 130 allows fluid to flow from pumping chamber 122 into discharge port 126 while preventing reverse flow. Inlet valve 128 and discharge valve 130 are of a kind generally known in the art and allow fluid flow therethrough in only one direction. This flow of fluid through second embodiment pumping unit 100 will be further described herein.
First pumping section 112 comprises a first piston or plunger 132 reciprocably disposed in first cylinder bore 118 . First plunger 132 is attached to a first connecting rod 134 which is in turn attached to a first crankshaft 136 . First crankshaft 136 is rotatably disposed in a first crankcase 138 which is attached to pump housing 116 adjacent to first cylinder bore 118 . The rotational mounting of first crankshaft 136 in first crankcase 138 is substantially known in the art.
Similarly, second pumping section 114 comprises a second piston or plunger 140 reciprocably disposed in second cylinder bore 120 . Second plunger 140 is attached to a second connecting rod 142 which is in turn attached to a second crankshaft 144 . Second crankshaft 144 is rotatably disposed in a second crankcase 146 which is attached to pump housing 116 adjacent to second cylinder bore 120 . The rotational mounting of second crankshaft 144 in second crankcase 146 is substantially known in the art.
Each of crankshafts 136 and 144 can have multiple plungers mounted thereon, not just the single ones illustrated. Also, crankshafts 136 and 144 can be rotated in opposite directions if desired.
FIG. 3 illustrates second embodiment pumping unit 100 in a maximum pumping configuration wherein first and second pumping sections 112 and 114 operate in phase with one another. That is, in this maximum pumping configuration, first and second plungers 132 and 140 always move in the same direction with respect to pumping chamber 122 . During a suction or intake cycle, first and second plungers 132 and 140 both move away from pumping chamber 122 toward a bottom dead center position, and during a pumping or discharge cycle, first and second plungers 132 and 140 both move toward pumping chamber 122 to a top dead center position. If first crankshaft 136 is rotated at an angle, Ø, from bottom dead center and second crankshaft 144 is rotated at an angle, β, from bottom dead center, then:
Ø=β
With second embodiment pumping unit 100 in this maximum pumping configuration, fluid enters pumping chamber 122 through inlet valve 128 . When the pressure of fluid in pumping chamber 122 is less than the pressure in inlet port 124 less the pressure necessary to overcome the force of the springs in inlet valve 128 , inlet valve 128 will open and fluid will flow inwardly therethrough. Fluid will not flow backward through discharge valve 130 . When first and second plungers 132 and 140 reach the end of the suction stroke in which they are the maximum distance away from pumping chamber 122 , they reverse direction and move toward pumping chamber 122 to form the pumping cycle. When the pressure of fluid in pumping chamber 122 is greater than the pressure in discharge port 126 plus the pressure necessary to overcome the force of the springs in discharge valve 130 , discharge valve 130 will open and fluid will flow outwardly therethrough. Fluid will not flow backward through inlet valve 128 . It will be seen by those skilled in the art that this operation of first and second pumping sections 112 and 114 in phase with one another will produce the maximum flow of fluid through second embodiment pumping unit 100 .
A zero discharge configuration of second embodiment pumping unit 100 is when first and second pumping sections 112 and 114 operate 180 degrees out of phase with one another. That is, in this zero pumping configuration, first and second plungers 132 and 140 always move in opposite directions with respect to pumping chamber 122 . During a first cycle, first plunger 132 moves toward pumping chamber 122 while second plunger 140 moves away from pumping chamber 122 . During a second pumping cycle, first plunger 132 moves away from pumping chamber 122 , and second plunger 140 moves toward pumping chambers 122 . If first crankshaft 136 is rotated at an angle, Ø, from bottom dead center and second crankshaft 144 is rotated at an angle, β, from bottom dead center, then:
Ø=β−180°
With second embodiment pumping unit 100 in this zero pumping configuration, substantially no fluid enters pumping chamber 122 through inlet valve 128 or is discharged therefrom through discharge valve 130 . It will be seen by those skilled in the art that the total volume of pumping chamber 122 does not change. The fluid in it is simply moved back and forth so that nothing changes and no fluid is pumped in or out. This assumes that any heating of the fluid by this movement and any related change in density of the fluid is insignificant.
Third Embodiment
Referring now to FIG. 4 , a third embodiment of the transmissionless variable output pumping unit of the present invention is shown and generally designated by the numeral 150 . Third embodiment pumping unit 150 is similar to second embodiment pumping unit 100 in that the cylinders are angularly disposed from one another. The same reference numerals are used for similar components. In third embodiment pumping unit 150 , however, plunger 132 can cross over plunger 140 as shown. This minimizes the unswept volume in pumping chamber 122 .
Gear Train Detail
FIGS. 5–7 show different embodiments of a gear drive train to operate pumping unit 10 , 100 or 150 . Referring specifically to FIG. 5 , one embodiment drive train 200 is shown. Drive train 200 may be used to drive any of the pumping unit embodiments previously described herein. As illustrated, drive train 200 is driven by a prime mover such as a diesel engine 202 , although other prime movers would also be acceptable. Diesel engine 202 has a dual power take-off 201 connected thereto so that rotational power is provided to a first drive shaft 204 and a second drive shaft 206 .
A first planetary gear reducer or gear train 208 is connected to first drive shaft 204 . First planetary gear reducer 208 has a first outer housing 210 with a set of planetary gears 212 , 214 , and 216 disposed therein and around a first sun gear 215 on an end of first drive shaft 204 . A first planet carrier 217 holds planetary gears, 212 , 214 , and 216 in relationship to one another.
Referring now to FIG. 8 , details of first planet carrier 217 are shown. Planetary gears 212 , 214 , and 216 have a planetary gear shaft 240 , 242 , and 244 correspondingly extending therefrom. Planetary gear shafts 240 , 242 , and 244 fit in openings 246 , 248 , and 250 , respectively, in first planet carrier 217 . As first drive shaft 204 is driven by diesel engine 202 , first sun gear 215 engages and drives planetary gears 212 , 214 , and 216 so that they orbit around first sun gear 215 . It will be seen by those skilled in the art that this causes corresponding rotation of first planet carrier 217 . First planet carrier 217 has a first output shaft 252 which is integral with or connected to first crankshaft 36 or 136 . A speed reducer (not shown) of a kind known in the art may be used between first output shaft 252 and first crankshaft 36 or 136 if desired.
Similarly, a second planetary gear reducer or gear train 218 is connected to second drive shaft 206 . Second planetary gear reducer 218 has a second outer housing 220 with a set of planetary gears 222 , 224 , and 226 disposed therein and around a second sun gear 225 on an end of second drive shaft 206 . A second planet carrier 227 holds planetary gears 222 , 224 , and 226 in relationship to one another.
Second planet carrier 227 is substantially identical to first planet carrier 217 previously described and shown in FIG. 8 . Second planet carrier 227 has a second output shaft 254 that is integral with or connected to second crankshaft 44 or 144 . Again, a speed reducer (not shown) of a kind known in the art may be used between second output shaft 254 and second crankshaft 44 or 144 if desired.
First outer housing 210 is fixed and cannot rotate. Second outer housing 220 is not fixed. It may be rotated about second drive shaft 206 . An adjustment mechanism 228 is used to rotate second outer housing 220 by an angle corresponding to the desired phase angle relationship between first and second pumping sections 12 and 14 , such as the maximum and zero pumping configurations previously described or anything in between. In the embodiment of FIG. 5 , adjustment mechanism 228 is shown as a lever 230 . Lever 230 can be actuated by hand or by some other means, such as a pneumatic or hydraulic cylinder (not shown).
Referring now to FIG. 6 , a different adjustment mechanism 228 ′ is shown having a spur gear drive. In this embodiment, planetary gears 222 , 224 , and 226 and second planet carrier 227 are the same as previously described. Planetary gears 222 , 224 , and 226 are disposed around second sun gear 225 and within a second outer housing in the form of a first spur gear 232 . A second spur gear 234 is engaged with the geared surface of first spur gear 232 and is mounted on a gear shaft 236 . Gear shaft 236 can be driven by any means known in the art such as a rotary actuator, servo motor, etc.
Referring now to FIG. 7 , an additional adjustment mechanism 228 ″ is shown having a worm gear drive. In this embodiment, planetary gears 222 , 224 , and 226 and second planet carrier 227 are the same as previously described. Planetary gears 222 , 224 , and 226 are disposed around second sun gear 225 and within a second outer housing in the form of a first gear 256 . A worm gear 258 is engaged with the geared surface of first gear 256 . A worm gear shaft 260 extends from worm gear 258 . Worm gear shaft 260 can be driven by any means known in the art such as a rotary actuator, servo motor, etc.
It will be seen, therefore, that the transmissionless variable output pumping unit of the present invention is well adapted to carry out the ends and advantages mentioned as well as those inherent therein. While several preferred embodiments have been shown for the purposes of this disclosure, numerous changes may be made by those skilled in the art. All such changes are encompassed with the scope and spirit of the appended claims.
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A transmissionless variable output pumping unit comprising a multiple crankshaft pump driven by a prime mover. The apparatus includes an adjustment mechanism for adjusting a phase angle between first and second crankshafts. Plungers in the pump are disposed in cylinders forming part of a pumping chamber. When the phase angle is at a minimum, the plungers operate together for maximum discharge from the pump. When the phase angle is at a maximum, the plungers operate substantially opposite one another for zero discharge. The phase angle may be infinitely adjusted between the minimum and maximum.
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FIELD OF THE INVENTION
[0001] The present subject matter relates generally to tower structures, and more specifically to methods and apparatus for assembling tower structures.
BACKGROUND OF THE INVENTION
[0002] Construction of towers for support of various items has been practiced for many years. Various towers of various materials, including wooden, steel, and, more recently, concrete, have been provided to support, for example, electrical transmission lines. In a like manner, wind driven apparatus including windmills and wind-driven power generators in various forms and designed for many purposes (including for example pumping of water from wells as well as, more recently, generation of electrical power) have also been developed.
[0003] Such towers are generally constructed of multiple pieces that are assembled at the location of the tower. The pieces are usually hoisted in place by a crane. Cranes can be very expensive to maintain and operate, and a substantial hourly cost is incurred for every hour the crane is on site.
[0004] For example, a large construction crane may require 16 truckloads to transport all of the component parts, substantial labor to assemble and inspect, and then substantial labor to disassemble. Accordingly, a method and apparatus for constructing a tower that minimizes or eliminates the need for a crane is desired.
SUMMARY OF THE INVENTION
[0005] The present invention broadly comprises a method and apparatus for constructing a tower. In one embodiment, the apparatus may include a structure including a foundation including a plurality of hydraulic cylinders; a truss tower located on the foundation and configured to support a tower built on the foundation; and a controller configured to control extension and retraction of the hydraulic cylinders.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] A full and enabling disclosure of the present subject matter, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0007] FIG. 1 illustrates a perspective view of an embodiment of the present invention;
[0008] FIG. 2 is a top view of the foundation of the embodiment shown in FIG. 1 ;
[0009] FIG. 3 illustrates a top view of the tower and a schematic of the cylinder control system;
[0010] FIG. 4 is a side view of all of the cylinders extended before the insertion of a new level;
[0011] FIG. 5 is a side view showing half of the cylinders retracted and half extended;
[0012] FIG. 6 is a side view of the first block that is fully inserted and the hydraulic cylinders below are extended to contact the block;
[0013] FIG. 7 is a side view of the insertion of the second block;
[0014] FIG. 8 is a side view of the completion of a level; and
[0015] FIG. 9 is a top view of an embodiment of the restraining truss shown in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Reference is presently made in detail to exemplary embodiments of the present subject matter, one or more examples of which are illustrated in or represented by the drawings. Each example is provided by way of explanation of the present subject matter, not limitation of the present subject matter. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present subject matter without departing from the scope or spirit of the present subject matter. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present subject matter covers such modifications and variations as come within the scope of the disclosure and equivalents thereof.
[0017] FIG. 1 shows a perspective view of an exemplary embodiment of an apparatus 10 for constructing a tower 80 in accordance with the present invention. Tower 80 supports wind turbine 82 , but towers made according to the present invention may support other equipment, power lines, or other objects. Any such towers may be constructed according to the present invention.
[0018] Apparatus 10 includes a foundation 20 and a truss tower 40 located on the foundation 20 . Foundation 20 includes a plurality of hydraulic cylinders 22 , shown in FIGS. 3-8 . Truss tower includes vertical legs 42 , upper restraining truss 44 , and lower restraining truss 46 . As shown in FIG. 2 , the base 42 A of each vertical leg 42 of the truss tower 40 rests on foundation 20 .
[0019] FIG. 1 shows a truss tower including two restraining trusses, but more than two can be included and are within the scope of the present invention. The restraining trusses 44 and 46 provide horizontal force to support the tower 80 during construction of the tower. In particular, the restraining trusses 44 and 46 counteract uneven forces on the tower 80 during the method of construction described hereafter.
[0020] FIG. 9 shows a close up top view of a restraining truss, such as upper restraining truss 44 . Each restraining truss includes force bearing devices 48 to transfer force from the truss tower 40 to the tower 80 . Further, the force bearing devices 48 allow tower 80 to move past vertically as additional levels are added to tower 80 from below. In the embodiment shown in FIG. 9 , the force bearing device includes rollers 49 to exert horizontal force on tower 80 while still allowing tower 80 to move vertically. However, other devices known in the art may be used in this manner. Further, the force bearing devices may include hydraulic cylinders 50 to tighten the force bearing device up to the wall of tower 80 . The embodiment shown in FIG. 9 includes a hydraulic cylinder 50 for each force bearing device 48 . However, fewer may be used as long as the restraining truss can be sufficiently tightened around tower 80 .
[0021] In the embodiment shown in FIGS. 1-9 , tower 80 has an octagonal cross-section. However, other cross-section shapes are possible, such as square or circular cross-sections. All of these modifications are within the scope of the invention.
[0022] Tower 80 as shown in FIG. 1 includes a wind turbine 82 located on top of levels 84 . In one embodiment, levels 84 are first constructed with a crane, the truss tower 40 is constructed around the levels 84 , and then the crane lifts the wind turbine 82 to the top of levels 84 . The following procedure is then used to add additional levels to the tower using hydraulic cylinders 22 . However, if a heavy object like a wind turbine is not going to be located at the top of the tower, then the truss tower 40 can be constructed over foundation 20 and all levels can be constructed using the hydraulic cylinders 22 . This would allow the elimination of the need for a crane, as the addition of levels using the hydraulic cylinders 22 only needs a forklift, as discussed hereafter.
[0023] In an embodiment for a tower 80 with a wind turbine 82 , 10 2 m levels 82 may be constructed using a crane, and a height of wind turbine 82 may be 50 m. Thus, each leg 42 would be 20 m tall, upper restraining truss 44 would be at 20 m in height while lower restraining truss 46 may be at approximately 8 m from the bottom of truss legs 42 . Truss legs 42 may be square of 12 inches on a side, and may be 22 feet apart from each other.
[0024] In the embodiment shown in FIG. 1 , foundation 20 is constructed, and hydraulic cylinders 22 and block supports 24 are installed in the foundation 20 . Hydraulic cylinders 22 are arranged in pairs, with a block support 24 extending between each pair of cylinders. A plurality of levels 84 are constructed using a crane, the truss tower 40 is constructed around levels 82 and on foundation 20 , and the wind turbine 82 is added to the top of levels 84 . Additional levels are then added using hydraulic cylinders 22 and block supports 24 as shown in FIGS. 4-8 . In the embodiment shown in FIGS. 1-9 , hydraulic cylinders 22 and block supports 24 are then removed from foundation 20 after the desired number of additional levels are added.
[0025] In the embodiment shown in FIGS. 1-9 , there are 24 hydraulic cylinders 22 . In one embodiment, cylinders 22 are sized to lift a concrete tower with a final weight of 1800 tons. However, towers of any dimensions and material may be constructed using this method and apparatus. The size and number of cylinders may vary depending on the dimensions of the tower and the building material. All of these modifications are within the scope of the present invention.
[0026] In this regard, in the embodiment shown in FIGS. 1-9 , each level 84 and 86 is slightly wider than the level above, as shown in FIG. 3 . When the final level is added, the bottom of this final level will line up with the top of foundation 20 .
[0027] The first step of the process is shown in FIG. 4 , in which all of hydraulic cylinders 22 are extended to push up tower 80 by the height of one level. In the embodiment shown in FIGS. 1-9 , all of the levels 84 and 86 have approximately a same height. However, different heights could be used as long as the extension height of hydraulic cylinders 22 is greater than the tallest level. At this step, the tower must slide past the force bearing devices 48 on the restraining trusses, as noted above.
[0028] As shown in FIG. 5 , one half of hydraulic cylinders 22 are then retracted to allow block 86 A of new level 86 to be inserted. As noted above, in the embodiment shown in FIGS. 1-9 , new level 86 is made of two equal sized blocks 86 A and 86 B. However, embodiments where three or more blocks are used and/or each block is more or less than half of each level are possible and are within the scope of the present invention.
[0029] Block 86 A is inserted by the use of a forklift. Block 86 A is then connected to the level above. Block 86 A may be adhered to the block above, or may have grooves or projections that mate with the block above, or both. During this time, uneven forces are placed on the existing tower 80 . Accordingly, restraining trusses 44 and 46 exert horizontal forces on the tower 80 to prevent tower 80 from tipping over due to these uneven forces.
[0030] At this point, the other half of the hydraulic cylinders 22 are retracted, as shown in FIG. 6 . This allows block 86 B to be inserted using a forklift, as shown in FIG. 7 . Block 86 B is then connected to the level above in a similar manner as block 86 A, as shown in FIG. 8 . This should end the uneven forces on the tower, and reduce the load on the truss tower 40 .
[0031] Finally, the new level 86 is pushed up the height of a level by extending all of the hydraulic cylinders 22 , as shown in FIG. 4 . Half of the hydraulic cylinders are then retracted to allow the next level to be added, as described above. However, in the embodiment shown in FIGS. 1-9 , the seams between the two blocks are alternated from level to level. That is, the seam between two blocks is only located on a particular face for every other level, as shown in FIG. 1 . Thus, for example, a first level 86 is constructed by lowering a front half of hydraulic cylinders 22 , adding block 86 A to the front opening, lowering the back half of hydraulic cylinders 22 , and then adding back block 86 B. The following level would be constructed by lowering either the right (or left) half of hydraulic cylinders 22 , adding block 86 A to the right (or left) opening, lowering the left (or right) half of hydraulic cylinders 22 , adding block 86 B to the left (or right) opening. This is accomplished using the control computer 60 shown in FIG. 3 .
[0032] Control computer 60 receives position and pressure readings from each of the cylinders 22 through lines 60 A ( FIG. 3 does not show all of lines 60 A). Control computer 60 then sends signals to control pressurized fluid to each cylinder 22 through line 60 C to pressure manifold 62 . Based on the signals from the control computer 60 , pressure manifold 62 supplies pressurized fluid to each cylinder 22 through a respective valve 62 A. (Not all of valves 62 A are shown in FIG. 3 .) Control computer 60 also controls a return valve on each cylinder 22 through line 60 B. (Not all of lines 60 B are shown in FIG. 3 .) When the return valve is opened by control computer 60 , fluid runs through a respective return line 66 A to fluid reservoir 66 . (Only one of the 24 return lines 66 A is shown in FIG. 3 ). Fluid from fluid reservoir 66 is pressurized by electrical or diesel pump 64 before it is supplied to the pressure manifold 62 .
[0033] Control computer 60 has several programs to control multiple sets of the cylinders 22 . As discussed above, in the embodiment shown in FIGS. 4-8 , half of cylinders 22 are controlled to extend and retract together, and the halves are alternated for each level between (1) right and left half and (2) front and back half. Thus, control computer 60 at has programs to extend and retract (1) the right half of cylinders 22 , (2) the left half of cylinders 22 , (3) the front half of cylinders 22 , and (4) the back half of cylinders 22 . Additional commands such as all extend and all retract can also be programmed into control computer 60 . Further, if each level includes more than 2 blocks, additional commands will be needed to control smaller subsets of cylinders 22 .
[0034] Accordingly, a tower 80 may be constructed with less use of a crane, or without the use of a crane at all. As a forklift is much cheaper to operate than a crane, a substantial cost savings may be gained by using the present method and apparatus for constructing a tower.
[0035] The present written description uses examples to disclose the present subject matter, including the best mode, and also to enable any person skilled in the art to practice the present subject matter, including making and using any devices or systems and performing any incorporated and/or associated methods. While the present subject matter has been described in detail with respect to specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art.
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A method and apparatus for constructing a tower, where the apparatus may include a structure including a foundation including a plurality of hydraulic cylinders; a truss tower located on the foundation and configured to support a tower built on the foundation; and a controller configured to control extension and retraction of the hydraulic cylinders.
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FIELD OF THE INVENTION
[0001] The present invention relates to a process for production of synthesis gas used for the production of liquid hydrocarbons, such as diesel and gasoline. The invention relates in particular to a process for the production of liquid hydrocarbons in the form of diesel in which the light-end fraction from the upgrading section downstream the Fischer-Tropsch synthesis of a gas-to-liquid (GTL) diesel process is recycled to the reforming section of the plant. More particularly the entire light-end stream is recycled back to the reforming section upstream desulfurization and before steam addition, in which the reforming section comprises desulfurization, pre-reforming, autothermal reforming (ATR) or catalytic partial oxidation (CPO), without using a steam methane reformer (SMR). In particular, the light-end stream is Liquefied petroleum gas (LPG). The invention encompasses also the recycle of light-end fraction of a GTL gasoline process to the reforming section of the plant.
BACKGROUND OF THE INVENTION
[0002] As used herein GTL diesel process means Fischer-Tropsch synthesis in which synthesis gas is converted into liquid hydrocarbons via Fischer-Tropsch reactions, while GTL gasoline process means a process in which synthesis gas is first converted to oxygenated compounds such as methanol and/or dimethyl ether and these are subsequently converted to gasoline.
[0003] In particular, a typical GTL diesel plant consists of the following main process units: (a) air separation, (b) syngas preparation via ATR, (c) Fischer-Tropsch synthesis of a raw product of wax and liquid, (d) upgrading comprising hydrocracking and other refinery steps.
[0004] In most GTL diesel plants the main final products are diesel, kerosene, naphtha and liquid petroleum gas (LPG). In some GTL diesel plants higher value products such as lube oil are also produced. The value of the naphtha is lower than the diesel and LPG value is in most cases lower than the naphtha. In some geographic locations the LPG (mainly C3/C4 fraction) and other constituents of the light-end stream can have a very low value and limited market, hence the investment which has to be made into the upgrading of the light-end stream can be high compared with the value of the product. It is therefore known to recycle LPG to the reforming section of the plant.
[0005] WO2004/000772 concerns a process for production of a blended syngas feed. A first syngas (synthesis gas) is formed by reacting methane with oxygen, while a second syngas is formed using LPG and CO 2 .
[0006] AU 20073566234 (WO2009/008092) discloses the recycle of a light-end fraction. According to this citation, LPG together with naphtha can be recycled into the syngas production step. This citation discloses hydrotreating of the Fischer-Tropsch product in the upgrading unit and does not require use of oxygen in the reforming stage, i.e. the synthesis gas producing unit is not an autothermal reformer but a steam methane reformer. Further, a particular and expensive catalyst in the form of supported ruthenium is used in order to avoid deactivation of the catalyst due to deposition of carbon derived from the recycle of the light-end fraction. In particular, the number of carbon atoms in the recycle light-end fraction stream is kept at 10-35% based on the number of carbon atoms of the natural gas fed to the synthesis gas producing unit, since at above 35% carbon deposition on the catalyst will take place. Below 10% it is stated that it is not possible to improve the raw material consumption.
[0007] WO2007/101831 discloses a process for the preparation of a Fischer-Tropsch (FT) synthesis product. After pre-reforming and partial oxidation, a syngas enters an FT synthesis. The FT product is separated into heavy and light streams, and the light stream (comprising inerts, CO 2 and C 1 -C 3 hydrocarbons) is recycled. A portion of the light stream is recycled to the pre-reformer and a portion is recycled to the burner of the partial oxidation step. However, such light stream of unconverted syngas, inerts, CO 2 and C1-C3 is what is normally known as FT tail gas; it is not the light-end fraction, in particular LPG, from an upgrading unit downstream FT synthesis. In addition, the light stream (tail gas) of this citation leads at least a portion of it directly to the burner of a non-catalyzed partial oxidation reactor.
[0008] WO01/60773 discloses a system and method for operating a GTL plant. In involves pre-reforming, syngas generating via e.g. autothermal reforming, FT synthesis and product upgrading steps. Light fractions from the upgrading stage, which includes hydrotreating and/or hydroisomerization, are recycled into the pre-reformer (line 162, FIG. 2 ). However, such light fractions are fed back precisely to the pre-reformer and after addition of steam. This can result in sulphur poisoning of the pre-reformer catalyst as well as catalyst deactivation due to carbon deposition as a result of the presence of olefinic hydrocarbons.
[0009] WO2013/033812 and US2013/0065974 disclose a process for the production of diesel via Fischer-Tropsch synthesis in which naphtha from the upgrading section is recycled as ATR feed through a pretreatment unit to which steam and hydrogen are added. Such unit may include a feed gas hydrotreater, sulphur removal and a pre-reformer and combined with natural gas feed. There is no disclosure of the recycle of light-end fractions, in particular LPG to the hydrocarbon feed, e.g. natural gas feed.
[0010] It would be desirable to provide a process that overcomes the shortcomings of the above known processes.
SUMMARY OF THE INVENTION
[0011] According to the present invention as recited in the appended claims, a process for the production of liquid hydrocarbons from a hydrocarbon feedstock is provided.
[0012] The process comprises the first step of:
[0013] (a) combining a light-end fraction stream from the upgrading stage of step (g) with a stream of natural gas to form said hydrocarbon feedstock;
[0014] By the term “hydrocarbon feedstock” is meant a stream used in the process which comprises hydrocarbons. In the broadest sense, hydrocarbons are organic compounds comprising hydrogen and carbon. The hydrocarbons may be as simple as e.g. methane CH 4 , and may comprise more complex molecules. The natural gas stream is a conventional feed having methane as its major constituent.
[0015] By the term “light-end fraction” is meant an off-gas from the upgrading stage (refinery stage) of Fischer-Tropsch, or gasoline synthesis, and which contains a wide range of constituents including hydrogen, carbon dioxide, carbon monoxide, methane, water, C1-C6 including C2-C6 fraction as well as C6+ constituents either as paraffins or olefins. The light-end fraction may comprise liquefied petroleum gas (LPG).
[0016] Step (b) of the process of the invention involves:
[0017] (b) passing said hydrocarbon feedstock through a hydrogenation stage to form a hydrogenated feedstock.
[0018] The present invention enables the elimination or reduction of the amount of external hydrogen needed in the hydrogenation of step (b) as the invention takes advantage of the hydrogen already present in the light-end fraction stream from the upgrading stage.
[0019] Hence, preferably the hydrogenation of step (b) is conducted without the addition of hydrogen to the hydrocarbon feedstock.
[0020] In the hydrogenation stage, part or all of the unsaturated hydrocarbons such as olefins are converted into paraffins according to the following reaction (given for olefins);
[0000] C n H 2n +H 2 ⇄C n H 2n+2 (for n≧2) (1)
[0021] The olefins are hydrogenated over a CoMo or NiMo hydrogenation catalyst. The hydrogenation of olefins reduces the potential for i.a. carbon laydown in downstream units, particularly the pre-reformer. Further, the hydrogenated stream is prepared for the subsequent desulfurization stage, i.e. hydrodesulfurization.
[0022] Hence, step (c) of the process of the invention involves:
[0023] (c) passing the hydrogenated feedstock through a desulfurization stage to form a desulfurized feedstock.
[0024] Sulphur traces in the gas are thereby removed over a catalyst bed comprising zinc oxide, thereby avoiding sulphur poisoning of the pre-reformer downstream as well as other downstream catalysts such as the Fischer-Tropsch synthesis catalyst.
[0025] Step (d) of the process of the invention involves:
[0026] (d) passing the desulfurized feedstock through a pre-reforming stage under the addition of steam to form a pre-reformed gas.
[0027] The desulfurized feedstock is subjected to a step of pre-reforming, preferably adiabatic pre-reforming before being directed to downstream reforming stage. In the adiabatic pre-reformer most or all of the higher hydrocarbons (hydrocarbon compounds with 2 or more carbon atoms) are converted according to the following reactions:
[0000] C n H m +nH 2 O→(½m+n)H 2 +nCO (2)
[0000] 3H 2 +CO⇄CH 4 +H 2 O (3)
[0000] CO+H 2 O⇄H 2 +CO 2 (4)
[0028] Reactions (3) and (4) are normally close to equilibrium at the outlet of the pre-reformer.
[0029] Preferably, the pre-reforming stage is conducted adiabatically in a fixed bed of nickel catalyst. Thus, the adiabatic pre-reformer contains preferably a fixed bed of catalyst having nickel as the active constituent on a suitable carrier, such as MgO/A1203 or Mg—Al spinel.
[0030] Contrary to the prior art, the invention enables the use of relatively inexpensive nickel catalysts in the pre-reformer and downstream reforming stages, as the risk of carbon laydown or deposition and sulphur poisoning are mitigated upstream after the light-end fraction stream has combined with the natural gas stream.
[0031] Step (e) of the process of the invention involves:
[0032] (e) passing the pre-reformed gas through an Autothermal reformer (ATR) or Catalytic Partial Oxidation unit (CPO) under the addition of an oxidant gas to form a synthesis gas.
[0033] Autothermal reforming (ATR) is described widely in the art and open literature. Typically, the autothermal reformer comprises a burner, a combustion chamber, and catalyst arranged in a fixed bed all of which are contained in a refractory lined pressure shell. Autothermal reforming is for example described in Chapter 4 in “Studies in Surface Science and Catalysis”, Vol. 152 (2004) edited by Andre Steynberg and Mark Dry.
[0034] In the ATR, oxidant gas, and in some cases steam is added. Synthesis gas (“syngas”) is formed by a combination of steam reforming and partial oxidation in the autothermal reformer.
[0035] By the term “oxidant gas” is meant a stream comprising oxygen, preferably more than 75 vol %, more preferably more than 85 vol % oxygen. Examples of oxidant gas are air, oxygen, mixture of oxygen and steam, and oxygen enriched air.
[0036] The synthesis gas leaving the ATR is free of oxygen and the temperature of this hot effluent gas from the ATR is between 900 and 1100° C., or 950 and 1100° C., typically between 1000 and 1075° C. The hot effluent synthesis gas leaving the autothermal reformer comprises carbon monoxide, hydrogen, carbon dioxide, steam, residual methane, and various other components including nitrogen and argon.
[0037] Preferably the reforming step (e) is conducted without the use of Steam Methane Reformer (SMR) (tubular reformer). The use of ATR or CPO instead of the SMR has the advantage in first of all production of a syngas with the best sutiable syngas ratio H 2 /CO for the hydrocarbon synthesis, i.e. close to 2.0 for FT synthesis. An SMR will produce surplus of H 2 due to the need of operating at high S/C ratios, normally well above 1.1, for instance 1.5 or higher, as well as with high CO 2 and CH 4 in the syngas which act as inerts in the hydrocarbon synthesis. In addition, the investment of an ATR based plant is lower than the SMR plant for the same amount of CO in the syngas.
[0038] Step (f) of the process of the invention involves:
[0039] (f) passing the synthesis gas through a Fischer-Tropsch synthesis stage to form a tail gas stream and a raw product stream of hydrocarbons.
[0040] In the Fischer-Tropsch synthesis the synthesis gas is converted to a raw stream of hydrocarbons basically in the form of wax and liquid, along with a tail gas containing unconverted synthesis gas. Tail gas is as used herein off-gas from Fischer-Tropsch synthesis which is not reused in this stage.
[0041] The final step (g) of the process of the invention involves:
[0042] (g) passing the raw product stream of hydrocarbons through an upgrading stage to form a final product stream of liquid hydrocarbons and a light-end fraction stream, in which the light-end fraction stream comprises a C1-C6 fraction and C6+ fraction containing paraffinic and olefinic hydrocarbons, but no naphtha.
[0043] The upgrading stage is a refinery stage in which the raw product stream of hydrocarbons is separated into individual components such as valuable diesel, as well as light-end fractions comprising LPG. In the present invention, this light-end fraction stream has no naphtha. Naphtha is a light-end fraction having hydrocarbons in the range C5-C10 or C4-C10 with main hydrocarbons in the C4-C9 range.
[0044] According to the present invention, the light-end fraction is recycled back to a point in the process which is well before pre-reforming, i.e. before steam addition and even before desulfurization. Hence, the risk of carbon laydown or deposition as well as sulphur poisoning in the pre-reformer and downstream synthesis units is reduced, while at the same time it is possible to obtain better carbon utilization in the overall process as well as lower natural gas consumption per unit of diesel product.
[0045] It has been found that the compared to light-end fractions such as LPG, the recycle of naphtha to the natural gas, despite reducing the amount of natural gas import and thus improving carbon utilization, results in lower process economy (higher capital costs). By recycling naphtha there is a need to operate the reforming section at a higher steam-to-carbon molar ratio to avoid carbon formation which conveys carrying more steam in the process and thus also a significant increase in tail gas addition in order to keep the H 2 /CO molar ratio in the synthesis gas at the desired level of about 2. In addition, the higher steam-to-carbon leads to higher inlet flow to pre-reformer and ATR. The higher flow in the ATR, in particular, implies that more oxygen is required thus resulting in significant higher investments in the air separation plant used to produce the oxygen.
[0046] The present invention enables therefore a better carbon utilization (less natural gas import) while at the same time providing a better process economy than the prior art.
[0047] In conventional Fischer-Tropsch processes, hydrotreating is conducted as part of the upgrading stage. In the present invention, the hydrotreatment is in a way provided via the hydrogenation stage upstream the desulphurization and pre-reforming stage, thus completely independent from the upgrading stage of the Fischer-Tropsch section, and rather as a part of the reforming section of the process while at the same time reducing or eliminating the use of external hydrogen in the hydrogenation stage.
[0048] In addition, the present invention reduces/eliminates the amount of equipment in the upgrading stage that otherwise would be required to upgrade the light-end stream. The alternative to upgrading is that this stream end as fuel-gas, which reduces the overall carbon efficiency of the plant.
[0049] In a particular embodiment in connection with one of the above or below embodiments, the upgrading stage (g) comprises hydrocracking but no hydrotreating.
[0050] In hydrocracking a catalyst such a zeolite is provided in order to cut C-C bonds; hence hydrocracking changes the boiling point of the liquid hydrocarbons or shorten the carbon length. In hydrotreating, the catalysts are different and the process is rather used for selective addition of hydrogen to saturate olefins and aromatics. The ranges of temperatures and pressures are also more moderate than in hydrocracking processes.
[0051] In a particular embodiment in connection with one or more of the above or below embodiments, the entire light-end stream is used in step (a). Hence, according to this particular embodiment the light-end stream is not divided but provided in its entirety into step (a), i.e. to the natural gas or other suitable feedstock prior to hydrodesulphurization and steam addition.
[0052] In a particular embodiment in connection with one or more of the above or below embodiments, the light-end fraction stream comprises a C1-C6 fraction and C6+ fraction containing paraffinic and olefinic hydrocarbons. Preferably the light-end fraction has a composition:
[0000]
H2
29
mole %
CO
4
mol %
CO2
11
mole %
CH4
6
mol %
N2
1
mole %
C2
3
mole %
C3
8
mole %
C4
18
mole %
C5
9
mole %
C6+
6
mole %
H20
5
mole %
[0053] in which a minor fraction of the hydrocarbons are olefins while the majority of the hydrocarbon fraction are paraffins. Further the stream may contain traces of sulphur components.
[0054] The light-end fraction stream may also comprise LPG, as defined below.
[0055] In another particular embodiment the light-end fraction stream is liquefied petroleum gas (LPG) constituted by a C2-C6 fraction, preferably having propane, butane, propylene and butylene (C3-C4) as its major constituents, where this C3-C4 fraction represents at least 95 mole %, preferably at least 95 mole %.
[0056] Preferably the LPG stream has the composition:
[0000]
C2
0.7 mole %
C3
28 mole %
C4
70 mole %
C5
1 mole %
C6
0.3 mole %
[0057] In a particular embodiment in connection with one of the above or below embodiments, the hydrogenation of step (b) is conducted under the addition of hydrogen to the hydrocarbon feedstock. Such addition of external hydrogen may be required when the light-end fraction stream is LPG either having low or no hydrogen content.
[0058] In a particular embodiment in connection with one or more of the above embodiments, the ATR or CPO stage is conducted in a fixed bed of nickel catalyst in which the active component is not solely a metal of the group consisting or Rh, Ru, Ir, Pt and mixtures thereof. Accordingly, in the present invention the catalyst in the ATR or CPO is nickel based, i.e. nickel is an active constituent, optionally together with e.g. Ir, but because of the reduced risks of carbon deposition, there is no need of using expensive catalysts in which the active constituent is solely Rh, Ru, Ir, Pt or a mixture of these, in particular Ru as disclosed in AU 20073566234 (WO2009/008092).
[0059] In another particular embodiment in connection with one or more of the above embodiments, tail gas from the Fischer-Tropsch synthesis of step (f) is recycled to hydrogenation stage (b), desulphurization stage (c), pre-reforming stage (d), reforming stage (e), or a combination thereof. The addition of tail gas which is a CO 2 -rich stream to the reforming section, preferably to the ATR or CPO in reforming stage (e), enables that there is sufficient carbon dioxide during the reforming stage to achieve the desired H 2 /CO molar ratio in the synthesis gas, typically about 2 for Fischer-Tropsch synthesis as described previously.
[0060] In another particular embodiment in connection with one or more of the above embodiments, step (e) further comprises passing the pre-reformed gas through a heat exchange reformer before the ATR or CPO, and using the hot effluent gas from the ATR or CPO as heat exchanging medium in the heat exchange reformer thereby cooling the hot effluent gas into said synthesis gas. The provision of the heat exchange reformer, preferably in series arrangement with the ATR or CPO, enables operation of the process at lower process steam-to-carbon molar ratios (S/C process ), e.g. at 0.4-1.3 often 0.6-1.1, and thereby reduction of equipment size downstream as there is less steam to be carried in the process.
[0061] The process steam-to-carbon ratio, S/C process , means the number of moles steam divided by the number of moles of hydrocarbon carbon. The number of moles of steam includes all the steam added to the hydrocarbon feedstock upstream the heat exchange reformer. The hydrocarbon carbon means the hydrocarbons present in the feedstock and includes the hydrocarbon carbon from the recycled light-end fraction. The S/C process ratio is measured upstream the heat exchange reformer, or upstream the pre-reformer.
[0062] There are other hydrocarbon synthesis than Fischer Tropsch for which the invention applies-suitably in the form of hydrocarbon synthesis processes for gasoline production involving methanol and/or dimethyl ether (DME) as intermediate building blocks, i.e. oxygenates, as for instance disclosed in our U.S. Pat. No. 4,520,216 and U.S. Pat. No. 4,481,305. In such processes there is also a light-end fraction stream from particularly the product upgrading stage (cleaning section) which may be recycled to the syngas section comprising the reforming stages, specifically to the produced synthesis gas, or to the gasoline synthesis in order to increase the carbon efficiency and limit the amount of hydrocarbons that ends as fuel in the hydrocarbon synthesis plant. In the reforming stage, a heat exchange reformer or Steam Methane Reformer (SMR) may suitably be combined with an ATR or secondary reformer (where enriched air, normally about 44% oxygen is added) to produce the syngas used in downstream production of methanol and/or DME as intermediate products (oxygenates) to the subsequent gasoline synthesis and final product upgrading.
[0063] US2010/0036186 discloses also a process for the production of liquid hydrocarbons in the gasoline range in which the effluent from a gasoline synthesis reactor is passed to a separation stage, whereby gasoline is separated together with LPG. An unconverted stream of unconverted gas lighter hydrocarbons is recycled to oxygenate synthesis reactor and synthesis stage located upstream. There is no disclosure of the recycle of LPG to the hydrocarbon feed, e.g. natural gas feed.
[0064] Accordingly, as recited in the appended claims the invention provides also a process for the production of liquid hydrocarbons in the form of gasoline from a hydrocarbon feedstock containing natural gas comprising:
[0065] (i) combining a light-end fraction stream from the upgrading stage of step (vii) with a stream of natural gas to form said hydrocarbon feedstock;
[0066] (ii) passing said hydrocarbon feedstock through a hydrogenation stage to form a hydrogenated feedstock;
[0067] (iii) passing the hydrogenated feedstock through a desulfurization stage to form a desulfurized feedstock;
[0068] (iv) passing the desulfurized feedstock through a pre-reforming stage under the addition of steam to form a 0 pre-reformed gas;
[0069] (v) passing the pre-reformed gas through an autothermal reformer (ATR), secondary reformer or Catalytic Partial Oxidation unit (CPO) under the addition of an oxidant gas to form a synthesis gas;
[0070] (vi) passing the synthesis gas through a methanol synthesis stage, dimethyl ether (DME) synthesis stage, or a combination of both, to form a raw product stream of oxygenates comprising methanol, DME or a mixture of both;
[0071] (vii) passing the raw product stream of oxygenates through a gasoline reactor to form a raw product stream of gasoline and passing said raw product stream through an upgrading stage to form a final product stream of liquid hydrocarbons comprising gasoline and a light-end fraction stream, in which the light-end fraction stream is liquefied petroleum gas (LPG) constituted by a C2-C6 fraction.
[0072] It would be understood that in step (vii) the gasoline reactor produces a product effluent which is cooled to provide separate effluents of water, a tail gas (unconverted gas) which is rich in CO 2 , as well as a liquid hydrocarbon phase of mixed gasoline and a light-end fraction in the form of LPG, i.e. raw product stream of gasoline or simply raw gasoline. The raw gasoline may be further processed by conventional means to obtain a lower-boiling gasoline fraction and the light-end fraction as LPG. Normally, LPG is not recycled to the reforming section of the plant, in particular to the hydrocarbon feed, e.g. natural gas feed.
[0073] In a particular embodiment tail gas from the gasoline reactor of step (vii), in particular from the upgrading stage of step (vii), is recycled to hydrogenation stage (ii), desulphurization stage (iii), pre-reforming stage (iv), reforming stage (v), or a combination thereof. Preferably, the tail gas is recycled to the gasoline reactor of step (vii).
[0074] In a particular embodiment in connection with the above or below embodiments, step (v) further comprises passing the pre-reformed gas through:
a heat exchange reformer before the ATR, secondary reformer or CPO, and using the hot effluent gas from the ATR, secondary reformer or CPO as heat exchanging medium in the heat exchange reformer thereby cooling the hot effluent gas into said synthesis gas, or a steam methane reformer (SMR) before the ATR, secondary reformer or CPO.
[0077] In another particular embodiment in connection with any of the above or below embodiments, the upgrading stage (vii) comprises hydrocracking but no hydrotreating.
[0078] In yet another particular embodiment in connection with any of the above embodiments, step (ii) is conducted under the addition of hydrogen to the hydrocarbon feedstock.
BRIEF DESCRIPTION OF THE FIGURES
[0079] The invention is further illustrated by reference to the attached FIGURE which shows a specific embodiment of the invention in which LPG recycle is used in the syngas section (reforming section) of a GTL plant, upstream the hydrogenation stage and before steam addition.
DETAILED DESCRIPTION
[0080] Referring to the appended FIGURE, a hydrocarbon feedstock 3 is formed by combining natural gas 1 with LPG recycle stream 2 from downstream upgrading unit of Fischer-Tropsch section for producing diesel or downstream synthesis section for production of gasoline (not shown). Hydrogen 4 is added to the hydrocarbon feedstock prior to heating in fired heater 30 using fuel source 7 . The heated hydrocarbon feed is then passed through hydrogenation reactor 40 containing a fixed bed 41 of CoMo or NiMo catalyst, then hydrodesulphurization unit (HDS) 50 containing a fixed bed 51 comprising ZnO to capture sulphur. The desulphurized feedstock 5 is then passed through adiabatic pre-reformer 60 containing a fixed bed of nickel catalyst 61 under the addition of steam 6 and further heating via fired heater 30 . The pre-reformed 8 gas is further heated and is combined with a CO2-rich recycle stream 9 such as Fischer-Tropsch tail gas to form stream 10 . The pre-reformed gas stream 10 is then passed through autothermal reformer (ATR) 70 comprising a bed of nickel based catalyst 71 . Oxygen 11 and steam 12 may be added to form a mixture 13 of oxygen and steam which is supplied to ATR 70 . Oxygen 13 and steam 12 can also be supplied independently. The hot effluent gas 14 from the ATR is then cooled in waste heat boilers 80 , 81 under the production of high pressure steam 15 using boiler feed water 16 . The cooled synthesis gas 17 is then passed through a final cooling and separation stage 90 , where water 18 (process condensate) is removed and synthesis gas stream 19 is produced for downstream process, such as Fischer-Tropsh synthesis for production of diesel, or methanol and/or DME followed by gasoline synthesis for production of gasoline.
EXAMPLE 1
[0081] In one embodiment a light-end fraction stream containing LPG components and other light gasses are withdrawn from separation step which could be a stripper column in the upgrading section. An example of light-end fraction stream composition is listed below:
[0000]
H2
29
mole %
CO
4
mol %
CO2
11
mole %
CH4
6
mol %
N2
1
mole %
C2
3
mole %
C3
8
mole %
C4
18
mole %
C5
9
mole %
C6+
6
mole %
H20
5
mole %
[0082] A minor fraction of the hydrocarbons are olefins while the majority of the hydrocarbon fraction is paraffins. Further the stream could contain traces of sulphur components.
[0083] The light-end stream containing LPG is recycled to the desulphurization reactor of the syngas section in which it is mixed with a natural gas stream. The olefins in the combined gas stream are hydrogenated over a hydrogenation catalyst under the addition of hydrogen (typical CoMo og NiMo type catalyst) thereby removing undesirable olefins and any sulphur components in the combined gas are then removed on the desulphurization catalysts of the subsequent desulphurization stage. The light-end stream containing LPG stream substitutes some of the natural gas fed to the process. The hydrogenated and sulphur depleted feed gas is then mixed with steam and sent to the pre-reformer followed by the ATR reformer.
[0084] As an example from a GTL plant an light-end stream with a flow of totally of 224 Nm 3 /hr (with above composition) is recycled back to the syngas section, in particular upstream the hydrogenation stage. Despite of the low recycle ratio of the light-end stream, i.e. about 2% of the natural gas feed, the amount of natural gas (NG) import is reduced by 3% from 11378 Nm 3 /hr to 11035 Nm 3 /hr. The syngas section continue to produce the same amount of syngas with the desirable H 2 /CO molar ratio=2.0 for Fischer-Tropsch synthesis, in an amount of 33700 Nm 3 /hr which is equivalent to a liquid production of approx 1000 BPD while at the same time avoiding sulphur poisoning as well as carbon deposition of the pre-reformer. The pre-reformer and the autothermal reformer can be operated with conventional nickel catalysts, i.e. without the need of using expensive catalysts based on Ru, Rh, Ir, or Pt as the sole active constituents.
[0085] EXAMPLE 2
[0086] In another embodiment the light-end gas from a separation step which could be a stripper column in the upgrading section has been further separated into a light end fuel gas and a LPG stream.
[0087] The LPG stream has the following composition:
[0000]
C2
0.7 mole %
C3
28 mole %
C4
70 mole %
C5
1 mole %
C6
0.3 mole %
[0088] A minor fraction of the hydrocarbons are olefins while the majority of the hydrocarbon fraction is paraffins.
[0089] The LPG stream is recycled to the desulphurization reactor of the syngas section in which it is mixed with the other hydrocarbon feed stream, namely natural gas. The olefins in the LPG stream are hydrogenated over the hydrogenation catalyst (typically CoMo og NiMo type catalyst). The LPG stream substitutes some of the natural gas coming (or other hydrocarbon feed stream coming from outside feed source). The hydrogenated and sulphur depleted feed gas is then mixed with steam and sent to the pre-reformer followed by the ATR reformer.
[0090] As an example from a GTL plant a LPG recycle stream of 224 Nm 3 /hr (with above composition) is recycled back to the syngas section, upstream the hydrogenation stage. Despite the low recycle ratio of LPG with respect to natural gas (about 2%), the amount of natural gas (NG) import is reduced by 5% from 11378 Nm3/hr to 10805 Nm3/hr. The syngas section continue to produce the same amount of syngas with the desired H 2 /CO molar ratio=2.0 for Fischer-Tropsch synthesis in an amount of 33796 Nm 3 /hr which is equivalent to a liquid production of approx 1000 BPD while at the same time avoiding sulphur poisoning as well as carbon deposition of the pre-reformer. As Example 1, the pre-reformer and the autothermal reformer can be operated with conventional nickel catalysts, i.e. without the need of using expensive catalysts based on Ru, Rh, Ir, or Pt as the sole active constituents.
EXAMPLE 3-COMPARATIVE
[0091] In another embodiment a light hydrocarbon fraction which is separated from the main hydrocarbon fraction in a separation step in a fractionation column. The main hydrocarbon fraction is a diesel fraction and the light end fraction is a naphtha fraction. The naphtha fraction is recycled to the syngas section and mixed with the other hydrocarbon feed upstream the desulphurization stage.
[0092] The naphtha stream contains long chain higher hydrocarbons and the syngas section must be operated at higher steam-to-carbon ratio to avoid carbon formation from the higher hydrocarbons in the reforming section and especially in the pre-reforming step. This will require a higher addition of high pressure steam to the hydrocarbon feed and thereby higher steam consumption. Most of the equipment will increase in size and thereby in cost due to the high steam-to-carbon molar ratios.
[0093] The naphtha stream is a stream with initial boiling point of 30° C. and final boiling point of 170° C. with main hydrocarbon in the C4-C9 range.
[0094] Naphtha Composition:
[0000]
Components
Mole %
C4
1.1
C5
12.5
C6
21.5
C7
32.6
C8
25.8
C9
7.6
[0095] As an example from a GTL plant a naphtha recycle stream of 650 kg/hr (with above composition) is recycled back to the syngas section. The amount of natural gas (NG) import is reduced by 19% from 11378 Nm 3 /hr to 9193 Nm 3 /hr, which improves carbon utilization, yet at the same time the recycle of Fischer-Tropsch tail gas increases by a factor 1.5-2 because of the naphtha process require operating at a higher steam-to-carbon ratio. The increase in the flow of such tail gas is needed to compensate for the higher steam-to-carbon ratio in order to obtain the desired H 2 /CO molar ratio of 2 in the synthesis gas used for Fischer-Tropsch synthesis. Accordingly, the costs of the tail gas recycle compressor increases. Since the higher steam-to-carbon ratio leads to higher inlet flow to the pre-reformer and ATR, a higher oxygen requirement in the ATR is necessary. The amount of oxygen import increases by 7% resulting in an associated increase in the investment of the air separation plant. The total flow through the plan increases and thereby most equipment will increase in size by 9%, with an associated increase in equipment cost. The syngas section continue to produce the same amount of syngas with H 2 /CO ratio=2.0 in an amount of 33796 Nm 3 /hr. Even though the natural gas consumption is reduced by 19% the operation cost and investment increases. This example illustrates that the recycle of naphtha is not beneficial to the process economy or the investment in the syngas section of the GTL plant, despite savings in carbon utilization in the form of reduced NG import.
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The invention relates to a process for the production of liquid hydrocarbons by the use of light-end fractions from downstream synthesis in the reforming section of the plant.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an amplifying circuit, and more particularly, to an amplifying circuit with high linearity and low power consumption.
[0003] 2. Description of the Related Art
[0004] As well known by the person of ordinary skilled in the art, input/output stage circuits can be basically divided into three categories, that is, class A circuit, class B circuit, and class AB circuit. Where the performance of class AB circuit falls between the performance of the class A circuit and the class B circuit. In contrast to the class A circuit, the class AB circuit's power consumption is lower. Furthermore, in contrast to the class B circuit, the class AB circuit can provide an improved linear relationship between an amplified signal and an input signal.
[0005] For details about the related circuit, please refer to “A Pipelined 5-M Sample 9-bit Analog-to-Digital Converter” published in the December 1987 issue of the JSSC. Another paper titled “A High-performance Micropower Switched-Capacitor Filter” published in the December 1985 issue of the JSSC. Finally, the paper titled “A Programmable 1.5V CMOS Class-AB Operational Amplifier with Hybrid Nested Miller Compensation for 120 dB Gain and 6 MHz UGF” is found in the 1994 edition of the ISSCC.
[0006] In the paper titled “A Compact Power-efficient 3V CMOS Rail-to-Rail Input Output Operational Amplifier for VLSI Cell Libraries” published in the ISSSC in 1994, an operational amplifier circuit is disclosed. Please refer to FIG. 1 . FIG. 1 is a circuit diagram of an operational amplifier 100 as disclosed in the said ISSSC's 1994 paper. As shown in FIG. 1 , the operational amplifier 100 comprises a class A input stage circuit 110 , a biasing circuit 120 , and an output circuit 130 , where the biasing circuit 120 and the output circuit 130 form a class AB output stage circuit.
[0007] In reference to FIG. 1 , the static current Iq of the output circuit 130 should be appropriately designed such that the entire operational amplifier circuit 100 can be operated at a best operational point when it performs a signal amplifying operation. This means a better linear relationship can be achieved such that the signal will have a larger swing.
[0008] Please refer to FIG. 2 . FIG. 2 is a diagram showing a characteristic curve of the output circuit 130 as shown in FIG. 1 . In FIG. 2 , Iq represents a static current when the input signal is a common-mode voltage (i.e., the differential voltage Vid is 0). I MAX and I MIN represent the maximum and minimum currents sustained by the output circuit 130 under the situation of input signal and output signal still keeping linearity. (That is, the transistors M 25 and M 26 operated in the saturation region).
[0009] As well known by the person of ordinary skilled in the art, in order to make the output signal achieve a maximum swing, the difference between I MAX and I MIN needs to be designed as large as possible. Please note that the swing can be equivalently regarded as an amplified degree without distortions. On the other hand, when there is no input signal (i.e., when the differential voltage Vid is 0), in order to reduce the power consumption, the static current Iq should be designed as small as possible.
[0010] However, the above-mentioned circuit cannot obtain the two advantages of amplified degree and the power consumption at the same time. Please note, the above-mentioned circuit uses the class A input stage circuit 110 , which indicates that the current from the input stage circuit 110 to the biasing circuit 120 is determined by the current sources Ib 1 and Ib 2 . Therefore, when the gate voltages of the transistor M 19 and M 20 are determined, the voltage difference V AB between the gate voltages of the transistors M 25 and M 26 and the static current Iq of the output stage circuit are also correspondingly determined at the same time. In other words, the operational point is determined. Finally, when the input signal is inputted into the operational amplifier 100 , the operational point does not change (e.g., the above-mentioned voltage V AB and the static current Iq remain the same).
[0011] Therefore, to achieve reduced power consumption of the entire circuit 100 , the static current Iq should be set to a smaller value. For example, this can be achieved through setting the gate voltages of the transistors M 21 through M 24 ). However, this action also influences the voltage difference V AB between the gate voltages of the transistors M 25 and M 26 such that the gate voltages of the transistors M 25 and M 26 are getting higher. In this way, the voltage differences between the gate and the source of the transistors M 25 and M 26 are also made smaller. As a result, the linearity of the output stage becomes worse and the maximum swing of the output signal is smaller.
[0012] Alternatively, if the maximum swing of the output signal is desired to be larger and a better linearity should be needed, the cross voltages of the transistors M 21 through M 24 should be larger. For example, adjusting the cross voltages of the transistors M 21 through M 24 to make the voltage difference between the gate and the source of the transistors M 25 and M 26 lower. However, in this way, when there is no input signal (i.e., the differential voltage Vid is 0), the static current Iq consumes more power.
[0013] From the above disclosure, it can be seen the power consumption and the signal swing cannot be optimized at the same time. It is apparent that a solution is needed.
SUMMARY OF THE INVENTION
[0014] In view of the above-mentioned problems, an object of the claimed invention is to provide an amplifying circuit, which can have a better linear relationship when an input signal is inputted into the circuit and can have a smaller power consumption when there is no input signal inputted into the circuit, to solve the prior art problems.
[0015] According to an embodiment of the claimed invention, an amplifying circuit is disclosed. The amplifying circuit comprises: a class AB input stage circuit, configured to receive an input signal and generating an inner signal according to the input signal; and a class AB output stage circuit, coupled to the class AB input stage, the class AB output stage circuit includes: a biasing circuit, configured to generate a first biasing signal and a second biasing signal according to the inner signal; and an output circuit, for generating an output signal according to the first biasing signal and the second biasing signal; wherein a voltage difference between the first biasing signal and the second biasing signal is corresponding to the input signal.
[0016] According to another embodiment of the claimed invention, an amplifying circuit is disclosed. The amplifying circuit comprises: an input stage circuit, configured to receive an input signal and generate a first current signal and a second current signal; an output stage circuit, the output stage circuit includes: a voltage generating circuit, configured to provide a voltage difference according to the first current signal and the second current signal; and an output circuit, configured to generate an output signal according to the voltage difference; wherein a sum of the first current signal and the second current signal is corresponding to a swing of the input signal.
[0017] The claimed invention amplifying circuit has better linearity when the input signal is swing, and has smaller power consumption when the input signal is not swing. Therefore, the amplifying circuit of present invention can simultaneously achieve optimized signal amplifying qualities and power consumptions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a circuit diagram of an operational amplifier according to the prior art.
[0019] FIG. 2 is a diagram showing a characteristic curve of the output circuit as shown in FIG. 1 .
[0020] FIG. 3 is a diagram of an operational amplifier according to a first embodiment of the present invention.
[0021] FIG. 4 is a diagram of the class AB output stage circuits as shown in FIG. 3 .
[0022] FIG. 5 is a diagram showing the characteristic curves of the present invention output stage circuit and the prior art output stage circuit.
[0023] FIG. 6 is a diagram of an operational amplifier according to a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Please refer to FIG. 3 . FIG. 3 is a diagram of an operational amplifier 300 according to a first embodiment of the present invention. As shown in FIG. 3 , the operational amplifier 300 comprises a class AB input stage circuit 310 , biasing circuits 320 and 321 , and output circuits 330 and 331 . Please note, the biasing circuit 320 and the output circuit 330 form a first class AB output stage, and the biasing circuit 321 and the output circuit 331 form a second class AB output stage.
[0025] Please note, because the operational amplifier 300 is a differential circuit, in order to help illustrate more simply hereinafter, only half of the operational amplifier 300 , specifically those comprising the class AB input stage 310 , the biasing circuit 320 , and the output circuit 330 , are illustrated. The operation and function of the half of the circuit 300 is the same as the other half of the circuit 300 , and thus the other half circuit is omitted herein for the sake of brevity and clarity.
[0026] As shown in FIG. 3 , the output circuit 330 comprises two cascaded transistors M 25 and M 26 for driving the output end Von. Furthermore, as shown in FIG. 3 , the gates (i.e., node A and node B) of the cascaded transistors M 25 and M 26 are coupled to the biasing circuit 320 . Therefore, the biasing circuit 320 can provide an appropriate cross voltage on the gates of the cascaded transistors through the node A and node B.
[0027] Please refer to FIG. 4 , which is a diagram of the class AB output stage circuits 320 and 330 shown in FIG. 3 . As shown in FIG. 4 , the transistors M 12 and M 18 are utilized as a current source for respectively providing fixed currents I BP and I BN . Please note that in FIG. 4 , only the transistors M 12 and M 18 are shown and the other transistors of the current mirror are omitted. The nodes C and D respectively receive current signals I PP and I PN from the class AB input stage 310 .
[0028] The PMOS transistor M 19 and the NMOS transistor M 20 form a resistor unit coupled between the nodes A and B. Moreover, the gates of the transistors M 19 and M 20 are respectively coupled to predetermined voltages V BP and V BN . In addition, the transistors M 19 and M 20 determine their gate-to-source voltage difference (Vgs) according to the current passing through them such that the gate voltages V A and V B of the transistors M 25 and M 26 are determined. Therefore, the circuit designer can appropriately design the currents I BP and I BN or the resistance of the resistor unit (i.e., M 19 and M 20 ) to determine an idea voltage difference (e.g., V A and V B ). Furthermore, a resistor can be also be used to replace the transistors M 19 and M 20 to generate the voltages V A and V B .
[0029] However, please note that the operation and the function of the biasing circuit 320 are different from those of the prior art biasing circuit 120 . As mentioned in the prior art, because the current signal outputted from the class A input stage circuit 110 is determined by the current sources Ib 1 and Ib 2 , the sum of the currents I PP and I PN respectively passing through the transistors M 19 and M 20 does not change according to the input signal. In other words, in the prior art, even the class A input stage 110 receives the differential input signal, the gate voltages V A and V B of the transistors M 25 and M 26 vary in the same amplitude and direction. The voltage difference V AB and the static current Iq do not change, and thus the power consumption and the signal swing cannot be optimized at the same time.
[0030] In this embodiment, unlike the prior art, the present invention utilizes the class AB circuit 310 as the input stage. The sum of the currents I PP and I PN vary according to the amplitude of the input differential input signal, therefore, the currents respectively passing through the transistor M 19 and M 20 vary accordingly such that the voltage difference V AB between the gate voltages of the transistors M 25 and M 26 change.
[0031] From the above disclosure, it can be seen that the voltage difference V AB between the gate voltages of the transistors M 25 and M 26 change according to the input signal. Therefore, through an appropriate parameter design, the present invention can cause the voltage difference V AB to be larger when the differential input voltage is 0 and thereby reduce the static current Iq of output circuit 330 such that the power consumption of the operational amplifier 300 can be reduced when there is no input signal inputted. On the other hand, when a differential signal is inputted into the operational amplifier 300 , the voltage difference V AB can be controlled to be a smaller value through appropriately assigning the sum of the currents outputted from the input stage 310 to the biasing circuit 320 such that the operational amplifier 300 can have a better linearity of the amplified signal and the input signal when the operational amplifier 300 performs an amplifying operation.
[0032] In other words, when the input differential voltage is 0, because the sum of the currents I PP and I PN outputted from the class AB input stage 310 to the biasing circuit is a known value, if the gate voltages V BN and V BP of the transistors M 19 and M 20 (or the current IBP and IBN) are well designed, an optimized static current Iq can be obtained.
[0033] On the other hand, when a differential signal is inputted into the operational amplifier 300 , because the sum of the currents I PP and I PN outputted from the class AB input stage 310 to the biasing circuit change, if the parameters of the class AB input stage 310 is well designed to make the voltage difference V AB smaller such that the entire circuit 300 can have an optimized linearity.
[0034] Please refer to FIG. 5 . FIG. 5 is a diagram showing the characteristic curves of the present invention output stage circuit 330 and the prior art output stage circuit 130 . Please note that in FIG. 5 , curve ( 1 ) is a characteristic curve of the present invention class AB output stage circuit 330 and curves ( 2 ) and ( 3 ) are associated with the prior art class AB output stage circuit.
[0035] As shown in FIG. 5 , in the prior art, if the linearity of the entire circuit should be raised, the curve ( 3 ) should be raised to the curve ( 2 ). In this way, the static current Iq is also raised to increase the power consumption accordingly.
[0036] But, in the curve ( 1 ) according to the present invention, it can be seen that the present invention operational amplifier 300 consumes the same static current of curve ( 3 ) yet achieves the same linearity (i.e., signal swing) of curve ( 2 ). From the above disclosure, it could be known that the present invention operational amplifier 300 can achieve better performance.
[0037] Furthermore, as mentioned previously, the biasing current 320 provides the voltage difference V AB according to the sum of the currents, and the sum of currents is generated according to the differential input signal. Therefore, the biasing current 320 can be regarded as changing the output current according to the input signal. The above-mentioned mechanism is called “feed-forward biasing.” In contrast to the prior art's local feedback biasing mechanism, the above-mentioned feed-forward biasing mechanism is not required to reference the feedback signal and can therefore be operated at a greater speed.
[0038] Please refer to FIG. 6 . FIG. 6 is a diagram of an operational amplifier 600 according to a second embodiment of the present invention. As shown in FIG. 6 , the operational amplifier 600 comprises a class AB input stage 610 , biasing circuits 620 and 621 , and output circuits 630 and 631 .
[0039] Please note, the difference between the second embodiment and the first embodiment is that in the second embodiment the transistors M 5 through M 8 of the class AB input stage 610 are coupled as a diode to provide an appropriate bias to the inner transistors M 1 through M 4 of the class AB input stage 610 . The other circuits are all the same as those of the first embodiment of the operational amplifier 300 and have similar operations and functions, therefore, they are omitted herein for the sake of brevity.
[0040] In contrast to the prior art, the amplifying circuit of the present invention has an improved linear relationship when the input signal swing, and reduced (i.e., improved) power consumption when input signal is not swing. Therefore, the present invention amplifying circuit can simultaneously achieve optimized signal amplifying qualities and power consumption.
[0041] While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention is not limited to the specific construction and arrangement shown and described, since various other
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An amplifier includes: a class AB input stage, receiving an input signal, for generating an inner signal according to the input signal; class AB output stage, includes: a biasing circuit, for providing a first voltage and a second voltage according to the inner signal; and an output stage, for generating an output signal according to the first voltage and the second voltage; wherein a voltage difference between the first voltage and the second voltage generated by the biasing circuit is corresponding to the input signal.
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TECHNICAL FIELD
The present invention is directed to circuits for recovering a clock signal from a data stream and, more specifically, to a programmable phase interpolator that can be used to generate a set of evenly spaced phase steps that span the period of a recovered clock signal. Enhanced phase resolution can be used to more accurately recover the clock signal and data from the data stream.
BACKGROUND OF THE INVENTION
A common function of transmit and receive stations is to extract a clock signal from the data stream transmitted between the stations and to use the recovered clock signal to properly synchronize the operations performed on the incoming data, e.g., sampling and decoding of the data. In order to use the clock signal, it must be of the same frequency as and as close in phase as possible to the transmitted data stream.
A phase picker clock recovery architecture adjusts the phase of a recovered clock signal in response to a filtered phase error provided by a phase detector. The phase detector compares the phase of the recovered clock signal with the incoming data, generating an error signal representing the phase difference between the signals. The error signal is used to drive an adaptive control loop which seeks to minimize the phase difference by selecting a different phase of N phases of a reference clock signal, provided by a clock generation module (CGM), to be an updated clock signal. The N phases of the reference clock signal generated by the clock generation module are provided by tapping off of an N/2 stage differential voltage controlled oscillator (VCO). The selected phase of the reference clock signal is then used as the recovered clock signal and compared to the data stream to update the error term. An N:1 phase multiplexer having the N phases of the reference signal as inputs is used to perform the actual phase selection.
The loop parameters of a phase picker clock recovery system are independent of PVT (process-voltage-temperature) and the CRM (clock recovery module) is completely digital.
A limitation of such architectures is that a phase picker CRM only works for narrow band clock recovery applications. In some situations, this is not a problem. For example, the ethernet 10BT, 100BX and 1000BX standards are such that a narrow band CRM is adequate. However, the problem with extending a phase picker type CRM to recover clocks for higher frequency protocols, such as 100 mb and 1000 mb ethernet, is that the jitter tolerance is limited by the phase adjust resolution of the phase multiplexer. Simulations using a platform that has been correlated well to silicon show that a phase adjust resolution of 200 ps is required for 100 mb ethernet clock recovery, while a 30 ps phase adjust resolution is required for 1000 mb ethernet. A phase adjust step of 30 ps requires a differential VCO stage of delay under 30 ps at slow PVT. This is impossible to implement on current CMOS processes, where such a delay is on the order of 500 ps.
In the absence of using a phase picker architecture, there are several available methods for enhancing the resolution of a phase multiplexer in order to improve the clock recovery function of a circuit.
Coupled VCOs have been used to enhance the number of phase steps that can be obtained from a single VCO. For example, in "Precise-Delay Generation Using Coupled Oscillators", a dissertation by John Maneatis, Stanford University, June 1994, a method of coupling MN stage ring oscillators is described. The method provides M*N phases of the VCO frequency with a phase difference between adjacent phases enhanced by a factor of M beyond that possible using a single N phase VCO.
Another method involves using an array of delay-locked-loops (DLL). This method is described by J. Christianson, CERN, Geneva, in a publication entitled "An Integrated High Resolution CMOS Timing Generator Based on an Array of Delay Locked Loops." The Christianson method uses M delay-locked-loops of N stages, the inputs for which come from consecutive stages of an M stage delay-locked-loop. This provides a delay resolution of a delay in the N stage phase-locked-loop divided by M.
Another approach to enhancing phase resolution uses a mixer to interpolate between two CGM phases, doubling both the number of phases and the phase adjust resolution. This procedure can be repeated (doubling again), but simulations have shown that beyond two doublings, the precision of the enhanced phase resolution steps degrades.
Finally, an uncompensated interpolation method using inverters with switchable loads to produce an adjustable delay is described by M. Bazes et al. in "An Interpolating Clock Synthesizer", IEEE Journal of Solid-State Circuits, Vol. 31, No. 9, September 1996. This method uses inverters with N switchable loads to create the adjustable delay. The delay interpolator is calibrated by determining how many loads are required to be connected to span one gross phase step. Once this number is determined, the remaining loads are disabled. The number of points in the interpolation change depends upon PVT. For example, for fast PVT, it may take ten loads to span the gross phase step, while at slow PVT, it may take only three. This makes the actual delay step of the interpolator a function of PVT, which is acceptable for a CGM, but it is not acceptable for a CRM, where the phase step resolution is a critical parameter.
What is desired is an apparatus for increasing the phase resolution of the clock signals selected by a phase multiplexer which is part of a clock recovery circuit and which overcomes the limitations of existing devices.
SUMMARY OF THE INVENTION
The present invention is directed to a programmable phase interpolator that can be used to span a clock signal's period with N linearly distributed phase steps. The resulting phase adjust resolution is finer than that of an inverter delay for a given process.
An important application of the invention is to enhance the phase resolution of a phase picker CRM architecture. This enables using the architecture for recovering clock signals from high data rate data streams. The invention does this in a way that minimizes power and area and allows optimization for multi-channel applications such as ethernet switches and repeaters.
Further objects and advantages of the present invention will become apparent from the following detailed description and accompanying drawings which sets forth an illustrative embodiment in which the principles of the invention are utilized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating utilization of a single clock generation module (CGM) and a phase multiplexer and interpolator block in accordance with the present invention to provide a phase adjust function in a multi-data rate, multi-channel environment.
FIG. 2 is a block diagram illustrating an embodiment of a central delay interpolator calibration circuit utilizable in the FIG. 1 circuit.
FIG. 3 is a block diagram illustrating an embodiment of a phase multiplexer and interpolation circuit utilizable in the FIG. 3 circuit.
FIG. 4 is a block diagram illustrating an embodiment of a delay interpolator circuit utilizable in the FIG. 3 circuit.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 the present invention will now be described in the context of a phase picker type clock recovery module (CRM) architecture which uses a clock generation module (CGM) 12 to provide twelve differential phases (phi [1:12]) of a 250 Mhz clock signal. These phases are provided to a phase multiplexer and a delay-locked-loop (DLL) calibrated adjustable load delay interpolator 10 that is used to break down the 333 ps (pico-second)-sized phase steps from the phase multiplexer into 55 ps-sized phase steps.
Referring to FIG. 1, the invention is described in the context of a multi-port, multi-channel environment. A single clock generation module (CGM) 12 and N phase multiplexers, one for each channel, is used to select one of M phases for each channel. The phase interpolator 10 provides the required phase resolution by creating a number of delay steps evenly spaced between the coarse phase steps of the phase multiplexer. Each phase multiplexer is advanced or retarded in response to pump-up (pumpup) or pump down (pumpdn) pulse streams received from phase comparator and pulse generators included in the clock recovery loop of each channel.
FIG. 1 shows an embodiment in which each channel (port [1:6]) consists of a 10 mb CRM and a 100 mb CRM. A more detailed description of the FIG. 1 system may be found in the U.S. patent application Ser. No. 09/080,740, entitled "10/100 MB Clock recovery Architecture for Switches, Repeaters and Multi-Physical Layer Ports", filed on May 18, 1998; application Ser. No. 09/080,740 is hereby incorporated by reference in its entirety.
The phase multiplexer and interpolator circuit 10 includes a central delay interpolator calibration block, which is shown in FIG. 2. The purpose of this block is to provides six current references to the phase interpolator block of each port. Each of the currents comes from a 6 bit digital-to-analog converter (DAC) 100 to a current providing a different delay. The following table shows relationship between control settings and output current:
______________________________________Control Setting Output Current______________________________________6'b000000 Iconst + 0 * delta.sub.-- I6'b100000 Iconst + 1 * delta.sub.-- I6'b110000 Iconst + 2 * delta.sub.-- I6'b111000 Iconst + 3 * delta.sub.-- I6'b111100 Iconst + 4 * delta.sub.-- I6'b111110 Iconst + 5 * delta.sub.-- I6'b111111 Iconst + 6 * delta.sub.-- I______________________________________
These reference currents are:
idly X0 [6:1] creates a delay in variable delay stage
idly X1 [6:1] creates this delay plus 55 ps in variable delay stage
idly X2 [6:1] creates this delay plus 110;s in variable delay stage
idly X3 [6:1] creates this delay plus 165 ps in variable delay stage
idly X4 [6:1] creates this delay plus 220 ps in variable delay stage
idly X5 [6:1] creates this delay plus 275 ps in variable delay
where the index refers to the destination port for the current. Note that idly X6 current outputs are only used internally to the delay calibrator and are not sent to ports. The reason for this will become apparent from the description that follows.
The reference currents are used in the delay interpolator blocks to create 6 delays, from constant delay to constant delay plus 275 ps, in 55 ps increments. The purpose of the FIG. 2 calibrator block is to insure that the delays occur in 55 ps increments. With reference current I -- ref to the DACs 100 constant, at fast PVT each delay increment would be less than at slow PVT. Thus the calibrator block adjusts Iout -- dac until the difference in delay between a delay interpolator block set to min delay and a delay interpolator block set to max delay is exactly equal to 1 gross phase step (in this case 333 ps).
As further shown in FIG. 2 the delay interpolator calibrator includes a DAC 100' with the control input set to all zeros (full delay) and biasing a variable delay element 102 with CGM phase phi2 as it's input, and a DAC 100" with the control input set to all ones (min delay) biasing a variable delay element 104 with CGM phase phil as its input, phi2 being advanced 333 ps from phil.
The variable delay stages 102 and 104 are conventional current controlled delay stages. The basic function is that the delay through this stage should increase as control current is decreased. The outputs of variable delay stages 102 and 104 are the input to a phase comparator in the delay locked loop (DLL).
The DLL block 106 implements the phase comparator and digital loop filter of a delay locked loop. The function is such that, if the calibration input (output of variable the delay stage 102) is leading that of the reference input (output of variable delay stage 104), then the control word output is decreased; otherwise, the control word is increased. Adjustment of control word with respect to leading and lagging of calibration and reference inputs is not direct, but attenuated with proportional control. The DLL block 106 modifies the control word to DAC 108 until the bias current for DACs 100' and 100", provided through current mirror 110, is such that the difference in delay between DAC 100' (set to max delay) and DAC 100" (set to min delay) is equal to the phase difference between phi1 and phi2, which is exactly 333 ps.
DAC 108 is an 8 bit binary weighted digital to analog converter. The 8 bit control word to DAC 108 controls the output current Iout-dac according to this formula:
Iout.sub.-- dac=control.sub.-- word[7:0]*I.sub.-- ref
The current mirror 110 takes the input current and creates multiple output currents of the same value as the input current.
Thus, each DAC 100 outputs 6 currents that are mirrored to the blocks that provide the phase muxing and interpolation in the actual clock recovery channels. This means that as a clock recovery channel's delay interpolator block's input control from the delay selector is changed by one bit, the delta delay will be exactly 55 ps. As stated above, each of the current sources provided by the DACs 100 are slightly weighted to compensate for the non -- linear delay vs. current characteristic of the variable delay stages.
Referring to FIG. 3, the phase multiplexer and interpolator block includes a phase multiplexer 111, a phase selector 112, a delay interpolator 114 and a delay selector 116.
As discussed above, the digital loop filter of a phase picker PLL outputs a pumpup and pumpdn pulse stream which is used to modify a 6 bit control word output of delay selector 116 in the following manner. The 6 bit control word will always contain exactly one bit set to "1", with all other bits set to zero. Every pumpup pulse causes the control word to shift the "1" one position to right, while every pumpdn pulse causes the control word to shift the "1" one position to left. For example, if the delay selector 116 contains 01000, 2 pumpup pulses will result in a of 00010; from here, 3 pumpdn pulses will result in a value of 10000.
The value of the delay selector 116 is used to select one of 6 delayed versions of the output of phase multiplexor 111, each of the delays differing by 55 ps. The following table shows the control word and associated delays and control currents from the calibration block (described above):
______________________________________Control Current used forWord selected var delay Delay______________________________________6'h100000 IdlyX5 [n] Const delay + 275 ps6'h010000 IdIyX4 [n] Const delay + 220 ps6'h001000 IdlyX3 [n] Const delay + 165 ps6'h000100 IdlyX2 [n] Const delay + 110 ps6'h000010 IdlyX1 [n] Const delay + 055 ps6'h000001 IdlyX0 [n] Const delay + 000 ps______________________________________
When the delay selector 116 contains 000001, and a pumpup pulse is received, the delay selector 116 shifts to 100000, and a pumpup pulse is sent to phase selector shift register 112. This causes the phase multiplexer 111 to select a phase advanced 333 ps from the current phase. For example, if the current phase is phi3, the phase mux 111 would select phi4. Since the delay selector 116 shifts to 100000 at same time that the phase mux 111 advances phase by 333 ps, the net result is advancing the phase by 55 ps, the same as if the delay selector 116 received a pumpup pulse when the value of delay selector 116 was 010000 (or some value other than 000001), causing the delay selector 116 to move to 001000. When the delay selector 116 contains 100000, and a pumpdn pulse is received, the delay selector 116 shifts to 000001, and a pumpdn pulse sent to phase selector 112. This causes the phase mux 111 to select a phase retarded 333 ps from the current phase. For example, if the current phase is phi3, the phase mux 111 will select phi4. Since the delay selector shifts to 000001 at same time that the phase mux 111 retards phase by 333 ps, the net result is retarding the phase by 55 ps, the same as if the delay selector 116 received a pumpdn pulse when the value of delay selector 116 was 001000 (or some value other than 100000), causing the delay selector 116 to move to 010000.
Phase selector 112 is a bidirectional shift register with a 1 bit always set; that bit and QZ are used to turn on one of the 12 transfer gates in the phase mux 111. The delay selector 116 is also just a bidirectional shift register with 1 bit always set; the bit's Q and QZ are used to turn on one of the 6 transfer gates in the delay selector 114. The mux in the delay selector 114 can be thought of as a fine tuning phase shifter, while the phase mux 111 can be thought of as a coarse tuning phase shifter.
The following table provides examples showing values of coarse and fine phase tuners while continuously advancing phase in response to pumpup signals:
__________________________________________________________________________ coarse phase adjust fine phase adjust total adjpi.sub.-- digital (4) clkmux.sub.-- sr (1) from last phase from last phase from last__________________________________________________________________________6'b001000 12'b00001000000 N/A N/A N/A6'b000100 12'b00001000000 0 -55 ps -55 ps6'b000010 12'b00001000000 0 -55 ps -55 ps6'b000001 12'b00001000000 0 -55 ps -55 ps6'b100000 12'b00000100000 -333 ps +275 ps -55 ps6'b010000 12'b00000100000 0 -55 ps -55 ps__________________________________________________________________________
For extremely accurate delay interpolation, it may be desirable to implement an architecture having two phase multiplexers per channel, with each channel doing its own calibration using the same interpolators that are doing the interpolation. The second phase multiplexer would always select a phase advanced from the current phase; and the delay selector for this second interpolator would be set such that the delay between the two delay interpolator outputs would always be 667 ps when the I -- ref is correctly calibrated. This approach adds power and area, but may be better suited to some applications. It is anticipated that using a central calibration circuit will be sufficient for 100BT, but a calibrator per channel may be required for 1000BT.
Physically, the phase multiplexers and phase interpolators are placed very close to a CGM. They take up a very small area (perhaps 10 sq mils for a single phase multiplexer and interpolator on a 0.35 um process), so they can be packed in close to the CGM which allows skew control. The output of the phase interpolator is a non skew critical signal, so the CRM's themselves may be placed very far from the CGM, preferable close to the TP-PMD block at each port. Similarly, the pumpup and pumpdn outputs from the pulse stream combiner are non skew critical.
The inventive approach to increasing phase resolution described above provides several advantages over previous approaches. The interpolator itself operates on only a single phase from the CGM (the output of the channels phase multiplexer), and adjusts the delay linearly between the gross phase steps. This enables only one phase multiplexer per CRM channel. While two clock signal phases are required by the calibrator, only one calibrator is required and can be shared with any number of CRM channels. Also, this type of interpolator is very powerful and area efficient since it only uses a small number of VCO stages (6 in this example), a small phase multiplexer (12:1 in this example), six differential delay stages biased by the calibration block, and a second phase multiplexer (6:1 in this example) used to select on of the six dealy stage outputs. A CGM with a small number of phases can have the phase resolution enhanced by this interpolator. In contrast, the coupled VCO method described requires multiplying the number of VCO stages by M, where M is the desired enhancement factor for the phase resolution. The method based on using delay-locked-loops requires M+1 DLL's, where M is the desired enhancement factor. The mixer approach requires N/2 mixers for a halving of resolution. Since the interpolation function is done post multiplexing, the skew on the N CGM phases entering the phase multiplexer can be controlled to a finer precision, since there are fewer signals being routed.
For purposes of comparison with the other phase resolution methods discussed above, consider a device with twelve integrated clock recovery channels requiring a phase resolution of 80 ps. The method of the present invention would require the following circuitry: one 12 phase 250 mhz CGM; one DLL calibrator for delay interpolators; twelve 12:1 phase multiplexers; and twelve delay interpolators consisting of six delay stages biased by the calibration, and a second phase multiplexer (6:1 in this example) used to select one of the six delay stage outputs. For comparison, the coupled ring oscillator approach would require: one 50 phase coupled ring osc VCO and twelve 50:1 phase multiplexers (very hard to match skew with this fan-in to multiplexer).
Although accurate phase error quantization is not required for 100BT ethernet, the phase interpolator provides a method of phase error quantization for PLL's that do need more accurate quantization. This is typically the case when the DCD portion of the jitter budget is a large fraction of the total jitter budget.
To lock to the center of a bimodal jitter distribution requires being able to quantize the phase error. The resolution of the quantization limits the ability of the loop to accurately lock to the center of a bimodal distribution.
One method of quantizing the phase error is to use a slowly rising edge on the 125 Mhz clock and comparators with levels set such that, as the rising edge reaches that level, a fast edge is triggered. This results in N 125 Mhz clocks, with N being the number of comparators. The delay between the clocks depends on how uniform the slowly rising edge rises and the accuracy of the comparator trip points. However, this solution is not robust over PVT.
Other approaches have used delayed locked loops to create precision delay lines which can be used to sample an input signal and quantize the phase error based on the resolution of the delay line. This approach limits the resolution of the phase compare to the minimum delay possible in the delay line, which is process limited.
In contrast, the present approach uses the phase interpolator described to create eleven precisely spaced delays, where the difference in delays span 1.3 ns, the range of a fixed jitter specified in the TP-PMD spec. This gives a phase quantization resolution of 118 ps, about 4X smaller than that could be achieved with a delay line using the same process. Each delay is on the order of 1 ns, but the delta delay is kept at 118 ps over PVT. The delta delays are calibrated by using the delay interpolator, with the difference being that the inputs to the min and max delay stages are two phases from the CGM separated by two, rather than one phase step. This has the effect of doubling the range of the interpolation.
Clk125 m from the phase multiplexer is the input to each of the eleven equally spaced delays, ranging from delay+0 ns to delay+1.3 ns in 118 ps increments. The center delay becomes RXC, while the five lower delays are increasingly advanced RXC's, and the five upper taps are increasingly retarded RXC's. RXC and the advanced and retarded RXC's are the D input to eleven flops. These are specially designed flops that have equal setup and hold times and, therefore, act as knife edge phase detectors. The clocks of the flops are connected to the incoming data stream. At each rising edge of data, the eleven flops Q's can be used to create a 3 bit lead vector, and 3-bit lag vector, each vector giving the amount of lead or lag error, in 118 ps increments.
The following hdl illustrates this approach:
reg [10:0]pc;//11 flops
wire [10:0]rxc -- dl://RXC d advanced and delayed in 118 ps increments
reg [2:0] lead -- err, lag -- err;//error vectors
//11 flops clocked by data, data input is rxc delay line
always@posedge data)
pc<=#1 rxc -- dl;
wire [5:0] lower -- pc=pc[10:5];
always@ (lower -- pc)
casex (lower -- pc)//synopsys parallel case
6'b111111:lead -- err#1 3'b110;
6'b011111:lead -- err#1 3'b101;
6'b001111:lead -- err#1 3'b100
6'b000111:lead -- err#1 3'b011
6'b000011:lead -- err#1 3'b010
6'b?????1:lead -- err#1 3'b0001
default:lead -- err#1 3'b000
endcase
wire [5:0] upper -- pc=pc[5:0];
always@ (upper -- pc)
casex (upper -- pc)//synopsys parallel -- case
6'b000000:lag -- err#1 3'b110;
6'b000001:lag -- err#1 3'b101;
6'b000011:lag -- err#1 3'b100
6'b000111:lag -- err#1 3'b011
6'b001111:lag -- err#1 3'b010
6'b0?????:lag -- err1 3'b001
default:lag -- err#1 3'b000
endcase
Data is recovered in the data recovery block, which is the same special flop used in phase comparators (1) and (2). The flop is clocked by the falling edge of RXC, with the D input being RX -- P. With the loop in lock, the falling edge of RXC is the optional sampling position.
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 equivalents of the features shown and described, or portions thereof, it being recognized that various modifications are possible within the scope of the invention claimed.
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A programmable phase adjuster spans a clock signal's period with N linearly distributed phase steps. The resulting phase adjust resolution is finer than that of an inverter delay for a given process. Enhancement of the phase resolution of a phase picker CRM architecture enables use of the architecture for recovering clock signals from high data rate data streams in a way that minimizes power and area and allows optimization for multi-channel applications.
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RELATED APPLICATION DATA
[0001] This application is based on and claims the benefit of U.S. Provisional Patent Application No. 60/451,123 filed on Feb. 27, 2003, the disclosure of which is incorporated herein by this reference.
BACKGROUND
[0002] This invention relates generally to automatic optical recognition of two-dimensional image data. More specifically, it relates to an apparatus and method for recognizing and analyzing two-dimensional image data, such as typewritten or printed text, by converting the two-dimensional data into three-dimensional data.
[0003] The problem of recognizing written characters by machine has been investigated in great detail. Many digital library projects have focused on application of automating character recognition to create computer accessible collections of historic and cultural materials to support scholarship in the humanities. Once in digital form, the ability to store, enhance, search and interact with the content permits powerful analysis and comparison. The original written resources involved in these projects range from typewritten or printed text, to handwritten manuscripts that can vary dramatically in the form and structure of the written characters.
[0004] Most digital library projects involving handwritten manuscripts work with images and human translations of handwritten materials. Some previous projects, however, have attempted to digitize and automatically translate handwritten manuscript materials using optical character recognition (OCR) techniques to convert the materials to machine-readable form. These projects include those described by Rath, T. and Manmatha, R., “Features for Word Spotting in Historical Manuscripts,” Proceedings of ICDAR 2003 Conference, Vol. 1, 218-22 (2002); T. Theeramunkong, C. Wongtapan, S. Sinthupinyo, “Offline Isolated Handwritten Thai OCR Using Island Based Projection with N-Gram Models and Hidden Markov Models,” Proceedings of ICADL 2002, Vol. 2555, 340-51 (2002); and T. Theeramunkong, V. Sornlertlamvanich, T. Tanhermhong, W. Chinnan, “Character Cluster Based Thai Information Retrieval,” Proceedings of the Fifth International Workshop on Information Retrieval with Asian languages, Hong Kong, China, 75-80 (2000); as well as the Shuhai Wenyuan Classical Chinese Digital Database and Interactive Internet Worktable project at the University of Hawaii at Manoa.
[0005] Automated recognition to provide access to printed textual materials involves scanning and computer assisted character recognition, typically using an OCR program to identify the letter forms to “translate” from the graphic image output of the scanner. The general process of character recognition of handwritten manuscripts is based on two-dimensional image recognition or stochastic methods applied to the two dimensional image. These include, for example, neural networking and HMM (Hidden Markov Models). In all cases, the script (page, letters, words etc.) is represented as two-dimensional bitmaps. Various methods then try to infer the letter from this two-dimensional image.
[0006] The key to machine recognition of handwritten materials is the ability to differentiate between the ascenders, descenders, loops, curls, and endpoints that define the overall letter forms. Identification of contractions, abbreviations, and punctuation creates similar challenges. Development of the techniques to extract the features from a handwritten line of characters is a significant challenge for computer scientists and has resulted in techniques to extract, sequence, cluster, categorize, and compare features to attempt to recognize and assign meaning to a given character.
[0007] The accuracy of the OCR process is directly proportional to the quality, regularity and resolution of the letter forms. For mechanically replicated letter forms, such as typed or typeset materials, this process is relatively straightforward. For handwritten materials with variation in letterform, however, the problem of recognition is extremely complex because the letter forms can vary significantly throughout a document. Human intervention can be used to identify and prompt problem letter forms and assist in “training” the OCR programs, which can significantly improve accuracy as similar documents are scanned.
[0008] Even with human intervention, however, complete recognition is complicated dramatically for handwritten materials, such as manuscripts or musical scores, due to variables in the content. One of the variables in handwritten content is the letter forms that vary significantly throughout the document. This problem is compounded when the letter forms overlap or merge with adjacent characters. Consequently the accuracy rates for OCR plunge dramatically even with human intervention to correct and train the recognition software, and accuracy rates fall below perfect recognition. For handwritten materials the accuracy rate reaches 85-90% for closed tests, but open tests where “trained” OCR programs are used to recognize new text similar to the proposed project, current accuracy rates range from 60-75%.
[0009] FIGS. 1 and 2 show two examples of the type of complex handwritten materials that illustrate some of the complexities that present problems in the automatic recognition of such text. FIG. 1 shows an example of handwritten text, and FIG. 2 shows an example of a rubric from Spanish archives from the 17 th century. These examples have been provided through the courtesy of the Hispanic Research Center at Arizona State University in Tempe, Ariz. The example of FIG. 1 shows the cursive writing with varying letter forms and overlapping characters that must be recognized automatically. In addition, these manuscripts include abbreviations, rubrics, and signatures that must be interpreted, such as the rubric shown in FIG. 2 . These examples demonstrate some of the problems presented in attempting to automatically recognize handwritten text. For instance, the cursive writing style of the examples results in a lack of separation between characters, which makes automatic recognition more difficult. They also demonstrate variation of letter forms. Unlike type written or printed text, each character varies slightly in shape and size from identical characters elsewhere in the document even when created by the same individual. For example, the bottom loop of the letter “y” in FIG. 1 runs into the line below it. In addition, the examples show different writing styles. They are written by different people and include different styles of cursive writing. The examples also show rubrics and abbreviations, i.e., sprinkled throughout the manuscripts are graphic images that convey meaning and must be recognized and associated with meaning more complex than a single letterform. They also illustrate accents and omitted characters. Accents, notations and sometimes missing characters are inserted between the rows of characters. These features of handwritten manuscripts greatly increase the complexity of the problem of automatic recognition of such manuscripts.
[0010] It is an object of the present invention to provide an apparatus and method for addressing the problems presented in attempting to automatically identify complex two-dimensional image data, such as handwritten text, manuscripts, signatures and the like.
[0011] Additional objects and advantages of the invention will be set forth in the description that follows, and in part will be apparent 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 methods and apparatus pointed out in the appended claims.
SUMMARY
[0012] To achieve the foregoing objects, and in accordance with the purposes of the invention as embodied and broadly described in this document, there is provided a method for converting a two-dimensional image or bitmap into three dimensional data. The two-dimensional image can represent a handwritten manuscript. A presently preferred method of the invention includes the steps of: converting the two-dimensional image into three-dimensional volumetric data; filtering the three-dimensional volumetric data; and processing the filtered three-dimensional (3D) volumetric data to resolve features of the two-dimensional image. The processing of the volumetric data can include using an isosurface extraction to extract a 3D surface mesh representing the image. The extracted surface mesh representation can then be used to resolve features of the two-dimensional image, such as separating overlapping lines in the manuscript. The processing of the volumetric data can include determining an axis or curve representing the median of a tubular portion of a surface mesh representation of the filtered three-dimensional volumetric data. The method can be used, for example, to differentiate between the ascenders, descenders, loops, curls, and endpoints that define the overall letter forms in a handwritten manuscript.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate the presently preferred embodiments and methods of the invention. Together with the general description given above and the detailed description of the preferred embodiments and methods given below, they serve to explain the principles of the invention.
[0014] FIG. 1 is an exemplary image of a handwritten manuscript, which illustrates some of the complexities of handwritten text that present problems in the automatic recognition of such text.
[0015] FIG. 2 shows an exemplary image of a rubric from a handwritten manuscript, which further illustrates complexities of handwritten text that present problems in the automatic recognition of such text.
[0016] FIG. 3 shows an exemplary image of original handwritten text to be processed for automatic recognition in accordance with the present invention.
[0017] FIG. 4 shows the letter “I” appearing in the handwritten text of FIG. 3 and isolated from that text.
[0018] FIG. 5 shows chain code for the letter “I” of FIG. 4 .
[0019] FIG. 6 is a block flow diagram of the process for converting a two-dimensional bitmap into three-dimensional data according to the invention.
[0020] FIG. 7 shows a three-dimensional representation of the surface mesh and tubular structures included in the mesh, which result from processing the two-dimensional image of a portion of the handwritten text of FIG. 3 according to the present invention.
[0021] FIG. 8 shows a three-dimensional representation of the surface mesh and tubular structures included in the mesh, which result from processing the two-dimensional image of the rubric of FIG. 2 according to the invention.
[0022] FIG. 9 shows a two-dimensional scanned image of initials “AR” written on paper using a felt-tipped marker.
[0023] FIG. 10 shows a three-dimensional representation of the surface mesh and tubular structures included in the mesh, which result from processing the two-dimensional image of FIG. 9 .
[0024] FIG. 11 shows a three-dimensional representation of the surface mesh and tubular structures included in the mesh, which result from processing the two-dimensional image of another example of the handwritten letter “I”.
[0025] FIG. 12 shows the three-dimensional surface mesh of FIG. 11 rotated on its “side” to show how the three-dimensional representation clearly separates overlap in the loop in the letter “I”.
[0026] FIG. 13 shows the medial curve of the three-dimensional representation of the letter “I” of FIG. 11 .
[0027] FIG. 14 shows the three-dimensional curve of FIG. 13 rotated at an angle, demonstrating the three-dimensional aspects of the curve.
[0028] FIG. 15 shows the three-dimensional curve of FIG. 13 rotated at a different angle.
DESCRIPTION
[0029] Reference will now be made in more detail to the presently preferred embodiments and methods of the invention as illustrated in the accompanying drawings. While the present invention will be described more fully hereinafter with reference to these examples and accompanying drawings, in which aspects of the preferred manner of practicing the present invention are shown, the description which follows is to be understood as being a broad, teaching disclosure directed to persons of skill in the appropriate arts, and not as limiting upon the present invention.
[0030] The present invention focuses on enhancing the capacity to automatically recognize complex two-dimensional information, such as handwritten manuscripts. The process of automatic recognizing handwritten manuscripts having the complexities discussed above can be broken down into the following major steps: (1) separating the rows of characters; (2) breaking down each word and then each character into an individual unit; (3) attaching meaning to characters, rubrics, and abbreviations; (4) proofing and correcting, initially to train the optical character recognition (OCR) program, then also to correct errors and add information not identified by the process; and (5) translating to other dialects and languages. The present invention can be used to address each of these steps.
[0031] Let us for the moment focus on individual characters. Chain codes can be used to approximate individual characters by straight-line segments. The use of chain codes is a well-known method for contour coding. Consider the example shown in FIGS. 4 -5 and focus on the letter “I”. A chain code can be considered as a piecewise linear approximation parameterized according to the movement of the pen. This means that the letter “I” must be approximated by straight-line segments, i.e. broken down into simple subunits. However the segments must be connected sequentially in the same manner as when the person wrote the letter. In case of this example, however, there is a loop in the letter “I”. Starting from left (assuming the writer wrote left to write) the pen moves right and up and then comes down goes over the previous mark and ends on the right. The resulting chain code is shown in FIG. 5 . The arrows 10 show the first half and the arrows 20 show the latter half in writing the letter “I”. By using the method of the invention, loops of a character, such as the loop of the “I” in FIGS. 4 and 5 , can be separated and converted into chain codes, as described below more fully. The invention can thus greatly simplify the task of separating characters (overlaps) and identifying the chain codes correctly within a single unit or character.
[0032] When a person writes with a pen on paper, the pen usually does not result in a stroke of opaque color on the paper. Rather, the color of the ink in the pen will combine with the color of the paper on which the ink is deposited. Thus, if a person writes a line that crosses another line, the effect is that the point where the two lines cross will appear darker than either line itself appears. Additionally, fluctuations in the pressure applied to the pen will affect the amount of ink dispensed as an individual writes. This results in changes in the amount of ink on the document, and affects the opacity and darkness of the line being drawn.
[0033] Where two lines cross on a piece of paper, a person can often intuitively sense which line passes above the other. Beginning artists are encouraged to explore this effect of how lines are perceived by doing line and contour drawings. Subtle variations in the intensity of the line give a viewer a sense of dimension that assists in recognizing written text. Some lines appear to come forward while others appear to sink backward, so even without chiaroscuro-shading or perspective, a clear impression of depth can be conveyed on an approximately two-dimensional piece of paper.
[0034] Given a sample of handwriting as a two-dimensional bitmap array of scalar intensity values, the present invention can be used to find a three-dimensional volume that will highlight the effects of the changes in opacity of the pen stroke. Successful application of this approach is based on several assumptions: (i) that the 3D volume data reflects the impression of depth and thickness of the line; (ii) that sufficient differences exist to mark relative depths where two lines cross; and (iii) that the volume data can consistently indicate which lines connect, and which lines pass in front of the others.
[0035] According to,the present invention, a two-dimensional script, image or bitmap is converted into three-dimensional data using a novel process. This three-dimensional data can be used to assist with the automatic recognition of the two-dimensional information. This technique provides a unique approach to character recognition not used by previous methods.
[0036] Referring to FIG. 6 , a presently preferred method of the invention includes the steps of: converting a two-dimensional image into three-dimensional volumetric data (step 100 ) i.e. voxelizing the data; applying filtering to smooth the voxel (volumetric) data (step 102 ); extracting from the voxel data a three-dimensional surface mesh (step 104 ) representing the character, which mesh includes one or more tubular structures; and post-processing the three-dimensional surface mesh (step 106 ) to find the medial axis or curves representing the median of the tubular structures of the surface mesh.
Converting 2D Bitmap Data to 3D Volume Data
[0037] According to a presently preferred method, the two-dimensional bitmap data is converted to three-dimensional volume data (step 100 ) as follows. First, the pixel at position (x, y) of the 2D bitmap is elevated to a voxel based on the value at pixel[x,y] so that the higher the intensity of the pixel, the higher the z-component of the voxel. Starting with a volume of all 0 voxels, those voxels near (x, y, pixel(x, y)) are given an intensity related to the intensity of the original pixel. Just using the original intensity works well. It will be understood, however, that other functions of the original intensity also can be used such as, for example, an exponential function.
[0038] After the voxels have been set, a number of scattered, unconnected points appear in the volume. Attempting to view the volume at this point would reveal mostly noise. To address this issue, the volume data can be filtered (step 102 ).
Filtering
[0039] Filtering to smooth the voxel data (step 102 ) can fill in all of the gaps and can be achieved by applying a blurring filter to the volume data. This filtering allows connections to form between voxels that are near each other to begin to form patterns. Multiple iterations of blurring can be performed until the points have melted into a field that has the highest intensity roughly along the path that a person would imagine a line follows on a piece of paper.
[0040] In a presently preferred method, the first filter used is a simple moving average filter. Each voxel is set to the value of the voxel+½ of the mean of all of the 26 neighbors of the voxel. The resulting averages are then allowed to feed into each other—computing a new value for voxel(x, y, z), and then using that newly computed value to find the new value for voxel(x+1, y, z). This type of filter is commonly used in 2D image editing tools to blur images. It will be understood by those of skill in the art, however, that other types of standard filters can also be applied to filter the volume data. One such filter, for example, is the Gaussian filter.
[0041] Exemplary pseudocode for implementing the conversion of two-dimensional data to three-dimensional volume data and for filtering the volume data is set forth below. By implementing this pseudocode on a computer readable medium a computer can be programmed for converting two-dimensional data to three-dimensional volume data according to the invention.
1 //Generate the volume (width by height by 15) 2 For z = 0...15−1 3 For x = 0...width−1 4 For y = 0..height−1 5 If pixel[x,y] in z*16−30 ... z*16+30 6 Voxel[x,y,z] = pixel[x,y] 7 Else 8 Voxel[x,y,z] = 0 9 10 11 //Apply the filter K times 12 For i = 0..K−1 13 For z = 0..15−1′ 14 For x = 0..width−1 15 For y = 0..height−1 16 Voxel[x,y,z] = (26*voxel[x,y,z] + voxel[x−1,y,z] +... +voxel [x−1,y−1,z−1])/(2*26)
3D Surface Extraction
[0042] Once the scanned two-dimensional data is converted into three-dimensional data (step 100 ) and appropriate filtering is used (step 102 ), an isosurface extraction algorithm can be applied to the three-dimensional data (step 104 ) to render an isosurface in the volumetric data.
[0043] One suitable isosurface extraction algorithm is a Marching Cubes algorithm, which is an algorithm for creating a polygonal surface representation of an isosurface through a 3D scalar field. Using a Marching Cubes program, one can define a voxel (or cube) by the pixel values at the eight corners of the cube. If one or more pixels of a cube have values less than the user-specified isovalue, and one or more have values greater than this value, then the voxel must contribute some component of the isosurface. By determining which edges of the cube are intersected by the isosurface, one can create triangular patches that divide the cube between regions within the isosurface and regions outside. By connecting the patches from all cubes on the isosurface boundary, one can generate a surface representation. The Marching Cubes algorithm is well known in the art and is described more fully in Lorensen, W. E. and H. E. Cline, “Marching Cubes: A High Resolution 3D Surface Construction Algorithm, Computer Graphics, vol. 21, no. 3, pp. 163-169 (July 1987) and in Watt, A., and Watt, M., Advanced Animation and Rendering Techniques (Addison-Wesley, 1992).
[0044] As will be apparent to those of ordinary skill in the art, there are many segmentation methods other than the Marching Cubes method that may be used for surface extraction from the 3D data. Segmentation of volume data is a process of voxel classification that extracts regions by assigning the individual voxels to classes in such a way that these segmented regions possess the following properties: (1) voxels within the same region are homogeneous with respect to some characteristic (e.g., gray value or texture); and (2) voxels of neighboring regions are significantly different with respect to the same characteristic. One example of such a segmentation method is described by A. Huang, G. Nielson, A. Razdan, G. Farin, D. Capco, and P. Baluch, “Line and Net Pattern Segmentation using Shape Modeling” IS&T/SPIE Conference, Visualization and Data Analysis 2003. Another example is described by J. Hu, A. Razdan, G. Nielson, G. Farin, D. Baluch, and D. Capco, “Volume Segmentation Using Weibull B-SD Fields,” IEEE Transactions on Visualization and Computer Graphics 9(3): 320-328 (2003). Still another suitable segementation process is described by J. Hu, G. Farin, M. Holecko, S. Massia, G. Nielson and A. Razdan, “Statistical 3D Segmentation with Greedy Connected Component Labelling Refinement,” Bioengineering Department, PRISM Lab and Computer Science Department, Arizona State University, Tempe, Ariz. The segmentation process described in International Application No. PCT/US03/10665 entitled “Three-Dimensional Digital Library System” and filed on Apr. 4, 2003, can be used to preprocess and improve the surface extraction. The descriptions of these segmentation process are incorporated herein in there entirety by this reference.
[0045] After the isosurface extraction algorithm is applied, the resulting mesh is a collection of triangles that converts the line or stroke into a three-dimensional surface mesh in the form of a tubular structure representing the line or stroke. This structure provides the dimensional data to detect which line segment of overlapping line segments lies on top of the other.
[0046] FIG. 7 shows an exemplary three-dimensional representation of the surface mesh and tubular structures of the mesh. The three-dimensional surface mesh of FIG. 7 results from processing the two-dimensional image of a portion of the handwritten text of FIG. 3 according to the present invention.
[0047] FIG. 8 shows a three-dimensional representation of the surface mesh and tubular structures included in the mesh, which result from processing the two-dimensional image of the rubric of FIG. 2 according to the invention. Comparing FIG. 8 to FIG. 2 , it will be noted that the three-dimensional representation of FIG. 8 has been rotated to demonstrate the three-dimensional aspects of the representation.
[0048] As another example, FIG. 9 shows a two-dimensional scanned image of initials “AR” written on paper using a felt-tipped marker. FIG. 10 shows a three-dimensional representation of the surface mesh and tubular structures included in the mesh, which result from processing the two-dimensional image of FIG. 9 .
[0049] FIG. 11 shows another example of a three-dimensional representation of the surface mesh and tubular structures included in the mesh, which result from processing the two-dimensional image of another example of the handwritten letter “I”. The surface mesh was generated using the Marching Cubes process. FIG. 12 shows the three-dimensional surface mesh of FIG. 11 rotated on its “side” to show how the three-dimensional representation clearly separates the overlap of the loop in the letter “I”.
[0050] As can be seen from FIGS. 7, 8 , and 10 - 12 , the 3D surface mesh resulting from surface extraction (step 104 ) can clearly separate the loops of a character. This greatly simplifies the tasks of identifying the chain codes correctly within a single unit or character. Similarly, the 3D surface mesh can separate overlapping characters, such as when a letter from one row of text intersects letters from a different row of text. Since we can distinguish the surfaces we can therefore distinguish which is the intruding surface and effectively eliminate or better separate the two characters.
Post-Processing
[0051] Further processing of the volume data can be performed (step 106 ) to find the medial axis or curves representing the median of the tubular structures of the surface or mesh representation. Since we can distinguish between the surfaces (i.e., which one is on top or bottom in a loop) we can effectively parameterize the axis or curve. The parameterized curve then solves the chain code problem encountered by 2D methods, which cannot distinguish lines that cross over, such the lines in a loop. This also can be used to solve the problem of identifying overlapping characters. For example, FIG. 13 shows a medial curve of the three-dimensional representation of the letter “I” of FIG. 11 . FIG. 14 shows the three-dimensional curve of FIG. 13 rotated at an angle, demonstrating the three-dimensional aspects of the curve. FIG. 15 shows the three-dimensional curve of FIG. 13 rotated at a different angle.
CONCLUSION
[0052] The above-described method and system of the present invention possesses numerous advantages as described herein. 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, representative devices, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the general inventive concept.
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A method is provided for converting a two-dimensional image or bitmap of a handwritten manuscript into three-dimensional data The three-dimensional data can be used to automatically recognize features of the manuscript, such as characters or words. The method includes the steps of: converting the two-dimensional image into three-dimensional volumetric data; filtering the three-dimensional volumetric data; and processing the filtered three-dimensional volumetric data to resolve features of the two-dimensional image. The method can be used, for example, to differentiate between ascenders, descenders, loops, curls, and endpoints that define the overall letter forms in handwritten text, manuscripts or signatures.
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TECHNICAL FIELD
The disclosure relates to a turbocharger system and a method of controlling a turbocharger system, particularly, a twin-turbocharger system incorporating electric turbo assist.
BACKGROUND
A turbocharger forms part of an engine, and comprises a turbocharger shaft driven by a turbine that rotates in response to exhaust gases from the engine. The principal purpose of the turbocharger is to compress gases using a compressor for introduction into the engine cylinders (called “boost”).
Multiple turbochargers can be implemented in a sequential arrangement. This can reduce the time required to bring the turbocharger to a speed where it can function effectively, known as turbo lag. When the boost pressure is too high, it can be reduced by causing the exhaust gases to bypass one of the turbochargers. The exhaust gases may instead be diverted through a wastegate. For example, in a two-stage air system, the wastegate may be situated in the High Pressure (HP) turbocharger stage, which is the stage closer to the engine, although it can also be situated in the Low Pressure (LP) turbocharger stage or in both turbocharger stages.
The operation of such systems may be explained using an example. Referring to FIG. 1 , there is shown an example torque-speed characteristic for an existing engine using measured data. The line in this drawing may specify the maximum torque attainable as a function of engine speed.
In this example, the engine generally runs at constant speed with sudden sharp changes in the demanded load. Plotting this engine operation on the torque-speed curve, points T1a, T2a and T3a represent what happens to engine speed and load at three time points during a transient event. In this example, the transient event is when the demanded load drops to 60% of the starting torque. The starting torque is shown at T1a, the changed torque is shown at T2a and the final system equilibrium torque is shown at T3a.
Referring next to FIG. 2 , there is illustrated examples of relevant parameters of an existing turbocharger system, when operated with the engine described by FIG. 1 . These may be effectively considered as real time histories of the relevant parameters for this sudden drop in demanded torque event. The abscissa may represent approximately 10 seconds of operation.
In this example, the engine speed is more or less constant, remaining within +/−5% of the rated speed. Then, after reaching a peak at T1a, the load torque is suddenly reduced. The engine power follows the torque since the speed is approximately constant.
The boost pressure being delivered at T1a exceeds that required to produce the new, lower, demanded torque. To prevent the engine accelerating due to the lower absorbed torque, the boost pressure is desirably reduced. The drop off in torque may be sensed through the rise in boost pressure.
The wastegate starts to open as a result of this sensed rise in boost pressure (as illustrated), causing the boost pressure to drop. In this way, the specific energy of the exhaust flow reaching the turbine is thus reduced and less energy is transferred to the compressor. The compressor speed and boost pressure start to decrease as the wastegate is opened. It should be noted that the turbocharger speed is directly related to boost pressure and will likely have the same trend as the boost pressure.
Between time T2a and time T3a, the sensed boost pressure adjusts the wastegate opening until the engine torque matches the demand. By time T3a the specific energy in the exhaust flow matches that required for the desired boost level and so the wastegate closes.
An electric turbo assist (ETA) turbocharger also generates electrical energy through rotation of the shaft. The generated energy can be stored in batteries, used in auxiliary electrical systems or fed to a motor connected to the engine crankshaft to improve engine response. The ETA system provides an additional mechanism to recover energy that might otherwise be lost where the energy in the exhaust gases exceeds what is needed to drive the compressor.
Applying ETA technology to a multiple turbocharger system poses a number of difficulties, due to the system complexity. JP-2005-009315 shows such a two-stage turbocharger system with dynamo-electric machines coupled to both stages and with a by-pass valve able to cause exhaust gases to by-pass the HP stage. The by-pass valve and dynamo-electric machines are controlled on the basis of the engine speed, engine load and whether the engine is decelerating. In some cases, opening the by-pass valve is considered appropriate. However, the energy efficiency of this implementation is limited and large losses can be incurred on the HP stage at high speeds.
WO-2010/039197 relates to a hydrogen fuelled powerplant including an internal combustion engine with an afterburner in the exhaust section and a two-stage turbocharger. In one embodiment, turbine generators are coupled to both stages of the turbocharger. The turbine generators are configured to remove excess energy resulting from the afterburner operation. Low-pressure and high-pressure wastegates are used to bleed off some of the pressurized exhaust when the engine speed or load changes and the compression capability of the system detrimentally overwhelms the engine requirements.
SUMMARY OF THE DISCLOSURE
A turbocharger system comprises: a gas input for receiving exhaust gases from an associated engine having an operating mode; a first turbocharger comprising a first compressor driven by a first turbine, arranged to be driven by the exhaust gases received at the gas input and configured to provide a compressed air output defining a boost pressure; a diversion mechanism, configured to affect the flow of exhaust gases between the gas input and the first turbine on the basis of the boost pressure, such that a proportion of the energy of the received exhaust gases is provided to the first turbine; a second turbocharger, arranged to be driven by exhaust gases passing through at least one of: the first turbocharger, the first turbine not being coupled to an electrical generator; and the diversion mechanism, and being coupled to an electrical generator operative to provide electrical power; and a controller, configured to adjust the operation of the electrical generator independently from the operating mode of the associated engine, in order to affect the boost pressure so as to cause the diversion mechanism to maximise the proportion of the energy of the received exhaust gases provided to the first turbine.
A turbocharger system comprises: a gas input for receiving exhaust gases from an associated engine having an operating mode, the received exhaust gases having an associated energy; a first turbocharger comprising a first compressor driven by a first turbine and configured to provide a compressed air output defining a boost pressure, the first turbocharger being arranged such that the first turbine is driven by the exhaust gases received at the gas input without a mechanism to divert the exhaust gases received at the gas input selectively; a second turbocharger, arranged to be driven by exhaust gases passing through the first turbocharger and being coupled to an electrical generator operative to provide electrical power, the first turbine not being coupled to an electrical generator; and a controller, configured to adjust the operation of the electrical generator independently from the operating mode of the associated engine, in order to affect the boost pressure.
A turbocharger system comprises a first turbocharger and a second turbocharger, the first turbocharger comprising a first compressor driven by a first turbine and providing a compressed air output defining a boost pressure and a method of controlling such a turbocharger comprises: receiving exhaust gases from an associated engine at a gas input, the associated engine having an operating mode; controlling a diversion mechanism selectively to affect the flow of exhaust gases between the gas input and the first turbine on the basis of the boost pressure, such that a proportion of the energy of the received exhaust gases is provided to the first turbine; causing the exhaust gases passing through at least one of: the first turbocharger; and the diversion mechanism to drive a second turbocharger; operating an electrical generator driven by the second turbocharger to provide electrical power, the first turbine not being coupled to an electrical generator; and adjusting the operation of the electrical generator independently from the operating mode of the associated engine, in order to affect the boost pressure and thereby cause the diversion mechanism to maximise the proportion of the energy of the received exhaust gases provided to the first turbine.
A turbocharger system comprises a first turbocharger and a second turbocharger, the first turbocharger comprising a first compressor driven by a first turbine and providing a compressed air output defining a boost pressure and a method of controlling such a turbocharger comprises: receiving exhaust gases from an associated engine at a gas input; driving the first turbine with the exhaust gases received at the gas input, without a mechanism to divert the exhaust gases received at the gas input selectively; causing the exhaust gases passing through the first turbocharger to drive a second turbocharger; operating an electrical generator driven by the second turbocharger to provide electrical power, the first turbine not being coupled to an electrical generator; and adjusting the operation of the electrical generator independently from the operating mode of the associated engine, in order to affect the boost pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
The turbocharger system and method of controlling a turbocharger system may be put into practice in various ways, one of which will now be described by way of example only and with reference to the accompanying drawings in which:
FIG. 1 shows an example torque-speed characteristic for an existing engine;
FIG. 2 illustrates examples of relevant parameters of an existing turbocharger system, when operated with the engine described by FIG. 1 ;
FIG. 3 shows a diagrammatic view of a first embodiment of a turbocharger system;
FIG. 4 shows a diagrammatic view of an engine system for use with a turbocharger system;
FIG. 5 shows a diagrammatic view of a second embodiment of a turbocharger system; and
FIG. 6 illustrates examples of relevant parameters of a turbocharger system for instance in accordance with FIG. 3, 4 or 5 , when operated with the engine described by FIG. 1 .
DETAILED DESCRIPTION
Referring to FIG. 3 , a diagrammatic view of a turbocharger system is shown. The turbocharger system 10 may comprise: an exhaust gas inlet 20 ; an exhaust gas outlet 23 ; an air inlet 30 ; a compressed air outlet 33 ; a first turbocharger 40 ; a wastegate 50 ; a second turbocharger 60 ; and a turbocharger electrical machine 70 . The first turbocharger 40 may comprise: a first turbine 41 ; a rotatable shaft 42 ; and a first compressor 43 . The second turbocharger 60 may comprise: a second turbine 61 ; a second rotatable shaft 62 ; and a second compressor 63 .
Exhaust gases from the engine may be received at the exhaust inlet 20 . Under normal operating conditions, the exhaust gases may be used to drive the first turbine 41 of the first turbocharger 40 , which is a HP turbocharger. This rotates the shaft 42 , which causes the first compressor 43 to act.
Having passed through the first turbine 41 , the exhaust gases may then be received at the second turbocharger exhaust gas inlet 22 . These exhaust gases may be used to drive the second turbine 61 . This causes the shaft 62 to rotate and drive the second compressor 63 . Air may be received at an inlet 30 and compressed by second compressor 63 . The compressed air may then be passed to the first turbocharger air inlet 32 . The first compressor 43 further compresses this air and it may then be directed towards air outlet 33 .
Under certain conditions, the wastegate 50 may be operated. In operation, exhaust gases received at exhaust gas inlet 20 may not all pass to the first turbine 41 , but are typically instead directed partially or fully to the second turbocharger exhaust gas inlet 22 , and drive the second turbine 61 instead. Such conditions may apply when the exhaust gas pressure or compressed air pressure becomes high and may therefore cause damage to the engine or make the engine run less than optimally. In practice, the exhaust gases will only fully pass through the wastegate 50 if there was a valve to shut off flow in the line feeding the turbine. Such a valve is not present in the embodiment of FIG. 3 , but could be added as an option.
Typically, the condition under which the wastegate 50 will be operated may depend upon a parameter that is a function of the compressor delivery (that is, boost) pressure, which is a function of the received energy from the exhaust gases since these provide the energy for rotation of the first turbine 41 , second turbine 61 or both. The boost pressure is normally measured directly. Alternatively or additionally, the rotational speed of the first turbocharger shaft 42 , second turbocharger shaft 62 or both can be measured as the boost pressure is closely related to these parameters.
Different types of wastegate exist. Both older, passive wastegates, and so-called “smart” or electronic wastegates use an indication of the boost pressure to determine the degree of wastegate opening. The desired boost level (boost demand) usually relates to the ratio of air to fuel required in the combustion chambers of the engine at that particular operating point. The wastegate may be set to open when the boost pressure rises above a set pressure level. The set pressure level may be dependent upon the boost demand, or independent of the boost demand.
In the older type of wastegate, a pneumatic feed of the instantaneous boost level, usually from somewhere in the intake manifold downstream of the first compressor 43 and compressed air outlet 33 , for example, after a charge cooler (not shown). It may then be fed to a wastegate actuator (not shown), in which the pressure acts on a sprung diaphragm or valve arrangement which rises or falls according to the pressure level. There is typically a linkage and lever arm which connects this to a wastegate flap valve (not shown) inside the housing of the first turbine 41 .
This operation is termed “passive” because the characteristic of opening against boost pressure for the wastegate 50 is set by specifying the spring rating in the actuator.
A “smart” wastegate is similar to the older wastegate, but the characteristic of wastegate opening against boost pressure can be modified by the Engine Control Module (ECM). This may use an electronic control valve which may control the pressure level seen by the wastegate actuator. In this case, there are effectively a number of characteristics of wastegate opening against boost pressure, calibrated to correspond to different engine operating points.
There are also other additional modifications to both older and “smart” wastegates (for example, secondary ports), which essentially seek to fine-tune the shape of the wastegate opening characteristic. For example in a basic wastegate, the wastegate flap may begin to open well before maximum boost is reached (a consequence of the nature of the spring system). The modifications attempt to make the opening more of a step response (by using stepper motors or solenoid valves).
Coupled to the second turbocharger 60 , there may be a turbocharger electrical machine 70 . This may comprise a rotor (not shown) driven by the rotatable shaft 62 and a stator (not shown), fixed in position. This electrical machine 70 is normally operated in a generator mode, in which rotation of the second rotatable shaft 62 causes induction of a current in the stator of the electrical machine 70 . Optionally, it can also be operated in a motor mode, in which a current is provided to the stator of the electrical machine 70 and this causes a force on the rotor and thus the rotatable shaft 62 , thereby driving the second compressor 63 . Due to the higher rotational speed of the high pressure turbocharger stage 40 in comparison with the low pressure turbocharger stage 60 , no electrical machine is usually applied on this stage. For example the high pressure turbocharger stage 40 may run at around 120000 rpm, whereas the low pressure turbocharger stage 60 may operate at 80000 rpm. Nonetheless, this makes a big difference to the design of the electrical machine 70 . Application of an electrical machine to the first turbocharger 40 would incur prohibitive losses due to the high speeds of the rotatable shaft 42 . By rotating the turbocharger shaft slower, even by a small difference, more power may be extracted. The power extracted is a function of torque and speed. Torque increases with the diameter of the rotor, but centrifugal stress increases with the square of the speed. Eventually, a stress limitation is reached, introducing losses.
Moreover, the low pressure turbocharger stage 60 may be significantly cooler than the high pressure turbocharger stage 40 . The exhaust gases may be cooler, following expansion in the high pressure turbocharger stage 40 . Thus, there may be less “heat soak” into the electrical machine 70 . Apart from centrifugal stress, a key limitation on the electrical machine may be that the temperature of the windings must be controlled to prevent melting.
To extract energy from the electrical machine 70 in the low pressure turbocharger 60 , when the electrical machine 70 is being operated in its generator mode, the first turbocharger 40 will be required to produce a higher compressive force in order to achieve the same level of boost. Consequently, the work balance will shift to the first turbocharger 40 , implying that the wastegate 50 will operate to a lesser degree. This provides more energy to the first compressor 43 . This control problem may be optimised by adjusting the current drawn from the electrical machine 70 on the basis of the boost requirements and the conditions under which the wastegate 50 will operate.
Effectively, the boost pressure may be controlled by operating the electrical machine 70 as a generator, rather than actuating the wastegate 50 on the first turbocharger 40 . Instead of actuating the wastegate 50 , a boost pressure sensor (not shown) may control the current in the circuit of the electrical machine 70 , and thus the torque extracted from the second rotatable shaft 62 . A control strategy may be employed to meet the desired boost optimally by control of the current of the electrical machine 70 , engine torque or both.
Specifically, for a given boost requirement, the current drawn from the electrical machine 70 may be set to a level such that operation of the wastegate 50 is minimised. This provides optimum engine thermal efficiency, since as much of the energy as possible from the exhaust gases generated by the engine is either used for providing boost or converted into electrical energy, which can be stored for later use.
This is advantageously effected in a way that is independent from the operating mode (or equivalently, point) of the engine. The operating mode may be understood as referring to the instantaneous speed and torque (load) of the engine, but the rate of change of speed or torque or both may also be understood. Moreover, for derivatives of the speed or torque or both can also be encompassed by the term operating mode.
By independent, it is not to be understood that the electrical machine 70 is not adjusted when there is a change in operating mode of the engine. A change in engine operating mode will likely cause a change in boost pressure and boost demand and adjustment of the electrical machine 70 is therefore probable. Rather, the term independently means that adjustment of the electrical machine 70 is not directly based on the operating mode of the engine, but preferably on the boost pressure. In other words, the current drawn from the electrical machine 70 may be set to minimise operation of the wastegate, irrespective of the operating mode of the engine.
In general, there is no one-to-one mapping between engine operating point and boost. Various operating points (which may be understood as combinations of speed and load) could require a single boost pressure value. Then, considering transient operation, the demanded boost could vary for the same starting engine speed and load depending on the desired end point and the response rate required. In these different contexts, the mapping between engine operating point and boost may be many-to-one (for example, in steady state operation) and one-to-many (for instance in transient operation). Moreover, the control of the electrical machine 70 may be based only on the desired boost and the determined boost pressure. The electrical machine 70 can then cause the low pressure turbocharger 60 to speed up or down accordingly, for instance by control of the current drawn using power electronics to affect the applied or absorbed torque thereby.
It may be beneficial not to use the wastegate, because it introduces mixing losses leading to poor turbine efficiency. Table 1 below summarises some example parameters for a turbocharger system with the wastegate open or shut, but with the same mass flow in either case. In other words, it reflects operation of the turbocharger system when the engine is operated at a constant speed.
TABLE 1
Variable
Wastegate open
Wastegate shut
Exhaust gas inlet pressure
381.6039
384.9759
(kPa)
Exhaust gas inlet
947.84
956.05
temperature (K)
Mass flow (kg/s)
0.18733
0.18733
Exhaust gas outlet pressure
221.5228
217.9665
(kPa)
Exhaust gas outlet
859.79
851.99
temperature (K)
Ratio of inlet to outlet
1.722639385
1.77
pressure
Isentropic efficiency
0.64547935
0.725597393
Isentropic efficiency (%)
64.54793496
72.55973931
In this example, a drop in turbine isentropic efficiency of 8 percentage points is predicted between turbine operation with wastegate shut and with wastegate open, for the same total mass flow rate. This is energy that cannot be recovered by the LP turbine.
The efficiency of the electrical machine 70 as a generator may be significantly greater than that of the wastegate or other diversion mechanism (although likely less than 100%). Efficiencies of typically greater than 95% can be reasonably expected, especially for low speeds. At higher speeds, the efficiency of the electrical machine 70 may be reduced.
Implementation of the electrical machine 70 on the low pressure turbocharger stage 60 rather than the high pressure turbocharger stage 40 is beneficial to the overall system efficiency. Lower rotational speed in the low pressure turbocharger stage 60 imply greater efficiency of the electrical machine 70 , as discussed above. For example, a 13 percentage point improvement in efficiency may be possible by dropping from 140000 rpm to 80000 rpm. Efficiencies greater than 90% may be reasonably expected, which is a significant improvement in comparison with previous wastegate operation.
Referring next to FIG. 4 , there is shown a diagrammatic view of an engine system for use with a turbocharger system. The engine system may comprise: an engine 80 ; the turbocharger system 10 ; a controller 90 ; and a sensor 95 .
The engine 80 may provide exhaust gases to the exhaust gas inlet 20 of the turbocharger system 10 . The turbocharger system 10 may then provide compressed air through compressed air outlet 33 . The pressure of the compressed air may be determined by sensor 95 and this may be passed to controller 90 . The controller 90 may then control the turbocharger electrical machine 70 , as described above, in order to minimise operation of the wastegate 50 .
The controller 90 may be a supervisory ETA controller that determines the torque level to be electrically extracted from (in generating mode) or applied to (in motoring mode) the second turbocharger shaft 62 of the turbocharger system 10 . In terms of power electronics, the supervisory ETA controller adjusts the level of electrical current to be used by the turbocharger electrical machine 70 . Like the wastegate system, the ETA controller may use a measurement of boost pressure (that is, pressure of gas at or downstream from the compressed air outlet 33 , for example downstream from the charge cooler), comparing it against desired boost pressure, to decide whether the second turbocharger shaft 62 needs to be slowed down (to reduce boost) or speeded up.
A benefit of the ETA system is that the same required effect (that is, boost control) is achieved, but with increased energy efficiency. Flow across the wastegate 50 leads to wastage of the energy in the exhaust gases when a lower level of pressure is required than that which could be achieved. By preventing operation of the wastegate 50 , this loss is minimized. Conversely, the proportion of the energy of the exhaust gases received at the exhaust gas inlet 20 that reaches the first turbocharger 40 is maximised. This proportion is desirably 100%, but in some cases it can be at least 95%, 90%, 75%, 50%, 25% or even less, depending on the state of the engine and turbocharger system.
The supervisory ETA controller can provide similar functionality to that of a “smart” wastegate. In other words, the relationship between the power drawn from turbocharger electrical machine 70 and the boost level or other parameter may be controlled by the ECM, in a similar fashion to the way that the relationship between operation of a “smart” wastegate and the boost level may be controlled.
Although an embodiment of the disclosure has been described above, the skilled person will contemplate various modifications. For example, the turbocharger electrical machine 70 can be implemented in various different ways.
In the above disclosure, the boost pressure has been used for control of the wastegate 50 and the electrical machine 70 . However, the skilled person will appreciate that other parameters can be used, particularly for control of the electrical machine. Typically, the parameter is a function of the energy of the exhaust gases received at the gas inlet 20 . Although a sensor 95 may be used to measure the parameter directly, the parameter may alternatively or additionally be provided by another part of the system, for example, by an ECM.
Wastegate 50 can be a “smart” wastegate. Then, an alternative method for controlling the turbocharger electrical machine 70 to that proposed above may be to use a physical measurement from the wastegate 50 to determine the current level of torque applied to the second turbocharger shaft 62 .
A wastegate is typically internal to a turbocharger and may comprise a short passage within the turbine housing from the volute to the exit, bypassing the rotor, and may be controlled by a plate type valve. However, an external wastegate (which may be referred to as a bypass valve) may use extra ducting in the exhaust manifold that is usually completely separate from the turbocharger. This may re-route some exhaust flow from upstream of the turbine to downstream of the turbine. An internal wastegate may not need to open a great deal but this may create a strong throttling effect leading to very high velocity around the valve. In practice, this usually disturbs the flow entering the turbine wheel (Table 1 above indicates how this results in reduced turbine efficiency). The external wastegate or bypass valve is by comparison normally more efficient and may cause less disturbance to the exhaust flow, at the usual cost of extra ducting and consequently trickier packaging. However, either method generally introduces energy losses because valves are used to direct the flow of gas.
Although the above considers a turbocharger system using a wastegate, an alternative mechanism for controlling the flow of energy between the first turbocharger and the second turbocharger can be employed. Referring next to FIG. 5 , there is shown a second embodiment of a turbocharger system 100 . Where the same features are shown as in FIG. 1 , identical reference numerals have been employed.
In this embodiment, a Variable Geometry Turbocharger (VGT) may be used in addition to or instead of a wastegate 50 . The first turbocharger 140 may be implemented as a VGT. The first turbocharger 140 may comprise a first turbine 141 and a first compressor 143 . Otherwise, the turbocharger system 100 may have the same features as the turbocharger system 10 shown in FIG. 1 .
The skilled person will also recognise that the turbocharger system 100 that uses the VGT first turbocharger 140 may replace the turbocharger system 10 shown in FIG. 2 . In that case, the controller 90 may control the turbocharger electrical machine 70 in order to affect the operation of VGT first turbocharger 140 , as will be explained below.
Where VGT systems are used, they typically supplant the need for a wastegate. Boost control may be achieved by changing the angles of the vanes in the VGT between and open and closed positions. For instance, at times of excess boost (where the boost pressure exceeds a desired level), the vanes can be opened, meaning less blockage to the exhaust flow. A blockage increases the speed of the exhaust gases and causes a higher proportion of their energy to be transferred to the turbine of the turbocharger. Thus when the vanes are open, the specific energy arriving at the turbine decreases and less energy is transferred to the compressor. The vane angle may therefore be controlled on the basis of a condition, similar to that controlling a wastegate. This condition may again be based on a parameter that is a function of the energy of the received exhaust gases, as explained above.
Although use of a VGT is usually more energy efficient than a wastegate, it can be less efficient than a fixed geometry turbine, dependent upon the setting of the vanes. Maximum efficiency is likely achieved when the vane angles are in the middle of their range and efficiency drops off as they move towards fully closed or fully open positions.
A control method according to the disclosure could be applied to maintain VGT vane angle within the most efficient vane angle range.
A wastegate, VGT or other such mechanism for diverting the flow of exhaust gases may cause a proportion of the energy of the received exhaust gases to be provided to the first turbocharger. This proportion can be varied between 0% and 100% inclusive. As noted above, providing 0% of the received exhaust gases to the first turbocharger is unusual though.
The skilled person will also recognise that embodiments of the present invention can be realised in which no wastegate, VGT or other diversion mechanism is employed. Control of the electrical machine 70 may supplant the need for a diversion mechanism.
Here, the LP turbocharger receives exhaust gases from the HP turbocharger, with no possibility for the exhaust gases to bypass the HP turbocharger. The turbocharger electrical machine 70 is controlled independently from the operating mode of the associated engine, in order to affect the boost pressure. This may be done on the basis of a parameter that is a function of the energy of the received exhaust gases, such as the pressure at the compressed gas outlet 33 , that is the boost pressure.
The turbocharger electrical machine 70 may be controlled on the basis of this parameter, for example in order to alleviate or avoid the condition of this pressure exceeding a set level. Nevertheless, a wastegate 50 or bypass valve (not shown) is preferable in such systems, if only to act as safety feature to prevent excess boost or over-speeding in the event of failure of the electronics operating the turbocharger electrical machine 70 .
Referring now to FIG. 6 , there are illustrated examples of relevant parameters of a turbocharger system for instance in accordance with FIG. 3, 4 or 5 , when operated with the engine described by FIG. 1 . These are similar parameters to those shown in FIG. 2 for comparison purposes. These may be effectively considered as expected time histories of the relevant parameters for the same sudden drop in demanded torque event. The abscissa may again represent approximately 10 seconds of operation.
It should be noted that the parameters shown in FIG. 6 are based on simulations, modelling the real world situation. They may be applicable to the designs shown in FIGS. 3 and, but they might more readily be understood in the context of the variant discussed above in which no diversion mechanism, such as wastegate or VGT is employed.
In this example, the engine speed is essentially constant, remaining within +/−5% of the rated speed. After reaching a peak at time T1b, the load torque is suddenly reduced. The engine power follows the torque since the speed is approximately constant.
The boost pressure being delivered at time T1b exceeds that required to produce the new, lower, demanded torque. To prevent the engine accelerating due to the lower absorbed torque, the boost pressure is desirably reduced. The drop off in torque may be sensed through the rise in boost pressure.
The electrical generator 70 of the second turbocharger 60 (the LP stage) is operated to absorb energy from the shaft 62 of the second turbocharger 60 by using associated power electronics to set the corresponding current level. This causes the boost pressure to drop. In this way, the energy transferred from the turbine 61 to the compressor 63 is thus reduced. The compressor speed and boost pressure start to decrease as more power is absorbed by the electrical generator. It should be noted that the turbocharger speed may be directly related to boost pressure, so these two parameters will likely have the same trend.
Between time T2b and time T3b, the sensed boost pressure adjusts the power absorbed by the electrical machine 70 until the engine torque matches the demand. By time T3b the specific energy in the exhaust flow matches that required for the desired boost level, so the level of power absorbed drops to zero.
The timescales in FIGS. 2 and 6 may be understood as being the same. Comparing FIG. 6 to FIG. 2 shows that time T3b occurs sooner after time T1b than time T3a occurs after time T1a. In FIG. 6 , the energy being removed from the exhaust gas flow by the electrical machine 70 is known via instrumentation of associated power electronics. In FIG. 2 , the energy removed from the exhaust flow by the wastegate is not known (whether it is a passive or “smart” wastegate). In view of these differences, the method of controlling boost using the electrical generator may be more precise and the target torque may be achieved more rapidly than by using a wastegate. The efficiency improvements discussed above are therefore manifest.
Thus, it should be clear that control over the boost may be effected by the electrical machine 70 without the need to operate (or even include) a diversion mechanism, such as a wastegate or VGT.
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A turbocharger system comprises: a gas input for receiving exhaust gases from an engine; a first turbocharger comprising a first compressor driven by a first turbine, arranged to be driven by received exhaust gases and providing a compressed air output defining a boost pressure a second turbocharger, arranged to be driven by exhaust gases passing through the first turbocharger or exhaust gases received at the gas input and being coupled to an electrical generator operative to provide electrical power, the first turbine not being coupled to an electrical generator; and a controller. A diversion mechanism may be configured to affect the flow of exhaust gases between the gas input and the first turbocharger. The controller may be configured to adjust the operation of the electrical generator independently from the operating mode of the associated engine, to affect the boost pressure.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application claims the benefit of provisional patent application 60/586,251 filed Jul. 8, 2004, and also is a continuation-in-part of U.S. patent application U.S. Ser. No. 10/748,115 Dec. 30, 2003, now abandoned, which is a continuation of U.S. patent application Ser. No. 09/671,531 Sep. 27, 2000 which is now issued as U.S. Pat. No. 6,668,915, which claims the benefit of provisional 60/156,364 Sep. 28, 1999, all of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
This invention pertains to the field of convective heat transfer.
BACKGROUND OF THE INVENTION
In the field of convective heat transfer, there is in general a tradeoff between heat transfer and pumping power. Power to operate a pump or fan to move a fluid involved in heat transfer is often an expense associated with achieving heat transfer. This is especially of concern in heat exchangers in which the fluid on at least one side is gas such as atmospheric air. Also this is especially of concern when, as is usually the case, there are limitations on the overall space which can be occupied by the heat exchanger. Designs, tradeoffs and calculational methods for heat exchangers are given in “Compact Heat Exchangers” by Kays and London. There is a continuing need for improvement in regard to the tradeoff between heat transfer and pumping power. Such improvement would increase the efficiency of any of the various devices employing forced convection heat transfer or even natural convection heat transfer.
Issued U.S. Pat. No. 6,669,815 discloses a geometry of fins designed to provide an improved ratio of heat transfer to pressure drop or pumping power, by using fin-to-fin spacings which are different in different regions of a fin array. The fin geometry of that patent is shown in FIG. 1 . The geometry illustrated in U.S. Pat. No. 6,668,915 accomplishes that intended goal, but in that geometry the flow may be subject to certain geometry-related flow losses at the changes of cross-sectional area. In U.S. Pat. No. 6,668,915, when the flow at transition region 175 of the second channel expands from a smaller flow cross-sectional area in region 170 to a larger flow cross-sectional area in region 180 , the flow on the right side of the narrow region 170 of the channel essentially may not have to shift at all, while the flow on the left side of the narrow region 170 of the channel may have to shift considerably more. Such flow shifting and associated possible separation of flow from its adjacent solid boundary are possible sources of loss of pressure or head, and so it is desirable for the flow to have to shift as little as possible. In order to avoid such separation of flow from solid boundaries, it has typically been necessary to maintain the divergence angle of the flow at a sufficiently small value, which in turn has required a considerable length of transition region in order to achieve a desired expansion of cross-sectional area.
Accordingly, it is desirable to provide designs of the type disclosed in U.S. Pat. No. 6,668,915 but having improved flow patterns in the transitions between regions, such as to provide for smoother flow and hence smaller pressure losses associated with the expansion or contraction. It also is desirable for the transition region to occupy as little of the overall flow length of the heat exchanger as possible.
BRIEF SUMMARY OF THE INVENTION
The invention includes a heat transfer geometry having a first channel and a second channel which are fluid mechanically in parallel with each other, and with each channel including an upstream region and a downstream region which are of unequal cross-sectional areas. In the first channel, contraction may occur upon going from the upstream region of the channel to the downstream region, and in the second channel expansion may occur upon going from the upstream region of the channel to the downstream region. The channel boundaries may be heat transfer surfaces, and additional heat transfer surface area may be provided in specific regions of specific channels. In this invention, in at least some instances, contraction and expansion may occur as a result of a shift of both the left and right boundaries of the channel. In a cell which is a pairing of a first channel and a second channel sharing a common inter-channel boundary, the overall exiting flow may be offset slightly from the overall entering flow. The invention also includes an array of such cells. An array may be such that the overall array of cells occupies a simple geometric envelope, which may be achieved by providing some cells or structure near the edges of the array, which may be different from the cells in the central portion of the array.
BRIEF DESCRIPTION OF THE ILLUSTRATIONS
The invention is illustrated in the following Figures, in which:
FIG. 1 shows the heat transfer geometry described in U.S. Pat. No. 6,668,915.
FIG. 2 illustrates a single cell, i.e., a paired first channel and second channel, of the present invention.
FIG. 3 is a close-up view showing a similar cell with curved boundaries.
FIG. 4 illustrates a similar cell with unequal lengths of fins in certain regions of the flowpaths.
FIG. 5 illustrates an array of such cells arrayed side-by-side.
FIG. 6 illustrates such an array with an edge region filled in.
FIG. 7 illustrates such an array with edge regions made part of the appropriate flowpaths.
DETAILED DESCRIPTION OF THE INVENTION
The invention includes a geometry of surfaces for heat exchange with a flowing fluid. The geometry may define a first channel for flow of a fluid and a second channel for flow of the fluid, with the first channel and the second channel being fluid mechanically in parallel with each other. The first and second channels may have overall flow resistances which are approximately equal to each other, and in the normal conditions of operation the first and second channels may carry flowrates which are approximately equal to each other.
The first channel may be defined at least in part by a first channel boundary 254 and an interchannel boundary 290 . The second channel may be defined at least in part by the interchannel boundary 290 and a second channel boundary 274 . The interchannel boundary 290 may be located between the first channel boundary 254 and the second channel boundary 274 . In the direction into or out of the plane of the paper, the channels may be defined by still other boundaries.
The first channel may comprise a first channel upstream region 250 having a first channel upstream region flow cross-sectional area, in series with a first channel downstream region 260 having a first channel downstream region flow cross-sectional area. In the first channel, between the first channel upstream region 250 and the first channel downstream region 260 , there may be a first channel transition region 255 . Similarly, the second channel may comprise a second channel upstream region 270 having a second channel upstream region flow cross-sectional area, in series with a second channel downstream region 280 having a second channel downstream region flow cross-sectional area. In the second channel, between the second channel upstream region 270 and the second channel downstream region 280 , there may be a second channel transition region 275 .
For purposes of discussion, it can be considered that in the first channel the first channel upstream region 250 is of larger flow cross-sectional area and the first channel downstream region 260 is of smaller flow cross-sectional area, i.e., the first channel transition region 255 is converging. Similarly, it can be considered that in the second channel the second channel upstream region 270 is of smaller flow cross-sectional area and the second channel downstream region 280 is of larger flow cross-sectional area, i.e., the second channel transition region 275 is diverging. It is understood, however, that these designations could be interchanged. It is possible, although not required, that the sum of the first channel upstream flow cross-sectional area and the second channel upstream flow cross-sectional area can equal the sum of the first channel downstream flow cross-sectional area and the second channel downstream flow cross-sectional area.
For any of the transition regions 255 and 275 , the transition can be formed by a shift of both of the two boundaries which principally define the particular channel (rather than a shift of only one of the two boundaries as was illustrated in U.S. Pat. No. 6,668,915). For example, in the first channel transition region 255 , both the first channel boundary 254 and the interchannel boundary 290 can shift so as to decrease the flow cross-sectional area as the fluid proceeds from the first channel upstream region 250 to the first channel downstream region 260 . These boundaries can shift in a substantially symmetric manner so that the first channel substantially maintains a symmetry about first channel centerline 292 . Similarly, in the second channel transition region 275 , both the second channel boundary 274 and the interchannel boundary 290 can shift so as to increase the flow cross-sectional area as the fluid proceeds from the second channel upstream region 270 to the second channel downstream region 280 . Again, these boundaries can shift in a substantially symmetric manner so that the second channel substantially maintains a symmetry about its own centerline 294 . Alternatively, it is possible for the various boundaries to shift in ways such that the individual channels do not maintain symmetry around their own respective centerlines.
If flow separates from adjacent solid boundaries, this generally creates additional pressure losses and is undesirable. Separation is typically associated with localized recirculating flow patterns. As investigated in the art of fluid mechanics dealing with diffusers, the question of whether or not an expanding flow separates from the walls which define its flowpath, or the extent of such separation, is determined by factors which include the angle of divergence of the walls. Accordingly, the angle of divergence alpha as defined in FIG. 2 (which is a half-angle of divergence rather than a full included angle) may be chosen so as to be less than 20 degrees, or less than 10 degrees, or less than 8 degrees, or less than 6 degrees, or any other angle which is appropriate for a given situation. In the second channel (which is the channel containing expansion 275 ), both the interchannel boundary 290 and the second channel boundary 274 may exhibit divergence at that angle; or, the angle at one of these boundaries may be different from the angle at the other of these boundaries. In the first channel, as determined by the first channel boundary 254 and the interchannel boundary 290 , there may be convergence at a convergence angle similar to that of the just-described divergence. Curved or partially curved configurations of the various channel boundaries are also possible. In a situation which includes curved boundaries, the shape of the curve may be chosen so as to provide desirable flow patterns at the transitions. The boundaries of the transition may comprise straight segments with fillets at each end of the transition, as illustrated in FIG. 3 .
The first channel boundary 254 , the interchannel boundary 290 and the second channel boundary 274 may all be disposed to engage in heat transfer with the fluid in the respective channels. Other boundaries of the channels (in the plane of the paper, not illustrated) may also be disposed to engage in heat transfer with the fluid in the respective channels, if desired. Any of the described regions can contain additional heat transfer surface area which may, for example, be in the form of fins. Alternatively or in addition, such additional heat transfer surface area can comprise perforated fins, or one or more fins punctured by one or more fluid-carrying tubes, or wire mesh, or a porous material, or pins, or tubes in crossflow, or tubes in other geometries. Although the first channel downstream region and the second channel upstream region are illustrated as not having any additional heat transfer surface area beyond the respective channel boundary and interchannel boundary, those regions could contain additional heat transfer surface area such as fins. Heat transfer for geometries other than simple fins, such as porous material or mesh, may be represented or approximated for calculation purposes as equivalent arrays of parallel-walled channels or tubes, as is known in the art, for example, the D'Arcy theory of flow through porous media. If fins are used for the additional heat transfer surface area in certain regions, the fins do not all have to be of the same length along the flow direction. FIG. 4 illustrates a pattern of unequal length fins which may be suitable.
Each region may have a heat transfer surface area associated with that region, which may be the sum of the heat transfer surface area of the appropriate channel boundary and the heat transfer surface area of the interchannel boundary and any additional heat transfer surface area which may be present in the particular region. The first channel upstream region total heat transfer surface area and the second channel upstream region total heat transfer surface area define a heat transfer surface area distribution factor which is the larger of those two quantities divided by their sum. The first channel upstream region flow cross-sectional area and the second channel upstream region flow cross-sectional area define a flow cross-sectional area distribution factor which is the larger of those two quantities divided by their sum. In the present invention, the heat transfer surface area distribution factor and the flow area distribution factor may be selected such that the heat transfer surface area distribution factor is greater than the flow cross-sectional area distribution factor. This criterion results in an improved value of heat transfer to pressure drop, as explained in greater detail in U.S. Pat. No. 6,668,915.
It is possible that the various boundaries which define the first channel and the second channel may be arranged as illustrated in the FIG. 2 , so that both the first channel maintains symmetry around its individual centerline 292 and the second channel maintains symmetry around its centerline 294 . It can be observed that in this geometry the overall output of the combination of the two just-described flowpaths does not exactly line up with the overall input of the combination of the same two flowpaths. (This is in contrast to the situation for the geometry of U.S. Pat. No. 6,669,815 which is illustrated in FIG. 1 .) Instead, in the design of FIG. 2 , there is a slight offset of the overall flow in the downstream regions and at the exit of the combination of the two channels, relative to the overall flow in the upstream regions and at the entrance of the combination of the two channels. It may be that in a particular application this offset can be accommodated as described elsewhere herein, and that the improved flow situation at the expansion 275 and contraction 255 makes this worthwhile.
A cell or apparatus can be considered to be, collectively, the first channel and the second channel, which share a common interchannel boundary. The overall cell can be defined by the first channel boundary and the second channel boundary. The invention also includes an assembly containing a plurality of such cells arranged side by side with each other. The first channel upstream region and the second channel upstream region together define a cell upstream region which is bounded by the first channel wall and the second channel wall in that region. Similarly, the first channel downstream region and the second channel downstream region together define a cell downstream region which is bounded by the first channel wall and the second channel wall in that region. In such an assembly, the first channel boundary of a certain cell can, on the other side of that boundary, be the second channel boundary of another cell. Thus, the first channel boundary and the second channel boundary can be inter-cell boundaries and can engage in heat transfer with fluid on both of their sides. Multiple cells may be used together to make a heat exchanger occupying a substantial frontal area. This illustrated in FIG. 5 using four cells.
For an overall assembly of heat transfer surfaces, it may be desirable that the entire assembly (array of cells) should fit within a simple shape envelope which may be a simple rectangle.
Use of a large number of cells could occur, for example, in a large heat exchanger requiring a large number of fins. If an application involves placement of many such cells side by side, it is possible that the slight offset (which would be less than half of the overall side-to-side dimension of one cell) may be a tiny fraction of to the overall side-to-side dimension of the assembly of cells. In this situation, there might be a fractional cell on the extreme left side and the extreme right side of the overall array which would be geometrically unavailable for flow, but this could be insignificant compared to the overall dimensions of the heat exchanger, and this space could simply be left unused for flow and heat exchange. This is illustrated in FIG. 6 , showing those spaces filled with filler 698 .
Alternatively, to avoid “wasting” any space in the frontal area of a heat exchanger, it is possible that a number of cells can be manufactured using the design described herein and can be centrally located in an array, and at least one cell of some other configuration can be manufactured near the boundary of the cell array, so as to give the overall array of cells the desired envelope. For example, for such unique cells the flow area distribution factor could be different from what it is in cells in the central region of the heat exchange array. This is illustrated in FIG. 7 , in which the left flowpath of the extreme left cell is different from that in typical cells, and the right flowpath in the extreme right cell is different from that in typical cells. Extra space left in as flow area is shown in FIG. 7 as regions 798 . It is also possible to have an unmatched flowpath or half-cell, i.e., the number of expansion-containing flowpaths in the overall array could be one more or one less than the number of contraction-containing flowpaths in the overall array.
Although various embodiments of the invention have been disclosed and described in detail, it should be understood that this invention is in no way limited thereby and its scope is to be determined by that of the appended claims.
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The invention includes a heat transfer geometry having first and second flow channels in parallel with each other. The flow cross-sectional area of individual channels varies along the length of the flowpath, with one channel undergoing an expansion and the other undergoing a contraction. Different amounts of additional heat transfer surface are located within different regions. In at least some instances, contraction and expansion may occur as a result of a shift of both the left and right boundaries which principally define the channel, and may occur symmetrically with respect to a centerline of the individual channel. With a cell being a first channel and associated second channel, the overall exiting flow may be offset slightly from the overall entering flow. An array may be formed containing multiple cells, and cells at edges of the array may be atypical so that the overall array fits within a simple geometric envelope.
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BACKGROUND
[0001] The capacitance of a capacitive sensor changes when an object approaches or touches the sensor. Since the sensors require no moving parts, capacitive sensors may be robust and reliable and widely used in many areas. In particular, capacitive sensors are used in human-to-machine interfaces such as buttons, jog wheels, switches, scroll bars and touch screens.
[0002] In many applications, capacitive sensors interface to digital electronic controllers via a capacitance-to-digital converter. Sigma-delta capacitance-to-digital converters have been used successfully in many applications. In a sigma-delta converter, a sigma delta modulator generates a binary sequence of zeros and ones that indicate whether the charge accumulated by the capacitance of the sensor is greater than or less than a reference charge accumulated on a reference capacitor. The sequence of zeros and ones may be integrated and decimated to determine the relationship of the sensor's capacitance to the reference capacitance.
[0003] One limitation of this approach is that the reference capacitance must be greater than the sensor capacitance. However, if the capacitance is too large, the sensitivity of the converter is reduced. One approach to reduce this limitation is to adjust the sampling time of the reference capacitance relative to the sampling time of the sensor capacitance. Another approach is to a use an additional offset capacitor that is clocked out of phase with the excitation signal. A still further approach is to adjust the voltage of the excitation signal.
[0004] In practice, the impedance of the sensor is not purely capacitive. Hence, a further limitation is that the conversion is that the conversion speed is limited by the discharge time of the sensor capacitance. The discharge time increases as the resistive component of the sensor impedance increases. This can be a significant limitation for applications such as touch screens, which utilize a matrix of sensing elements and require multiple conversions for a single position estimate.
[0005] A further limitation is that electromagnetic interference generated by the converters is concentrated in very narrow frequency bands that are multiples of the clock frequencies.
[0006] A still further limitation is that a converter may be sensitive to noise, such as electromagnetic interference from synchronous components.
BRIEF DESCRIPTION OF THE FIGURES
[0007] The accompanying figures, in which like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the present invention.
[0008] FIG. 1 is an example capacitance-to-digital converter in accordance with some embodiments of the invention.
[0009] FIG. 2 is an example a switched offset capacitance in accordance with some embodiments of the invention.
[0010] FIG. 3 is a graphical representation of an exemplary charge transfer function.
[0011] FIG. 4 is a graphical representation of clock signals and an integrator voltage in a capacitance-to-digital converter.
[0012] FIG. 5 is a graphical representation of clock signals in a capacitance-to-digital converter in accordance with some embodiments of the invention.
[0013] FIG. 6 and FIG. 7 are graphical representations of clock signals and integrator voltages in a capacitance-to-digital converter in accordance with some embodiments of the invention.
[0014] FIG. 8 is a simplified block diagram of a touch and proximity sensor in accordance with some embodiments of the invention.
[0015] FIG. 9 is further block diagram of a touch and proximity sensor in accordance with some embodiments of the invention.
[0016] FIG. 10 is a graphical representation of clock signals generated by a random or pseudo-random sequence in a capacitance-to-digital converter, in accordance with some embodiments of the invention
[0017] Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention.
DETAILED DESCRIPTION
[0018] Before describing in detail embodiments that are in accordance with the present invention, it should be observed that the embodiments reside primarily in combinations of method steps and apparatus components related to capacitance testing. Accordingly, the apparatus components and method steps have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
[0019] In this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by “comprises . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.
[0020] It will be appreciated that embodiments of the invention described herein may a one or more application specific integrated circuits (ASICs), in which each function or some combinations of certain of the functions are implemented as custom logic. Thus, methods and means for these functions have been described herein. Further, it is expected that one of ordinary skill, notwithstanding possibly significant effort and many design choices motivated by, for example, available time, current technology, and economic considerations, when guided by the concepts and principles disclosed herein will be readily capable of generating such integrated circuits with minimal experimentation.
[0021] FIG. 1 is an example capacitance-to-digital converter in accordance with some embodiments of the invention. In FIG. 1 , the converter 100 generates a binary sequence of zeros and ones 102 that indicate whether the charge accumulated by the capacitive element 104 of a sensor 106 is greater than or less than a reference charge generated by a reference charge generator 107 . In the embodiment shown in FIG. 1 , the reference charge generator 107 includes a reference capacitive element 108 . The binary sequence 102 may be integrated and decimated in a filter 110 , which may be integrated in the same circuit as the converter 100 , to determine the relationship of the sensor's capacitive element 104 to the reference capacitive element 108 . The capacitive element 104 of the sensor 106 is driven by an excitation voltage 112 that is output from the converter 100 and produces an output signal 114 that is fed back to the converter 100 . In this example, the excitation voltage 112 is provided by a voltage reference source 116 that is coupled via a clocked transmission gate 118 . The gate 118 is driven by a first clock signal, denoted as Φ 1 . During a sampling interval when the first clock signal is asserted, the gate 118 is closed and the capacitance of the sensor samples the excitation voltage. The capacitive element 104 is also coupled to ground via another clocked transmission gate 120 driven by a second clock signal, denoted as Φ 2 . In contrast to prior converters, the signal Φ 2 is not the complement of Φ 1 , as will be discussed in more detail below.
[0022] The reference capacitive element 108 of the reference capacitance generator 107 is coupled to the voltage reference source 116 by a clocked transmission gate 122 and to ground via a clocked transmission gate 124 . During an integration interval, the clocked transmission gate 126 is closed and the capacitances 104 and 108 are coupled to an integrator 128 . In the embodiment shown, the integrator 128 comprises a capacitor ‘Cint’ coupled around an amplifier ‘A’. When the clocked transmission gate 130 is closed the capacitive elements are coupled to ground. If gate 122 is closed during the sampling interval, the reference capacitive element 108 also samples the reference voltage, and the sum of the accumulated charges is fed to the integrator 128 . If gate 122 is closed during the integration interval, charge is held in the reference capacitive element 108 and the difference of the charges is passed to the integrator. Thus, the relative timing of the transmission gates controls the charge fed into the integrator 128 . The output from the integrator 128 is passed to a comparator 132 that compares the integrated value to a threshold (such as ground, for example) and generates the binary output sequence 102 . A clock generator 134 generates the first and second signal clock signals 136 . The clock generator may incorporate a pseudo random noise sequence (PRNS) generator, as will be discussed below with reference to FIG. 10 . The binary output sequence 102 is input to feedback logic 138 where it is combined with the first and second clock signals Φ 1 and Φ 2 to produce the switch control signals 140 (Φ 3 and Φ 4 ) that control the clocked transmission gates of the reference capacitance generator 107 . If the integrator output is high, the gates 118 and 122 are operated out of phase (e.g. Φ 3 =Φ 2 , Φ 4 =Φ 1 ). If the integrator output is low, the gates 118 and 122 are operated in phase (e.g. Φ 3 =Φ 1 , Φ 4 =Φ 2 ).
[0023] In general, control of the clocked transmission gates 118 , 120 , 126 and 130 is independent of the comparator output 102 , while control of the gates 122 and 124 is dependent upon the comparator output.
[0024] In one embodiment, the dynamic range of the converted is increased by adding a charge compensation circuit 142 . The charge compensation circuit 142 generates a charge 144 that at least partially compensates for the charge accumulated in the sensor capacitive element 104 . In the exemplary embodiment shown in FIG. 1 . An offset capacitor 146 samples a reference voltage when clocked transmission gate 148 is closed and is coupled to the integrator 128 when clocked transmission gate 150 is closed. The sampling is synchronized with the sampling of the sensor capacitive element 104 .
[0025] The offset capacitor may be a selectable capacitor, the capacitance of which is controlled by a signal on control line 152 . The control signal is generated from an offset select logic circuit 154 . In one embodiment the capacitance of the selectable offset capacitor is selected dependent upon the binary output sequence 102 . For example, the capacitance may be selected dependent upon the ratio of ones to zeros in the binary output sequence. In a further embodiment, the capacitance is programmed dependent upon characteristics of the sensor 106 .
[0026] In practice, the sensor 106 is not purely capacitive, but includes a resistive component, as indicated by the series resistors 156 and 158 shown FIG. 1 . The series resistance indicated by the series resistors 156 and 158 slows the rate at which the capacitive element 104 can be charged or discharged. This will be discussed below with reference to FIG. 3 .
[0027] FIG. 2 shows an exemplary offset capacitor 146 . The capacitor 146 has a selectable capacitance and comprises a number of individual capacitive elements 146 ′ arranged in parallel. Switches 202 are individually controlled by a control line 152 and allow the elements to be selectively couple to ground 204 .
[0028] FIG. 3 is a graph showing a charge transfer function 302 , denoted as T(t). The charge transfer function 302 corresponds to the proportion of the total charge in a capacitive element that transferred to or discharged from the element as a function of time, t. The charge transfer begins at time t=t 0 and the transfer is substantially discharged at time t=t 1 . In general, the charge transfer is not instantaneous, since the capacitive element, or the connections to it, have a finite resistance. The higher the resistance, the lower the initial slope of the charge transfer function 302 . The time constant, that is the time for the capacitor to charge to 63.2% of its full charge, is equal to the produce of the resistance and the capacitance. Generally, although never 100% charged, the capacitor is considered to be fully charged after five time constants.
[0029] FIG. 4 is a graphical representation of clock signals and an integrator voltage in a capacitance-to-digital converter, plotted as a function of time. A first clock signal 402 (φ 1 ) controls the excitation signal supplied to the capacitive element to be sensed and a second clock signal 404 (φ 2 ) controls integration of charges. In this example, the second clock signal 404 is the complement or inversion of the first clock signal 402 and both clock signals are symmetrical. The clock signals control transmission gates, as described above. In this example, high signal level indicates that a gate is open and allows transmission (or, equivalently, that a switch is closed), while a low signal level indicates that the gate is closed. The bottom graph 406 , labeled ‘V’, shows an example of a voltage level resulting from integration of a charge. Generally, the voltage level will increase or decrease during the integration period depending on the sign of the charge being integrated.
[0030] In prior converters, the speed of conversion is limited by the discharge time, t 1 -t 0 .
[0031] In operation, the average integrated charge over the conversion period is
[0000] Q=C SENS ×V REF −C OFF ×V REF −R×C REF ×V REF (1)
[0000] where V REF is the reference voltage, C SENS , C REF , C OFF are the sensor, reference and offset capacitances and R is difference between the number of ones and the number of zeros in the output sequence 102 , divided by the total number of values in the output sequence. This expression assumes that the sampling and integration times are sufficient for the capacitive elements to be fully charged and discharged and that the same reference voltage is applied to each capacitive element.
[0032] The integrated charge is controlled, by the binary output sequence, to be zero, so the capacitance of the sensed capacitive element is given by
[0000] C SENS =C OFF +R×C REF (2)
[0033] Since the ratio R is less than or equal to one, inclusion of the offset capacitance allows sensor capacitances larger than the reference capacitance to be measured.
[0034] FIG. 5 is graphical representations of a first clock signal 502 and a second clock signal 504 in a capacitance-to-digital converter. In accordance with one embodiment of the invention, a first clock signal 502 has a cycle 506 (denoted as ‘Tcycle’ in the figure). In each cycle, the clock signal has a logic value one for a first interval 508 (denoted as Ts) and logic value zero for a second interval 510 in each cycle of the first clock signal. The first clock signal is used to generate an excitation signal that has a first voltage during the first interval 508 of the first clock signal and a second voltage value (which may correspond to an electrical ground) during the second interval 510 of the first clock. The excitation signal is supplied to the sensed capacitive element to accumulate an electrical charge on the capacitive element. The accumulated charge is dependent upon the applied voltage, so the capacitive element is said to have ‘sampled’ the applied voltage. In each clock cycle 512 of the second clock, the second clock signal 504 has a logic value one for a first interval 514 (denoted as ‘Ti’) and logic value zero for a second interval 516 in each cycle of the second clock signal. A reference electrical charge is generated dependent upon the current binary value of the binary sequence and a combination of the reference charge and the electrical charge on the capacitive element is integrated during the first interval 514 of the second clock to produce an integrated electrical charge. This integrated charge is compared to a threshold to obtain a next binary value of the binary sequence. The binary value is dependent upon whether the integrated electrical charge is above or below the threshold.
[0035] In one embodiment of the invention, the cycle 506 of the first clock signal has a non-constant duration and the cycle of the second clock signal has a non-constant duration. The varying clock rate reduces electromagnetic radiation from the converter and reduces the sensitivity of the converter to external noise. Such clock signals with varying cycle times are termed ‘spread spectrum clocks’, since the spectrum of the signal is spread across a range of frequencies.
[0036] In general, when the clock rate is high enough, the capacitances may not have time to fully charge or discharge during a clock cycle. We denote the proportion of maximum charge transferred to the sensed capacitive element during the sample interval as T 1 and denote the proportion transferred from the element during the integration interval as T 2 . Assuming that the charge transfer functions T 1 , T 2 are both constant over the conversion period, the average integrated charge is expressed as
[0000] Q=T 2 ×T 1 ×C SENS ×V REF −C OFF ×V REF −R×C REF ×R REF (3)
[0037] Where, as before, V REF is the reference voltage, C SENS , C REF , C OFF are, respectively, the sensor, reference and offset capacitances, and R is ratio of ones to zeros in the output stream 102 . It is assumed that the offset and reference capacitance circuits have very little resistance, so that the capacitors are fully charged and discharged in each cycle.
[0038] The integrated charge is controlled, by the binary output sequence, to be zero. Hence, the capacitance of the sensed capacitive element is
[0000]
C
SENS
=
1
T
1
T
2
×
[
C
OFF
+
R
×
C
REF
]
,
(
4
)
[0039] Since the ratio R is less than or equal to one, inclusion of the offset capacitance allows larger sensor capacitances to the measured. In addition, if the integration times are small enough, the sensitivity of the converter can be adjusted by controlling the ratio of sampling times.
[0040] In a first embodiment of the invention, the clock rate is varied but the rate is controlled to be sufficiently slow at all times that the proportions T 1 ,T 2 are substantially equal to unity. This condition satisfies the assumption that the charge transfer functions T 1 ,T 2 are constant over the conversion period. It is noted that the proportions T 1 ,T 2 depend upon the electrical properties of the sensed capacitive element and the connections to it. Thus, the minimum cycle duration may be selected dependent upon the electrical properties of the sensed capacitive element and the connections to it.
[0041] FIG. 6 is a graphical representation of a first clock signal 502 , a second clock signal 504 and an integrator voltage 406 in a capacitance-to-digital converter in accordance with some embodiments of the invention. In FIG. 6 , the first clock signal 502 and the second clock signal 504 have variable duration clock cycles. However, the minimum sample interval Ts and the minimum integration interval Ti are long enough that the sensed capacitive element has time to substantially charge and discharge in each cycle. As a result, the change in the integrator voltage 406 depends only on the comparator output signal, and is independent of the clock cycle period.
[0042] In a further embodiment of the invention, the clock rate is varied (i.e. a spread spectrum clock is used), but the integration and sampling times are kept constant over the conversion time. The clock is therefore asymmetric. Again, this satisfies the assumption that the charge transfer functions T 1 , T 2 are constant over the conversion period.
[0043] The charge transfer functions, T 1 and T 2 , are functions of time and depend upon the electrical characteristics of the sensor. If these characteristics are known (for example from calibration measurements) an absolute value of the sensed capacitance may be obtained. Otherwise, since the scaling factor
[0000]
1
T
1
T
2
[0000] is constant, the expression may be used to compare a number of capacitive elements with similar charge transfer characteristics—such as the elements of a capacitive touch screen.
[0044] FIG. 7 is a graphical representation of a first clock signal 502 , a second clock signal 504 and an integrator voltage 406 in a capacitance-to-digital converter in accordance with some embodiments of the invention. In FIG. 7 , the first clock signal 502 and the second clock signal 504 have variable duration clock cycles. However, the sample interval Ts and the integration interval Ti are constant from one cycle to the next during a conversion. As a result, the change in the integrator voltage 406 depends only on the comparator output signal, and is independent of the clock cycle period, even though the sensed capacitive element may not have time to fully charge and discharge (in the figure, the integrated voltage level is still rising or falling at the end of each integration period).
[0045] FIG. 8 is a simplified block diagram of a touch and proximity sensor in accordance with some embodiments of the invention. The sensor comprises a number of row elements, R 1 , R 2 , R 3 , . . . , R m , and a number of column elements C 1 , C 2 , C 3 , . . . , C n , arranged to form a grid. The elements may be positioned in a touch screen of a portable electronic device, for example. A capacitance-to-digital converter 100 converters a capacitance of the sensor to a binary sequence 102 that may be filtered and decimated in digital filter 110 to provide a multi-bit, digital representation 804 of the capacitance. The digital representation 804 may be input to a processor to provide a man-machine interface, for example. The converter 100 supplies an excitation signal 106 that is amplified in amplifier 806 and fed to column switch 808 . The column switch is controlled to select the column element to which the excitation is applied. Similarly, a row switch 810 is controlled to select the row element that is to be sensed. The sensed signal 108 is passed back to the converter 100 . In operation, each row-column pair is selected in turn.
[0046] FIG. 9 is further block diagram of a touch and proximity sensor in accordance with some embodiments of the invention. FIG. 9 shows a more detailed view of a section of touch and proximity sensor. In this example, each row and each column comprise a connected line of diamond shaped conductors. The matrix of sensing elements is sometimes referred to as a Transparent Diamond Matrix and may be stacked on top of or integrated with a display of an electronic device. When a capacitive object, such as a finger, stylus, pen etc. is touching the sensor or is moved into the proximity of the sensor in a region 902 , the capacitance 904 between row and column elements in the region is increased. In the example shown, the capacitance is increased for the four element pairs (C i-1 , R j-1 ), (C i , R j-1 ), (C i-1 , R j ) and (C i , R j ). If the capacitive object is moved away slightly, more elements pairs will be affected, but the change in capacitance for each pair will be reduced. Thus, for sensing both touch and proximity, the converter 100 should be able to measure a wide range of capacitances. The use of an offset capacitance is one way of achieving this. Additionally, since the capacitance changes may be small, the converter should be insensitive to noise. Use of a variable speed clock reduces the converter's sensitivity to noise. Still further, for a sensor with a high spatial resolution, many element pair must be sensed for each position measurement, so it is advantageous for the converter sensor to have a short conversion time.
[0047] In one embodiment, the first and second clock signals are generated from a pseudo-random binary sequence or random binary sequence. An example is shown in FIG. 10 . A random or pseudo-random sequence 1002 is generated. Circuits for generating pseudo-ransom sequences are well known to those of ordinary skill in the art. At each rising edge of the pseudo-random sequence 1002 , a fixed duration pulse is generated in a first clock signal 502 . At each falling edge of the pseudo-random sequence 1002 , a fixed duration pulse is generated in a second clock signal 504 . In this manner, two interleaved, but uncorrelated, clock signals are obtained. These may be used as Φ 1 and Φ 2 (or Φ 2 and Φ 1 ). Other methods for generating the spread spectrum clock signals Φ 1 and Φ 2 will be apparent to those of ordinary skill in the art.
[0048] In the foregoing specification, specific embodiments of the present invention have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present invention. The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued.
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A capacitance-to-digital converter for an extended range of capacitances includes a reference capacitor and one or more offset capacitors. Electrical charge accumulated in the offset capacitors is used to at least partially cancel the charge accumulated in a sensed capacitance to facilitate matching with a charge accumulated in the reference capacitor. The residual charge is passed to an integrator, the output from which is quantized and used to control switching of the capacitors. Immunity to tonal external noises and improved conversion speed are achieved by controlling the capacitor switching with a spread spectrum clock. The capacitance-to-digital converter may be used, for example, for sensing of the capacitances of capacitive elements in touch and proximity displays or other user interfaces.
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BACKGROUND OF THE INVENTION
[0001] The invention concerns a rearview mirror arrangement, especially a lightweight mirror assembly for commercial vehicles.
[0002] Outside mirrors of this kind and of variously different construction are already known in the present state of the technology. A mirror pane is adjustably affixed by a pivoting mechanism to a housing part, which part is appropriately connected to the body of the vehicle, allowing the mirror to swing in reference to the housing part. The housing part is, as a rule, a solid plastic part, produced by injection molding. It is generally of a basin-like construction in which further mirror components or corresponding connection points for additions are installed. In particular, for large truck and bus mirrors, the carrying structure for outside mirrors is based on tubing or plates, which are affixed directly to the mirror holder which projects toward the vehicle body. This construction is disclosed by EP-A-0 590 510. The housing part serves then as a covering of the back side of the mirror plate and supports the pivoting mechanism. The housing also provides a streamlined sheathing of the outside mirror. Such construction is extremely expensive and heavy.
[0003] A problem with this tube and plate construction is that relatively strong vibrations occur in the rearview mirror assembly during the operation of the vehicle. In order to reduce these vibrations, EP 0 865 967 A2 proposes a carrying tube structure encased in a foamed molded part. Again, the disadvantage of this is that the entire carrying structure is heavy.
[0004] A very light design, which is adaptable to smaller mirrors, is taught by DE 44 29 604 A1. In this case, the tube construction is fully dispensed with and the foam element itself remains as the support structure. For this purpose, a gradiated foam is employed as a one-piece element or the element can be composed of several shells.
OBJECTIVES AND SUMMARY OF THE INVENTION
[0005] It is thus the objective of the present invention to make available a sufficiently stable rearview mirror which also offers the greatest possible reduction in vibration.
[0006] The achievement of this objective is accomplished by the features of the invention.
[0007] Since a blown, hollow plastic body, originating from a plastic blank, is used as a carrier, the result is a very light structure so that even in the case of a cantilevered mirror, or outboard carrier construction, the basic rigidity of the plastic hollow body assures a sufficient stability. At first, it appears doubtful that a blown plastic hollow body would exhibit sufficient stability to be used as a carrier for a rearview mirror arrangement for commercial vehicles. However, by means of the substantial reduction in the weight, the demands for achieving stability are likewise reduced, so that a blown plastic hollow body does indeed offer sufficient stability.
[0008] Because of the fact that the plastic blank is made with varying wall thicknesses, the corresponding wall thickness of the finished carrier, that is, the plastic hollow body, can be controlled to specification for location and thickness. That is, the wall thicknesses of the carrier is increased in locations of high stress, i.e. at the point of juncture with the vehicle body, while the thicknesses in zones of lesser stress may be reduced. Also, a grid-like rib structuring on the inner side of the plastic hollow body may be used to increase rigidity.
[0009] In accord with a further advantageous embodiment of the invention, the plastic hollow body encompasses a multitude of hollow spaces, which are enhanced by, for instance, inset pieces or correspondingly designed bubble formations. By these measures, the stability is additionally increased and also the possibility exists to fill specified hollow spaces with filling materials.
[0010] In accord with another advantageous embodiment of the present invention, the plastic hollow body is constructed in multiple layers, whereby, first, an increased stability is achieved, and second, outer layers can be provided, which are especially smooth and/or acceptable for high quality lacquering.
[0011] In accord with a further advantageous embodiment of the invention, the possibility exists of introducing, either in or to the hollow spaces, a stiffening structure whereby the rigidity of the carrier is additionally increased.
[0012] In accord with a further advantageous embodiment of the invention, a filling material for the hollow spaces comprises plastic foam, such as polyurethane (PU) foam, a gradient foam or a multi-component hard foam, which binds itself firmly to the inside wall of the hollow spaces and thus increases the stability of the carrier. Moreover, the harmonic vibratory properties of the carrier can be advantageously addressed by the appropriate choice of foam density or its degree of softness, so that during commercial driving the unavoidable vibrations are strongly damped and also as a result, less wear on the mirror assembly is incurred.
[0013] Additionally or alternatively, there may be injected into a portion of the hollow spaces, or into various hollow spaces, a viscous fluid mass, for instance a gel or a gelatinous filling material which will also favorably affect specific vibratory and damping characteristics.
[0014] In accord with a further advantageous embodiment of the invention, a granulate and/or sand may additionally or alternatively be placed in the hollow spaces. In this way, the fill material can comprise exclusively sand or granulate, or a mixture thereof, or yet a mixture with the above described gel, gelatine or foam. Once again, the stability is favored in a positive way and again the specific vibratory and damping characteristics can be advantageously controlled with attention to specifics.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Further details, features and advantages of the invention will become evident from the following description of a preferred embodiment. The description is made with the aid of the drawings. There is shown in:
[0016] [0016]FIG. 1 a a schematic sideview of a first embodiment of the invention with a carrier in the form of a blown plastic hollow body with a single, continuous hollow space,
[0017] [0017]FIG. 1 b a sectional view along the line A-A of FIG. 1 a ,
[0018] [0018]FIG. 2 a a perspective view of a second embodiment of the invention, with a rearview mirror, which possesses a carrier in the form of two bearing arms,
[0019] [0019]FIG. 2 b a sectional view along the line B-B of FIG. 2 a,
[0020] [0020]FIG. 3 a schematic sideview of a third embodiment of the invention with a carrier in the form of a plastic, hollow body with a multitude of hollow spaces, and
[0021] [0021]FIG. 4 a partial sectional view of a fourth embodiment of the invention with a carrier comprised of a blown plastic hollow body with added elements for rigidity.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] Reference will now be made in detail to the presently preferred embodiment of the present invention, examples of which are illustrated in the drawings. The examples are provided by way of explanation of the invention and are not meant as a limitations of the invention. For example, features illustrated or described as part of one embodiment can be used on another embodiment to yield yet a third embodiment. Accordingly, it is intended that the present invention include such modifications and variations.
[0023] [0023]FIGS. 1 a and 1 b schematically present a first embodiment of the invention. The rearview mirror arrangement encompasses a carrier 2 in the form of a plastic hollow body 2 , blown from an extruded plastic blank and having a closed wall 3 . On the vehicle end of the plastic hollow body 2 , screw holes 4 are provided, in order to affix the carrier 2 , i.e., the rearview mirror arrangement, to the vehicle body. On the distal end of the plastic hollow body 2 remote from the vehicle, a first mirror 6 and a second mirror 8 are mounted in respective recesses 7 and 9 . Both mirrors, 6 and 8 include, respectively, an adjusting mechanism 10 and 12 , by means of which the mirrors are secured to the plastic hollow body 2 . The wall 3 of the plastic hollow body 2 is thicker at locations of higher stress than at locations of more moderate stress (not shown).
[0024] The FIGS. 2 a and 2 b show a second embodiment of the invention with a carrier 20 in the form of a hollow plastic body. The hollow plastic body 20 includes a shell shaped mirror housing 22 and two carrier arms, respectively 24 and 26 , which are of one piece with the mirror housing 22 . The two carrier arms 24 and 26 are hollow, and exhibit respectively a hollow space 28 which is filled with filling material 27 . Preferably polyester urethane foam, gradient foam, multi-component foam and the like may be used as the filling material 27 . The carrier 20 possesses, on the distal end of the mirror housing remote from the vehicle, an additional hollow space 29 , the interior of which, likewise is filled with foam 27 . By filling the hollow spaces 28 and 29 with foam 27 , first, the stability is improved, since the foam binds itself to the interiors of the walls in the hollow spaces 28 and 29 , that is, adheres to the walls. Second, because of the foam the vibratory characteristics are positively influenced, that is, the vibration is damped.
[0025] [0025]FIG. 3 shows a third embodiment of the invention with a carrier 30 in the form of a hollow plastic body, wherein the hollow plastic body exhibits a plurality of bubble shaped hollow spaces 32 and 34 . In this case, the bubble shaped hollow spaces 32 are empty, while the bubble shaped hollow spaces 34 are at least partially filled with a filling material 36 . Because of the plurality of the hollow spaces 32 , 34 , first, the weight is reduced and second, by means of the dividing walls 33 between the hollow spaces 32 , 34 , the stability is increased. By filling of a portion of the hollow spaces, namely the hollow spaces 34 , with a filling material 36 , the vibratory properties of the mirror assembly are influenced in such a way, that less vibration occurs, that is to say, the vibrations are damped. Additionally, in the case of the third embodiment, carrier arms 38 are constructed of metal, by means of which the stability of the carrier 30 is additionally increased.
[0026] [0026]FIG. 4 shows a fourth embodiment of the invention, with a carrier 40 in the form of a plastic hollow body, by which on the interior walls of the plastic hollow body 40 , grid type stiffening ribs 42 are provided. These grid shaped, stiffening ribs 42 can be made by providing correspondingly different wall thicknesses in the plastic blank before the blowing of body in the blow mold. The grid shaped stiffening ribs 42 also contribute to the increase of the stability of the carrier 30 .
[0027] It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope and spirit of the invention. It is intended that the present invention includes such modifications and variations as come within the scope of the appended claims and their equivalents.
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A rearview mirror assembly blowmolded carrier for vehicles and method of blowmolding the carrier are provided. The mirror assembly has a blowmolded carrier with a hollow space and a recess to affix a mirror element.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a filter cartridge, in particular a suction filter cartridge, according to the preamble of claim 1 . The invention also comprises a seat element for such a filter cartridge. The inlet area and the outlet opening of the filter cartridge are arranged at the bottom area of the filter cartridge, which also includes a lateral inlet or outlet in a lower section of the inflow and outflow chamber adjacent to the bottom.
2. Description of Related Art
Suction filter cartridges are used in water vessels of automatic drink dispensers, e.g., for hot drinks, provided with a suction pump, such as e.g., coffee makers etc. The inlet and outlet openings of the suction filter cartridge are located in the bottom area of the otherwise completely enclosed cartridge housing. A seat element is arranged in the water vessel of the device, adjusted to the outlet opening, which may be a separate component or be formed at a water vessel. This seat element has an outlet opening as well, through which the filtered water can flow out of the water vessel. The seat element serves to accept the suction filter cartridge inserted into this seat element.
Due to the fact that the outlet opening of the water vessel is connected to the suction pump of the device, the water to be filtered is suctioned out of the water vessel, passes the filter medium or filter media in the cartridge, and reaches the outlet opening in a filtered state.
Due to the fact that the suction filter cartridge is arranged inside the water vessel of the device the filter cartridge floats when the water vessel is filled. In order to prevent floating and thus a separation of the filter cartridge from the outlet opening of the seat element of the water vessel special fastening means are provided. According to a known solution the suction filter cartridge is screwed onto the seat element. Here it is disadvantageous that suction filter cartridges with an asymmetrical filter housing cannot be screwed into narrow water vessels. Additionally, in deep and narrow water vessels tools are necessary to screw in the cartridge.
Another resolution provides for the suction filter cartridge to be placed onto the seat element and to turn over a clamping element after the insertion in order to fix the suction filter cartridge in its position.
From WO 99/01220 a suction filter cartridge is known, in which the water inlet opening is arranged at the bottom and a pass for water through the filter media is provided in the up-current. Furthermore, a downspout is provided for guiding the water downwards to an extraction connector of the water vessel located at the bottom. Here, the mixture of filter means comprising activated carbon and ion exchangers are floated during operation, counteracting any compression of the filter bed.
The downspout is arranged centrally inside the suction filter cartridge, so that the bottom connector of the suction filter cartridge can also occur centrally. Here, the inlet opening is arranged circularly in the suction filter cartridge.
An axial closing element is necessary to seal the outlet channel from the inlet channel.
The suction filter cartridge comprises at its bottom fixing elements, by which it can be connected to a seat element. Additionally it is necessary, though, that the suction filter cartridge is supported on the lid of the water vessel in order to prevent floating of the suction filter cartridge in a filled water vessel. Here, it may be necessary in deep water vessels to extend the suction filter cartridge at the top, e.g. by a rod.
Such additional securing elements are frequently not arranged correctly, thus the tight seat on the seat element is not ensured.
BRIEF SUMMARY OF THE INVENTION
Therefore, the object of the invention is to provide a filter cartridge, in particular a suction filter cartridge, which goes without any additional securing elements, can be inserted in a simple manner, and ensures a reliable seal in the area of the outlet opening.
This object is attained in a filter cartridge, in which a snap-on rim is provided in the outlet opening, pointing inwardly, which can be turned down from a first lower snap position into an upper second snap position and vice versa.
The corresponding seat element is characterized by a connecting sleeve engaging the outlet opening of the filter cartridge, having at least one actuator, which moves the snap-on rim from the first lower snap position into the second upper snap position when placed onto the filter cartridge, in which the snap-on rim contacts the connecting sleeve in a sealing and clamping manner.
Preferably the actuator is a circular shoulder arranged at the connecting sleeve.
The filter cartridge with the snap-on rim situated in the lower snap position is placed onto the seat element from the top and pressed downward until the snap-on rim turns upwards and hereby engages the connecting sleeve of the seat element. The seat element is adjusted to the snap-on rim such that with a turned-over snap-on rim the filter cartridge contacts the connecting sleeve in a sealing manner and is fixed. The turn-over signals to the operator that the filter cartridge has taken its predetermined sealing position. This prevents a faulty positioning by the operator.
In order to remove the filter cartridge it is only pulled out upwards, which turns the snap-on rim back into its lower snap position.
Preferably the outlet opening is provided with an outlet sleeve, with a snap-on rim being linked to its lower end. The snap-on rim may be linked via a film link.
The snap-on rim is preferably a flat edge strip extending radially inward.
The edge strip is preferably embodied as a ring.
The snap-on rim settles in two stable positions, namely a lower position and an upper one. The intermediate position of the snap-on rim is an unstable position, from which based on its tension it automatically turns into one or the other position. The snap-on rim advantageously comprises an elastic plastic.
By the turn-over process of the snap-on rim radial forces act upon the outlet sleeve, which may lead to a widening and perhaps to a reduction of the clamping forces in the upper second snap position. Therefore, it is advantageous for the outlet sleeve to be surrounded by a circular stabilizer.
Advantageously the circular stabilizer is provided with an angled collar protruding into the outlet opening, which the snap-on rim contacts in the first lower snap position. This ensures a defined original position for the snap-on rim.
Preferably the circular stabilizer is arranged rotary at the outlet sleeve. The rotation of the circular stabilizer allows to provide an bypass adjustable in its cross-section, which connects the inlet area to the outlet opening.
The adjustable bypass is preferably sized such that not the entire crude water immediately flows from the inlet opening into the outlet opening. Preferably the bypass is designed such that no more than 50% of the crude water can be diverted to the outlet opening.
In particular, this is possible when the inlet area of the filter cartridge surrounds the outlet sleeve in a circular fashion.
According to a first variant the outlet sleeve is provided with at least one first opening. The circular stabilizer is provided with a cylindrical section contacting the outlet sleeve, at which preferably a closing element or in which preferably at least one second opening is provided, which can be aligned to the first opening. In this case the first and second opening(s) combined form the bypass opening(s).
By rotating the circular stabilizer the cross-section of the first opening of the outlet sleeve can be adjusted such that the added amount of the untreated crude water can be added to the water treated by the filter means in the filter cartridge, adjusted in a controlled manner. Using such a bypass the performance of the filter cartridge can be adjusted to the water quality such that the water best for the aroma and best for the automatic drink dispensers can be provided. Depending on the water quality found on the location of the automatic drink dispensers and the selected coffee brand entirely decarbonized water may not be optimal for the development of the aroma, and even the machine parts may be damaged. When decarbonization is not adjusted, in the worst case scenario, corrosion of the metal components may develop. Then the consequences are high maintenance and repair costs.
Additionally, the integrated bypass increases the capacity of the filter cartridge. When based on the water quality less performance is necessary, it is adjustable and the filter cartridge softens to the same level for a longer period of time.
Preferably the second opening of the circular stabilizer has a size that is greater than or equal to a size of the first opening of the outlet sleeve.
The circular stabilizer preferably contacts the outlet sleeve in a sealing manner. This prevents that in closed first openings unintentionally crude water can enter the outlet opening, in particular through the second openings of the circular stabilizer between the circular stabilizer and the outlet sleeve.
A second variant provides at least one bypass opening in the bottom wall of the outflow chamber. The bypass opening is preferably closed by a closing element arranged at the circular stabilizer, with the crude water amounts flowing through the bypass opening can be adjusted by way of rotating the circular stabilizers.
The closing element may be an arc-shaped collar arranged at a circular stabilizer, which preferably contacts the underside of the bottom wall of the outflow chamber in a sealing manner.
Instead of a closing element, similar to the first variant, the collar may be provided with one or more second opening(s), which can be aligned to the opening(s) in the bottom wall of the outflow chamber.
Different from the first variant, the crude water does not reach the outlet sleeve immediately, rather it is guided into the interior of the outflow chamber, allowing this crude water also to be filtered.
The extent crude water is guided into the interior chamber of the outflow chamber can be defined by the length of the riser surrounding a bypass opening. The lower section of the outflow chamber is therefore jointly used by the already filtered water and by the crude water introduced via the bypass opening.
The jointly used area may be provided with a fill of activated carbon for dechlorinizing the bypass water. Depending on the type and form of the fill material a separating layer may be provided on the fill, comprising a fleece, for example, in order to prevent any mixing with the filter means, arranged perhaps thereabove, e.g., made from an ion exchanging material.
This jointly used area inside the down-current chamber may also be separated by an intermediate floor not penetrable by liquids. In the chamber formed between the bottom and the intermediate floor a filter medium may be arranged, particularly an activated carbon fleece.
Both the up-current chamber as well as the down-current chamber may be provided with at least one filter means. It has shown advantageous for the up-current chamber to be provided with an fluidized bed and the down-current chamber with a packed bed. The advantage of the equipment of both filter chambers with filter means lies the fact that the risers and/or downspouts of prior art, extending over the entire height of the suction filter cartridge, can be omitted. The fluidized bed in the up-current chamber causes only a slight loss of pressure.
Advantageously the outlet sleeve and/or the circular stabilizer, are provided, preferably below the first opening, with at least one sealing bead extending around the perimeter such that any unintended bypass is prevented.
In a simple embodiment the seat element may be provided with a base plate, at which the connecting sleeve is arranged.
At least one spacer is arranged on the base plate in order to allow or to facilitate the inflow of crude water into the filter cartridge. When inserting the filter cartridge it rests to the spacer.
Furthermore, at least one positioning element may be provided on the base plate in order to facilitate the insertion of the filter cartridge on the seat element.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The foregoing summary, as well as the following detailed description of preferred embodiments of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the following, exemplary embodiments of the invention are explained in greater detail using the drawings. A suction filter cartridge is described as an example for the filter cartridge according to the invention. It is shown:
FIG. 1 a perspective view of a suction filter cartridge having an attached seat element,
FIG. 2 a a vertical cross-section through FIG. 1 showing a filter cartridge with an attached seat element,
FIG. 2 b an enlarged representation of the outlet area of the suction filter cartridge shown in FIG. 2 a,
FIG. 3 a vertical cross-section through the suction filter cartridge shown in FIGS. 1 and 2 a, b , without a seat element,
FIG. 4 an enlarged perspective representation of the lower section of the suction filter cartridge shown in FIGS. 1 through 3 , partially in a cross-section,
FIG. 5 a perspective top onto of seat element shown in FIGS. 1 and 2 a, b,
FIG. 6 an enlarged cross-section of the lower area of the suction filter cartridge according to another embodiment,
FIG. 7 a perspective bottom view to the outlet opening of the suction filter cartridge.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 a suction filter cartridge 1 is shown in a side view. The suction filter cartridge 1 has a central housing part 2 , which has the down-current chamber 2 a , and a housing part 3 laterally mounted to the housing part 2 . The off-set arrangement of the housing parts 2 and 3 serves the purpose that the up-current and down-current chambers can be embodied with a large volume at a narrow width of the water vessel.
The suction filter cartridge 1 is supported on a seat element 30 , which is located in or at the outlet opening of the water vessel (not shown). The suction pump, not shown either, is connected to the outlet opening. During operation water is suctioned out of the water vessel into the suction filter cartridge 1 and removed through the outlet opening. The seat element 30 may also be an integral component of the water vessel. The seat element 30 has a base plate 31 , on which position elements 32 are arranged in an annular manner, which will be described in greater detail in the following.
FIG. 2 a, b show a vertical cross-section through the suction filter cartridge 1 with an attached seat element 30 . In the central housing part 2 there is a down-current chamber 2 a , which may be filled with a packed bed made from a filter material. An up-current chamber 3 a is located in the attached housing part 3 with the bottom wall 3 b , which may comprise a fluidized bed made from a filter material. This up-current chamber 3 a is separated by a vertically arranged separating wall 6 from the down-current chamber 2 a . In the embodiment shown here the separating wall 6 is a component of the circumferential wall of the down-current insert 9 , which is additionally provided with a bottom wall 7 with a centrally arranged floor grid 8 . Both chambers 2 a , 3 a are connected to a connection opening 5 via a connection chamber 4 arranged in the upper area of the suction filter cartridge 1 .
The inlet area 10 is arranged in the lower section of the suction filter cartridge 1 , embodied as a circular channel 12 . Said circular channel 12 is formed by a circular wall 11 , protruding downwards from the central and attached housing 2 , 3 , and an outlet sleeve 21 surrounding the outlet opening 20 of the down-current chamber 2 a . The circular chamber 12 mouths in empties into the up-current chamber 3 a via a grid 13 in the bottom wall 3 b . The grid 13 is provided with the inlet openings 14 .
The outlet sleeve 21 is provided with first openings 25 , connecting the inlet area 10 and/or the circular channel 12 with the outlet opening 20 . This represents slot-shaped openings 25 , arranged distributed over a section of the perimeter of the outlet sleeve 21 . At the lower end of the outlet sleeve 21 a closed circular snap-on rim 22 is linked via a film link 23 , which protrudes radially inward into the outlet opening 20 . At the exterior wall of the outlet sleeve 21 a circular stabilizer 50 is arranged, having a cylindrical section 51 and a collar 52 , inclined at an angle towards the inside. In the cylindrical section 51 second openings 53 are arranged (also see FIG. 4 ), which can be aligned by rotating the circular stabilizer 50 to the first openings 25 . The first and second openings 25 , 53 together form the bypass openings.
The seat element 30 is provided with a connecting sleeve 33 surrounding its outlet opening 37 , comprising a lower section 33 a and a section 33 b with its diameter being reduced. A circular shoulder 35 , pointing upwards in an inclined fashion, is arranged between the two sections 33 a , 33 b , forming the actuator for the snap-on rim 22 . Bars 34 span over the outlet opening 37 at the upper section 33 b.
When placing the suction filter cartridge 1 onto the seat element 30 the snap-on rim 22 is grasped by the circular shoulder 35 and turned upward into the second snap position, in which it contacts the section 33 b of the connecting sleeve 33 in a sealing and clamping manner, thus fixing the suction filter cartridge 1 . The exterior diameter of section 33 b is slightly larger than the interior diameter of the snap-on rim 22 in its second snap position, in order for the desired clamping forces to develop. Additional closing elements are unnecessary.
When the water vessel is filled and/or the suction pump is switched off the suction filter cartridge cannot float. Additional fixing or fastening means for the suction filter cartridge 1 are therefore not necessary.
The seat element 30 is provided with positioning elements 32 , comprising the towering centering elements 32 a and the spacers 32 b . The circular wall 11 of the suction filter cartridge 1 is supported on the spacers so that crude water can flow into the suction filter cartridge 1 through the intermediate space between the base plate 31 and the circular wall 11 . This way, inlet channels 36 are formed (see FIG. 2 b ) between the positioning elements 32 .
In FIG. 3 the suction filter cartridge 1 is shown with the snap-on rim 22 in its lower snap position, in which the snap-on rim 22 is supported on the collar 52 of the circular stabilizer 50 . In order to seal the gap between the circular stabilizer 50 and the outlet sleeve 21 the circular stabilizer 50 is provided with an encircling sealing bead 24 at the cylindrical section 51 .
In FIG. 4 the lower section of the suction filter cartridge 1 is shown enlarged and in a perspective. The rotary circular stabilizer 50 is provided with second openings 53 , which are located opposite to the first openings 25 . By rotating the circular stabilizer 50 these second openings 53 can be aligned to the first openings 25 . Depending on the level of overlapping of the openings 25 , 53 more or less crude water can be guided from the inlet area 10 directly into the outlet opening 20 .
The seat element 30 is shown in a perspective in FIG. 5 . It is discernible that the connecting sleeve 33 is surrounded by an annulus of positioning elements 32 .
FIG. 6 shows the lower section of a suction filter cartridge 1 according to another exemplary embodiment relating to the bypass openings. Differently from the previously described embodiments, here at least one bypass opening 26 , preferably embodied as bores in the bottom wall 21 a , connect the outlet sleeve 21 with the circular wall 11 . This bottom wall 21 a is also shown in FIGS. 2 a , 2 b , 3 , and 4 , with the bottom wall 7 of the down-current insert 9 resting on said bottom wall 21 a . In the embodiment shown in FIG. 6 the bottom wall 7 is omitted so that the bottom wall 21 a closes the down-current chamber 2 a at the bottom. The crude water flowing into the circular channel 12 through the bypass openings 26 , with in FIG. 6 only one bypass opening 26 being shown, is not guided immediately into the outlet opening 37 but into the interior of the down-current chamber 2 a , provided at a distance from the bottom wall 21 a with an intermediate floor 7 a permeable by liquids. The permeability of the intermediate floor 7 a is limited to a central area 7 ′. By said intermediate floor 7 a another chamber 60 is separated in the lower section of the down-current chamber 2 a . Inside said chamber 60 risers 27 are arranged bypassing the bypass openings 26 . The crude water is guided upwards through these risers 27 and deflected by the not permeably circular area 7 ″ of the intermediate floor 7 a . In chamber 60 a filter material may be arranged, for example a fleece, which is held by needles 15 .
In order to close and/or release the bypass openings 26 , the circular stabilizer 50 is provided with a closing element 54 at the upper edge, which is formed to the circular stabilizer 50 . In order to prevent unintentional bypassing this closing element 54 contacts the underside of the bottom wall 21 a in a sealing manner. The closing element 54 comprises an arc-shaped collar, as discernible from FIG. 7 . By rotating the circular stabilizers 50 the bypass openings 26 may be released or closed.
In FIG. 7 a perspective bottom view to the outlet opening 20 of the suction filter cartridge 1 is shown. The collar 52 is provided with markings 55 showing the operator the present position of the circular stabilizer 50 . The circular stabilizer 50 may be rotated by the operator via corrugation, so that he/she can adjust the desired amount of liquids that shall be deflected into the outlet opening 20 . Additionally the closing element 54 is shown as an arc-shaped collar of the circular stabilizer 50 .
LIST OF REFERENCE CHARACTERS
1 Suction filter cartridge
2 Central housing part
2 a Down-current chamber
3 Attached housing part
3 a Up-current chamber
3 b Bottom wall
4 Connecting chamber
5 Connecting openings
6 Separating wall
7 Bottom wall
7 ′ Permeable section
7 ″ Impermeable section
7 a Intermediate floor
8 Bottom grid
9 Down-current insert
10 Inlet area
11 Circular wall
12 Circular channel
13 Grid
14 Inlet opening
15 Needles
20 Outlet opening
21 a Bottom wall
21 Outlet sleeve
22 snap-on rim
23 Film link
24 Sealing bead
25 First opening
26 Bypass opening
27 Riser
30 Seat element
31 Base plate
32 Positioning element
32 a Centering element
32 b Spacers
33 Connecting sleeve
33 a Lower section
33 b Upper section
34 Bar
35 Circular shoulder
36 Inlet channel
37 Outlet opening
50 Circular stabilizer
51 Cylindrical section
52 Collar
53 Second openings
54 Closing element
55 Marking
60 Chamber
It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is 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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The invention relates to a filter cartridge ( 1 ), especially a suction filter cartridge, which is provided, in the outlet opening ( 20 ), with an inward-pointing, peripheral snap-on rim ( 22 ) which can be folded from a first lower snap position into a second upper snap position and vice versa. The invention also relates to a seat element ( 30 ) for such a filter cartridge, comprising a connection sleeve ( 33 ) which engages with the outlet opening ( 20 ) of the filter cartridge ( 1 ). Said connecting sleeve ( 33 ) comprises at least one actuator which displaces, when the filter cartridge ( 1 ) is placed on the rim, the snap-on rim from a first lower snap position to the second upper snap-on rim from a first lower snap position to the second upper snap positioning which the snap-on rim rests against the connecting sleeve ( 33 ) in a sealing and clamping manner.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to providing a cover that both cushions and provides a finished surface for a pole. More specifically, the present invention relates to cushioning and covering a lally column of the type found in the basement of a residence or office. Further, the invention relates to cushioning and covering various types of cylindrical poles where it is desired to provide a finished exterior surface and at the same time cushion the pole.
2. Brief Description of the Prior Art
In conventional residential and commercial construction, the structure's first floor is typically supported by a foundation that runs around the periphery of the building as well as by a number of lally columns that support horizontal joists, which in turn support the flooring above the joists. These lally columns are typically cylindrical steel poles having a height of about 71/2 feet and a diameter of 2 to 12 inches. Typically, one end of the lally column supports the joist above and the other end is supported by the concrete floor of the basement. Further, lally columns can be used in types of environs other than basements.
The steel lally columns are often finished with paint. The steel lally columns tend to weather or rust because they are stored outside in construction yards prior to installation in buildings. Thus, the exterior surfaces lally columns are rough and unsightly. When a basement room is being finished to create a recreation room, in the case of a house, or a storage room, in the case of a commercial building, the lally columns present a hazard. More specifically, in a basement recreation room, children tend to play games or ride tricycles, and a steel lally column presents a serious risk of injury.
Steel poles are also used in environs other than in basements or as lally columns. More specifically, steel poles are used to support basketball backboards and rims, volleyball nets and other sports equipment. It would be desirable to cushion the poles against the impact of humans playing sports in the area adjacent the pole.
In the case of a basketball backboard support pole, these poles are wrapped with a thick pad of foam rubber encased in a vinyl fabric cover. The foam pads are held in position with buckles or other attachment means that are unsightly and bulky. U.S. Pat. No. 3,181,849 discloses a shock absorbing guard for a pole which is made of a molded rubber composition or a synthetic rubber product. The cylindrical pad is attached to the pole with two plates that are screwed together. The shock absorbing guard disclosed in this patent would be very expensive to manufacture and would be unsightly because of the method of attachment and would absorb moisture due to the nature of material used. Various types of pole covers are disclosed in the following patents: U.S. Pat. No. 5,006,386 to Menichini; U.S. Pat. No. 3,884,495 to Petock; U.S. Pat. No. 5,173,990 to Owen; and U.S. Pat. No. 4,606,167 to Thorne. All of these patents disclose complicated pole guards that result in unsightly and cumbersome attachment mechanisms. In the heating and plumbing field, it is often desirable to jacket pipes to insulate for heat loss. The following U.S. Patents disclose pipe coverings in the non-analogous field of plumping, which covers would not be suitable for finishing and providing a cushion for a lally column, a basketball pole or similar pole support: U.S. Pat. No. 1,811,984 to Taft; U.S. Pat. No. 4,605,043 to Grenier; U.S. Pat. No. 4,748,060 to Fry et al.; and U.S. Pat. No. 3,560,287 to Helling.
It is an object of the present invention to provide a cushioned pole cover and method of applying the cover so that lally columns in existing structures can be finished. It is a further object of the invention to provide a kit for covering a lally column wherein the height of the cover can be sized to the height of the lally column.
It is a further object of the invention to provide a method of covering a pole that can be done by an unskilled person using common household tools, such as scissors and the like. It is a further object of the invention to provide a cover that is inexpensive to produce, that is relatively lightweight and that can be shipped in a compact form.
It is a further object of the invention to provide a cover that has a high gloss smooth surface that is made of a tough, durable material, and preferably a material that is maintenance free and easy to clean. It is a further object of the invention to cover the pole with materials that will not absorb moisture.
It is also an object of the invention to provide a kit for covering a lally column or other pole that can be installed in a few minutes. It is a further object of the invention to provide a cushioning cover that will cushion impact and will maintain its shape after impact.
SUMMARY OF THE INVENTION
In accordance with the present invention a kit for cushioning and finishing a lally column or other pole is provided. The kit comprises a first sheet of cushioning material having a generally rectangular shape and having a width at least equal to the circumference of the pole to permit the sheet to be wrapped around the pole. It is preferred that the sheet of cushioning material be wrapped around the pole approximately two times and that the material be made from flexible closed cell plastic film, also referred to as "bubble wrap."
A second sheet of cushioning material preferably having substantially the same rectangular shape and dimensions as the first sheet is provided and also has a width at least equal to the circumference of the pole to permit the sheet to be wrapped around the pole, preferably approximately two times. The first and second sheets have a combined height that is greater than the height of the pole. During installation of the first and second sheets, the first sheet is placed so that one edge abuts the floor, and the first sheet is wrapped tightly around the pole and secured to the pole by the use of adhesive tape. The second sheet is wrapped loosely around the pole and pushed to the top of the pole so the top edge of the sheet abuts the ceiling. In the case of a lally column, this will create an overlap of the second cushion sheet over the first cushion sheet. The second sheet is marked at the place where it begins to overlap the first sheet and is cut along such marking with a common household pair of scissors. Once the second sheet is cut to the desired height, it is then wrapped tightly around the pole and secured in place with adhesive tape. Thus, the pole is now cushioned, and a cover is placed on the pole.
A first cover sheet is provided and has a width greater than the circumference of the cushioned pole. A second cover sheet is provided and has a width greater than the circumference of the cushioned pole. The cover sheets are preferably made of a thin polymeric material, and most preferably polyvinyl chloride sheeting having a thickness of between about 0.01 and about 0.1 inch, most preferably about 0.015 to about 0.05 inch. An adhesive is located on the interior surface of both of the cover sheets and adheres the cover sheets to the cushioned sheets to provide a smooth and generally uniform exterior surface for the pole. Preferably, the combined height of the first and second cover sheets is substantially greater than the height of the lally column, and one of the cover sheets overlaps the other.
In accordance with the method of installation, the first cover sheet is placed with its bottom edge abutting the floor, and the first cover sheet is wrapped tightly over the cushion material which has already been applied to the pole. The first cover sheet is adhered to the first cushion sheet by the adhesive on the interior surface of the cover sheet. The second cover sheet is located so that its top edge abuts the ceiling of the basement, and the second cover sheet is wrapped tightly over and adhered to the second sheet of cushion material. Because the combined height of the first and second cover sheets is greater than the height of the lally column, a substantial overlap is provided, thereby providing a smooth, nearly continuous surface. Since the exterior surface of the polymeric cover sheet is preferably finished in a smooth, attractive manner, once the cover sheets are applied to the cushion sheets, the pole is finished.
Preferably, the adhesive on the inside of the cover sheets is self-stick adhesive applied along at least one edge, and preferably three edges of each of the first and second cover sheets. A removable release tape is placed over the adhesive and may be removed to expose the adhesive during application of the cover sheets.
A person installing the kit can install a cover in five to ten minutes with standard household tools such as a pair of scissors.
The bubble wrap material is thin and can be easily cut with a conventional pair of scissors and can be sized to the desired height of the lally column. The tough cover sheets, which are preferably made of polyvinyl chloride sheet plastic, need not be cut nor measured to fit and may be installed in an overlapping fashion. The cover sheets are made of a tough, abrasion resistant plastic which covers the pole and protects the underlying bubble wrap. Thus, when the covered pole is impacted by a person or object, the cover sheet flexes inwardly against the underlying bubble wrap and cushions the impact. Because the cover sheets have some resiliency, they will return to the original shape after impact.
The kit includes two cushion sheets and two cover sheets as well as instructions, and may optionally include adhesive tape. The four sheets of material may be tightly wound together and wrapped in a cylindrical package, thus simplifying shipment of the product and ease of transport by the consumer.
These and other advantages of a kit for cushioning and finishing a pole and a method of finishing a pole will be apparent from the following detailed description of the invention with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a lally column that has been covered with a kit for cushioning and finishing a pole;
FIG. 2 is a perspective view of a pole wherein the pole is being covered in accordance with the first step of the method of applying a cushion sheet;
FIG. 3 is a perspective view of a pole wherein the pole is being covered in accordance with the second step of the method of applying a cover;
FIG. 4 is a perspective view of a pole wherein the pole is being covered in accordance with the third step of the method of applying a cover;
FIG. 5 is a perspective view of a pole after a kit for cushioning and finishing the pole has been applied; and
FIG. 6 is a sectional view along the plane 6--6 of FIG. 5.
DETAILED DESCRIPTION
Referring to FIG. 1, a pole covered in accordance with the present invention is shown. A lally column 10 is of the type that is typically found in the basement of a residence or commercial building and comprises a cylindrical steel pole that is supported on a concrete floor 12. The upper end of the pole 10 supports a joist 14. In the basement of a typical residence, there may be as few as six and as many as 30 lally columns for supporting the floor joists 14. The lally column typically has a height of between about 6 and about 10 feet, and a typical height for a lally column used in the United States is about 71/2 feet. A lally column has an external diameter of between about 2 and about 12 inches. A typical lally column used in the United States has an exterior diameter of approximately 4 inches. As shown in FIG. 1, the cover sheet and the cushioning material is broken away at the upper region of the covered pole to expose the internal construction of the pole cover. Referring to FIGS. 2-4, the method of applying the kit for cushioning and finishing the pole will be described in detail, with each of the components described in detail.
Referring to FIG. 2, the pole 10 is first wrapped with a first sheet of cushioning material 16 that has a rectangular shape having a width at least equal to the circumference of the pole 10 to permit the sheet to be wrapped around the pole 10 completely. Preferably, the sheet of cushioning material 16 is wrapped around the pole 10 approximately two times. The sheet 16 has a height 18. A second sheet of cushioning material 20 is provided and preferably has the same dimensions as the first sheet 16. The sheet 20 preferably has a height 22 that is equal to the height 18 of the first cushioning sheet 16. As shown in FIG. 1, the lally column pole 10 has a height 24. Preferably, the combination of heights 18 and 22 is larger than the height 24 of pole 10.
Referring to FIG. 2, the first cushioning sheet 16 is placed on the pole 10 and tightly secured in position with adhesive tape 26 that may optionally be supplied with the kit. Once the first cushion sheet 16 is placed in position, the second cushion sheet 20 is wrapped loosely around pole 10 as shown by arrow 28. The upper edge 30 of the top cushion sheet 20 is placed against the under surface of joist 14 (joist 14 is shown in FIG. 1), and thus, the second cushion sheet 20 will overlap slightly with the first cover sheet 16. The person installing the second cushion sheet 20 will mark with a pen the position of overlap, and a line 32 will be drawn on the sheet 20 of cushion material, defining an overlap segment 34. The installer will then cut the sheet 20 with a pair of scissors or other conventional cutting tool to remove segment 34 of sheet 20. Once the segment 34 has been removed, the sum of heights 18 and 22 of sheets 16 and 20 will be equal to the height 24 of pole 10, and then the second cover sheet 20 can be wrapped tightly around the pole 10 and secured in place with adhesive tape 26. In the case of a drop ceiling or raised floor, the height 24 would be the distance between the floor and the ceiling.
Cushion sheets 16 and 20 are preferably flexible closed cell plastic film, also referred to as "bubble wrap." The plastic film is made from the primary component polyethylene and has air pockets or bubbles spaced throughout the surface of the material. Preferably, the material includes nylon in a weight percent of five percent or more. The nylon increases the bursting strength and reduces the loss of air from inside the bubbles. The thickness of the material ranges from about 0.2 inch to about 1 inch. The flexible closed cell plastic film is quite useful in connection with the cover of the present invention, because it is relatively inexpensive, generally available, and can be cut with ordinary household tools such as scissors or a knife. When wrapped around a pole at least one time, and preferably two times, the flexible closed cell plastic film provides an excellent cushion. However, the flexible closed cell plastic film is not sufficiently durable to be used as an exterior surface. More specifically, the material that forms the closed cell bubbles is thin polymeric material, more particularly, a thin polyethylene material, and may puncture or pop under pressure.
Referring to FIG. 3, the next step in the process of applying a cover will now be described. A first cover sheet 38 is secured to the bottom of the pole 10. The cover sheet 38 has a width greater than the circumference of the cushioned pole 10. The first cover sheet 38 has a height 40 which is preferably between 3 and 5 feet, and most preferably 4 feet. A second cover sheet 50 is provided and preferably has the same dimensions as the first cover sheet 38. The cover sheets 38 and 50 have an interior surface 42 that has an adhesive 44 applied to the surface 42. More specifically, the adhesive strip 44 runs along at least one edge 46 of the cover sheets 38 and 50. Preferably, the strips of adhesive 44 run along three edges 46, 48 and 49 of cover sheets 38 and 50. The adhesive strip 44 is covered with a release tape 52 that may be peeled away as shown by arrow 54 in FIG. 3. When cover sheet 38 is placed upon the pole 10, it is wrapped tightly around the cushion sheet 16 and adhered in place with adhesive strip 44, as shown particularly well in FIG. 4.
As shown in FIG. 4, the second cover sheet has a height 56. Preferably, the combined height 40 and 56 of the two cover sheets 38 and 50 is substantially greater than the height 24 of the pole 10. Thus, as shown in FIGS. 4 and 5, when the top edge 58 of the cover sheet 50 is placed adjacent the underside of the joist 14, the bottom of cover sheet 50 overlaps cover sheet 38 by at least several inches.
The cover sheets 38 and 50 have beginning edges 39 and 51 that are aligned when installed so that the finishing edges 37 and 47 also align.
The cover sheets 38 and 50 preferably have the same width and height, although this is not necessary. In the most preferred embodiment of the invention, the height 18 of cushion sheet 16, the height 22 of cushion sheet 20, the height 40 of cover sheet 38 and the height 56 of cover sheet 50 are substantially equal. When a kit containing the various components is shipped, the two cushion sheets and the two cover sheets are wrapped together, and form a lightweight package that can be shipped inexpensively.
The cover sheets 38 and 50 are preferably made from a thin polymeric material that is abrasion resistant, and that is resilient so that when it is impacted, it will return to its original shape. In accordance with a preferred aspect of the invention, a thin sheet made from polyvinyl chloride is preferred. It is preferred that the polymeric material have a thickness of between about 0.01 inches and about 0.1 inches. It is most preferred that the thickness be in the range from about 0.015 to about 0.05 inch. Preferably, cover sheets 38 and 50 have precurled memory, so that they wrap around the pole 10 readily and will package readily. More specifically, during manufacture, the polymeric sheet is formed in an arc and heated during the manufacture of the sheet to put a permanent curl in the sheet. Thus, when the sheets 38 and 50 are wrapped around the cushioned pole, the sheet is very easy to handle and apply.
The kit has been described for use with a pole such as a lally column in a basement. However, the pole could be any type of column and could in fact have a non-cylindrical shape. More specifically, because the cushion material is flexible and the cover sheets 38 and 50 are flexible, if the kit is applied to a rectangular or square pole, the cover sheets 38 and 50 and the cushioned sheets 16 and 20 will deform and provide a clean, smooth cover which softens the corners of the rectangular or square column.
In addition, while the kits are particularly suited for covering a cylindrical column having a 4 inch diameter and a 71/2 foot height, it should be understood that it may be desirable for a user to purchase two kits when applying the product to a pole that has a greater height. More specifically, if the pole had a height of 15 feet, two kits could be utilized. If one wanted to cover two poles each having a height of about 10 feet, the user could purchase three kits and apply three cushion sheets and three cover sheets to one 10-foot pole and apply the other three cover sheets and cushion sheets to the other pole. In addition, while it is desirable to provide a kit with two cover sheets and two cushion sheets, it is possible to provide a kit with three or more cushion sheets and cover sheets.
Further, if one chooses to cover a pole that has a substantially greater diameter than 4 inches, multiple kits could be used. More specifically, if one were attempting to cover a 71/2 foot pole, but the pole was 8 inches in diameter, it would be possible to cover such a pole using additional cover sheets and cushion sheets.
A kit for covering a pole in accordance with the present invention is particularly useful in covering lally columns. The kit has four major components, which can be installed in just a few minutes. Further, the kit does not require any specialized tools and simply requires a device for cutting the flexible closed cell plastic film. While the pole cover has been described with respect to a lally column wherein the column has a predetermined height, the kit may also be used in connection with a pole where it is desired to finish and cushion the pole. More specifically, the kit can be used to cover a basketball support pole, volleyball stansions and other devices utilized in sporting events. The kit is particularly easy to ship, because it can be packaged by tightly winding the four major components into a cylinder, shrink wrapping the cylinder, and shipping the cylinder with the instructions and labeling under the shrink wrap. Because the kit is compact, the kits can be shipped in multiple units.
It should be understood that the foregoing is illustrative and not limiting and that obvious modifications may be made by those skilled in the art without departing from the spirit of the invention. Accordingly, reference should be made primarily to the accompanying claims, rather than the foregoing specification, to determine the scope of the invention.
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A method and a kit for cushioning and covering a pole is disclosed. First and second sheets of cushioning material are wrapped around a pole, with the second sheet of cushioning material being cut to fit the height of the pole. A first cover sheet is applied to the cushion sheet and is secured in place to cover a portion of the pole. A second cover sheet is applied to the cushion sheet and overlaps the first cover sheet to finish the pole, thereby providing a cushioned pole that is covered with an abrasion resistant, tough cover.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of copending U.S. patent application Ser. No. 10/215,815, filed on Aug. 9, 2002, which is hereby incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
1) Field of the Invention
The present invention relates to apparatuses and methods for forming thermoplastic materials and, more specifically, to apparatuses and methods for bending thermoplastic sheets to form ducts, channels, arcs, spirals, and the like.
2) Description of Related Art
Longitudinal passages such as ducts, channels, arcs, spirals, and the like are used to provide passageways for a wide variety of applications. For example, tubular ducts are widely used for air flow in aircraft environmental control systems. Similarly, ducts provide passageways for transporting gases for heating and ventilation in other vehicles and in buildings. Water distribution systems, hydraulic systems, and other fluid networks also often use ducts for fluid transport. In addition, solid materials, for example, in particulate form can be delivered through ducts and channels. A variety of longitudinal shapes can also be used as conduits in which electrical wires or other components are placed. Such longitudinal passages for the foregoing and other applications can be formed of metals, plastics, ceramics, composites, and other materials.
One conventional aircraft environmental control system utilizes a network of ducts to provide air for heating, cooling, ventilation, filtering, humidity control, and/or pressure control of the cabin. In this conventional system, the ducts are formed of a composite material that includes a thermoset matrix that impregnates, and is reinforced by, a reinforcing material such as Kevlar®, registered trademark of E.I. du Pont de Nemours and Company. The thermoset matrix is typically formed of an epoxy or polyester resin, which hardens when it is subjected to heat and pressure. Ducts formed of this composite material are generally strong and lightweight, as required in many aircraft applications. However, the manufacturing process can be complicated, lengthy, and expensive, especially for ducts that include contours or features such as beads and bells. For example, in one conventional manufacturing process, ducts are formed by forming a disposable plaster mandrel, laying plies of fabric preimpregnated with the thermoset material on the mandrel, and consolidating and curing the plies to form the duct. The tools used to mold the plaster mandrel are specially sized and shaped for creating a duct of specific dimensions, so numerous such tools must be produced and maintained for manufacturing different ducts. The plaster mandrel is formed and destroyed during the manufacture of one duct, requiring time for curing and resulting in plaster that typically must be removed or destroyed as waste. Additionally, the preimpregnated plies change shape during curing and consolidation and, therefore, typically must be trimmed after curing to achieve the desired dimensions. The jigs required for trimming and for locating the proper positions for features such as holes and spuds are also typically used for only a duct of particular dimensions, so numerous jigs are required if different ducts are to be formed. Like the tools used for forming the mandrels, the jigs require time and expense for manufacture, storage, and maintenance. Additionally, ducts formed of conventional thermoset epoxies typically do not perform well in certain flammability, smoke, and toxicity tests, and the use of such materials can be unacceptable if performance requirements are strict. Further, features such as beads typically must be post-formed, or added after the formation of the duct, requiring additional manufacture time and labor.
Alternatively, ducts can be formed of thermoplastic materials. A thermoplastic duct can be manufactured by cutting a sheet of thermoplastic material to a size and shape that corresponds to the desired dimensions of the duct, bending the sheet to the desired configuration, and joining longitudinal edges of the sheet to form a longitudinal joint or seam. For example, apparatuses and methods for forming thermoplastic ducts and consolidation joining of thermoplastic ducts are provided in U.S. application Ser. Nos. 10/216,110 and 10/215,833, titled “Thermoplastic Laminate Duct” and “Consolidation Joining of Thermoplastic Laminate Ducts,” both filed on Aug. 9, 2002 and assigned to the Assignee of the present invention. Such thermoplastic ducts can be formed by retaining the thermoplastic sheet in the bent configuration until the ends are joined, and then releasing the duct so that the resulting joint continues to restrain the duct in the bent configuration. However, stresses induced in the thermoplastic material during bending can cause the duct to deform or distort from the desired configuration after joining, e.g., when released from the joining apparatus.
Thus, there exists a need for improved apparatuses and methods for forming a thermoplastic sheet to correspond generally to a desired configuration in a substantially unstressed condition. The method should not require the laying of individual plies on a disposable plaster mandrel. Preferably, the method should be compatible with thermoplastic ducts, including reinforced thermoplastic ducts formed from flat sheets, which provide high strength-to-weight ratios and meet strict flammability, smoke, and toxicity standards.
SUMMARY OF THE INVENTION
The present invention provides an apparatus and method for forming sheets to desired configurations. The sheets can be formed to the desired configuration of a finished shape such as an arc, channel, or spiral. Alternatively, each sheet can be formed as a preform that generally corresponds to the desired configuration of a finished shape such as a duct and is subsequently joined to form the finished shape. Joining can be accomplished by consolidation joining. The sheets can be formed from thermoplastic materials, such as flat sheets of reinforced thermoplastic laminate that are lightweight, strong, and perform well in flammability, smoke, and toxicity tests.
According to one embodiment of the present invention, the apparatus includes a rotatable roller, an elastically flexible shaper, and a heater. The apparatus can be used to hold the sheet in a predetermined configuration while the heater is used to heat the sheet. The shaper receives the thermoplastic sheet on one side so that rotation of the roller advances the shaper around the roller to bend the thermoplastic sheet. An index feature can be provided on the shaper for engaging the thermoplastic sheet so that the adjustment of the index feature toward the roller advances the thermoplastic sheet around the roller. The apparatus can also include a second shaper that is disposed on the thermoplastic sheet so that the second shaper is bent between the sheet and the roller and advancement of the second shaper toward the roller urges the thermoplastic sheet radially outward from the roller. Longitudinal members can be configured to adjust radially toward the roller to bend the thermoplastic sheet to a predetermined configuration.
According to another embodiment of the present invention, the apparatus includes at least two support members that extend, for example, in a longitudinal direction, to define at least one space therebetween. A shaper is configured to be disposed with one side against the support members so that the shaper extends across the at least one space. The shaper receives the thermoplastic sheet on a side opposite the support members and bends partially around the members, which can be adjustable. A heater is configured to heat the thermoplastic sheet to a processing temperature less than a glass transition temperature of the thermoplastic member and within about 70° F. of the glass transition temperature.
The present invention also provides a method of forming a thermoplastic sheet. According to one embodiment of the present invention, the thermoplastic sheet is disposed on a first side of a shaper. A longitudinal roller connected to the shaper is then rotated, for example, by at least one revolution, to advance the shaper circumferentially around the roller so that the thermoplastic sheet is disposed between the roller and the shaper and bent to a predetermined shape. Longitudinal members can be radially adjusted toward the roller to bend the thermoplastic sheet to a predetermined configuration. The shaper can be advanced toward the roller so that the shaper adjusts radially outward from the roller to define a maximum size for the thermoplastic sheet, for example, so that an index feature of the shaper engages the sheet and adjusts the sheet radially outward from the roller. According to one aspect, a second shaper is disposed on the sheet so that the second shaper is advanced around the roller between the sheet and the roller. The second shaper can be adjusted radially outward from the roller to urge the thermoplastic sheet to a predetermined configuration. The thermoplastic sheet is heated to a processing temperature, for example, within about 70° F. of a glass transition temperature of the thermoplastic sheet. The thermoplastic sheet can be cooled in the apparatus to a temperature below about 70° F. less than the glass transition temperature before the sheet is removed.
According to another embodiment of the present invention, at least two support members are provided with a space therebetween. A shaper is disposed on the support members so that the shaper extends across the space and bends partially around the support members to a predetermined shape. A thermoplastic sheet is disposed on the shaper and heated to a processing temperature. The thermoplastic sheet can be cooled to a temperature below about 70° F. less than the glass transition temperature of the thermoplastic sheet while the thermoplastic sheet and the shaper are disposed on the support members. The support members can be adjustable. According to one aspect, a second shaper can be disposed on the thermoplastic sheet opposite the first shaper and some of the support members can be adjusted in a direction toward the sheet so that the sheet is bent between the support members.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
FIG. 1 is a perspective view illustrating a forming apparatus according to one embodiment of the present invention;
FIG. 2 is a perspective view illustrating a formed sheet according to one embodiment of the present invention;
FIG. 2A is a perspective view illustrating a formed sheet according to another embodiment of the present invention;
FIG. 3 is a section view illustrating the forming apparatus of FIG. 1 , shown with the shaper in a first position;
FIG. 4 is a section view illustrating the forming apparatus of FIG. 1 , shown with the shaper advanced to a second position;
FIG. 5 is a section view illustrating a forming apparatus according to another embodiment of the present invention, shown with a second shaper disposed on the sheet and both shapers advanced to the second position;
FIG. 6 is a section view illustrating a forming apparatus according to another embodiment of the present invention, shown with the shaper in a first position and with longitudinal members in a first position;
FIG. 7 is a section view illustrating the forming apparatus of FIG. 6 , shown with the shaper in a second position and with the longitudinal members in a second position;
FIG. 8 is a perspective view illustrating a forming apparatus according to another embodiment of the present invention;
FIG. 9 is a section view illustrating the forming apparatus of FIG. 8 , shown with a thermoplastic sheet and a shaper disposed on the support members;
FIG. 10 is a section view illustrating a forming apparatus with a second set of support members, according to another embodiment of the present invention; and
FIG. 11 is a perspective view illustrating a forming apparatus according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not 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 invention to those skilled in the art. Like numbers refer to like elements throughout.
Referring now to FIG. 1 , there is shown a forming apparatus 10 for forming a formed sheet 60 , such as the one shown in FIG. 2 , from a thermoplastic member, such as a thermoplastic sheet 50 . Forming generally refers to bending the thermoplastic member to a bent or curved configuration and processing the member, for example, using heat, so that the member generally remains in a desired configuration when unrestrained. The formed sheet 60 can be a finished shape, such as an arc, spiral, channel, and the like. Alternatively, the formed sheet 60 can be used as a preform, i.e., a formed shape that is joined or otherwise processed to form a finished shape and remains in the desired configuration when unrestrained. For example, the flat sheet 50 can be bent and heated to form the cylindrical formed sheet 60 , shown in FIG. 2 , which extends from a first end 62 to a second end 64 and defines a passage 66 . Longitudinal edges 68 , 70 of the formed sheet 60 can define a gap therebetween, can be overlapped, or can be joined to form a seam or joint. If used as a preform, the longitudinal edges 68 , 70 of the formed sheet 60 can be joined to form a duct which, when unrestrained, defines a partially closed cylindrical shape. The preform can be formed to have a diameter slightly larger or smaller than the desired diameter of the duct. Thereafter, the formed sheet 60 can be subjected to a compressive or expansion force for holding the formed sheet during subsequent processing, such as joining, to arrive at the desired configuration of the duct. The longitudinal edges 68 , 70 , or other portions of the formed sheet 60 , can be joined using adhesives, heat, or other joining methods. For example, joining can be achieved by applying heat and pressure to the edges 68 , 70 to form the seam. As the thermoplastic material of the formed sheet 60 is heated above its glass transition temperature, the material becomes plastic and the pressure consolidates and joins the interface. Joining can be performed by manual or automated methods, for example, as described in U.S. application Ser. No. 10/215,833, titled “Consolidation Joining of Thermoplastic Laminate Ducts,” the entirety of which is incorporated herein by reference. Thus, as used throughout this application, the term “formed sheet” refers generally to a sheet that has been formed to a curved or bent configuration, including sheets that are formed to a final desired configuration without joining, preforms that require joining or other processing to achieve the final configuration, and partially closed shapes that are formed by joining such preforms.
The shape of the formed sheet 60 is determined by projecting the desired shape of the formed sheet 60 onto the flat sheet 50 . Although the ends 62 , 64 and edges 68 , 70 of the formed sheet 60 are shown to be straight and parallel in FIG. 2 , the formed sheet 60 can alternatively be straight, curved, tapered, or otherwise contoured. For example, there is shown in FIG. 2A an alternative formed sheet 60 , which defines a non-uniform, or transitional, radius that tapers between the ends 62 , 64 . The sheet 50 and, hence, the formed sheet 60 can also define a variety of features such as holes, for example, for connecting spuds, brackets, and the like to the formed sheet 60 . Methods and apparatuses for forming sheets and for determining geometric patterns that correspond to ducts are provided in U.S. application Ser. No. 10/216,110, titled “Thermoplastic Laminate Duct,” the entirety of which is incorporated herein by reference. It is also appreciated that marks can be provided on the formed sheet 60 , for example, to accurately identify the location of post-formed features such as beads, bells, and assembly details or to facilitate the manufacture or assembly of the formed sheet 60 , as also provided in the application entitled “Thermoplastic Laminate Duct.”
Preferably, the formed sheet 60 is formed of a thermoplastic sheet or of a composite laminate that includes a thermoplastic matrix and a reinforcing material. Thermoplastic materials are characterized by a transition to a plastic state when heated above a glass transition temperature. For example, the formed sheet 60 can be formed of polyetherimide (PEI) or polyphenol sulfide (PPS), both of which can be thermoplastic. Thermoplastic PEI is available under the trade name Ultem®, a registered trademark of General Electric Company. According to one embodiment of the present invention, each formed sheet 60 is comprised of a composite material that includes a matrix of thermoplastic PEI that is reinforced with a reinforcing material such as carbon, glass, or an aramid fabric such as a Kevlar® aramid, or fibers of such a material. Alternatively, the formed sheet 60 can be formed of other thermoplastic materials, which can be reinforced by other reinforcing materials, or can include no reinforcing materials.
The formed sheet 60 can be used in numerous applications including, but not limited to, environmental control systems of aerospace vehicles. For example, the formed sheet 60 can be used as a preform that is used to form a duct, as described above. The resulting duct can be used as a passage in a system though which air is delivered to provide heating, cooling, ventilation, and/or pressurization of an aircraft cabin. Alternatively, the formed sheet 60 can be used without further processing, for example, as a channel or conduit for wires or cables. The ends of the formed sheet 60 can be connected to other channels, ducts, tubes, formed sheets, or other devices such as ventilators, compressors, filters, and the like. Multiple formed sheets 60 can be connected so that a longitudinal axis of each formed sheet 60 is configured at an angle relative to the longitudinal axis of the adjoining formed sheet(s). Thus, the formed sheet 60 can be connected to form an intricate passage system (not shown) that includes numerous angled or curved passages for accommodating the various devices connected by the passage system and for meeting layout restrictions as required, for example, on an aircraft where space is limited. In addition, formed sheets according to the present invention can be used to form barriers or walls that are used to separate lighted areas from darker areas, people from secure areas, or cold from warm areas. Further, the formed sheets can provide visual barriers.
The forming apparatus 10 shown in FIG. 1 includes a roller 12 and a shaper 14 , both of which are provided on a frame 16 . The roller 12 extends longitudinally and is supported by the frame 16 such that the roller 12 is rotatable. The roller 12 can be at least partially surrounded by an insulative heat shroud 18 , which extends parallel to the roller 12 and facilitates the heating of a space 20 within the shroud 18 by a heater 22 . The heater 22 can be any of various types of heaters such as electric and gas heaters, and can be positioned on either end of the shroud 18 or along the longitudinal length of the shroud 18 . The heater 22 can be configured to heat the sheet 50 through the shroud 18 or by heating air that is blown into the space 20 within the shroud 18 . Alternatively, the apparatus 10 can be used without the shroud 18 , and the heater 22 can be configured to heat the space around the roller 12 . The roller 12 can also be heated directly by a heater, for example, by an electric heater disposed within the roller 12 .
The shaper 14 is an elastically flexible laminar sheet, i.e., a sheet that can be bent from its initial configuration during forming without undergoing any appreciable plastic deformation so that the shaper 14 can return to its initial configuration after processing and can be re-used. The shaper 14 can be formed of a variety of materials, including, for example, a sheet of stainless steel which is about 0.015 inches thick. In the illustrated embodiment, the shaper 14 is configured so that a first edge 24 is parallel to the roller 12 and connected to the roller 12 , though in other embodiments, the first edge 24 can be oriented in other configurations and need not be connected to the roller 12 . The shaper 14 is slidably adjustable relative to the roller 12 so that a second edge 26 of the shaper 14 opposite the first edge 24 is adjustable between first and second positions. In the first position, the shaper 14 extends from the roller 12 as shown in FIGS. 1 and 3 . In the second position, the second edge 26 of the shaper 14 is adjusted toward the roller 12 and the shaper 14 is at least partially bent around the roller 12 , as shown in FIG. 4 . The shaper 14 can engage tracks 17 or other features provided on the frame 16 , which maintain the second edge in a parallel arrangement with the roller 12 . By the term “advanced” it is generally meant that a portion of the shaper 14 that is not bent around the roller 12 is adjusted toward the roller 12 to increase the portion of the shaper 14 that is bent around the roller 12 , for example, by increasing the diameter of the portion bent around the roller 12 or by further extending the shaper 14 circumferentially around the roller 12 . If the apparatus 10 is configured as shown in FIGS. 3 and 4 , the shaper 14 can be advanced by adjusting the second edge 26 toward the roller 12 .
Adjustment of the shaper 14 to the second position can be accomplished by rotating the roller 12 in a first direction, clockwise as shown in FIGS. 3 and 4 , so that the first edge 24 of the shaper 14 rotates around at least part of the roller 12 , the shaper 14 bends, and the second edge 26 of the shaper 14 is advanced toward the roller 12 . As the roller 12 is rotated in a second direction, counterclockwise in FIGS. 3 and 4 , the shaper 14 unrolls from the roller 12 and the second edge 26 is retracted from the roller 12 . The roller 12 can be actuated by an automated device such as an electric motor or the roller can be manually actuated, for example, by a crank 13 that is rotated by an operator. Alternatively, the roller 12 can be configured to rotate freely so that the shaper 14 can be advanced toward the roller 12 , either manually or by an actuator, thereby rotating the roller 12 and rolling the shaper 14 around the roller 12 . In another embodiment, the first edge 24 of the shaper 14 is not connected to the roller 12 , and the shaper 14 can be advanced into the shroud 18 so that the shaper 14 bends around the roller 12 , which can remain stationary. In either case, the second edge 26 of the shaper 14 can be adjusted relative to the roller 12 while the roller 12 is held in place so that a portion of the shaper 14 that is disposed around the roller 12 is adjusted radially outward from the roller 12 to a desired configuration, generally defining a maximum circumference of the sheet 50 , as described further below.
The extent to which the shaper 14 is rolled around the roller 12 can be determined according to the desired shape of the formed sheet 60 . For example, the shaper 14 and thermoplastic sheet 50 can be advanced slightly more than one revolution around the roller 12 so that the resulting formed sheet 60 defines a generally cylindrical shape with overlapping longitudinal edges that can be joined to form a tubular duct. Alternatively, the sheet 50 can be rotated less than one revolution around the roller 12 to form an arc or, channel, or spiral, or the sheet 50 can be rotated more than one revolution to form a spiral shape.
During operation, the thermoplastic sheet 50 is disposed on the shaper 14 as shown in FIG. 1 so that the sheet 50 is rolled around the roller 12 between the shaper 14 and the roller 12 . While the sheet 50 is supported between the shaper 14 and the roller 12 , the heater 22 can be used to heat the sheet 50 , e.g., by connecting a power supply (not shown) to the heater 22 and energizing the heater 22 . Preferably, the sheet 50 is heated to a processing temperature that is less than the glass transition temperature of the thermoplastic material of the sheet 50 . For example, the processing temperature can be between about 5° F. and 70° F. less than the glass transition temperature. In the case of PEI, which has a glass transition temperature of about 417° F., the sheet 50 can be heated to a processing temperature of between about 347° F. and 412° F. The sheet 50 can be maintained at the processing temperature for a predetermined period, such as about 10 minutes, after which the heater 22 can be turned off and the formed sheet 60 is preferably at least partially cooled in the apparatus 10 . The formed sheet 60 can be removed from the apparatus 10 through openings 28 , 30 at the longitudinal ends of the heat shroud 18 , or the heat shroud 18 can be configured to disassemble or otherwise open to facilitate the removal of the formed sheet 60 . Alternatively, the formed sheet 60 can be removed by reversing the load process, i.e., unwinding the formed sheet 60 from the heat shroud 18 in a direction opposite to the direction in which the sheet 50 is inserted so that the formed sheet 60 unwinds around the outside of the heat shroud 18 .
The thermoplastic sheet 50 can be a precut sheet that corresponds to the desired dimensions of the formed sheet 60 so that the formed sheet 60 is trimmed only slightly or not at all after processing in the apparatus 10 . Alternatively, the thermoplastic sheet 50 can be part of a long continuous sheet, such as a roll of thermoplastic laminar material, and the sheet 50 can be cut during or after processing. In either case, the shaper 14 can include an index feature that engages a portion of the sheet 50 so that the adjustment of the sheet 50 into the apparatus 10 can be easily controlled and/or measured. For example, the shaper 14 can include a gate 32 at the second edge 26 , as shown in FIGS. 1 , 3 , and 4 . The sheet 50 can be disposed on the shaper 14 so that an edge of the sheet 50 rests against the gate 32 , and the gate 32 prevents the sheet 50 from slipping relative to the shaper 14 when the shaper 14 is advanced around the roller 12 .
According to one embodiment of the present invention, the sheet 50 is disposed on the shaper 14 , and the roller 12 is rotated through a predetermined angle of rotation. The roller 12 can be rotated using the actuator or crank 13 , or the second edge 26 of the shaper 14 can be urged toward the roller 12 to rotate the roller 12 . The roller 12 is then held at the desired rotational position while the second edge 26 of the shaper 14 is adjusted toward or away from the roller 12 to increase or decrease the diameter of a generally cylindrical portion of the shaper 14 bent around the roller 12 . By keeping the second edge 26 parallel to the first edge 24 , a constant radius can be imparted to the formed sheet 60 . Alternatively, the second edge 26 can be positioned in a non-parallel, or skewed, relationship relative to the first edge 24 so that a non-uniform, or transitional radius, is imparted to the formed sheet 60 , i.e., the radius at one end 66 is different than the other end 64 of the formed sheet 60 .
The shaper 14 also adjusts the sheet 50 to a desired configuration. For example, the sheet 50 can be engaged by the gate 32 , and the gate 32 can be adjusted toward the roller 12 so that substantially all of the sheet 50 is bent around the roller 12 . Thus, if the sheet 50 is long enough to extend substantially from the first edge 24 of the shaper 14 to the gate 32 , the sheet 50 will be disposed against the shaper 14 when the shaper 14 is bent around the roller 12 . The length of the sheet 50 can be selected according to the desired size of the finished shape, and the gate 32 can be adjustable on the shaper 14 so that the shaper 14 can be used for sheets 50 of different lengths, the length of each sheet 50 generally determining the circumferential size of the formed sheet 60 . If the sheet 50 is longer than the circumference of the formed sheet 60 , the formed sheet 60 can be trimmed after forming.
A second shaper 34 similar to the first shaper 14 can also be disposed on the thermoplastic sheet 50 so that the second shaper 34 is rolled around the roller 12 between the sheet 50 and the roller 12 , as shown in FIG. 5 . The second shaper 34 can be slidably adjustable toward the roller 12 , as described above in connection with the first shaper 14 . Thus, the first shaper 14 can be advanced a predetermined distance toward the roller 12 to define a maximum outer dimension of the formed sheet 60 , and the second shaper 34 can be advanced a predetermined distance toward the roller 12 to urge the sheet 50 radially outward toward the first shaper 14 . The shapers 14 , 34 can be adjusted radially outward by advancing the rollers 14 , 34 after the roller 12 has been rotated to a desired position and held in that position. Alternatively, the shapers 14 , 34 can be adjusted radially outward by advancing the shapers 14 , 34 while the roller 12 is being rotated, the shapers 14 , 34 being advanced at a rate faster than the speed of a periphery of the roller 12 . The second shaper 34 can be connected to the roller 12 or the first shaper 14 , or the second shaper 34 can be connected to neither. In the illustrated embodiment, however, the second shaper 34 is also attached to the roller 12 , albeit at a location spaced circumferentially from the location at which the first shaper 14 is attached to the roller 12 so that the sheet 50 may be disposed therebetween. Additionally, the second shaper 34 can have a gate 35 or other index feature for engaging the sheet 50 . As shown, for example, the gate 35 of the second shaper 34 may extend toward the first shaper 14 such that the sheet 50 is retained therebetween.
In another embodiment of the present invention, the apparatus 10 includes one or more radially adjustable members 40 , as shown in FIGS. 6 and 7 . Each member 40 can be a longitudinal member such as a rod, a shoe, or the like that extends generally parallel to the roller 12 . The members 40 are configured to be adjusted relative to the roller 12 to provide support to the shaper 14 and the sheet 50 . The members 40 can be adjusted to a first position, shown in FIG. 6 , so that the members 40 do not interfere with the entry and bending of the shaper 14 and sheet 50 around the roller 12 . The members 40 can then be adjusted toward the roller 12 to bias the shaper 14 and the sheet 50 to a particular configuration. For example, if the shaper 14 and sheet 50 do not maintain a cylindrical shape when bent around the roller 12 , the members 40 can be actuated radially inwards, as shown in FIG. 7 , to engage the shaper 14 and urge the shaper 14 to the desired configuration. The members 40 can also be used to bend the shaper 14 to other shapes, including shapes with flattened portions or complex curves. Any number of members 40 can be provided in the apparatus 10 , and the members 40 need not be straight or extend the entire length of the apparatus 10 . Further, the members 40 can be positioned within the shaper 14 , i.e., between the sheet 50 and the roller 12 , so that the members 40 can be actuated outward toward the sheet 50 and shaper 14 .
FIGS. 8 and 9 illustrate an alternative forming apparatus 110 in which a shaper 114 , similar to the shaper 14 described above, is supported on a plurality of support members 140 that are supported by a frame 116 . The support members 140 can be longitudinal members such as rods or other shapes that are arranged in a generally parallel configuration, as shown in FIG. 8 , so that the members 140 define spaces 142 therebetween. In other embodiments, the support members 140 can be arranged in other configurations, in which the support members 140 need not be parallel. A heater 122 can be provided within each member 140 or elsewhere in the apparatus 110 , and the apparatus 110 can be partially or completely enclosed by an insulative shroud 118 . The thermoplastic sheet 50 is disposed on a first side of the shaper 114 , and a second side of the shaper 114 is disposed against the members 140 so that the shaper 114 extends across the spaces 142 between the members 140 and so that the sheet 50 can bend between the members 140 , as shown in FIG. 9 . The shaper 114 and the sheet 50 can be bent by gravity, or opposing support members 144 can be provided, as shown in FIG. 10 , for urging the sheet 50 to a desired configuration. A second shaper 134 can also be provided on the sheet 50 opposite the first shaper 114 , as shown in FIG. 10 , i.e., between the sheet 50 and the members 144 .
Each of the members 140 , 144 can be adjustable in position, for example, in a direction transverse to the longitudinal direction of the members 140 , 144 . Thus, as shown in FIG. 10 , each of the members 140 , 144 can be adjusted in any direction to determine the shape of the formed sheet 60 . The members 140 , 144 can be mounted on tracks or other adjustable supporting devices, and each member 140 , 144 can be adjusted manually, or actuators can be provided for such adjustment. For example, FIG. 10 illustrates a plurality of actuators 146 , each of which is configured to extend or retract a respective one of the members 140 , 144 toward or away from the sheet 50 .
During one typical method of operation, the shaper 114 is disposed on the members 140 , the sheet 50 is disposed on the shaper 114 , the second shaper 134 is disposed on the sheet 50 , and the members 140 , 144 are adjusted to a desired configuration. The heater 122 is used to heat the sheet 50 , preferably to a processing temperature that is less than the glass transition temperature of the thermoplastic material of the sheet 50 , as described above. The sheet 50 can be maintained at the processing temperature for a predetermined period, after which the heater 122 can be turned off. Preferably, the formed sheet 60 is at least partially cooled in the apparatus 110 . The formed sheet 60 is then removed from the apparatus 110 .
The support members 140 can define different shapes than that shown in FIGS. 8–10 . For example, as shown in FIG. 11 , an apparatus 110 a can include one or more rod- or tube-shaped support members 140 a defining ends that extend from a frame 116 a and upon which a shaper 114 a can be disposed. The shaper 114 a can extend perpendicular to the longitudinal direction of the support member 140 a , and the sheet 50 can be disposed on the shaper 114 a . Further, the shaper 114 a and, hence, the sheet 50 can be elastically deformed to a compound contour, i.e., bent about more than one axis. For example, as shown in FIG. 11 , the shaper 114 a can define a partial spherical surface.
As described above, the edges 68 , 70 or other portions of the formed sheet 60 can be joined, for example, by consolidation joining. Further, the formed sheet 60 can be post-formed to provide additional contours or features, such as bells, beads, and the like. A discussion regarding the formation of features such as bells and beads through post-forming, i.e., after the forming and/or the consolidation joining of the sheet, is provided in U.S. application Ser. No. 10/215,780, titled “Post-Forming of Thermoplastic Ducts” filed Aug. 9, 2002, which is assigned to the Assignee of the present invention and the entirety of which is incorporated herein by reference. It is also appreciated that marks can be provided on the thermoplastic sheet, for example, to accurately identify the location of such post-formed features or to facilitate the manufacture or assembly of the formed sheets, as provided in the application entitled “Thermoplastic Laminate Duct.”
Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. For example, it is appreciated that each of the components of the described apparatuses can be formed of a variety of materials such as aluminum, steel, and alloys thereof, and each of the working surfaces of the apparatuses can include a low friction layer or release layer, e.g., Teflon®, registered trademark of E.I. du Pont de Nemours and Company. The release layer can be a durable layer of material or a release agent that is wiped or sprayed periodically onto the working surfaces. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
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There are provided apparatuses and related methods for forming sheets. The formed sheets can be formed of a thermoplastic material, such as flat sheets of reinforced thermoplastic, which can be lightweight, strong, and perform well in flammability, smoke, and toxicity tests. The apparatus includes a heater for heating the sheet to a processing temperature and a structure for configuring the sheet to a desired shape using one or more rollers, shapers, longitudinal members, and/or support members.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention generally relates to fertilizers and, more specifically, to a system and method for manufacturing fertilizers from poultry litter.
[0003] 2. Description of Related Art
[0004] Poultry litter is one of the most valuable litters produced by livestock. Poultry litter is a very good source of plant nutrients and soil amendment when properly processed. In particular, poultry litter is managed primarily for its nitrogen (N) value. However, nitrogen availability from poultry litter is the most difficult of the three primary nutrients (nitrogen (N), phosphate (P 2 O 5 ) and potassium (K 2 0 )) to predict. About one-third of the total nitrogen in poultry litter is in the ammonium form (NH 4 —N) and the rest is in an organic form. The amount of nitrogen available for plant uptake is ammonium nitrogen plus the amount of organic nitrogen that mineralizes during the growing season. Poultry litter has the following average nutrient content: a fertilizer grade of about 3-3-3 (N—P 2 O 5 —K 2 O); total nutrients of about 60-60-60 (lbs/ton); and available nutrients of first season of about 40-40-30 (lbs/ton).
[0005] Poultry litter is most valuable immediately after it is removed from the poultry house. The nitrogen in the litter can be preserved if it is stored in an enclosed structure (e.g., dry storage barn) or in a deep covered pile. Poultry litter should be handled like commercial fertilizers and should not be stored outside and exposed to the weather. Litter stored outside and exposed to the weather will decompose rapidly, and rain can leach valuable nutrients into surface waters. Moreover, when poultry litter is exposed to air and moisture, the ammonium form of the total nitrogen (NH 4 —N) is converted to the organic form. This composted litter or litter that has been exposed to the weather over time is less valuable to the crop. Currently, there is no effective and environmentally sound solution for managing surplus poultry litter and, thus, there is a need for an effective system and method for manufacturing fertilizers from poultry litter.
SUMMARY OF THE INVENTION
[0006] Exemplary embodiments of the invention include systems and methods for manufacturing fertilizer nutrients from poultry litter. Features of the invention include heating and pasteurizing raw material; drying the heated and pasteurized material; reducing the dried material to a powder; and pelleting the powder to granular and homogenized pellets. The poultry litter fertilizer is high in nitrogen and provides a good source of nutrients for many crops.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate exemplary embodiments of the invention and, together with the detailed description of the invention, explain various aspects and principles of the invention.
[0008] [0008]FIG. 1 is an illustration of a system for manufacturing fertilizer from poultry litter in accordance with an exemplary embodiment of the invention; and
[0009] [0009]FIG. 2 is a flowchart illustrating a method for manufacturing fertilizer micronutrients according to an exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0010] The following detailed description refers to the accompanying drawings that illustrate exemplary embodiments of the invention. Other embodiments are possible and modifications may be made to the exemplary embodiments without departing from the spirit and scope of the invention. Rather, the scope of the invention is defined by the appended claims.
[0011] [0011]FIG. 1 is an illustration of a plant 100 for manufacturing fertilizer from poultry litter in accordance with an exemplary embodiment of the invention. The fertilizer manufacturing plant 100 includes a raw area ventilation system 105 , a raw feed system 110 , a dryer system 115 , a pelleting and screening system 120 , and a finish area ventilation system 125 . To begin, surplus litter is transported from farms to the fertilizer manufacturing plant 100 by specially-designed, sealed trucks so as to preserve the nitrogen in the litter. The trucks unload the surplus litter inside the fertilizer manufacturing plant 100 , where the raw area ventilation system 105 operates to prevent dust and odor from escaping to the environment. The raw area ventilation system 105 includes special filters 106 and scrubbers 107 that ensure that the air leaving the plant is just as clean or cleaner than the outside air. That is, in an air treating process, scrubbers 107 strip all the odor causing compounds out of the air before emitting it to the atmosphere. The raw feed system 110 segregates the wet and dry raw material or litter and feeds the raw material or litter to the dryer system 115 . The dryer system 115 heats and pasteurizes the raw material so as to remove and destroy bacteria. The dryer system 115 includes grinders 117 that reduce the dried material to a powder before it is transferred to the pelleting and screening system 120 . Moisture captured in the air treating process may be re-used in the pelleting and screening system 120 to balance moisture content. The pelleting and screening system 120 produces pellets comprising primarily of organic matter and humus as further described herein. It is preferable that the pelleting and screening system 120 includes two pellet mills 122 , each operating at 500-horsepower and capable of producing 10 tons of pellets per hour. The pellets are approximately 1-6.5 mm long. The pellets are very useful for commercial row crop operations that are suffering from micronutrient deficiencies or low organic matter. The finished pellets are cooled and stored in a finished product room, which is regulated by the finish area ventilation system 125 . The finish area ventilation system 125 is similar to the raw area ventilation system 105 . The finished product can then be loaded into trucks or rail cars for bulk shipment to nutrient deficient regions.
[0012] [0012]FIG. 2 is a flow diagram illustrating a poultry litter fertilizer manufacturing process in accordance with an exemplary embodiment of the invention. Poultry producers often have surplus litter from their farms. A first step in the process is to remove the surplus litter from the farms in step 202 . Next, the surplus litter is transported to another plant or site where it can be processed to micronutrients in step 204 . The surplus litter, for example, may be loaded into specially designed, covered and leak-proof aluminum trailers dedicated for transport to a pellet processing plant. At 206 , the litter trucks are unloaded in a raw material room of the pellet processing plant, where a negative air system changes several times an hour, e.g., 10 times per hour, so as to prevent dust and odor from escaping to the outside environment. The wet and dry litter is segregated into designated feed hoppers at 208 with a front-end loader before moving to a dryer.
[0013] The negative air system is an air-filtration system that ensures that no odor or dust is emitted into the environment. In particular, thermal energy is used to break down the chemical properties of odor-causing compounds. The air-filtration system is preferably 99.9 percent efficient in eliminating odor.
[0014] The negative air system includes scrubbers for removing odor from the air. The treated air contains moisture, which is captured and re-used in the pelleting process as further described herein. At 210 , the litter is pasteurized in a dryer to destroy bacteria. The litter should be heated to about 180° F. to 225° F. Next, at 212 , the dried litter is reduced to a consistency of fine sand by, e.g., a hammer mill. The reduced dried litter is then transported to a pellet mill at 214 , which produces pellets comprising primarily of organic matter and humus.
[0015] The pellets produced by the pellet mills are hot, typically 200° F., and need to be cooled to within about five degrees (F) of ambient temperature as shown at 216 so as to ensure product quality. At 218 , the cooled pellets are transported to a finished product room via a system of conveyors and elevators. The finished product room operates on a similar negative air system used in the raw material room. The finished product room (of the pellet plant) can store 7,000 tons of pellets. The pellets are loaded with a front-end loader onto an in-ground conveyor and transported to waiting rail cars and trucks. The finished product is tested on a regular basis (e.g., weekly) by an in-house and/or an outside agency for quality control. Each pellet plant is capable of loading 30 rail cars in 24 hours or the equivalent of about 350 tons per hour. The finished product is shipped to nutrient deficient regions internationally.
[0016] The invention offers poultry producers an environmentally sound solution for managing surplus poultry litter. The invention recycles both valuable nutrients and organic material without creating any waste byproducts. The final product of the invention—pasteurized, all-natural fertilizer pellets called MicroStart60® (MicroStart60® is a registered trademark for a fertilizer of Perdue-AgriRecycle LLC)—can be easily shipped from poultry-producing areas to nutrient-deficient regions across the country and around the globe. In particular, MicroStart60® is a fertilizer comprising a wide variety of micronutrients, humus and organic matter that help produce significant increases in normal crop yields year after year. MicroStart60® is ideal for commercial row crop farming, i.e., MicroStart60® is especially formulated for precision agriculture so as to increase crop yield and health. MicroStart60® helps crops take up more nutrients while adding humus, organic matter and essential trace elements back into the soil and, thus, it improves vital water retention. MicroStart60® also includes proper amounts of Nitrogen (N), Phosphate (P 2 O 5 ), Potassium (K 2 O), and other important secondary nutrients and trace elements that are vital to healthy plant growth. By incorporating MicroStart60® into a current fertilizer program, one can expect to maximize the soil's nutrient content as well as its nutrient availability. In other words, MicroStart60® acts like a surfactant, making a chemical fertilizer work harder and last longer.
[0017] MicroStart60® comprises micronutrients and about 60% organic matter for commercial row crop farming and precision agriculture. Features of MicroStart60® include: improved organic components of the soil; increased water retention in the soil; harder working and longer lasting chemical fertilizer; improved nutrients that prevent runoff and resultant nutrient loss; a 3-4-3, 3-3-3, or 4-4-3 Nitrogen-Phosphorous-Potassium (N—P—K) nutrient content (it should be noted that poultry litter has the highest percent of N—P—K of any available natural fertilizer); improved exchanged capacity of the soil and its pH buffering ability; long term benefits to the soil, as opposed to short-term benefits of common chemical fertilizer; providing water insoluble nitrogen that is released slowly over a long period of time; providing a residual value that can feed next year's crop and the soil life within the soil; providing pellets that flow easily and broadcast evenly through both conventional and air flow spreaders; and approval by the Organic Materials Review Institute for organic crop production.
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A system and method for manufacturing fertilizer nutrients from poultry litter. The method of the invention includes heating and pasteurizing raw material; drying the heated and pasteurized material; reducing the dried material to a powder; and pelleting the powder to granular and homogenized pellets. The poultry litter fertilizer is high in nitrogen and provides a good source of nutrients for many crops.
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TECHNICAL FIELD
Fracture stimulation of a well, and more particularly to a method and system for determining formation properties. Particularly, this disclosure is directed to determining formation properties associated with production potential from the formation.
BACKGROUND
Oil and gas wells produce oil, gas, and/or by-products from underground reservoirs. Oil and gas reservoirs are formations of rock containing oil and/or gas. The type and properties of the rock may vary by reservoir and also within reservoirs. For example, the porosity and permeability of a reservoir rock may vary from reservoir to reservoir and from well to well in a reservoir. The porosity is the percentage of core volume, or void space, within the reservoir rock that can contain fluids. The permeability is an estimate of the reservoir rock's ability to flow or transmit fluids. A reservoir may include a plurality of reservoir zones, and the zones may have properties different from each other, and the properties within a zone may vary. Further, different reservoir zones may be formed from different types of rock.
Oil and gas production from a well may be stimulated by fracture, acid or other production enhancement treatment. In a fracture treatment, fluids are pumped downhole under high pressure to artificially fracture the reservoir rock in order to increase permeability and production. In some implementations, a pad, which is fracture fluids without proppants, is first pumped down the well until formation breakdown. Then, the fracturing fluid with proppants is pumped downhole to hold the fractures open after pumping stops. At the end of the fracture treatment, a clear fluid flush may be pumped down the well to flush the well of proppants.
In some instances, an initial treatment or minifracture may be performed before a production stimulation fracture treatment to calculate formation and fracture properties. In some implementations, the initial treatment may be an injection falloff test.
SUMMARY
A first aspect is directed to a method including determining a process zone stress for a subterranean zone intersected by a wellbore using a fracture analysis system and determining whether to perform a stimulation treatment to the subterranean zone based on the determined process zone stress.
A second aspect is directed to a method for determining whether to perform a stimulation treatment on a subterranean zone of a subterranean reservoir. The method may include performing a fracture injection falloff test on the subterranean zone and collecting well shut-in pressure data after cessation of the fracture injection falloff test. The method may also include determining process zone stress of the subterranean zone using the shut-in pressure data and determining whether to perform a stimulation treatment on the subterranean zone based on the process zone stress.
A third aspect may include a system for determining whether to perform a stimulation treatment to a subterranean zone based on an estimated profitability potential of the subterranean zone. The system may include a fracture control engine operable to control a fracture injection falloff test performed in a zone of a well and a fracture analysis engine operable to receive and process data from the fracture injection falloff test for determining a process zone stress. The fracture control engine may be operable to control a subsequent fracturing operation only if the process zone stress is below a threshold value.
One or more aspect may include one or more of the following features. Determining a process zone stress for a subterranean zone intersected by a wellbore may include performing a fracture injection falloff test, collecting data from the fracture injection falloff test, and determining the process zone stress using the collected data. Determining the process zone stress using the collected data may include determining an instantaneous shut-in pressure, determining a fracture closure pressure, and determining the process zone stress from the instantaneous shut-in pressure and fracture closure pressure. Determining a fracture closure pressure may include utilizing a graphical methodology to determine the fracture closure pressure. Utilizing a graphical methodology to determine the fracture closure pressure may include utilizing at least one of a G-function methodology, square-root-of-time methodology, and log-log plot methodology to determine fracture closure pressure. Determining a fracture closure pressure may include using a mechanical technique to determine the fracture closure pressure. Determining a process zone stress for a subterranean zone intersected by a wellbore may include determining a normalized process zone stress gradient for the subterranean zone. A stimulation treatment may be performed when the normalized process zone stress gradient is less than or equal to 0.12 psi/ft. Determining the process zone stress may include correlating historical production stimulation fracturing data of the well to determine process zone stress. Correlating historical production stimulation fracturing data of the well to determine process zone stress may include generating a history-match fracture model.
One or more aspects may also include one or more of the following features. Determining process zone stress of the subterranean zone using the shut-in pressure data may include determining a normalized process zone stress gradient. Determining process zone stress of the subterranean zone using the shut-in pressure data may include determining an instantaneous shut-in pressure, determining a closure pressure, and determining the process zone stress using the instantaneous shut-in pressure and closure pressure. Determining a closure pressure may include determining the closure pressure using a graphical methodology. Determining the closure pressure using a graphical methodology may include using a G-function methodology, a square-root-of-time methodology, or a log-log plot methodology to determine the closure pressure. Performing a fracture injection falloff test on the subterranean zone may include performing a diagnostic fracture injection test.
One or more aspects may also include one or more of the following features. The threshold value may be between 1,100 psi and 1,900 psi. The fracture analysis engine may be coupled to one or more sensors adapted to collect the data from the fracture injection falloff test. The fracture injection falloff test may be a diagnostic fracture injection test. The process zone stress may be a normalized process zone stress gradient. The threshold for the normalized process zone stress gradient may be 0.12 psi/ft.
The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 illustrates one embodiment of a fracture treatment for a well.
FIG. 2 is an example G-function plot for determining closure pressure.
FIG. 3 is an example square-root-of-time plot for determining closure pressure.
FIG. 4 is an example log-log plot for determining closure pressure.
FIG. 5 shows a schematic of an example minifracture analysis system.
FIG. 6 is an example Shalelog™ of a subterranean zone.
FIG. 7 is an example DFIT treatment plot.
FIG. 8 is a log-log plot for determining closure pressure of an example DFIT.
FIG. 9 is another example G-function plot.
FIG. 10 is an example history match plot of a subterranean zone.
FIG. 11 is an example plot of a proposed fracturing treatment design.
FIG. 12 is an example history match plot of a fracturing treatment.
FIGS. 13A-B show another example well log indicating coal seams intersected by a well.
FIG. 14 is another example history match plot.
FIG. 15 is a treatment plot for an example stimulation treatment.
FIG. 16 shows an example method for determining whether to perform a fracturing treatment based on Process Zone Stress.
DETAILED DESCRIPTION
FIG. 1 illustrates an example implementation of a fracture treatment 10 for a well 12 . The well 12 may be an oil and gas well intersecting a reservoir 14 . The reservoir 14 may be an underground formation of rock containing oil and/or gas. The reservoir 14 may include one or more zones, each accessed by a well 12 or otherwise. For example, a zone, such as zone 16 , may be vertically or horizontally spaced in the reservoir 14 . However, the reservoir 14 may include additional or fewer subterranean zones. The well 12 may in other embodiments, intersect other suitable types of reservoirs 14 .
The fracture treatment 10 may include a production stimulation fracturing treatment or an initial fracture injection falloff test or other suitable treatment. The fracture injection falloff test may also be referred to as a mini fracture (“minifrac”) test. An example fracture injection falloff test is a Diagnostic Fracture Injection Test (“DFIT”) 15 . In the course of an initial fracture injection falloff test, such as the DFIT, a fracture fluid without proppant is injected into a well to fracture a subterranean zone. In some instances, the fracture fluid may be water, a two percent KCL solution, or other suitable fluid. Other suitable tests may be used. For the purposes of this description, DFIT will be discussed, although it will be understood that the fracture injection falloff test is not limited to a DFIT, but, rather, is merely used as an example.
Referring to FIG. 1 , the well 12 may include a well bore 20 , casing 22 , and well head 24 . The well bore 20 may be a vertical bore, a horizontal bore, a slanted bore or other deviated bore. The well bore 20 may also include one or more laterals extending therefrom into the reservoir 14 . The casing 22 may be cemented or otherwise suitably secured in the well bore 20 . Perforations 26 may be formed in the casing 22 at the level of the reservoir 14 to allow oil, gas, and by-products to flow into the well 12 and be produced to the surface 25 . Perforations 26 may be formed using shape charges, a perforating gun or otherwise.
For the DFIT 15 , a work string 30 may be disposed in the well bore 20 . The work string 30 may be coiled tubing, sectioned pipe, or other suitable tubing. A fracturing tool 32 may be coupled to an end of the work string 30 . The fracturing tool 32 may include a SURGIFRAC or COBRA FRAC tool manufactured by Halliburton of 10200 Bellaire Blvd., Houston, Tex., or other suitable fracturing tool. Packers 36 may seal an annulus 38 of the well bore 20 above and below one or more zones (e.g., zone 16 ) of the reservoir 14 . Packers 36 may be mechanical, fluid inflatable, or other suitable packers.
One or more pump trucks 40 may be coupled to the work string 30 at the surface 25 . The pump trucks 40 pump fracture fluid 58 , such as a fracturing fluid described above, down the work string 30 to perform the DFIT 15 . The pump trucks 40 may include mobile vehicles, equipment such as skids or other suitable structures.
One or more instrument trucks 44 may also be provided at the surface 25 . The instrument truck 44 may include a fracture control system 46 for monitoring and controlling the DFIT 15 . The fracture control system 46 communicates with surface and/or subsurface instruments to monitor and control the DFIT 15 . In some implementations, the fracture control system 46 may control the pump truck 40 and fluid valve to stop and start the DFIT. In some instances, the surface and subsurface instruments may include surface sensors 48 , down-hole sensors 50 , and pump controls 52 .
Surface and down-hole sensors 48 and 50 may include pressure, rate, temperature, and/or other suitable sensors. Pump controls 52 may include controls for starting, stopping, and/or otherwise controlling pumping as well as controls for selecting and/or otherwise controlling fluids pumped during the DFIT 15 . Surface and down-hole sensors 48 and 50 as well as pump controls 52 may communicate with the fracture control system 46 over wire-line, wireless, or other suitable links. For example, surface sensors 48 and pump controls 52 may communicate with the fracture control system 46 via a wire-line link while down-hole sensors 50 communicate wirelessly to a receiver at the surface 25 that is connected by a wire-line link to the fracture control system 46 . In other instances, the down-hole sensors 50 may upon retrieval from the well 12 be directly or otherwise connected to fracture control system 46 .
The instrument truck 44 may also include a fracture analysis system 47 operable to analyze data obtained from a minifrac test. The fracture analysis system 47 may collect and record various data types during a minifrac test and determine Process Zone Stress (“PZS”) (sometimes referred to as “net pressure”) to aid in determining whether a production stimulation fracturing treatment should be performed. Although the fracture analysis system 47 is shown as being included in the instrument truck 44 , the fracture analysis system 47 may be located at another location at or remote from the well 12 .
In operation, the fracturing tool 32 is coupled to the work string 30 and positioned in the well 12 . The packers 36 are set to isolate one or more subterranean zones of the reservoir 14 , such as zone 16 . The pump trucks 40 pump fracture fluid 58 down the work string 30 to the fracturing tool 32 . The fracture fluid 58 exits the fracturing tool 32 and creates a fracture 60 in the one or more subterranean zones 16 . In the example shown, the fracture 60 is formed in the subterranean zone 64 . However, a fracture 60 may be formed in additional zones. In a particular embodiment, a fracture fluid 58 may include a fluid pad pumped down the well 12 until breakdown of the formation in the one or more subterranean zones 16 . The DFIT 15 may be otherwise suitably performed.
For example, in some instances, pumping rates during a DFIT 15 may be three to six barrels per minute (bpm). However, the pumping rates may vary based on estimates associated with the subterranean zone 16 . For example, the material type and estimated properties (e.g., permeability) of the subterranean zone 16 and injection rate may affect the pumping rate. When breakdown of the subterranean zone 16 is achieved, the pumping rate may be maintained at a constant rate and variations to the pumping rate may be avoided. Once shut-in is achieved, disturbance of the well 12 may be avoided while the data is collected.
An example DFIT includes injecting a volume of fluid into the well at a desired fluid flow rate. In some instances, the injected fluid is fresh water that does not include proppant. Also, the volume of fluid injected is less than the fluid injected during a production stimulation fracture treatment. For example, a fluid volume of approximately 1,077 gallons injected into the well at a rate of approximately three bpm may be used. However, other fluid volumes at different rates may also be used.
A purpose of the DFIT 15 is to initiate a fracture in the subterranean zone and obtain data associated with the fracture. For example, instantaneous shut-in pressure (“ISIP”) and fracture closure pressure may be obtained from the DFIT 15 . Once the fluid is injected into the well, such as well 12 , the well is shut in and pressure falloff within the well is measured. In instances where the well maintains a column of liquid, a pressure gauge may be placed at the surface to measure the changing pressures over the shut in period. In other instances, such as for wells that do not maintain a column of liquid, a pressure gauge may be located downhole in order to measure the pressure data. Pressure data may be measured at 0.01 psi increments. Other data may also be collected. For example, temperature, fluid injection rate, pump speed, time, seismic data, and/or other data may be collected. The collected data may be transmitted to the instrument truck 44 for recordation. The recorded data may be analyzed to determine, for instance, the ISIP and fracture closure pressure. When the ISIP and closure pressure is obtained by analyzing the DFIT data, the PZS may be obtained with the following equation: PZS=(ISIP−closure pressure).
In some instances, pressure data for determining ISIP is measured at the surface, such as with a sensor located at the surface 25 . However, in other instances, the pressure data may be measured at the subterranean zone 16 with a pressure sensor disposed in the well 12 in or near the subterranean zone 16 . Similarly, closure pressure may be determined as a pressure at the surface 25 or subterranean zone 16 . Thus, when determining PZS, the ISIP and closure pressure used should be with reference to the same location, e.g., at the surface 25 or at the location of the subterranean zone 16 . Converting a pressure measured at the surface 25 to the corresponding pressure existing at the subterranean zone 16 may be performed by adding hydrostatic head pressure at the depth of the subterranean zone 16 to the pressure measured at the surface 25 .
Data collected by the fracture analysis system 47 from the DFIT 15 may be used to determine formation properties and residual fracture properties before the production stimulation fracture treatment. Thus, the DFIT 15 may be conducted to breakdown, i.e., form a fracture in, a formation, such as subterranean zone 16 , and determine properties of the subterranean zone based on collected data. For example, data collected from a DFIT 15 may be used by and/or in connection with the fracture analysis system 47 to determine closure pressure of the generated fracture, ISIP, pore pressure, and an estimated permeability of the subterranean zone. Further, the fracture analysis system 47 may use the collected data to determine PZS as an indicator of the production potential of the subterranean zone 16 . For example, the fracture analysis system 47 may determine these properties by analyzing pressure falloff data obtained during shut-in of the well 12 . In some instances, collection of the data by the fracture analysis system 47 may be started prior to injection of fluid into the well 12 . Also, in some implementations, data may be collected by the fracture analysis system 47 once every second from the beginning through the end of the DFIT.
The formation permeability is an estimate of the reservoir rock's ability to flow or transmit fluids. The PZS is a spatial variable that defines fracture tip effects and their influence on hydraulic fracture stimulation. The PZS associated with a reservoir zone or portion thereof may be an indicator of the reservoir zone's resistance to fracture. Thus, PZS may be used to determine the productivity potential of the subterranean zone or portion thereof in which the initial treatment was performed. Further, PZS may also be used to determine whether the costly production stimulation fracture treatment should be performed.
PZS may be an indicator of a reservoir zone's resistance to initiate and propagate a fracture and, thus, the productivity potential of the reservoir zone. PZS may not be an absolute measure of the productivity potential of a reservoir zone since tip effects, which are cumulatively referred to as PZS, may vary during fracturing. For example, the PZS value may vary depending on whether a fracture tip of a fracture (such as fracture 60 ) is moving or stationary at each point along the perimeter at that point. However, tip effects associated with PZS may be separated from contributions due to perforations and near wellbore effects. Further, even though PZS can vary, the initially determined PZS value may be used as an indicator of the productivity potential of the subterranean zone, since PZS generally increases during the course of a fracture treatment conducted with or without proppant. Moreover, the PZS value determined as a result of a DFIT may be reliably used as an indicator of the reservoir zone's productivity potential since the PZS is generally higher during the production stimulation fracture treatment. Accordingly, the PZS obtained during the DFIT allows one to determine whether a subterranean zone will be a good producer of reservoir fluids and, thus, whether to perform a production stimulation fracturing treatment. Therefore, performing a DFIT and obtaining the PZS can reduce costs where the PZS indicates a poor producing potential.
Additionally, PZS is independent of reservoir type. That is, a PZS of a certain value is indicative of poor productivity regardless as to the material type forming the reservoir zone or portion thereof. Rather, PZS includes effects of fluid lag, intact rock strength, and other non-linear stress dissipations around a fracture tip, each of which restrict growth of the fracture in the reservoir zone. Thus, PZS is not related to only one property.
With and/or in connection with the fracture analysis system 47 , the closure pressure may be determined in any number of ways. For example, the fracture analysis system 47 may be used to determine closure pressure according to one or more graphical methods. In some instances, the fracture analysis system 47 may be operable to generate the plots shown in FIGS. 2 , 3 , and 4 . Still further the fracture analysis system 47 may be operable to determine closure pressure based on the plots shown in FIGS. 2 , 3 , and 4 and/or the methodologies associated with the FIGS. 2 , 3 , and 4 . Thus, the fracture analysis system 47 may be operable to determine closure pressure using example graphical techniques such as a standard Cartesian falloff plot, a square-root-of-time plot, a semi-log plot, a log-log plot, and a G-function plot.
In addition to graphical techniques, mechanical techniques may be used to determine closure pressure. Example mechanical techniques may include a pulse test and the use of tiltmeters.
Determining closure pressure using some example graphical techniques (interchangeable referred to as “graphical methodologies” or “graphical methods”) is described, although, as explained, other methodologies may be used. According to some implementations, the fracture analysis system 47 may be used to determine closure pressure according to one or more methods. For example, the fracture analysis system 47 may be operable to generate the plots shown in FIGS. 2 , 3 , and 4 . Still further the fracture analysis system 47 may be operable to determine closure pressure based on the plots shown in FIGS. 2 , 3 , and 4 and/or the methodologies associated with the FIGS. 2 , 3 , and 4 .
Referring to the G-function plot shown in FIG. 2 , an expected signature of the G-function semilog derivative is a straight line through the origin, e.g., zero G-function and zero derivative. Closure pressure is identified by the departure of the semi-log derivative of pressure with respect to G-function (Gδp/δG) from the straight line through the origin. Particularly, closure pressure is indicated by the dashed vertical line 200 .
The data collected from the DFIT 15 and analysis results therefrom may be used to determine whether a subsequent fracture treatment should be performed and, if so, aid in the design of a subsequent fracture treatment. Thus, the fracture treatment 10 may also include a production stimulation fracture treatment, a follow-on fracture treatment, a final fracture treatment, or other suitable fracture treatment (collectively referred to as “production stimulation fracture treatment”). A production stimulation fracture treatment may include injecting a fluid into the well 12 along with one or more additives, such as a gel, acid, proppant, and/or other desired materials.
FIG. 3 shows an example square-root-of-time plot (“sqrt(t)”) for determining closure pressure. In using the sqrt(t) method, closure pressure is indicated by an inflection point on the pressure v. square-root-of-time plot (“P v. sqrt(t)”). The inflection point may be located by plotting the first derivative of pressure versus sqrt(t) and locating the point of maximum amplitude of derivative. As shown in FIG. 3 , the dashed vertical line intersects the pressure versus sqrt(t) plot at the point of fracture closure. The point of fracture closure is verified using a semilog derivative of the P v. sqrt(t) curve. The fracture closure point falls at the point on the semilog derivative curve where this curve begins to deviate from the straight portion of this curve. The fracture closure point satisfies both of the criteria described above. Dashed vertical line 300 indicates closure pressure as determined using the G-function method.
A further graphical method is described with respect to FIG. 4 . FIG. 4 shows a log-log plot for determining closure pressure. Included in the plot is a pressure difference curve (ΔP v. Δt) and the dashed curve is a semilog derivative with respect to shut-in time. In many cases, the pressure difference curve and the semilog derivative curve are parallel in the time portion immediately before fracture closure. The slope of the parallel lines is indicative of the flow regime established during leakoff before fracture closure. Separation of the two parallel lines identifies closure pressure. Particularly, closure pressure is indicated by the point where the slope of the semilog derivative plot changes slope from positive to negative.
Various pressure transient analysis software packages are available to determine closure pressure based on the data obtained from the DFIT 15 . For example, Pumping Diagnostic Analysis Toolkit (PDAT) computer software may be used to perform one or more of the graphical methodologies to determine closure pressure. PDAT is a software package used to analyze minifrac pumping data and is a proprietary software package developed and used by Halliburton of 10200 Bellaire Blvd., Houston, Tex. However, any other software program capable of analyzing minifrac data to determine closure pressure may be used.
FIG. 5 schematically shows an example of the fracture analysis system 47 that may utilize one or more computer programs, including pressure transient analysis software and hydraulic fracture simulation software, to analyze received data and determine one or more pieces of information related to a fracture treatment, such as a DFIT 15 . For example, the fracture analysis system 47 may be used to determine closure pressure and/or PZS.
One or more of the fracture control system 46 or the fracture analysis system 47 may be implemented as an integrated computer system such as a personal computer, laptop, or other stand-alone system. In other embodiments, the fracture analysis system 47 may be implemented as a distributed computer system with elements of the fracture analysis system 47 connected locally and/or remotely by a computer or other communication network. Also, the fracture control system 46 may be implemented as a distributed computer system having elements connected locally and/or remotely by a computer or other communication network. The fracture control system 46 and the fracture analysis system 47 may include any processors or set of processors that execute instructions and manipulate data to perform the operations such as, for example, a central processing unit (CPU), a blade, an application specific integrated circuit (ASIC), or a field-programmable gate array (FPGA). Processing may be controlled by logic which may comprise software and/or hardware instructions. The software may comprise a computer readable program coded and embedded on a computer readable medium for performing the methods, processes and operations of the respective engines. The fracture control system 46 and the fracture analysis system 47 may be operable to receive, process, store, analyze, and output reservoir-related data. For example, the reservoir-related data may include fracturing-related data, such as fracture planning, simulation, stimulation, and analysis data. Further, the fracture control system 46 and the fracture analysis system 47 may be integrated or partially integrated and/or share one or more components and/or process. Still further, the fracture control system 46 and the fracture analysis system 47 may be stand-alone systems.
In some implementations, the fracture analysis system 47 may include a data collection and processing unit 500 , a pressure transient analysis engine 510 , a hydraulic fracture simulation engine 520 , a historical production stimulation fracturing database 530 , and a user interface 540 . The fracture analysis system 47 may and/or components of the fracture analysis system 47 may include additional, different, or other suitable components.
Data collection and processing unit 500 receives and/or communicates signals to and from surface and down-hole sensors 48 and 50 as well as pump controls 52 . The data represent, for example, physical conditions of the well 12 , the reservoir 14 , and/or the fracture treatment. The data collection and processing unit 500 may correlate received signals to a corresponding measured value, filter the data, fill in missing data and/or calculate data derivatives used by one or more of the pressure transient analysis engine 510 and/or the hydraulic fracture simulation engine 520 . The data collection and processing unit 500 may include data input/output (I/O) and a database or other persistent or non-persistent storage.
The pressure transient analysis engine 510 and hydraulic fracture simulation engine 520 may each be coupled to the data collection and processing unit 500 and the user interface 540 . Accordingly, each may access data collected and/or calculated and each may be accessed by an operator or other user via the user interface 540 . The hydraulic fracture simulation engine 520 may also be coupled to the historical production stimulation fracturing database 530 . The user interface 540 may comprise a graphical interface, a text based interface or other suitable interface. The user interface 540 may be used to interact with the pressure transient and analysis engine 510 , the hydraulic fracture simulation engine 520 , and/or the historical production stimulation fracturing database 530 as well as to view output information respectively therefrom.
In some implementations, the pressure transient and analysis engine 510 includes PDAT. However, the pressure transient and analysis engine 510 may include other or different software programs for analyzing the collected DFIT data to determine PZS. The pressure transient and analysis engine 510 utilizes the data from the DFIT stored or otherwise maintained in the data collection and processing unit 500 . Particularly the pressure transient and analysis engine 510 uses the collected data from the DFIT to determine ISIP and closure pressure and, ultimately, determine the PZS. In determining the closure pressure, the pressure transient and analysis engine 510 may use one or more of the methodologies described above, such as the Cartesian falloff plot, the square-root-of-time plot, the semi-log plot, the log-log plot, and/or the G-function plot. Examples of some of these methodologies are discussed above with respect to FIGS. 2 , 3 , and 4 .
In some instances, the pressure transient and analysis engine 510 determines PZS according to the following relationship: PZS=ISIP−closure pressure. The resulting PZS value may be used to determine the production potential of the subterranean zone and, thus, whether a production stimulation fracture treatment should be performed. In some instances, a PZS value of 1,900 psi or above may be an indication of a subterranean zone with poor production potential. In other instances, a PZS value of 1,400-1,500 psi or greater may be deemed a poor risk and represent a poor production potential. Further, a PZS value of 1,100 psi or lower may be determined to be a good indicator of production. Thus, a production stimulation fracture treatment may be applied and/or only applied to a subterranean zone having a PZS value of 1,100 psi or less. In those instances where the PZS value exceeds a value indicating a poor production potential, the production stimulation fracture treatment may be avoided, i.e., not performed. Still further, a production stimulation fracturing treatment may not be performed on a subterranean zone where a PZS indicating a poor production potential value is determined at any location along the subterranean zone. Determination of PZS as well as one or more other aspects for performing the DFIT 15 , collecting and/or analyzing data from the DFIT 15 , and any other aspect related to the determination of whether to perform a production stimulation fracture treatment (including the design thereof) may be performed automatically or otherwise suitable made. For example, in some instances, the PZS may be determined automatically by the fracture analysis system 47 while also being stored and/or displayed for operator review.
In other implementations, a normalized value of PZS, referred to hereinafter as “normalized process zone stress gradient” or “normalized PZS gradient”, may be used. The normalized PZS gradient may be determined using the determined PZS value and the subterranean depth at which the subterranean zone is located. In such cases, the determined PZS value is divided by the depth of the subterranean zone (understanding that this is the depth or approximate depth at which the fracture formed during the DFIT). Thus, a PZS that may otherwise be considered indicative of a poor production potential, the normalized PZS gradient may indicate a profitable producing well. In some instances, a normalized PZS gradient value at or above 0.12 psi/ft. may be indicative of a well having a poor production potential, and, thus, a production stimulation fracture treatment may be avoided, i.e., not performed. In other instances, a subterranean zone having a normalized PZS gradient value at or below 0.12 psi/ft. may be deemed a good risk and having an acceptable production potential. In such instances, a production stimulation fracture treatment may be performed.
In still other implementations, a normalized PZS gradient value may be used in connection with the determined PZS value. A PZS for a subterranean zone may be determined to be 1,400 psi, which may be determined to have a poor production potential. Thus, a production stimulation fracture treatment may be avoided based on this PZS value. However, by normalizing the PZS value based on the depth of the subterranean zone (at a depth of approximately 15,000 ft. in this example), the resulting normalized PZS gradient value is 0.09 psi/ft. (1,400 psi/15,000 ft.=0.09 psi/ft.). As 0.09 psi/ft. is less than 0.12 psi/ft., this subterranean zone is determined to have good production potential.
For subterranean zone having a good production potential based on the determined PZS and/or normalized PZS gradient, the properties of the subterranean zone determined from the DFIT data (e.g., permeability and pore pressure) may be sent to the hydraulic fracture simulation engine 520 . The hydraulic fracture simulation engine 520 may include fracture modeling software that may be used to design and/or model a production stimulation fracture treatment. In some instances, the hydraulic fracture simulation engine 520 may include GOHFER® produced by Barree & Associates, LLC of 7112 W Jefferson Ave, Suite 106, Lakewood, Colo. However, the hydraulic fracture simulation engine 520 may include other or different fracture design software tools, packages, or programs for designing the production stimulation fracturing treatment.
In other implementations, the PZS value may be determined using historical production stimulation fracturing data of a well, such as well 12 . Historical production stimulation fracturing data includes data obtained from a production stimulation fracturing treatment, such as a fracturing treatment performed for the purposes of increasing or otherwise enhancing production from the well, such as well 12 . The historical production stimulation fracturing data may be located in the historical production stimulation fracturing database 530 . The historical production stimulation fracturing data may be fed into the hydraulic fracture simulation engine 520 , such as GOHFER, and obtain a PZS estimate using the historical production stimulation fracturing data. The historical production stimulation fracturing data may include, for example, log data, pressure data, injection rate data, and proppant concentration data. This PZS estimate may be in a similar manner as the PZS determined from the DFIT data.
For a well intersecting multiple subterranean zones that have a potential for producing subterranean fluids, in some implementations, the lowest subterranean zone may be isolated and a DFIT thereon. If the determined PZS for this subterranean zone shows a poor producing potential, the next subterranean zone above the first subterranean zone may be isolated and analyzed. That is, a DFIT may be performed on the next subterranean zone and a PZS obtained. A production stimulation fracture treatment may be performed or not performed based on the determined PZS value. The next-above subterranean zone may then be analyzed, and so forth.
Examples are now described with reference to FIGS. 6-15 . Example 1 is described with reference to FIGS. 6-12 . FIG. 6 shows a ShaleLog™ of an example subterranean zone formed from shale. The shale is intersected by a well. Perforations formed in the shale are located at approximately 5,960 to 6,018 ft. A DFIT was performed in this zone. The treatment plot is shown in FIG. 7 . The DFIT consisted of approximately 1,077 gallons of fresh water injected at an average rate of approximately 3 bpm. The ISIP obtained was 7,261 psi, which resulted in a fracture gradient of 1.22 psi/ft. The falloff data was collected for approximately 45 hours and 40 minutes. The pressure falloff data was analyzed using the log-log plot methodology described above and in SPE 107877. The log-log plot is shown in FIG. 8 .
Referring to FIG. 8 , the first derivative curve 800 in the plot has a portion with a negative ¾slope (m=−0.75). A semilog derivative curve 810 includes a portion having a positive slope of approximately one-quarter (m=+0.251) in the prior to closure pressure 820 , indicating bilinear flow before closure pressure 820 . Closure pressure 820 is indicated by the change in slope from positive to negative in the semilog derivative curve 810 . Closure pressure 820 is estimated to be 5,270 psi (0.88 psi/ft). After fracture closure indicated by 820 , the first derivative curve 800 shows negative 3/2slope (m=−1.497) and the semilog derivative curve 810 shows a negative one-half slope (m=−0.499) indicating that pseudo-linear flow was observed during shut-in.
In FIG. 9 , the G-function derivative analysis plot 900 shows pressure-dependent type leakoff during shut-in. A hump associated with fissure opening pressure is very shallow, and, consequently, it is difficult to identify a unique fissure opening pressure. Closure pressure is estimated to be 5,270 psi. This suggests that the pressure change or “delta P” between the fissure opening pressure and closure pressure is minimal. Noise observed in the plot is caused by bad data scatter observed during shut-in.
Using the relationship explained above, the PZS was estimated to be approximately 1,990 psi (PZS=7,261 psi−5,270 psi=1991 psi). This methodology may also be applied to subterranean zones formed from shale, subterranean coal, as well as to other reservoirs and subterranean zones. If the PZS is determined to be above a threshold value, a subsequent production stimulation fracture treatment may be avoided. For example, a threshold PZS value may be selected to be 1,100 psi, and this determined PZS stress is above the threshold. Consequently, a subsequent production stimulation fracture treatment may not be performed.
FIG. 10 shows a history match of a subsequent fracturing treatment (performed subsequent to the fracture injection falloff test) made to the shale. The history match was made using GOHFER. The fracturing treatment was aborted without pumping any proppant because the treating pressure was close to the maximum treating pressure of 7,000 psi. In order to obtain the GOHFER match, the PZS used in the model was increased to approximately 3,200 psi. This value exceeds that obtained from the DFIT (i.e., approximately 1,990 psi), which confirms that the PZS estimated from a fracture injection falloff test is a good starting point and likely the minimum that can be expected and can vary during injection of the fracture fluid, such as fracture fluid 58 . If the PZS determined from a DFIT is high, one can expect that the actual PZS in the formation would be at least equal to or higher that this value.
It is noted that, although PZS was used in the analysis, the same result may be obtained by using a normalized PZS gradient value. For example, if an average depth of the subterranean zone is used ((5,960 ft.+6,018 ft.)/2=5,989 ft.), the normalized PZS gradient is 0.33 psi/ft., which is greater than 0.12 psi/ft.
To verify this analysis, a calibrated pre-fracturing model was created using GOHFER and used to model a design for a second fracturing treatment. The pre-fracture model showed that, unless the high PZS is mitigated, the treating pressure during the second fracturing treatment would exceed the maximum treating pressure of 7,000 psi. The proposed design for the second fracturing treatment made using the GOHFER model is shown in FIG. 11 .
The second fracturing treatment was also cut short due to the treating pressure approaching the maximum treating pressure, confirming the results of the pre-fracturing model. The GOHFER history match of the second fracturing treatment is shown in FIG. 12 . The PZS value used in the model remained the same, approximately 3,200 psi., as identified in the history match of the first fracturing treatment. The correspondence of these values confirms that the high PZS estimated from the DFIT and later confirmed by the GOHFER fracture model for this zone is valid. It is also noted that, the production from the shale in the instant subterranean zone was low. As a result, the well intersecting this subterranean zone was temporarily plugged and abandoned.
A second example is described with reference to FIGS. 13-15 . The second example involves a well that intersects a subterranean zone formed from subterranean coal (“coal seam”), referred to as the “intersecting well”. A type log of the coal seams intersected by the intersecting well is shown in FIGS. 13A-B . The perforations in the target coal seams are located at the following depths: 1922 ft., 1927-1928 ft., 1935-1942 ft., 1953-1955 ft., and 1955-1960 ft. The stimulation in these coal seams were cut short due to the treating pressure approaching the maximum limit. Although a DFIT was not performed in the intersecting well, a DFIT was performed in an offset well. The DFIT data showed that the offset well exhibited a moderately high PZS value of approximately 500 psi. The DFIT data from the offset well was used to perform a history match using GOHFER in order to estimate a PZS value for the intersecting well. This data is illustrated in FIG. 14 . The history match resulted in a PZS value of 2250 psi and a normalized PZS gradient value of 1.16, both of which are extremely high.
Although the PZS and normalized PZS gradient values were high, the well was re-stimulated. A treatment plot from the additional stimulation treatment is shown in FIG. 15 . While the additional stimulation treatment was successful, the resulting production from the intersecting well was very poor. Consequently, the history match determined using the DFIT data from the offset well confirmed that these coal seams have a much higher PZS and correspondingly poor production.
In other implementations, an approximate PZS value for which a fracture injection falloff test was not conducted may be obtained. For example, in some cases the reservoir zone data and historical production stimulation fracturing data may be used to generate a history match fracture model using a fracture modeling software program. In some instances, the fracture model may be prepared using GOHFER. The fracture model can include determination of an approximate PZS value for the subterranean zone. The estimated PZS value obtained using the fracture modeling software may be used in a manner similar to the PZS value obtained using DFIT data. That is, if the PZS value is above a threshold value, a stimulation treatment to the subterranean zone may be avoided.
FIG. 16 is a flowchart for an example method 1600 for determining the use of a stimulation treatment on a well 12 . At 1602 , an injection shut-in test, such as the DFIT 15 , is performed on the well 12 as explained above. The data from the injection shut-in test is collected at 1604 . Data may be collected by one or more physical sensors in the well 12 and relayed to the data collection and processing unit 500 for processing by the fracture analysis system 47 . At 1606 , the ISIP is determined, and the closure pressure is determined at 1608 . The ISIP and/or the closure pressure may be determined by the fracture analysis system 47 , with or without operator interaction. The ISIP and closure pressure is to obtain the PZS at 1610 . By operation of the fracture analysis system 47 , PZS may be stored, displayed, printed, or otherwise recorded. At 1612 , a determination is made as to whether the determined PZS value indicates a good production potential. In some instances this determination may be performed automatically. At 1614 , a good production potential is indicated, and a production stimulation fracture treatment is designed at 1618 . This determination may be made based on the determined PZS value equal to or less than a threshold value. Alternately or in combination, this determination may be made based on a normalized PZS gradient value being at or below a threshold value. The production stimulation fracture treatment is performed at 1620 . If a poor production potential is indicated at 1616 , a production stimulation fracturing treatment is not performed. Thus, in some implementations, a production stimulation fracture treatment may be performed only if the PZS is at or below a threshold. Also, in one or more implementations, a production stimulation fracture treatment may be avoided or not performed if the PZS is above the threshold.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.
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Methods for determining whether to perform a stimulation treatment on a subterranean zone are disclosed. Process zone stress (“PZS”), indicative of a production potential of the subterranean zone, is determined, and a determination is made as to whether the PZS exceeds a preselected value. A PZS exceeding the preselected value may indicate a poor production potential, and a stimulation treatment of the subterranean zone may be avoided. As a result, a substantial cost saving associated with the avoided stimulation treatment may be realized.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a Divisional Application of U.S. application Ser. No. 11/447,788 filed on Jun. 6, 2006, now U.S. Pat. No. 7,___,___, the entire contents of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to devices powered by energy generated by impacts and, more particularly, to consumer devices, such as a flashlight powered by an impact.
[0004] 2. Prior Art
[0005] In general, all chemical batteries contain hazardous and/or corrosive chemicals, have a relatively short shelf life, are relatively expensive and introduce waste disposal problems, with the latter being particularly the case for lithium based batteries and most rechargeable batteries. To satisfy the need for alternative power source solutions for various devices in general and for flashlights in particular, products have been developed that utilize coil and magnets to generate electrical energy. Bicycle dynamo and cranking type of dynamos have long been used to generate electrical energy. Similar coil and magnet generators have also been used in flashlights in the form of rotary crank type and sliding shaking type generators. The crank type generators are relatively heavy and bulky and when designed to be small as is needed for flashlights, they are cumbersome and tiring to crank. The shake type linear motion generators generate very small amounts of electrical energy during each shaking cycle, and are also relatively heavy. Each of such cranking and shaking devices are limited by the physical ability of the person providing the energy to crank or shake the device. In addition, the availability of low cost LED (Light Emitting Diode) lights that consume significantly less electrical energy than conventional light bulbs have made flashlights that harvest energy from the environment, including the user induced actions, much more practical. This is particularly the case for flashlights that are to be used in emergency situations and/or for use in locations where electricity is not available such as in the beach, during hiking, and the like, where flashlights with rechargeable batteries are not practical.
[0006] The only source of energy that is available to humans that could be harvested is mechanical energy. The energy to be harvested by any energy harvesting power source is mechanical in nature. The difference between any such energy harvesting power sources is: 1) in the method of transferring mechanical energy to the energy harvesting device; and 2) in the method of transforming mechanical energy to electrical energy.
[0007] A superior method of transferring mechanical energy to the energy harvesting device is ergonomic and does not put undue stress on the user limbs and joints. The method must also be efficient in making available the work done by the human subject to mechanical energy that can be harvested. In addition, the transferred mechanical energy is preferably stored in an intermediate medium to lengthen the period of time available for its conversion to electrical energy since it is generally easier and more efficient to convert mechanical energy to electrical energy and store it in electrical storage devices such as capacitors and rechargeable batteries. The means of transforming mechanical energy to electrical energy is also desired to produce high enough voltage to make the process of charging rechargeable batteries and/or capacitors more efficient.
[0008] A need therefore exists for methods and related devices for efficient transfer of the work done by human muscles to mechanical energy that can be harvested efficiently and transformed into electrical energy.
SUMMARY OF THE INVENTION
[0009] Accordingly, a device is provided. The device comprising: a housing; a powered element disposed on or in the housing; and an impact power producing element housed on or in the housing and operatively connected to the powered element, the impact power producing element producing power upon an impact of at least a portion of the housing with another surface; wherein the impact power producing element comprises a mass and one or more spring elements connected at a first end to the mass and at a second end directly or indirectly to the housing and the impact power producing element further comprises one or more magnet elements and a coil, wherein the impact causes a relative motion between the one or more magnet elements and the coil.
[0010] The one or more magnet elements can be at least the mass.
[0011] The one or more spring elements can comprise one or more cantilever beams and the impact power producing element can comprise a piezoelectric element disposed on one or more surfaces of the one or more cantilever beams.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] These and other features, aspects, and advantages of the apparatus of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
[0013] FIG. 1 illustrates a cross sectional schematic view of a first embodiment of an impact powered flashlight.
[0014] FIG. 2 illustrates a variation of the mass-spring unit of the embodiment of FIG. 1 .
[0015] FIG. 3 illustrates a cross sectional schematic view of a second embodiment of an impact powered flashlight.
[0016] FIG. 4 illustrates a cross sectional schematic view of a third embodiment of an impact powered flashlight.
[0017] FIG. 5 illustrates a cross sectional schematic view of a fourth embodiment of an impact powered flashlight.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Although the present invention is applicable to numerous types of devices, it is particularly useful in the environment of a flashlight. Therefore, without limiting the applicability of the present invention to a flashlight, it will be described in such environment. Those skilled in the art will appreciate that the methods of the present invention can be utilized for other devices, such as cell phones, PDA's, cameras, laptop computers and the like. Where the device includes interior electronics, such as circuit substrates, which may be prone to breakage, the device can also be designed such that the interior electronics are less prone to breakage from impacts. Designing electronic devices to be impact resistant, such as from dropping, are well known in the art.
[0019] The primary method of mechanical energy transfer to the generator mechanism described herein is an impulsive motion, such as an impact force. The user is intended to provide the impact (impulsive) force to the device by hitting it on some relatively hard object, hitting it on some relatively hard surface, dropping it repeatedly onto some relatively hard surface, or through other impact inducing actions. The user action results in the storage of certain amount of mechanical energy in the device in the form of potential energy, or kinetic energy, or their combination. The stored potential energy is then transformed into electrical energy through the vibration of the system, which generates varying force on at least one piezoelectric element or the like, which in turn generates varying charges (an AC voltage), which is then harvested by the system electronics using well known techniques, and used to charge a capacitor and/or rechargeable battery and/or directly to provide power, such as to provide light, preferably through an LED or other low power light source. The induced vibration may be axial, in bending, in torsion, or their combination.
[0020] Referring now to FIG. 1 , there is shown a first embodiment of a device using such an impact (or other impulsive motion) to provide power for at least one powered element associated with the device, in the form of a flashlight shown schematically in FIG. 1 . The flashlight 10 has a powered element in the form of a light source 11 , which can be one or a plurality of LEDs or other low power light source (collectively referred to as the light source 11 ). The light source 11 can be mounted in a housing 12 that contains the energy harvesting electronics and the electrical energy storage device(s), collectively indicated as element 25 . Such energy storage devices are well known in the art, such as low leakage capacitors and/or rechargeable batteries and a detailed description thereof will be omitted for the sake of brevity. The impact force or vibration motion to mechanical energy storage mechanism is preferably positioned in a handle 13 , away from the more sensitive electronics 25 and light source 11 . The impact force or vibration motion to mechanical energy storage mechanism can comprise an impact power producing element, such as at least one mass-spring unit 20 , with at least one relatively rigid mass 14 and at least one transition elements, such as one or more spring elements 15 . As discussed below, the impact power producing element also functions with the application of other impulsive motions, such as shaking, either directly or incidental. The housing 21 of the handle and preferably the light source housing 12 are constructed strong enough to resist moderate impact and drops, such as with plastic. A bottom surface 22 of the flashlight can be constructed of a durable material that can withstand repeated impacts, such as one or more high-strength plastics. When the user hits the bottom surface 22 of the handle housing on a relatively rigid surface, the mass 14 is accelerated downwards in the direction of arrow 23 during the duration of the impact. Simply, this occurs since once the handle housing is stopped suddenly during a small period of time Δt (usually a few milliseconds depending on the physical characteristics of the impacting surfaces and on how rigid the impacted structure behaves), then the mass 14 , which is free to accelerate, begins to accelerate and continues to accelerate during nearly the same period of time Δt. At the completion of this acceleration period, the mass 14 has reached a certain velocity V 0 and has traveled a certain distance D 0 . If the effective mass 14 of the mass-spring unit 20 is m and the effective spring rate of the mass-spring unit 20 is K, then the total mechanical energy E m stored in the mass-spring unit 20 as a result of the aforementioned impact (impulse) force is:
[0000] E m =0.5 m V 0 2 +0.5 k D 0 2 (1)
[0021] Following the impact, the mass-spring unit 20 will begin to vibrate. The spring element(s) 15 will then exert a varying force on the piezoelectric elements 24 positioned on at least one end of the spring elements 15 , which in turn generate a varying charge with a certain voltage that is harvested by the harvesting and storage electronics 25 and made available to power the light source 11 or other powered element associated with the device. As is known in the art, the piezoelectric elements can be made in stacked form, which are widely available commercially, for low voltage applications. As shown in FIG. 1 , the mass 14 can be positioned in between two spring elements 15 , each of which can exert a varying force on a corresponding piezoelectric element 24 positioned at two ends of the handle 13 . The piezoelectric elements 24 can be electrically connected to the storage electronics 25 or directly to the light source 11 through appropriate wiring in the housing 12 .
[0022] The mass 14 can be an integral part of the spring element(s) 15 as shown in FIG. 2 . In this configuration, the entire mass-spring unit 20 can be constructed with a single spring wire helically wound with at least one compressed coil section 26 , which acts as the relatively rigid mass 14 of the mass-spring unit 20 .
[0023] It will be appreciated by those skilled in the art that coil and magnet type of mechanical to electrical energy generators may also be used instead of the aforementioned piezoelectric elements with the above method of storing mechanical energy due to impact (impulsive) forces for relatively slow transformation into electrical energy. The schematics of one such embodiment is shown in FIG. 3 . All elements of this embodiment may be identical to that of the embodiment shown in FIG. 1 with the difference that the piezoelectric elements 24 are replaced with the coil 27 and magnet 28 elements. The magnet 28 can be the mass 14 of the mass-spring unit 20 (and not the coil 27 ), to eliminate the need to attach wires to the vibrating mass 14 . Following the impact or other impulsive motion, the magnet 28 vibrates inside the coil, therefore causing it to generate an AC current, which is then harvested by the harvesting and storage electronics 25 .
[0024] It is appreciated by those familiar with the art that one or more mass-spring elements can also be mounted perpendicular to the long axis of the flashlight handle to be responsive mostly to an impact or other impulsive motion to the side of the flashlight. The schematic of such an embodiment is shown in FIG. 4 . The at least one mass-spring unit 40 (in the schematic of FIG. 4 , two of the mass-spring units shown in FIG. 1 or 2 are used) is similarly attached to piezoelectric elements 41 to harvest the stored mechanical energy during vibration of the mass-spring unit 40 as previously described by the harvesting and storage electronics 25 . The lateral impact can be to the more rigid end 22 of the handle 13 in the direction of arrow 43 . However, any lateral and/or axial impact or their combination will accelerate the mass 26 of the mass-spring unit 40 . It is appreciated by those skilled in the art that the mass-spring unit 40 would similarly respond to an axial impact in the direction of the arrow 42 by vibrating in the axial direction, and the lateral component of the spring force on the piezoelectric element would similarly produce charges that can be harvested by the harvesting and storage electronics 25 .
[0025] As was previously described, the impact or other impulsive motion induced vibration may be axial (i.e., in the direction of the length of the flashlight), in bending, in torsion, or their combination. When the impact is essentially in the axial direction 35 and generated by hitting the bottom surface of the flashlight on a relatively hard surface, bending deflection can be readily induced as shown schematically in FIG. 5 by at least one cantilever beam generator assembly 30 , consisting of a beam 34 that is attached to the housing 21 of the handle 13 of the flashlight, preferably aided by at least one tip mounted mass 31 (the mass can be an integral part of the beam). At least one piezoelectric element 33 is attached to the surface of the beam 34 , preferably close to its base (the end attached to the flashlight) so that it is subjected to high tensile strain on one side of the beam 34 and compressive strain on the other side of the beam 34 . The varying charge generated due to the applied compressive and tensile strains on the piezoelectric elements is then supplied to and harvested by the harvesting and storage electronics 25 . It is appreciated by those familiar with the art that the piezoelectric elements 33 can be pre-stressed in compression so that during the aforementioned vibration they are not subjected to tensile stress since piezoelectric elements can be very brittle and can withstand only small tensile strains.
[0026] It is noted that since the disclosed methods and embodiments rely on vibration of mass-spring units, mechanical energy is transferred to the mass-spring units during other flashlight acceleration and deceleration cycles other than those due to impact (impulsive) forces imparted somewhere on the flashlight body. For example, if the flashlight is placed inside a car, the vibration of the car will induce vibration of the flashlight mass-spring unit and thereby generate electrical energy that is stored, preferably in rechargeable batteries, for later use. The same process occurs if a person carries the flashlight in his/her pocket or purse or briefcase, etc., while walking or otherwise moving and would have a charged flashlight for use when needed.
[0027] Although the embodiments disclosed herein are discussed as providing electrical energy upon an impact of the device against a surface, then can also provide electrical power upon the application of any other impulsive motion, such as by shaking, which can be directly applied (such as by a person shaking the device with his or her hand) or incidentally applied (such as due to movement while being stored in a car, pocketbook etc.). However, unlike the shaking apparatus of the prior art, transition elements, such as the spring elements are provided for storing potential energy, which is in turn converted to electrical power, such as by the piezoelectric elements or magnet/coil arrangements. A shaking impulsive motion working solely on a movable mass, has limitations as to the frequency by which the mass can vibrate (less than 10 Hz), while the addition of the transition elements, such as the spring elements, can produce much higher frequencies, such as between 10-300 Hz and possibly higher, with the impact impulsive motion generally providing the higher frequencies in the range.
[0028] 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 device including: a housing; a powered element disposed on or in the housing; and an impact power producing element housed on or in the housing and operatively connected to the powered element, the impact power producing element producing power upon an impact of at least a portion of the housing with another surface; wherein the impact power producing element comprises a mass and one or more spring elements connected at a first end to the mass and at a second end directly or indirectly to the housing and the impact power producing element further comprises one or more magnet elements and a coil, wherein the impact causes a relative motion between the one or more magnet elements and the coil.
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BACKGROUND OF INVENTION
This invention relates generally to an apparatus for removably securing structures to the ground. More specifically, this invention relates to an anchor for removably securing a cover over a trench or hole in the ground.
Access holes are dug in the street or right-of-way to access and locate underground utilities. If the hole must be left unfilled for continuing work the next day or for later inspection, the common practice is to place one or more heavy cover plates of 0.5″-1.25″ steel over the opening in the ground. The cover plates are held in place simply by their sheer weight. Despite the weight, however, the plates may be dislodged by traffic, vibration, or vandalism, leaving an opening in the ground that is dangerous to vehicles, people, and pets who pass by. Material loosened while digging the trench can thus also be exposed, flying into and breaking vehicle windshields. In locations where a plate is likely to be dislodged or must be left for a longer period of time, tar or asphalt is often laid around the perimeter of the cover to further secure it in place. This method is somewhat more secure, but requires additional effort, equipment and materials and makes intentional plate removal messy and more difficult. It is desirable to have a device for securing covers over access holes and trenches.
Holes and trenches come in many shapes, sizes and substrate materials. Holes may be circular or square. Trenches may cut a straight path, or have curves or corners. Some trenches and holes have straight vertical walls, while the walls are sloped in others. The substrate into which the hole or trench is cut may be composed of hard material like rock, or softer material like dirt or sand, into which it is difficult to anchor. For openings cut in asphalt or concrete, the cavity below the opening may undercut the opening, leaving an overhang of asphalt or concrete. A device used to secure covers over these openings must accommodate all sizes and shapes of trenches and holes, as well as a variety of substrate materials.
It is an object of this invention to provide a device which removably secures a cover to the ground. It is another object of this invention to provide a device which secures one or more cover plates to the ground in a way that prevents the cover from being inadvertently dislodged. It is another object of this invention to secure a cover to the ground in a way that it can be easily removed to inspect the hole or trench, or to backfill when work or inspection is complete. It is another object of this invention to provide a device which removeably secures the cover to asphalt, concrete, soil or other surface material. Another object is to provide an anchoring device that is weather resistant.
BRIEF SUMMARY OF THE INVENTION
The present invention provides an earth anchor to secure a cover over a trench or hole in the ground. The device has a retaining cap which is attached to a rod. Extendible arms are connected to the rod below the cap. The end of the rod opposite the cap is inserted into the hole or trench until the cap rests at ground level, either on top of a cover plate or on the ground itself. For large holes, the cap retains separate cover plates over the hole; for small holes, the cap acts as a cover itself. The arms are extended by a jack screw, rack and pinion, or other means until they contact the substrate or underside of the cover plates and clamp the same between the cap and the arms. The cover can be removed by reversing the motion of the jack screw or rack and pinion, and retracting the arms, thereby freeing the device to be removed from the hole.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of the first embodiment of the device employed in a trench, securing a cover plate to the ground over the trench.
FIG. 2 is a perspective view of the first embodiment of the device employed in a trench, securing cover plates to each other over the trench.
FIG. 3 is a top view of the first embodiment of the invention.
FIG. 4 is a side view of the first embodiment of the invention, showing the hinged arms partially extended by means of a jack screw.
FIG. 5 is a cross-section view of the first embodiment of the invention, showing the hinged arms in a closed position substantially parallel to the jack screw.
FIG. 6 is a side view of the first embodiment of the invention, showing the straight arms in a closed position.
FIG. 7 is a cross-section view of the first embodiment of the invention, showing the arms partially extended by means of a rack and pinion.
FIG. 8 illustrates a second embodiment of the device employed in a hole, showing use of the cap itself as the cover for the hole.
FIG. 9 illustrates a third embodiment of the device employed in a trench, securing cover plates to the ground and shoring trench walls.
FIG. 10 is a cross-section view of the third embodiment of the invention, showing the arms partially extended by means of a jack screw.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention is best understood by reading the following description in conjunction with reference to the accompanying FIGS. 1-10 in which like numerals refer to like parts throughout the drawings. FIG. 1 shows a first embodiment of the device, indicated generally as 10 , installed in a trench 9 , wherein the device serves to secure one or more cover plates to the ground. The device 10 is shown securing a cover plate 8 to the ground 6 so that the cover plate 8 does not lift up or otherwise become dislodged by traffic, vibration or vandalism. The device 10 is installed by inserting it through an aperture 5 in the cover plate 8 or, alternatively, abutting the edge of a cover plate, if no aperture is available, so that the lower portion of the device is suspended. An aperture 5 in the body of the cover plate 8 is shown at the distal end of the cover plate in FIG. 1 . (The aperture in the proximal end of the cover plate is hidden in the figures by the cap 12 .) An aperture 4 in the edge of the cover plate 8 is shown in FIG. 2. A cap 12 rests on top of the cover plate 8 .
As shown in FIG. 3, an aperture in the cap 12 allows access to the end of a rod 11 , which is connected to the cap 12 in a manner which allows the rod to turn independently of the cap 12 . At least one extendible arm 14 is slidably connected to the rod 11 so that when the rod is turned, the arm moves through a range of positions from a position substantially parallel to the rod to substantially perpendicular to the rod 11 . A jack screw or rack and pinion system is used to extend the arms, as described below. The arm 14 is extended until it contacts or penetrates the ground 6 . More than one arm 14 may be used to accommodate different trench sizes and cover plate configurations. Preferably two arms are used to secure a cover plate 8 over a hole or trench, the arms positioned opposite each other on the rod 11 , as shown in FIG. 1. A foot 15 is attached to each arm 14 to engage the ground more securely than the arm alone. The foot may be pivotally attached to the arm. Projections, or teeth, are added to the foot 15 to enable the foot 15 to better secure the anchor to the ground. When the device is to be removed, the rod 11 is turned in a reverse direction so that the arms retract.
The rod 11 can be attached to the cap 12 in any way which allows the cap 12 to float, i.e., the rod 11 turns while the cap 12 remains in place. A modified H-beam structure, indicated generally as 20 , is shown in FIGS. 3, 5 , 6 , and 7 . Preferably the rod 11 does not extend above the cap 12 because a relatively smooth cap surface is desired so that vehicles driving over the cap 12 will have a smooth ride and tires will not be damaged. The edges of the cap 12 may be beveled to make the transition from the cap 12 to the ground or cover place more smooth. The rod 11 is encased in a tube 16 , having a slot 17 along the lengthwise axis of the tube to accommodate each arm as it extends through its full range of positions. The tube 16 is also attached to the cap 12 . The tube 16 adds structural integrity to the device, which must be rugged enough to survive heavy traffic for extended periods of time, and helps keep the means for extending the arms free of dirt and debris. If desired, a locking mechanism can be used to prevent the rod 11 from being turned by unauthorized personnel, thereby preventing the anchor from being removed and preventing dangerous situations from arising due to an uncovered hole or trench.
FIG. 2 shows the device 10 securing together two cover plates 8 used to cover the trench 9 to prevent objects or animals from falling in. Instead of clamping the cover plate 8 to the ground, as shown in FIG. 1, the device clamps the cover plate 8 to another cover plate 8 . Like the first embodiment above, the device 10 effectively secures the cover plate 8 to the ground so that it does not lift up or otherwise become dislodged by traffic, vibration or vandalism. Of course, a combination of the first embodiment and second embodiment may be utilized in the field, wherein one arm engages the ground and another arm engages another cover plate.
FIG. 8 shows a second embodiment of the device 10 , employed as the cover for a hole having an opening smaller than the cap 12 . The device is lowered into the hole 30 until the cap 12 rests on the ground 6 . The arms 14 are extended until they engage the ground 6 or, in a hole where the cavity has undercut the pavement, the arms clamp the cap 12 to the overhanging substrate.
To implement the ground anchor, the arms must be extended. Several means are available for transforming the circular motion of the turning rod 11 into an extension motion of the arm. FIGS. 1-5 and 8 show the present invention utilizing an externally threaded rod 11 in combination with an internally-threaded collar (hidden behind the cross-member 18 in the Figures) attached to hinged arms. The end of the rod 11 that is accessible through the cap 12 is configured to make the rod 11 easy to turn. For example, the end may be shaped to receive a flathead or Phillips screwdriver, an Allen wrench, or it may be shaped as a hexnut so that it can be easily turned with a lug wrench. When the rod 11 is turned in a forward direction, the collar follows the threads, causing it to move up the rod 11 , thereby extending the arms. When the device is to be removed, the rod 11 is turned in a reverse direction so that the arms retract. This configuration is commonly known as a jack screw. Refer to FIG. 5 which most clearly illustrates an embodiment with hinged arms. Each arm has two links, a first link 51 and a second link 52 . One end of each link is pivotally attached to a flange on the foot 15 , creating a single hinged arm having two links. The foot 15 is the point that is farthest from the rod 11 when the arm is extended. The free end 53 of the first link 51 is pivotally attached near the top of the rod 11 or tube 16 . The free end 54 of the second link 52 is attached to the collar. When the rod 11 is turned in a forward direction, the collar follows the threads, causing it to move up the rod 11 and closing the hinge point, thereby extending the arms. FIG. 4 shows the arms in an extended position. When the rod 11 is turned in a reverse direction, the collar moves down the rod 11 and opens the hinge point, thereby collapsing the arms. FIG. 5 shows the arms in a collapsed position.
FIG. 6 shows an embodiment with straight arms. One end of each arm 21 is pivotally attached to the collar (again, hidden behind the cross-member 18 in the Figures). When the rod 11 is turned in a forward direction, the collar follows the threads, causing it to move up the rod 11 and causing the arms to move from a position substantially parallel to the rod 11 to a position substantially perpendicular to the rod 11 . When the rod 11 is turned in a reverse direction, the collar moves down the rod 11 and the arms are collapsed. Multiple arms can be attached to the collar, so that the jack screw can operate more than one arm simultaneously. However, some situations may require that a single arm be used to secure the device in place, in which case the unused arm may hang suspended in mid-air.
Another means for extending the arms is a rack-and-pinion system shown in FIG. 7 . Instead of using hinged arms attached to a collar, single link arms are attached to a rack 70 having teeth 71 . The teeth 71 of the rack 70 mesh with the teeth 77 of a pinion gear 72 which is coaxial with the rod 11 . The rack 70 is substantially perpendicular to the rod 11 and cooperates with the pinion gear 72 to extend the arms in a direction substantially perpendicular to the rod 11 . The pinion gear 72 is internally threaded to travel up and down the rod 11 . The rod 11 is turned to cause the pinion gear 72 to moved to the desired height. Once the desired height is reached, the clutch spring 74 is activated to drop the clutch gear 74 into place and engage the pinion gear 72 . As the rod 11 is turned in a forward position, the clutch causes the pinion gear 72 to rotate and extend the rack 70 , so that the arms are forced into the sides of the hole or trench. In a hole where the cavity has undercut the pavement, the arms clamp the cap 12 to the overhanging substrate. When the device is to be removed, the rod 11 is turned in a reverse direction so that the arms retract.
The third embodiment of the invention is shown in FIGS. 9 and 10. The foot is replaced with a plate which can be used to shore up the sides of the trench or hole, as shown in FIGS. 9 and 10. The shoring plates 90 are pivotally attached to a mounting flange 91 of the shoring arms 92 to shore up walls 93 of a trench 9 . Preferably the shoring arms 92 are extended by means of a jack screw. The device is installed by inserting the rod 11 into the trench until the cap 12 rests on the ground or pavement, providing support for the device to hang in the cavity. As the rod 11 is turned, the arms extend until the plates abut the walls of the cavity, thereby shoring up the walls.
Preferably the cap 12 and tube 16 are made of material sturdy enough to withstand heavy traffic and weather, preferably steel. The mechanical components, such as the rod, collar, pinion gear, may instead be made of a high-strength, weather resistant material such as nylon or plastic. To prevent the device from being dislodged due to dynamic vibration caused by traffic, a dampening spring may be included between the cap and the arms.
The objects of this invention are achieved through the aforementioned improvements. It will be understood that various modifications may be made to the ground anchor and the method of using it without departing from the purview of the appended claims. Although certain preferred embodiments have been shown and described, it should be understood that other embodiments and modifications that achieve these objects may be apparent to those of skill in the art and are within the scope of the appended claims.
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The present invention provides an earth anchor to secure a cover over a trench or hole in the ground. The device has a retaining cap which is attached to a rod. Extendible arms are connected to the rod below the cap. The end of the rod opposite the cap is inserted into the hole or trench until the cap rests at ground level, either on separate cover plates or on the ground itself. For large holes, the cap retains separate cover plates over the hole; for small holes, the cap acts as a cover itself. The arms are extended by a jack screw, rack and pinion, or other means until they contact the substrate or underside of the cover plates and clamp the same between the cap and the arms. The cover can be removed by reversing the motion of the jack screw or rack and pinion, and retracting the arms, thereby freeing the device to be removed from the whole.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to rotary drilling of subterranean formations and, more specifically, to a rotary drill bit exhibiting particularly beneficial characteristics for drilling slow drilling shales as well as for high rate of penetration drilling.
2. State of the Art
Equipment used in subterranean drilling operations is well known in the art and generally comprises a rotary drill bit attached to a drill string, including drill pipe and drill collars. A rotary table or other device such as a top drive is used to rotate the drill string from a drilling rig, resulting in a corresponding rotation of the drill bit at the free end of the string. Fluid-driven downhole motors are also commonly employed, generally in combination with a rotatable drill string, but in some instances as the sole source of rotation for the bit. The drill string typically has an internal bore extending from and in fluid communication between the drilling rig at the surface and the exterior of the drill bit. The string has an outer diameter smaller than the diameter of the well bore being drilled, defining an annulus between the drill string and the wall of the well bore for return of drilling fluid and entrained formation cuttings to the surface.
An exemplary rotary drill bit includes a bit body secured to a steel shank having a threaded pin connection for attaching the bit body to the drill string, and a body or crown comprising that part of the bit fitted on its exterior with cutting structures for cutting into an earth formation. Generally, if the bit is a fixed-cutter or so-called “drag” bit, the cutting structure includes a plurality of cutting elements including cutting surfaces formed of a superabrasive material such as polycrystalline diamond and oriented on the bit face generally in the direction of bit rotation. A drag bit body is generally formed of machined steel or a matrix casting of hard particulate material such as tungsten carbide in a (usually) copper-based alloy binder.
In the case of steel body bits, the bit body is usually machined, typically using a computer-controlled five-axis machine tool, from round stock to the desired shape, including internal watercourses and passages for delivery of drilling fluid to the bit face, as well as cutting element pockets or sockets and ridges, lands, nozzle displacements, junk slots and other external topographic features. Hardfacing is applied to the bit face and to other critical areas of the bit exterior, and cutting elements are secured to the bit face, generally by inserting the proximal ends of studs on which the cutting elements are mounted into apertures (sockets) bored into the bit face or, if cylindrical cutting elements are employed, by inserting the substrates into pockets bored into the bit face. The end of the bit body opposite the face is then threaded, made up and welded to the bit shank.
The body of a matrix-type drag bit is cast in a mold interiorly configured to define many of the topographic features on the bit exterior, with additional preforms placed in the mold defining the remainder of such features as well as internal features such as watercourses and passages. Tungsten carbide powder and sometimes other metals to enhance toughness and impact resistance are placed in the mold under a liquefiable binder in pellet form. The mold assembly, including a steel bit blank having one end inserted into the tungsten carbide powder, is placed in a furnace to liquify the binder and form the body matrix with the steel bit blank integrally secured to the body. The blank is subsequently affixed to the bit shank by welding. Superabrasive cutting elements, also termed “cutters” herein, may be secured to the bit face during the furnacing operation if the elements are of the so-called “thermally stable” type, or may be brazed by their supporting (usually cemented WC) substrates to the bit face, or to WC preforms furnaced into the bit face during infiltration. Such superabrasive cutting elements include polycrystalline diamond compacts (PDCs), thermally stable polycrystalline diamond compacts (generally termed “TSPs” for thermally stable products), natural diamonds and, to a lesser extent, cubic boron nitride compacts.
During a typical drilling operation using such a rotary bit, drilling fluid is pumped from the surface through the internal bore of the drill string to the bit (except in a reverse flow drilling configuration such as is described in U.S. Pat. No. 4,368,787, wherein drilling fluid passes down the annulus and up the interior of the drill string). In conventional bits, the drilling fluid flows out of the drill bit through a crow's foot or one or more nozzles placed at or near the bit face for the purpose of removing formation cuttings (i.e., chips of material removed from the formation by the cutting elements of the drill bit) and to cool the cutting elements, which are frictionally heated during cutting. Both of these functions are extremely important for the drill bit to efficiently cut the formation over a commercially viable drilling interval. That is, because of the weight on bit (WOB) applied by the drill string necessary to achieve a desired rate of penetration (ROP) and the frictional heat generated on the cutters due to WOB and rotation of the bit, without drilling fluid or some other means of cooling the bit, materials comprising the drill bit and particularly the cutting elements attached to the bit face would structurally degrade and prematurely fail. Moreover, even if it were possible to cool the bit without drilling fluid but no means of removing the cuttings from the bit face was employed, the cutting elements (and the bit) would simply become balled up with material cut from the formation and would not be able to effectively engage and further penetrate into the formation to advance the well bore.
The need to efficiently remove cuttings from the bit during drilling has long been recognized in the art. Junk slots formed on the exterior of the bit body adjacent the gage of the bit provide channels for drilling fluid to flow from the face of the drill bit past the gage and to the annulus above, between the drill string and the side wall of the well bore, generally termed the well bore annulus. The pressure of the drilling fluid as delivered to the cutting elements through the nozzles or other ports or openings must be sufficient to overcome the hydrostatic head at the drill bit, and the flow velocity sufficient to carry the drilling fluid with entrained cuttings through the well bore annulus to the surface.
In a conventional bladed rotary drill bit, there may be a plurality of nozzles, each associated with one or more blades, the nozzles directing drilling fluid to cool and clean cutting elements of the blades. There may also be a plurality of junk slots, positioned between the blades and extending along the gage of the bit, to promote the flow of drilling fluid along each blade through its respective, associated junk slot. However, because the position and angular orientation of each nozzle is usually different relative to the centerline of the bit, and nozzle flow volumes may vary due to the hydraulics of the internal bit passages delivering the drilling fluid to the nozzles, the magnitude and orientation of flow energy of the drilling fluid will vary from one junk slot to the next. Consequently, because a relatively higher flow energy generates an adjacent zone or area of relatively lower hydraulic pressure in the manner of a venturi, drilling fluid emanating from a particular nozzle that would ideally flow past the desired cutting elements of a particular blade and up through the associated junk slot may actually be pulled or drawn downward and even laterally (circumferentially) across the exterior of the blade into a low pressure zone created by a fluid jet of another junk slot. In effect, some junk slots of conventional bits will have a positive or upward flow of drilling mud, while others will have a negative or downward flow resulting from thiefage of a part of the fluid flow by an adjacent junk slot flow zone and destruction of the desired, beneficial flow pattern in the junk slot from which the fluid is stolen. In addition, typical prior art bit designs include stagnant flow regions in and above the junk slots, usually adjacent, behind and above the blades where no appreciable drilling fluid flow, either positive or negative, occurs. These stalled or stagnant flow areas or “dead zones” may be the result of unexpected and undesired vortices that may enhance or even initiate negative flow in some junk slots, or may be the result of bad design which fails to recognize the effect of bit topography on flow of adjacent fluid. If such a disrupted flow pattern occurs, cuttings generated during the drilling process that would normally flow up through the annulus may circulate from a positive flowing junk slot to a negative flowing junk slot, or may accrete in place adjacent or above a blade, the result in either case, particularly at low flow rates, being bit balling as the cuttings mass increases. In other words, these recycling or stationary cuttings impede cutting efficiency of the cutters by obstructing access by the cutting elements to the formation. In addition, stagnant or reduced flow of drilling fluid results in less effective cooling of the cutting elements in those areas where the flow is impaired.
One arrangement to promote clearing of cuttings from a bit has been to position nozzles in the face of the drill bit to direct drilling fluid across the faces of the cutting elements to essentially peel cuttings from the cutting elements, as disclosed in U.S. Pat. No. 4,913,244 to Trujillo. U.S. Pat. No. 4,794,994 to Deane et al. discloses impacting the cutting elements with rearwardly directed fluid flow bounced off of the formation ahead of the cutting elements. Another solution, to remove cuttings from the cutting elements immediately after shearing from the formation by impacting them with a forwardly directed fluid jet from behind the cutting elements, is disclosed in U.S. Pat. No. 4,883,132 to Tibbitts. Such inventive structure is employed in the ChipMaster™ series of drag bits offered by Hughes Christensen Company. Another arrangement for directing fluid flow on the bit face, that of restricting fluid flow on the bit face and directing same through the use of spirally placed dams, is disclosed in U.S. Pat. No. 4,492,277 to Creighton. Yet another approach, to sweep the formation directly with fluid emanating from nozzles on the bit, is disclosed in European Patent Application 0 225 082 to Fuller et al.
In an attempt to more efficiently cut into the formation, variously-configured fluid courses have been devised, including those of U.S. Pat. No. 4,887,677 to Warren et al., which discloses a progressively widening diffuser that allows fluid to be flowed through a narrow throat of a fluid course in front of the cutting element and out a progressively widening diffuser, purportedly resulting in a significantly reduced pressure in front of the cutting elements. U.S. Pat. No. 4,245,708 to Cholet et al. discloses a junk slot having an upwardly directed nozzle placed in a venturi configuration to enhance the flow of drilling fluid through the junk slot. A similar arrangement is disclosed in U.S. Pat. No. 4,540,055 to Drummond et al. in the form of an air-drilling assembly, wherein upwardly aimed nozzles are placed on a sub above a rock bit between and parallel to vanes on the exterior of the sub.
It has also been recognized in the art that creating a flow vortex proximate the cutting elements may be desirable. For example, U.S. Pat. No. 4,733,735 to Barr et al. discloses a rotary drill bit having an exterior surface region adjacent the front surface of each blade and shaped to promote a vortex flow of drilling fluid across the cutting elements of that blade and partial recirculation of the drilling fluid before passage of same from the bit and up the annulus. Similarly, in U.S. Pat. No. 4,848,491 to Burridge et al., it is acknowledged that a bit may be configured to form a vortex to recirculate a portion of the drilling fluid directed into a junk slot by a nozzle.
One of the more elaborate methods and apparatus for removing drilling mud disclosed in U.S. Pat. No. 4,744,426 to Reed includes a downhole motor and “fan” that pulls the drilling mud from around the drill bit. Such a device, however, is a complex mechanical structure and adds to the cost of the drill string. U.S. Pat. No. 5,651,420 to Tibbitts et al., assigned to the assignee of the present invention and incorporated herein by this reference, also discloses a number of movable or dynamic structures for drill bits to assist with cuttings removal and bit cleaning.
U.S. Pat. No. 5,199,511 to Tibbitts discloses a unique bit configuration wherein the flow path from the bit interior to an area above the gage is located within the bit crown, the cuttings entering an interior flow area after being cut, then being swept upwardly by the drilling fluid.
U.S. Pat. No. 5,284,215 to Tibbitts discloses an enlarged and undercut junk slot for enhancing fluid flow, which structure extends upwardly into the bit shank area above the crown.
None of the aforementioned references, however, provide a structure and flow path directing and enhancing positive, independent flow of drilling fluid and entrained cuttings through all of the junk slots of a drill bit, substantially eliminating cross-flow and thiefage between junk slots and minimizing stagnant or dead flow zones in areas within and above the junk slots, which zones promote cuttings accretion and bit balling. Thus, it would be advantageous to provide a drill bit and other drilling-related structures with enhanced hydraulic characteristics affording such advantages.
One such solution to the above-mentioned problems is proposed by U.S. Pat. No. 5,794,725 to Trujillo et al., assigned to the assignee of the present invention and hereby incorporated herein by this reference. This patent provides a recirculation capability in a number of different embodiments, and bits according to the patent have been successful in reducing these problems, although the configuration of the bit, particularly in terms of optimizing its hydraulic design, is somewhat complex.
The aforementioned phenomenon of bit balling has become a more serious problem in recent years with the more widespread use of water-base drilling fluids. Traditional, oil-base drilling fluids have been used with some success for decades to help mitigate the problem of bit balling, but their use is becoming more limited because of environmental concerns. Further, oil-base fluids do not always prevent bit balling. Designing a bit to minimize balling has been, in the prior art, often attempted by using a low number of relatively tall blades carrying a relatively few, relatively large (such as 19 mm or ≈0.75 inch diameter) PDC cutters, and employing relatively deep (measured radially) junk slots. The low numbers of cutters and blades permits better focus of hydraulic energy, while the tall blades provide a greater standoff from the formation and thus increased spatial volume between the bit face and the formation face, and the deepened junk slots aid removal of formation cuttings past the side of the bit between the gage pads and up into the well bore annulus. It has recently been recognized, as disclosed in U.S. patent application Ser. No. 08/934,031 to Trujillo et al., now U.S. Pat. No. 6,125,947, assigned to the assignee of the present invention and hereby incorporated herein by this reference, that substantially balancing junk slot entrance areas and hydraulic flows associated therewith with formation cuttings volumes generated by blades associated with the respective junk slot hydraulic flows, and carefully apportioning (and in some cases balancing) the formation cuttings volumes between blades, can be beneficial in alleviating bit balling.
However, past work in the field has overlooked a significant characteristic of bit balling which has recently been recognized by the inventor herein: that bit balling originates or initiates at the gage of the bit and not on the bit face. Once the bit gage (i.e, a junk slot) is blocked, the mass of formation cuttings builds back down toward the bit face and onto the face, until the bit completely balls.
Taking into consideration all of the recent improvements offered by the assignee of the present invention, there still remains a substantial, long-felt need in the industry for a rotary drag bit which is substantially resistant to bit balling in plastic formations, and which is capable of achieving a relatively high rate of penetration (ROP) even in normally difficult, slow-drilling formations, such as shales.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a fixed cutter, or rotary drag, bit exhibiting an enhanced resistance to bit balling and an improved rate of penetration, in comparison to conventional bits.
The rotary drag bit of the present invention includes an auger-like blade configuration, wherein positively raked, relatively tall blades carrying superabrasive cutters lean forward in a cantilevered manner in the direction of bit rotation to provide increased clearance and volume between the bit face and the formation to facilitate removal of cuttings coming off the tops of the cutters from the bit face. A trailing outer end of each blade is substantially contiguous with a leading end of an elongated gage pad cantilevered to provide extra junk slot cross-sectional area and comprising a segment of a helix and raked rotationally forwardly in the manner of the blades. The longitudinal lengths of the gage pads and the blades in combination with their rakes provide a stabilizing structure which substantially completely circumferentially encompasses the bit body. The slope or pitch of the helix angle of the gage pads may be varied, as desired, to optimize hydraulic efficiency, requirements of directional drilling, and stability needs. The bit of the present invention also includes nozzles positioned on the bit face proximate, or even partially disposed in, trailing ends of the blades and aimed toward the leading edge of a blade following each respective nozzle to improve cleaning of the blades and to improve the hydraulic energy and fluid velocities along the gage. The bit also preferably includes relatively large, aggressively raked superabrasive cutters having a ground relief on the substrate supporting the superabrasive table rotationally behind the table to minimize contact of the substrate material with the formation.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIGS. 1A and 1B comprise perspective views of an embodiment of a drill bit according to the invention, inverted from its normal drilling orientation for clarity;
FIG. 2 comprises a side elevation of the bit of FIG. 1, also inverted from its normal drilling orientation;
FIG. 3 comprises a frontal, or face, elevation, looking upward at the bit of FIG. 1 as it would be oriented during drilling; and
FIGS. 4A through 4E respectively depict frontal, side, top, side sectional and oblique transverse sectional elevations of a superabrasive cutter preferably employed with the bit of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 through 4 of the drawings, rotary drag bit 10 according to the invention comprises a bit body 12 having a longitudinal axis or centerline L. Bit body 12 may be a steel body or matrix body as previously described, or of any other suitable construction. In the preferred embodiment, bit body 12 is a matrix bit body. A particularly useful technique for fabricating a matrix bit body 12 (and which can also be applied to steel body bits) is so-called “layered manufacturing”, wherein a series of vertically superimposed layers of a material is defined under computer control to form a porous, three-dimensional bit body preform which is subsequently infiltrated with a liquified metal binder as known in the art of matrix-body bit fabrication. U.S. Pat. Nos. 5,43,380 and 5,544,550 to Smith, assigned to the assignee of the present invention and disclosing and claiming a number of such layered manufacturing techniques and bits and bit components produced thereby, are each hereby incorporated herein by this reference.
A plurality of generally radially extending blades 14 , three in this instance, protrudes above the bit face 16 , defining fluid courses 18 between each blade 14 . Fluid courses 18 are extremely steeply angled in comparison to conventional bits, falling away from the longitudinal axis of bit body 12 at about a 45° angle as best appreciated in FIGS. 1A and 2. Blades 14 are not only notably tall, but lean, or are raked, forwardly, taken in the direction of bit rotation. Such a forward rake, in conjunction with the cantilevered nature of the blades, particularly at their radially outer extents, provides an elongated clearance cavity 20 under the rotationally and longitudinally leading, or outermost, edge 22 of each blade 14 . Stated another way, at least a portion of each blade 14 overhangs, or leans over, a portion of the fluid course 18 leading that blade. Clearance cavity 20 contributes significantly to the spatial volume SV 1 , SV 2 and SV 3 , respectively defined between a fluid course 18 , two rotationally adjacent blades 14 flanking that fluid course, and the face of a formation being drilled by bit 10 . Further, the rotationally forward rake of blades 14 provides added strength in comparison with conventional blades oriented substantially parallel to the centerline or longitudinal axis of a bit, as impact with a hard formation or more likely, a hard stringer as encountered in some soft formations, will be taken more in line with the orientation of the blade 14 .
A plurality of superabrasive cutters 100 is mounted to the longitudinally leading edges 22 of each blade 14 , cutters 100 being preferably disposed into pockets 30 extending rotationally to the rear of each blade 14 from the leading edge thereof to a trailing wall 32 at the trailing end of the pockets 30 . In the preferred embodiment, cutters 100 preferably comprise PDC cutters including a diamond table 102 formed on and bonded to a cemented tungsten carbide substrate 104 (see FIGS. 4A through 4D) under high pressure, high temperature conditions, as is well known in the art. Cutters 100 are generally cylindrical, and pockets 30 are defined by a sidewall of a slightly larger radius than the diameter of substrate 104 , a brazing compound (not shown) being employed to secure each cutter 100 by its substrate 104 into its associated pocket 30 . Of course, if bit body 12 were a steel body, cutters 100 might be secured to elongated studs, the ends of which would be inserted, as by press fitting, into apertures drilled into blades 14 . It is preferred, as shown, that cutters 100 be of limited number and of relatively large diameter, such as 19 mm (≈0.75 inch) or 25 mm (≈1 inch) to optimize hydraulic clearing of each cutter. The cutting faces 106 of cutters 100 are substantially circular, but other shapes, including half-circular, oval, elliptical, rectangular, triangular, and other polyhedral shapes, may also be employed. Circular cutting faces 106 with sharp edges exhibiting neither a significant chamfer or radius are preferred, in accordance with the teachings of U.S. patent application Ser. No. 08/934,486 to Tibbitts et al., now U.S. Pat. No. 6,006,846, assigned to the assignee of the present invention and hereby incorporated herein by this reference. Likewise, extremely smooth, or so-called “polished” cutting faces in accordance with U.S. Pat. Nos. 5,447,208 and 5,653,300 to Lund et al., assigned to the assignee of the present invention and hereby incorporated herein by this reference, are also preferred. As noted with more particularity below with respect to the description of FIGS. 4A through 4E, it is preferred that the substrates 104 of cutters 100 be relieved behind the cutting edge 108 of cutting face 106 to minimize contact with the formation. It is also contemplated that the superabrasive cutters 100 may also include TSPs (for example, in an array or mosaic arrangement), natural diamonds or cubic boron nitride compacts. It is preferred, however, that the superabrasive cutters 100 employed have a cutting face extending in two dimensions substantially transverse to the direction of bit rotation and a cutting edge at an outer periphery of the cutting face.
An elongated gage pad 40 extends substantially contiguously from each blade 14 , gage pads 40 each being forwardly rotationally raked in the manner of blades 14 so as to each define a partial segment of a helix. As shown, the gage pads 40 are of substantially constant width transverse to their longitudinal extents and for a substantial majority thereof. The radially outer bearing surfaces 42 of gage pads 40 may be provided with wear-resistant elements such as tungsten carbide bricks 43 (shown as rectangular, but circular or other configurations are entirely suitable) and natural diamond or thermally stable diamond structures 45 or, alternatively, may be provided with hard surfacing such as a plasma-sprayed material, a diamond film surface, or otherwise as known in the art. Junk slots 44 , defined between gage pads 40 , each communicate with an associated fluid course 18 over a large-radius transition zone 46 also encompassed between adjacent gage pads 40 . A portion of each gage pad 40 is cantilevered rotationally forwardly over a portion of its rotationally leading junk slot 44 so as to define a clearance cavity 48 at the rotationally trailing side of that junk slot 44 which communicates with clearance cavity 20 of each blade 40 to enlarge the junk slot cross-sectional area transverse to the direction of flow, while maintaining an enlarged radially outer bearing surface 42 . Junk slots 44 enlarge at their lower ends 50 due to truncation at lower end 52 in a longitudinal direction of gage pads 40 to reduce any tendency toward inception of bit balling. Junk slots 44 open onto the exterior of bit shank 90 , which may bear breaker flats 92 thereon as shown, above which (as the bit is oriented for drilling) exterior threads 94 (conventionally API threads) form a pin connection suitable for mating with a threaded box connection of a drill collar or motor drive shaft.
The slope, or pitch, of the helix angle of the gage pads relative to longitudinal axis L may be, as noted previously, optimized for hydraulic efficiency, cutter density, requirements of directional drilling, and stability needs.
For example, it has been noted in tests of a bit configured according to the invention that the helical segment configuration of gage pads 40 has, at higher rotational speeds, acted to reduce pressure on the bit face. This indicates that the gage pads, in concert, appear to function like a pump impeller as the bit rotates with respect to the sidewall of the well bore, literally pulling drilling fluid with entrained formation cuttings upwardly off of the bit face and into the well bore annulus. Thus, variation of the gage pad pitch angle may be used to facilitate this pumping action, a shallower pitch resulting in a more significant pumping action at relatively lower rotational speeds. Pitch may be expressed in terms of angle with respect to the longitudinal axis L of the bit 10 , or may be expressed in so many degrees of circumferential travel of a gage pad 40 (and associated radially outer edge 24 of a blade 14 ). For example, a blade (or gage pad) with a 16° per inch pitch would extend circumferentially 16° for every inch of longitudinal elongation. Thus, if a blade or gage pad so pitched extended five inches longitudinally, it would rotate or extend about 80° circumferentially of the bit body 12 .
Specific adaptation of the bit according to the present invention to directional drilling, and particularly medium and short-radius drilling, may also be effected by reducing the pitch of the gage pads to shorten bit body 12 , thus facilitating turns while retaining the aforementioned stabilization characteristics, as well as fluid and cuttings removal from the bit face.
If stability is a primary concern and directional drilling is not involved, or long-radius drilling only is an objective, the gage pads 40 may be elongated and the pitch thereof made relatively steep to provide enhanced stability, while still retaining some pumping efficiency to enhance fluid removal from the bit face.
The pitch of gage pads 40 and of the radially outer edges 24 of blades 14 can also be optimized to increase the cutter density of the bit. While conventional bit designs either increase blade count or blade height to provide enhanced mounting area (i.e., blade edge length) for cutter mounting, the former of which may compromise bit hydraulics and the latter of which may reduce blade strength under impact, a bit according to the present invention can provide such enhanced mounting area without the addition of blades or an increase in blade height by using a relatively shallow pitch for radially outer blade edges 24 to extend the length thereof, as clearly shown in FIGS. 1A and 1B of the drawings. Thus, a three-blade bit according to the invention may provide, for example, substantially the same cutter density as a four-blade, conventional design.
It will be appreciated, particularly with respect to FIGS. 2 and 3, that the radially outer edges 24 of the blades 14 lie substantially radially adjacent radially outer bearing surfaces 42 of gage pads 40 , there being a rather marked angular transition 26 between the leading edges 22 of blades 14 and radially outer edges 24 . Thus, associated radially outer edges 24 of blades 14 and bearing surfaces 42 of gage pads 40 substantially circumferentially encompass bit body 12 . Gage pads 40 themselves afford a circumferentially extending bearing surface exceeding 270°. This large circumferential extent of the gage pads affords, without the necessity of an overly enlarged gage pad or pads, the ability to design a bit according to the present invention as a so-called “anti-whirl” bit. Such bits use an intentionally unbalanced and oriented lateral or radial force vector, usually generated by the bit's cutters, to cause one side of the bit to ride continuously against the sidewall of the sell bore to prevent the inception of bit “whirl”, a well-recognized phenomenon wherein the bit precesses around the well bore and against the side wall in a direction counter to the direction in which the bit is being rotated. Whirl can result at the least in an over-gage and out-of-round well bore, and at its worst, in damage to the cutters and bit itself. The large, elongated gage pads of the bit of the present invention provide sufficient bearing area so that an unduly enlarged, dedicated “bearing” gage pad to accommodate the lateral force vector such as is employed in prior art anti-whirl bits is unnecessary. It must be emphasized, however, that the bit of the present invention is entirely suited for designs other than anti-whirl designs, and it is believed that the stability afforded by the cooperative blade and gage pad design of the present invention largely alleviates any need for designing and fabricating a bit according to the present invention as an anti-whirl bit. In accordance with the invention, it is preferred that the gage pads 40 and outer edges 24 of blades 14 provide circumferential envelopment of the bit body 12 of at least 180°, up to and including in excess of 360° (wherein each gage pad and associated radially outer blade bearing surface respectively circumferentially overlaps an adjacent radially outer blade bearing surface and gage pad).
It should also be noted that the enhanced circumferential bearing surface provided by the orientation of the gage pads 40 and blades 14 of bit 10 permits a marked reduction in width W of the gage pads 40 (see FIG. 2) in comparison to conventional bit designs and thus permits a consequent increase in the circumferential area, or width, available for junk slots 44 to further enhance hydraulics and the ability of bit 10 to clear formation cuttings from the bit face 16 . Stated another way, the helical segment configuration of gage pads 40 and the radially outer edges 24 of blades 14 provides excellent circumferential coverage of the gage with radial bearing surfaces without wide gage pads. Thus the width of each gage pad is substantially less than the width, measured in the same direction, of each junk slot.
Bit 10 includes four nozzles 60 a - 60 d thereon, nozzles 60 a, 60 b and 60 c each being disposed over bit face 16 proximate a juncture between each fluid course 18 and the blade preceding that fluid course 18 , portions of the apertures in which nozzles 60 a through 60 c each reside actually being located in rotationally trailing surfaces of blades 14 . Nozzles 60 a through 60 c are oriented to be at least partially aimed toward the blade 14 rotationally following that nozzle, such orientation being greatly facilitated by the relatively high (taken longitudinally) position on bit 10 . Nozzle 60 d is disposed substantially centrally on the bit face 16 , slightly offset from the centerline or longitudinal axis L of the bit 10 . Nozzles 60 a through 60 c are each sized to deliver drilling fluid to the fluid courses 18 with which that respective nozzle 60 a, 60 b, or 60 c is associated, substantially in proportion to the relative volume of formation cuttings generated by the cutters 100 on the blade 14 rotationally trailing that fluid course 18 , as a percentage of the total formation cuttings volume. In other words, drilling fluid volume is apportioned by nozzles 60 a through 60 c between the spatial volumes SV 1 , SV 2 and SV 3 in accordance with the relative proportion of formation cuttings volume generated by the respective blades 14 associated with each spatial volume SV 1 , SV 2 and SV 3 with respect to the total formation cuttings volume. Substantially centrally located nozzle 60 d may provide drilling fluid flow to all fluid courses 18 , and thus spatial volumes SV 1 , SV 2 and SV 3 , although nozzle 60 d may be tilted so as to provide a dominant flow to a particular fluid course 18 and associated spatial volume SV. It should also be noted that, while drilling fluid flow from each of nozzles 60 a through 60 c is predominantly radially outward in the fluid course 18 associated with that nozzle, some minimal flow may cross over into another fluid course 18 , either across the center of the bit face around a radially inner edge of a blade 14 , or under (as the bit is oriented during drilling) a blade 14 . The orifice sizes as well as the orientations of each of nozzles 60 a through 60 d may be adjusted to minimize such cross-flow through mathematical modeling and empirical testing in a drilling simulator or test well, both such techniques being generally known in the art. In addition, a specific method of flow adjustment employing nozzle orientation disclosed in U.S. Pat. No. application Ser. No. 08/934,031 to Trujillo et al., U.S. Pat. No. 6,125,947, assigned to the assignee of the present invention and incorporated herein by this reference, may be employed to assist in apportioning the volume and direction of flow. The nozzle orientations may also be adjusted to direct more flow toward a cutter or cutters 100 carried by a particular blade 14 , which cutters require additional cleaning flow due to the formation cuttings volume generated, as well as reducing flow toward cutters which generate a smaller, or no measurable, cuttings volume. As with flow volumes, formation cuttings volume for a given cutter 100 may be predicted mathematically or tested empirically in a drilling simulator or test well. Mathematical modeling of the flow characteristics of a bit optimized according to the present invention indicates that minor balling or accretion of formation cuttings in one or more junk slots 44 will affect the balance of flow therebetween, but that the inception of balling, unlike in conventional bits, will not lead to aggravated or severe balling with a consequent occlusion of one or more junk slots 44 , followed by the fluid courses 18 .
Referring now to FIGS. 4A through 4E of the drawings, PDC cutter 100 comprises, as previously mentioned, diamond table 102 formed onto substrate 104 , cutter 100 defining a longitudinal extent between the front of the diamond table 102 and the rear of the substrate 104 . Diamond table 102 exhibits a circular cutting face 106 having a peripheral cutting edge 108 for engaging the formation. The diamond table 102 and supporting end of substrate 104 may be configured, as shown, in accordance with the disclosure of U.S. patent application Ser. No. 08/935,931 to Scott et al., U.S. Pat. No. 6,202,771, assigned to the assignee of the present invention and hereby incorporated herein by this reference, although this is not a requirement for cutter 100 . As may best be appreciated with reference to FIGS. 4B and 4C, substrate 104 , while cylindrical proximate its leading end 110 and extending rearwardly therefrom on cylindrical leading sidewall portion 112 for a short distance behind cutting edge 108 , is relieved in area 114 further to the rear, extending to trailing end 116 . The term “relieved” or “relief” as used herein means that the substrate sidewall lies within an outer envelope defined by the cylindrical sidewall, so as to be laterally or radially recessed from the envelope. The relief, in the preferred embodiment, includes an arcuate surface 118 of like diameter to the diameter of leading sidewall portion 112 proximate leading end 110 , but oriented at an acute angle (for example, a 15° angle is shown) to the longitudinal axis 120 of cutter 100 .
Longitudinally extending flats 122 flank arcuate surface 118 to ease the transition into trailing cylindrical sidewall portion 124 , which is contiguous with leading sidewall portion 112 . By way of example only, cutter 100 as shown comprises a 19 mm (≈0.75 inch) diameter cutter. It will be appreciated that the relief in area 114 , even when using a slightly negative, a neutral, or even a slightly positive fore and aft rake (also commonly termed “back rake”) for PDC cutters 100 , minimizes contact area between substrates 104 of PDC cutters 100 and the formation face being engaged by PDC cutters 100 . Thus, WOB is concentrated more on the diamond table 102 and leading sidewall portion 112 of each cutter 100 , reducing required WOB to achieve a given DOC and reducing friction between bit 10 and the formation and resulting detrimental generated heat and any consequent tendency for heat checking of the substrate as well as heat-induced degradation of the diamond table. In practice, it is contemplated that PDC cutters 100 may be mounted with their cutting faces 106 at a back rake angle of between about 0° and negative 40°. It is currently preferred that the back rake angle be between about 5° and 10° negative. Negative 5° is currently contemplated as being optimum for slow drilling, overpressured shales. PDC cutters 100 may also be mounted with their cutting faces 106 at the aforementioned neutral fore-and-aft rake angle, or even a positive rake angle.
It is expressly contemplated that PDC cutters 100 may be configured with cutting faces of oval, square, tombstone or other suitable configuration.
By way of comparison with conventional bits, an 8.5 inch prototype bit according to the present invention was run in soft shales and weak sands and averaged 60 to 100 feet per hour over large portions of a 1700 foot interval running 0 to 2,000 lbs. WOB. Average ROP for the interval was 41 feet per hour. In comparison, planned ROP for a Hughes Christensen ChipMaster™ bit to be run in the interval was only 12 feet per hour, based on the previous best demonstrated performance in the area in a substantially identical formation and using the same drilling fluid system, as bit balling had proven to be a limiting factor in ROP.
In drilling with a bit according to the present invention and as part of a preferred method of drilling with such bits, it is contemplated that either WOB may be controlled to inhibit bit balling, or bit rotational speed may be increased to enhance the bit's ability to clear formation cuttings as WOB is increased through the aforementioned pumping effect provided by the gage pads. It is further contemplated that, for a given depth of cut and WOB, various rotational speeds will provide an optimum ROP due to the enhanced hydraulics and formation cuttings clearance capability afforded by the bit design of the present invention.
While the rotary drag bit of the present invention has been described in the context of a preferred embodiment, it is not so limited. Those of ordinary skill in the art will recognize and appreciate that many additions, deletions and modifications to the preferred embodiment may be effected without departing from the scope of the invention as defined by the claims which follow.
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A fixed cutter, or rotary drag, bit for drilling subterranean formations, exhibiting an enhanced resistance to bit balling and an improved rate of penetration. The bit includes an auger-like blade configuration, wherein positively raked, relatively tall blades lean rotationally forward to provide increased clearance and volume between the bit face and the formation to facilitate removal of cuttings coming off the tops of the cutters from the bit face. The blades are each substantially contiguous with an elongated, helical gage pad raked rotationally forwardly in the manner of the blades, the longitudinal lengths of the gage pads and the radially outer edges of the blades in combination with their slope providing a stabilizing structure which substantially completely circumferentially encompasses the bit body. The slope or pitch of the helix angle of the blade edges and gage pads may be varied as desired to optimize hydraulic efficiency, cutter requirements of directional drilling, and stability needs. The bit also includes nozzles positioned on the bit face and aimed toward the face of a blade following each respective nozzle to improve cleaning of the blades and to improve the hydraulic energy and fluid velocities along the gage. The bit also preferably includes aggressively raked superabrasive cutters having a ground relief on the substrate supporting the diamond table rotationally behind the table to minimize contact of the substrate material with the formation.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the priority of US provisional application No. 61,137,690, filed on Aug. 1, 2008, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a minimally invasive approach to perform transesophageal surgical, orthopedic and neurosurgical procedures in the mediastinum, cervical and thoracic cavities. The invention describes devices and methods to create a transesophageal access to said structures and surrounding structures to perform a body of surgical procedures while the heart is beating with or without the need for general anesthesia. A key improvement in access to these spaces is provided by provision of an intra-esophageal liner to facilitate transesophageal passage and to reinforce such passages; and to provide, or to catty means for providing, for the sealing of openings through the esophageal wall to prevent permeation of fluids into adjacent compartments, unless desired. These technical improvements are applicable to all forms of transesophageal surgery, and perhaps to other types of surgery as well.
BACKGROUND OF THE INVENTION
[0003] Access to the human heart, the thoracic cavity, the neck structures, the cervical spine and the dorsal spine has always been difficult and a source of active research, especially recently with the advancement in technology that has led to improved methods of minimally invasive surgery, orthopedic procedures and neurosurgical procedures. Heart disease is the leading cause of death connected to all age groups in the United States. The esophagus has a close proximity to the heart and the posterior mediastinum, which has allowed the use of transesophageal fine needle aspiration and transesophageal biopsy techniques to be used extensively in recent years to obtain tissue samples. Most of the posterior mediastinal tissues are accessible for biopsy by this route, including the lungs and lymph nodes. The technique has proven to be safe and reproducible with minimal complications. A discussion of such techniques and some of their key uses can be found in U.S. Pat. No. 6,689,062 and in related pending cases, which provide a full background describing this promising new technique. Other groups are also exploring transesophageal surgery, as described for example in WO 2007/149588. In exploring this new area of minimally invasive surgery, it has been found that one of the important but difficult details that need improvement is managing the passage of instruments across the esophageal wall. Surgery via the esophagus has numerous attractions for thoracic and cervical surgeries, but precision location of the entry site, and reliable and simple closure of the site after surgery each present novel problems and require new approaches. We present herein an improved technology for such control.
SUMMARY OF THE INVENTION
[0004] Accordingly, it is a principal object of the invention to provide novel methods and means for locating, using, and closing sites in the esophagus for performing transesophageal surgery at any of the previously described sites, or others that may become useful.
[0005] In one aspect, a liner (also called a “liner device” herein) is used to demarcate the selected areas of the esophagus. The liner is a piece of a material which is placed at the selected site, optionally with the assistance of imaging techniques. The liner is made of a biocompatible material and optionally is degradable in situ. The liner may be affixed to the selected site via any of several methods. These include adhesives, vacuum, mechanical affixing devices, and simple passive positioning. The liner has numerous optional additional properties, including transparency for visibility; prefabricated penetration locations; radioopaque markers or other location aids; and carriage of other devices, including device sensing and control means, taking advantage of the propinquity of the esophagus to the heart and other organs that might be monitored following a procedure.
[0006] The invention provides procedures that can safely and accurately create a transesophageal access into the mediastinum, the thoracic cavity and the cervical cavity. The procedures can be carried out without the need for stopping the heart, or for cardiopulmonary bypass, general anesthesia, or gross or minor thoracotomy. This transesophageal access as described herein can be used to perform a variety of diagnostic and therapeutic surgical, orthopedic and neurosurgical procedures.
[0007] The invention comprises a liner device for facilitating the controlled and reversible creation of an opening in the wall of a body lumen, for example the esophagus, through which an endoscopic device can be inserted to perform surgery in adjacent tissues, particularly in the cervical and thoracic regions. The liner device is a structure that lines part of the lumen walls of a hollow body organ or body cavity, in proximity to an organ or a structure outside the lumen structure. The invention deals in particular with the lumen of the esophagus, as a lumen of particular value for the use of the invention. However, any body lumen or cavity can be used for the same techniques, sometimes with certain modifications in each specific case. The lumen liner device allows for elongated surgical devices to be deployed across the lumen wall, to target extraluminal organs or structures for the performance of diagnostic and therapeutic procedures.
[0008] The liner device may have a side opening mechanism with or without a supporting structure. The liner device may be of any convenient form, including without limitation a complete tubular structure, an incomplete or partial tubular structure, a curtain-like covering, or a generally planar structure, including for example a plate or patch. The complete tubular liner has two ends, with a side opening, or a location at with a side opening can be created, somewhere on the sidewall between the two ends. The incomplete tubular liner is any cutoff section of a cylinder with a side opening on its wall. The rest of the cutoff section is used for fixation. The plate or patch is any flat structure large enough to cover the perforation in the wall. The plate or patch may also comprise or consist essentially of mechanisms for opening and closing an opening in the lumenal wall (“side opening mechanisms”, or SOM).
[0009] In general, the liner is held in place by adhesive means and/or mechanical means, and optionally is temporarily held in place by an inflatable balloon or other temporary mechanism. The liner is eventually removed, or is manufactured so as to detach or degrade in situ. The side opening in the liner is a partial or complete passage through the liner to give access to the adjacent or nearby tissue of the lumen, such as the esophagus. In use, an endoscopic instrument is directed to the opening in the liner, and passes through the opening, with completion of the opening in the liner if required, followed by passage through a nearby portion of the esophagus or other lumenal tissue.
[0010] After removal of the instrument, the opening created in the lumen is at least partially closed by passive or active blocking of the opening. In one embodiment, the liner is flexible but tends to return to its original shape, which typically is a shape which fits the wall of the body lumen. Then, after passage of an endoscope through the liner and the wall of the lumen, and its removal after surgery, the opening tends to be closed by the relaxation of the liner.
[0011] In other embodiments, the opening in the liner is actively closed by the surgeon or other operator, in addition to or in replacement of passive closing. In one embodiment, the side opening is a mechanism that can be deployed mechanically or electronically (wired or wireless), for example by means of the action of an endoscope inside the liner.
[0012] In some embodiments there are two liners, nested inside each other and sliding with respect to each other along or around the inside of the lumen. In one embodiment each tube has a side opening. In one position, both side openings are aligned together in one open position. Any rotation or longitudinal motion of either tube closes the opening by de-aligning the side openings away from each other. In other embodiments, the liner side-opening is a camera-like shutter mechanism; or, the liner may have a side opening as a flap of the side wall.
[0013] In some embodiments, the liner is fixed to the esophageal wall. There are multiple methods of fixation of the liner circumferentially to the esophageal wall. The particular details of fixation of the liner to the lumenal wall are not critical aspects of the invention, and can include, without limitation, liner fixed to the esophageal wall by means of hooks or spikes, or by glue. The liner can be fixed in position by other means such as vacuum, stitching, stapling, suturing, welding or balloon inflation.
[0014] The upper and lower ends of the liner can be closed by diaphragms to prevent any fluid or contamination from entering into the surgical field from above or below. At least the upper diaphragm will typically have a slit or other means to allow for passage of an endoscope. The liner can also have balloons on the proximal and/or distal ends to prevent fluid contamination from above or below.
[0015] The liner can also carry other devices, including for example a CCD chip or other chips that can convey images of the liner position in the esophagus, of the liner lumen or of images through the side opening. The liner can also be equipped with operative elements such as piezoelectric cells for ultrasound guidance either alone or combined with transesophageal ultrasound for stereoscopic recognition. The liner can also be powered for motor or mechanical movement, heart treatment, cryotherapy, or magnetic or electromagnetic wave production/reception. All such enhancements are optional, and may instead be provide by other means in lumens that use liners for the basic purpose of controlling instrument penetration and flow through the tissue of the wall of a lumen, particularly the esophageal lumen.
[0016] The liner can be made of two layers sliding on each other, for example for longitudinal movement upwards or downwards. This general design also can be used for alignment design of two-sided openings, with a variety of directions in which overlap of holes on opposite sides of the device can be created to allow passage to instruments, or abolished or prevented to deny passage to fluids and the like. These mechanisms are distinct from a non-moving SOM (side opening mechanism), in which generally a mechanical element, for example a shutter is moveable by an endoscope instrument or other means to open and close openings through the lumen of an organ, such as the esophagus. In general, closeable opposed holes will be used for simple cases, and more complex closure devices will be used when multiple or repeated access is likely to be needed.
[0017] In other aspects of the invention, the liner is made to fit to the outside surface of an endoscope so that it can be delivered to a target location. The portion of the scope carrying the liner can have one or more means for visualization of the lumen wall to assist in accurate placement. The liner may be fixed, inflated and attached to the esophageal wall in the target segment. When the liner is placed, it is oriented so that the side opening mechanism (SOM) is facing the target area or organ outside the esophagus.
[0018] In one example, the side opening mechanism is facing posteriorly towards the thoracic spine. A scope is passed through the SOM to the thoracic spine for a variety of procedures that can be performed from this location, including interventions on the vertebral column, disks, nerves and related structures, disk removal, disk excision or lysis, laser application or cuts, bony or cartilaginous interventions, biopsies, tumor removal, bone removal, spinal cord manipulations, nerve root treatment or injection, and the like.
[0019] In another example, the side opening mechanism is facing anteriorly to the heart, and is used for a variety of procedures including atrial mapping and ablation, treatment of arrhythmia, valvular heart disease treatments, occlusion of septal defects, etc. The side-opening mechanism may be facing anteriorly towards the lungs and anterior mediastinum for a variety of procedures both diagnostic or therapeutic, directly or in related structures, with the procedures including biopsy, tumor staging, imaging, injection, delivery of materials, cryotherapy, RF treatment, and laser treatment on tissues including lungs, great vessels, trachea, LN, esophagus, nerves, diaphragm, and lymphatics.
[0020] The invention comprises means for improved surgical procedures, and methods for their use. In one aspect, means are provided for isolating esophageal lumen tissue from contact with fluids, said means comprising a liner which is applied to said tissue to cover said tissue on at least one of the inside and the outside of said lumen. In another aspect, said liner has a pre-formed location for creation of a hole to allow for passage through said liner, and may have a valve mechanism is placed in contact with said hole, and/or a closed distal end. Said valve mechanism can be operated during a procedure affecting at least one of said esophageal tissue, and other tissue accessible through said hole. Said liner may further comprise a side opening mechanism.
[0021] The liner device may be affixed to tissue by at least one attachment means, which may comprise at least one of vacuum, mechanical force, balloon inflation, welding, suturing, adhesives including glues, and mechanical devices including hooks, pins, frames, rings and rods. The material of said liner may be characterized in being one or more of degradable in vivo, antimicrobial in effect, and having more than one layer.
[0022] The liner device may be deployed with the use of a deployment device, in which said deployment device is sufficiently long that it may be passed through a patient's mouth and advanced to at least the distal esophagus, and still have its proximal end outside of the patient's body. The liner typically has a form selected from a shield, a cut section of a tubular structure or an incomplete tubular structure, or a complete tubular or cylindrical structure.
[0023] The invention also comprises a method of performing transesophageal surgery by placing a liner in a target segment in the esophagus, wherein the liner is a barrier and may comprise a complete or partial side opening to allow devices to go through the esophageal wall to a target structure/organ outside the esophageal wall after the liner and the esophageal wall have been penetrated to create an opening. Said side opening can be closed by one or more of spontaneous closure upon withdrawal of an instrument; active closure of a valve; and the activation of a side opening mechanism (SOM).
[0024] In this method, the opening may placed in either or both of the cervical and thoracic regions of the esophagus, and it typically faces at least one of posteriorly, laterally, and anteriorly. The liner may be used in procedures including but not limited to tumor excision or biopsy; placement of drugs, tissues, and radioactive materials; bronchial biopsy, airway bypass, manipulation of great vessels of the thorax, and pulmonary artery bypass. The procedures to be performed may include disk surgery, vertebral column surgery, spinal cord surgery, nerve root surgery, spinal and paraspinal muscle surgery, vascular surgery, oncologic surgery, laser surgery, delivery of energy to tissue, delivery of tissue or genetic material, delivery of surgical devices in general, delivery of cardiac pacemaker or diaphragmatic pace maker, and performance of procedures affecting the esophagus itself including fundoplication, and stomach pacemaker implantation. The procedures to be performed may include cardiac procedures including mapping, cardiac ablation, valve surgery, closure of septal defects, laser surgery, delivery of energy to the heart and related structure for pacing or to enhance contractility, delivery of drugs or genetic material, and delivery of surgical devices to the heart and related structures.
[0025] The procedures to be performed include procedures on the lungs, bronchi, nerves, lymphatics, great vessels of the thorax, bony or cartilaginous structures, diaphragm, phrenic nerve, gastroesophageal junction and on the esophagus itself, including the delivery of an esophageal band for satiety or an intra-esophageal valve for reflux.
[0026] The invention further comprises a method wherein more than one side opening may be created in the esophagus, by one or both of use of at least one liner having more than one side opening, and use of more than one liners having at least one side opening. In addition, a liner may be placed in a tubular body lumen, including the esophagus, the intestine, the genitourinary (GU) tract, the cardiovascular system, the pulmonary system, the canaliculi of the inner ear, and the lymphatic system.
[0027] In addition, the liner, or the opening in said tubular body lumen wall, can be sprayed or painted with sealant material to enhance closure of the perforation site. Any sealant can be used, including foam, glue, collagen, and the like.
[0028] Any endoscope may be used in the invention, including but not limited to one or more of a conventional scope, a therapeutic scope with custom made specifications, a robotic scope or a remotely operated scope, such as a telemedical or telesurgical scope.
[0029] A liner device of the invention may serve to isolate a partial or full perforation in the wall of the esophagus, wherein the isolation of the perforated portion of said wall prevents contamination of the perforation site by covering it. Said liner device may be one of a generally planar device and a device that is fully or partially tubular.
BRIEF DESCRIPTION OF THE FIGURES
[0030] FIG. 1 shows a basic liner of the invention.
[0031] FIG. 2 shows a liner placed in the esophagus, with a catheter penetrating the liner for therapy on the heart.
[0032] FIG. 3 shows a liner held in place by a frame.
[0033] FIG. 4 shows a tubular liner and its deployment.
[0034] FIG. 5 shows liner devices being deployed with the aid of fastening systems.
[0035] FIG. 6 shows means of closing openings through the liner to prevent leakage of fluids.
[0036] FIG. 7 shows the use of valves to regulate fluid passage through a liner.
[0037] FIG. 8 shows a liner with a closed distal end, optionally with a tube passing through said distal end for other procedures.
[0038] FIG. 9 shows inflatable liners.
[0039] FIG. 10 shows liners with vacuum-assisted adherence to a lumen wall.
[0040] FIG. 11 shows liners on both inside and outside surfaces of a lumen.
[0041] FIG. 12 shows a procedure using two openings.
[0042] FIG. 13 shows methods of steering a catheter or other device.
[0043] FIG. 14 shows additional steering methods.
[0044] FIG. 15 describes an integrated deployment device for use in the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0045] A novel liner device is described herein that is used for the isolation of a partial or full thickness perforation in the wall of a luminal body structure or a body cavity. The liner device is passed through the esophagus to a site on the wall of the esophagus, where it is used to isolate a perforation of the esophagus from contact with body fluids. The liner may be applied on the inside, the outside, or both sides of the esophageal lumen. The isolation of a perforated portion of the esophageal lumenal wall allows the perforation to heal while the liner device prevents direct communication or contact between the perforation site and the lumen of said organ or cavity. Because of the normally rapid healing of the esophagus, an isolation period of 24 hours or more is often sufficient.
[0046] The liner or ancillary devices may also isolate structures surrounding the lumen, by blocking flow from the inside of the lumen, or by directly treating structures outside of the lumen, including the outside of the lumen. The liner prevents contamination of a perforation site by covering the site, and can keep the perforation edges free of contamination until healing occurs spontaneously, or until mechanical approximation of the edges of the perforation.
[0047] The liner device of the invention is of particular usefulness where the cavity wall is the esophageal wall and the lumen is the esophageal lumen, in regions along the whole length of the esophagus. This is because the esophageal lumen, compared for example to the stomach, has exposure to an especially wide variety of body fluids during a healing process. However, the liner device is potentially useful in other lumens, especially when they are non-secretory.
[0048] The lumen liner is a simple device e.g. a disk, membrane, or patch, or a barrier that may be tubular or partially tubular. Said liner device allows the acute or immediate, subacute or delayed, chronic or recurrent passage of instruments, drugs, material or the like from outside of the body into an organ, space, body lumen or body cavity, through a passage in said liner. This means that the liner can be removed immediately after single procedure(s), or can be left for a period of time and then removed (or allowed to degrade in situ), or it can be permanently implanted to the wall of the luminal body organ or cavity for continuous use.
[0049] A simple liner device is shown in FIG. 1 . As shown generically in FIG. 1A , a liner 10 , which can also be called a membrane, a shield or a patch, can be a planar material. FIG. 1B shows the liner 10 of FIG. 1A liner applied to the interior wall 111 of a lumen 12 , such as the esophagus. The liner is typically placed as shown in FIG. 1C to cover a site at which the lumen 12 is to be perforated by a device 14 , most commonly from inside the lumen as shown at 13 , but optionally from the outside or both sides (not illustrated here), which may require separate inside and outside liners to be attached. The catheter may carry a needle 15 or other penetration aid. The liner can have any shape, some of which are shown in FIGS. 1D-1H , including circular, triangular, rectangular, irregular, square, or generally any flat design. The liner can be double layered, having two opposing membranes that cover the wall at the same time (not illustrated).
[0050] FIG. 2 , a schematic cross section of part of the human body, shows how a liner is used in a medical procedure. A depositing catheter (not shown) deposits a liner 10 in the esophagus 21 near the posterior side of the heart 22 , and above the stomach 24 . The depositing catheter is withdrawn, and a second catheter 14 is inserted through the esophagus 21 to the liner 10 . A needle 15 is extended out of the catheter and through the liner 10 , and penetrates the posterior side of the heart 22 . Any of a variety of procedures can be performed, including for example electroablation of arrhythmia-causing tissue. In contrast to NOTES-type procedures performed through the stomach, the approach of the present invention is more direct, and does not require the penetration of the diaphragm, or the stilling of natural breathing, in order to perform certain cardiac procedures.
[0051] The liner may be held in place, and/or held in a particular position, by a frame, as shown in FIG. 3 . In one embodiment, shown in FIG. 3A , a liner 10 is attached to a framework generally shaped like the esophageal lumen, comprising hoops 31 and 32 , and connecting pieces 33 . The frame and the liner can be retrieved at the end of a procedure. Alternatively, the liner, or both the frame and liner, can be made of biodegrading materials that will spontaneously disappear after completion of local healing. FIG. 3B shows a meshwork of connectors 34 connecting hoops 31 and 32 to form a tubular enclosure, to which a liner can later be attached (not illustrated.) FIG. 3C shows a liner 10 carried on a fabric or mesh 36 ; the fabric is held in place by partial hoops 35 . FIG. 3D shows a band 37 , and a liner 10 which is placed so that a band 37 keeps the esophagus patent at the site. An optional second band 38 is shown in a dotted outline. A frame may also be used to produce a two layered liner, with an interior space, optionally filled with a foam or other filling.
[0052] In another embodiment, the liner can be tubular, covering the entire inside of the esophagus or other lumen at a site; or it can be partially tubular, with complete tubular sections and other sections that do not cover the entire circumference. Some embodiments of tubular liners are shown in FIG. 4 . A basic tubular liner 41 is shown in FIG. 4A , and the same liner 41 is shown inside the lumen of the esophagus 42 in FIG. 4B . FIG. 4C shows a slit at 43 in liner 41 , through which a catheter 14 penetrates. A tubular lumen can be implanted as shown in FIG. 4D as a double layer, with one section 45 pressed against the wall of the esophagus, another section 46 being exposed to the interior of the esophagus, and so providing a potential pathway between these layers, for example at point 47 . If the liner has some intrinsic stiffness, it can be shaped to hold a position in the esophagus as shown in FIG. 4E , with projections 48 to help hold location, and a general liner location at 49 , which may be single layered as in FIG. 1 or double layered as in FIG. 4D . Such a double-layered structure can be used enhance self-sealing after removal of a penetrating device. For example, the space can be filled with fluid, such as a foam, and/or with a viscous, slow-setting adhesive material, before or after implantation. When a device is pushed through the liner, the foam can prevent leakage through the resulting hole during the procedure. When the device is removed, the fluid can rearrange to fill the space occupied by the device, and can set so as to prevent any fluid passage.
[0053] Fasteners may be used to retain a liner at a location, as illustrated in FIG. 5 . In a first embodiment ( FIG. 5A ), a fastener 51 is retained at a site by an application of adhesive material 50 to the site. In embodiment 5B, a variety of standard fasteners are used to affix a liner 51 to a site, including a bent pin 52 , a screw-in helix 53 , and a hook 54 . In FIG. 5C , a bent needle 55 affixes a liner 51 to a tissue site, and a thread 511 allows subsequent removal. In FIGS. 5D and 5E , a fastening system is shown in perspective and cross section, comprising a deformed disc 58 having an optional preformed slit 591 ; an affixing ring 57 with teeth 59 ; and a manipulation device 56 which can adhere to disc 58 , for example by vacuum, and guide a catheter or other instrument to the site.
[0054] FIG. 6 illustrates some means of closing openings created in a liner. Liner 10 is shown intact in FIG. 6A , and is affixed to a tissue site. In FIG. 6B , a slit 60 or other opening is made in liner 10 and a device 64 is passed through the opening 60 . In FIG. 6C , the device is withdrawn, and the opening 60 is substantially or completely closed (as indicated by opposing arrows) by resilience of the liner 10 . In FIG. 6D , a slit 60 in a liner 10 is covered by a flap 62 , which is affixed at its upper edge 63 to liner 10 or to another locus. In FIG. 6E , the flap 62 is pulled back sufficiently towards its upper edge 63 to expose slit opening 60 , through which an instrument 64 is passed. In FIG. 6F , first the instrument 64 is removed (note upward arrow); then the flap 62 is closed, as indicated by an arrow, closing slit 60 and minimizing or preventing fluid passage therethrough. FIG. 6G shows a liner 10 with a slit cover 65 affixed to liner 10 by a connection 66 , which permits rotation of cover 65 around connector 66 , for example a rivet or other fastener. In FIG. 6H , the cover 65 is rotated and exposes a slit 60 . An instrument can be passed through slit 60 (not illustrated), and then removed, and the cover 65 can be restored to its original position, preventing leakage. In FIG. 6I , sliding cover 67 is retained on liner 10 by retainers 68 . The sliding cover can be moved (as shown by a double headed arrow) so as to obscure slit 60 and minimize passage of fluids through it, or to expose slit 60 for instrument passage.
[0055] FIG. 7 illustrates the use of valves more complex than a slit. Such valves can potentially achieve better controlled or more reliably closed action than a simple slit, although requiring somewhat greater complexity. In FIG. 7A , liner 10 , positioned at the site where passage through the esophageal wall is desired, has a iris-type valve 70 mounted on it. In this embodiment, the valve 70 is operated by a remote connection 71 . In FIG. 7A , the valve 70 is closed. In FIG. 7B , the valve 70 is partially open, in the center of the iris at 72 . Other valve types besides iris valves can be used in such a system.
[0056] FIG. 7C shows a valve arrangement which can close or open two passages by movement of a control linkage from a remote site. Liner 73 , which may be double walled like liner 41 of FIG. 4 , is shown in place in the esophagus (which is not illustrated). Liner 73 has an upper insert 74 which blocks the passage inside of liner 73 , and also contains two passages 75 , for example for fluid, or for instrument passage or other purposes. These passages 75 emerge from the side of the liner 73 at 75 bis. A control element 76 can rotate a wheel 77 about an axis 78 that is perpendicular to the wheel 77 . This moves a set of holes 79 , which lead to passages through the wheel 77 , into or out of alignment with the external passages 75 , thereby opening or closing the passages.
[0057] FIG. 8 shows options for the distal end of the liner 10 . In one embodiment, the liner 10 , which is generally in contact with the esophageal tissue 80 , is closed at its distal limit 81 . In another embodiment, not illustrated, the distal end 81 is open. In another embodiment, the distal end 81 is pierced by one or more passages 82 , which will typically have a distal end 83 , through which fluids, sampling devices, and the like can be passed.
[0058] FIG. 9 shows some of the uses of inflatable balloons for controlling position and passage in devices of the invention. In FIG. 9A , a double-walled liner device 90 , located at a target site in the esophagus and contacting the esophageal wall 80 , has a connection 91 to a source of pressurized fluid, and a passage route in its side having a valve area 92 comprising a slit or other closeable opening 93 . The distal end 94 of the liner device 90 is typically closed, as illustrated, but such closure is not required. When the device 90 is inflated with pressurized fluid, as shown in FIG. 9B , the esophagus is locally distended, and a port area 95 is created on the lumenal side of opening 93 . This provides maneuvering room for passage of an instrument through the opening 93 with proper alignment, and completely seals the area against fluid bypass.
[0059] FIG. 9C is arranged somewhat differently, and pressurized fluid injected through tube 91 inflates an upper balloon 96 and optionally additionally, or instead, inflates a lower balloon 97 . This confines any leakage through opening 93 to a limited space.
[0060] In FIG. 10 , a double layered liner 100 with a space between sealed-together layers has a first side that is perforated and connected proximally to a vacuum source, directly or otherwise, to allow its controllable and reversible affixation to a wall of the esophagus or other targeted tissue. In FIG. 10A , a generally planar double-layered liner 100 has vacuum holes 101 on one side, and not on the other side (not shown), and has a connection to vacuum at 102 . A slit or other port 103 is disposed in the vacuum side of the liner. In cross-section 10 B, the wall 105 of the esophagus is shown, as well as the interior space 106 of the liner 100 . Likewise, in FIG. 10C , a tubular liner 110 has vacuum ports in its outer wall 111 , and not in its inner wall, and a vacuum connection via hose 112 to its inner volume 116 . The tubular liner 110 has a central space 114 , seen in FIG. 10D , while the planar liner 100 leaves an open space 104 inside the wall 105 of the esophagus. With either device, application of vacuum at the port 102 or 112 will firmly and reversibly affix the liner to the wall of the esophagus, allowing passage of instruments through openings 103 or 113 without significant leakage of fluids into other compartments. The liner device is then easily removed by relieving the vacuum, and withdrawing the liner, for example by the vacuum connection.
[0061] FIG. 11 shows two views of a catheter 120 penetrating the esophageal wall 121 and having liners 122 , 123 as sealing elements on both sides of the wall 121 . The liners can be designed so that their openings close upon removal of the catheter.
[0062] FIG. 12 shows two catheters 130 , 131 emerging from slits in the wall 132 of the esophagus. The emergence slits lie between sites of occlusion of the esophagus, 133 and 134 , which may be provided by an inflatable device like the one shown in FIG. 9C , or by other means. The first catheter 130 carries a detachable snare 135 , which has been closed around the esophagus 132 to limit the diameter of the esophagus, for example to decrease the speed of eating by a patient. The second catheter 131 carries illumination and viewing means operating through its tip region 136 , allowing observation of the process of setting and sizing the loop of the snare 135 . FIG. 12 illustrates the importance of being able to control the direction in which a device penetrates the esophagus, and the utility of kits providing for two or more devices to be operated simultaneously.
[0063] FIG. 13 shows devices with a steerable exit port. In FIG. 13A , a first embodiment of a generally cylindrical lining device 140 having a central lumen 141 is provided in two sections, upper section 142 and lower section 143 . The device is delivered to a section of the esophageal lumen 144 at which a port is to be created. A wire 145 or other control means can rotate the lower section 143 of the device with respect to upper section 142 , thereby controlling the position at which a catheter would penetrate the lumen wall 144 . If the plane between section 142 and 143 is inclined, as illustrated, then a rotation will also cause a local bending of the esophagus, and control the angle as well as the rotational position at which a device will emerge from the lumen 141 .
[0064] A different embodiment, shown in FIG. 13B , has a device 155 with upper and lower inflatable balloons 150 , and a center passage with an inlet at 151 and a rotatable outlet 152 which can allow access through the lumen wall 153 at various rotational positions, through various outlets in the lower section 154 of the device.
[0065] FIG. 14 shows alternative means of selecting the rotational position of exit of a catheter or other device through the wall of the esophagus, by rotation of the esophagus itself. In a first embodiment 14A, a liner device 160 has a rigid upper section having two control wires 162 , 163 and an entrance port 164 and exit port 165 for a catheter or other device. By applying torque to the device via the control wires 162 , 163 , the distal end 166 of the device will rotate with respect to the proximal end 167 , allowing control of the exit direction of a device passing through the entrance 164 and exiting through exit 165 . In a second embodiment 14B, a liner device 171 , similar to the liner in FIG. 7C , is placed in the esophageal lumen 170 . Application of twisting motion to control wires 172 , 173 can twist the liner, and with it the lumen, to allow emergence of a catheter or other apparatus at a desired rotational angle with respect to the patient's body as a whole.
[0066] FIG. 15 shows a particular complete deployment device or integrated of the invention, and is described in more detail below.
Uses and Other Aspects of the Invention
[0067] The liner can be used to facilitate surgical procedures through the wall of a luminal structure or body cavity wherein said procedures can be conducted either with removal of the tubular liner device or self absorption, for example within 36-48 hours after the procedure. Or, the procedure can be sub-acute placement to allow for a planned second operative step or a redo; or it can be a chronic (long term) placement as a launching station to the neck compartment or the thoracic cavity to deploy pace makers or batteries, to perform various diagnostic and therapeutic procedures via endoscopy when the scope interrogates an embedded intramural ring, which may itself be a part of the original liner device that did not degrade after implantation of the liner.
[0068] The liner device may be made of a sterile, antiseptic and/or antimicrobial material. The material of the liner may be a solid; or may be a foam, or a layered foam, or a spreadable separator material, applied by painting, spraying or layering of a semisolid or foamy state of an applied material to cover a perforation site in the wall of the luminal organ or cavity.
[0069] Moreover, the semisolid or foam layer may have a pre-manufactured flap or valve positioned around a pre-made hole in the layer to allow for passage of endoscopes or other devices. In some embodiments, a foam or semisolid layer later collapses on itself and seals any hole made through said layer during the passage of instruments, and so obviates the need for a pre-manufactured hole for passage of said instruments.
[0070] Likewise, a material in a fluid state or semisolid state, which adheres to some extent to an elastic membrane or sheath, can be coated onto the elastic membrane and lined with or covered with another layer of elastic membrane or sheath, providing support on both sides of the fluid or semisolid layer, thereby constituting a triple layer liner device structure made of two layers of sheath filled with fluid and/or foam in between said layers. This type of triple layered structure can have a pre-manufactured hole across the three layers to allow for passage of instruments. The presence of a fluid or foam layer as a middle layer between the outer two layers of the sheath can seal off the communication between said sheath layers after withdrawal of instruments.
[0071] In another type of a triple layer design liner device, a liner can have two un-aligned pre-manufactured holes, one hole in the internal layer and the other in the external layer, but not aligned with each other, so that the scope or tubular instrument passes across the liner triple layer device in a zigzag fashion which seals off the holes against each corresponding wall after withdrawal of instruments.
[0072] Similar results can be obtained by using small patches, carried on an endoscope or other instrument (not illustrated), which have asymmetric holes in their surfaces, and which can be induced to oppose each other during the course of withdrawal of an instrument. In general, the liner can be sealed whenever two layers of membrane, disk, patch or barrier oppose each other, for example slideably with respect to each other. The sliding of the components can align two holes (one on each layer) so that they are together (open position), away from each other with no overlap of the holes (closed position) or with partial overlap of the holes (partially opened/closed). The exact shape of the components is not critical. Such a liner device can isolate a partial or full thickness perforation in the wall of a lumenal body structure or a body cavity from inside, outside or both sides. The isolation of the perforated portion of said wall allows the perforation to heal while the liner device prevents direct communication or contact between the perforation site and the lumen of said organ or cavity and/or its surrounding structures from outside. Said liner prevents contamination of perforation site by covering it and keeps the perforation edges sterile until healing occurs spontaneously or by mechanical approximation of edges of said perforation. The liner device may be a complete or incomplete cut section of a tubular device, as well as planar. The devices may adhere to the lumenal wall by any of the mechanisms discussed above (adhesives, pins, inflatables, etc.).
[0073] In another aspect of the invention, a central pre-manufactured hole may be made to include a rotating or revolving mechanism with open, semi-open or closed phases. For example, a device may be made of two successive linear disks, membranes, patches or barriers, wherein each linear device of the two has a hole in its wall to allow for the passage of instruments, but wherein said holes are not aligned across from each other in the plane of the device. Later, the withdrawal of the instrument from the device creates an opposition of the two components, disks etc of the liner device, in a way that seals the hole on each wall by closing it against the other wall (versus against the other hole). Where this is arranged, clearly the exact shape of the membranes is not critical, and need not match exactly, as long as the separated holes do not face each other after the procedure is completed.
[0074] A preferred embodiment has a first layer with a side opening and an overlying second layer with a second side opening on the wall. When the two tubes slide on each other, the two side openings can be aligned into one opening (open position) or can be aligned away from each other (closed position) or a position in between (partial opening).
[0075] The invention also includes the case in which the liner device is a vertical sheet attached to the wall of a luminal body structure or body cavity along its longitudinal axis. For example, said vertical sheet, which may be square, rectangular, irregular or other convenient shape in two dimensions, typically has upper and lower ends. In some embodiments, illustrated in FIGS. 3 and 4 , each end of a vertical sheet or a patch may have a U-shaped transverse collar running around the interior or exterior wall of the lumen and holding the liner against the lumen. Such collars can fix the liner device to the wall from inside, outside or both sides. The vertical sheet may have at least one side opening to allow passage of devices. The side opening can be fitted with a valve mechanism as described in FIG. 7 . An adhesive may be used to adhere the device to a lumen wall, or vacuum can be used as shown in FIG. 10 .
[0076] Generally, any part of a liner device can be used to fix the liner to the wall of said lumenal organ or cavity e.g. with glue, hooks, pins, spines, balloons, collars and the like. There may also be only one collar, attached to only one end of a tube, sheet or patch, the whole device attached to the wall of the lumen by the above means.
[0077] In some embodiments, the liner may be supplemented or replaced with one or two end plates, which span the lumen and block it off. Each plate may have a central hole for passage of devices. An example of such an embodiment is seen in FIG. 14 . The plates, which may have self-closing slits for passage of devices such as an endoscope (not illustrated), isolate the target segment of the lumen from either or both ends against secretions, leakage or contamination. The plates may be made of materials similar to the liners described previously. The plates may be affixed to the walls of the lumen by means such as those recited above.
[0078] In another embodiment, the liner device has a valve mechanism on or connected to a hole (for example, a slot in a rubbery liner septum) to allow for passage of surgical devices or scopes through the valve mechanism and across the perforation in the wall, while having the opening be self sealing against fluid passage. (See FIG. 7 , for example.) The liner, as described above, may seal a perforation in the lumen wall by directly blocking fluid passage. In addition, or instead, flow of fluid and passage of instruments can be accommodated and reversibly blocked by a side opening mechanism, or “SOM”. The SOM is a device that can be attached to a liner, or itself be a liner, which device has means for reversible closure. An example of a valve-type SOM is sown in FIG. 7 . Any device can be used that is operative in this fashion, including, without limitation, a shutter that moves up and down, side-to-side or diagonally with respect to any barrier; a pair of shutters moving away from or towards each other; simple or double flaps; a hinged door mechanism; a fitted stopper; an iris; a zipper; and the like. An iris-like SOM is used in the Figures to indicate any of these options. In addition, while a SOM is generally illustrated herein as attached to a liner having greater area, the liner, patch or sheet may be reduced sufficiently, or eliminated, so that the SOM is effectively or actually adhered to a location where a hole is to be made, without requiring an additional liner, patch or sheet element. As illustrated, a SOM will usually have a control means operable from outside the patient, or by remote means. The SOM may be affixed to the wall of the lumen by vacuum, as shown schematically in FIG. 10 for liners.
[0079] Closure can also be achieved by other methods, including without limitation applying a one-layer device; conducting a procedure; and covering the hole in the device with an adhesive patch ejected onto the site by an endoscope or other delivery device (not illustrated.)
[0080] As an example of how a liner may be delivered to the target site on an endoscopic instrument, a tubular liner device may be delivered to a target segment in the esophagus by being secured on an endoscope, with or without a side-viewer eye for placement. The scope segment that carries the tubular liner preferably has an inflation mechanism to push the liner wall into the mucosa of the esophageal wall circumferentially with or without fixation mechanism. The scope segment carrying the liner can be transparent to allow for vision during placement. The transparent segment may have light/vision capability on the side wall of the scope or inside the scope lumen. This is especially helpful when the liner is also transparent.
[0081] The liner may comprise one or more chemically or pharmaceutically useful substance for absorption across the esophageal wall, or for direct treatment of the esophagus. The liner may also comprise valves to control the amount of material that can pass through the lumen where it is implanted. Such controls may operate either directly through the lumen, or as a regulated flow through the wall of the lumen. A liner may comprise a tubular structure in the form of a sterile elongated sheath that has an upper opening and a side opening. Each opening may have a valve mechanism (e.g., a funnel shaped valve or a SOM). The side opening may have a SOM, Instruments, scopes and devices can pass from the upper opening to the side opening, while covered by the sheath. The sheath can be filled with sterile fluid for sealing.
[0082] As another closing mechanism, a tubular double-walled liner may have two holes, an inlet hole and an outlet hole, for example one near each end of the tubular liner (not illustrated). The holes are not on the same vertical plane. Optionally, they are perpendicular to each other on a cross section prospective. Instruments pass from the inlet hole on one wall, and down the lumen of the tubular liner to come out from the outlet hole, before they reach the wall of the luminal organ (e.g. the esophagus) and come out from the wall penetration. The outlet hole is aligned with the wall penetration. The tubular liner is fixed opposite the wall of the luminal organ (esophagus) e.g. by glue. The lumen of the tubular liner is also lined with glue from inside. Once the instrument is withdrawn upon completion of the procedure, the outside wall of the tubular liner collapses against and seals the perforation in the wall of the organ; the inlet and outlet holes are sealed against an opposing wall of the tubular liner. The lumen of the tubular liner is obliterated after collapse of the two walls together and adherence to each other by means of the lumen-lined glue.
Other Deployment Mechanisms
[0083] Regular endoscopes can also be used to perform most surgical procedures suggested by the current invention as methods of transesophageal surgery in the neck and thorax. However, in another embodiment, a multifunctional, powered or non-powered, guide wire system with an array of functions, sizes and shapes is provided for use with the transluminal access system provided by the liner system. The invention teaches the use of the novel guide wire system with flexible functionality and smaller size compared to currently used scopes. These special guide wires pass through small penetration in the esophageal wall and reach target locations outside the esophagus in the cervical and thoracic regions. The system is applicable to other lumens and routes of entry into the body.
[0084] A scope with a side viewer may be used to deploy a tubular liner device. After the liner is securely fixed to the esophageal wall, a needle tip is used to make a partial thickness perforation in the esophageal wall. The perforation is dilated by blunt dissection (dilators) until full thickness perforation is achieved at minimal tissue damage. Such a system can take advantage of the protection provided by the liner system, while using a thin, minimally disruptive instrument for operating outside the confines of the esophagus or other access lumen. This reduces trauma and simplifies management of many procedures. For example, any of various ablation techniques can become simpler, more accurate and less traumatic.
Use of a Liner as a General Deployment Device
[0085] In addition to deployment of a liner via a scope, a deployment device or apparatus can be used as a means for placing a tubular liner at a target location on the wall of a luminal organ or cavity. The deployment device is a long, hollow, tubular structure that carries a tubular liner over its circumference at some location between its upper and lower ends. There is a circumferential balloon between the tubular liner and the wall of the deployment device (DD).
[0086] FIG. 15 is a diagram of a deployment device (DD). A deployment device will be tailored to a particular procedure, or to a family of procedures, and there will be numerous detailed arrangements. The arrangement of FIG. 15 is an example of the kinds of devices contemplated, and is not a limiting embodiment. In FIG. 15 , the endoscopic deployment device 180 has five inlets or inputs: 181 , optical and electrical connections; 182 , vacuum; 183 , spray for antiseptic or other fluid; 184 , air for sealing balloons; 185 , air for a deployment balloon for deploying a liner. The periphery of the device barrel 186 has segments 187 carrying a sealing balloon, 188 having vacuum ports, 189 comprising a deployment balloon for expanding to deploy a liner 190 , the liner having a port region or other provision for an opening 194 , against the inner wall 195 of the esophagus, and optionally at least one spray zone 191 for spraying an antiseptic or other fluid and optionally a further sealing balloon 192 ; and finally a segment 193 containing optical components, lights, ultrasound and other imaging equipment, and the like.
[0087] A deployment device will typically have at least three proximal ports, including a vacuum port, a liner balloon port, and a sealing balloon port. There are, in this particular embodiment, three sealing balloons, two vacuum port areas 188 to increase the degree of sealing, and at least one spray area 191 , for example for dispensing antiseptic. Between the vacuum ports is a tubular liner 190 and a deployment balloon for the liner 189 . There may also be a number of circumferential balloons above and below the liner. At least one balloon above the liner and/or below the liner can seal the lumen of said luminal organ when inflated in a donut shaped fashion. The balloon inside the liner pushes the liner towards the wall of the luminal organ upon inflation, and can push the liner's external wall into contact with the internal wall of the organ.
[0088] The deployment device may also have numerous pores. The pores may be continuous with an underlying space, or each pore opening or group of openings may be directly connected to a separate channel. In either case the pores, shown in segment 191 , can be used to spray the internal aspect of the luminal organ with solutions or powdered materials. The sprayed material may comprise antiseptic solutions or cleansing solutions, for example prior to performing a procedure. They can also be used to apply vacuum to the wall of said organ when required for more secure isolation of the segment. It could be possible to improve sealing by alternating vacuum and pressure areas in any order.
[0089] Through the hollow core of the deployment device (not illustrated), medical and surgical instruments, including but not limited to endoscopes, ultrasound probes, suture devices, scalpels, lasers, grabbers, radiofrequency ablators, etc., can be passed from its proximal end outside the body to its distal end at the operation field. Such instruments and probes can also be used at points along the barrel of the deployment device. The deployment device may further comprise an inner sheath (not illustrated) that can be removed or stripped to expose a sterile inner surface.
[0090] The deployment device may be used to deploy a tubular liner in a patient prior to a procedure in which general anesthesia is not necessarily required. For example, in the case of the esophageal lumen, there are no pain receptors in the wall, and hence conscious sedation can be used during the procedure without having to put the patient to sleep or use intubation. In the case of an esophageal procedure a spot in the esophagus is identified by imaging or by ultrasound guidance. The deployment device with a liner 190 for implantation is introduced into the esophagus and situated so that the liner overlies this predetermined segment. The sealing balloons 187 of the apparatus are deployed, creating an enclosed space which contains the segment in which the port is to be deployed. Antiseptic is injected through special channels of the apparatus and is delivered to clean the area. Vacuum suction is applied to the channels to remove antiseptic and to create a tighter seal between the apparatus and the esophageal wall. The liner 190 is then expanded by its deployment balloon 189 to push the liner 190 against the esophageal wall 194 . If desired, the liner may be attached to the lumen wall by additional means, as previously described. A transesophageal opening is created by surgical incision through the dedicated area 194 of the liner, which may be preceded or accompanied by the further addition of valve mechanisms or other accessories as described above.
[0091] Following the opening of a passage, procedures are performed, and then the instruments are removed; the port is sealed or the liner is allowed to close or assisted in closing; the balloons are deflated; and the deployment device is removed. The patient will generally be held for observation and to ensure stabilization of vital signs, but in simple cases, no further treatment may be required.
Example 1
Transesophageal Microaccess for Spine Treatment
[0092] Cervical and thoracic spine disorders are of special importance due to the complexity of the bony/cartilaginous structures in relation to the spinal cord. For disorders like cervical disk disease, the current surgical solutions are very complex and involve dissection through many layers of tissues, and affect many sensitive vascular, neurological or lymphatic structures before the surgeon is able to reach the target lesion in the disk area between cervical vertebrae. This applies to both the anterior as well as the posterior approach.
[0093] What is needed is a simpler, less invasive and more precise method to reach the cervical disk/vertebral lesion and related structures without the need to dissect through many tissue layers. The posterior “Transesophageal Microaccess” approach is described below. As will be shown, the access to the cervical spine through the esophageal wall is short, wide and relatively direct as the esophagus is directly related to the vertebral column posteriorly. The esophagus is cleaned by antiseptic solutions to decrease any amount of infectious agents in the surgical field.
[0094] The devices to perform the surgery include a deployment scope, a liner, an obturator, and a therapeutic scope or device. The deployment scope is the scope that carries the liner on at least part of its wall to be delivered to a target segment in the esophagus. In one embodiment of the invention, the part scope that carries the liner is transparent; in another preferred embodiment the liner itself is also transparent so that the esophageal wall can be imaged during deployment. There may be an external imaging device e.g. fluoroscopy, to direct the liner placement to a target area in the cervical spine. Once the liner is at the target location, the scope is rotated along its short (horizontal) axis to direct the side opening mechanism posteriorly to face the vertebral column at the level of the lesion. In a preferred embodiment there is an inflation mechanism between the liner and the carrying deployment scope that when activated can push the liner wall outward into the esophageal mucosa for fixation. In another preferred embodiment there is no inflation or expansion of the liner but the fixation of the liner to the esophageal wall is achieved by means of mechanical attachment e.g. spikes, hooks or by glue or the like.
[0095] The Liner: In one embodiment, the liner is a tubular structure with two ends, proximal and distal, and a side opening mechanism between the two ends. In a preferred embodiment, the liner is transparent for better vision/placement; in another embodiment the liner is made of biodegradable material e.g. starch or other food or biodegradable materials that will be digested in a day or two, or other acceptable time frame. The liner may be made of expansile or non expansile material as above. In a preferred embodiment, the proximal and distal openings are covered with a slotted diaphragm that allows the carrying scope or any other surgical instrument to pass through, but will seal the ends when no device is passed in either end. The side opening mechanism can be a simple slot, an iris, a flap, a shutter, double shutters or opposing ends, or any simple structures that allow for opening, closure or partial closure of the side opening.
[0096] The Obturator After the liner is situated in place at the target segment, with the side opening mechanism facing the lesion posteriorly towards the vertebral column, an opening device or obturator is passed from the mouth to the proximal end of the liner across the slotted diaphragm and through the side opening mechanism to start a perforation in the esophageal wall. In a preferred embodiment of the invention, the obturator is a blunt dissection tool with a sharp short needle at the tip that is retracted after initial partial penetration into the mucosa. The blunt head is pushed out of the esophageal wall and a surgical perforation is made opposite and external to the side opening mechanism. The obturator is removed from the field.
[0097] The Therapeutic Scope: a specialized surgical scope is passed from the mouth to the esophageal lumen across the proximal end of the liner into the side opening mechanism (in its fully open phase). The scope is passed through the esophageal wall penetration to the surgical field of the cervical vertebral column. Surgical interventions are applied according to the specific pathology. In a preferred embodiment of the invention, lysis and absorption of the nucleus bulbosus of the intervertebral disk is followed by fixation of the vertebral bodies. It is understood that any form of spinal or vertebral procedure can be achieved from this location. The operating scope can be of any known type, including flexible, semi rigid, robotic, manual or remotely (telemedically) operated.
[0098] After the procedure is completed, the side opening mechanism is closed, covering the esophageal wall mucosal incision until it heals spontaneously by first intention. This usually takes place within hours to a day. After that the liner can either be removed or left to be digested spontaneously. The upper and lower end of the liner are sealed as mentioned above which prevents secretions from above (saliva) or below (gastric content) from spoiling the surgical field or track into the liner lumen.
Other Features
[0099] The current invention provides specific devices and methods to facilitate the performance of all surgical, orthopedic and neurosurgical diagnostic and therapeutic procedures in the neck and thoracic region. Such procedures are currently done by conventional surgical approaches. Conventional approaches are not satisfactory and highly invasive. In the case of Cervical Spine surgery for example, said procedures either include the anterior or the posterior neck approaches. The anterior approach involves extensive dissection through multiple layers and structures of the neck with resultant intra operative and post operative morbidity and complications and delayed painful recovery plus the external skin wounds. The posterior approach is less extensive in terms of surgical dissections but is more risky because it involves manipulation of the cervical spinal cord, in cases of cervical discectomy for example. The invention teaches the Transesophageal approach to the neck. The transesophageal cervical approach to the vertebral column and cervical spinal cord provides a short, fast and accurate access in a minimally invasive fashion that obviates the disadvantages of either the anterior or posterior approaches. It can be done without the need of general anesthesia. Many other medical, orthopedic and neurosurgical procedures can be also performed using the transesophageal approach, including, in particular and without limitation, known procedures for surgery in the cervical and thoracic cavities.
[0100] In another aspect, a liner may further comprise other types of component. In one embodiment, a liner carries at least one means for sensing conditions, reporting data, and/or applying a local stimulus. This can allow monitoring of local conditions without additional connections to carry data, or to exert local effects (such as cautery), or simply to allow accurate detection of position via RFID and the like. Also included are simple locating means such as radio-opaque materials, or luminescent materials to allow local optical detection.
[0101] Having fully described the invention, it will be seen that the objects set forth above are efficiently attained. Since certain changes may be made in the above method and constructions while obtaining the same effect, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. It is also to be understood that the following claims are intended to cover all of the generic features of the invention described herein.
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The current invention describes methods of transesophageal access to the neck and thorax to perform surgical interventions on structures outside the esophagus in both the cervical and the thoracic cavity. It describes a liner device made of a complete or partial tubular structure, or a flat plate, the liner having means to facilitate creation of a side opening, which may include a valve. The liner with its side opening form a port structure inside the esophageal lumen. The port structure allows elongated surgical devices to pass through a perforation across the full thickness of the esophageal wall to outside location, in a controlled way. The elongated surgical devices can be diagnostic scopes, therapeutic scopes, manual elongated surgical devices, robotic arms or the like. After being deployed outside the esophagus, the surgical devices can access structures outside the esophagus, in the neck and thorax in 360 degrees of freedom around the esophageal circumference. These structures can be bony, cartilaginous, spinal, vascular, soft tissue, deep tissues, lymph nodal, cardiac, pulmonary, tracheal, nervous, muscular or diaphragmatic, skin and subcutaneous tissues of the neck, skin and subcutaneous tissues of the anterior chest wall, skin and subcutaneous tissues of the skin of the back, and skin and layers of the breast.
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The invention relates to the design of a winding machine with a multitwist spindle for textile working of endless fibers and yarn, where arbitrary adjustable revolutions of a multitwist spindle and of a winding-on mechanism are synchronized.
Twisting arrangements, using single twist spindles with a rotating countershaft, double twist, three twist and multitwist spindles are known. There is no synchronizing between the spindle and the winding head in these arrangements, since all spindles on the machine have their own drive. This design cannot secure a uniform height of twists for each winding head. This irregularity reduces the quality of the thread. Another drawback of these arrangements is that the support of the spindle with regard to the takeup mechanism does not provide an arrangement utilizing standard components, so that the winding head and spindle are an independently controllable unit.
SUMMARY OF THE INVENTION
These drawbacks are eliminated by a winding machine with a multitwist spindle according to this invention, the main feature of which is that a multitwist spindle and a winding-on mechanism are independently supported by a common supporting frame. The supporting frames can be arranged one above the other or one in front of the other. The multitwist spindle with the winding-on mechanism form an independently controllable unit with a common driving shaft. A multitwist spindle is situated between a first and a second stand. A first pulley is on a right half-axle or on a half-axle if the countershaft is suspended on the half-axle. A hollow shaft terminating by a pulley and by a main pulley is fixed to the main toothed wheel. A first small pulley and a small pulley are arranged on a driving shaft between a second stand and the gear case. A first toothed wheel and a toothed wheel are connected with a take-up roller, a distributor and a guiding roller.
The advantages of the winding machine with a multitwist spindle are that the revolutions of the multitwist spindle are arbitrary adjustable with respect to the winding-on mechanism, whereby the first small pulley and the small pulley on the driving shaft, connected by a belt, by a first toothed belt and a belt provide a synchronization of revolutions of the multitwist spindle with the take-up speed of the winding-on mechanism. The common main pulley provides an independent control of the working unit.
DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of a winding machine with multitwist spindle are shown on the attached drawings, wherein:
FIG. 1 is an overall sectional elevation of a winding machine with a multitwist spindle with a first external and a second internal carrier.
FIG. 2 is an overall sectional elevation of a winding machine with a multitwist spindle with a first internal and a second external carrier.
DESCRIPTION OF PREFERRED EMBODIMENTS
The winding machine according to this invention is designed so that a first stand 3, a second stand 4, a gear case 22 and a stand 27 are supported on a supporting frame 1. A multitwist spindle is arranged between the first stand 3 and the second stand 4. Its left half-axle 9, firmly connected with a first external carrier 41 and with a second pulley 14 is rotatably supported by the first bearing 6 of the first bearing housing 5, firmly connected to the first stand 3 and the right axle 10, connected firmly with the second external carrier 42 and with the first pulley 13 is rotatably supported by the second bearing 8 of the second bearing housing 7 fixed to the second stand 4. If the multitwist spindle 12 comprises solely a first internal carrier 40 as shown in FIG. 2, the half-axle 11, firmly connected to the first pulley 13, is rotatably supported by the second bearing 8. In the gear case 22, the first toothed wheel 23 firmly connected to a take-up roller 26 and a second toothed wheel 30 firmly connected to a distributor 29 are supported by the stand 27, which supports, futhermore, a main toothed wheel 31 and a toothed wheel 36, firmly connected to a guiding roller 34. A hollow shaft 32 firmly connected with the main toothed wheel 31 terminates by a pulley 37 and by a main pulley 35. A driving shaft 19 provided with a second small pulley 18, a first small pulley 17 and a small pulley 20 is rotatably connected by a second toothed belt 16, a first toothed belt 15 and a belt 38 with the second pulley 14, the first pulley 13 and the pulley 37 respectively.
The winding machine with a multitwist spindle according to this invention operates so that after starting the drive, the main pulley 35 transmits the rotating motion over the hollow shaft 32 to the main toothed wheel 31, to the second toothed wheel 30 with the distributor 29, to the first toothed wheel 23 with the take-up roller 26, to the toothed wheel 36 with the guiding roller 34 and to the pulley 37. The belt 38 transmits the motion to the small pulley 20 and over the driving shaft 19 to the first small pulley 17 and to the second small pulley 18. The first toothed belt 15 transmits the motion to the first pulley 13 and to the right half-axle 10 with the second external carrier 42 or to the half-axle 11 with the second internal carrier 40, as in FIG. 2. The second toothed belt 16 transmits the motion over the second pulley 14 to the left half-axle 9 with the first external carrier 41 or with the first internal carrier 39. The fibre 21 taken off from the counter-shaft 2 to the take-up bobbin 24 receives for one revolution of the first internal carrier 39 and the second internal carrier 40 two twist, for one revolution of the first external carrier 41 and of the second external carrier 42 further two twists. The winding machine can be advantageously used for working of endless fibers and yarn in textile and fiber working plants, where a minimum coefficient of non-uniformity of twists is required.
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A winding machine with a multitwist spindle for textile working of fibres and yarn with a synchronized movement of the multitwist spindle and the winding-on mechanism, both of which are mutually independently supported by a supporting frame.
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BACKGROUND
[0001] 1. Field of the Invention
[0002] This invention relates to instruments, more specifically to an instrument for the cutting and removing of stitches from a lockstitch seam made by a sewing machine. In the process of joining various types of fabrics occasionally, there is a need to remove or modify the stitched seam.
[0003] 2. Background
[0004] Removing or modifying a stiched seam traditionally this required the use of at least two instruments. One instrument was used to cut the thread or stitch at two points, both extremities of the seam that was to be removed; typically, a scissor-like device was used. Once the length of the seam, approximately ½″ comprising of 6 or 7 stitches, was severed a second instrument, usually a tweezers-like device or forceps was used to grasp one end of the thread and remove it from the joined fabric by pulling it along the length of the stitch.
[0005] The U.S. Pat. No. 6,608,698 issued to Mindheim (1950) describesa a tweezers configuration with cutting blades positioned at right angles to the arms of the tweezers. The thread is grasped in points, as operator continues to squeeze, the blades come together and cut thread. Due to the position of the blades being above the grasping edge the tweezers must be inserted deep into the fabric.
[0006] The U.S. Pat. No. 2,998,649 to Miller et al. (1961) describes a pair of tweezers with a single inclined plate with knife edge mounted at right angles on inside surface of lower arm. When tweezers is squeezed thread plate indexes into slot cut into inside surface of upper arm. Thread on incline will be cut as place engages slot.
[0007] The U.S. Pat. No. 3,266,493 to Cummings (1966) depicts a combination of tweezers and scissors. The device can be rotated by the fingers to position either the scissors or gripping points to cut and pluck the stitches.
[0008] U.S. Pat. No. 4,052,979 to Tuthill et al. (1977) demonstrates a disposable suture cutter formed of tweezers that are held between the fingers and thumb. The tweezers have opposed free ends with one of the free ends shaped so that it can be inserted under a suture with a suture retaining groove for holding the suture. A cutting blade is attached to the other free end of the tweezers. The cutting blade is attached to the other free end of the tweezers. The cutting blade end of the tweezers allows for movement traversely and downwardly to cut the suture being held by the retaining groove.
[0009] U.S. Pat. No. 5,015,252 to Jones (1991) depicts a surgical forceps device with inward facing points at the end of spaced apart arms that are specifically designed to hold the sides of a surgical incision together during suturing. The handle of the forceps provides for a knife blade that is partially exposed by a notch in the handle.
[0010] U.S. Pat. No. 5,023,997 to Salvi (1991) demonstrates a pair of tweezers enables cutting by pointing inward two sharp metallic ends, perpendicular to the two legs surfaces of the tweezers. It is also equipped with a removable actuating lever made of one bent piece of metal.
[0011] U.S. Pat. No. D493,255 to Lamagna (2004) illustrates a pair of tweezers that do have a sharpened blade for cutting threads.
[0012] U.S. Patent Publication 2005/02622704 (2005) depicts a seam ripper that cuts threads via a radial motion.
SUMMARY OF THE INVENTION
[0013] The present invention discloses an improved thread cutting apparatus useful in the removal of stitched connections, comprised of a pair of spaced apart arms joined at one end to form a pair of tweezers or forceps, which can be held between the thumb and forefinger. When pressure is applied by the clamping action of the thumb and forefinger, the distal ends of the spaced apart arms will make contact, so as to be able to grasp items, such as thread or sutures.
[0014] The material used for the device has sufficient resiliency to allow for resistance to deformation caused by the squeezing action of the thumb and forefinger and will return to its original position after manipulation.
[0015] The two arms are joined near their proximal ends and have a hole penetrating through the assembly of sufficient diameter to enable a cord, wire or lanyard to pass through for the purpose of hanging the implement around the neck or to secure to one's wrist.
[0016] The distal ends of the spaced apart arms taper and terminate into sharp points and sections of the arms nearest the distal ends are beveled on each side to form knife-like edges, but as few as one knife-like edge is contemplated. However, by having two knife-like edges or blades, one on each arm, on the same side of the tweezers assembly one unit can be rotated and used by right or left-handed users.
[0017] Because the device may be used by either right handed or left-handed persons it may have selective marked so that the user can easily properly orient the device to perform the stitch removal, such as different colored lines on the arms visible when the device is in the proper orientation for the dexterity of the user.
[0018] Removing of a stitched seam requires three steps. The first is to insert or thrust the pointed edge of the device between the stitch and the fabric that will cause the thread to be in contact with the blade or knife-like edge of tweezers. As the pointed tip drives further between the stitches it acts as a wedge stretching the thread and eventually cutting it along the interface between it and the blade or sharp knife-like edge.
[0019] The second step is to repeat the previous action on a different point on the stitched seam, thus forming the desired length of stitch to be removed. Once the stitch is severed in these two places, the third step requires grasping either loose thread end with the distal point of the tweezers and removing the thread.
BRIEF DESCRIPTION OF THE DRAWINGS.
[0020] Taking the following specifications in conjunction with the accompanying drawings will cause the invention to be better understood regarding these and other features and advantages. The specifications reference the annexed drawings wherein:
[0021] FIG. 1 is an isometric view of the thread cutting apparatus; and
[0022] FIG. 2 is a top plan view of the thread cutting apparatus; and
[0023] FIG. 3 is an isometric view of the thread cutting apparatus showing the manner of cutting and removing a stitched seam.
DETAILED DESCRIPTION
[0000] 1. Overview
[0024] The preferred embodiment or “Tweezor” combines the functionality of these two separate tools conveniently into one instrument, so that the cutting action and the grasping and pulling action can be performed by a single instrument, which alleviates the need for the operator to switch tools and so makes the stitch removal process more efficient.
[0025] Moreover, the preferred embodiment also provides for a means of hanging the device around one's neck, as is customary for long arm quilters. More succinctly, the preferred embodiment comprises a traditional style pair of tweezers with sharpened side edges, which can either pluck or cut the seam by varying the orientation and movement of the instrument.
[0026] The device is particularity useful for commercial long arm quilters who need to remove yards of stitching as quickly as possible. In addition, because the stitches are held in bating and are cushioned rather that lie on flat fabric as in a garment seam this cushion allows the point of the device to be inserted without difficulty.
[0027] Additionally, it is foreseeable that this invention can be utilized for cutting and removing a variety of thread-like connections, such as various machine stitches, hand stitches, woven material, fine wire, fishing line or surgical sutures.
[0028] While describing the invention and its embodiments, various terms will be used for the sake of clarity. These terms are intended to not only include the recited embodiments, but also all equivalents that perform substantially the same function, in substantially the same manner to achieve the same result.
[0000] 2. Description of the Drawings
[0029] A preferred embodiment of the present invention discloses an improved tweezers or thread cutting apparatus.
[0030] As shown in FIG. 1 and indicted generally by the reference number 100 is comprised of a pair of spaced apart arms 110 and 120 joined at the assembly's end 200 to form a pair of tweezers or forceps, which can be held between the thumb and forefinger. The spaced apart arms 110 and 120 are generally rectangular in cross section.
[0031] The assembly is preferably made of a metallic material that has sufficient resiliency to allow for resistance to deformation caused by the squeezing action of the thumb and forefinger, but then again, composite or plastic materials may also be contemplated, so long as this material can resist deformation and return to its original position after manipulation. This material should be suitable to be sharpened to a knife-edge or to allow for the insertion of a sharp blade edge such as a razor blade.
[0032] In the preferred embodiment, the two arms 110 and 120 are joined near their end 200 by fusion welding with a hole 190 penetrating through the thread cutting apparatus 100 near the assembly's end 200 of sufficient diameter to enable a cord, wire or lanyard to pass through for the purpose of hanging the implement around the neck or to secure to one's wrist.
[0033] The distal ends of spaced apart arms 110 and 120 taper and terminate into sharp points 130 and 140 . The spaced apart arms 110 and 120 are beveled on each side to form knife-like edges 150 and 160 that extend from the sharp points 130 and 140 towards the assembly's end 200 .
[0034] In the preferred embodiment, knife-like edges 150 and 160 occur only on one side of the thread cutting apparatus 100 and then for a length less than the majority of each of the arms 110 and 120 .
[0035] In other embodiments, it has been contemplated to have as few as one knife-like edge 150 , but by having knife-like edges 150 and 160 , one on each arm 110 and 120 on the same side of the thread cutting apparatus 100 allows for one unit to be rotated and used by right or left-handed users.
[0036] It is also contemplated that by sharpening only one side of the device helps protect the user from inadvertent injury and also adds to the strength of the thread cutting apparatus 100 by maximizing the amount of material is on each spaced apart arms 110 and 120 .
[0037] The preferred embodiment contemplates the knife-like edges having a length of 0.5 inches running from point of the arms.
[0038] Now referring to FIG. 2 . FIG. 2 depicts the thread cutting apparatus in a top plan view and illustrates the use of orientation guides 170 and 180 . Because the device may be used by either right handed or left-handed persons it is important for the user to quickly discern whether or not he has the device properly orientated to perform the stitch removal. In one embodiment, the orientation guide 170 is a thin blue line that would be visible when the device is in the proper orientation for a left-handed person while the other orientation guide 180 is a thin red line that would be visible when the device is orientated for proper right-handed use. This is for illustrative purposes and it is obvious that different colors may be used or different symbols or letters to notify the user of the proper orientation of the device.
[0039] Now referring to FIG. 3 . As shown in FIG. 3 a thread cutting apparatus 100 in an isometric view showing the manner of cutting and removing a stitched seam.
[0040] In one embodiment where the removal of machine-sewn stitches is desired the optimum width of each arm 110 and 120 at the mid point of the blade or knife-like edge 150 and 160 should be about 1/12″ which corresponds to the typical spacing between machine sewn stitch. The sharp points 130 and 140 should be tapered to a point and be thin enough to be easily inserted under a stitch without damaging the underlying material or fabric. Once a sharp point 130 or 140 is further inserted under a stitch the corresponding knife-like edge either 150 or 160 will severe at least one side of the stitch by a wedge-like action.
[0041] The manner of using the device is similar to that of a traditional tweezers, which are held between the forefinger and thumb. When the device is held in the right hand, the arm 120 nearest the stitches (the lower arm) will have the knife-like edge 160 on the left side and the orientation guide 180 possible a thin red line on the flat surface of the arm 120 will be visible to the operator. The pointed end of the arm or sharp point 140 is inserted under single stitch of the line of stitching to be removed, taking care not to pierce the fabric. As the sharp point 140 is pushed further under the stitch loop, the two ends of the thread will eventually be stretched over the taper of the arm and the knife-like edge 160 will cut the thread to the left. The thread cutting apparatus is then withdrawn and the operation is repeated at a point 3 to 5 stitches away from the severed thread and the process repeated. Either sharp point 130 or 140 is then inserted under the stitch midway along the cut seam which is pinched or grasped with both pointed ends 130 and 140 of the Tweezor and plucked to release the thread from the lockstitches formed with the bottom thread.
[0042] When the device is held in the left hand, the arm 130 nearest the stitches (the lower arm) will have the knife-like edge 150 on the right side and orientation guide 170 possibly a thin blue line on the flat surface of the arm 110 will be visible to the operator. All further operations remain the same.
[0043] The term “thread” should not be limited to threads used to join pieces of cloth. The term “thread” can also refer to any material with thread like properties, such as a suture, which is used to join materials (e.g. skin in surgical applications).
[0044] The invention has been described in terms of the preferred embodiment. One skilled in the art will recognize that it would be possible to construct the elements of the present invention from a variety of means and to modify the placement of the components in a variety of ways.
[0045] While the embodiments of the invention have been described in detail and shown in the accompanying drawings, it will be evident that various further modifications are possible without departing from the scope of the invention as set forth in the following claims.
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A thread cutting apparatus that is held between the thumb and forefinger used to cut and remove stitched seams in fabric and the like combining the feature of traditional tweezers and scissors, so that only one tool is needed for the removal process of stitches.
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BACKGROUND OF THE INVENTION
A. Field of the Invention
This invention relates to the wet spinning process for producing yarn of copolymers consisting essentially of recurring units of the formulas ##STR1## and ##STR2## where Ar is ##STR3## R is a C 1 to C 4 alkyl and the mole ratio of (a) units to (b) units is between 20:80 and 95:5. More specifically, the invention relates to the improvement of applying a certain zirconium-containing finish to the yarn during the wet spinning process whereby the twist efficiency of such yarn is significantly increased. The term "twist efficiency", as used herein means the ratio, expressed as a percentage, of the tenacity of a cord plied from strands of a given yarn to the tenacity of a single strand of the yarn, i.e. ##EQU1## The terms "O/H COPOLYMER", "O/H YARN" and "O/H CORD" are used herein to refer to the above-described copolymer, yarn thereof, and cord formed from yarn thereof, respectively.
B. Description of the Prior Art
There is a continuing demand in the tire industry for the development of a higher tenacity cord for use in the carcass of a tire. Yarns of organic polymers (e.g. nylons and polyester) are presently used in forming carcass cords. The cords are formed by plying two or more twisted strands of the yarn to provide a highly twisted configuration having tenacities in the 7 to 10 grams per denier range; the highly twisted configuration of the cords is necessary for good fatigue resistance properties. O/H YARN has a relatively high tenacity when compared to that of either nylon or polyester yarn. However, cord formed from twisted strands of O/H YARN although having good fatigue resistance has a much lower tenacity than expected due to the poor twist efficiency of O/H YARN. Normally, yarns have twist efficiencies of at least 65% (nylon 66 is ≧ 72%), whereas in the case of O/H YARN its twist efficiency is ≦ 50%.
Accordingly, it is an object of this invention to increase the twist efficiency of O/H YARN.
Another object of the invention is to provide a high tenacity cord suitable for use in the carcass of tires.
Other objects and advantages of the invention will become apparent from the following detailed description thereof.
SUMMARY OF THE INVENTION
In general, the objects of the invention are accomplished by applying a certain zirconium-containing finish to O/H YARN during the production thereof. More specifically, the invention relates to an improvement in the wet spinning process for producing O/H YARN whereby the twist efficiency of the yarn is increased. In carrying out the wet spinning process a sulfuric acid polymer solution (i.e. dope) is extruded through orifices of a spinneret into an aqueous coagulation bath to form filaments which are washed free or substantially free of sulfuric acid, dried, hot-drawn at a temperature between about 200° and 500° C. and collected. The improvement of this invention comprises applying to the yarn after the yarn is washed and prior to the yarn being hot-drawn a finish comprising a stable aqueous emulsion of at least one polyalkoxylated silicone oil and at least one dissolved water-soluble zirconium salt. Preferably, the finish is applied to the yarn between the washing and drying steps of the process while the yarn is still wet.
The term "silicone oil" is used herein in accordance with conventional terminology. The term "polyalkoxylated silicone oil", as used herein, means a silicone oil having sufficient structural groups of the formula (R--O) where R is a C 2 to C 4 alkylene, for example --CH 2 CH 2 --, ##STR4## or --CH 2 CH 2 CH 2 -- to render the oil capable for forming stable emulsions with water. The groups may be chain extended groups and/or appendent to a Si atom of the chain. Preferred polyalkoxylated silicone oils for use in practicing this invention have a molecular weight ranging from about 2000 to 120,000 and higher, with the higher molecular weight and more highly alkoxylated oils being particularly preferred. In addition to the polyalkoxylated silicone oil(s), the finish may also contain one or more silicone oils.
It is believed that the improvement in the twist efficiency of O/H YARN obtained by practicing the present invention is due in part at least to the fact that when zirconium is present in the finish the resulting hot-drawn yarn has better filament separation (i.e. less fusion of the filaments) than when the zirconium is omitted from the finish. It is further believed that better filament separation permits the individual filaments of the yarn to move more freely inside cord plied therefrom and thereby more evenly distribute the load on the cord throughout the individual filaments. It is therefore important that the zirconium remain in the finish and that the liquid components of the finish do not separate. In this regard the polyalkoxylated silicone oils is an essential component of the finish. The polyalkoxylated silicone oil component, in addition to being a lubricant for the yarn, forms stable emulsions with water and also ties up the zirconium by some mechanism (most likely by chelation or reaction) and thereby prevents zirconium from becoming ineffective such as would result if the zirconium were to migrate to the inside of the fiber.
The O/H YARNS to which a finish has been applied in accordance with the present invention have good tensile properties and good adhesion-to-rubber characteristics and, therefore, are particularly useful in forming cords for reinforcing flexible rubber articles such as tires and belts.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Finishes useful in practicing the present invention comprise three components: water, water-soluble zirconium salt(s) and polyalkoxylated silicone oil(s).
Any water-soluble zirconium salt may be used in formulating the finishes. Representative such salts include the acetate, bromide, chloride, oxalate and sulfate of zirconium and ammonium zirconium carbonate with zirconium acetate being preferred. The amount of zirconium present in the finishes may range from 0.001% to about 10% by weight, based on the weight of silicone oil, with a range of between about 0.005 and 5% normally providing satisfactory results.
Any polyalkoxylated silicone oil may be used in formulating the finishes which forms a stable emulsion with water. Suitable polyalkoxylated silicone oils are commercially available and include, for example, silicone oils of the formulas: ##STR5## where R is a C 2 to C 4 alkylene, for example, ethylene or propylene and m, n, x and y are integers.
In addition to the polyalkoxylated silicone oil(s), the finish may also contain one or more silicone oils, such as polysiloxanes of the formulas: ##STR6## where R' is alkyl or phenyl, with not more than one R' on each Si atom being phenyl, and x is a whole number. Such polysiloxanes include those consisting essentially of phenylmethyl groups ##STR7## and dimethyl groups ##STR8## in a 30:70 to 95:5 ratio, respectively.
The finish may be prepared by combining the components in a conventional manner, for example, by dissolving the zirconium salt(s) in water, adding the water to the oil or blend of oils (or vice versa) and then sufficiently mixing the components to obtain a stable emulsion. The water serves to dilute the oil(s) and to facilitate accurate metering of the other components onto the yarn. Also, the water cleanly vaporizes from the yarn during drying of the yarn. From 01. to 25% by weight of the silicone oil component has been found to produce satisfactory results. The exact amount of polyalkoxylated silicone oil and water to be used in formulating the finishes will be apparent to a skilled practitioner and will depend on such factors as the rate at which the finish is applied to the yarn.
The finish may be applied to the yarn by conventional techniques such as by passing the yarn through a bath containing the finish or by using rolls which transfer the same from the bath to the yarn. Normally, the amount of oil(s) applied to the yarn may range from about 0.1 to about 10%, based on the weight of yarn, with a range of from about 0.5 to about 3% normally providing satisfactory results. The amount of zirconium applied to the yarn may range from 0.001 to about 2% by weight, based on the weight on yarn, with a range of 0.005 to 1% usually providing satisfactory results. While greater amounts of zirconium can be applied to the yarn, such amounts are not economically warranted. Preferably, the finish is applied to the wet yarn before the yarn is dried so that the water is vaporized from the yarn during the drying step.
The following examples are given to further illustrate the invention wherein, unless otherwise specified, percentages and parts are by weight.
In the examples O/H YARNS are produced by a wet spinning process wherein a sulfuric acid dope is extruded through orifices of a spinneret into an aqueous medium such as water or dilute sulfuric acid maintained at a temperature between 0° C. and 95° C. with ambient temperature being preferred. The spinneret may be immersed in the medium but is preferably positioned a short distance (0.32 to 5.1 cm) above the medium. The filaments formed in the medium are converged to form a yarn, withdrawn from the medium and thoroughly washed with water alone or combinations of alkaline solution and water to remove H 2 SO 4 therefrom. After the washing step, a finish is applied to the yarn while it is still wet and, then the yarn is dried, such as by passing the yarn over a heated roll or pair of heated rolls (110°-140° C.). After the yarn is dried, the yarn is hot-drawn at a temperature between about 200° and 500° C. in a conventional manner. The hot-drawing of the yarn may be accomplished by continuously advancing the yarn through a zone in which the yarn is heated and drawn several times its length (i.e. 1 to 30 times its length). The yarn is then taken up (e.g. wound onto a bobbin). The yarn may be heated by passing it through a heated environment, e.g. through an oven heated by conventional means such as by infrared lamps, electricity, etc., or by passing the yarn over a heated surface, generally convex in shape, such as a hot shoe. The yarn is hot-drawn or stretched in the heated zone by withdrawing the yarn at a speed (V 2 ) greater than the speed (V 1 ) at which the yarn is advanced into the heated zone. Normally, V.sub. 2 represents the speed at which the yarn is collected. The draw ratio (DR) attained by the hot-draw step is conveniently expressed by DR = V 2 /V 1 . Normally, the tenacity of O/H YARN increases with increasing DR values. Where high tenacity O/H YARN is desired, it is a common practice to operate the process at the maximum draw ratio that can be utilized without frequently breaking the yarn, for example, at a DR equal to about 85% of DR b , where DR b represents a draw ratio at which the yarn on the average will break.
The dope is prepared by reacting at a temperature between 80° and 170° C., preferably, at between 130° and 150° C. for from 4 to 6 hours, reactants consisting of (i) terephthalic acid (TA) and/or isophthalic acid (IA), (ii) the dialklester of TA and/or IA and (iii) hydrazine sulfate in oleum containing sufficient SO 3 to take up the water formed by the reaction. The mole ratio of reactants (i) to (ii) is from 95:5 to 20:80 with 40:60 to 60:40being preferred for high strength fiber applications. (iii) is present in a molar excess of a mole ratio of 1:1, (iii) to [(i) + (ii)], at least 0.5 mole %, for example, 0.8 to 4.0 mole % excess. The polymer of suitable fiber-forming molecular weight is normally formed in from 2 to 10 hours. Sufficient amounts of the reactants are used to provide a dope containing in solution from 1 to 15% by weight of polymer. A preferred dope is prepared from TA, the dimethyl ester of TA and hydrazine sulfate where the mole ratio of TA to the ester thereof is 1:1.
EXAMPLE 1
This example describes the preparation of an aqueous emulsion useful in practicing the present invention. Equal parts of an organopolysiloxane with dimethyl and phenylmethyl groups in a 50/50 ratio (obtained commercially from Dow Corning under the Tradename Dow Corning 550 Fluid) and of an organopolysiloxane (molecular weight ≈ 5000) having dimethyl and phenylmethyl groups and one polyethyleneoxide side chain (obtained commercially from Dow Corning under the Tradename Dow Corning FF-400) were mixed and warmed to 33° C. to form an oil blend. Deionized water was warmed to 33° C. and vigorously agitated while the oil blend was added thereto over a three minute period. After all of the oil blend was added to the water, agitation was continued for 10 minutes. The resulting emulsion contained 1 part of oil blend per 9 parts of water or 10% by weight of oil blend.
EXAMPLE 2
This example illustrates the substantial benefits gained by utilizing the improvement of the present invention in preparing yarn of O/H COPOLYMER consisting essentially of recurring units of the formula: ##STR9##
A spinning run was made in which O/H YARN of the above O/H COPOLYMER was prepared using substantially the procedure hereinabove described. Dope, obtained by polymerizing terephthalic acid, dimethylterephthalate and hydrazine sulfate in oleum, was extruded into aqueous sulfuric acid to form 20 filament yarn which was washed, neutralized, again washed, dried, hot-drawn at a draw ratio of 4.6 over a hot-shoe (384° C.) and wound onto a bobbin to provide a drawn yarn having a denier of between 20-23. During the spinning run 4 samples of yarn (2A-2D) were collected to which a silicone oil base finish was applied to each yarn between the washing and drying steps while the yarn was still wet. The finish applied to one yarn sample (2A) consisted of the emulsion described in Example 1 diluted 20 fold with deionized water. The finish applied to the other yarn samples consisted of the same diluted emulsion to which a specified amount of zirconium had been added. The zirconium was added by dissolving zirconium acetate in a portion of the deionized water used to dilute the oil blend.
Each yarn sample was cut into equal lengths and sufficient of the lengths were plied with 2 turns per inch (tpi) to provide a nominal 1300 denier yarn. Two equal lengths were then cut from this yarn. A right-hand twist of 11 tpi was imparted to each length of the 1500 denier yarn. Then, the two twisted yarns were plied with 11 tpi of left-hand twist to provide a 1500/2 11 × 11 tpi balanced tire cord. Cords prepared from yarn samples 2B-2D had good cord-to-rubber adhesion properties. The tenacity of each yarn and cord was determined in a conventional manner using an Instron Tester (Instron Engineering Corporation, Canton, Mass.) providing a constant extension rate of 10% per minute with a gauge length of 25 cm being used. The tenacities in grams per denier (gpd) of the yarns along with the amount of zirconium contained in the finish applied thereto and other data are given in the following Table. The tenacities given in the table represent the average of five determinations or breaks.
TABLE I______________________________________ Finish Wt. Oil % Yarn Yarn Cord CordSample Blend Zr Denier Tenacity Denier Tenacity______________________________________2A 0.5 0 1535 12.53 3514 6.952B 0.5 0.0074 1541 13.23 3497 7.382C 0.5 0.0148 1526 12.99 3470 6.992D 0.5 0.0370 1532 13.39 3492 7.55______________________________________
The results in Table I show that the addition of zirconium to a silicone base finish with other processing conditions being held constant provides cords of higher tenacity than when zirconium is omitted from the finish.
EXAMPLE 3
A silicone oil base finish diluted with water to provide a finish containing 2% by weight of oil blend was prepared using the same procedure as described in Example 1 except that, instead of using 1 part of Dow Corning 550 Fluid per part of Dow Corning FF-400, 3 parts of an organopoly-siloxane consisting of phenylmethyl and dimethyl groups in a 88.5/11.5 ratio (Dow Corning 710 Fluid) was used. To individual portions of this finish zirconium acetate and/or water was added in the same manner as set forth in Example 2 to prepare the following finishes:
______________________________________Finish % Oil Blend Zr______________________________________A 2 0.06%B 2 0.03%C 2 none______________________________________
Yarns and cords were made as described in Example 2 with one of the above finishes being applied to each of the yarns. Cords prepared from yarns to which Finish A and B were applied had good cord-to-rubber adhesion properties.
The tenacities of the resulting yarns and cords were determined and are given in the following table:
TABLE II______________________________________ Denier Tenacity(gpd)Sample Finish Yarn Cord Yarn Cord______________________________________1 C 1566 3568 10.92 6.462 B 1575 3521 11.57 7.593 A 1481 3371 11.67 7.004 C 1561 3488 9.58 5.855 A 1571 3456 11.34 6.85______________________________________
The results in Table II show that in each instance the addition of zirconium to the finish with all other processing variables being held constant provides cords having higher tenacities than when zirconium is omitted from the finish. Also, yarns to which zirconium was applied had noticeably better filament separation.
EXAMPLE 4
This example illustrates a preferred embodiment of the invention wherein the finish is prepared employing as the polyalkoxylated silicone oil a high molecular weight (approximately 100,000) hydroxyl end-blocked dimethyl polysiloxane of the formula: ##STR10## This silcone oil was obtained commercially from Dow Corning (DC-1111). Finishes containing varying amounts of this silicone oil, water and zirconium acetate were prepared and applied to yarn samples prepared as described in Example 2. Cords were prepared from the resulting yarn samples in the manner described in Example 2, except in this instance the cords were 1500/2 8 × 8 tpi instead of 1500/2 11 × 11 tpi. The tenacities (T) in grams per denier, elongation-to-break (E) in percentage and modulus (M) in grams per denier were determined for each yarn and cord and are given in Table III along with the amount of silicone oil, zirconium (Zr) and any other materials which were used in formulating the finishes. It will be understood that each finish consists of water plus the materials listed in the Table.
TABLE III______________________________________ Sili-Yarn cone Dispersion Yarn(2tpi)Sample Oil Agent Zr T/E/M Cord______________________________________1 1.0% none none 17.3/6.5/323 10.8/8.8/2142 1.0% none .03% 17.4/6.7/319 11.7/8.8/2133 1.0% none .06% 16.9/6.3/203 11.0/8.1/1394 1.0% .2% FF400 .03% 15.1/6.3/276 12.1/8.7/2095 1.0% .2% FF400 none 14.9/6.3/275 11.4/8.9/2046 1.0% .3% FF400 .03% 14.2/6.1/267 11.4/8.2/2017 1.0% .2% .03% 15.9/6.3/305 12.4/8.4/244 Ethomeen8 1.0% .2% none 16.2/6.8/292 10.7/9.2/205 Ethomeen*______________________________________ *Ethomeen - Trademark of Armour Industrial Chemical Company for polyethoxylated amines with alkyl groups ranging from C.sub.8 to C.sub.18
The results in Table III show that cord formed from yarns prepared in accordance with the present invention have higher tenacities than corresponding yarns from which zirconium has been omitted from the finish. In samples 4-8 the finish contained a small amount of additional emulsifying agent.
|
Yarns of phenylene oxadiazole/N-alkylhydrazide copolymers are made by a wet spinning process involving the steps of extruding, coagulating, washing, drying, hot-drawing and collecting. These yarns when formed into cord lose considerable tenacity, that is, cords plied from these yarns have considerably less tenacity than the individual yarns making up the cords. It has been found that this loss in tenacity in forming cords can be significantly reduced by applying a certain zirconium-containing finish to the yarn during its preparation. The finish is applied after the yarn is washed and while it is still wet.
| 3
|
BACKGROUND OF THE INVENTION
The present invention is directed to a crane control apparatus for a crane where a load is suspended on a crane cable from a cable suspension point of the crane.
For the control of the crane, exact information on the position and/or the velocity of the load is of great importance. However, this position and/or load velocity of the load can usually not be measured directly, but has to be calculated from measurements that do not directly describe the load position and/or load velocity but related quantities.
For example, in many crane control apparatuses, the cable angle and/or the cable angle velocity is measured by a sensor, from which the load position and/or velocity is calculated. For example, a gyroscope located on a cable follower can be used for measuring cable angle velocity.
However, because of measurement noise and other uncertainties, a purely kinematic model for calculating the position and/or velocity of the load from the sensor input of the sensor is often insufficient for providing the exactness required by usual crane control applications.
Therefore, state observers have been used for estimating at least the position and/or velocity of the load from the sensor input by using a physical model of the load suspended on the crane cable. An example of such a system is shown in DE 100 641 82.
Such observers usually use the cable angle and/or the cable angle velocity as state variables, as this simplifies calculations of the expected measurement signals of the sensors, which relate to the same quantities. The load position and/or velocity is then derived from these state variables.
SUMMARY OF THE INVENTION
The present invention is directed to improving such a crane control apparatus comprising an observer for estimating at least the position and/or velocity of the load.
This object is solved by a crane control apparatus according to the features herein.
Preferred embodiments of the present invention are the subject matter herein.
The present invention shows a crane control apparatus for a crane where a load is suspended on a crane cable from a cable suspension point of the crane. The crane control apparatus comprises an observer for estimating at least the position and/or velocity of the load from at least one sensor input of a first sensor by using a physical model of the load suspended on the crane cable. The crane control apparatus of the present invention is characterized in that the physical model of the observer uses the load position and/or the load velocity as a state variable. The inventors of the present invention have realized that this choice of the state vector has a strong impact on the input values necessary for the observer.
In particular, the inventors of the present invention have realized that if the cable angle and its derivative are used as state variables, the dynamics of this state vector will directly depend on the acceleration of the cable suspension point. In contrast, if the load position and/or the load velocity are used as state variables, as in the observer of the present invention, the dynamics of this state will depend, at least in a first order approximation, only on the position of the cable suspension point and not on the acceleration of the cable suspension point.
This phenomenon can best be understood when one looks at the impact of a movement of the cable suspension point on the cable angle on one hand, and the load position on the other hand: It is apparent that a movement of the cable suspension point will have an immediate effect on the cable angle, while the load will, because of its inertia, at first remain at its position. Therefore, the observer of the present invention, where the load position and/or the load velocity are used as state variables, will depend less or not at all on the acceleration of the cable suspension point.
In industrial implementations, the suspension point position is usually measurable with high accuracy. However, the suspension point acceleration is not that easy to quantify. Differentiation methods get quite involved when it comes to differentiating twice. Actuator models which reconstruct the acceleration from valve currents and friction models also carry large uncertainties. The present invention therefore provides a better observer design, because the observer depends less or not at all on this value.
In a preferred embodiment, the present invention provides a crane control apparatus for controlling the position and/or velocity of the load suspended on the rope by using feedback control, where the position and/or the velocity of the load is determined by the observer and used as feedback. The present invention uses an observer design where an inertial coordinate system is used for modelling the load swing. This eliminates the need of measuring the boom tip acceleration and therefore improves the observer performance during acceleration phases.
In a preferred embodiment of the present invention, the observer uses the position of the cable suspension point as an input. In particular, in the present invention, the physical model of the observer describes the dynamics of the load position and/or the load velocity in dependency on the position of the cable suspension point using a model of the pendulum dynamics of the load suspended on the cable.
The position of the cable suspension point used as an input for the observer of the present invention can be calculated from at least one sensor input of a second sensor. For example, this sensor can measure a luffing and/or a slewing angle of the boom of the crane. Alternatively or in addition, control signals for the actuators for controlling the position of the cable suspension point can be used for determining the position of the cable suspension point.
The physical model used in the observer can be a linearized model of the load suspended on the rope, e.g. a linear pendulum model. However, in a preferred embodiment the physical model is a non-linear model.
The observer of the present invention may use the velocity of the cable suspension point as an input. In particular, this velocity of the cable suspension point might be necessary as an input if a non-linear model is used and/or if the cable velocity is measured by the first sensor. The velocity of the cable suspension point can for example be numerically calculated from the measured position of the cable suspension point or from actuator models which reconstruct the velocity from valve currents.
However, in a preferred embodiment, the observer of the present invention is independent of the acceleration of the cable suspension point. Thereby, the large uncertainties involved in obtaining this acceleration can be avoided.
This is possible in the present invention because the acceleration of the cable suspension point only plays a minor role for the state variables used for the observer. It has to be noted that when an exact non-linear model is used, the acceleration of the cable suspension point plays a role at higher orders of the dynamics of the load position and/or the load velocity. However, in the present invention, the acceleration of the cable suspension point can be set to 0 without significantly deteriorating the model output. Therefore, when a non-linear model is used, the acceleration of the cable suspension point is preferably set to 0.
The observer of the present invention preferably works as follows: It predicts a future state of the system based on the current estimation of the state of the system and inputs, wherein these inputs may comprise a previous sensor input of the first sensor and/or the position of the cable suspension point, and may comprise further data. Further, the observer predicts a future sensor value of the first sensor. The difference between the real measurement and the predicted measurement of the first sensor is then used to correct at least the estimated state.
The model used in the observer may at least comprise a model of the pendulum dynamics of the load suspended on the cable. However, the model may also take into account other effects that might have an influence on the measurement values of the first sensor. For example, the observer may comprise a disturbance model for sensor offset. Thereby, effects of an offset of the sensor can be eliminated. Further, the observer may comprise a disturbance model for string oscillation of the cable. Thereby influences of such oscillations may be reduced. Further, the observer of the present invention may take into account sensor noise and/or process noise.
In a preferred embodiment of the present invention, the physical model of the observer is based on a single pendulum model of the load suspended on the cable. However, for certain applications, where load suspension means with a large mass and/or large distance form the load are used to suspend the load, the observer may also be based on the double pendulum dynamics of the load suspended on the suspension means which are in turn suspended on the cable. For example, the load may be suspended on a traverse by chains and the traverse suspended on the cable. For such purposes, the observer may be based on the double pendulum model.
Preferably, in the present invention, at least one absolute load position and/or absolute load velocity in a coordinate system that is independent of the position of the cable suspension point is used as a state variable. Further, at least the load position and/or load velocity in a radial direction of the crane is used as a state variable. However, in a preferred embodiment, the horizontal load position and/or velocity in two directions is used as a state variable. Further, the vertical load position and/or velocity may be used.
For example, the load position and/or load velocity may be described in Cartesian coordinates. Alternatively, polar coordinates might be used for the load position and/or load velocity. Cartesian coordinates were already used in document DE 10 2009 032 267 A1 for a crane control itself. However, in this document, no observer set-up was described.
In a preferred embodiment of the present invention, the cable angle is not used as a state variable. Thereby, the above described problems are avoided.
Nevertheless, the observer of the present invention may be used with a first sensor that measures the cable angle and/or the cable angle velocity. From these sensor inputs, the observer of the present invention estimates the state vector, this state vector comprising the load position and/or the load velocity. Further, the observer predicts expected measurement values for such a sensor, in order to compare them with the real measurements.
Preferably, the sensor is a gyroscope. Further, the sensor may be located on a cable follower. In particular, such a cable follower may be attached to a boom tip of the crane, in particular by a cardanic joint. The cable follower preferably follows the motion of the cable, such that the sensor attached to the cable follower will follow the motion of the cable, as well.
In a preferred embodiment, the observer of the present invention uses an extended Kalman filter for estimating the load position and/or the load velocity. Such an extended filter comprises a state estimation based on the current state and the inputs. Further, the Kalman filter comprises a covariance estimation for estimating a covariance of the state estimation. Further, the Kalman filter will predict an expected measurement. This expected measurement will be compared with the real measurement in order to correct both the state estimate and the covariance estimate.
Preferably, the Kalman filter uses a time in discretization of the model dynamics. Preferably, a single Newton step is used for this purpose.
The crane control apparatus of the present invention preferably is used in order to control the movement of a crane on the basis of an operator input and/or an automated control system. In particular, the crane control apparatus may be used in order to control the motors of the crane. Further, the crane control apparatus may be used for moving or positioning the load on a desired track or to a desired position. This control is now based on the load position and/or velocity estimated by the observer of the present invention.
Further, the crane control apparatus of the present invention may comprise an anti-sway control for avoiding unwanted pendulum or rotational motion of the load. Preferably, this anti-sway control is based on the estimate of the position and/or velocity of the load provided by the observer of the present invention as state-feedback.
Further, the crane control apparatus of the present invention may comprise a trajectory planning module for planning trajectories of the load suspended on the cable.
The present invention may in particular be used for controlling a crane having a boom having a horizontal luffing axis, around which the boom may be luffed up and down in a vertical plane. For this purpose, for example, a luffing cylinder may be used. Further, the crane may have a vertical slewing axis, around which the boom may be turned. For this purpose, for example, the boom may be attached to a tower that can be rotated around the slewing axis. Further, the cable length may be controlled by a hoisting winch of the crane.
In a preferred embodiment, the cable is directed from the hoisting winch around a cable suspension point located at the tip of the boom to the load.
The crane of the present invention may in particular be a harbour crane and/or a mobile crane. In a preferred embodiment, the crane of the present invention is a mobile harbour crane.
The present invention further comprises a crane control method for a crane where a load is suspended on a crane cable from a suspension point of the crane, wherein an observer is used for estimating at least the position and/or velocity of the load from at least one sensor input by using a physical model of the load suspended on the crane cable, wherein the physical model of the observer uses the load position and/or a load velocity as a state variable.
The method of the present invention has the same advantages as the crane control apparatus described above.
Preferably, the crane control method of the present invention has the features of the preferred embodiments of the crane control apparatus described above. In particular, the crane control method may use a crane control apparatus as described above.
The present invention further comprises a crane control software, in particular a crane control software stored on a computer-readable storage medium, comprising code implementing a crane control apparatus or a crane control method as described above. Such a crane control software may, for example, be used to update an existing crane control apparatus.
Preferably, the crane control apparatus may use a computer which can run the crane control software of the present invention.
Further, the present invention comprises a crane having a crane control apparatus as described above. Further, the crane may be a crane as described above in conjunction with the control apparatus of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is now described by a way of embodiments and figures. Thereby, FIGS. 1 to 9 show:
FIG. 1 : An embodiment of a crane using a crane control apparatus of the present invention,
FIG. 2 : a simple crane model explaining the influence of different state definitions,
FIG. 3 : a diagram showing a pendulum model for a single pendulum observer,
FIG. 4 : an embodiment of a first sensor mounted on cable followers mounted on the cable of a crane,
FIG. 5 : a diagram showing the crane movement and the load swing during a luffing sequence, with a rope length of l=48 m,
FIG. 6 : a comparison between the load velocity estimate of the observer of the present invention and a GPS reference measurement,
FIG. 7 : an embodiment of a crane with a double pendulum load configuration,
FIG. 8 : a diagram showing a pendulum model for a double pendulum observer and
FIG. 9 : a comparison of a hook velocity estimate according to a observer of the present invention and a measured hook velocity by GPS for the double pendulum case, with a hook mass of m H =2.2 t, a load mass of m L =2.5 t, and cable lengths of L 1 =35 m and L 2 =5 m.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an embodiment of a crane according to the present invention, in particular of a harbour mobile crane as it is used for moving loads in a harbour. The crane may have a load capacity of up to 140 t and a cable or rope length of up to 80 m.
The embodiment of the crane of the present invention comprises a boom 1 , which can be luffed up and down around a horizontal luffing axis 2 , with which the boom is linked to a tower 3 . The tower 3 may be turned around a vertical slewing axis by which the boom 1 is slewed, as well. The tower 3 is further mounted on an undercarriage 6 , which is moveable by driving units 7 . For slewing the tower 3 , a slewing drive that is not shown in the figure is used. For luffing the boom 1 , the hydraulic cylinder 4 is used.
The cable or rope 20 to which the load 10 is attached is guided around a pulley arranged at the boom tip, the boom tip therefore forming the cable suspension point for purposes of the present invention. The length of the cable 20 might be controlled by a hoisting winch.
At the end of the cable 20 , load suspension means may be arranged, for example a manipulator or a spreader by which the load 10 might be suspended on the cable.
The crane of the present invention may comprise two cable strands that go from the boom tip to the load.
Further, FIG. 4 shows an embodiment of a first sensor that may be used for providing input values for the observer of the present invention. In particular, the first sensor 36 may be mounted on a cable follower 35 for measuring the cable angle and/or the cable velocity. In particular, the sensor 36 might be a gyroscope for measuring the cable velocity. The first sensor may measure the cable angle or cable velocity both in tangential and in radial directions of the crane, for example by using two gyroscopes arranged accordingly.
The cable follower shown in FIG. 4 may be attached to the boom tip 30 of the boom 1 by cardanic links 32 and 33 just under the main cable pulley 31 . The cable follower 35 comprises pulleys 36 , by which it is guided on the cable 20 , such that the cable follower 35 follows the movements of the cable 20 . The cardanic links 32 and 33 allow the cable follower to move freely around a horizontal and a vertical axis. However, turning movements of the cable follower are avoided.
The present invention now provides a crane control apparatus for controlling the position and/or velocity of the load suspended on the rope by using feedback control, where the position and/or the velocity of the load is determined based on measurements and used as feedback. The present invention now provides an observer design where an inertial coordinate system is used for modelling the load swing. This eliminates the need of measuring the boom tip acceleration and therefore improves the observer performance during acceleration phases.
The rest of the description is organised as follows:
In Section 2 the coordinate system is introduced. This choice is particularly important for crane observer design since it eliminates the need to measure the suspension point acceleration. The single-pendulum model and the observer are designed in Section 3. Afterwards, Section 4 deals with the double-pendulum model. The performance of both observers is validated using reference measurements.
2. CHOICE OF COORDINATE SYSTEM
Prior-art systems use the position of the load suspension point and its velocity as state variables, and also the so-called “rope angle” and its derivative. In FIG. 2 these quantities are called p A , {dot over (p)} A , φ and {dot over (φ)}. Assuming the model input u to be the acceleration of the suspension point, l being the rope length and g the gravitational acceleration, the linearized dynamic model will be:
p
¨
A
=
u
,
(
1
a
)
φ
¨
=
-
g
l
φ
-
1
l
u
.
(
1
b
)
Eqn. (1b) is a differential equation describing the load sway. It can be seen that the pendulum is excited by the acceleration u of the suspension point. In this invention a different choice of the state vector is used for crane modeling. Introducing the horizontal load position p L =p A +lφ and its derivative {dot over (p)} L ={dot over (p)} A +l{dot over (φ)} as states, the dynamic model (1) can be restated as:
p
¨
A
=
u
,
(
2
a
)
p
¨
L
=
-
g
l
(
p
L
-
p
A
)
.
(
2
b
)
The dynamics of (1) and (2) are identical. There is still an important difference when it comes to observer design between (1b) and (2b): Eqn. (2b) does not depend on the acceleration u but on the suspension point position p A .
In industrial implementations, the suspension point position p A is usually measurable with high accuracy. However, the suspension point acceleration u is not that easy to quantify. Differentiation methods get quite involved when it comes to differentiating twice. Actuator models which reconstruct the acceleration u from valve currents and friction models also carry large uncertainties. Being aware of this finding, the load position p L is used as a state variable in this invention.
3. SINGLE-PENDULUM OBSERVER
The goal of this section is to design a single-pendulum observer. Contrary to the preliminary examination in Section 2, the full nonlinear model of the main pendulum dynamics is presented in Subsection 3.1. After the measurement equation is determined (Subsection 3.2), an Extended Kalman Filter is composed (Subsection 3.3) and finally experimental results are shown (Subsection 3.4). For simplicity, all calculations are presented only for the planar (two-dimensional) case.
3.1 Pendulum Modeling
In crane control systems, it is generally assumed that the rope is massless and that the load can be modeled as a point mass. This leads to the “single-pendulum” model of a crane.
The position of the boom tip p L =(p L1 ,p L2 ) T and its time derivatives are assumed to be known. The same holds for the rope length l. With these inputs, the dynamics of the load position p L =(p L1 ,p L2 ) T can be set up using the Newton-Euler-method (see FIG. 3 ). As a generalized coordinate q the horizontal load position q=p L1 is used. The overall load position p can be expressed in terms of this generalized coordinate:
p
_
L
=
(
q
p
A
2
-
l
2
-
(
q
-
p
A
1
)
2
)
.
(
3
)
The load velocity {dot over ( p )} L can be written as:
p _ . L = ∂ p _ L ∂ q q . + ∂ p _ L ∂ t = J _ q + . v _ _ ( 4 )
with the abbreviations:
J
_
=
∂
p
_
L
∂
q
=
(
1
q
-
p
A
1
l
2
-
(
q
-
p
A
1
)
2
)
,
(
5
)
v
_
_
=
∂
p
_
L
∂
t
=
(
p
.
A
2
-
l
l
.
+
(
q
-
p
A
1
)
p
.
A
1
l
2
-
(
q
-
p
A
1
)
2
)
.
(
6
)
Similarly, the load acceleration can be expressed as:
p ¨ L = J _ q ¨ + ∂ J _ ∂ t q . + ∂ J _ ∂ q q . 2 + ∂ v _ _ ∂ t + ∂ v _ _ ∂ q q . , ( 7 )
where
∂ J ∂ t , ∂ J ∂ q , ∂ v _ _ ∂ t and ∂ v _ _ ∂ q
where can be calculated from Eqs. (5) and (6). Newton's second law for the load mass is:
m p _ ¨ L = ( 0 - m g ) + F _ R , ( 8 )
with the load mass m, the gravitational acceleration g and the rope force vector F R . With (7) plugged in and the rope force F R being eliminated using D'Alembert's principle, the pendulum dynamics are:
( J _ T J _ ) q ¨ = J _ T [ ( 0 - g ) - ∂ J _ ∂ t q . - ∂ J _ ∂ q q . 2 - ∂ v _ _ ∂ t - ∂ v _ _ ∂ q q . ] , ( 9 )
which can be considered as a differential equation:
{umlaut over (q)}=f q ( q,{dot over (q)}, u ). (10)
The model inputs u are the position, velocity, and acceleration of the boom tip as well as the rope length and its time derivatives. All these quantities are needed to evaluate J and {umlaut over (v)} and the derivatives of these terms in Eqn. (9) 2 : 2 The position and velocity of the boom tip can be measured using incremental encoders. Unfortunately those signals were too noisy for finding the accelerations {umlaut over (p)} A1 , {umlaut over (p)} A2 , and {umlaut over (l)}. However, experiments have shown that these accelerations do not influence the filtering results much. Since the analysis in Section 2 revealed that the linearized model does not depend on the accelerations at all, this observation is not unexpected. Therefore {umlaut over (p)} A1 ≈{umlaut over (p)} A2 ≈0 can be assumed.
u =( p A1 ,p A2 ,{dot over (p)} A1 ,{dot over (p)} A2 ,{umlaut over (p)} A1 ,{umlaut over (p)} A2 ,l,i,{umlaut over (l)} ). (11)
A reasonable initial condition for this model is to assume the load to be vertically below the boom tip, q(0)=p A1 , having no load swing, {dot over (q)}(0)={dot over (p)} A1 .
3.2 Expected Measurement Signal
The gyroscopes are attached to the rope near the tip of the boom (see FIG. 4 ). In general, gyroscopes measure the rotation rate of the device in its own body-fixed coordinate system. However, since only a planar problem setup is considered, the body-fixed rotation rate is the same as the inertial rotation rate. Therefore the rotation rate ω hope is simply the time-derivative of the rope angle φ (cf. FIG. 2 ). The rope angle can be expressed as:
φ
=
arcsin
(
q
-
p
A
1
l
)
.
(
12
)
Assuming changes in the rope length to be negligible, i≈0, the ideal measurement signal is therefore:
ω
rope
=
ⅆ
φ
ⅆ
t
=
q
.
-
p
.
A
1
l
2
-
(
q
-
p
A
1
)
2
.
(
13
)
Real gyroscope measurements include a number of disturbances. In this case the major gyroscope error is a simple (mainly temperature-dependent) signal offset. This offset is a common problem of MEMS sensors, but since changes in the sensor offset are much slower than the pendulum dynamics, they cause no problems. A simple offset disturbance model is:
{dot over (ω)} offset =0. (14)
An important measured disturbance are the higher-order string oscillations. Especially for long ropes and low load masses, crane ropes resonate just like guitar strings. These oscillations are also easily be dealt with. The first two harmonic frequencies of a vibrating string are
f 1 = 1 2 l F R μ and f 2 = 1 l F R μ , ( 15 )
where l is the rope length, F R the rope force and μ the mass per meter of the rope. Higher-order harmonic frequencies could be calculated in the same way, however, they are not yet dominant at the rope lengths under consideration. Since these string oscillations are quite sinusoidal, a simple disturbance model is:
{umlaut over (ω)} harmonic,1 =−2 πf 1 ω harmonic,1 , (16)
{umlaut over (ω)} harmonic,2 =−2 πf 2 ω harmonic,2 . (17)
Another well-known pendulum disturbance is wind. However, experience shows that even for large containers, wind forces are not challenging for crane control. Therefore this model provides no wind disturbance compensation even though the LHM cranes are equipped with wind sensors.
The presented crane model is observable as long as the frequencies of the different oscillators do not match. In case of the LHM cranes, the weight of the hook itself guarantees that the harmonic frequencies are considerably higher than the main pendulum oscillation frequency even for short rope lengths.
3.3 Observer Setup
An Extended Kalman Filter requires the observer problem to be stated in the form:
{circumflex over ( x )}( t k )= f ( {circumflex over ( x )} ( t k-1 ), u ( t k-1 )), {circumflex over ( x )} ( t 0 )= {circumflex over (x)} 0 , (18)
{circumflex over ( y )}( t k )= h ( {circumflex over ( x )} ( t k ), u ( t k )), (19)
where {circumflex over (x)} is the estimated state vector, u the model input and ŷ the expected measurement. Here, the state vector combines the pendulum dynamics (9) and the disturbance model dynamics (14), (16), and (17):
{circumflex over ( x )} =( q,{dot over (q)},ω offset ,ω harmonic,1 ,{dot over (ω)} harmonic,1 ,ω harmonic,2 ,{dot over (ω)} harmonic,2 ). (20)
Eq. (18) is in time-discrete form while (10), (14), (16), and (17) were given in continuous-time form. Therefore, they have to be discretized. The disturbance models (14), (16), and (17) are linear with time-invariant parameters 3 , and can therefore be discretized analytically. For discretizing the nonlinear pendulum dynamics (10) however, an integration scheme is needed. This integration scheme has to be stable when applied to undamped oscillators. A modified one-step Rosenbrock formula is found to comply with these requirements. It is implicit, therefore a series of Newton iterations can be used to calculate the solution. It turned out that a single Newton step is enough to generate a stable pendulum motion prediction even without observer feedback 4 . Therefore the pendulum state prediction {circumflex over (x)} 12 (t k ) can be found by solving the system of linear equations: 3 Changes in the harmonic frequencies f 1 and f 2 occur slowly and can therefore be neglected. 4 Another advantage of doing only a single Newton step is that the required Jacobian is also needed for the EKF covariance prediction. That means that the first Newton step can be done at almost no additional computational costs.
[ I - 0.5 h · ∂ f _ q ∂ x ^ _ 12 t k - 1 ] · [ x ^ _ 12 ( t k ) - x ^ _ 12 ( t k - 1 ) ] = h · f _ q | t k - 1 , ( 21 )
where h=t k −t k-1 is the discretization time, f q are the continuous-time pendulum dynamics, and {circumflex over (x)} 12 (t k )=[q(t k ),{dot over (q)}(t k )] denotes the first two elements of {circumflex over (x)} (t k ). The output equation (19) does not require discretization. It combines the ideal measurement signal (13) with the disturbance signal models (14), (16), and (17):
ŷ=h ( {circumflex over (x)} , u )=ω rope =ω offset =ω harmonic,1 +ω harmonic,2 . (22)
With the system model in the form (18), (19), the well-known EKF prediction-correction filtering method can be applied repeatedly. When the algorithm is called at time tk, the old state estimate {circumflex over (x)} (t k-1 ) is taken and its propagation over the discretization time h is simulated. At
the same time, the system matrix of the linearized model
A ( t k - 1 ) = ∂ f _ ∂ x ^ _ t k - 1
is used to predict the covariance of the state estimation. The predicted state and the associated covariance are called {circumflex over (x)} − (t k ) and P − (t k ):
{circumflex over (x)} − ( t k )= f ( {circumflex over ( x )} ( t k-1 ), u ( t k-1 )),
P − ( t k )= A ( t k-1 )· P ( t k-1 )· A ( t k-1 ) T +h/ 2( Q+A ( t k-1 )· Q·A ( t k-1 ) T ). (24)
The predicted estimation covariance P − (t k ) and the linearization of the output equation
H ( t k - 1 ) = ∂ h ∂ x ^ _ t k
are used to calculate the Kalman gain K(t k ):
K ( t k )·[ H ( t k )· P − ( t k )· H T ( t k )+ R]=P − ( t k )· H T ( t k ) (25)
Then the difference of the real measurement y to the predicted measurement ŷ at time t k is used to correct both the state and the covariance estimate:
{circumflex over ( x )} ( t k )= {circumflex over (x)} − ( t k )+ K ( t k )·( y ( t k )−{circumflex over ( y )}( t k )), (26)
P ( t k )= P − ( t k )− K ( t k )· H ( t k )· H ( t k )· P − ( t k ). (27)
The parameters used for this algorithm on the Liebherr LHM crane are given in Table 1. Please note that only the diagonal elements of the process noise matrix Q were set. Therefore, only those are given in Table 1.
TABLE 1 Parameters and Ranges Symbol Name Value l Rope length 5-120 m g Gravitational acceleration 9.81 m/s 2 PA1, PA2 Boom Workspace 10-48 m F R Rope force 9-1020 kN μ Rope weight 9 kg/m R Sensor noise 2 · 10 −5 rad 2 /s 2 Q q Process noise 0.2 m 3 /s 2 Q q 2 m 2 /s 4 Qω offset 2 · 10 −5 rad 2 /s 4 Qω harmonic 1 rad 2 /s 4 Qω harmonic 1 · 10 −4 rad 2 /s 4 h Discretization time 0.025 s
3.4 Results
FIG. 5 shows the position of the boom tip during a luffing sequence as well as the observed load position. It can be seen that the load is always accelerated towards the boom tip. For the same luffing sequence, FIG. 6 compares the load velocity estimation from the presented observer with GPS reference measurements. Those reference measurements were recorded with a Novatel RT-2 receiver with RealTime-Kinematic capabilities (RTK-GPS) 5,6 . It can be seen that the observed state estimation is in good accordance with the GPS reference measurements. 5 The antenna was placed on the load and therefore measured the horizontal load position pL 1 (and not the plotted velocity p′L 1 ). However, there was a systematic bias in the GPS position measurements compared to the observer. The reason for this offset was a small, unmodeled crane tower deflection which depends on the crane load. Therefore the GPS position measurements were differentiated and the resulting GPS load velocity was used as a reference for the observer's load velocity estimation. 6 It must be noted that the RTK-GPS system is adequate for experimental reference measurement only. In real crane applications the hook can easily be surrounded by containers or might be lowered into the ship's hull where the GPS antenna has no reception.
4. DOUBLE-PENDULUM OBSERVER
When handling general cargo, double-pendulum configurations as seen in FIG. 7 are common. In this section the crane model is therefore extended to a double-pendulum configuration.
4.1 Double-Pendulum Modelling
The modeling of the double-pendulum is essentially analogous to Section 3.1. The length of the rope between boom tip and hook is l 1 and the rope length between hook and load is l 2 . Unlike l 1 , the distance between the hook and the load cannot change. Therefore l 2 is considered constant. As shown in FIG. 8 , the hook and load are modelled as point masses with the positions p H =(p H1 ,p H2 ) T and p L =(p L1 ,p L2 ) T . In order to shorten the calculations, both positions can be written in a single vector:
p =( p H1 ,p H2 ,p L1 ,p L2 ) T . (28)
Using the horizontal coordinates of the hook and of the load as generalized coordinates, q 1 =p H1 and q 2 =p L1 , the position vector can be expressed as follows (see FIG. 8 ):
p _ = ( q 1 p A 2 - s 1 q 2 p A 2 - s 1 - s 2 ) , ( 29 )
where s 1 and s 2 are:
s 1 =√{square root over ( l 1 2 −( q 1 −p A1 ) 2 )}, s 2 =√{square root over ( l 2 2 −( q 2 −q 1 ) 2 )}. (30)
Even though the dimension of the problem has changed, the expressions for the velocity and acceleration are nearly the same as for the single-pendulum in (4) and (7):
p
.
_
=
∂
p
_
∂
q
_
q
.
_
+
∂
p
_
∂
t
=
J
q
.
_
+
v
_
_
,
(
31
)
p
_
¨
=
J
q
_
¨
+
(
∂
J
∂
t
+
∂
J
∂
q
1
q
.
1
+
∂
J
∂
q
2
q
.
2
)
q
.
_
+
∂
v
_
_
∂
t
+
∂
v
_
_
∂
q
_
q
.
_
.
(
32
)
Applying Newton's second law to the point masses gives:
M p _ ¨ = ( 0 - m H g 0 - m L g ) + ( F _ R 1 - F _ R 2 F _ R 2 ) , ( 33 )
where F R1 and F R2 are the rope force vectors and M is the mass matrix: M=diag(M H , M H , M L , M L ′. With (32) plugged into (33) and D'Alembert's principle being applied, the following double-pendulum dynamics can be obtained:
(
J
T
MJ
)
q
_
¨
=
J
T
M
[
(
0
-
g
0
-
g
)
-
(
∂
J
∂
t
+
∂
J
∂
q
1
q
.
1
+
∂
J
∂
q
2
q
.
2
)
q
_
.
-
∂
v
_
_
∂
t
-
∂
v
_
_
∂
q
q
_
.
]
.
(
34
)
The structure of the differential equation {umlaut over (q)} =f q ( q , {dot over (q)} , u ) as well as the inputs u have not changed compared to the single-pendulum case. Also, the measurement equation has not changed compared to (13), except for the variable names:
ω
rope
=
q
.
1
-
p
.
A
1
l
1
2
-
(
q
1
-
p
A
1
)
2
.
(
35
)
Therefore the Extended Kalman Filter is implemented in the same way as in the single-pendulum case.
It has to be noted that it is possible to lose observability if one of the natural harmonic oscillation frequencies (15) matches the second eigenfrequency of the double pendulum. In case of the LHM cranes, this can only happen at long rope lengths (l 1 >80 m) and light loads (m 2 <2000 kg). An additional sensor system in the hook could be used to distinguish between harmonic oscillations and double-pendulum dynamics.
4.2 Results
To validate the results of the double-pendulum observer, an RTK-GPS system was installed on the crane; the antenna was put on the hook. FIG. 9 shows both the observed load velocity and the velocity measured via GPS. Until about 380 s in the measurement, both eigenfrequencies of the double-pendulum can be seen. Afterwards the primary oscillation is attenuated by the crane operator, leaving only the second eigenmode oscillating. It can be seen that the observed load velocity matches the reference measurement very well.
5. CONCLUSION
A load position observer was presented for both a single-pendulum and a double-pendulum crane configuration. The observers are implemented as Extended Kalman Filters. The required input signals are the boom tip position which can be measured using incremental encoders and the angular rope velocity, measured by gyroscopes. Natural harmonic oscillations of a crane rope as well as a gyroscope sensor offset were taken into account. The presented observers were tested on Liebherr Harbour Mobile cranes. In an experimental setup, an RTK-GPS system was used to measure the hook position for reference. The RTK-GPS measurements have shown that the observer works as expected both in the single pendulum and in the double pendulum case.
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The present invention relates to a crane control apparatus for a crane where a load is suspended on a crane cable from a cable suspension point of the crane, comprising an observer for estimating at least the position and/or velocity of the load from at least one sensor input of a first sensor by using a physical model of the load suspended on the crane cable, whereby the physical model of the observer uses the load position and/or the load velocity as a state variable.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the field of vehicles and, more particularly, to vehicle air conditioning systems and related methods.
[0003] 2. Related Art
[0004] Seals used in sealing fluid circulation connections in vehicle air conditioning systems typically can be purchased only as an individual seal or as an assortment of similar seals in a container. The purchase of individual seals can be time consuming and expensive when a plurality of different seals used in making fluid circulation connections in a vehicle air conditioning system needs to be replaced. Also, trying to make sure that one of the seals purchased will actually retrofit or work for replacing an existing damaged seal, for example, can be difficult as well. Additionally, when a seal assortment is sold as a package, however, these assortments conventionally do not cover a plurality of different seals of a vehicle air conditioning system needed to replace the existing plurality of different seals in fluid circulation connections in the vehicle air conditioning system. It also can be difficult to determine which seals in an assortment package match or correspond to which types of vehicle air conditioning systems.
[0005] For example, in retail automotive part stores, such as AutoZone or Pep Boys, when an individual such as a vehicle owner attempts to purchase an o-ring seal used for sealing a fluid circulation connection of a vehicle air conditioning system such as a seal for connecting a hose or fluid line to a drier, a condenser, an evaporator, a compressor, an expansion valve, or an accumulator, the store personnel often will not know what the individual needs. As a result, the vehicle owner may attempt to bring the o-ring seal that needs replacing with them to the retail store. The store personnel then try to match the particular o-ring seal with one of numerous seals in a box kit full of different sizes of o-ring seals. This process often can take 20 minutes or longer and may not ensure that the vehicle owner leaves with the correct seal or any replacement o-ring seal at all.
[0006] Situations with vehicle dealer service or parts centers often are not much better. For example, if a vehicle owner goes to a dealer for an o-ring seal for an air conditioning system of a particular vehicle, the dealer personnel often attempt to look up the air conditioning system in some type of computer or microfiche system having numerous other parts and systems stored therein. This memory look up or retrieval process also often can be time consuming. Sometimes this process results in the identification of the original equipment manufacturer's part number for the seal and other times these seals are sold only with the component device part for the air conditioning system, e.g., drier, condenser, evaporator, compressor, expansion valve, or accumulator, associated with the air conditioning system. Then, it must be determined whether the individual o-ring seal is in stock, has to be ordered, or is even available from the dealer. Additionally, personnel of non-dealer affiliated installation garages likewise often have to go to retail automotive part stores or vehicle dealer or also themselves look through box kits full of different sizes of o-ring seals in hope of finding a desired replacement seal. This problem is then compounded or made significantly worse when trying to replace a plurality of different seals associated with the air conditioning system.
[0007] As a result, the process for replacing one or more seals in a vehicle air conditioning system clearly can be difficult, time consuming, frustrating, and expensive for both the vehicle owner and the retail automotive part store, vehicle dealer, vehicle part installation garage, and others involved in the seal replacement process.
SUMMARY OF THE INVENTION
[0008] In view of the foregoing, embodiments of the present invention advantageously provides a seal kit for a vehicle air conditioning system and associated methods that significantly reduce the time and expense associated with servicing or replacing seals, and particularly a plurality of seals, in a vehicle air conditioning system. Embodiments of the present invention also advantageously provides a seal kit for a vehicle air conditioning system and methods of forming and using a seal kit that has enough seals to retrofit, cover, or replace a plurality of air condition system connection seals of one of a plurality of preselected vehicle air conditioning systems. Embodiments of the present invention additionally advantageously provides a seal kit for a vehicle air conditioning system and methods of doing business with such seal kits that significantly reduces the inventory and shelf or floor space needed by distributors of seals for vehicle air conditioning systems. Embodiments of the present invention still also advantageously provides a seal kit for a vehicle air conditioning system that significantly reduces the time needed for distributors, such as retail automotive part stores, vehicle dealers, and vehicle part installation garages, and users of such seals, such as vehicle owners or users, personnel at vehicle dealer service centers, and personnel at vehicle part installation garages, to match seals needed for a vehicle air conditioning system, such as an air conditioning system, of a particular year, make, model, and/or engine type of a vehicle. Embodiments of the present inventions further provide a seal kit and related methods that provide all of the seals needed to make all or substantially all of a vehicle air conditioning system fluid connections when mounted in a vehicle
[0009] More particularly, according to an embodiment of the present invention, a seal kit is provided which includes a container and a set of a plurality of retrofit seals positioned in the container and adapted to retrofit a set of a plurality of existing seals of any one preselected group of different vehicle air conditioning systems corresponding to a preselected group of different vehicles. Each vehicle air conditioning system of the preselected group of different vehicle air conditioning systems has the set of the plurality of existing seals defined by a plurality of existing seals used in making a plurality of air conditioning system fluid connections in one of the preselected group of different vehicles. The set of the plurality of retrofit seals has a total number of seals less than the entire set of a total combined number of seals needed to retrofit all sets of the plurality of existing seals needed to make all of the plurality of air conditioning system fluid connections in all of the preselected group of air conditioning systems.
[0010] According to another embodiment of the present invention, a seal kit is provided to retrofit a set of a plurality of existing seals of any one of a preselected group of different vehicle air conditioning systems corresponding to a preselected group of different vehicles. The seal kit includes a container and a set of a plurality of seals positioned in the container and adapted to retrofit all of a set of a plurality of existing seals of any one preselected group of different vehicle air conditioning systems corresponding to a preselected group of different vehicles. Each of the preselected groups of different vehicle air conditioning systems has a plurality of existing seals defined by a plurality of existing seals used in making a plurality of vehicle air conditioning system fluid connections in one of the preselected group of different vehicles. The seal kit can also include an indicator associated with the container to indicate the group of different vehicles to which the entire set of a plurality of seals operatively retrofits.
[0011] The present invention further provides an embodiment of a seal kit which includes a container and a plurality of subsets of a plurality of retrofit seals associated with the container to retrofit a plurality of existing seals of at least two different vehicle air conditioning systems. Each of the plurality of subsets of the plurality of retrofit seals is enough of a plurality of seals to completely retrofit a preselected group of seals used in making system fluid connections in at least one of the at least two different air conditioning systems. Also, each of the plurality of subsets can have at least one seal in common with at least one other of the plurality of subsets of the plurality of seals. The seal kit can also include an indicator associated with the container to indicate at least two different air conditioning systems to which the plurality of subsets operatively retrofit. By overlapping the seals within the individual sets or subsets, the total number of seals needed to be packaged and stored is greatly reduced. This can significantly reduce the costs involved in producing seals, reduce the inventory needed as well as shelf space or floor space, and enhance value to users by ensuring that a complete or substantially complete set of seals for making system fluid connections in a selected vehicle air conditioning system is provided.
[0012] An embodiment of the present invention also provides a method of forming a seal kit. A method of forming a seal kit includes providing a container and positioning a plurality of subsets of a plurality of seals for at least two different vehicle air conditioning systems within the container so that a combined total number of the plurality of seals of all of the plurality of subsets defines a set of a plurality of seals. Each of the plurality of subsets of the plurality of seals preferably is enough of a plurality of seals to completely retrofit all of the system fluid circulation connections of at least one of the at least two different vehicle air conditioning systems. Each of the plurality of subsets has at least one seal in common with at least one other of the plurality of subsets of the plurality of seals. The method can also include indicating at least two different air conditioning systems to which the plurality of subsets operatively retrofit.
[0013] Another method of forming a seal kit according to an embodiment of the present invention includes determining a first set of a plurality of seals needed to make system fluid connections in an air conditioning system of a first vehicle, determining a second set of a plurality of seals needed to make system fluid connections in an air conditioning system of a second vehicle, and determining a third set of a plurality seals needed to retrofit a set of the plurality of seals needed to make system fluid connections of only one of the air conditioning systems of the first and second vehicles. The total number of seals in the third set of the plurality of seals preferably is less than the total combined number of seals needed to retrofit all of the plurality of seals of both the air conditioning systems of the first and second vehicles. Also in the method, the total number of seals in the third set can be greater than a set of the plurality of seals of only one of the air conditioning systems of the first and second vehicles. The method also includes positioning the determined third set of the plurality of seals into a container. The method also can include associating an indicator, e.g., by use of a database, a look-up table, connected to the container, or positioned in the container, with the container to indicate the first and second vehicles to which the set of a plurality of seals operatively retrofits. The indicator preferably includes at least the make and model of each of the first and second vehicles.
[0014] An embodiment of the present invention additionally provides a method of using a seal kit. The method of using a seal kit includes opening a container having a set of a plurality retrofit seals positioned therein and needed to retrofit a set of a plurality of existing seals needed to make system fluid connections in only one vehicle air conditioning system of a plurality of vehicle air conditioning systems of a plurality of vehicles. The total number of seals in the set of the plurality of retrofit seals is less than the total combined number of seals needed to retrofit all of the existing seals needed to make system fluid connections in all of the plurality of vehicle air conditioning systems of the plurality of vehicles and greater than a set of the plurality of retrofit seals of only one of the air conditioning systems of the plurality of vehicles. The combination of the container and the set of the plurality of seals contained therein define a seal kit. The method also includes replacing at least one of the plurality of seals of the only one air conditioning system of the plurality of air conditioning systems of the plurality of vehicles with at least one corresponding seal from the seal kit.
[0015] An embodiment of the present invention further provides a method of doing business. The method of doing business includes providing a container having a set of a plurality seals needed to retrofit a set of a plurality of seals of only one air conditioning system of a plurality of air conditioning systems of a plurality of vehicles. A total number of seals in the set of the plurality of seals preferably is less than the total combined number of seals needed to retrofit a set of the plurality of seals of the air conditioning systems of the plurality of vehicles and greater than a set of the plurality of seals of only one of the air conditioning systems of the plurality of vehicles. The combination of the container and the set of the plurality of seals contained therein define a seal kit.
[0016] Another method of doing business also is provided which includes distributing a seal kit having at least one replacement seal contained therein as one of a plurality of seals. The seal kit indicates at least a plurality of makes and models, e.g., and can also include engine type, of a plurality of vehicles and has a set of the seals of a vehicle air conditioning system of any one of the plurality of vehicles contained therein to thereby reduce the time needed to select the at least one replacement seal for an air conditioning system of a particular make and model of a vehicle. The method can also include the seal kit having a container containing a set of a plurality seals needed to retrofit a set of a plurality of seals of only one air conditioning system of a plurality of air conditioning systems of the plurality of vehicles. A total number of seals in the set of the plurality of seals preferably is less than the total combined number of seals needed to retrofit a set of the plurality of seals of the vehicle air conditioning systems of the plurality of vehicles and greater than a set of the plurality of seals of only one of the vehicle air conditioning systems of the plurality of vehicles.
[0017] A method of doing business according to yet another embodiment of the present invention includes providing a seal kit having at least one of a set of a plurality of seals in the seal kit needed to make system fluid connections in a vehicle air conditioning system. The seal kit also is associated with an indication of at least one of a plurality of vehicles having the vehicle air conditioning system associated therewith to thereby reduce the amount of time needed to select the at least one replacement seal for the vehicle air conditioning system of a particular vehicle.
[0018] Accordingly, embodiments of the present invention advantageously provides a seal kit for a vehicle air conditioning system that has a complete set of seals for a range of vehicles, e.g., year, make, model, and engine type. The seal kit, for example, can advantageously have more seals than are needed for any one vehicle within the range of vehicles, but always has a compete set for any one vehicle within the range of vehicles. Notably, the seal kits are not used for separate individual vehicles and thereby save inventory and manufacturing costs by combining a plurality of vehicles in one seal kit and yet advantageously assuring that a set of the seals for each of the vehicles are included within the seal kit. Each seal kit, for example, can have at least one extra seal not needed in the vehicle air conditioning system of a vehicle in which one or more seals are to be replaced. If all seals in making system fluid connections in the vehicle air conditioning system have been replaced, then the at least one extra seal, for example, would be for another vehicle within the range or group of vehicles indicated in some manner as being associated with the seal kit.
[0019] Embodiments of a seal kit, according to the present invention, simplifies and shortens the selling cycle by condensing multiple similar vehicles' seal requirements into kits allowing the ready identification of system seals by year, make, model, and when applicable, engine type. The condensing of individual components or seals into kits also allows reduction of inventory. The identification by year, make, model, and engine type speeds the selling process by quickly identifying the necessary kit and allowing one kit to be sold instead of multiple components or seals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Some of the features, objects, and advantages of embodiments of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
[0021] [0021]FIG. 1 is an environmental view of an air conditioning system of a vehicle having a plurality of seals associated with vehicle air conditioning system fluid circulation connections as defined by an embodiment of the present invention;
[0022] [0022]FIG. 2 is an exploded perspective view of a seal kit to make system fluid circulation connections of a vehicle air conditioning system illustrating a plurality of different seals positioned in a container and being retrofit into vehicle air conditioning system fluid circulation connections for a vehicle air conditioning system according to an embodiment of the present invention;
[0023] [0023]FIG. 3 is an environmental view of a seal kit to make system fluid circulation connections associated with a vehicle air conditioning system being formed according to an embodiment of the present invention and a system to research seals needed in forming or to identify a seal kit for making substantially all of the system fluid circulation connections associated with a plurality of different vehicle air conditioning systems of a plurality of different vehicles of an embodiment of the present invention;
[0024] [0024]FIG. 4 is a perspective view of a seal kit to make vehicle air conditioning system fluid circulation connections associated with a vehicle air conditioning system having an indicator associated therewith to indicate year, make, model, and/or engine type of a vehicle according to an embodiment of the present invention;
[0025] [0025]FIG. 5 is a perspective view of a seal kit to make fluid circulation connections associated with a vehicle air conditioning system having no indicator on a container thereof which indicates make, model, and/or engine type of a vehicle according to another embodiment of the present invention;
[0026] [0026]FIG. 6 is a front plan view of a user interface of a computer having software stored thereon of a system for indicating a seal kit to make system fluid circulation connections associated with a plurality of different vehicle air conditioning systems of a plurality of different vehicles according to an embodiment of the present invention;
[0027] [0027]FIG. 7 is a front plan view of a seal kit to make system fluid circulation connections in a vehicle air conditioning system illustrating the overlapping of seals within the container for first, second, and third vehicles according to an embodiment of the present invention;
[0028] [0028]FIG. 8 is a perspective view of seal locations for a plurality of system fluid circulation connections associated with a vehicle air conditioning system according to an embodiment of the present invention;
[0029] [0029]FIG. 9A is a front plan view of a seal kit to make system fluid circulation connections in a vehicle air conditioning system illustrating a set of a plurality of different seals of an air conditioning system of a first vehicle being removed therefrom and having additional seals remaining in a container of the seal kit according to an embodiment of the present invention;
[0030] [0030]FIG. 9B is a front plan view of a seal kit to make system fluid circulation connections in a vehicle air conditioning system of FIG. 9A illustrating a set of a plurality of different seals of a vehicle air conditioning system of a second vehicle being removed therefrom and having additional seals remaining in the container of the seal kit according to an embodiment of the present invention;
[0031] [0031]FIG. 9C is a front plan view of the seal kit to make system fluid circulation connections for a vehicle air conditioning system of FIGS. 9A and 9B illustrating a set of a plurality of different seals of a vehicle air conditioning system of a third vehicle being removed therefrom and having additional seals remaining in the container of the seal kit according to an embodiment of the present invention;
[0032] [0032]FIG. 10 is a table illustrating part numbers of a plurality of seal kits to make system fluid circulation connections for a vehicle air conditioning system and each seal kit having a corresponding plurality of makes and models of a plurality of vehicles according to an embodiment of the present invention; and
[0033] [0033]FIG. 11 is a flow chart of a method of forming one or more seal kits to make system fluid circulation system connections for a vehicle air conditioning system according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0034] The present invention now will be described more fully hereinafter with reference to the accompanying drawings in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not 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 invention to those skilled in the art. Like numbers refer to like elements throughout, and prime or double prime notation, if used, indicates like elements in alternative embodiments.
[0035] [0035]FIGS. 1-10 illustrate embodiments of a seal kit 15 for a vehicle air conditioning system 50 according to the present invention. The seal kit 15 advantageously includes a container 16 , e.g., preferably a single container such as a plastic bag as illustrated, a box, a sack, or other types of containers as understood by those skilled in the art, and a set (indicated by the combined numbers elements 20 , 30 , 40 ), of a plurality of retrofit seals 21 , 31 , 41 , e.g., having different types, shapes, and sizes, positioned in the container 16 and adapted to retrofit a set of a plurality of existing seals of any one preselected group of different vehicle air conditioning systems 50 , 50 , 50 corresponding to a preselected group of different vehicles (see FIGS. 1, 7, 8 , 9 A- 9 C, and 10 ). Each vehicle air conditioning system of the preselected group of different vehicle air conditioning systems has the set of the plurality of existing seals defined by a plurality of existing seals used in making or needed to make a plurality of vehicle air conditioning system fluid circulation connections, and preferably all of the system fluid circulation connections, in one of the preselected group of different vehicles. The set of seals are preferably all of the seals necessary to seal system fluid circulation connections of a vehicle air conditioning system such as those connections at the dryer 53 , 53 ′, 53 ″, condenser 52 , 52 ′, 52 ″, evaporator 54 , 54 ′, 54 ″, compressor 51 , 51 ′, 51 ″, accumulator 55 , expansion valve where used, and hose fittings 58 (see FIGS. 8-9C). These connections, for example, preferably do not include internal seals or integral seals such as valve cores, switch seals, shaft seals, compressor internal seals, compressor manifold internal seals (when the manifold is layered), orifice tube seals, accumulator internal seals, control valve seals, service cap seals, or sight glass gaskets. The set of retrofit seals, for example, are preferably and advantageously those seals needed by a mechanic to repair or retrofit the system fluid circulation connections of the vehicle air conditioning system as these are the types of seals commonly replaced. Although, in this embodiment, the description is related to system fluid circulation connections, it will be understood by those skilled in the art that the invention can include those seals needed to repair an individual component within the vehicle air conditioning system as well. Nevertheless, although not necessarily preferred, the inclusion of one or more seals needed to repair an individual component within the air conditioning system in the set of seals can form part of the invention as well as understood by those skilled in the art. In the embodiments illustrated and described herein, and by way of example, each of the individual subsets 20 , 30 , 40 of retrofit seals in combination form the entire set (referenced by numbers herein as the series of 20 , 30 , 40 together also) of the plurality of retrofit seals 21 , 31 , 41 (see FIGS. 7, 8, 9 A, 9 B, and 9 C). The vehicle air conditioning systems 50 , 50 ′, 50 ″ are described and illustrated herein primarily in terms of an air conditioning system which often has several different types and sizes of seals and in which a leakage in refrigerant or coolant fluid can often be critical. Nevertheless, as understood by those skilled in the art, other types of air conditioning systems can be used as well according to the present invention.
[0036] Each of the preselected groups of different vehicle air conditioning systems 50 , 50 ′, 50 ″ has a predetermined set 20 , 30 , 40 of seals 21 , 31 , 41 which can be defined by at least one manufacturer of each of the preselected group of different air conditioning systems 50 , 50 ′, 50 ″ components of an air conditioning system, by a vehicle manufacturer, or by an air conditioning system of component supplier, as being a set of the seals 21 , 31 , 41 of each of the preselected group of air conditioning systems 50 , 50 ′, 50 ″ and corresponding to one of a preselected group of different vehicles (see FIGS. 5 and 9A- 9 C). The entire set 20 , 30 , 40 of a plurality of seals 21 , 31 , 41 also can include at least one more seal than needed to retrofit a set of the seals 21 , 31 , 41 of any one of the preselected group of the plurality of vehicle air conditioning systems 50 . In other words, in the example as described and illustrated, when one of the subsets 20 is used to make a plurality of or all of the system fluid circulation connections within an air conditioning system 50 , then other portions of other subsets still remain 30 , 40 . These other portions, however, preferably are not complete sets as some of the seals in one of the subsets (such as the subset 20 , but also the other subsets 30 , 40 as well) overlap with seals in the other subsets (such as the subsets 30 , 40 , but also the other subset 20 as well if one of the subsets 30 , 40 are used). A total number of seals in the set of the plurality of seals 21 , 31 , 41 preferably is less than the total combined number of seals needed to retrofit all sets of the plurality of existing seals needed to make all of the plurality of air conditioning system fluid connections of all of the preselected group of air conditioning systems. By overlapping the seals 21 , 31 , 41 within the individual sets or subsets 20 , 30 , 40 , the total number of seals needed to be packaged and stored is greatly reduced. This can significantly reduce the costs involved in producing seals, reduce the inventory needed as well as shelf space or floor space, and enhance value to users by ensuring that a complete or substantially complete set of seals for a selected air conditioning system is provided. The recognition that and provision of such an overlapping combination forms part of the present invention as well.
[0037] As illustrated, an embodiment of a seal kit 15 of the present invention includes a container 16 and a plurality of subsets 20 , 30 , 40 of a plurality of seals 21 , 31 , 41 for at least two different air conditioning systems 50 , 50 ′, 50 ″ positioned in the container 16 . Each of the plurality of subsets 20 , 30 , 40 of the plurality of retrofit seals 21 , 31 , 41 is enough of a plurality of seals to retrofit substantially all or all of the system fluid circulation connections, e.g., see FIG. 8, at least one of the at least two different air conditioning systems 50 , 50 ′, 50 ″ and having at least one seal in common with at least one other of the plurality of subsets of the plurality of seals. The seal kit can 15 also include an indicator 17 associated with the container 16 to indicate at least two different air conditioning systems 50 to which the plurality of subsets operatively can be serviced, converted, replaced, or retrofitted (see FIGS. 4, 6, and 10 ). As shown in FIGS. 5-6, for example, an indicator can be stored in and displayed on a computer or microfiche user interface to provide a part number indication 18 , 18 ′ to a user. In other words, no indicator ( 17 ′ or 18 ′) may be on the container itself, but instead may be a look-up table or interface on a computer, book, database, or other data library as understood by those skilled in the art.
[0038] For example, according to an embodiment of the present invention, a seal kit 15 , 15 ′ is provided to retrofit a set 20 , 30 , 40 of a plurality of seals 21 , 21 ′, 31 , 31 ′, 41 , 41 ′ of any one of a preselected group of different vehicle air conditioning systems corresponding to a preselected group of different vehicles. The seal kit 15 includes a container 16 and a set 20 , 30 , 40 of a plurality of retrofit seals 21 , 31 , 41 positioned in the container 16 and adapted to retrofit a set of a plurality of existing seals of any one preselected group of different vehicle air conditioning systems corresponding to a preselected group of different vehicles. Each of the preselected groups of different vehicle air conditioning systems can have a predetermined set of existing seals defined by being a set of the existing seals of each of the preselected group of air conditioning systems and corresponding to one of a preselected group of different vehicles to make system fluid circulation connections therefore as understood by those skilled in the art. The total number of retrofit seals in the set of the plurality of seals 20 , 30 , 40 preferably is less than the total combined number of seals needed to retrofit all sets of the plurality of the existing seals needed or used to make all of the plurality of air conditioning system connections of all of the preselected group of vehicle air conditioning systems. The set of a plurality of seals 20 , 30 , 40 preferably includes at least one more seal than needed to entirely retrofit a set of the seals of any one of the preselected group of the plurality of vehicle air conditioning systems 50 , 50 ′, 50 ″. The at least one more seal can be a seal adapted to retrofit a seal in another one of the plurality of vehicle air conditioning systems in the preselected group. A smaller set or subset of the seals of each of the plurality of vehicle air conditioning systems 50 , 50 ′, 50 ″ is included within the set of a plurality of seals 20 , 30 , 40 , and the set only has enough seals to retrofit only one of any one of the plurality of vehicle air conditioning systems 50 , 50 ′, 50 ″. Also, at least two of the plurality of seals 20 , 30 , 40 of the set preferably have different shaped outer perimeters. In other words, the plurality of seals 20 , 30 , 40 with the entire set can advantageously have different shapes and sizes as illustrated.
[0039] As perhaps best shown in FIG. 4, the seal kit 15 can also include an indicator 17 associated with the container 16 to indicate the group of different vehicles to which the entire set 20 , 30 , 40 of a plurality of seals operatively retrofits. The preselected group of vehicles indicated by the indicator 17 associated with the container 16 includes at least the make and model, and also preferably engine type, of each of the vehicles in the preselected group of vehicles. The indicator 17 is positioned in at least one of the following locations: on an indicator portion attached to the container 16 , on an outer surface of the container 16 , within the container 16 , on at least one of the plurality of seals 20 , 30 , 40 within the container 16 , adjacent the container 16 such as on a separate sheet, document, label, shelf, or other region adjacent the container 16 , or associated with the container 16 such as in separate reference material, a printed table, a handbook, a catalog, electronic data, an electronic data file, or an electronic user interface (see FIG. 6). For example, as shown in FIG. 4, the indicator 17 can be provided by a label having indicia thereon associated with the indicator portion attached to an end portion of the container 16 , but various other positions of the indicator can be provided as well as understood by those skilled in the art.
[0040] As shown in FIGS. 1-11 and as described above, the present invention also provides methods of forming a seal kit, methods of using a seal kit, and methods of doing business. An embodiment of a method of forming a seal kit 15 includes providing a container 16 and positioning a plurality of subsets 20 , 30 , 40 of a plurality of seals 21 , 31 , 41 for at least two different air conditioning systems 50 within the container 16 so that a combined total number of the plurality of seals of all of the subsets 20 , 30 , 40 defines a set of a plurality of seals. Each of the plurality of subsets 20 , 30 , 40 of the plurality of seals 21 , 31 , 41 preferably is enough of a plurality of seals to completely retrofit at least one of the at least two different air conditioning systems 50 and having at least one seal in common with at least one other of the plurality of subsets of the plurality of seals. The method also can include indicating at least two different air conditioning systems 50 to which the plurality of subsets 20 , 30 , 40 operatively retrofit (see, e.g., FIGS. 4 and 7).
[0041] Another embodiment of the present invention, for example, provides a method of forming a seal kit 15 which includes determining a set of a plurality of seals of an air conditioning system 50 of a first vehicle 20 , determining a set of a plurality of seals 20 , 30 , 40 of an air conditioning system 50 of a second vehicle 30 , and determining a set of a plurality seals needed to retrofit a set of the plurality of seals 20 , 30 , 40 of only one of the air conditioning systems 50 of the first and second vehicles. The set of the plurality of seals 20 , 30 , 40 preferably is less than the total combined number of seals needed to retrofit a set of the plurality of seals 20 , 30 , 40 of both the air conditioning systems 50 of the first and second vehicles and greater than a set of the plurality of seals 20 , 30 , 40 of only one of the air conditioning systems of the first and second vehicles. The method also includes positioning the determined set of the plurality of seals into a container 16 . The method also can include associating an indicator with the container 16 to indicate the first and second vehicles to which the set of a plurality of seals 20 , 30 , 40 operatively retrofits. The indicator 17 preferably includes at least the make and model of each of the first and second vehicles.
[0042] As shown in FIGS. 3 and 8, for example, in forming 60 the seal kit 15 , for example, research is conducted on what seals are needed for each make and model of vehicle for an air conditioning system, e.g., air conditioner, associated with that make and model of vehicle (block 61 ). For example, such as shown in FIG. 3, the research can be conducted on a computer having access to a global communication network such as the world wide web through the Internet having access to one or more databases or through separate stand-alone or intranet type databases as well as understood by those skilled in the art. Alternatively, each of the manufacturers or suppliers of air conditioning systems can be researched and the associated seals with each air conditioning system of the manufacturers or suppliers researched as well. Then, vehicles can be researched which have a particular type of air conditioning system. After using either research technique, a set of the seals are then acquired from a supplier, a manufacturer, a distributor, or otherwise manufactured directly and sorted and grouped into a seal kit 15 , 15 ′ (see FIGS. 3-6) covering at least two vehicles (block 62 ). A determination can be made from the database as to which vehicles use similar sets of seals (block 63 ). Vehicles that can be serviced by one package or container of seals with the least amount of seals remaining can be grouped together (block 64 ). Enough seals for making all or substantially all of the fluid connections for system each of the at least two vehicles, and extra seals not used for one of the at least two vehicles due to the overlap of types of seals between the vehicles. All seals that need to be packaged together to cover servicing of any vehicle in that group can be determined (block 65 ) and a database of seal kits and which vehicles each kit will service can be compiled (block 66 ). The container 16 , by a label, some type of code, or other indicator 17 , can identify or indicate which group of vehicles for which the seal kit 15 can be used for air conditioning systems 50 for those vehicles (block 67 ) such as the air conditioning system of those vehicles. This can be done numerous ways as understood by those skilled in the art such as by assigning a part number to each package or container of seals that will service any of a preselected or predetermined group of vehicles (block 67 ).
[0043] The method of forming can also include determining at least one seal of a first set of the plurality of seals 21 , 31 , 41 of the air conditioning system of the first vehicle that is the same seal as at least one of a second set of the plurality of seals 21 , 31 , 41 of the air conditioning system 50 of the second vehicle so that the at least one seal defines at least one common seal (block 62 ). The step of determining the set of plurality of seals 21 , 31 , 41 needed to retrofit a set of the seals of only of the air conditioning systems 50 can include determining that only one of the at least one common seal is within the set 20 , 30 , 40 of the plurality of seals 21 , 31 , 41 to thereby reduce the number of seals needed. The method can also include determining a third set of a plurality of seals 41 of an air conditioning system 50 of a third vehicle, e.g., at least one other vehicles or multiple other vehicles, and determining that none of the seals of at least one of a set of the plurality seals 21 of the air conditioning system 50 of the first vehicle and a set of the plurality of seals 31 of the air conditioning system of the second vehicle are the same so that no seals are found to be in common. Alternatively, for example, the method can include determining a set of a plurality of seals 41 of an air conditioning system 50 of a third vehicle, determining at least one seal of a set of the plurality of seals 41 of the air conditioning system 50 of the third vehicle that is the same seal as at least one of a set of the plurality of seals 21 of the air conditioning system 50 of the first vehicle so that the at least one seal defines at least one common seal, and determining a plurality of seals 21 of a set of the plurality of seals of the air conditioning system 50 of the first vehicle that are the same plurality of seals of a set of the seals of the plurality of seals 31 of the air conditioning system 50 of the second vehicle so that the plurality of seals defines a plurality of common seals. The plurality of common seals preferably are greater than the at least one common seal so that the number of common seals between the air conditioning systems of the first and second vehicles is greater than the number of common seals between the air conditioning systems of the first and third vehicles.
[0044] The method still also can include the steps of determining a first set 20 of the plurality of seals 21 of the vehicle air conditioning system 50 of the first vehicle and determining a second set 30 of the plurality of seals 31 of the vehicle air conditioning system 50 of the second vehicle each includes conducting research into a manufacturer (including supplier or vehicle manufacturer) of the vehicle air conditioning system 50 to determine a third set of the seals of the vehicle air conditioning system of the first and second vehicles or the alternative as described above. Then, the method can include determining at least one seal of a first set of the plurality of seals 21 of the air conditioning system 50 of the first vehicle that is the same seal as at least one of a second set of the plurality of seals 31 of the air conditioning system 50 of the second vehicle so that the at least one seal defines at least one common seal. The step of determining the set of plurality of seals 20 , 30 , 40 needed to retrofit a set of the seals of only of the air conditioning systems 50 includes determining that only one of the at least one common seal is within the set of the plurality of seals to thereby reduce the number of seals needed.
[0045] An embodiment of the present invention additionally provides a method of using a seal kit 15 such as shown in FIGS. 1-2, 8 - 10 , and 11 . The method of using includes opening a container 16 having a set 20 , 30 , 40 of a plurality seals 21 , 31 , 41 positioned therein and needed to retrofit a set of a plurality of existing seals needed to make system fluid connections in only one air conditioning system 50 of a plurality of air conditioning systems 50 , 50 ′, 50 ″ of a plurality of vehicles. The total number of seals in the set 20 , 30 , 40 of the plurality of retrofit seals 21 , 31 , 41 preferably is less than the total combined number of seals needed to retrofit all of the existing seals needed to make system fluid connections in all of the plurality of the vehicle air conditioning systems of the plurality of vehicles and greater than a set of the plurality of seals of only one of the air conditioning systems of the plurality of vehicles. The combination of the container 16 and the set 20 , 30 , 40 of the plurality of seals 21 , 31 , 41 contained therein define a seal kit 15 . The method also includes replacing at least one of the plurality of seals 21 , 31 , 41 of the only one air conditioning system 50 of the plurality of air conditioning systems of the plurality of vehicles with at least one corresponding seal from the seal kit 15 . The method can also include selecting an air conditioning system 50 , 50 ′, 50 ″, of a particular make and model of a vehicle that corresponds to the container 16 prior to the step of opening the container 16 . The container 16 preferably has an indicator 17 associated therewith to indicate the particular year, make, model, and engine type of the vehicle for the air conditioning system 50 . The method can further include removing the at least one of the plurality of seals 20 , 30 , 40 from the container 16 of the seal kit 15 prior to the step of replacing the at least one of the plurality of seals 21 , 31 , 41 . The air conditioning system 50 , for example, advantageously can be an air conditioning system, and at least two of the plurality of seals 21 , 31 , 41 of the set 20 , 30 , 40 of the seal kit 15 can have different shaped outer perimeters.
[0046] An embodiment of the present invention further provides a method of doing business. The method of doing business includes providing a container 16 having a set 20 , 30 , 40 of a plurality of retrofit seals 21 , 31 , 41 needed to retrofit a set of a plurality of existing seals of only one vehicle air conditioning system 50 of a plurality of air conditioning systems of a plurality of vehicles. The total number of seals in the set (combination of subsets 20 , 30 , 40 ) of the plurality of seals 21 , 31 , 41 preferably is less than the total combined number of seals needed to retrofit a set of the plurality of seals of the air conditioning systems 50 of the plurality of vehicles and greater than a set of the plurality of seals of only one of the air conditioning systems of the plurality of vehicles. The combination of the container 16 and the set 20 , 30 , 40 of the plurality of seals 21 , 31 , 41 contained therein define a seal kit 15 . The method can also include providing a plurality of the seal kits 15 . Each of the plurality of seal kits 15 has a different set 20 , 30 , 40 of a plurality of seals 21 , 31 , 41 . The method can also include selling the plurality of seal kits 15 to a distributor of vehicle component parts. Each of the plurality of seal kits 15 has an indicator 17 associated therewith to indicate a plurality of makes and models of vehicles to which the plurality of seals 20 , 30 , 40 operatively retrofit a corresponding air conditioning system 50 thereof.
[0047] The method can also include storing the plurality of seal kits 15 at a distributor facility of the distributor, identifying a user's desire for a replacement of at least one seal of an air conditioning system 50 of a particular make and model of a vehicle, selecting one of the plurality of seal kits 15 that indicates the particular make and model of the vehicle, and distributing the selected one of the plurality of seal kits 15 to the user from the distributor facility. The method can further include providing a plurality of the seal kits 15 . Each of the plurality of seal kits 15 has a different set 20 , 30 , 40 of a plurality of seals 21 , 31 , 41 and has an indicator 17 associated therewith to indicate a plurality of makes and models of vehicles to which the plurality of seals 21 , 31 , 41 operatively retrofit a corresponding air conditioning system 50 thereof. The method can still further include identifying a user's desire for a replacement of at least one seal of an air conditioning system 50 of a particular make and model of a vehicle, selecting one of the plurality of seal kits 15 that indicates the particular make and model of the vehicle, and distributing the selected one of the plurality of seal kits 15 to the user. The method yet further can include providing a plurality of the seal kits 15 , storing the plurality of seals kits 15 at a selected location, and distributing the plurality of seal kits 15 . The only one air conditioning system 50 and the plurality of air conditioning systems 50 each can be provided by an air conditioning system, and at least two of the plurality of seals 21 , 31 , 41 of the set 20 , 30 , 40 of each of the plurality of seal kits 15 can have different shaped outer perimeters.
[0048] Another method of doing business also is provided which includes distributing a seal kit 15 having at least one replacement seal contained therein as one of a plurality of seals 20 , 30 , 40 . The seal kit 15 indicates a plurality of makes and models of a plurality of vehicles and has a set of the seals of an air conditioning system 50 of any one of the plurality of vehicles contained therein to thereby reduce the time needed to select the at least one replacement seal for an air conditioning system 50 of a particular make and model of a vehicle. The method can also include the seal kit 15 having a container 16 containing a set of a plurality seals 20 , 30 , 40 needed to retrofit a set of a plurality of seals of only one air-conditioning system 50 of a plurality of air conditioning systems of the plurality of vehicles. The set of the plurality of seals 20 , 30 , 40 preferably is less than the total combined number of seals needed to retrofit a set of the plurality of seals 20 , 30 , 40 of the air conditioning systems 50 of the plurality of vehicles and greater than a set of the plurality of seals of only one of the air conditioning systems of the plurality of vehicles. The method also can include providing a plurality of the seal kits 15 each of which have a different set or subset 20 , 30 , 40 of a plurality of seals 21 , 31 , 41 , and selling the plurality of seal kits 15 to a distributor of vehicle component parts. Each the plurality of seal kits 15 has an indicator 17 associated therewith to indicate a plurality of makes and models of vehicles to which the plurality of seals 21 , 31 , 41 operatively retrofit a corresponding air conditioning system 50 thereof. This method can also include storing the plurality of seal kits 15 at a distributor facility of the distributor, identifying a user's desire for a replacement of at least one seal of an air conditioning system 50 of a particular make and model of a vehicle, selecting one of the plurality of seal kits 15 that indicates the particular make and model of the vehicle, and distributing the selected one of the plurality of seal kits 15 to the user from the distributor facility.
[0049] A method of doing business, according to yet another embodiment of the present invention, includes providing a seal kit 15 , 15 ′ having at least one replacement or retrofit seal contained therein as one of a set of a plurality of seals 21 , 31 , 41 in the seal kit 15 , 15 ′ needed to make system fluid connections in a vehicle air conditioning system. The seal kit 15 , 15 ′ can have associated therewith an indication of at least one of a plurality of vehicles having the vehicle air conditioning system associated therewith to thereby reduce the amount of time needed to select the at least one replacement seal for the vehicle air conditioning system of a particular vehicle. The seal kit can include a container having a set of a plurality of seals needed to retrofit a set of a plurality of existing seals of only one air conditioning system of a plurality of vehicle air conditioning systems of the plurality of vehicles. The total number of seals in the set of the plurality of seals preferably is less than the total combined number of existing seals needed to retrofit a set of the plurality of existing seals of all of the air conditioning systems of all of the plurality of vehicles and greater than a set of the plurality of seals of only one of the air conditioning systems of the plurality of vehicles. A plurality of seal kits can also be provided as described above herein according to this embodiment. The method can also include storing the plurality of seal kits at a selected location to thereby reduce the amount of inventory of seals otherwise, needed for distributing such as when otherwise storing large quantities of individual seals.
[0050] Further still, embodiments of the present invention can also include a method of doing business which includes identifying at least one component of a vehicle air conditioning system, such as one of the system fluid connection components, e.g., dryer, condenser, evaporator, compressor, expansion valve, accumulator, and/or one or more hoses, linking a seal kit, such as described herein, to the at least one component so that the seal kit can be offered for sale with the at least one component. For example, this allows the ability to link this type of particular seal kit to a component or other air conditioning system item that a retail store or other component distributor is selling. Such linking can be accomplished by electronic data storage, computers, databases, catalogs, look up table, and other references by codes, icons, or other techniques as understood by those skilled in the art. If a compressor is being located for selling to a customer, then a seal kit associated with that compressor can be offered for sale as well. Embodiments of the present invention provide a specific seal kit to an air conditioning component requiring seal connections during service so that when the air conditioning system is sold to the consumer or customer, the customer is notified that a seal kit is available for this specific component connections and other system connections on the customer's vehicle. The method can also include offering the linked seal kit for sell to a potential purchaser of the at least one component and selling the linked seal kit and the at least one component to the potential purchaser so that the potential purchaser defines an actual purchaser.
[0051] In the drawings and specification, there have been disclosed embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation, the scope of the invention being set forth in the following claims.
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A seal kit for vehicle air conditioning systems and associated methods are provided. The seal kit includes a container and a set of a plurality of retrofit seals positioned in the container and adapted to retrofit a set of a plurality of existing seals of any one preselected group of different vehicle air conditioning systems corresponding to a preselected group of different vehicles. The seal kit simplifies and shortens the selling cycle by condensing multiple similar vehicles' seal requirements into kits allowing the ready identification of system seals by year, make, model, and when applicable, engine type. The condensing of individual components or seals into kits also allows reduction of inventory. The identification by year, make, model, and engine type speeds the selling process by quickly identifying the necessary kit and allowing one kit to be sold instead of multiple components or seals.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of, claims priority to, and incorporates by reference in its entirety, pending U.S. application Ser. No. 10/780,037, filed 17 Feb. 2004, and titled “Method, System, and Device for Storing Cremains”, which is a continuation-in-part of, claims priority to, and incorporates by reference in its entirety, abandoned U.S. application Ser. No. 10/351,125, filed 19 May 2003, and titled “Container”.
BRIEF DESCRIPTION OF THE DRAWINGS
A wide variety of potential embodiments will be more readily understood through the following detailed description, with reference to the accompanying drawings in which:
FIG. 1 is a perspective view of an exemplary embodiment of a box-urn 1000 ;
FIG. 2 is a cross-sectional assembly view, taken along line A-A of FIG. 1 ;
FIG. 3 is a cross-sectional assembly view, taken along line B-B of FIG. 1 ;
FIG. 4 is a perspective view of an exemplary embodiment of a columbarium wall 4000 ;
FIG. 5 is a front view of an exemplary embodiment of a columbarium wall 5000 ;
FIG. 6 is a cross-sectional view, taken along line C-C of FIG. 5 ;
FIG. 7 is an alternative cross-sectional view, taken along line C-C of FIG. 5 ;
FIG. 8 is a flow diagram of an exemplary embodiment of a method 8000 ;
FIG. 9 is a flow diagram of an exemplary embodiment of a method 9000 ; and
FIG. 10 is a flow diagram of an exemplary embodiment of a method 10000 .
DEFINITIONS
When the following terms are used herein, the accompanying definitions apply:
box-urn—a permanently sealed cremains urn that defines a cremains space and comprises an opposing pair of substantially rectangular and substantially planar sides coupled to an opposing pair of substantially rectangular and substantially planar ends coupled to a substantially rectangular and substantially planar face that opposes a substantially planar lid. brick—a molded rectangular block of clay baked by the sun or in a kiln until hard and used as a building and/or paving material. burial—the act of depositing a dead body or remains in the earth, in a tomb or vault, or in the water, usually with attendant ceremonies. cap—a protective cover or seal. capping—applying on top of. cinerary—a place for keeping the ashes of a cremated body. columbarium—a sepulchral facility with niches for holding cinerary urns. course—a continuous layer of building material, such as brick or tile, on a wall or roof of a building. cremains—cremated remains. facade—a principal front of a structure, having some architectural pretensions. face—the most significant or prominent surface of an object. foundation—the basis on which a thing stands, is founded, or is supported. interlock—to unite or join closely. masonry—anything constructed of the materials used by masons, such as stone, brick, tiles, or the like. mortared—joined with mortar. mortise—a cavity in a piece of wood prepared to receive a tenon and thus form a joint. niche—a recess in a wall. rectangular—defined by four right angles. roofing material—shingles, slate, seamed metal, shakes, terra cotta tiles, etc. sepulchral—of or pertaining to a funeral, burial, tomb, vault, grave, and/or monuments erected to the memory of the dead. structural masonry block—a usually hollow building block made with concrete. tenon—a projection on the end of a piece of wood shaped for insertion into a mortise to make a joint. tongue and groove joint—a mortise joint made by fitting a projection on the edge of one board into a matching cavity (e.g., groove, hole, etc.) on another board. urn—a vessel or container of various forms. wall—an upright architectural partition with a height and length greater than its thickness and serving to enclose, divide, define, or protect an area or to support another structure. waterproof material—a weather resistant material that sheds water, such as pre-cast concrete, stone (e.g., marble, granite, etc.), roofing material, etc. wood—the fibrous material which makes up the greater part of the stems and branches of trees and shrubby plants. Often used as a building material. wooden—constructed primarily of wood.
DETAILED DESCRIPTION
FIG. 1 is a perspective view of an exemplary embodiment of a cremains container and/or box-urn 1000 , which can be comprised of a first portion 1400 to which a lid 1500 is adapted to be attached. First portion 1400 can comprise a face 1300 , which can be substantially rectangular and/or substantially planar. First portion 1400 can comprise an opposing pair of sides 1100 , 1150 , either of which can be substantially rectangular and/or substantially planar. First portion 1400 can comprise an opposing pair of ends 1200 , 1250 , either of which can be substantially rectangular and/or substantially planar. Face 1300 can be interlocked to either or both of sides 1100 , 1150 . Face 1300 can be interlocked to either or both of ends 1200 , 1250 . Either or both of sides 1100 , 1150 can be interlocked to either or both of ends 1200 , 1250 . First portion 1400 can define a cremains cavity 1800 . Lid 1500 can be attached to first portion 1400 to close cremains cavity 1800 and form a cremains space 1900 . If lid 1500 is attached permanently to first portion 1400 , cremains space 1900 can be substantially airtight. Box-urn 1000 and/or first portion 1400 can be defined by a length UL, width UW, and/or height UH. In certain exemplary embodiments, the maximum value of UL, UW, and UH can be about 12 inches or less. In certain exemplary embodiments, box-urn 1000 and/or at least certain components thereof, can be manufactured from wood, such as walnut, oak, cherry, and/or pine.
FIG. 2 is a cross-sectional assembly view, taken along line A-A of FIG. 1 , and FIG. 3 is a cross-sectional assembly view, taken along line B-B of FIG. 1 . Face 1300 can be attached to sides 1100 , 1150 , and ends 1200 , 1250 to form first portion 1400 . The attachment can utilize glue, such as a carpenter's and/or weatherproof glue, e.g., Tight-Bond II from Franklin International of Columbus, Ohio. The attachment can utilize a joint, such as a mortise and tenon and/or tongue and groove. For example, face 1300 can comprise one or more side grooves 1720 and/or one or more end grooves 1740 adapted to receive corresponding one or more side tongues 1620 and/or one or more end tongues 1640 . Note that the placement of and grooves and tongues, and/or mortises and tenons, is not critical, so long as a sturdy joint is formed. Thus, face 1300 can comprise one or more tongues and/or tenons. Although not shown, either of sides 1100 , 1150 can be interlocked, such as via a joint, to either of ends 1200 , 1250 . The joint can utilize glue, a mortise and tenon construction, and/or a tongue and groove construction. In certain exemplary embodiments, a tenon and/or tongue can have a round cross-section, such as a dowel, and the corresponding mortise and/or groove can have a round cross-section, such as a hole.
First portion 1400 can define a cremains cavity 1800 that can be enclosed to form a cremains space 1900 by attachment of lid 1500 , which can closely fit into first portion 1400 and onto a lid seat 1440 . Because cremains space 1900 can be substantially airtight, when placing lid 1500 on lid seat 1440 , a portion of the air within cremains cavity 1800 can escape from cremains cavity 1800 via vent holes 1540 , thereby allowing lid 1500 to mate flushly into first portion 1400 . Prior to mating lid 1500 to first portion 1400 , glue can be applied to lid seat 1440 , first portion 1400 , and/or lid 1500 , thereby allowing lid 1500 to be permanently sealed to first portion 1400 . Screws 1520 , which can be made of stainless steel, brass, etc., can project substantially through vent holes 1540 in lid 1500 and interface with receiving holes 1420 in first portion 1400 to attach lid 1500 to first portion 1400 , thereby applying sufficient pressure to help any applied glue set properly. Prior and/or afterwards to mating lid 1500 with seat 1440 and/or first portion 1400 , glue can be applied to screws 1520 , vent holes 1540 , and/or receiving holes 1420 to allow the interaction therebetween to seal vent holes 1540 , thereby rendering cremains space 1900 substantially airtight. In certain exemplary embodiments, cremains space 1900 can remain substantially airtight when exposed to temperatures ranging from about −30F to about −300F, including all values and subranges therebetween, such as from about −20F to about 180F. In certain exemplary embodiments, cremains space 1900 can comprise a volume of at least about 200 cubic inches.
In certain exemplary embodiments, a protective finish and/or sealant, such as a polyurethane wood finish, can be applied to an exterior surface 1320 of box-urn 1000 to help preserve box-urn 1000 and/or prevent moisture from penetrating box-urn 1000 . In certain exemplary embodiments, a pin, plate, and/or plaque, etc. can be adhered to an exterior surface 1320 of box-urn 1000 . In certain exemplary embodiments, the pin can relate to a civic society, social club, military unit and/or honor, etc. In certain exemplary embodiments, the plaque can be brass and/or can be engraved with information regarding the deceased, such as name, rank, unit of military service, civic society, birth date, death date, etc. In certain exemplary embodiments, a box-urn can measure approximately 7½ inches to approximately 7⅞ inches by approximately 3½ to approximately 3⅞ inches by approximately 11½ inches to approximately 11⅞ inches. In certain exemplary embodiments, exterior edges and/or corners of box-urn 1000 can be rounded and/or smooth to prevent injuries and/or to ease handling of box-urn 1000 . In certain exemplary embodiments, box-urn 1000 can resemble a piece of fine furniture.
FIG. 4 is a perspective view of an exemplary embodiment of a columbarium wall 4000 . In certain exemplary embodiments, columbarium wall 4000 can comprise a foundation 4100 , which can be formed of, for example, concrete, stone, and/or structural blocks. In certain exemplary embodiments, supported by foundation 4100 can be one or more foundational courses 4200 , 4300 , which can be formed of, for example, concrete, stone, and/or structural blocks. Supported by foundational courses 4200 , 4300 , and/or foundation 4100 can be numerous masonry courses 4400 , 4500 , 4600 , 4700 , each of which can be formed of mortared structural masonry blocks 4720 , 4740 arranged in a predetermined block pattern 4900 . In certain exemplary embodiments, masonry blocks 4720 , 4740 can measure approximately 8 inches by approximately 8 inches by approximately 16 inches.
Defined by predetermined block pattern 4900 can be a plurality of niches 4820 , 4840 , which can be regularly-spaced and/or located external to each masonry block 4720 , 4740 . Niches 4820 , 4840 can be dimensioned to receive at least one box-urn. In certain exemplary embodiments, a niche can receive 2, 3, 4 or more box urns.
In an alternative embodiment, one or more of masonry courses 4400 , 4500 , 4600 , 4700 can be replaced by cast-in-place concrete, curable foam, etc. For example, using forms, such as a stamped metal form which has been embossed to define niches 4820 , 4840 , one or more of masonry courses 4400 , 4500 , 4600 , 4700 , and/or block pattern 4900 can be formed from concrete, spray foam (e.g., pre-foamed and/or foamed-in-place polyurethane, ozone-friendly polyurethane, polyisocyanurate, etc.), etc. In another alternative embodiment, a plastic grid can replace one or more of masonry courses 4400 , 4500 , 4600 , 4700 and/or block pattern 4900 , and/or define niches 4820 , 4840 . Such a grid can be pre-fabricated and/or can be fabricated in the field. In any event, masonry courses 4400 , 4500 , 4600 , 4700 and/or block pattern 4900 , and/or a replacement thereof, can define a wall defining a plurality of niches 4820 , 4840 .
The niches 4820 of one course 4500 can be offset along a length L (shown on FIG. 5 ) of wall 4000 with respect to the niches 4840 of a vertically and/or horizontally adjacent course 4600 and/or 4400 . Each niche 4820 , 4840 can define a niche length NL, niche width NW, and/or niche height NH. Niche length NL can be substantially greater than niche width NW and/or niche height NH. Each block 4720 can define a block length BL, block width BW, and/or block height BH. Block length BL can be substantially greater than block width BW and/or block height BH. Block length BL can extend substantially horizontally. Niche length NL can extend substantially horizontally. Niche length NL can extend substantially perpendicular to block length BL. Each block 4720 can define one or more cavities 4760 that can extend substantially horizontally.
FIG. 5 is a front view of an exemplary embodiment of a columbarium wall 5000 . In certain exemplary embodiments, columbarium wall 5000 can comprise a foundation 5100 , which can be formed of, for example, concrete, stone, and/or structural blocks. In certain exemplary embodiments, supported by foundation 5100 can be one or more foundational courses 5200 , 5300 , which can be formed of, for example, concrete, stone, and/or structural blocks. Supported by foundational courses 5200 , 5300 , and/or foundation 5100 can be numerous brick layers 5400 , 5500 , etc., each of which can be formed of mortared structural brick courses 5410 , 5420 , 5430 , 5510 , 5520 , 5530 arranged in a predetermined brick pattern 5800 . Defined by predetermined brick pattern 5800 can be a plurality of niche entrances 5600 , 5700 which can be regularly-spaced and/or covered with a plurality of removable bricks 5620 or a plaque or plate 5720 . The niche entrances 5600 of one course can be offset along a length L of wall 5000 with respect to the niche entrances 5700 of an adjacent course. Wall 5000 can comprise a cap 5900 that can extend along a length CL that is somewhat larger than length L, thereby overlapping the predetermined brick pattern 5800 and/or protecting wall 5000 from the vertical entrance of water and/or debris. Cap 5900 can be constructed of waterproof material.
In certain exemplary embodiments, wall 5000 can be comprised by a sepulchral facility. In certain exemplary embodiments, one or more facades of wall 5000 can match a décor of a nearby sepulchral facility, church, and/or cemetery. Grounds near a columbarium wall can be landscaped, and/or provided with one or more benches, fountains, gardens, and/or religious symbols.
FIG. 6 is a cross-sectional view, taken along line C-C of FIG. 5 . As shown, wall 5000 can define a width W. Likewise, cap 5900 can define a cap width CW, which can be somewhat larger than W, thereby overlapping wall facades 6100 , 6200 and/or protecting wall 5000 from the vertical entrance of water and/or debris. Cap 5900 can overlay an upper-most or top course 6750 of wall 5000 , which can be formed of mortared structural masonry blocks 6520 , 6540 arranged in a predetermined block pattern 6900 that defines a plurality of box-urn niches 6400 . Adjacent predetermined block pattern 6900 can be a wall facade 6100 , which can be constructed of bricks (or stones, etc.) arranged in a predetermined pattern, which can include a plurality of brick layers 5500 . Covering an entrance 5600 to a box-urn niche 6400 can be a plurality of bricks (stones, etc.) 5620 , which can be oriented such that their lengths or longest dimensions are directed vertically. Bricks 5620 can be inset and/or recessed slightly from the adjacent courses, such as by approximately 0.25 to approximately 1 inch. Adjacent an opposite side of predetermined block pattern 6900 can be a rear wall facade 6200 , which can be constructed of bricks, stone, stucco, concrete, etc.
FIG. 7 is an alternative cross-sectional view, taken along line C-C of FIG. 5 . As shown, wall 5000 can define a width 2 W, that is approximately twice as wide as the width W of wall shown in FIG. 6 . Likewise, cap 5900 can define a cap width 2 CW, which can be somewhat larger than 2 W, thereby overlapping wall facades 7100 , 7200 and/or protecting wall 5000 from the vertical entrance of water and/or debris. Wall 5000 can be formed of mortared structural masonry blocks arranged in a predetermined block pattern 7900 that defines a plurality of box-urn niches 7400 , 7500 , which can be offset from each other with respect to width 2 W. Adjacent predetermined block pattern 7900 can be a wall facade 7100 , which can be constructed of bricks arranged in a predetermined pattern, which can include a plurality of brick layers 5500 . Covering an entrance 5600 to a box-urn niche 7400 can be a plurality of bricks 5620 . Adjacent an opposite side of predetermined block pattern 6900 can be a rear wall facade 7200 , bricks arranged in a predetermined pattern. Covering an entrance 5640 to a box-urn niche 7500 can be a plurality of bricks 5660 .
FIG. 8 is a flow diagram of an exemplary embodiment of a method 8000 for constructing a columbarium wall. At activity 8100 , a foundation can be constructed. At activity 8200 , courses of masonry blocks can be constructed in a predetermined pattern. At activity 8300 , the masonry blocks of at least certain courses can be arranged to form niches. At activity 8400 , one or more facades, formed for example of a predetermined pattern of bricks, can be constructed and/or installed adjacent the predetermined pattern of masonry blocks. A sufficient number of loose bricks can be inserted into the niche for later use. At activity 8500 , the niche entrances can be covered, such as using one or more removable mortared bricks (not necessarily the bricks stored in the niche), potentially oriented such that their longest dimension extends vertically. At activity 8600 , a cap can be installed over the wall.
FIG. 9 is a flow diagram of an exemplary embodiment of a method 9000 for utilizing a box-urn. At activity 9100 , a non-permanently attached lid can be removed from a first portion of a box urn to expose a cremains cavity. At activity 9200 , cremains can be placed in the cremains cavity. At activity 9300 , the cremains cavity can be closed via applying the lid to the first portion of the urn box while venting the cremains space formed by the mating of the lid to the first portion. At activity 9400 , the lid can be adhered to the first portion. At activity 9500 , the vent holes can be sealed.
FIG. 10 is a flow diagram of an exemplary embodiment of a method 10000 for placing a box-urn in a niche of a columbarium wall. At activity 10100 , a covering, such as a plurality of bricks, can be removed from a niche entrance. At activity 10200 , the niche can be prepared to receive a box-urn, such as via removing from within the niche any facade bricks knocked into the niche, any stored loose bricks, and/or any loose mortar. At activity 10300 , the box-urn can be placed in the niche, such as via sliding the box-urn into the niche. At activity 10400 , the niche can be closed, such as via mortaring the previously stored loose bricks across the entrance and/or installing a plate or plaque over the entrance and/or bricks covering the entrance. At activity 10500 , the niche can be sealed.
Still other embodiments will become readily apparent to those skilled in this art from reading the above-recited detailed description and drawings of certain exemplary embodiments. It should be understood that numerous variations, modifications, and additional embodiments are possible, and accordingly, all such variations, modifications, and embodiments are to be regarded as being within the spirit and scope of the appended claims. For example, regardless of the content of any portion (e.g., title, field, background, summary, abstract, drawing figure, etc.) of this application, unless clearly specified to the contrary, there is no requirement for the inclusion in any claim of the application of any particular described or illustrated activity or element, any particular sequence of such activities, or any particular interrelationship of such elements. Moreover, any activity can be repeated, any activity can be performed by multiple entities, and/or any element can be duplicated. Further, any activity or element can be excluded, the sequence of activities can vary, and/or the interrelationship of elements can vary. Accordingly, the descriptions and drawings are to be regarded as illustrative in nature, and not as restrictive. Moreover, when any number or range is described herein, unless clearly stated otherwise, that number or range is approximate. When any range is described herein, unless clearly stated otherwise, that range includes all values therein and all subranges therein. Any information in any material (e.g., a United States patent, United States patent application, book, article, etc.) that has been incorporated by reference herein, is only incorporated by reference to the extent that no conflict exists between such information and the other statements and drawings set forth herein. In the event of such conflict, including a conflict that would render a claim invalid, then any such conflicting information in such incorporated by reference material is specifically not incorporated by reference herein.
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Certain exemplary embodiments comprise a device comprising: a first wooden portion comprising a substantially rectangular and substantially planar face interlocked to an opposing pair of substantially rectangular and substantially planar sides and to an opposing pair of substantially rectangular and substantially planar ends, the sides interlocked to said ends, said first wooden portion defining a cremains cavity; and a substantially planar wooden lid adapted to be attached to the first wooden portion and to permanently close said cremains cavity to form an airtight cremains space, the wooden lid comprising a plurality of vents adapted to vent the cremains cavity upon attachment of the wooden lid to the first wooden portion and to be sealed upon permanently closing of the cremains cavity.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit under any relevant U.S. statute to U.S. Provisional Application No. 61/756,017 filed Jan. 24, 2013, titled EER METER AND OPTIMIZING FEEDBACK CONTROL FOR DX AIR-CONDITIONERS.
FIELD OF THE INVENTION
The present invention relates generally to heating, ventilation, air conditioning, and refrigeration (HVAC&R) equipment. It specifically addresses optimization of the cooling and/or heating capacity relative to the power usage, to continuously maximize the energy efficiency ratio and the coefficient of performance, and the cooling or heating capacity relative to the power consumption, under actual operating conditions.
BACKGROUND OF THE INVENTION
The thermodynamic method used in nearly all air conditioners, refrigerators and heat pumps is the vapor compression cycle also called the refrigeration cycle. The basic cycle uses four primary components: a compressor, a condenser, an expansion device, and an evaporator; some systems may use additional components such as a receiver, additional heat exchangers, two or more compressors, and/or an accumulator and other specialized components such as a liquid-vapor separator or a vortex separator and/or a surge tank or refrigerant reservoir or vessel. The four primary components are piped in series to form a closed loop system that carries out the changes in temperature, pressure and state of the working fluid refrigerant that form the basic vapor compression cycle. Furthermore, within air conditioners, refrigerators, and heat pumps outside of the refrigeration cycle there are typically ancillary components that move the desired heat transfer medium, such as the blowing of air or of flowing of water that is to be cooled or heated, across the primary heat exchangers being the condenser coil and the evaporator coil. In addition there is typically a control circuit that energizes and de-energizes the driven components including the compressor and such as fan motors, pump motors, damper actuators, and valves accordingly to meet a desired temperature, ventilation and/or humidity or other set points and operating parameters.
The present invention makes adjustments to an air conditioning, refrigerating or heating system for the purpose of maximizing measured EER, COP and/or IEER in a feedback loop utilized to optimize cooling or heating capacity relative to power consumed. The efficiency of vapor compression cycles is numerically described by an energy efficiency ratio (EER) and/or a coefficient of performance (COP). The EER generally refers to the air conditioning, refrigerating or heating system and is the ratio of the heat absorbed by the evaporator cooling coil over the input power to the equipment, or conversely for heat pumps, the rate of heat rejected by the condenser heating coil over the input power to the equipment. EER is defined as the ratio of cooling or heating provided to electric power consumed, in units of Btu/hr per Watt. EER varies greatly with cooling load, refrigerant level and airflow, among other factors. The COP generally refers to the thermodynamic cycle and is defined as the ratio of the heat absorption rate from the evaporator over the rate of input work provided to the cycle, or conversely for heat pumps, the rate of heat rejection by the condenser over the rate of input work provided to the cycle. COP is a unitless numerical ratio. In addition, there is a standard weighted average of EER at four conditions known as the integrated energy efficiency ratio (IEER), which relates to an estimation of the energy efficiency over conditions experienced during a cooling season. Also, there is the seasonal energy efficiency ration (SEER) that is used instead of the IEER for smaller air conditioning units. Either effect of lowering capacity or increasing power manifest in reduced energy efficiency and a reduced EER, COP and IEER while making adjustments to increase capacity without increasing power, or reducing power without decreasing capacity, or both increasing capacity and reducing power will manifest in an increased EER, COP and IEER.
The actual operating EER or COP is key to maximizing efficiency, because it provides an absolute, realistic and continuous assessment of operational efficiency with feedback so a harmonized adjustment of operating parameters can be conducted. Measuring the EER, COP and IEER of systems based on the vapor compression cycle is difficult, more so while operating in a field environment rather than a test laboratory. An accurate heat absorption or heat rejection measurement for these systems is quite complex and requires measurement of the mass flow rate of fluid through the heat exchanger along with enthalpies entering and leaving the heat exchanger; a detailed description of EER and COP measurement is provided for a related invention that is disclosed separately.
The measured EER and COP are affected by the load under which the air conditioning, refrigeration or heating system is running; the load is a function of the evaporating and condensing temperatures. An increase in evaporating temperature will raise the measured EER and COP, as will a decrease in condensing temperature; as can be predicted by the thermodynamic cycle parameters. Likewise, lower evaporating temperature will reduce the measured EER and COP, as will higher condensing temperature.
The prior art does not make adjustments to the operating parameters or the components of the air-conditioning, refrigeration or heat pump system according to the measured EER or COP, neither to increase the evaporating temperature or decrease the condensing temperature, nor to adjust other parameters that effect the refrigerant subcooling or superheat, or the refrigerant composition in the case of systems using mixtures of two or more refrigerants, or of the refrigerant mass flow rate, or the refrigerant pressures, to maximize the EER or COP. An energy management system for refrigeration systems by Cantley (U.S. Pat. No. 4,325,223) relies on inference of energy efficiency rather than a direct measurement; the inference is based on relative comparison of compressor power data and other system parameters stored in memory; and the system does not make control adjustments according to the system energy efficiency ratio, rather it controls evaporative cooling. An invention by Spethmann (U.S. Pat. No. 4,327,559) applies to chilled water systems rather than direct expansion (DX) systems; and simply balances the trade-off between colder chilled water versus faster fan airflow using ratio relays. A method by Enstrom (U.S. Pat. No. 4,611,470) also applies only to chilled water systems; the described method for performance control of heat pumps and refrigeration equipment depends on the chilled water temperature and does not mention refrigerant temperature or pressure measurements. The purpose of an invention by Bahel, et al. (U.S. Pat. No. 5,623,834) is diagnostics and fault correction, rather than energy efficiency optimization; and only the fan speed and thermostatic expansion valve are controlled based on relative comparison of two temperatures and the thermal load calculated via a thermostat. Two patents by Cho, et. Al (U.S. Pat. No. 6,293,108) disclose methods for separating components of refrigerant mixtures to increase energy efficiency or capacity, however, energy efficiency ratio is neither measured nor is it a basis for adjustments. Chen, et al. (U.S. Pat. No. 7,000,413) discloses control of a refrigeration system to optimize coefficient of performance, yet there is no detailed description of how COP is calculated. Adjustment is carried out to achieve a reference COP stored in memory rather than being an optimization process. Also, the primary application of Chen, et al. is transcritical systems using carbon dioxide refrigerant; an embodiment for measurement of the refrigerant flow rate is not described; and only water flow rate and the expansion valve are adjusted. Automatic refrigerant charge adjustment methods by Kang, et al. (U.S. Pat. No. 7,472,557), Murakami, et al. (U.S. Pat. No. 8,056,348), and McMasters, et al. (U.S. Pat. No. 8,272,227) simply adjust charge to match published charging tables or reference temperature or pressure values, which are not optimized values, rather they are non-optimal compromise values that work under a wide range of operating conditions and load.
SUMMARY OF THE INVENTION
The controller continuously makes adjustments to any or all of the operating parameters of an air-conditioning, refrigeration or heat pump system to maximize the measured EER and COP. Operating parameter values, such as motor speeds, temperature set points, or actuator positions, are continuously optimized as conditions change, such as changes in ambient temperature, and cooling or heating load, so that efficiency is as high as possible within the physical constraints of the system and the operating conditions. The invention utilizes a genuine and accurate measurement of the EER of the DX cooling, refrigeration, or heating unit, proportional to standard units of cooling capacity per unit of energy use (Btuh per Watt, or MBH per kW) and/or COP (unitless).
The preferred embodiment is a system-mounted control device that can be installed as an enhancement of or alternative to standard air conditioner, refrigerator and heat pump system controllers. An alternative embodiment is an embedded control sequence program in a building automation system (BAS) or energy management system (EMS). Accurate, direct, standard EER and COP measurements are clearly displayed by the controller, along with diagnostic messages identifying out of range values if so desired, allowing a technician to immediately appraise the operating efficiency of the system. EER and COP measurements are based on signals from a plurality of sensors. Sensor data is utilized to calculate the difference between the heat content of the refrigerant at the entrance and exit of the cooling coil (evaporator) or of the heating coil (condenser), and the system or compressor power demand. EER is calculated as the rate of heat transport at the evaporator for cooling or at the condenser for heating divided by the real power input to the system and is provided in units of Btuh per Watt on a display and as an analog or digital signal that is utilized in a control loop. In a similar manner, COP is calculated as the rate of heat transport divided by the real power input to the compressor and provided as a unitless (Watts per Watt) display and as an analog or digital signal. The cooling or the heating being delivered and the power consumed can also be displayed or transmitted by an analog or digital signal, as can any of the other measured, stored, intermediate, or calculated parameters, if desired.
The EER measurement is continually calculated by a microprocessor in a control loop at pre-defined time intervals while operating parameters are iteratively adjusted by changing output values. The adjustment direction, increase or decrease, and relative magnitude, large or small, is first calculated according to measured conditions and a log of previous values stored in memory. Then, with each large or small, increase or decrease, iteration of operating parameter change, the EER measurement after the system has restabilized is compared with the previous EER measurement, and the resulting change in EER is evaluated as either positive, not significant, or negative. A positive change in EER results in iteration of the next operating parameter, and a negative change in EER results in re-adjustment of the parameter. After a pre-defined number of iterations, or if the change in EER is less than a pre-defined convergence value, the next operating parameter is adjusted. The iteration sequence is continued until all operating parameters have been adjusted to achieve the maximum EER, and the control loop repeats with the first operating parameter. In this way, the maximum EER is continuously achieved by incrementally adjusting each operating parameter to realize an incremental increase in EER, even as conditions such as ambient temperature are changing.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in, and form a part of the specification, illustrate one preferred embodiment of the present invention and together with the description serve to explain the principles of the invention. The invention is shown purely by way of example with reference to the preferred embodiment and the drawings. The invention is not limited to the precise arrangements and instrumentalities shown in the document.
In the drawings:
FIG. 1 is a schematic representation of an air conditioner, refrigerator or heat pump showing the connections from the output of the EER controller to the various components that are controlled to adjust the system operating parameters.
FIG. 2 is a block diagram showing the input sensor signals; the signal pathways between the sensors, the controller unit, the operating parameter outputs, and the display; the output signals; and the signal output display and connections.
FIG. 3 is a schematic representation of an air conditioner, refrigerator or heat pump showing the primary and secondary components of a basic vapor compression cycle and the preferred positioning of the temperature, pressure, flow, voltage, and current sensors in accordance with the present invention.
FIG. 4 is a schematic representation of an air conditioner, refrigerator or heat pump showing the primary and secondary components of a vapor compression cycle having a refrigerant reservoir coupled to the circuit via charge and discharge valves; and the preferred positioning of the temperature, pressure, flow, voltage, and current sensors in accordance with the present invention.
FIG. 5 is a flowchart of the steps of the preferred process for determining the adjustment of the outputs of an embodiment having three operating parameters. EER and COP from data obtained via the sensors and processor and the value of signal outputs that maximize EER are determined in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A schematic representation of an air conditioner, refrigerator or heat pump showing the connections from the output of the EER controller to components that are controlled to adjust system operating parameters is shown in FIG. 1 . Controller 20 generates voltage output signals proportional to operating parameter settings that maximize the energy efficiency ratio and coefficient of performance of the system as load and operating conditions vary. Voltage output signal V 1 as shown in controller detail block diagram FIG. 2 is connected to evaporator fan motor speed control 19 shown in FIG. 1 , which is a variable frequency drive or other motor speed control, as would be known to one skilled in the art, that can vary the speed of evaporator fan motor 17 driving evaporator fan 5 . Voltage output signal V 2 as shown in controller detail block diagram FIG. 2 is connected to condenser fan motor speed control 18 shown in FIG. 1 , which is an electrically commutated motor speed control or other motor speed control, as would be known to one skilled in the art, that can vary the speed of condenser fan motor 16 driving condenser fan 10 . Voltage output signals V 3 and V 4 shown in controller detail block diagram FIG. 2 are connected to refrigerant solenoid valves 12 and 15 , respectively, which allow refrigerant to flow into our out of, respectively, vessel 11 . Voltage signal V 5 shown in controller detail block diagram FIG. 2 is connected to compressor 1 to vary the operation of the compressor, as would be known to one skilled in the art. The controller can operate with some or all of the outputs as illustrated in the preferred embodiment, or other or additional outputs that vary one or more operating parameters of the air conditioner, refrigerator or heat pump illustrated in FIG. 1 by the output connection to expansion device 3 .
A block diagram showing the input sensor signals; the signal pathways between the sensors, the controller unit, the operating parameter outputs, and the display; the output signals; and the signal output display and connections is shown in FIG. 2 . Eleven sensors and one optional sensor are arranged vertically along the controller input bus; their functions and connections are as follows. Transducer T 4 W 4 is the evaporator air inlet temperature and humidity sensor (ETWS). Signals from transducer T 4 W 4 are hardwired to an analog input when attached to a packaged air-conditioner, refrigerator or heat pump, or via a 2.4 GHz IEEE 802.15.4 RF wireless transmission or other wireless transmission as would be known to one skilled in the art, to the controller unit input when the transducer must be remotely positioned some distance away in the air handling unit of a split system. T 4 is an RTD type element concurrent with element W 4 thin-film capacitor, though it can be another type of element responsive to air relative humidity as would be known to one skilled in the art, and is housed together with circuitry requiring an excitation voltage to produce two 0-5 VDC scalable signals, one proportional to temperature and the other to humidity. All other sensors except T 4 W 4 are normally positioned on the outdoor section of a split system and are hardwired or plugged into the controller unit. External flow sensor F 1 is the refrigerant flow thermal sensor (RFS), which introduces a small quantity heat into the flow stream and measures the heat dissipation using two RTD temperature elements as would be known to one skilled in the art. An ultrasonic flow sensor, or a Doppler transit-time sensor or other sensor responsive to refrigerant mass or volume flow rate or velocity as would be known to one skilled in the art, or an intrusive sensor such as a turbine, vortex, magnetic or other sensor type as would be known to one skilled in the art can be used for F 1 . Depending on the flow rate and heat dissipation, F 1 can operate in constant temperature differential mode, or, if conditions are such that a sufficient temperature differential cannot be maintained the mode is switched to constant current. Bubble fraction sensor B 1 is optional, and if used, signals a 0-5 VDC output proportional to the sensed volume fraction of vapor in the liquid, as would be known to one skilled in the art. V 1 is the power voltage sensor (PVS) directly attached to a line and the neutral or ground power phases conductors if the equipment is single-phase, and two line power phases if the equipment is three-phase or other voltage sensor type as would be known to one skilled in the art. A 1 is the power current sensor (PCS); a current probe attached around an insulated line power phase conductor, or other sensor type as would be known to one skilled in the art, which senses current and transforms it by a 1000:1 ratio into a low current milli-Amp signal for input to the controller unit. Sensors V 1 and A 1 are connected directly to the controller input bus in the preferred embodiment, alternatively connected to power transducer VA 1 ′ having a 0-5 VDC output signal proportional to power, as would be known to one skilled in the art. Sensors T 1 , T 2 , T 3 and T 5 are type-K chromel-alumel thermocouples with 0.0 mV reference output at 0 Celsius and 4.096 mV at 100 Celsius, alternatively, resistance temperature detectors (RTD) or other sensors responding to changes in temperature as would be known to one skilled in the art can also be used; these are the liquid temperature sensor LTS, the vapor temperature sensor VTS, the condenser air inlet temperature sensor CTS, and the unit discharge air temperature sensor DTS. Signal from the thermocouple are transmitted to the analog thermocouple inputs via chromel-alumel insulated conductors, where an IC-compensated thermocouple input circuit, or other type of circuit as would be known to one skilled in the art, precisely transduces temperature from mV to ±0.25° C. as a 0-5 VDC scalable signal.
Excitation voltage for transducers P 1 , P 2 and P 3 , which have micro-electric mechanical system (MEMS) strain-gauge sensing elements that are chemically compatible with refrigerants and refrigerant oils, and for transducers T 4 W 4 , F 1 and B 1 , is provided by the control unit. Alternatively, other types of pressure sensors and transducers can be used as would be known to one skilled in the art. In the control unit, conditioned 0-5 VDC signals from the sensors/transducers are converted from analog form to digital form via a general purpose 16-bit multi-channel analog to digital convertor (ADC), or other type of convertor as would be known to one skilled in the art, with unipolar single-ended inputs with an external reference voltage, mounted on a printed circuit board (PCB) comprising a bus header, a field header, and digital logic circuitry with an octal 16-bit ADC; where the field header connects to the signals and the bus header interfaces to the central processing unit (CPU). The ADC sequentially converts each analog sensor signal from the native zero to reference voltage DC range to a binary value=V(sensor)/V(reference)*65536, to support mathematical manipulation by drivers and program code executed by the CPU.
The CPU package of the preferred embodiment consists of either a 25 MHz Freescale MC9S12A512 16-bit flash microprocessor, or a 16 MHz Motorola 68HC11F1 microprocessor, 1 MB Flash and 512K RAM and 320 bytes of EEPROM, with connections via a synchronous SPI serial interface and dual RS232/485 ports; alternatively other architecture microprocessors with various flash, RAM and/or EEPROM configurations be utilized to execute standard C or other program code language as would be known to one skilled in the art. The CPU accepts user input via a keypad for data entry and display selection as needed, or alternatively, from an IEEE 802.11 b/g touch screen device, or other wireless protocol as would be known to one skilled in the art. The microprocessor executes the ADC and DAC drivers and compiled ANSI-standard C program code that filters out-of-range values, calculates the EER and COP, and executes the control loop according to the flowchart in FIG. 5 . Output values from the CPU are converted to analog signals by a 12-bit multi-channel digital to analog convertor (DAC), as would be known to one skilled in the art. Output signals EF and CF are 0-10 VDC proportional to the numerical setpoints of the speed of the evaporator fan 5 variable frequency drive and condenser fan 10 electronically commutated motor, or other motor speed control which responds to an input signal to achieve a desired motor speed as would be known to one skilled in the art. Output signals DS and CS are two-state 0 VDC or 5 VDC connected either directly, or indirectly via a relay as would be known to one skilled in the art, to solenoids actuating discharge valve 12 and charge valve 15 respectively or other type of actuated valves as would be known to one skilled in the art. In the preferred embodiment output signal CC is a two state 0 VDC or 5 VDC that energizes the compressor contactor, which in turn energizes compressor 1 , alternatively if compressor 1 is an inverter driven or variable speed compressor output signal CC is 0-10 VDC proportional to the setpoint of the speed of compressor 1 .
The text/graphics display driver that in one embodiment has a wired connection to a 256 by 256 pixel LCD display screen or, alternatively, has a connection via standard wireless IEEE 802.11 b/g packet based protocol, or other wireless transmission and reception protocol as would be known to one skilled in the art to a separate or remote display device The measured EER, COP, cooling or heating being delivered and the power consumed is displayed on the wired LCD screen, or on the display of the user's wired or wirelessly connected device, or transmitted by an analog or digital signal, as can any of the other measured, stored, intermediate, output, and/or calculated parameters, as selected using the keypad or wireless touch screen input.
A schematic representation of a basic air conditioner, refrigerator or heat pump showing the primary and secondary components of a basic vapor compression cycle and the preferred positioning of the temperature, pressure, flow, voltage, and current sensors is shown in FIG. 3 . A schematic representation of an air conditioner, refrigerator or heat pump showing the primary and secondary components of a vapor compression cycle having a refrigerant reservoir coupled to the circuit via charge and discharge valves is shown in FIG. 4 . As the differences between the schematic shown in FIG. 3 and that shown in FIG. 4 are only the presence of refrigerant reservoir vessel 11 along with its tubing sections 13 and 14 connecting to control valves 12 and 15 , the detailed description herein applies to FIG. 1 , FIG. 3 and FIG. 4 using the same component part numbers, and serves to illustrate how the present invention can be similarly applied to various configurations of various components used in air conditioners, refrigerators and heat pumps. Refrigerant working fluid flows in the shown sealed system in a closed circuit in which an hermetically sealed, open-drive, positive displacement, centrifugal or other type of compressor 1 , and a condenser heat exchanger coil 2 , and an expansion device such as a thermostatic expansion valve, an electronic expansion valve, a fixed orifice, a capillary tube, or other flow control valve 3 , and an evaporator heat exchanger coil 4 are arranged. As refrigerant flows through the circuit it changes phase as indicated in the diagram from {circle around (1)} Gas (superheated vapor), to {circle around (2)} liquid, to {circle around (3)} a mixture of liquid and vapor, to {circle around (4)} vapor. Refrigerant is made to flow from the closed circuit into refrigerant reservoir vessel 11 , which is included in the sealed system, by opening valve 12 , which allows refrigerant to flow from tubing 7 into tubing 13 . Refrigerant is made to flow into the closed circuit from refrigerant reservoir vessel 11 by opening valve 15 , which allows refrigerant to flow from tubing 14 into tubing 8 .
Fan, pump, or blower 5 causes the medium that is to be cooled, typically air or water, to flow through or over the evaporator heat exchange coil 4 , where flowing liquid refrigerant absorbs the heat from the medium and changes phase from liquid to vapor, and flows into tubing 9 to compressor 1 . The temperature of the medium to be cooled is sensed by T 4 , placed at the inlet of the evaporator coil, and if the medium is air the sensor is a combination temperature relative humidity sensor T 4 /W 4 . The temperature of the cooled medium is sensed by T 5 placed at the discharge of the air conditioner or refrigerator system. The temperature of the refrigerant vapor in tubing 9 is sensed by T 2 for cooling and refrigeration, and by T 2 ′ for heating. Sensors T 2 , T 4 , and T 5 are thermocouples, though resistance temperature detectors (RTD) or other sensors responding to changes in temperature as would be known to one skilled in the art can be used, or T 4 is an RTD type concurrent with element W 4 thin-film capacitive sensor, though it can be another type of sensor responsive to air relative humidity as would be known to one skilled in the art. In compressor 1 the specific volume of the refrigerant working fluid is reduced thereby increasing its pressure and temperature and the refrigerant is discharged as a superheated vapor or gas into tubing 6 and then to condenser 2 . Fan, pump or blower 10 causes the medium that is to be heated, typically air or water, to flow through condenser heat exchange coil 3 , where heat is absorbed by the medium from the flowing vapor refrigerant, which changes phase from vapor to liquid, and flows into tubing 7 , where its temperature is sensed by T 1 , and then to expansion device 3 . Expansion device 3 can be an orifice, a thermostatic expansion valve (TXV), a capillary tube, an electronic expansion valve (EXV), a flow control valve, an expander, or other type of expansion device as would be known to one skilled in the art. Bubble fraction sensor B 1 is optional, and if used it is mounted onto a liquid line sight glass, if needed, to sense the presence of small amounts of vapor if the sight glass is not clear, as would be known to one skilled in the art. The flow rate of liquid refrigerant in tubing 7 is sensed by F 1 . Non-intrusive external flow sensor F 1 is a thermal sensor, though an ultrasonic sensor, or a Doppler transit-time sensor or other sensor responsive to refrigerant mass or volume flow rate or velocity, or an intrusive sensor such as a turbine, vortex, magnetic or other sensor type can be used. The temperature of the medium to be heated is sensed by T 3 , placed at the inlet of the condenser coil. Sensors T 1 and T 3 are thermocouples, though resistance temperature detectors (RTD) or other sensors responding to changes in temperature as would be known to one skilled in the art can be used. As refrigerant passes through the expansion device 3 it experiences a pressure loss approximately equal to the increase in pressure driven by compressor 1 minus pressure losses in the tubing and heat exchangers, its temperature is reduced and it flows as a mixture of vapor and liquid into tubing 8 , and then to evaporator 4 and the cycle is completed.
FIG. 4 shows application of the invention to a cycle having additional components, illustrated by the addition of refrigerant reservoir vessel 11 . In response to controller signal DS, valve 12 is pulsed open to allow a small amount of refrigerant to exist the circuit by flowing from tubing 7 to tubing 13 . In response to controller signal CS, valve 15 is pulsed open to allow a small amount of refrigerant to exist the circuit by flowing from tubing 8 to tubing 14 , thereby the valves being actuated for reducing/removing or adding/increasing refrigerant charge level. The pressure of liquid refrigerant entering expansion device 3 is sensed by P 1 , the pressure of vapor refrigerant leaving evaporator coil 4 is sensed by P 2 , and the pressure of the refrigerant in vessel 11 is sensed by P 3 . Sensors P 1 , P 2 and P 3 are micro-electric mechanical system (MEMS) strain-gauge type having a one piece stainless steel sensing element chemically compatible with refrigerants and refrigerant oils; although other types of pressure sensors with similar characteristics as would be known to one skilled in the art can be used. The voltage and current of the electrical power driving compressor 1 and fans, blowers, and/or pumps 5 and 10 are sensed by V 1 and A 1 , where sensor V 1 is directly attached to a line and the neutral or ground power phases conductors, and A 1 is a current probe attached around an insulated line power phase conductor as would be known to one skilled in the art.
A flowchart of the steps of the preferred process for determining the adjustment of the outputs of an embodiment having three adjustable operating parameters is shown in FIG. 5 , although alternate embodiments with fewer or additional operating parameters operating in cooling or heating modes can be similarly controlled by the present invention. EER and COP from data obtained via the sensors and processor and the value of signal outputs are utilized to maximize EER. An initial DAT set point is provided to a proportional-integral-derivative control function, as would be know to one skilled in the art, which controls fan motor speed so that the discharge air temperature, which is provided as feedback to the PID function, meets the DAT setpoint, and concurrently the EER is measured continuously and stored in memory at pre-defined time intervals. When the DAT has reached a steady-state convergence value, the controller then increments the DAT setpoint by the value dT, which for cooling is determined by comparison of the load SHR, or sensible heat ratio, to the cooling coil SHR. The load SHR is calculated by the ratio of the difference between the evaporator entering temperature T 4 and the space temperature setpoint to the difference between the evaporator entering absolute humidity calculated from T 4 /W 4 and space absolute humidity setpoint calculated from the space temperature and humidity setpoints. The cooling coils SHR is calculated by the ratio of the difference between the evaporator entering temperature T 4 and the cooling coil saturation temperature, to the difference between the absolute humidity calculated from T 4 /W 4 and the saturated absolute humidity at the cooling coil saturation temperature, which is calculated from T 2 and P 2 using formulas as would be known to one skilled in the art. DAT increment dT is negative if the load SHR is less than the cooling coil SHR and positive if the cooling coil SHR is less than the load SHR. When the system has restabilized, either after a pre-defined stabilization period or after the DAT and EER have reached convergence values, the EER is compared relative to the EER prior to the increment of DAT setpoint and if the EER has increased the control loop proceeds to the next operating parameter to be iterated. If the EER has decreased, the sign of dT is changed, from positive to negative or negative to positive, and EER is again compared after the system restabilizes. The controller then proceeds to the next operating parameter, and increments the CF setpoint by the value dC, which is determined by comparison of the refrigerant liquid subcooling and the condenser temperature split against stored values. The refrigerant liquid subcooling is the temperature difference between the saturated liquid temperature calculated from P 1 and T 1 , and the liquid temperature T 1 using formulas as would be known to one skilled in the art, and the condenser temperature split is the difference between the saturated liquid temperature and air temperature T 3 . CF increment dC is less than 1 if the liquid subcooling or the condenser split are below stored values, and greater than 1 if either are above stored values. When the system has restabilized, either after a pre-defined stabilization period or after the EER has reached a pre-defined convergence value, the EER is compared relative to the EER prior to the increment of CF setpoint and if the EER has increased the control loop proceeds to the next operating parameter to be iterated. If the EER has decreased, dC is changed, from greater than 1 to less than 1 or from less than 1 to greater than 1, and EER is again compared after the system restabilizes. If the air conditioner, refrigerator or heat pump has refrigerant charge adjustment valves, the controller then increments the RC setpoint by the value dR, or if there are no further adjustments the control loop returns to initiate another DAT increment. The RC setpoint dR is determined by comparison of the refrigerant liquid subcooling and the condenser temperature split against stored values. RC increment dC is negative if the liquid subcooling or the condenser split are below stored values, and positive if either are above stored values. When the system has restabilized, either after a pre-defined stabilization period or after the EER has reached a pre-defined convergence value, the EER is compared relative to the EER prior to the increment of RC setpoint and if the EER has increased the control loop proceeds to the next operating parameter to be iterated. If the EER has decreased, the sign of dC is changed, from positive to negative or negative to positive, and EER is again compared after the system restabilizes. If there are additional operating parameter adjustments, such as refrigerant composition, damper position, compressor speed, and/or others as would be known to one skilled in the art, the iteration sequence is continued until all operating parameters have been adjusted to achieve the maximum EER, and the control loop repeats with the first operating parameter. In this way, the maximum EER is continuously achieved by incrementally adjusting each operating parameter to realize an incremental increase in EER, even as conditions such as ambient temperature are changing.
Although this invention has been described and illustrated by reference to specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made which clearly fall within the scope of this invention. The present invention is intended to be protected broadly within the spirit and scope of the appended claims.
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Measured EER and COP are affected by the load under which an air conditioning, refrigeration or heating system is running; the load is a function of the evaporating and condensing temperatures. The invention makes adjustments for the purpose of maximizing measured EER and COP in a feedback loop utilized to optimize cooling or heating capacity relative to power consumed. The maximum EER is continuously achieved by incrementally adjusting each operating parameter to realize an incremental increase in EER, even as conditions such as ambient temperature are changing.
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FIELD OF THE INVENTION
The present invention relates to the field of cut diamonds and more particularly to a triangular star shaped diamond adapted to generate a hearts and arrows pattern comparable and substantially equivalent to the hearts and arrows pattern generated by an ideal round cut diamond when exposed to light.
BACKGROUND OF THE INVENTION
A hearts and arrows pattern was successfully developed for a round shaped diamond possessing a nearly perfect round shape and having symmetrical and equal cut facets polished to satisfy the following requirements for its cut facets, angle parameters and alignment relationships:
The shape of the diamond must be perfectly symmetrical 8 main crown and 24 subsidiary crown facets 8 main bottom and 16 subsidiary bottom facets All main facets (crown & bottom) have to be polished at a perfect 45° angle to each other All facets are perfectly aligned All the bottom main facets are of equal size and at an angle ranging from 40.6°-41.0° All the bottom subsidiary facets are of equal size and at an angle which is exactly 1.2° steeper than the main facets (main bottom angle 40.6°-41.0°+subsidiary 41.8°-42.2°) All the main crown facets are of equal size and at an angle ranging from 33.8°-35.1°. They have to be perfectly aligned on the main bottom facets. All the subsidiary crown facets are of equal size and perfectly aligned on the main crown and subsidiary bottom facets and polished at an equal angle. The ideal proportions for the round cut diamond are:
total depth 59.4%-62.4% crown height 14.5%-16.0% girdle thickness 1.5%-2.95% Roundness 99.0%-100% Table size: 53.0%-57.5%
Although diamonds are typically cut into many geometrical shapes other than round such as, for example, a heart shape, oval, pear, marquis, princess, emerald, etc., only the round cut diamond has a nearly perfect symmetrical shape and can be polished to provide perfectly equal and symmetrical facets. Accordingly, in the diamond industry, it is widely believed that it is impossible to obtain a true hearts and arrows pattern in a non-symmetrically shaped diamond. Interestingly, what is common to all of the above shaped diamonds, other than the round shape, is its asymmetry. Moreover, if one follows the traditional method used in the diamond industry, of positioning the facets in line with the shape of the diamond, a true hearts and arrows pattern will indeed not be realizable.
A new diamond shape was discovered in accordance with the subject invention that can be cut from a rough diamond having a relatively triangular shape into a diamond having a novel triangular star shape which will yield a true hearts and arrows pattern when exposed to light. A traditional triangular shaped diamond is cut to form facets in line with the shape of the diamond and does not yield a hearts and arrows pattern. The traditional triangle cut has the following facets:
15 girdle facets 3 main crown facets 9 crown star facets 12 crown half facets 1 table facet 3 main pavilion facets 12 pavilion half facets Total number of facets: 55
SUMMARY OF THE INVENTION
The triangular star shaped diamond of the present invention possesses a heretofore unknown faceting pattern which yields a hearts an arrows pattern substantially equivalent to the hearts and arrows pattern in a round diamond. It is essential to the faceting pattern in the triangular star shaped diamond of the present invention that each main crown facet have a symmetrical facet in an opposing relationship and at least one edge in parallel alignment with an edge of the opposing main crown facet. It is also desirable in giving the diamond a star shape that it contain an equal number of girdle facets polished to align the girdle facets at a predetermined angle to ensure the girdle facets are of substantially equal length and outline a triangular shape. The triangular star shaped diamond of the present invention comprises: six main crown facets twelve crown half facets, a table facet, six main pavilion facets and an equal number main girdle facets, preferably six, separating the crown facets from the pavilion facets with each main crown facet having a symmetrical main crown facet in an opposing relationship and at least one edge in parallel alignment with an edge of the opposing main crown facet. Moreover, in the triangular star shaped diamond of the present invention the main pavilion facets are aligned to the main crown facets and not to the shape of the diamond. In addition, the triangular shaped diamond of the present invention should also preferably include twelve pavilion half facets and six crown star facets. The total number of facets in the triangular star shaped diamond of the present invention should preferably be 49.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages will become apparent from the following detailed description of the invention when read in conjunction with the accompanying drawings of which:
FIG. 1A is a table view of a traditional triangle cut diamond;
FIG. 1B is an upside down table view of the traditional triangle cut diamond of FIG. 1A ;
FIG. 2 is a top view of the triangular star shaped diamond of the present invention showing in dotted lines the shape of the rough diamond before it is cut into a triangular star shaped diamond and showing the initial girdle facet lines before being polished;
FIG. 3 is another top view of the triangular star shaped diamond of the present invention showing how the main crown facets are polished in accordance with the subject invention;
FIG. 4 is a pavilion or bottom view of the triangular star shaped diamond of the present invention showing the six main pavilion facets;
FIG. 5 is a pavilion or bottom view of the triangular star shaped diamond of the present invention showing the arrangement of the twelve pavilion half facets and the six main pavilion facets relative to the center or cutlet of the diamond with the main pavilion facets providing a star shape;
FIG. 6 is another top view of the triangular star shaped diamond of the present invention showing the main crown facets, crown half facets and crown star facets in an arrangement surrounding the table facet, with the outer lines of the crown half facets H 1 -H 12 shown in dotted lines to make it clear from FIG. 6 that the shape of the dotted lines correspond to the shape in FIG. 3 .
FIG. 7 is yet another top view of the triangular star shaped diamond of the present invention showing the main crown facets and crown star facets in an arrangement showing the main pavilion facets and pavilion half facets projecting through the table facet and displaying a star pattern; and
FIG. 8 is a side profile view of the triangular star shaped diamond of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A diamond is a crystal which functions as a prism for dispersing light by means of reflection and refraction. A traditional cut triangular diamond is shown in FIGS. 1A-1B and possesses three main crown facets and three main pavilion facets with the facets positioned in line with the shape of the diamond. In sharp contrast, the triangular shaped diamond 10 of the present invention is cut, as is shown in FIGS. 2-8 and more specifically as shown in FIG. 3 , to form six main crown facets identified by the capital letters: A, B, C, D, E and F with each of the six main crown facets having a substantially equal and oppositely positioned main crown facet surrounding a single Table facet T and having at least one edge in parallel alignment with a corresponding edge of the oppositely positioned main crown facet. For example, facet A lies opposite facet D with each of the facets A and D having edges 12 and 15 aligned in parallel. Moreover, in contrast with tradition, the main crown facets A-F are not polished in line with the shape of the diamond 10 .
As shown in FIG. 2 , the triangular shaped diamond 10 of the present invention has six girdle facets A 1 , A 2 , B 1 , B 2 , and C 1 , C 2 respectively. The shape of the diamond 10 is initially formed from a rough diamond having a generally triangular shaped geometry as shown in FIG. 2 using dotted lines to illustrate the rough shape of the diamond. The diamond 10 is initially polished to form three initial girdle facets A′, B′ and C′ which are symmetrically disposed about the body of the rough diamond 10 . The initial girdle facets A′, B′ and C′ are cut at preferably 60° from each other. The initial girdle facet A′, B′ and C′ are then polished to divide each initial girdle facet into two girdle facets at preferably 20° on each side (left and right) from the center of each initial girdle facet such that two girdle facets A 1 , A 2 are formed from the initial girdle facet A′; two girdle facets B 1 , B 2 are formed from the initial girdle facet B′ and two girdle facets C 1 , C 2 are formed from the initial girdle facet C′. This forms six girdle facets A 1 , A 2 , B 1 , B 2 and C 1 , C 2 from the initial three girdle facets A′, B′ and C′ with each of the girdle facets A 1 , A 2 , B 1 , B 2 and C 1 , C 2 being essentially of equal length and give the diamond 10 the triangular shape upon which the crown facets are polished as shown in FIG. 3 .
The main crown facets A-F are polished onto the diamond 10 such that each of the six main crown facets will have a substantially equal and oppositely positioned main crown facet. However, the main crown facets are not in alignment with the main girdle facets and are in fact shifted from a corresponding main girdle facet by polishing each main crown facet at a predetermined angle away from the adjacent corresponding girdle facet. Each of the three main crown facets A, C and E should preferably be directed 15° away from its adjacent corresponding main girdle facet in a first common direction and the main crown facets B, D and F should be directed the same 15° away from its adjacent corresponding main girdle facet but in a common second direction opposite the first direction such that each main crown facet has an edge in parallel alignment with an edge of an opposing main crown facet, i.e., opposing edges 12 and 15 of main crown facets A and D should be in parallel alignment, opposing edges 13 and 16 of main crown facets B and E should be in parallel alignment and opposing edges 14 and 17 of main crown facets C and F should be in parallel alignment respectively. The main crown facets A-F are preferably polished within an angle degree range of 33.8°-35.2° and are polished to be substantially of equal size and depth.
The pavilion side of the diamond is then polished to provide six main pavilion facets PA, PB, PC, PD, PE and PF, as is shown in FIGS. 4 and 5 , with each pavilion facet polished at an angle degree ranging from 40.6°-41.1° in alignment corresponding to the six main crown facets A-F and not to the shape of the diamond. The six pavilion facets PA-PF are triangular in shape, meet at the common culet point 20 which is at the center of the diamond 10 and form a star-like pattern. Two pavilion half facets are polished about each main pavilion facet to form a total of 12 pavilion half facets PH 1 , PH 2 , PH 3 , PH 4 , PH 5 , PH 6 , PH 7 , PH 8 , PH 9 , PH 10 , PH 11 and PH 12 . All of the pavilion half facets are polished within an angle degree range of 42.4°-43.4° and should be substantially of the same height as measured from the culet point 20 but will be of varying depth levels as is evident in FIG. 5 wherein facet PH 1 has a significantly higher depth level than facet PH 2 , facet PH 4 has a significantly higher depth level than PH 3 and PH 5 has a significantly higher depth level than PH 6 etc. Nevertheless each of the pavilion facets are substantially identical in height and angle degrees.
The crown star and crown half facets are preferably polished after the pavilion side of the diamond has been polished to form six crown star facets S 1 , S 2 , S 3 , S 4 , S 5 and S 6 as is shown in FIGS. 6 and 7 surrounding the table facet T and within an angle degree range of 13.8°-16.8° but in an arrangement such that three of the crown star facets S 1 , S 3 and S 5 have a substantially common shape which is different from the substantially common shape of the crown star facets S 2 , S 4 and S 6 . This is due to the non-alignment of the main crown facets and the main girdle facets as explained earlier. Lastly, the crown half facets H 1 , H 2 , H 3 , H 4 , H 5 , H 6 , H 7 , H 8 , H 9 , H 10 , H 11 and H 12 are polished within an angle degree range of 35.4°-40.6°. However, because of the anomalies in the alignment of the main crown facets and the girdle facets it is preferred to polish the crown half facets H 1 , H 4 , H 5 , H 8 , H 9 and H 12 within an angle degree that is at least 2° higher than the crown half facets H 2 , H 3 , H 6 , H 7 , H 10 and H 11 .
The triangular shaped diamond of the present invention will yield a hearts and arrows pattern substantially equivalent to the hearts and arrows pattern of the round cut despite its asymmetrical shape provided it is shaped and cut in accordance with the present invention as hereinabove taught and preferably when cut to satisfy the optimum parameters set forth below in Table I:
TABLE I
Total Depth:
59.4%-67.8%
Table size
52.4%-58.2%
Pavilion Depth
46.2%-49.8%
Crown Height
13.6%-16.8%
Main crown angle
33.8°-35.2°
Main pavilion angle
40.6°-41.1°
Crown star facet angle
13.8°-17.4°
Crown halves facet angle
34.6°-43.4°
Pavilion halves facet angle
42.4%-43.4
The diamond should be measured repeatedly as to insure the cut parameters are obtained. The angles and dept size should be verified for accuracy using conventional analyzers.
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A triangular star shaped diamond adapted to display a hearts and arrows pattern when exposed to light comparable to the hearts and arrows pattern in a round diamond, comprising: six main crown facets, twelve crown half facets, a table facet, six main pavilion facets and an even number of main girdle facets separating the crown facets from the pavilion facets with each main crown facet having a symmetrical main crown facet in an opposing relationship and at least one edge in parallel alignment with an edge of the opposing main crown facet.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an improvement in a belt conveyor that includes protrusions formed on a conveyor belt and holes formed on a pulley that mesh the protrusions.
2. Prior Art
FIG. 6 shows one type of belt conveyor system. In this system, an elongated protrusion 2 ′ is formed on the back surface of a conveyor belt 1 ′ so as to extend in the belt running direction, and this elongated protrusion 2 ′ fits in a peripheral groove 4 ′ formed in the periphery of the pulley 3 ′. This system is disclosed in, for instance, Japanese Utility Model Application Laid-Open (Kokai) No. H3-56712.
This belt conveyor prevents the conveyor belt 1 ′ from meandering thanks to the engagement of the protrusion and the groove. However, the engagement between the protrusions and the groove does not transmit the driving force of the pulley to the belt.
Other types of belt conveyors are shown in FIGS. 7 and 8. In FIG. 7, teeth 6 ′ are formed on the back of the conveyor belt 5 ′, and these teeth 6 ′ are meshed with teeth 8 ′ formed in the periphery of the pulley 7 ′. In FIG. 8, a cogged belt 10 ′ is attached to one side of the conveyor belt 9 ′ and a flanged wheel 12 ′ is mounted on one side of the pulley 11 ′ so that the cogs of the belt and the flanges of the wheel mesh each other. This conveyor is disclosed in, for instance, Japanese Patent Application Laid-Open (Kokai) No. H9-124123.
In these belt conveyors, the conveyor belt 5 ′ (FIG. 7) and the conveyor belt 9 ′ (FIG. 8) which is equipped with the cogged belt 10 ′ are respectively used as a timing belt; and the pulley 7 ′ (FIG. 7) and the pulley 11 ′ which is equipped with the flanged wheel 12 ′ (FIG. 8) are respectively used as a timing pulley.
In all of these prior arts, the cross sectional shape of the teeth is trapezoid. Because of this shape, when the driving-force-transmission power weakens or when the belt is stretched out, the belt tension becomes weak. When this happens, the belt tension needs to be adjusted.
The biggest problem with these belt conveyors is that different types of belts are required for different types of belt conveyors. For example, the belt 5 ′ in FIG. 7 and the belts in FIG. 8 are all different. Also, the belt having teeth that mesh the teeth of a timing belt formed at the center of a pulley (see FIG. 7) and the belt having teeth for meshing the teeth of a timing belt formed at both ends of a pulley (not shown) are different.
SUMMARY OF THE INVENTION
In view of the above, the first object of the present invention is to provide a conveyor belt that is free from meandering and does not require adjustment of belt tension. Another object of the present invention is to facilitate the manufacture of a driving roller and to make it possible to use a common belt for different types of conveyors.
To accomplish the first object, in the present invention, each of the protrusions formed on the back surface of a conveyor belt comprises inwardly curved front and rear sides thus tapering towards the top, and the periphery of a pulley is formed with holes that are shaped so as to fit the protrusions.
With this structure, the peculiarly shaped protrusions of the conveyor belt and the holes of the pulley that are shaped so as to fit the protrusions drive the conveyor when they mesh with each other, thus preventing the conveyor belt from meandering. Since the protrusions of the belt and the holes of the pulley are constantly meshed with each other, the belt tension is constant at all times, eliminating the need for tension adjustment.
Preferably, the pulley is a separate unit from and is detachable from the roller. As a result, the pulley and the roller can be manufactured independently, and the pulley can be easily attached to the roller. Moreover, the holes of the pulley can be made by pressing (burring), so that the manufacturing process of components is easy.
The conveyor belt, which has a fixed width and the protrusions thereon, may be used alone. Instead, such a belt having the protrusions can be fastened at a certain position on the back surface of a flat (wide) belt.
In other words, a conveyor for carrying goods can be easily composed using the fixed width conveyor(s). By fastening the fixed width conveyor belt(s) at a certain position(s) on the back surface of a flat (wide) belt, it is possible to use same type of flat belts for rollers having pulleys at different locations. For instance, for a roller with pulleys mounted at both ends thereof, fixed width belts are provided on both edges of a flat belt; and for a roller with a pulley at its center, a single fixed width belt is provided at the center of a flat belt. In either case, since the conveyor belts have the same fixed width, the fixed width conveyor belts can be fastened at appropriate locations (edges or center, for instance) on the back surface of the flat belts of the same type. Thus, the same type of flat belts can be commonly used for rollers having pulleys at different locations.
BRIEF DESCRIPTIONS OF THE DRAWINGS
FIG. 1 is a partially cut-away perspective view of a conveyor for carrying articles according to the present invention in which two fixed width conveyor belts are used with a space in between;
FIG. 2 is an enlarged longitudinal cross-sectional view of the pulley and conveyor belt, illustrating the protrusions on the back surface of the conveyor belt meshing with the holes formed in the pulley;
FIG. 3 is an exploded perspective view showing the pulleys separated from the roller;
FIG. 4 is a partially cut-away perspective view of a conveyor for carrying articles according to the present invention in which two fixed width conveyor belts are fastened to the back surface of a flat belt so as to correspond to the pulleys at both ends of the roller;
FIG. 5 is a partially cut-away perspective view of a conveyor for carrying articles according to the present invention in which a single fixed width conveyor belt is fastened to the back surface of a flat belt so as to correspond to the pulley at the center of the roller;
FIG. 6 is a longitudinal sectional view of a prior art conveyor belt for preventing meandering of the belt;
FIG. 7 is a partially cut-away perspective view of a conventional belt conveyor in which teeth are formed on the back surface of the conveyor belt so as to engage with teeth formed in the pulley; and.
FIG. 8 is a perspective view of another conventional belt conveyor in which a cogged belt is attached to one side of the conveyor belt, and a flanged wheel is mounted at one end the pulley so that the cogs of the belt and the flanges of the wheel mesh with each other.
DETAILED DESCRIPTION OF THE INVENTION
Preferred embodiments of the present invention will be described below with reference to FIGS. 1 to 5 . Though pair of rollers 2 are used in the embodiments, FIGS. 1 through 5 show only one roller 2 and the following description is made for the shown roller 2 .
FIGS. 1, 4 and 5 illustrate examples of a conveyor for carrying articles using a fixed width conveyor 1 .
In the embodiments of FIGS. 1 and 4, a roller 2 is equipped with pulleys 3 at its both ends, and two fixed width conveyor belts (endless belts) 1 are respectively mounted on the pulleys 3 . In the embodiment of FIG. 5, a roller 2 is equipped with a single pulley 3 at its center, and a fixed width conveyor belt (endless belt) 1 is mounted on this single pulley 3 .
In both embodiments, protrusions 1 a are formed on the back surface of each of the conveyor belts 1 and holes 3 a are formed in the periphery of the pulley 3 ; and these protrusions 1 a and holes 3 a are meshed with each other.
The protrusions 1 a and the holes 3 a have peculiar shapes as best seen from FIG. 2 . More specifically, each of the protrusions 1 a of the conveyor belt 1 comprises inwardly curved front and rear sides so as to taper towards the top or the tip end (The terms “front” and “rear” are used with reference to the direction of the rotation of the belt). In other words, the protrusions 1 a are shaped like the teeth of a chain sprocket. On the other hand, each of the holes 3 a of the pulley 3 is shaped so as to fit and snugly receive each of the protrusions 1 a of the belt 1 .
By shaping the protrusions 1 a of the conveyor belt 1 and the holes 3 a of the pulley 3 as described above, the protrusions 1 a of the conveyor belt 1 and the holes 3 a of the pulley 3 that are shaped so as to fit the protrusions 1 a drive the conveyor as they mesh and engage with each other, thus preventing the conveyor 1 from meandering. Since the protrusions 1 a of the conveyor 1 and the holes 3 a of the pulley 3 are meshed with each other constantly, the belt tension can remain steady, requiring no tension adjustments.
In the embodiment shown in FIG. 3, each of two pulleys 3 is a separate unit and is detachable from the roller 2 . The pulleys 3 are mounted to the roller 2 by mounting bolts 4 (see FIGS. 1 and 4 ). Each pulley 3 is mounted on the shaft 2 a that protrudes from both ends of the roller 2 , and the mounting bolts 4 are inserted through the insertion holes 3 b of the pulley 3 and screwed into the threaded holes 2 b of the roller 2 that are formed in both ends of the roller 2 . The pulleys 3 are thus attached to the roller 2 .
With the structure above, the pulleys 3 and the roller 2 can be manufactured separately, and the pulleys 3 can be mounted on the roller 2 easily. Moreover, the holes 3 a of the pulley 3 can be made by pressing (burring). Accordingly, the manufacture of the components (pulleys and rollers) can be simplified.
As described above, the width of the conveyor 1 is fixed; and in FIG. 1 a pair of fixed width conveyor belts 1 is used without the aid of another (different) belt so as to form a conveyor for carrying articles. Thus, a conveyor for carrying articles is comprised of fixed width conveyor belts and is obtained easily without any additional, different type of belts.
In the embodiments of FIGS. 4 and 5, on the other hand, a conveyor for carrying articles comprises a fixed width conveyor belt(s) 1 fastened to the back surface of a flat (wide) belt (wide endless belt) 5 that is larger in width than the belt(s) 1 . In FIG. 4, two fixed width conveyor belts 1 are fastened to the back surface of the flat belt 5 so that the belts 1 having the protrusions 1 a positionally correspond to pulleys 3 , and these belts 1 are mounted on the pulleys 3 provided at both ends of the roller 2 . In FIG. 5, a single fixed width conveyor belt 1 is fastened to the back surface of a flat (wide) belt 5 so that the belt 1 having the protrusions 1 a corresponds to the pulley 3 , and this belt 1 is mounted on the pulley 3 that is at the center of the roller 2 . The fixed width conveyor(s) 1 is fastened to the flat belt 5 by way of, for instance, sewing and welding.
As seen from the above, in the present invention, a fixed width conveyor belt(s) 1 is fastened at a certain position (at the center or near the side edges, for instance) of the back surface of the flat (wide) belt 5 . Accordingly, the same flat belt 5 can be used even if the mounting positions of the pulley(s) 3 on rollers 2 are different.
For instance, for a roller 2 with pulleys 3 mounted at both ends thereof, fixed width conveyor belts 1 are provided on both edges of a flat belt 5 ; and for a roller 2 with a pulley 3 at its center, a single fixed width conveyor belt 1 is provided at the center of a flat belt 5 . In either case, since the conveyor belts 1 have the same fixed width, the belts 1 can be fastened at appropriate locations (edges or center, for instance) on the back surface of the same type of flat belts 5 . Thus, the same type of flat belts 5 can be commonly used for rollers 2 having pulleys 3 at different locations.
As described above, on the back surface of each conveyor belt 1 , the protrusions 1 a each having inwardly curved front and rear sides that taper towards the top (or tip end) are provided. In addition, in the periphery of the pulley 3 , holes 3 a that are shaped so as to fit the protrusions 1 a are provided.
In addition, according to the present invention, the meandering of the conveyor is effectively prevented, and the belt tension is prevented from weakening, thus eliminating the need for tension adjustments.
Furthermore, the pulleys and rollers can be manufactured separately, and they can be assembled together easily. In addition, the holes in the pulley(s) can be opened by a pressing (burring) method. In other words, the components of the conveyor can be manufactured easily.
Also, according to the present invention, the same flat belt can be used for rollers that have pulley(s) at different positions.
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A belt conveyor comprising an endless, fixed-width belt mounted on a pulley provided on rollers. Protrusions are formed on the back surface of the endless, fixed-width belt, and each of the protrusions has a shape comprising inwardly curved front and rear sides and tapering towards its tip end, and the pulley that is detachably mounted to each of the rollers is formed with holes, and each of the holes has a shape that fits each of the protrusions of the belt. The protrusions of the belt snugly engage with holes of the pulley, thus preventing meandering of the rotating belt.
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This is a division, of application Ser. No. 780,194, filed Mar. 22, 1977, now U.S. Pat. No. 4,092,262, issued May 30, 1978 which is a Divisional Application of Ser. No. 609,115, filed Aug. 29, 1975, now U.S. Pat. No. 4,035,258 issued July 12, 1977; which is a Divisional Application of Ser. No. 391,663, filed Aug. 27, 1973, now U.S. Pat. No. 3,936,387, patented Feb. 3, 1976; which is a continuation-in-part of Ser. No. 223,779, filed Feb. 4, 1972, now abandoned.
FIELD OF THE INVENTION
This invention relates to azeotropic compositions of chlorofluorohydrocarbons with alcohols, ethers, or ketones. In a further aspect, the invention relates to new solvent compositions. In another aspect, the invention relates to methods of removing excess solder flux from circuit boards.
BACKGROUND OF THE INVENTION
Azeotropic mixtures are liquid mixtures of two or more substances which mixtures behave like single substances in that the vapor produced by partial evaporation of the azeotropic liquid has the same composition as does the liquid. Azeotropic compositions exhibit either a maximum or minimum boiling point as compared with that of other but non-azeotropic mixtures of the same substances or components.
Chlorofluorohydrocarbons have found usage for a variety of purposes. For some solvent purposes, however, the chlorofluorohydrocarbons in themselves have not exhibited adequate abilities. Particularly deficient have been the chlorofluorohydrocarbons in dissolving excess solder flux from printed circuits. Printed circuits are formed from a soft metal on a solid nonconducting surface such as a reinforced phenolic resin. During the manufacturing processes, the solid surface of support is coated with the soft metal. The particular desired portion or configuration of metal is coated with an acid-impervious protective coating, and the excess unprotected metal is removed by an acid etching process.
The protective coating subsequently must be removed since solder joints must ultimately be made onto the printed circuit. After the impervious coating is removed, the circuits are coated with a rosin flux to permit the joints to be soldered, and after soldering the rosin flux itself must be removed. For removal of such coatings and fluxes, highly efficient uniform composition solvents are desirable.
OBJECTS OF THE INVENTION
It is an object of this invention to provide novel azeotropic compositions.
It is a further purpose of this invention to provide new compositions of matter useful for dissolving solder flux.
Other aspects, objects, and the several advantages of my invention will be readily apparent to one skilled in the art to which the invention most nearly pertains from the reading of my description and consideration of my appended claims.
DESCRIPTION OF THE INVENTION
I have discovered useful azeotropes of 1,2-dichloro-1-fluoroethane with each of the tetrahydrofuran, methyl ethyl ketone, methanol, ethanol, isopropanol; and of 1,2-dichloro-1,2-difluoroethane with each of tetrahydrofuran, methyl ethyl ketone, acetone, ethanol, and isopropanol.
An azeotrope may be defined as a constant boiling mixture which distills without change in composition. Yet, at a differing pressure, the composition indeed may vary, at least slightly, with the change in distillation pressure, which also changes, at least slightly, the distillation temperature. An azeotrope of A and B may represent a unique type of relationship with a variable composition.
Thus, it should be possible to fingerprint the azeotrope, which may appear under varying guises depending upon the conditions chosen, by any of several criteria: The composition may be defined as an azeotrope of A and B, since the very term azeotrope is at once definitive and limitative, requiring that A and B indeed form this unique composition of matter which is a constant boiling admixture. Or, the composition may be defined as a particular azeotrope of a weight percent relationship or mole percent relationship of A:B, but recognizing that such values point out only one such relationship, whereas a series of relationships of A:B may exist for the azeotrope, varied by influence of temperature and pressure. Or, recognizing that broadly speaking an azeotrope of A:B actually represents a series of relationships, the azeotropic series represented by A:B may in effect be fingerprinted or characterized by defining the composition as an azeotrope further characterized by a particular boiling point at a given pressure, thus giving identifying characteristics without unduly limiting the scope of the invention.
EXAMPLES
The following data are presented in order to assist in disclosing and describing my invention, and, therefore, are not intended to be limitative of the reasonable scope thereof.
The azeotropes of my invention were prepared by distilling mixtures of the chlorofluorohydrocarbon and the other component until the overhead temperature reached a constant value and the composition of the distillate remained unchanged as verified by GLC analysis, thereby establishing the existence of a minimum boiling azeotrope in each case.
The azeotropes were tested as solvents for solder flux on printed circuits.
EXAMPLE I
Azeotropic compositions were prepared and characterized by the properties tabulated below:
TABLE I__________________________________________________________________________ Composition of AzeotropeAzeotrope.sup.(a) Chlorofluoro- Chlorofluoro-B.P. (Pressure) hydrocarbon Alcohol hydrocarbon/Alcohol__________________________________________________________________________56°C (742 mm) 141.sup.(b) Methanol (73.5/26.5 wt.% (64.4/35.6 area %65° C (749 mm) 141 Ethanol 81.2/18.8 wt. %68° C (740 mm) 141 Isopropanol 81.3/16.6(.sup.(d) wt.%52° C (741 mm) 132.sup.(c) Methanol 90.4/9.6 wt. %56-57° C (748 mm) 132 Ethanol 94.9-95/5-5.1 wt.%47° C (744 mm) 132 Isopropanol 98.7/1.3 wt. %__________________________________________________________________________ .sup.(a) B. P. is the boiling point for the azeotropic composition at substantially atmospheric in each case. The pressure showing was the atmospheric barometric pressure taken from daily laboratory readings. .sup.(b) 141 represents 1,2-dichloro-1-fluoroethane .sup.(c) 132 represents 1,2-dichloro-1,2-difluoroethane .sup.(d) Remaining 2.1 weight per cent not identified.
The azeotropes were tested as solvents for removal of solder flux from commercial circuit boards, with results as shown below, along with comparative runs:
TABLE II______________________________________ Wt. % of FluxRuns Solvent Systems Dissolved______________________________________1 141/methanol 97.02 141/ethanol 91.53 141/isopropanol 95.74 132/methanol 98.75 132/ethanol 94.06 132/isopropanol 98.07 113.sup.(e) 28.48 1,1,1-trichloroethane 82.69 113/ethanol azeotrope 66.510 113/ethanol/acetone azeotrope 57.011 113/isopropanol azeotrope 69.512 141 51.313 132 74.2______________________________________ .sup.(e) 113 represents 1,1,2-trichloro-1,2,2-trifluoroethane.
The data in Table II show that the novel azeotropic compositions of this invention were more effective than several commercially available solvents or of 141 or 132 alone in removing solder flux from printed circuit boards.
EXAMPLE II
azeotropic compositions were prepared and characterized by the properties tabulated below:
TABLE III______________________________________ Approximate Weight Per Cent Composition of AzeotropeAzeotrope Chlorofluoro- Chlorofluoro-B.P. (Pressure) hydrocarbon Ether hydrocarbon/Ether______________________________________74° C (739 mm) 141 THF.sup.(f) 61.8/38.270° C (739 mm) 132 THF 45.9/54.1______________________________________ .sup.(f) THF represents tetrahydrofuran.
The azeotropes were tested as solvents for removal of solder flux from commercial circuit boards, with results as shown below, along with comparative runs with other similar materials.
TABLE IV______________________________________Runs Solvent Systems Wt. % of Flux Dissolved______________________________________14 141/THF 10015 132/THF 10016 1,1,1-Trichloroethane 82.617 113/ethanol azeotrope 66.518 141 51.319 132 74.2______________________________________
The data in Table IV above show that the novel azeotropic compositions of this invention were more effective in removing solder flux from printed circuit boards than several commercially available solvents or 141 or 132 alone.
EXAMPLE III
Azeotropic compositions were prepared and characterized by the properties tabulated below:
TABLE V______________________________________ Approximate Wt. % Chloro- Composition fluoro- of AzeotropeAzeotrope hydro- Chlorofluoro-B.P. (Pressure) carbon Ketone hydrocarbon/ketone______________________________________80° C (atmospheric) 141 MEK.sup.(g) 54.1/45.980° C (743 mm) 132 MEK 39.8/60.266° C (736 mm) 132 Acetone 72.3/27.7______________________________________ .sup.(g) MEK represents methyl ethyl ketone.
The azeotropes were tested as solvents for removal of excess solder flux from commercial circuit boards, with the results as shown below, along with comparative runs with other materials.
TABLE VI______________________________________Runs Solvent Systems Wt. % of Flux Dissolved______________________________________20 141/MEK 10021 132/MEK 9822 1,1,1-Trichloroethane 82.623 113/ethanol azeotrope 66.524 113/ethanol/acetone azeotrope 57.025 141 51.326 132 74.2______________________________________
The data in Table VI above show that the novel azeotropic compositions of this invention were more effective in removing solder flux from printed circuit boards than several commercially available solvents or 141 or 132 alone.
EXAMPLE IV
Flash point data were obtained for azeotropic compositions of my discovery:
TABLE VIII______________________________________ Flash Point of alcohol, etherRun Azeotrope or ketone.sup.(i)No. Azeotrope Flash Point, ° F.sup.(h) Component Alone______________________________________27 141/methanol 46° F 51° F28 141/ethanol 75° F.sup.(j) 56° F29 141/isopropanol -- 53° F30 132/methanol 46° F 51° F31 132/ethanol 75° F.sup.(k) 56° F32 132/isopropanol 75° F.sup.(l) 53° F33 141/THF 40° F 6° F34 132/THF 36° F 6° F35 141/MEK -- 23° F36 132/MEK 42° F 23° F37 132/Acetone 45° F 15° F______________________________________ .sup.(h) Flash point determination in accordance with ASTM Method D-56. .sup.(i) Flash point data obtained from Shell Chemical Co. Brochure IC-71-18. .sup.(j) Burned at 75° F, not self-extinguishing. .sup.(k) Did not burn at 75° F; supported combustion of vapors and air, but was self-extinguishing. .sup.(l) Did not burn at 75° F; did not support combustion, but wa self-extinguishing.
Data on two azeotropes were not obtained as indicated by the dashes above. The flash point data in general show that the inventive azeotropes are less hazardous in most cases than the alcohol, ether, or ketone non-chlorofluorohydrocarbon component alone. The azeotropes in most cases have higher flash points than does the second component alone.
It will be understood that the description given hereinabove of the use of azeotropic compositions of my invention in cleaning or dissolving solder flux is given for illustrative purposes only, that the invention itself is not restricted to such specific embodiments, and that other techniques may be employed. These unique azeotropic compositions will have applications as solvents for greases, oils, waxes, aerosol propellants, and the like; and in cleaning electric motors, compressors, photographic film, oxygen storage tanks, lithographic plates, typewriters, precision instruments, gauges, sound tape, cloth, clothing, and the like. It will be readily apparent that the novel azeotropic compositions can be used for a variety of purposes as indicated by my general description and suggestions.
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This invention relates to azeotropic compositions of 1,2-dichloro-1-fluoroethane or of 1,2-dichloro-1,2-difluoroethane with certain alcohols, ethers, or ketones.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional patent application 61/702,409, filed Sep. 18, 2012, and to U.S. provisional patent application 61/775,074 filed Mar. 8, 2013, which are incorporated by reference herein in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not applicable
BACKGROUND
[0003] The present invention, and inventive system, is a new and novel locking and protection mechanism for pipes and pipelines, that prevents unauthorized access to metering valves and damage to valve sensing equipment. The present invention can protect, but is not limited to, water meter, oil and gas valves. In one embodiment of the present invention, the present invention is installed and works in conjunction with the existing pipelines, including, but not limited to, water, oil, and gas pipelines to prevent tampering with the meters attached to such valves and pipelines and thereby preventing theft of the fluids, or gasses, running through those pipelines, pipes or valves. In one embodiment of the present invention, by inserting the locking unit onto a valve meter assembly, such as a water pipe, the fluid flow may be regulated or controlled to an existing business, residence, or shop, by preventing the tampering with the fluid meter and/or the spud nut, or the equipment monitoring these devices. In one embodiment of the present invention the present inventive device can secure the actual spud nut of the pipeline valve, as opposed to other embodiments of the present invention in which the meter valve itself is secured.
[0004] In one embodiment of the present invention contains a new and novel extension for a transponder for a meter, or any device that uses a transponder, that needs to be extended. The transponder could be used separately from the locking device, or as a unit, just as the locking device can be used separate from the transponder extender. In the past, transponders have been known to detach from devices, such as water meters, either from fluid material flow detaching them, through fluid movement, or due to flimsy construction elements that cause the transponders to detach by being struck by a physical object, as in when a worker is doing work near the transponder and knocks the transponder off the meter. Transponders that are compromised cannot transmit signals thereby causing a disruption in services for the pipelines, pipes and valves as well as the fluid, or gas, flowing through them. If the transmitter is not signaling then it is possible that the pipeline is being tampered with and/or the lock system has been compromised.
[0005] In several embodiments of the present invention, the present inventive system allows a user to control the monitoring of fluids, and gases, which through the pipelines, pipes and/or valves and will decrease theft of said fluids, or gasses, as well as increase the security and accuracy of data transmitted by protecting the transmitting equipment, valves, or meters themselves.
SUMMARY
[0006] In various embodiments, the present invention describes a system that attaches to an existing pipeline, pipeline meter, and or pipeline valve, to secure the metering valve attached to the pipeline and prevent tampering with the meter, pipeline or pipeline valve. In other embodiments pipeline security is enhanced because the meter transponder associated with the pipeline, or pipe, is elevated and therefore not as prone to accidental dislodging. In several embodiments of the present invention, the meter valve can be for a water meter, or other fluid or gas flow meter. In several embodiments of the present invention, the inventive system is designed to prevent unauthorized tampering with pipelines, such as water, oil, or gas lines, by providing a covered lock on the actual metering device associated with said pipelines, and/or preventing the transponder associated with the pipeline from being accidentally removed. In one embodiment of the present invention, the inventive device has two locking covers, and base, that mechanically and releasably interact with each other and cover the metering device prior to being locked. In one embodiment of the present invention the locking device connects with a base underneath the item to be locked and a top unit thereby allowing it to lock the meter, or pipeline.
[0007] In one embodiment of the present invention, the present inventive locking device is placed on the existing pipeline, and can directly secure the spud nut of the pipeline therein. In this embodiment of the present invention, the inventive device has upper and lower portion locking halves that mechanically and releasably interact with each other and cover spud nut prior to being locked. In one embodiment of the present invention two halves of the locking device connected with a rectangular base underneath the invention thereby allowing it to lock the spud nut.
[0008] In several embodiments of the present invention, the present invention is also designed to extend the meter transponder away from the metering device, such as in the case of a water meter, thereby preventing the fluid flow from dislodging the transponder off the meter and stopping the transmission of signals from the transponder. In several embodiments, the present invention also allows for increased visibility so workers working near the meter can see the transponder easier and therefor and not accidentally physically strike and dislodge the transponder off of the meter. It is envisioned that the present invention can be used on any device that needs a transponder to be elevated, or any electrical device needing to transmit signals. In several embodiments of the present invention, the present invention can comprise at least two extension pieces that can adjust relative to each other and raise the transponder so that it can transmit a signal past the water meter box.
[0009] By preventing access to the meter valve, spud nut, and/or preventing the accidental dislodging of a transponder associated with pipeline, the owner and/or regulator of the pipeline has better control over their respective fluid enforcement. The embodiments of the present invention offer interchangeable bases, extensions and security straps depending on the size of meter, transponder, pipeline, or spud nut to be protected.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For a more complete understanding of the present disclosure, and the advantages thereof, reference is now made to the following descriptions to be taken in conjunction with the accompanying drawings describing specific embodiments of the disclosure, wherein:
[0011] FIG. 1 illustrates an exploded view of one embodiment of the locking mechanism of the present invention with a male and female housing;
[0012] FIG. 2 illustrates an exploded view of one embodiment of the locking mechanism of the present invention with a spud nut lock;
[0013] FIG. 3 illustrates one embodiment of the locking tool for several embodiments of the present invention;
[0014] FIG. 4 illustrates an exploded view of the dove tail embodiment of the extender of the present invention;
[0015] FIG. 5 illustrates an exploded view of the ovoid slot and track embodiment of the extender of the present invention; and
[0016] FIG. 6 illustrates an assembled view of one embodiment of the locking system on the spud nut and the extender on a meter.
DETAILED DESCRIPTION
[0017] In the following description, certain details are set forth such as specific quantities, sizes, etc. . . . so as to provide a thorough understanding of the present embodiments disclosed herein. However, it will be evident to those of ordinary skill in the art that the present disclosure may be practiced without such specific details. In many cases, details concerning such considerations and the like have been omitted inasmuch as such details are not necessary to obtain a complete understanding of the present disclosure and are within the skills of persons of ordinary skill in the relevant art.
[0018] Referring to the drawings in general, it will be understood that the illustrations are for the purpose of describing particular embodiments of the disclosure and are not intended to be limiting thereto. Drawings are not necessarily to scale.
[0019] While most of the terms used herein will be recognizable to those of ordinary skill in the art, it should be understood, however, that when not explicitly defined, terms should be interpreted as adopting a meaning presently accepted by those of ordinary skill in the art. In cases where the construction of a term would render it meaningless or essentially meaningless, the definition should be taken from Webster's Dictionary, 11th Edition, 2008. Definitions and/or interpretations should not be incorporated from other patent applications, patents, or publications, related or not, unless specifically stated in this specification or if the incorporation is necessary for maintaining validity. “Pipeline” or “pipe” as defined herein is to include any tubular through which a fluid or gas will, can, or does flow. “Valve” as defined herein is to include any junction point on a pipeline or pipe. “Meter” as defined herein is to include any device use, and attached to a pipeline, pipe, or valve that is designed to measure variables in the pipeline or pipe, including, but not limited to speed, pressure, flow, and/or volume. “Spud nut” as defined herein is to include the connective device that connects the meter to the pipeline or pipe. “Flat bottom” as defined herein may include a plurality of shapes that do not have a flat bottom, but rather any three dimensional geometric shape suitable for forming a bottom of a locking device.
[0020] One or more illustrative embodiments incorporating the invention disclosed herein are presented below. Applicants have created a revolutionary, and novel security system, and meter extender, for pipelines, pipes, valves, as well as tubulars.
[0021] As shown in FIG. 1 , in one embodiment of the present invention the inventive lock system 1 may be constructed with a female housing unit 40 , a male housing unit 50 , and a flat bottom 30 . Also illustrated is the meter valve 6 , in this illustration a water meter valve as is commonly used in the industry to attach to a pipeline 3 , although it is envisioned that the present locking system 1 , could be used on a plurality of different pipelines that utilize meter valves 6 similar in construction to a water meter valve. The present locking system 1 is also preferably designed to fit around a plurality of pipelines 3 and can be sized and constructed accordingly. As illustrated the female housing unit 40 , a male housing unit 50 , and a flat bottom 30 may be constructed of materials such as metals, iron, hard plastics or other materials that would provide a suitable locking material for a pipeline 3 . The female housing unit 40 , a male housing unit 50 , and a flat bottom 30 may also all be constructed of different materials than each other.
[0022] In one embodiment of the present invention, the female housing unit 40 is preferably constructed to be of a solid three dimensional shape with a partially hollowed interior. The female housing unit 40 may be constructed of any geometric shape provided that the disclosed features present in this application are included and met. In one embodiment of the present invention, female housing unit 40 is preferably constructed to have two orifices 42 and 44 respectively on side walls 41 and 43 . Orifice 42 , on side wall 41 , is preferable constructed to be larger in diameter than orifice 44 and designed to have a security member 90 , pass through it when the present inventive device is assembled. In one embodiment of the present invention there is a threaded receiving orifice 47 which is near the top of the female housing unit 40 , is internal to female housing unit 40 , does not pass through to the exterior of 40 , and is coincides to the corresponding orifice 46 on male housing unit 50 , such that when assembled the threaded screw 15 can mechanically engage both orifices 46 and 47 and pass through them therein securing the female housing unit 40 and the male housing unit 50 together. In several embodiments of the present invention screw 15 has a proprietary head which is substantially shaped in a similar face pattern as to the female engagement face 194 of the locking nut 197 . ( FIG. 3 ). Screw 15 adds a second level of security for this embodiment of the locking system 1 .
[0023] As illustrated, in several preferred embodiments of the present invention, the bottom side of the female housing unit 40 is machined with two slit housings 48 that are, in some embodiments, machined and designed slide over the flat bottom 30 when the present lock system 1 is assembled. Also illustrated on the lower area of female housing unit 40 is the meter valve interface 49 which is preferable machined to fit snuggly over the meter valve 6 when the device is assembled ( FIG. 6 ). Valve interface 49 is preferably designed to accommodate any size standard meter valve 6 . Female housing unit 40 is also preferably designed to have side walls 41 and 43 which will encompass the security straps 13 and 11 when the unit is lock system 1 is assembled.
[0024] In one embodiment of the present invention, the male housing unit 50 is preferably constructed to be of a solid three dimensional shape with a hollow interior and have two orifices 52 and 54 respectively on side walls 51 and 53 . Orifice 52 , on side wall 51 , is preferable constructed to be larger than orifice 54 and designed to have a security member 90 , pass through it when the present inventive device is assembled. In one embodiment of the present invention there is a threaded receiving orifice 46 which is near the top of the male housing unit 50 and is perpendicular to the corresponding orifice 47 on female housing unit 40 , such that when assembled the screw 15 can mechanically engage both orifices 46 and 47 and pass through them therein securing the female housing unit 40 and the male housing unit 50 together as a second added security feature for this embodiment. As illustrated, in several preferred embodiments of the present invention, the male housing unit 50 is machined specifically, to mechanically slide over the female housing unit 40 , when engaged, and also slide over the flat bottom 30 when the present locking device is assembled. Ergo, male housing unit 50 and female housing unit 40 need to be machined to be compatible. Also illustrated on the lower area of male housing unit 50 is the meter valve interface 59 which is preferable machined to fit snuggly over the meter valve 6 when the device is assembled. Valve interface 59 is preferably designed to accommodate any size standard valve 6 . Male housing unit 50 is also preferably designed to have side walls 51 and 53 which will encompass the female housing unit 40 when the unit is lock system 1 is assembled.
[0025] In one embodiment of the present invention, the flat bottom 30 is preferably constructed to be of a solid three dimensional shape and have two orifices 38 respectively on side walls 31 and 33 . Flat bottom 30 is also preferably constructed to have a concave face 32 which will face and engage the meter 6 , when the device is assembled. The flat bottom base 30 , can have a flat bottom or a bottom of any other three dimensional geometric configuration. In one preferred embodiment the side walls 31 and 33 rise higher than the concave face 32 . The two side walls 31 and 33 are preferably machined to have square faces 36 cut out of their surfaces opposite the interior of the concave face 32 . In several embodiments of the present invention, the square faces 36 are machined to have two orifices 38 which enter into the flat bottom 30 , but do not traverse through the flat bottom 30 or perforate the concave face 32 .
[0026] In one embodiment of the present invention, the flat bottom 30 is mechanically attached to two security straps 13 and 11 . Security straps 13 and 11 may be constructed of materials such as metals, iron, hard plastics or other materials that would provide a suitable locking material for a pipeline 3 . Located distal to each other on security strap 13 are orifices 21 and 23 . Located distal to each other on security strap 11 are orifices 22 and 23 . Orifices 22 , 42 and 52 are preferably constructed so as to be of the same or similar diameter when the present lock system 1 is engaged wherein the Orifices 22 , 42 and 52 , are aligned to as to allow for the locking security member 90 to mechanically be passed through them and secured.
[0027] In one embodiment of the present invention, the security member 90 comprises a threaded locking screw 91 and a housing insert 92 . The locking screw 91 is preferably machined to be constructed with a flat surface, standard head 93 . In several embodiments of the present invention, the housing insert 92 is preferably constructed with a head 95 that is larger in diameter than the housing insert 92 itself and the orifice 52 as well. Housing insert 92 is preferably constructed with and orifice 97 through which the locking screw 91 may pass. In assembly of the security member 90 , the locking screw 91 is inserted into the housing insert 92 via the orifice 97 with the standard head 93 engaging the head 95 , which is preferably constructed with a standard head engagement indention 98 ( FIG. 2 ) such that the standard head 93 is flush with the engaging head 95 . The security member 90 is then placed in to the orifices 52 and 54 such that the locking screw 91 will pass through orifice 54 . The locking screw 91 can then be tightened by the locking nut 197 ( FIG. 3 ). In several embodiments of the present invention the order of assembly for the security member 90 may be rearranged.
[0028] One embodiment of the present invention, the present invention is assembled in the following manner, the flat bottom 30 is mechanically attached to two security straps 11 and 13 by screwing in screws 37 into orifices 23 found on security straps 11 and 13 . This assembly is then placed under meter valve 6 . After this step, the female housing unit 40 is then place onto the flat bottom 30 and slid over the security straps 11 and 13 , such that the security strap 11 is covered by the side wall 41 and the security strap 13 is covered by the side wall 43 . The female housing unit is then slid over water meter valve 6 . At this point the orifices 44 and 22 are preferably aligned with each other. The next step in assembly is to slide the male housing unit 50 over the female housing unit 40 and lining up the orifices 54 and 44 such that they are aligned and the meter valve 6 reverse half is covered by the male housing unit 50 . Orifice 54 may have a recessed ledge 54 a, in order that the locking nut 197 is flush with the male housing 50 . In some embodiments female housing 40 may have a recessed ledge 44 a on orifice 44 that allows for the locking nut 197 to flush with the female housing 40 . In some embodiments of the present invention the orifices 44 and 54 are designed to have a wide enough diameter such that the locking nut 197 is adjacent and touching the securing strap 13 . At this point, the security member 90 is placed through the orifice 52 and 42 and locking screw 91 is placed through the head 95 and of the housing insert 92 . The locking screw 91 is then moved into the housing insert 92 and screwed into the locking nut 197 vie tightening the locking nut 197 with the unlocking tool 198 . As an option, and as illustrated, the final locking screw 15 can then be screwed into the orifice and 46 and 47 there in locking the lock system 1 together. In several embodiments of the present invention, final locking screw 15 has a proprietary locking nut 197 a similar in design and shape to 197 .
[0029] As shown in FIG. 2 , in one embodiment of the present invention the inventive lock system 1 may be used without a both a female housing unit 40 and a male housing unit 50 . In this embodiment of the present invention, flat bottom, hollow housing unit 107 , and security straps 113 and 111 may be constructed of materials such as metals, iron, hard plastics or other materials that would provide a suitable locking material for a pipeline 3 . In this embodiment of the present invention the flat bottom 130 , is modified to be shorter than the flat bottom 30 . In one embodiment of the present invention, the flat bottom 130 is preferably constructed to be of a solid three dimensional shape and have two orifices 138 respectively on side walls 134 . Flat bottom 130 is also preferably constructed to have a concave face 132 facing opposite the flat bottom surface. The flat bottom base 130 , can have a flat bottom or a bottom of any other three dimensional geometric configuration. In one embodiment the side walls 134 are the same level as concave face 132 . The two side walls 134 are preferably machined to have square faces 136 cut out of their surfaces opposite the interior of the concave face 132 . In several embodiments of the present invention, the square faces 136 are machined to have two orifices 138 which enter into the flat bottom 130 , but do not traverse through the flat bottom 130 or perforate the concave face 132 . In this embodiment, the locking system 101 is also preferably designed to fit around a plurality of pipelines 3 and can be sized accordingly. As further illustrated, in this embodiment of the present invention, the flat bottom 130 will engage the spud nut 5 of the meter valve 6 when then locking system 101 is engaged. As further illustrated, in some embodiments of the present invention there is a shelf 125 machined onto the flat bottom 130 and adjacent to the square face 136 .
[0030] In one embodiment of the present invention, the hollow housing unit 107 is preferably constructed to be of a solid three dimensional shape and have two orifices 139 and 135 respectively on side walls 152 and 151 . Hollow housing unit 107 , orifice 135 , on side wall 151 , is preferable constructed to be larger than orifice 139 . Also illustrated on the lower area of housing unit 107 is that meter valve interface 149 which is preferable machined to fit snuggly over the spud nut 5 of the meter valve 6 when the device is assembled. Valve interface 149 is preferably designed to accommodate any size standard valve. As illustrated the housing unit 107 may be constructed of materials such as metals, iron, hard plastics or other materials that would provide a suitable locking material for a pipe line. Housing unit 107 is also preferably designed to have side walls 151 and 152 which will encompass the security straps 111 and 113 when the unit is locking system 101 is assembled.
[0031] In one embodiment of the present invention, the flat bottom 130 is mechanically attached to two security straps 111 and 113 . Security straps 113 may be constructed of materials such as metals, iron, hard plastics or other materials that would provide a suitable locking material for a pipe line 3 . As illustrated, in some embodiments of the present invention, the security straps 111 and 113 may be designed with bases 25 which may be positioned facing the flat bottom 130 when the locking system 101 is assembled. When assembled, the bases 25 rest on the shelves 125 . Located distal to each other on security straps 113 are orifice 123 and 128 . Located distal to each other on security strap 111 are orifice 123 and 127 . Orifice 127 is preferably constructed to be of the same or similar diameter to orifice 135 .
[0032] As illustrated in FIG. 2 , in one embodiment of the present invention, the security member 90 comprises a locking screw 91 and a housing insert 92 with a head 95 . The head 95 is preferable constructed to be able to mechanical fit snuggly with the orifice 135 such that the head 95 will be in contact with, adjacent to, and rest on the ledge 133 of the orifice 135 . This will prevent in any embodiment the security member 90 from falling into the body of the lock system 1 or being dislodged.
[0033] One embodiment of the present invention, is assembled in the following manner, the flat bottom 130 is mechanically attached to two security straps 111 and 113 by placing the bases 25 on to the respective shelves 125 . At this point, the security straps 111 and 113 are mechanically attached to the flat bottom 130 by screwing in screws 137 into orifices 123 . This assembly is then placed under the spud nut 5 of meter valve 6 . After this step, the housing unit 107 is then place onto the flat bottom 130 and slid over the security straps 111 and 113 , such that the security strap 113 is covered by the side walls and security strap 111 is covered by side wall 152 and the spud nut 5 is covered by the housing unit 107 . At this point the orifices 135 and 127 are preferably aligned with each other. The security member 90 is then placed through the orifice 135 and 127 with housing insert 92 and threaded end of the locking screw 91 moving through orifice 39 . The locking screw 91 is then moved into the housing insert 92 and screwed into the locking nut 197 vie tightening the locking nut 197 with the unlocking tool 198 ( FIG. 3 ).
[0034] Shown in FIG. 3 , is one embodiment of the unlocking tool 198 used in several embodiments of the present invention. As illustrated, the unlocking tool 198 has a female engagement face 194 . Female engagement face 194 is preferably designed with a proprietary shape, as illustrated a rounded cross, but any proprietary three dimensional shape. The engagement face 194 is preferably designed to engage with the corresponding male face 194 a that is raised from the locking nut 197 . Locking nut 197 is preferably designed to have internal threads 1197 to engage the locking screw 91 then the present inventive device is assembled. Both female engagement face 194 and male engagement face 194 a are preferably designed to matingly engage such that when in use the locking nut 197 can be rotated to either tighten to the locking screw 91 to the locking nut 197 or loosen it from the locking nut 197 . In many embodiments the female engagement face 194 may be switched with the male engagement face 194 a such that the female engagement face is located on the unlocking tool 198 and the male engagement face is located on the locking nut 197 . The unlocking tool 198 maybe designed to standardly engage a socket wrench, and or torque wrench on the non-locking nut 197 engagement side.
[0035] As shown in FIG. 4 , is one embodiment of extender of the present invention and lock security system. FIG. 4 illustrates one embodiment of the base plate 205 of the extender 300 of the present invention, however the extender 300 can be used with any device that attached to a meter 1300 in a similar fashion to a transponder. In many embodiments of the present invention, base plate 205 may be composed of hard plastic, metal or other materials suitable for use in creating a solid, wear resistant extender 300 . As illustrated, base plate 205 is preferably composed to have an upper end 210 and a lower end 215 . The upper end 210 is distinguished from the lower end 215 by being of a smaller width than the lower end 215 . Base plate 205 is preferably rectangular in construction, however, other geometric shapes can be utilized. As illustrated, on the lower end 215 , there is an extension 220 that comes out of the body of the base plate 205 . The extension 220 is preferably hollow with an orifice 225 that runs through the body core of the base plate 205 . In some embodiments of the present invention, as illustrated, it is preferably that orifice 225 is machined to allow for screw 227 to mechanically be inserted in to the orifice 225 thereby giving the extender 300 more rigidity while in use, however not all embodiments require the use of screw 227 . In some embodiments of the present invention, it is preferably that orifice 278 is machined to allow for screw 279 to mechanically be inserted in to the orifice 228 thereby giving the extender 300 more rigidity while in use, however not all embodiments require the use of screw 279 . Also, illustrated in this embodiment is the moving plate toggle 280 , which can be inserted below the moving plate 250 on the recessed area 230 . Toggle 280 is preferably constructed with an oval shaped head 281 , as illustrated, and dovetails into the track so that it may slide into the dovetail track of recessed area 230 (as illustrated). Head 281 can be of any geometric shape that can fit and rotate in the recessed area 230 . In one embodiment of the present invention, head 281 is preferably designed to be rotated 90 degrees when in use such that it wedged in to the dove tail track of recessed area 230 thereby keeping the upper end 210 from moving towards the base plate 205 .
[0036] In some embodiments of the present invention, the upper end 210 is preferably constructed to have a recessed area 230 that forms a dove tailed track on the upper end 210 . The recessed area, or track, 230 may be constructed to have multiple orifices 235 that bore through the width of the upper end 210 , this is not a necessary feature of several embodiments of the present invention though. In some embodiments of the, present invention, orifices 235 are preferably constructed to allow for screws 260 to be mechanically inserted into the orifices 235 thereby allowing the moving plate 250 to be adjusted relative to the base plate 205 .
[0037] On the back side of the base plate 205 on the lower end 215 there are receiving ends 200 . Receiving ends 200 are preferably designed as hollowed out receptors for receiving the feet or protrusions 1100 that extend from the meter 1300 . See FIG. 5 .
[0038] FIG. 4 illustrates one embodiment of the present invention, moving plate 250 may be composed of hard plastic, metal or other materials suitable for use in creating a solid, wear resistant base. Moving plate 250 is preferably constructed to have a general rectangular shape with two prongs 265 on the top portion. The two prongs 265 are preferably constructed to have orifices 270 which bore through the width of the moving plate 250 . The prongs 265 are preferably constructed to engage the back sleeves 1215 of a transponder 1210 , or other similar electrical device. See FIG. 6 . It is envisioned that screws, or tap in screws 267 , can be placed into the orifices 270 when the extender is attached to the transponder 1210 thereby increasing the stability of the prongs 265 in the back sleeves. FIG. 6 .
[0039] FIG. 5 shows one embodiment of the present invention in exploded view with the ovoid and track configuration. In some embodiments of the present invention, such as showing in FIG. 5 , moving plate 250 is preferably constructed to have a raised area 255 on the lower side. The raised area 255 is preferably designed to be ovoid in shape and to fit snuggly into the recessed area 230 , in this embodiment, not dove tailed, of the base plate 205 . The raised area 255 is preferably designed to have orifices 240 that bore completely through the moving plate 250 . The orifices 240 are preferably designed to mechanically engage screws 260 in order to engage the base plate 205 when assembled.
[0040] FIG. 6 shows one embodiment of the present invention, as a group system, as it can be attached to a meter 1300 , in this case, a water meter. It should be noted that in many embodiments of the present invention, that the present invention can be utilized on any mechanical device that needs to have a transponder, or other electrical device elevated. Meter 1300 , is of the design typically used in the industry with protrusions 1100 that are usually designed to engage a transponder 1210 in the sleeves 1215 . As shown in FIG. 6 , the extender 300 is lowered on to the protrusions 1100 so that the protrusions 1100 insert into the receiving ends 200 . The height of the extender 300 can be modified be removing the screws 260 and raising or lowering the moving plate 250 relative to the base plate 205 while still in the recessed area 230 . When the desired height is reached, the screws 260 can be put back in and aligned with the proper orifices in the recessed area 230 . The transponder 1210 is then lowered on the prongs 265 so that the prongs engage the sleeves 1215 . Optionally, screws can be put through the orifice 270 of the extender 300 in order to press against the inner body of the sleeves 1215 thereby increasing the tight fit of the prongs 265 in sleeve 1215 .
[0041] As also illustrated in FIG. 6 in assembled form, the flat bottom 130 is mechanically attached to two security straps 111 and 113 by placing the bases 25 on to the respective shelves 125 . At this point, the security straps 111 and 113 are mechanically attached to the flat bottom 130 by screwing in screws 137 into orifices 123 . This assembly is then placed under the spud nut 5 of meter valve 6 . After this step, the housing unit 107 is then place onto the flat bottom 130 and slid over the security straps 111 and 113 , such that the security strap 113 is covered by the side walls and security strap 111 is covered by side wall 152 and the spud nut 5 is covered by the housing unit 107 . At this point the orifices 135 and 127 are preferably aligned with each other. The security member 90 is then placed through the orifice 135 and 127 with housing insert 92 and threaded end of the locking screw 91 moving through orifice 39 . The locking screw 91 is then moved into the housing insert 92 and screwed into the locking nut 197 via tightening the locking nut 197 with the unlocking tool 198 ( FIG. 3 ). As shown this assembled lock system 101 and extender 300 are locked down on a spud nut 5 and meter 1300 .
[0042] As also illustrated in FIG. 6 in assembled form, the present invention operates, once installed by preventing a user from accessing the spud nut 5 (or meter valve 6 in other embodiments such as in FIG. 1 ) and tampering with the fluid, or gas flowing though the spud nut 5 or meter valve 6 without first disassembling the locking system 1 or 101 . Also illustrated is the extender 300 which elevates the transponder 1210 , or other electrical device away from the meter 1300 and makes it more visible and less prone to being knocked off the meter 1300 .
[0043] Although several preferred embodiments of the present invention have been described in detail herein, the invention is not limited hereto. It will be appreciated by those having ordinary skill in the art that various modifications can be made without materially departing from the novel and advantageous teachings of the invention. Accordingly, the embodiments disclosed herein are by way of example. It is to be understood that the scope of the invention is not to be limited thereby.
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In various embodiments, the present invention describes a system that attaches to an existing pipeline, pipe, valve or meter in order to prevent unwanted theft and tampering with fluids and gasses flowing through the pipeline, pipe, valve or meter. In one embodiment of the present invention, the inventive device has two locking halves that mechanically and releasably interact with each other and cover the metering device prior to being locked. In one embodiment of the present invention one housing frame connect with a rectangular base underneath the invention thereby allowing it to lock the meter. In one embodiment of the present invention the electronic signal devices are elevated from the meter thereby preventing accidental dislodging and tampering.
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FIELD OF THE INVENTION
[0001] The present invention relates to the general field of press studs. While not being limited thereto, the invention has been devised with particular regard to a female component for a press stud, also known as a press fastener, to be fitted, for example, on a fabric flap in order to connect it to another fabric flap on which a corresponding male component has been fitted.
BACKGROUND OF THE INVENTION
[0002] There are various known press studs in which the female component comprises a cavity housing a magnet, a spring, a plastic ring or other retaining member for the purpose of securing, in use, a corresponding male component in connection with the female component, while still allowing it to be detached with a small degree of force.
[0003] These female components of press studs operate in the correct manner, but the manufacturing method, based on the cutting and bending of one or more metal sheets, limits the configurations that can be obtained. Purely by way of example, female components for press studs having square or polygonal outer profiles cannot be produced, except by means of complicated and costly operations which do not always give satisfactory results in terms of appearance. Furthermore, it is practically impossible to use the conventional techniques for manufacturing female components of press studs with complex profiles, such as star-shaped, knurled, or more generally scalloped profiles.
SUMMARY OF THE INVENTION
[0004] The object of the present invention is to provide a female component for a press stud which can be produced simply and economically, in configurations and shapes which may be complex, while maintaining an excellent capacity for connection to the male component by means of a retaining member housed and secured permanently in the female component.
[0005] In order to achieve the aforementioned objects, the present invention proposes a female component of a press stud comprising a monolithic body made by hot forming, defining a housing seat to accommodate a retaining member housed in the housing seat and intended to lock a corresponding male component in position during use, with a locking lip, integral with the monolithic body, extending from the housing seat and partially closing the housing seat to secure the retaining member therein.
[0006] A female component whose body is monolithic and produced by hot forming can offer a very considerable freedom of choice regarding the shape which can be produced, with benefits in relation to the creativity of designers and the demands of the fashion market. At the same time, the housing seat and the locking lip deformed so as to partially close the seat can securely house within the female component a retaining member capable of providing the technical functionality, in terms of the locking and release of the press stud, which is typical of press studs according to the prior art, produced by cutting and bending sheet metal.
[0007] Preferably, the retaining member is an elastically deformable member. More specifically, an annular plastic member may advantageously be used. In a variant, however, the retaining member has general properties of magnetic attraction.
[0008] Advantageously, the monolithic body and the locking lip integral therewith are made of plastic, or aluminium or an alloy thereof, or zinc or an alloy thereof such as brass or, more preferably, Zamak. The hot forming may include methods of hot moulding, injection or pressure casting, for example the injection of plastic material or Zamak, or hot pressing of brass.
[0009] The locking lip initially extends from the retaining member housing seat to allow the latter to be mounted in the monolithic body. The locking lip is then advantageously bent by crimping, upsetting or plastic deformation in general, preferably by a cold process, to partially close the housing seat, thus forming an annular edge which allows the retaining member to be secured in the housing seat.
[0010] The invention also relates to a press stud comprising a female component of the aforementioned type, interacting with a corresponding male component of a generally known type. The male component may also be made by hot forming, for example by the hot moulding, injection or pressure casting of aluminium or alloys thereof, zinc or alloys thereof, such as brass or Zamak, or plastic.
[0011] The present invention also relates to a method for producing a female component of a press stud, comprising the steps of:
hot forming a monolithic body of a female component of a press stud, defining within it a housing seat from which there extends a locking lip which is integral with the monolithic body, inserting a retaining member into the housing seat, partially closing the housing seat by deforming the locking lip in order to secure the retaining member in the housing seat.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Further characteristics and advantages of the invention will be made clear by the following detailed description of a preferred embodiment of the invention, which refers to the attached drawings, given purely by way of non-limiting example, in which:
[0016] FIG. 1 is a longitudinal section through a press stud with a male component fastened to a female component according to the present invention,
[0017] FIG. 2 is a longitudinal section through the female component of the press stud of FIG. 1 ,
[0018] FIG. 3 is a plan view, taken in the direction of the arrow III, of the female component of FIG. 2 ,
[0019] FIG. 4 shows a longitudinal section through a female component according to a variant of the present invention,
[0020] FIG. 5 shows a longitudinal section through the female component of FIG. 2 during the production process, and
[0021] FIG. 6 shows a longitudinal section through the female component of FIG. 4 during the production process.
DETAILED DESCRIPTION
[0022] With reference to FIG. 1 , the reference numeral 10 indicates the whole of a press stud comprising a male component 12 engaged by a snapping action or by pressure in a female component 14 , using an elastically deformable member which, in the specific example shown in the figures, is composed of an elastic ring 16 , preferably made of plastic and preferably having a substantially polygonal shape. The characteristics of an elastic ring 16 of this type are, for example, those illustrated in the document WO 1997/15207 filed by the present applicant. Clearly, the type and shape of the elastically deformable member housed in the female component is not essential for the purposes of the present invention, and can therefore be varied widely, not being limited to the example shown in the appended drawings. For example, the elastically deformable member may be a metal split ring. The elastic ring 16 may also be replaced with another retaining member, for example a magnetic member, which may be non-annular, in which case the male component will have a known shape suitable for engagement with this magnetic member.
[0023] The male component 12 is inserted into the female component 14 in an axial direction Z-Z and is secured therein by the elastic ring 16 . For this purpose, the male component 12 , of a generally known type, comprises a base structure 22 from which a stem 20 projects, this stem terminating in a head 18 . The stem 20 has a portion 20 a of smaller diameter than that of the head 18 , such that the elastic ring 16 engages elastically with this portion 20 a in the closed configuration of the press stud 10 , after the head 18 has been passed through it.
[0024] The base structure 22 of the male component 12 can be fixed, for example, to a flap of a garment by one of the methods known in the art, for example by sewing, riveting, stapling, gluing, or another known method. The shape of the male component 12 illustrated by way of example in FIG. 1 is not to be considered as limiting the present invention. For example, if the female component comprises a magnetic retaining member, the male component may be similar or identical to the female component described above, or, more generally, it is not necessary for a portion of the stem 20 a to have a smaller diameter than the head 18 .
[0025] Turning now to FIGS. 2 and 3 , it can be seen that the female component 14 comprises a base structure formed by a monolithic body 30 with an external contour 32 which is, for example, polygonal. This shape has been selected purely as an illustration and example of the present invention and is not to be considered as limiting the innumerable possible shapes of the monolithic body 30 , particularly its profile which is completely visible to a user, comprising both the lateral perimetric surface and portions of the front surface which are visible to the user, for example after the female component has been fitted to a garment or the like. The shape of the monolithic body 30 may be different from the illustrated polygonal shape, and may, for example, be round, square, elliptical, heart-shaped or star-shaped, or, more generally, may be scalloped or may have any imaginative or geometrical shape, whether symmetrical or otherwise.
[0026] In a substantially central area of the monolithic body 30 , on the side opposite that which is to be placed in contact with a fabric or substrate, in other words on the side which is visible when the female component is fixed to a fabric or substrate, there is a cavity 34 which extends along the axis Z-Z. An inner portion 34 a of the cavity is substantially cylindrical or preferably slightly flared to facilitate the forming of the female component during its production, and has a (maximum) diameter which is smaller than that of an outer annular portion 34 b which acts as a housing seat 38 for the elastic ring 16 . A locking lip 40 , preferably annular and bent radially towards the axis Z-Z, secures the elastic ring 16 , or other similar retaining member, in the housing seat 38 .
[0027] The monolithic body 30 and the locking lip 40 of the female component are formed integrally with each other as one piece from a single material. In particular, they are not produced by the deformation of a sheet of metal, as in a known method for forming female components for press studs, but are produced by hot forming, for example by hot moulding, injection or pressure casting of metal or metal alloy, such as aluminium and its alloys, zinc and its alloys such as brass and Zamak, or plastic materials. The zinc alloys known as Zamak are particularly suitable for the application of the present invention, because they are easily workable and economical.
[0028] The female component 14 may also be formed from plastic, in which case the locking lip 40 is again formed integrally in one piece with the monolithic body 30 . In this case, the forming method preferably includes the use of injection moulding for forming these parts.
[0029] FIG. 4 shows a variant of the female component 114 , with identical numbers indicating elements identical to those described above. The female component 114 comprises a base structure formed by a monolithic body 130 with an external contour 132 which is, for example, polygonal. As in the embodiment described above, the polygonal shape depicted here has been chosen purely as an illustration and example of the present invention, and is not to be considered as limiting.
[0030] In a substantially central area of the monolithic body 130 , on the side to be placed in contact with a fabric or substrate, there is a cavity 134 which extends along the axis Z-Z. The cavity 134 acts as a housing seat 138 for a ring of elastic material 16 (or other similar retaining member) and for a cup-shaped body 150 . The cup-shaped body 150 has a lateral wall 152 which is preferably substantially cylindrical, and a base 154 having a hole 156 for fixing the female component 114 to a fabric or other substrate. At the end opposite the base 154 , the lateral wall 152 of the cup-shaped body 150 is extended in the form of an enlarged annular edge 158 , having a greater diameter than the lateral wall 152 , within which the elastic ring 16 is housed. A locking lip 140 , which extends from the monolithic body 130 and is preferably annular, is bent towards the axis Z-Z and secures the ring of elastic material 16 and the edge 158 of the cup-shaped body 150 in the housing seat 138 .
[0031] The monolithic body 130 and the locking lip 140 of the female component 114 are formed integrally with each other, in one piece, from a single material, while the cup-shaped body 150 is a separate element. In particular, the cup-shaped body is preferably produced by deformation of a metal sheet, while the monolithic body 130 is produced by the hot forming of metal, metal alloy or plastic, as described above for the monolithic body 30 of the first embodiment.
[0032] The female component 14 , 114 is produced in successive processing steps. In a first step, a molten material (plastic or metal) is formed in a mould into a monolithic body 30 , 130 having a locking lip 40 ′, 140 ′, as shown, respectively, in FIG. 5 , which relates to the first embodiment of the female component 14 , and in FIG. 6 , which relates to the second embodiment of the female component 114 . The locking lip 40 ′, 140 ′ extends around the edge of the cavity 34 , 134 in the direction of the axis Z-Z, so that there are no undercut parts which would complicate the demoulding of the piece after the solidification of the molten material.
[0033] With reference to the first embodiment of FIG. 5 , the open locking lip 40 ′ of the female component 14 allows the ring of elastic material 16 or other retaining member to be inserted into the cavity 34 . After insertion, the open locking lip 40 ′ is deformed and bent towards the axis Z-Z, so as to assume the configuration of FIGS. 2 and 3 , in which the final locking lip 40 partially closes the cavity and secures the elastic ring 16 therein.
[0034] In the second embodiment, shown in FIG. 6 , both the elastic ring 16 or other retaining member and the cup-shaped body 150 are inserted into the cavity 134 when the lip 140 ′ is open. The open locking lip 140 ′ is then deformed and bent towards the axis Z-Z, so as to assume the final configuration of FIG. 4 , in which the final locking lip 140 partially closes the cavity 138 and secures the elastic ring 16 therein.
[0035] If the component is made of metallic material, then, depending on the dimensions and thickness of the locking lip 40 , 40 ′; 140 , 140 ′, it is possible to carry out the operation by hot or cold crimping, upsetting or, more generally, deformation. On the other hand, if it is made of thermoplastic material, it is preferable to heat the component locally to make the lip sufficiently malleable to be deformed so as to partially close the housing cavity 134 .
[0036] As mentioned above, the production process described here provides a simple and economical way of obtaining a component with a practically unlimited range of customization options in terms of the perimeter, designs, relief, processing, inserts, and the like, which would be impossible for a component made from a suitably formed sheet, owing to the limitations imposed by its processing.
[0037] Clearly, provided that the principle of the invention is retained, the forms of embodiment and the details of construction can be varied widely from what has been described and illustrated, without departure from the scope of the invention.
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A female component of a press stud including a monolithic body made by hot forming and defining a housing seat for a retaining member housed in the housing seat and intended to lock a corresponding male component in position selectively during use. A locking lip, integral with the monolithic body, extends from the housing seat and is deformed so as to partially close the housing seat in order to secure the retaining member therein. In order to produce the female component, the monolithic body is hot formed, and the locking lip is deformed after the introduction of the retaining member into the housing seat, by hot or cold crimping, upsetting or deformation in general.
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FIELD OF THE INVENTION
[0001] The present invention relates to a convenience structure for closing or occupying unwanted space between a window blind structure and a window frame, and more specifically a structure to provide users with a window shade system for bordering a window blind structure, to enhance the shading of light, to help save money, time, and to provide variety, and a more organized and decorative window shading system.
BACKGROUND OF THE INVENTION
[0002] In the past, there have been several different methods for supplementing previous blind structures which typically are arranged to have too small of a horizontal dimension such that light is admitted at the side edges. This problem has a range of physical shortcomings from a custom installation with minimum clearance between the ends of the horizontal blinds to a mis-fit installation where gross amounts of mis-fit creates from one to several inches of gap horizontally. In both cases there is unwanted peripheral light, especially along the vertical edges.
[0003] Horizontal length shortcomings may typically be handled by slat or louver additions, where possible, or by providing an additional vertical attachment to the bottom louver. In many cases, both vertical and horizontal gaps are attempted to be eliminated by methods consisting of major construction and/or mechanic installation, which can be costly. One of the methods consists of installing a peripheral partially enclosing window molding to encroach on all sides of the window frame. While this solution does solve the problem of having too much of an opening between the end of the window blinds and the window frame, it can be expensive and time consuming to install, and it may require some minor construction and or modification to the installation site where it is being installed.
[0004] Further, the window molding solution may use materials such as plastic or a material like wood, warping and rotting from cyclical exposure to the sunlight and moisture changes from the open window. As a result, these materials may have to be replaced often. When typical window moldings remain in a normal setting such as a house, the window moldings can be easily ruined by everyday occurrences such as water damage, thermal cracking, wood rot, bowing and fracturing, children's abuse of the molding, chipped paint, and termites. To replace the damaged window moldings with new ones, the user would have to destructively remove the damaged moldings, buy new moldings, have an installer install them or begin measuring and cutting them for a custom installation. This can be very costly and time consuming for the user.
[0005] Another need for blocking out light includes the case of a mis-match results from a blind installation where an oddly sized window makes it impossible for a buyer to purchase a standard size of blind without having space between the blind and the window frame. Many people have become so frustrated that the blinds do not appropriately fit the window that they have simply given up and erected any object, such as messily glueing aluminum foil to a window or putting up cloth as a cheap way to cover up the space. Both of these solutions look unprofessional and are at the most, quite temporary, not to mention that these seemingly simple solutions might be more costly in the long run from the sloppy nature of the installation.
[0006] Most window extensions used to block out extra light are usually made out of plastics, a material that while durable and unaffected by moisture, isn't the most flexible material, and if used near a window where it can be in direct sunlight, the plastic can warp, and if colored, will most likely fade. Rubber, like plastic, can also warp due to it's tendency to expand when heated, and if colored, will also fade with time.
[0007] For both the plastic and rubber material options, use would occur by applying the materials directly to the window surface. This solution.would not enable easy selective admission and blockage of light without installation and un-installation. After direct application, if the user decided to remove the rubber or plastic sun blockers, a residue behind of adhesive would be left behind which would cause the expenditure of more money for removal.
[0008] The ability to inexpensively and simply block out light from improper sized blinds is conventionally not available, or is not available at a reasonable cost. What is therefore needed is a device or structure which can easily and affordably provide sun blocking in the gap between horizontal blinds and window openings. The device needs to be easy to use so it will be more convenient. It needs to be simple to use and easy to removed. Users will not have to do a lot of preparation, installation and clean up. The device needs to be simple and inexpensive, so a majority of the general public can afford it. The device needs to help in reducing the time and effort spent in removing, changing, and installing side sun blocking structure.
SUMMARY OF THE INVENTION
[0009] A blind extension system with removable soft side blinders of the present invention provides an organizational system which can be used to reduce light due to improper sized blinds without damaging the blinds or the window frame itself. In one embodiment, a sock-like structure is used to attach lengths of decorative materials at the outer ends of horizontal blinds. The sock-like structures are provided periodically along the vertical length of a projecting soft, decorative material. A series of extension pins can be used to assist the horizontal extension of the soft decorative material sufficient to reach the sides of the window opening space.
[0010] Alternative methods of attachment are shown including a first embodiment of a clip attachable with vertical movement onto the elongate edge of a louver, and a second embodiment of a clip which is attachable with horizontal movement directly onto the end edge of the louver.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention, its configuration, construction, and operation will be best further described in the following detailed description, taken in conjunction with the accompanying drawings in which:
[0012] [0012]FIG. 1 is a plan, semi sectional view of a horizontal blind set within a window opening and having the decorative light blocking members attached with a sock-like structure;
[0013] [0013]FIG. 2 is a perspective view illustrating the sock-like attachment of one vertical length of soft decorative material, along with the optional use of a force extension pin;
[0014] [0014]FIG. 3 is a closeup view, similar to that seen for FIG. 1 and illustrating further details of the vertical decorative light blocking structure;
[0015] [0015]FIG. 4 is a side sectional view taken along line 4 - 4 of FIG. 3;
[0016] [0016]FIG. 5 is a side sectional view of a further embodiment seen as a clip installed by vertical movement onto the top or bottom of a louver;
[0017] [0017]FIG. 6 is a side view of a further embodiment and illustrating a rear view of a clip installed by horizontal movement onto the end of a horizontal louver; and
[0018] [0018]FIG. 7 is a sectional view taken along line 7 - 7 of FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] A description of the inventive and decorative light blocking assembly 21 seen with respect to a horizontal blind set 23 shown within a window opening defined by vertical side walls 25 and 27 and a bottom wall 29 . It is assumed that the top of the blind set 23 has appropriate top head rail and does not transmit light at its upper end. In some cases, horizontal blind sets 23 may be provided with several additional overlapping horizontal blind louvers to cover any gap between the head rail and the first horizontal louver.
[0020] As a result, the light gap predominantly results between the vertical blind set 23 and the vertical side walls 25 and 27 . This is seen in FIG. 1 as a side gap 31 adjacent vertical side wall 25 and a side gap 33 adjacent vertical side wall 27 . A horizontal gap 35 is seen adjacent bottom wall 29 , but this type of gap can be readily filled with a layer of cloth material affixed to the bottom wall 29 , or by adding a width of material to a bottom one of a series of louvers 37 .
[0021] Decorative light blocking assembly 21 has a vertical length of material 41 , and a series of attachment structures, which in FIG. 1 are shown as a series of periodically occurring sock-like structures 43 . The sock-like structures 43 are so named because one of the expected methods for engaging the ends of the louvers 37 is expected to be an elastic expansion similar to that seen in footwear.
[0022] The sock-like structures 43 may be made of elastic material which will open to admit the end of the louvers against an elastic closure force. The sock-like structures 43 may have a pair of open ends or may have one closed end and one open end. The use of one closed end may help in stabilization, but overall integrity will depend upon materials chosen and the holding forces involved. Where a close-ended sock-like structure 43 is used, the open ends should be oriented to the same side of the vertical length of material 41 .
[0023] The sock-like structures 43 are arranged in a same orientation along the length of the vertical length of material 41 and open to one side. It is expected that the decorative light blocking assembly 21 will be provided in two lengths, one as a right side length with the sock-like structures 43 having openings attached to hang down from the vertical length of material 41 so that the openings of the sock-like structures 43 open to the left, and one as a left side length with the sock-like structures 43 having openings attached to hang down from the vertical length of material 41 so that the openings of the sock-like structures 43 open to the right.
[0024] Once the sock-like structures 43 are fitted onto the end of one of the louvers 37 , the sock-like structures 43 it would be held in place by a combination of elastic closure force against the louver 37 , as well as friction between the inside sock-like structures 43 and the louver 37 . This dual mechanism for holding contemplates the possibility of selection of material for the sock-like structures 43 which has enhanced friction and elasticity, as well as the addition of materials to sock-like structures 43 to enhance elastic hold and frictional engagement, including stiffeners and added elastic.
[0025] As will be seen, the sock-like structures 43 , preferably manage to engage the vertical length of material 41 so as to stabilize the pivot point between the sock-like structures 43 and the vertical length of material 41 . In the normal movement of vertical blinds, a given louver 37 will move through an arc from a closed position where the top of the louver 37 is directed toward the inside of a room and where the lower edge sits atop the next most adjacent louver, to an arcing position through a nearly horizontal position, to a second closed position with the bottom the louver 37 being directed toward the inside of a room and where the lower edge sits atop the next most adjacent louver below it, to an arcing position through a nearly horizontal position, and then to a second closed position with the bottom of the louver 37 directed toward the inside of the room and with the same edge which was on the bottom in the first closed position now on top and adjacent the louver 37 above it.
[0026] The pivot point between the sock-like structures 43 and the vertical length of material 41 follows the location of this edge so that the vertical length of material 41 can follow inside of the room, cover the sock-like structures 43 , and so that the vertical length of material 41 will have a close adjacency relationship with respect to the internally directed surfaces of the louvers 37 at both closed positions. At the middle, open position the vertical length of material 41 continues to cover the sock-like structures 43 , although the sock-like structures 43 may be seen if the vertical length of material 41 is viewed at an angle from either above or below the louver 37 . At the middle, open position the vertical length of material 41 only has close adjacency to the edge of the louvers 37 farthest from the window.
[0027] Thus the arrangement of providing pivoting about the edge of the louvers 37 closest to the center of a room in which the window opening is located and farthest from the window is such that the decorative light blocking assembly 21 will not bind the movement of the louvers 37 and will always be in a close, light blocking relationship with the louvers 37 when louvers 37 are brought to either of their closed positions.
[0028] The effectiveness of the decorative light blocking assembly 21 can be seen in FIG. 1 with reference to the side gaps 31 and 33 which represent the space between the ends of the horizontal louvers to the vertical side walls 25 and 27 . The decorative light blocking assembly 21 can be seen to reduce the side gaps 31 and 33 to what is shown as a smaller gap 51 and 53 , respectively. In reality, the smaller gaps 51 and 53 are shown as such for understanding, but will preferably be so small that they will be de minimis or zero. The actual showing and identification of a gap is to enable an outer edge 55 to be identified and discussed.
[0029] Preferably, the decorative light blocking assembly 21 will be made predominantly of soft cloth material, especially for the vertical length of material 41 . The amount of material which extends beyond the ends of the louvers 37 , and across the side gaps 31 and 33 has to be upheld from the periodically occurring sock-like structures 43 . If the vertical length of material 41 is too flimsy, or if it is not well supported by the periodically occurring sock-like structures 43 , it may droop or tend to fold in one direction or the other and leave an enlarged smaller gaps 51 and 53 . Conversely, if the vertical length of material 41 is too rigid it may engage the vertical side walls 25 and 27 and create a vertically elongate slit type gap 51 and 53 . The preferred material should urge the vertical length of material 41 into close, consistent, sweeping, light blocking proximity to the vertical side walls 25 and 27 .
[0030] An option, and for optional use, the sock-like structures 43 may be fitted with a pocket for carrying a support member 59 to effectively extend a portion of the support ability garnered by the sock-like structures 43 across the width of the vertical length of material 41 . The pocket carrying the support member 59 need not extend completely across to the outer edge 55 , especially depending upon the material used for the material 41 .
[0031] Further, it is expected that the user will observe the width of the side gaps 31 and 33 to determine if the width is sufficient that support members 59 will be needed. Further to this judgement, it is noted that the periodically occurring sock-like structures 43 are shown as extending all the way over to the outer edge 55 , but need not do so. In the configuration shown where they do extend all the way to the outer edge 55 , the user has to back them off from a position where the periodically occurring sock-like structures 43 are completely fitted over the ends of the louvers 37 to which they are attached.
[0032] This “backing off” from full conforming fit is done so that the outer edge 55 can be moved toward the vertical side walls 25 and 27 to reduce the size of the side gaps 31 and 33 to minimize the smaller gaps 51 and 53 , preferably to zero. Ideally the back off of the periodically occurring sock-like structures 43 will be equally shared on both sides of the horizontal blind set 23 so that one decorative light blocking assembly 21 will not be over-extended (at least not more than the other decorative light blocking assembly 21 on the other side.
[0033] Note also the term “periodically” in the phrase periodically occurring sock-like structures 43 . Horizontal blind sets may be available in certain standardized width of louvers 37 , having a standardized overlap and standard spacing. The decorative light blocking assembly 21 , however may or may not have a completely matched set of periodically occurring sock-like structures 43 . Where additional material of the vertical length of material 41 exists between two periodically occurring sock-like structures 43 , the material is simply left to form a horizontal fold.
[0034] The end edges of the horizontal fold still simply abut the vertical side walls 25 and 27 , and even provide some stress relief over what would otherwise be a potentially tightened length of the vertical length of material 41 which would not gently abut the vertical side walls 25 and 27 . Further, since the sock-like structures 43 are periodically occurring, any resulting horizontal folds from extra material will also periodically occur, forming a gentle wide curved fold at the bottom of each expanse of material between the periodically occurring sock-like structures 43 .
[0035] As shown in FIG. 1, the periodically occurring sock-like structures 43 are connected to every fifth louver 37 . In practice, a periodically occurring sock-like structures 43 can be provided for each louver 37 . In this event, the excess material would be even between each louver 37 and form a more regular decorative pattern. Alternatively, where the periodically occurring sock-like structures 43 is connected to every other louver 37 , the periodicity of the excess material is still regular and controlled, but has a periodicity twice that of the vertical height position of each louver 37 . Depending upon how the louvers 37 are set to rotate, the availability of excess material of the vertical length of material 41 might actually change depending upon the angular position of the louvers 37 .
[0036] Moreover, the vertical length of material 41 is intended to be selected based upon its color, its light transmissive or blocking qualities, and a pattern which might preferably match or complement window and room decor. For example, the cloth material from which the vertical length of material 41 is constructed might match the curtains, a valance, or the furniture. The vertical length of material 41 could be chosen to admit some light or to create a pattern upon application of rear lighting. Further, the type of cloth material from which the vertical length of material 41 is made could vary widely, including all cloth, paper, plastic and other types of material. Rayon or nylon may be preferred in some cases due to the silence which would result from movement of the horizontal blind set 23 and thus movement of the outer edge 55 of the vertical length of material 41 against the vertical side walls 25 and 27 .
[0037] [0037]FIG. 2 illustrates a rear view to illustrate the attachment of the periodically occurring sock-like structures 43 to individual louvers 37 . Because of the louver 37 overlap, each overlapping louver 37 has to be broken away in order to see the details of the periodically occurring sock-like structures 43 with respect to the vertical length of material 41 . Further, many of the structures seen in FIG. 2 are much larger than they would actually be in an actual embodiment, and where overlap of the louvers 37 sandwiching any of the structures adjacent the sock-like structures 43 is had, there will be little or not separation created between louvers 37 .
[0038] Referring to the top of FIG. 2, one way to extend support from the louvers 37 is had by creating a pocket 61 to one side of the periodically occurring sock-like structures 43 by providing a first stitch 63 spaced apart from a second stitch 65 , with the support member 59 snugly held by the pocket 61 formed between the two stitches.
[0039] By forming the pocket 61 more closely adjacent the louver 37 , the position of the support member 59 is stabilized along its projection away from the louver 37 . The pocket could be added beneath the louver 37 , or on sock-like structure 43 at a broad surface of the louver 37 . It is because the stiffness or support ability of the sock-like structure 43 ends at the end of the louver 37 that the support member 59 may be optionally needed. In the alternative, the sock-like structure 43 could be made of a more laterally supportive material. However, support member 59 enables the user to introduce, control or eliminate the projected support from the louver 37 .
[0040] The bottom of FIG. 2 illustrates the use of a stiffening member 67 sewn between the sock-like structure 43 and the vertical length of material 41 . A single stitch 69 is sewn straight through an area of the joined ends of the sock-like structure 43 and at least one layer of the vertical length of material 41 . The upper end of vertical length of material 41 as seen in FIG. 2 illustrates it as being two layers, generally doubled over in order to enable a rear layer 71 to accept stitching and to be covered over by a facing or front layer 73 to enable an untrammeled decorative appearance facing into the room. The double layering of the vertical length of material 41 can be by finished stitching, gluing or any other technique.
[0041] Referring to FIG. 3, a plan view corresponding to the perspective view of FIG. 2 is seen. At the top of FIG. 3, the support through the support member 59 is seen as extending support to the outer edge 55 by virtue of underlying support of the top of the louver 37 . Again, the support member 59 could be backed off from its position all the way into the pocket 61 to produce more flexibility at the outer edge 55 . At the lower end of FIG. 3 is seen the plastic insert which is sewn directly with the stitch 69 and which transmits support toward the outer edge 55 . However, as can be seen, the plastic insert 67 stops about one quarter to one eighth of an inch short of the outer edge 55 , in this case in order to provide increased flexibility but only at an abbreviated end width of the vertical length of material 41 .
[0042] Referring to FIG. 4, a side view corresponding to the plan view of FIG. 3 is seen and illustrates further details of the foregoing description. Again, the periodically occurring sock-like structures 43 can be more numerous or less numerous covering every louver 37 or every other louver 37 or every third louver 37 , or every fourth louver 37 , or as is shown, every fifth louver 37 . A clearer view of the strip of plastic 67 is seen as creating a very low side profile. Both methods shown in FIGS. 2-4 enable advantageous pivoting of the vertical length of material 41 through the periodically occurring sock-like structures 43 .
[0043] Referring to FIG. 5, an alternate attachment and pivoting structure is shown from the same side viewpoint as FIG. 4, but which uses a vertical path of attachment clip 81 which attaches directly to the top of the louvers 37 . The clip is preferably of resilient plastic and has a base member 83 and an upper member 85 opposing the base member 83 and forming a pinching structure for pinching engagement of one upper (or lower) main, longer or elongate edge of the louver 37 .
[0044] As is also shown, a stitch 87 has been used to sew the attachment clip 81 directly to the rear layer 71 . The attachment clip 81 has a thin profile and provides pivoting again very near the elongate edge of the louver 37 .
[0045] Referring to FIG. 6, a further embodiment of an attachment clip is seen as an end clip 91 . End clip 91 attaches to the end surface of the louver 37 and has both a thin profile and a narrow profile. The thin profile brings the vertical length of material 41 closer to the louvers 37 . The narrow profile insures that the width of the end of the louver 37 occupied will be so abbreviated that there will be no interference with the louver to louver contact on closure.
[0046] This is illustrated in FIG. 6 where the louver 37 to louver 37 contact on closure is seen. The clip 91 has an under-louver base 93 which is preferably sewn with a stitch 95 near an edge of the louver 37 . From the under-louver base 93 , an opposing member 97 opposes the under-louver base 93 to form a louver 37 engaging clip structure. Thus the advantages of a near louver 37 edge pivot is seen, but with the added advantages of end attachment, no elongate edge interference in one closure direction, and a thin profile.
[0047] Referring to FIG. 7, a top view illustrates a section taken through the upwardly extending (with respect to FIG. 6) portion which is stitched with stitch 95 to the rear layer 71 . The stitch 95 may occur just across from or even beyond the upper (as shown in FIG. 6) elongate edge of the louver 37 .
[0048] The invention has been described in terms of a user selectable and install-able horizontal blind side edge addition. However, the materials, configuration and technique of the present invention may be applied to any movable structure for which blocking extension is desired and especially a decorative extension having the ability to provide and extension of structural support. It especially relates to any structure which enables structural support to be extended based upon user preference as well as upon selection of materials and addition of user adjustable structural support extensions.
[0049] Although the invention has been derived with reference to particular illustrative embodiments thereof, many changes and modifications of the invention may become apparent to those skilled in the art without departing from the spirit and scope of the invention. Therefore, included within the patent warranted hereon are all such changes and modifications as may reasonably and properly be included within the scope of this contribution to the art.
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A blind extension system with removable soft side blinders or light blocking structures provides an organizational system which can be used to reduce light due to improper sized blinds without damaging the blinds or the window frame itself. In one embodiment, a sock-like structure is used to attach lengths of decorative materials at the outer ends of horizontal blinds. The sock-like structures are provided periodically along the vertical length of a projecting soft, decorative material. A series of extension pins can be used to assist the horizontal extension of the soft decorative material sufficient to reach the sides of the window opening space. Alternative methods of attachment are shown including a first embodiment of a clip attachable with vertical movement onto the elongate edge of a louver, and a second embodiment of a clip which is attachable with horizontal movement directly onto the end edge of the louver.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. Pat. Appl. Ser. No. 09/096,877, filed on Jun. 12, 1998, now U.S. Pat. No. 6,243,608 the specification of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to wireless communication systems for devices implanted in the body, and more particularly to optical communication between an implanted device and a device external to the body.
2. Description of the Related Art
Implantable devices have become a standard method of treating various medical conditions, many of which relate to the heart. Examples of devices which are routinely implanted include pacemakers, defibrillators, and nerve stimulators. These devices and others which have not yet become routine (such as implanted personal identification chips) are being provided with large memories for storing vast amounts of data. In the case of medical devices, this data may include physiological data such as the electrogram (electrical waveform at the electrodes), instantaneous heart rate, blood pressure, volume pumped, body temperature, etc., and configuration data such as mode of operation, amplifier sensitivity, filter bandwidth, and error messages. Often the device stores data that has been collected over a period of hours or days. This data is periodically retrieved by a doctor to monitor the patients condition and to monitor the device's status. In response, the doctor might re-program the device for a different mode of operation, sensitivity setting, etc.
A method is needed to retrieve this data rapidly. The retrieval needs to be rapid so as to minimize the inconvenience to the patient who will usually have to remain in the doctors office for the data retrieval process. To download four megabytes of medical device data, for example, at 20 Kbit/s would take nearly a half-hour—an undesirably long time for both the patient and medical professional or technician.
One method for data retrieval is the use of electromagnetic coupling between a pair of coils. One coil is excited to induce a current in the other. Modulation of the excitation signal can be detected in the induced current, and so communication is achieved The problem with this is bandwidth. The coils each have a self-inductance which acts to attenuate high frequency signals, so that the bandwidth of communications is limited.
Another method for data retrieval is to provide a direct electrical connection. A wire connected to the implanted device is passed directly through the skin and coupled to the external device. Inherent with this technique is increased discomfort and increased risk of infection.
Thus, another method is needed to transfer a large amount of data quickly from the implanted device to the external device with minimal discomfort.
SUMMARY OF THE INVENTION
Accordingly, there is provided herein a system for communicating between an implantable device and an external device. In one embodiment, the system includes an implantable device having a large memory and an external unit which downloads information from the memory for analysis and display. The implantable device includes a light-emitting diode (LED) and a modulator for driving the LED. The LED emits a modulated light signal representing the data that is stored in memory. One light frequency range which may be used is 4.3×10 14 -5.0×10 14 Hz, as body tissue exhibits good transmission in this range. The external device includes a photo-multiplier tube (PMT) for detecting and amplifying the modulated light signal, and a demodulator for equalizing and demodulating the detection signal produced by the PMT in response to modulated light.
These components will support a high bandwidth optical channel capable of carrying as much as 500 Mbit/s or more, and thereby provide for a substantially reduced data retrieval time. The implantable device may further include a receiver coil which has currents induced in response to a communication signal from the external device. A power converter may be coupled to the receiver coil to convert the induced currents into energy for powering the LED.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings in which:
FIG. 1 shows an implantable medical device having optical telemetry, implanted in an environment within which a high-bandwidth channel would be desirably employed;
FIG. 2 is a block diagram of an implantable pacemaker/defibrillator;
FIG. 3 is a schematic diagram illustrating communications between an implantable device and an external device;
FIG. 4 is a block diagram of portions of an external device;
FIG. 5 is a block diagram of a telemetry module which supports an optical communications link;
FIG. 6 shows an exemplary configuration of the system; and
FIG. 7 shows a second exemplary configuration of the system.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of examples in the drawings and will herein be described in detail It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The following description illustrates the principles of the invention with respect to an implantable pacemaker (“pacer”) and an external device (“programmer”). The invention, however, is directed to an improved telemetry link between any implantable device and any external device configurable to download information from the implantable device. Thus, the invention applies to implantable cardioverter/defibrillators (ICD's), nerve stimulators, drug delivery devices, or any other implantable device configured to transmit data to an external device.
Turning now to the figures, FIG. 1 shows a human torso 102 having a heart 104 and an implanted pacer 106 Also shown is a wand 108 which is an extensible portion of an external programmer 110 . Wand 108 is placed on an exterior surface of torso 102 near to the pacer 106 . In the embodiment shown, pacer 106 is a pacemaker coupled to heart 104 to assist in regulating its operation. In any case, pacer 106 includes a memory for storing data for later retrieval. In the case of a pacemaker, the data may represent measured physiological signals such as cardiac voltages (EKG signals), blood temperatures, oxygen levels, sugar levels, etc.
Illustratively, programmer 110 is a programmer/analyzer for use by a physician. The programmer/analyzer operates to download information stored in pacer 106 by transmitting signals which place the pacer in a mode for downloading, and thereafter detecting signals sent by the device. Then, under control of the physician or other medical professional, the programmer/analyzer operates to analyze and display the information in a format which allows the physician to diagnose any problems. After performing an analysis, the physician may instruct the programmer/analyzer to adjust operating parameters of pacer 106 . If this is the case, the programmer/analyzer provides new operating parameters to pacer 106 .
FIG. 2 is a block diagram of an exemplary pacer 106 . Pacer 106 has a power supply 202 coupled to a microprocessor 204 . Power supply 202 provides support to all the devices shown in FIG. 2 through connections not shown. Microprocessor 204 is coupled to a memory 206 , a first interval timer 208 , and a second interval timer 210 via an I/O (input/output) bus 211 . Microprocessor 204 is also coupled to control an atrium sensor/stimulator 212 and a ventricle sensor/stimulator 214 , each of which may be coupled to the heart by flexible leads. Finally, microprocessor 204 is coupled to a telemetry module 218 to communicate with programmer 106 .
Microprocessor 204 preferably is programmable and operates according to a program stored in a nonvolatile memory. The program often is parameterized—i.e. one or more of the operations the microprocessor performs is alterable by setting a parameter. For example, the microprocessor may be programmed to periodically trigger atrium stimulator 212 . One of the parameters for this operation might be a value specifying the rate at which the stimulator is triggered. The parameters may be provided to microprocessor 204 via telemetry module 218 and stored in memory 206 .
Pacer 106 in FIG. 2 uses first interval timer 208 to determine the delay between trigger signals applied to atrium stimulator 212 and ventricle stimulator 214 . Further, second interval timer 210 measures the time since the last heartbeat sensed by the atrium sensor/stimulator 212 or ventricle sensor/stimulator 214 . When either timer elapses, the elapsed timer asserts an interrupt to microprocessor 204 to notify microprocessor 204 that the set amount of time has passed. Microprocessor 204 determines the source of the interrupt and takes the appropriate action. For example, if a maximum time has elapsed since the last heartbeat, microprocessor 204 might trigger atrium sensor/stimulator 212 .
Microprocessor 204 preferably also monitors one or more physiological signals. For example, microprocessor 204 may detect cardiac voltage signals via atrium sensor 212 and/or ventricle sensor 214 . Blood pressure, body temperature, and adaptive configuration data may also be monitored. These signals preferably are logged in memory 206 for later retrieval by programmer 110 . Memory 206 preferably is large enough to store a variety of physiological signals that are monitored over a period of several days. This amount of data may comprise several megabytes of data. Memory 206 preferably is implemented as dynamic random access memory (DRAM) or other suitable memory type.
Atrium sensor/stimulator 212 is an interface circuit between microprocessor 204 and a heart lead coupled to an atrium of the heart. Similarly, ventricle sensor/stimulator 214 is an interface circuit between microprocessor 204 and a heart lead tat is coupled to a ventricle of the heart. These interface circuits are configured to apply a customized electrical energy pulse to the respective region of the heart in response to a trigger signal from microprocessor 204 . Interface circuits 212 , 214 may also be configured to measure cardiac voltage signals from the electrodes so that microprocessor 204 can monitor the performance of the heart. The microprocessor 204 may store the cardiac waveforms (or “electrograms”) in memory for subsequent retrieval by a medical technician.
Telemetry module 218 may be designed to be activated by programmer 110 when wand 108 enters into proximity with pacer 106 . This event causes telemetry module 218 to be activated and to notify microprocessor 204 of an incoming communication. Microprocessor 204 monitors the incoming communication from programmer 110 and stores programming data or parameters, and responds to any requests. For example, one request might be to transfer the data from memory 206 to programmer 110 . In this case, microprocessor 204 provides the data from memory 206 to telemetry module 218 for transferal to programmer 110 .
FIG. 3 is a schematic diagram of the communications channels employed by pacer 106 and programmer 110 . A wand transmitter 302 provides a communication signal which is transmitted to a pacer receiver 304 through body tissues 306 . This communication signal, for example, might represent a programmer request for the pacer 106 to transmit data. This technique using a pair of coils is well known to those of ordinary skill in the art. An example of this technique is illustrated in U.S. Pat. No. 5,314,453, which is hereby incorporated by reference as though completely set forth herein.
To provide a download of a substantial amount of data in as short a time as possible from pacer 106 to programmer 110 , a high bandwidth connection in the reverse direction (i.e. from the pacer to the programmer) is desired. This high-bandwidth connection comprises a pacer transmitter 308 which transmits a modulated light signal to a wand receiver 310 through body tissues 306 . It is contemplated that wand transmitter 302 and implant receiver 304 are coils that communicate via a shared inductive coupling. Thus one embodiment uses an inductive coupling communications link for programmer 110 to transmit data and commands to pacer 106 , and an optical communications link to transmit data and status information from pacer 106 to programmer 110 . Alternatively, an optical link could be used to communicate in both directions.
It is contemplated that implant transmitter 308 includes an LED that emits light in the infrared (<4.3×10 14 Hz), visible (4.3×10 14 -7.3×10 14 Hz) or ultraviolet (>7.3×10 14 Hz) frequency ranges, and that wand receiver 310 includes a light sensor sensitive to light emitted by implant transmitter 308 . The various frequencies (colors) of light experience differing amounts of attenuation by body tissues 306 . The light emitted by implant transmitter 308 preferably experiences relatively small losses while passing through body tissues 306 . Experiments have been done using a light frequency of 5.42×10 14 Hz (green light), but somewhat lower frequencies such as 4.3×10 14 -5.0×10 14 Hz may be preferred, and 4.5×10 14 -4.7×10 14 Hz may be more preferred.
FIG. 4 is a block diagram of portions of one embodiment of a programmer 110 . Programmer 110 includes a microprocessor 402 , a modulator 404 , a transmit coil 406 , a light sensor 408 , and a demodulator 410 . Microprocessor 402 accepts and responds to user input (via controls not shown) and initiates communications with pacer 106 . For example, if a user requests a download of data from pacer 106 to programmer 110 , microprocessor 402 formulates a command signal, and sends the signal to modulator 404 . Modulator 404 converts the command signal into a modulated signal for driving transmit coil 406 . The signal driving the transmit coil produces a changing magnetic field which induces a current in a receive coil in pacer 106 . Pacer 106 processes the induced current in a manner described further below. Pacer 106 can transmit signals to programmer 110 by modulating a light signal. The modulated light signal may be greatly attenuated by body tissues. When enabled, light sensor 408 detects and amplifies the modulated light signal to produce a detection signal. Demodulator 410 demodulates the detection signal and converts it into the data transmitted by the pacer 106 . Demodulator 410 then provides the data to microprocessor 402 for eventual analysis and display.
Because the optical signal may be greatly attenuated (i.e. reduced in intensity) by body tissue, light sensor 408 preferably is highly sensitive and must be protected from ambient light. This protection may be provided in the form of an enable signal which is asserted only when be ambient light is blocked, e.g. when the wand is pressed flat against the torso. In one implementation, the enable signal may be asserted when a mechanical switch is closed upon pressing the wand against the torso. In another implementation, the enable signal may be asserted when a phototransistor adjacent to the light sensor 408 detects that the light intensity has fallen below a predetermined threshold.
One light sensor which is contemplated for use in wand 108 is a PMT (photomultiplier tube) such as R5600-01 PMT from Hamamatsu Corporation. PMT's are well known and widely available, and are able to detect single photons while maintaining a low noise level. This light sensor is advantageously sensitive to light in the frequency range from 4.3×10 14 to 20.0×10 14 Hz.
In another embodiment, light sensor 408 comprises a photodiode which may be robust enough to withstand ambient light and sensitive enough to detect attenuated light emissions from the pacer. This right sensor advantageously does not require an enable signal and the means for generating the enable signal.
FIG. 5 shows a block diagram of an illustrative telemetry module 218 of pacer 106 . Telemetry module 218 comprises an implant receiver coil 502 , a current sensor 504 , a demodulator 506 , a power converter 508 , a modulator 510 , and a light source 512 . A communication signal from wand 108 induces a current in coil 502 . Current sensor 504 detects the induced currents and produces an amplified detection signal representative of the communication signal sent by wand 108 . Demodulator 506 demodulates the communication signal to obtain the commands, data and/or parameters being sent by wand 108 . Microprocessor 204 processes the demodulated signal and determines an appropriate response. For example, if the transmitted data represents a download request, microprocessor 204 will initiate a download of the requested data stored in memory 206 , i.e. the microprocessor will cause data from memory 206 to be supplied to modulator 510 .
Referring still to FIG. 5, power converter 508 is coupled to implant receiver coil 502 to convert the induced currents into stored energy. As modulator 510 converts the data from microprocessor 204 into a modulated signal, it uses stored energy from power converter 508 to drive right source 512 in accordance with the modulated signal. Light source 512 may be an LED (light emitting diode) which emits light with a frequency suitable to pass through the body to the wand. Preferably the LED emits light with a frequency between 4.3×10 14 and 5.0×10 14 Hz, but other frequencies may be used as well. The light emitted is modulated in accordance with the modulated signal from modulator 510 . The modulated light may be detected and demodulated by wand 108 to recover the data stored in memory 206 as described above.
In one embodiment, power converter 508 employs a full-wave rectifier to convert the currents induced in coil 502 into a unidirectional charging current. The power converter also includes a bank of switching capacitors to be charged by the unidirectional charging current and thereafter step up the voltage to charge an energy storage capacitor. Current sensor 504 may be configured to detect the induced currents by sensing the voltage drop across one or more diodes in the full-wave rectifier.
In another embodiment, the LED is powered by power supply 202 of pacer 106 . Power converter 508 may be included for the purpose of recharging power supply 202 .
Various modulation schemes may be employed for the communication channels. The wand-to-implant communications channel may use pulse-width modulation (PWM), frequency-shift keying (FSK), or other suitable techniques. The implant-to-wand communications channel may also employ any suitable techniques such as pulsecode modulation (PCM) and simplex signaling. Both channels may employ channel coding for error detection, timing, and/or constraining power usage. Such channel coding techniques are known to those of ordinary skill in the art. It is noted that light sensor 408 may be configured to generate a detection signal which is proportional to the light intensity, and that consequently both digital and analog amplitude modulation signaling is also supported by the contemplated configuration.
FIG. 6 shows an exemplary configuration of wand 108 and pacer 106 shown in cross-section. Wand 108 is pressed against body tissues 306 proximate to the location of pacer 106 and in active communication with pacer 106 . Pacer 106 comprises power supply 202 , electronics module 602 , implant receiver coil 502 , light source 512 , and header 604 . Electronics module 602 includes microprocessor 204 , memory 206 , timers 208 , 210 , sensor/stimulators 212 , 214 , current sensor 504 , demodulator 506 , power converter 508 , and modulator 510 . Electronics module 602 and the components it contains may be constructed as a circuit board Header 604 is a transparent portion of pacer 106 which may include electrical connectors for the heart leads (FIG. 2) and light source 512 . Alternatively, right source 512 may be located in electronics module 602 . As electronics module 602 is normally placed in an opaque portion of pacer 106 , light source 512 is configured to emit light in the direction of the transparent header 604 . A mirror may be located within header 604 to redirect the modulated light toward wand 108 . This mirror may be concave to reduce dispersion of the modulated right signal. For either placement of light source 512 , header 604 may also have a portion of its exterior surface configured as a lens to reduce the dispersion of the modulated light signal. Some of these configurations are described in U.S. Pat. No. 5,556,421, which is hereby incorporated by reference in its entirety.
Wand 108 illustratively comprises modulator 404 , transmit coil 406 , light sensor 408 , demodulator 410 , ambient light detector 606 , reflective surface 608 , interface module 610 , and user interface 612 In one embodiment, light sensor 408 is placed near a convergence point of light rays that reflect from reflective surface 608 . Reflective surface 608 is designed to increase the light-gathering ability of wand 108 . Ambient light detector 606 is positioned within the concavity defined by reflective surface 608 and/or adjacent to light sensor 408 . Ambient light detector 606 provides the enable signal discussed in FIG. 4 when a sensitive light sensor 408 is employed. Ambient light detector 606 may be a photo-transistor or photodiode or any other photosensitive device robust enough to withstand anticipated light levels when wand 108 is separated from torso 102 . Interface module 610 may be a line driver/buffer for communications with the rest of programmer 110 , and may further comprise a power supply or converter for powering the electronics of wand 108 . User interface 612 may comprise buttons for user input (e.g. begin download) and lights for user feedback regarding the status of the communications link with the implanted device. Directional lights may also be provided to aid the user in positioning the wand to achieve the highest communications signal-to-noise ratio and the maximum communications rate for downloading information from the memory of the pacer.
FIG. 7 shows a second exemplary configuration of wand 108 , in which mechanical switches 702 rather than ambient light detector 606 are used to provide the enable signal of FIG. 4 . Mechanical switches 702 are pressure sensitive and positioned on the face of the wand so that when the wand is correctly pressed against the torso, the normally open switches are all closed. Variations on this may be employed so long as the enable signal is only asserted when the light sensor 408 is shielded from excessive light levels.
Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.
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A system is provided for optically communicating with an implantable device. In one embodiment, the system includes an implantable device having a large memory and an external unit which downloads information from the memory for analysis and display. The implantable device includes a light-emitting diode (LED) and a modulator for driving the LED. Although various frequencies can be used, frequencies which experience relatively little attenuation through body tissue are presently preferred. The external device includes a photo-multiplier tube (PMT) and a demodulator for equalizing and demodulating the detection signal produced by the PMT in response to detected light. A high bandwidth channel (perhaps as much as 500 Mbits/sec) is created by these components. This channel advantageously allows for a substantially reduced download time.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an end-of-scan reporting system. More particularly, the present invention relates to a system that reports the completion of a scanning session to a user through computer peripheral components.
2. Description of the Related Art
Due to progress in multi-media technologies, advanced image processing techniques have lead to the development of many peripheral image processors. A scanner is one of the imagining processors that have recently become an indispensable piece of equipment. Developed from earlier versions of the black-and-white palm top scanner, full color high-resolution scanners capable of producing fine real images are widespread nowadays.
Currently, most scanners in the market have a user interface capable of reporting to the user as soon as a scanning session is complete so that the user can plan the next task. In general, when a picture or document is being scanned, a user must watch for the end of the scanning session. As soon as a scanning session is complete, a scan completion icon appears on a computer screen through the user interface. Next, the user has to replace the page with a new one and then watch the computer screen again to find out when the scanning session ends. This type of operation is likely to prevent the user from performing other tasks. Alteratively, if the user spends time doing other tasks, the user may miss the end of session notice displayed on the computer screen and leave the scanner in an idle state. Hence, the current method of operating the scanner is quite inconvenient.
Some higher-grade scanners now include an automatic document feeder (ADF) so that the user can put a number of pages into a tray and extend each scanning session. At the end of the multi-pager scanning session, an end-of-scanning icon is similarly displayed on the computer screen through the user interface so that the user is notified. However, if the user is occupied with some other tasks at that time, the end-of-scan notice may be missed. Hence, the scanner will still be left in an idle state for quite some time.
SUMMARY OF THE INVENTION
The invention provides a method of reporting the end of a scanning session to a user. The method includes determining the types of peripheral devices needed to report to the user at the end of a scanning session. When the current scanning task is complete, the selected peripheral devices automatically informs the user of the end of the scanning session.
This invention also provides a method of reporting the end of a scanning session to a user. The method includes using a computer to detect all the available peripheral devices for reporting the end of a scanning session. The most suitable peripheral device or devices for reporting end of scanning session to the user are then chosen. After the current scanning session is complete, the end of session notice is signaled to the user via the selected peripheral devices. Next, the computer decides if there is any further scanning task to perform. If there is any other scanning task to perform, the most suitable peripheral device or devices for reporting the end of a scanning session to the user is again chosen. If no more tasks are pending, the reporting system halts.
Accordingly, the present invention is to provide a reporting system capable of notifying a user of the end of a scanning session through computer peripheral devices. In addition, the invention is to provide a method of reporting the end of a scanning session to a user in real time so that subsequent scanning operations can proceed immediately with no delays. Hence, idle item of the scanner is greatly reduced.
It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWING
The accompanying drawing is included to provide a further understanding of the invention, and is incorporated in and constitutes a part of this specification. The drawing illustrates embodiments of the invention and, together with the description, serves to explain the principles of the invention. In the drawing,
FIG. 1 is a flow chart showing the steps carried out in an end-of-scanning reporting system according to this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawing. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.
The end-of-scan reporting system in this invention is achieved by appending application programs to the user interface program of a scanner. When the user interface picks up an end-of-scan signal from the scanner, an end-of-scan icon will be displayed on the computer screen as before. However, the system is also capable of reporting the end of scanning session to a user through a user-defined peripheral device or devices so that the user can continue or terminate the scanning task immediately. Hence, machine idle time is reduced.
The peripheral devices for reporting the end of a scanning session to a user can be a sound card capable of emitting a sound, the loudspeaker inside a computer system, a network card inside a computer system capable of sending electronic mail to a user's mailbox, or a data recorder capable of dialing a user's telephone number, pager number or mobile telephone number.
FIG. 1 is a flow chart showing the steps carried out in an end-of-scanning reporting system according to this invention. In step 10 , before a user begins some scanning task, the computer makes a quick search for all the peripheral devices available for reporting end-of-scan to the user. The purpose of making such a search is to ensure that the desired reporting device or devices are present. In step 20 , a suitable peripheral device or devices for reporting the end of scanning session are selected. In general, the most convenient method of reporting is chosen. For example, sound may be broadcast from a sound card or from the on-board computer loudspeaker. Alternatively, the end of scanning notice may be e-mailed to a pre-specified user mailbox. In some cases, a digital data recorder may be used to dial a telephone number, a mobile telephone number or a pager number to notify the user. The scanning task is conducted in step 30 . The scanning task includes scanning a single page or a number of pages using an automatic paper feeder. After the scanning operation, the pre-selected peripheral device or devices are activated to report the end of a scanning session in step 40 . After reporting the end of a scanning session, the system must make a conditioned return. In step 50 , the system detects whether there is a scanning task waiting. If there is a scanning task pending, the system jumps back to step 20 where the available peripheral devices are again detected. Otherwise, if no scanning task is waiting, the system terminates.
In summary, one major advantage of this invention is the utilization of existing peripheral device to report the end of a scanning session to a user. Through the notification made by the peripheral devices, the user is able to activate the next scanning task quickly so that idle time of the scanner is greatly reduced.
It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents.
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A reporting system capable of reporting the end of a scanning session to a user through existing computer peripheral devices is proposed. By reporting at the end of a scanning session, the user can proceed with subsequent scanning operations with no delay. Hence, idle time of the scanner is greatly reduced.
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[0001] This application is a continuation of Ser. No. 11/041,814, filed Jan. 21, 2005, which is to be abandoned in favor of this application, after this application is filed, which is a divisional of Ser. No. 10/261,050, filed Sep. 30, 2002, now Pat. No. 6,869,639.
DISCLOSURE
[0002] This invention relates generally to a method for operating and constructing what is known as a metering size press, film press and/or film coater, and particularly a film coater which uses a doctor to smooth the applied film of coating on the paper web. More particularly the coater and method of the present invention produce a smoother, more uniformly coated paper by reducing or eliminating film split, orange peel and/or fiber rise defects.
BACKGROUND OF THE INVENTION
[0003] In a film coater, an applicator applies a film of coating onto a roll surface and the roll surface in turn, transfers the coating onto the surface or side of a moving paper web. Generally, the film coater rolls can be paired to form a nip through which the web runs and the coating is transferred.
[0004] While various forms of applicators have been used with film coaters, one version uses a form of short dwell time coater or applicator (SDTA) to apply the coating onto the web. Generally, placement of these applicators is in the III and IV quadrants (with reference to the conventional four quadrant I, II, III and IV of a 360° circle) in order to obtain proper drainage of the coating overflow at the front gap of such type coaters.
[0005] Normally, in film coaters, the web generally runs downward through the nip formed between the pair of rolls. However, it has come to be recognized that there are disadvantages to such arrangement. One disadvantage is that all the equipment required is crowded into the lower III and IV quadrants. Also, as the roll surfaces pass by the nip and separate from the web, a film split phenomenon or action occurs, producing another disadvantage. During such film split action, small droplets or mist of coating are formed between the separating roll surface and web. Such small droplets or misting tend to fall back onto the coated web, moving downwardly as it leaves the coating nip, producing non-uniform coating defects on the just coated web.
[0006] The excess coating droplets or mist falling onto the downwardly moving web, could still produce coating imperfections even if subsequently doctored, as starting with uneven coating cannot always be overcome to form uniformly coated paper. Film split phenomenon (as the paper is locally wetter) also raises surface fibers which contributes to surface roughness on the coated web. Also, film split phenomenon causes a local uneven pattern on the coated sheet surface referred to as “orange peel pattern”. Further, the higher the operating speed, the greater the problem “film split” and “film split” droplets or misting become. Prior art film coaters have had operating speeds for these reasons, producing smooth paper at about 4500 ft./minute (1370 meters/minute) or less on the lighter grade (28 to 34 lbs.) papers produced.
SUMMARY OF THE INVENTION
[0007] The method and film coater of the present invention minimize potential imperfections in the formed coated surface. To this end, the film coater is preferably constructed and operated to have the web run upwardly (and not downwardly) through the film coater nip to substantially eliminate the effect of “film split” droplets or “misting” and minimize other “film split” effects, such as orange peel and fiber rise. With such arrangement, any excess film coating droplets or mist will tend to fall back toward the film coating rolls and not, to any significant degree, onto the newly coated web itself.
[0008] In the present invention, smoothing devices are placed after the film coater application nip to carry out a smoothing operation to level any incipient orange peel pattern as well as to lay down the raised surface fibers to improve surface smoothness and final paper quality.
[0009] The film coater of the present invention is constructed to provide novel subsequent smoothing of the coated web after it leaves the film coating nip to eliminate any residual “film split” appearance. This smoothing can be provided by a rod (grooved or not), blade (flexible or bent type) or similar doctoring device. Where the smoothing takes place some distance from the film coater nip, or to enhance smoothing of the coated paper after it leaves the film coating nip, the coated web may be treated by showers, such as a water mist or steam shower, before and/or after smoothing. Another alternative would be to carry out the smoothing operation in a humid or steam environment, as might be provided by a humid or steam enclosure.
[0010] While a blade could be used, preferably the smoothing operation is carried out by a roll type smoothing doctor located downstream, and preferably above the coating nip. During smoothing, it is not anticipated or intended to remove coating, but perhaps some coating may be removed without operating outside of the scope of the present invention.
[0011] With this construction and operation, the web moves upwardly rather than downwardly, through the film coater nip wherein generally the desired coat weight of coating is applied to one or both sides of the web. The coated web then continues to travel upwardly past the showers which apply a steam or water mist to the coating, prior to and/or after moving past the smoothing doctor. Where both sides of the web are simultaneously coated, the smoothing doctors may be staggered to smooth one side at a time. Further, the web can be dried, or if need be, turned, such as by an air turn, to carry out remainder of the paper making/coating process, such as drying, subsequent coating and, typically, eventual winding of the web into a roll. As noted above, alternatively, instead of steam, a water mist shower might be utilized, the function of either shower being to keep the coating levelable to enhance smoothing and/or provide a smooth surface on the paper web. Alternatively, the above mentioned humidity or steam enclosure could be provided downstream of the nip and the smoothing take place therein. It is believed that with the present invention, coating operating speeds can be considerably increased to speeds of up to 6500 ft/minute (1981 meters/minute) or beyond, with good control of orange peel, fiber rise and surface smoothness.
OBJECTS OF THE INVENTION
[0012] Accordingly, it is an object of the present invention to provide a method and apparatus for substantially minimizing, if not altogether eliminating the effect of “film split” on the coated web surface of a film coater.
[0013] Still another object of the present invention is to provide a method and apparatus for substantially minimizing, if not altogether eliminating the effect of “film split” droplets and/or “misting.”
[0014] It is another object of the present invention to provide a method of operating a film coater to provide a smooth coating at high web and coating speeds.
[0015] It is still another object of the present invention to provide a film coater for operating at high speeds to provide a smooth surface.
[0016] Yet another object of the present invention is to provide a method of operating a film coater with an upwardly running web.
[0017] Yet another object of the present invention is to provide a film coater for an upwardly running web.
[0018] A still further object of the present invention is to provide a method of operating a film coater utilizing at least one smoothing doctor.
[0019] Yet a further object of the present invention is to provide a film coater incorporating at least one smoothing doctor.
[0020] A further object of the present invention is to provide a method of operating a film coater utilizing steam and/or water mist showers.
[0021] Another object of the present invention is to provide a film coater incorporating steam and/or water mist showers.
[0022] Still a further object of the present invention is to provide a method and a film coater with an upward running web, with steam showers above the film coater nip and with at least one smoothing doctor above the film coater nip.
[0023] Yet another object of the present invention is to provide showers before and/or after the at least one smoothing doctor, which smoothing doctor may comprise a smoothing roll.
[0024] Still another object of the present invention is to provide a method and a film coater using a humid atmosphere or steam enclosure in which to carry out the smoothing operation.
[0025] These and other objects of the method and film coater of the present invention will become apparent from the following written description and accompanying drawing.
DESCRIPTION OF THE DRAWING
[0026] FIG. 1 is a schematic elevational view of the components and method of the present invention, illustrating a film coater with an uprunning paper web, utilizing steam and/or water mist showers below smoothing rolls to provide a smooth coated paper surface at high speeds.
[0027] FIG. 2 is a schematic elevational view of the components and method of the present invention, illustrating a film coater with an uprunning paper web, utilizing steam and/or water mist showers above smoothing rolls to provide a smooth coated paper surface at high speeds, with another set of optional showers shown below the smoothing rolls in phantom or dashed lines.
[0028] FIG. 3 is a schematic elevational view of the components of the present invention illustrating a film coater with a downrunning paper web, utilizing an alternative or optional steam or humid enclosure over the smoothing rolls.
DESCRIPTION OF THE INVENTION
[0029] Referring now to the drawings in greater detail, there is illustrated therein the method or process and apparatus generally identified by the reference numeral 8 , of the present invention.
[0030] The apparatus 8 is seen to comprise a film coater 10 including at least one roll 12 onto a roll surface 14 of which at least one coating applicator 16 applies a film of coating, which is in turn transferred onto at least one side 18 of a moving paper web 20 . As shown in FIG. 1 , a pair of rolls 12 are generally paired to form a nip 22 therebetween through which the web 20 moves, at which point the film of coating on the two roll surfaces 14 is transferred onto the two sides 18 of the web 20 adjacent the rolls 12 . The coated web is designated as 21 .
[0031] Typically, if the web 20 is moved through the nip 22 in a downward direction, there are the inherent disadvantages to producing a smooth coated paper surface, as is discussed above. In the instant apparatus 8 , it is desired to move the web 20 upwardly through the nip 22 , and not downwardly, to eliminate the disadvantages associated with downward motion of the web 20 .
[0032] As shown, the web 20 moves upwardly past a lead or guide roll 30 and into and through the nip 22 , where the film of coating applied to the outer surface 14 of each roll 12 by a corresponding coating applicator 16 is transferred to a corresponding side 18 of the web 20 . It is understood only one side or both sides of the web could be coated. While a “film split” action may still occur, the resulting film droplets fall back onto the roll surfaces 14 A returning to the applicators 16 , and the droplets do not fall onto the finished coated sheet or web 21 , as they did in prior art downwardly running film coaters. Generally in the present invention, the application onto and doctoring of the new coating on the roll surfaces renders any film split droplets harmless as the roll surfaces are rewetted with fresh coating by applicators 16 prior to transferring the fresh coating again to the web 20 at nip 22 .
[0033] The web 20 then proceeds upwardly past the nip 22 , and engages at least one smoothing doctor 32 along and against a side 18 thereof which has a film of coating 21 thereon, the smoothing doctor 32 in this instance being a doctor roll which levels and smoothes the coating film. The doctor 32 is carried on a supporting beam 34 across the web to support structures on either side of the web. Typically for a film coater coating both sides of the web, one smoothing doctor 32 is provided to engage each side 18 of the web 20 , in staggered fashion, as illustrated, so that one side 18 of the web may be smoothed first and the other side 18 is smoothed next.
[0034] To aid in smoothing, the apparatus 8 is proposed to include at least one shower 40 adjacent each smoothing doctor 32 , mounted in a manner to be below or upstream of the smoothing doctor 32 , as shown in FIG. 1 , or to be above or downstream of the smoothing doctor 32 , as shown in FIG. 2 . In another alternative or optional embodiment, as illustrated in FIG. 2 , optional showers 40 can also be incorporated to position each smoothing doctor 32 between a pair of upper and lower showers 40 . The upstream shower assists smoothing as it keeps the coating levelable before doctoring. The downstream shower assists smoothing as it prolongs the flowability of the coating after doctoring. Of course, one or the other or both locations, upstream or downstream, could be used. Alternatively, coating rheology may be such that showers are not deemed necessary before or after doctoring.
[0035] The shower after the doctoring roll 32 helps minimize any “film split” effect caused by the coated sheet leaving the smoothing roll 32 . Similarly, a shower before the smoothing roll helps minimize “film split” effect when the coated web leaves the film coater nip and to enhance the smoothing action of the doctors. Preferably, the smoothing rolls do not and are not intended to remove a significant, if any, amount of coating from the web, but are intended primarily to just smooth the coated web leaving the film coater. Of course, the removal of a small amount of coating is still within the teaching of the invention, and would not avoid infringement. The smoothing action would help level any fibers that were raised by the film splitting action back down to the coating surface.
[0036] The smoothing doctor or roll 32 would be of a length to extend across the web being coated, and of say ⅜ inch to 1½ or 2 inches in diameter. If a larger diameter smoothing rod or roll is used, say of ½ of an inch or more, if desired, it could be of “sweated” construction, that is, having a tubular construction and/or with a cooling passage, say for chilled water running through it. It is believed that web tension would provide sufficient force against the smoothing doctor to accomplish the desired smoothing action.
[0037] Each shower 40 includes a head 42 directed toward the side 18 of the web 20 moving therepast, with the head 42 delivering steam and/or a water mist against the web 20 , to maintain smoothability of the film of coating by keeping same from drying too soon. Thus, the showers 40 are provided to maintain the film of coating moist for enhanced smoothing action.
[0038] Once leveling and smoothing is accomplished, then drying of the film of coating may be achieved through use of conventional dryers (not shown) located downstream or after, say, an air turn 50 .
[0039] Moving of the web 20 upwardly through the apparatus 10 , while maintaining the coating applicators 16 in the III or IV quadrant of each roll 12 will not only substantially minimize, if not altogether eliminate, “film split” and “film split” droplets or misting from adversely effecting web surface quality, but will also allow for faster processing and increased paper production speed and capacity.
[0040] For ease of threading the webbing through the coater, the steam showers could be made retractable from the web during threading. One way to accomplish this would be to mount the showers with the doctors so that when the smoothing rolls or doctors are retracted, the showers will move with them to permit easy thread of the web in the film coater.
[0041] While it is desirable to have an uprunning web, the use of the smoothing doctor and smoothing action after the web leaves the nip would be advantageous in film coater with other type web runs, be it downward, horizontal or at some angle.
[0042] The film coater and method of the present invention would work with various type applicators applying coating to the roll surface such as SDTA, jet or fountain applicator with blade or rod metering, on curtain type applicators.
[0043] While a smoothing doctor in the form of a rod say from 0.375 inches to 1.500 inches would be used, a blade would also be used, say of from 0.015-0.250 inches. The thicker blade could be hollow and chilled with cold water or held in a chiller holder. A thin blade could also be held by a chilled holder.
[0044] Referring to FIG. 2 , the alternative arrangement of showers are shown. And if needed, the shower locations of either FIG. 1 or FIG. 2 could be used, or the shower locations of both FIGS. 2 and 3 could be used.
[0045] Another alternative would be to conduct the smoothing operation in a humid environment, such as a steam or water vapor filled enclosure. The humidity or steam would help keep the coating pliable for smoothing and help prevent any “build up” of coating on the smoothing apparatus itself. It should be understood that misting or steam showers could also be provided within the enclosure or the source of the humidity for the smoothing operation. Alternatively, the humidity or steam enclosure could be used without any other showers.
[0046] Referring to FIG. 3 , a film coater, but this time with a downrunning web is shown. For convenience, the portions of FIG. 3 similar to those shown in FIG. 1 are given the same reference numeral, except the reference numeral is primed, that is, the roll 12 of FIG. 1 would be shown as 12 ′ in FIG. 3 . The principal differs in FIG. 3 are that the web 20 ′ run is downrunning and the smoothing doctors 32 ′ are now located in an enclosure 100 which would contain humidity (water vapor or steam) 101 . The enclosure has an entrance 102 and an exit 104 for the web 20 ′. If desired, showers of either type (steam or water) could be located in the enclosure to provide the humidity or the water vapor or steam could come from one or more outlets 106 . The operation of the 8 ′ apparatus of FIG. 3 is generally similar to apparatus 8 of FIG. 1 , except the advantage of collecting any misting coat onto the deporting roll surfaces, instead of the web, would not be enjoyed. However, the effects of the smoothing rolls or doctors 32 ′ and smoothing operation in providing a smoother paper, reducing fiber rise and orange peel would be present.
[0047] It will be understood by those skilled in the art, of course, that other treatments, such as subsequent coating, if desired, and ultimate winding into a roll, can be accommodated by both the apparatus 8 and method as described above.
[0048] Also, arrowheads are shown in the Figures of the drawings to indicate the general direction of web movement and roll rotation.
[0049] As used herein, the term “film coater” may also encompass “metering size press” or “film press”. As used herein, the term “uprunning web” is a web that travels upward from the film coater nip at an angle of 300 either side of vertical.
[0050] As described above, the apparatus 8 or 8 ′ and method of the present invention provide a number of advantages, some of which have been defined above and others of which are inherent in the invention. Also, modifications including equivalent structure and/or steps may be provided without departing from the teachings herein. Accordingly, the scope of the invention is only to be limited as necessitated by the accompanying claims, and that equivalent elements and steps to those recited therein would fall within the scope of those claims.
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An improved film coater which utilizes one or more coater or applicators to transfer coating to the outer surfaces of at least one more rolls, which in turn transfers the coating from the roll surface to one or more sides of the web for coating paper is disclosed. The coater or applicator includes a smoothing doctor on the web and downstream of the one or more rolls, and may also utilize humidity from one of steam showers or a humidity enclosure to assist smoothing. The web may run in any direction, but preferably runs upwardly from the roll toward the doctor to reduce “film split” droplets effect. The present invention also reduces the fiber rise and arrange peel pattern on the coated web, resulting in a smooth uniform coated paper.
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The present invention claims the benefit of Korean Patent Application No. 2003-16458 filed in Korea on Mar. 17, 2003, which is hereby incorporated by reference for all purposes as if fully set forth herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a liquid crystal display module, and more particularly to a liquid crystal display module that has a heat resistant structure.
2. Description of the Related Art
Generally, a liquid crystal display (LCD) includes a liquid crystal display module, driving circuitry for driving the liquid crystal display module, and a case.
The liquid crystal display module consists of a liquid crystal display panel having liquid crystal cells arranged in a matrix between two glass substrates, and a backlight unit for irradiating light onto the liquid crystal display panel. The liquid crystal display module is arranged with optical sheets for directing light vertically from the backlight unit toward the liquid crystal display panel.
In such liquid crystal display panel, the backlight unit and the optical sheets must be engaged with each other in an integral shape so as to prevent light loss, and protected from damage caused by an external impact. To this end, there are provided a case for the LCD enclosing the back light unit and the optical sheets including the edge of the liquid crystal display panel.
Referring to FIG. 1 , the conventional liquid crystal display module includes a main support 14 , a backlight unit and a liquid crystal display panel 6 disposed at the inside of the main support 14 , a guide panel 30 arranged on the main support 14 to support the liquid crystal display panel 6 and secure optical sheets 8 of the backlight unit, and a case top 2 for enclosing the edge of the liquid crystal display panel 6 and the side surface of the main support 14 .
The liquid crystal display panel 6 is comprised of an upper substrate 3 and a lower substrate 5 . A liquid crystal is injected between the upper substrate 3 and the lower substrate 5 , and the liquid crystal display panel 6 is provided with a spacer (not shown) for constantly keeping a gap between the upper substrate 3 and the lower substrate 5 . The upper substrate 3 of the liquid crystal display panel 6 is provided with a color filter, a common electrode and a black matrix, etc. Signal wiring such as data line and a gate line, etc. (not shown) is formed at the lower substrate 5 of the liquid crystal display panel 6 , and a thin film transistor (TFT) is formed at an intersection between the data line and the gate line. The TFT switches a data signal to be transmitted from the data line into the liquid crystal cell in response to a scanning pulse (i.e., a gate pulse) from the gate line. A pixel electrode is formed at a pixel area between the data line and the gate line. One side of the liquid crystal display panel 6 is provided with data and gate pad areas connected to the data lines and the gate lines, respectively. A data tape carrier package mounted with a data driver integrated circuit (not shown) for applying a data signal to the data lines is attached onto the data pad area. Further, a gate tape carrier package mounted with a gate driver integrated circuit (not shown) for applying a scanning pulse (i.e., a gate pulse) to the gate lines is attached onto the gate pad area.
An upper polarizing sheet 4 a is attached onto the upper substrate 3 of the liquid crystal display panel 6 while a lower polarizing sheet 4 b is attached onto of the rear side of the lower substrate 5 of the liquid crystal display panel 6 .
The main support 14 is the product of a mold, the inner sidewall surface of which is molded into a stepped coverage face. The inner bottom layer of the main support 14 is mounted with a backlight unit including a reflective sheet 12 , a light guide plate 10 , a plurality of optical sheets 8 and a lamp housing (not shown). The upper surface of the main support 14 is provided with a protrusion protruded perpendicularly.
The backlight unit includes a lamp 22 , a lamp housing (not shown) for enclosing the lamp, a light guide plate 10 for progressing a light inputted from the lamp 22 into the liquid crystal display panel 6 , a reflective sheet 12 arranged at the rear side of the light guide plate 10 , and a plurality of optical sheets 8 disposed on the light guide plate 10 .
Light generated from the lamp 22 is incident, via an incidence face of the light guide plate 10 , into the light guide plate 10 . The lamp housing reflects light from the lamp 22 into an incidence face of the light guide plate 10 .
The reflective sheet 12 reflects light incident thereto through the rear side of the light guide plate 10 into the light guide plate 10 , thereby reducing light loss. In other words, if light from the lamp 22 is incident to the light guide plate 10 , then light having progressed into the lower surface and the side surface of the light guide plate 10 is reflected by the reflective sheet 12 to thereby be redirected toward the front side thereof.
The plurality of optical sheets 8 vertically raise light outputted from the light guide plate 10 to thereby improve the light efficiency. To this end, diffusing sheets are provided for diffusing light outputted from the light guide plate 10 into the entire area, and two prism sheets for redirecting the angle of the light diffused by the diffusing sheets vertically with respect to the liquid crystal display panel 6 . Thus, light outputted from the light guide plate 10 is incident, via the diffusing sheets and then the plurality of optical sheets 8 , to the liquid crystal display panel 6 .
As shown in FIG. 2 to FIG. 4 , the optical sheets 8 are provided with ears 16 a , 16 b and 16 c extending into each side surface thereof, each of which is provided with a hole 18 . Each hole 18 of the ears 16 a , 16 b and 16 c is inserted into the protrusion 20 of the main support 14 . By such an assembly structure of the holes 18 and the protrusions 20 , the optical sheets 8 are secured to the main support 14 .
The guide panel 30 supports the liquid crystal display panel 6 , and is fixed on the upper surface of the main support 14 to secure the optical sheets 8 . To this end, the side surface of the guide panel 30 is provided with a securing part for securing the liquid crystal display panel 6 , and the rear surface is provided with a protrusion hole 32 into which the protrusion 20 of the main support 14 is inserted.
The case top 2 is prepared into a square band shape having a plane part and a side part, each of which is bent perpendicularly. The case top 2 encloses the edge of the liquid crystal display panel 6 and the guide panel 30 engaged to the main support 14 .
In an assembling method of the liquid crystal display module, the reflective sheet 12 and the light guide plate 10 are sequentially disposed on the main support 14 . Then, the optical sheets 8 are inserted into the protrusion 20 of the main support 14 . In other words, the holes 18 defined at the ears 16 a , 16 b and 16 c of the optical sheets 8 are inserted into the protrusion 20 of the main support 14 .
Subsequently, the guide panel 30 is engaged with the protrusion 20 of the main support 14 to which the optical sheets are secured. In other words, the protrusion hole 32 defined at the rear surface of the guide panel 30 is inserted into the protrusion 20 of the main support 14 . Thus, the guide panel 30 is inserted into the protrusion 20 of the main support 14 to thereby pressurize and secure the optical sheets 8 .
After the optical sheets 8 and the guide panel 30 are assembled to the main support 14 , the liquid crystal display panel 6 is loaded onto the securing part of the guide panel 30 . Then, as shown in FIG. 1 , the case top 2 is assembled to enclose the edge of the liquid crystal display panel 6 secured to the guide panel 30 , the side surface of the guide panel 30 and the side surface of the main support 14 .
In order to secure the optical sheets 8 , a pair of upper and lower ears 16 a and 16 b are defined at one side of the optical sheets 8 , and one ear 16 c is defined at the middle portion of a side opposed to the one side provided with the upper and lower ears 16 a and 16 b . Each ear 16 a , 16 b and 16 c is provided with a hole 18 for engaging it to the protrusion 20 of the main support 14 .
Each hole 18 defined at the ears 16 a , 16 b and 16 c of the optical sheets 8 is inserted into the protrusion 20 of the main support 14 to be secured into the main support 14 .
Consequently, the guide panel 30 is secured to the protrusion 20 of the main support 14 into which the optical sheets 8 have been inserted and secured. In other words, the protrusion hole 32 defined at the rear surface of the guide panel 30 is inserted into the protrusion 20 of the main support 14 . Thus, the guide panel 30 is inserted into the protrusion 20 of the main support 14 to thereby pressurize and secure the optical sheets 8 .
The optical sheets 8 of the liquid crystal display module are especially susceptible to heat from the lamp (which, although not shown, is disposed in the lower left hand corner of FIG. 4 ). The optical sheets 8 expand in two directions, a machine direction (MD) axis and a transverse direction (TD) axis, when heat is applied to them.
A thermal expansion coefficient in the MD axis of a general optical sheet is 3.8×10 −4 Cm 2 /° C. while a thermal expansion coefficient in the TD axis thereof is 2.7×10 −4 Cm 2 /° C. A ratio of a thermal expansion coefficient in the MD axis to a thermal expansion coefficient in the TD axis of such an optical sheet must be less than two to be relatively stable when heat is applied. Nevertheless, because of the disparity between the thermal expansion coefficients, a wrinkle 17 (i.e. deformation) occurs in the optical sheet to some extent when heat is applied.
Moreover, when a high light-convergence optical sheet such as a dual brightness enhancement film (DBEF) sheet is used, the thermal expansion coefficient of the optical sheet is increased due to an expansion process that occurs in the course of the assembling process. A thermal expansion coefficient in the MD axis of the DBEF sheet is 8.1×10 −5 Cm 2 /° C. while a thermal expansion coefficient in the TD axis thereof is 1.5×10 −5 Cm 2 /° C. As mentioned above, a ratio of a thermal expansion coefficient in the MD axis to that in the TD axis of the DBEF sheet is more than five. If heat is applied to such a DBEF film by the lamp, a wrinkle appears at the optical sheet 8 . Particularly, since a middle portion of the optical sheet 8 that has a large difference between the thermal expansion coefficients is secured by means of the hole 16 c and the protrusion 20 , a sizeable wrinkle appears in the optical sheet 8 .
SUMMARY OF THE INVENTION
Accordingly, embodiments of the present invention provide a liquid crystal display module that is less susceptible to heat and decreases or eliminates deformation caused by applied heat.
In one embodiment of the invention, a liquid crystal display module according to an embodiment of the present invention includes a main support and an optical sheet secured onto the main support. The optical sheet is secured to the main support through a first securing point close to one corner of a first side of the optical sheet and secured to the main support through a second and third securing points close to corners of a second side of the optical sheet opposing the first side of the optical sheet.
In the liquid crystal display module, the main support may include a plurality of protrusions, the protrusions disposed at the first, second and third securing points. In this case, the optical sheet may include a plurality of holes into which the protrusions are inserted and further the optical sheet may include a plurality of ears, the ears provided with the holes and protruding toward an outside of the optical sheet.
The liquid crystal display including the protrusions may further include a guide panel for securing the optical sheets at the upper portion thereof. In this case, the guide panel may include a hole into which the protrusion is inserted case.
The liquid crystal display module may further include a liquid crystal display panel supported by the main support and a light guide plate and a reflective sheet supported by the main support at the lower portion of the optical sheet.
The number of the securing points on the first side of the optical sheet may be different from the number of securing points on the second side of the optical sheet.
The optical sheet may have a partially different thermal expansion coefficient.
The optical sheet may include a dual brightness enhancement film (DBEF).
One or more of the securing points may be positioned at a region less than 1/10 of the entire length of the optical sheet.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other advantages of the invention will be apparent from the following detailed description of the embodiments of the present invention with reference to the accompanying drawings, in which:
FIG. 1 is a schematic section view showing a structure of a conventional liquid crystal display module;
FIG. 2 is a plan view of the optical sheet shown in FIG. 1 ;
FIG. 3 is a section view of the optical sheet taken along the I–I′ line in FIG. 1 ;
FIG. 4 is a perspective view of the optical sheet shown in FIG. 1 ;
FIG. 5 is a schematic section view showing a structure of a liquid crystal display module according to an embodiment of the present invention;
FIG. 6 is a plan view of the optical sheet shown in FIG. 5 ;
FIG. 7 is a section view of the optical sheet taken along the I–I′ line in FIG. 5 ; and
FIG. 8 is a perspective view of the optical sheet shown in FIG. 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 5 to FIG. 8 , a liquid crystal display module according to an embodiment of the present invention includes a main support 114 , a backlight unit and a liquid crystal display panel 106 disposed at the inside of the main support 114 , a guide panel 130 arranged on the main support 114 to support the liquid crystal display panel 106 and secure optical sheets 108 of the backlight unit, and a case top 102 for enclosing the edge of the liquid crystal display panel 106 and the side surface of the main support 114 .
The liquid crystal display panel 106 is comprised of an upper substrate 103 and a lower substrate 105 . A liquid crystal is injected between the upper substrate 103 and the lower substrate 105 , and the liquid crystal display panel 106 is provided with a spacer (not shown) for constantly keeping a gap between the upper substrate 103 and the lower substrate 105 . The upper substrate 103 of the liquid crystal display panel 106 is provided with a color filter, a common electrode and a black matrix, etc. Signal wiring such as data line and a gate line, etc. (not shown) is formed at the lower substrate 105 of the liquid crystal display panel 106 , and a thin film transistor (TFT) is formed at an intersection between the data line and the gate line. The TFT switches a data signal to be transmitted from the data line into the liquid crystal cell in response to a scanning pulse (i.e., a gate pulse) from the gate line. A pixel electrode is formed at a pixel area between the data line and the gate line. One side of the liquid crystal display panel 106 is provided with data and gate pad areas connected to the data lines and the gate lines, respectively. A data tape carrier package mounted with a data driver integrated circuit (not shown) for applying a data signal to the data lines is attached onto the data pad area. Further, a gate tape carrier package mounted with a gate driver integrated circuit (not shown) for applying a scanning pulse (i.e., a gate pulse) to the gate lines is attached onto the gate pad area.
An upper polarizing sheet 104 a is attached onto the upper substrate 103 of the liquid crystal display panel 106 while a lower polarizing sheet 104 b is attached onto the rear side of the lower substrate 105 of the liquid crystal display panel 106 .
The main support 114 is a product formed from a mold, the inner sidewall surface of which is molded into a stepped coverage face. The inner bottom layer of the main support 114 is mounted with a backlight unit including a light guide plate 110 integral with a reflective sheet 112 , a plurality of optical sheets 108 and a lamp housing (not shown). The upper surface of the main support 114 is provided with a perpendicular protrusion 120 .
The backlight unit includes a lamp 122 , a lamp housing (not shown) for enclosing the lamp, a light guide plate 110 for directing light inputted from the lamp into the liquid crystal display panel 106 , a reflective sheet 112 arranged at the rear side of the light guide plate 110 , and a plurality of optical sheets 108 disposed on the light guide plate 110 .
Light generated from the lamp 122 is incident, via an incidence face of the light guide plate 110 , into the light guide plate 110 . The lamp housing reflects light from the lamp 122 into an incidence face of the light guide plate 110 .
The reflective sheet 112 re-reflects light incident thereto through the rear side of the light guide plate 110 into the light guide plate 110 , thereby reducing light loss. In other words, if light from the lamp 122 is incident to the light guide plate 110 , then light having progressed into the lower surface and the side surface of the light guide plate 110 is reflected by the reflective sheet 112 to thereby be reflected toward the front side thereof.
The plurality of optical sheets 108 vertically direct light outputted from the light guide plate 110 to thereby improve the light efficiency. To this end, diffusing sheets are provided for diffusing light outputted from the light guide plate 110 into the entire area, and two prism sheets for vertically directing the angle of the light diffused by the diffusing sheets with respect to the liquid crystal display panel 106 . Thus, light outputted from the light guide plate 110 is incident, via the diffusing sheets and then the plurality of optical sheets 108 , to the liquid crystal display panel 106 .
As shown in FIG. 6 to FIG. 8 , the optical sheets 8 are provided with ears 116 a , 116 b and 116 c extending into each side surface thereof, each of which is provided with a hole 118 . Each hole 118 of the ears 116 a , 116 b and 116 c is inserted into the protrusion 120 of the main support 114 . By such an assembly structure of the holes 118 and the protrusions 120 , the optical sheets 108 are secured to the main support 114 .
The guide panel 130 supports the liquid crystal display panel 106 , and is fixed on the upper surface of the main support 114 to secure the optical sheets 108 . To this end, the side surface of the guide panel 130 is provided with a securing part for securing the liquid crystal display panel 106 , and the rear surface is provided with a protrusion hole 132 into which the protrusion 120 of the main support 114 is inserted.
The case top 102 is prepared into a square band shape having a plane part and a side part, each of which is bent perpendicularly. The case top 102 encloses the edge of the liquid crystal display panel 106 and the guide panel 130 engaged to the main support 114 .
In an assembling method of the liquid crystal display module, the reflective sheet 112 and the light guide plate 110 are sequentially disposed on the main support 114 . Then, the optical sheets 108 are inserted into the protrusion 120 of the main support 114 . In other words, the holes 118 defined at the ears 116 a , 116 b and 116 c of the optical sheets 108 are inserted into the protrusion 120 of the main support 114 .
Subsequently, the guide panel 130 is engaged with the protrusion 120 of the main support 114 to which the optical sheets 108 are secured. In other words, the protrusion hole 132 defined at the rear surface of the guide panel 130 is inserted into the protrusion 120 of the main support 114 . Thus, the guide panel 130 is inserted into the protrusion 120 of the main support 114 to thereby pressurize and secure the optical sheets 108 .
After the optical sheets 108 and the guide panel 130 are assembled to the main support 114 , the liquid crystal display panel 106 is loaded onto the securing part of the guide panel 130 . Then, as shown in FIG. 5 , the case top 102 is assembled to enclose the edge of the liquid crystal display panel 106 secured to the guide panel 130 , the side surface of the guide panel 130 and the side surface of the main support 114 .
As above, the optical sheets 108 in the liquid crystal display module expand in two directions: a machine direction (MD) axis and a transverse direction (TD) axis when heat is applied to the optical sheets 108 .
A ratio of a thermal expansion coefficient in the MD axis to a thermal expansion coefficient in the TD axis of a general optical sheet is less than two.
However, when a high light-convergence optical sheet such as a dual brightness enhancement film (DBEF) sheet is used, a thermal expansion coefficient of the optical sheet is increased due to an expansion process in the course of the assembling process. Thus, a ratio of a thermal expansion coefficient in the MD axis to that in the TD axis of the DBEF sheet is more than five.
In the embodiment of the present invention, in order to secure the optical sheets 108 , one side of the optical sheets 108 are provided with a pair of upper and lower ears 116 a and 116 b , and a side of the optical sheets 108 opposing the side provided with a pair of upper and lower ears 116 a and 116 b is provided with an ear 116 a at the upper portion of a traverse direction (TD) axis. The thermal expansion coefficient in the traverse direction (TD) axis is smaller than in the machine direction (MD) axis.
Each ear 116 a , 116 b and 116 c is provided with a hole 118 for engaging with the protrusion 120 of the main support 114 . The hole 120 defined at each ear 116 a , 116 b and 116 c of the optical sheets 108 is positioned at a region less than 1/10 of the entire length of the optical sheet 108 from the end of the optical sheet 108 as indicated in the following equation:
D≦A/ 10 (1)
(wherein D represents a position of the hole and A represents entire length of the optical sheet)
The hole 118 defined at each ear 116 a , 116 b and 116 c of the optical sheets 108 is inserted into the protrusion 120 of the main support 114 to thereby secure the optical sheets 108 .
Subsequently, the guide panel 130 is secured to the protrusion 120 of the main support 114 into which the optical sheets 108 have been inserted and secured. In other words, a protrusion hole 132 defined at the rear surface of the guide panel 130 is inserted into the protrusion 120 of the main support 114 . Thus, the guide panel 130 is inserted into the protrusion 120 of the main support 114 to thereby pressurize and secure the optical sheets 108 .
As described above, a liquid crystal display module according to the present invention defines the ear 116 c at the upper portion of the TD axis than the MD axis. This reduces or prevents a wrinkle caused by applied heat due to the difference in thermal expansion coefficients between the MD axis and the TD axis of the optical sheet.
Although the present invention has been explained by the embodiments shown in the drawings described above, it should be understood to the ordinary skilled person in the art that the invention is not limited to the embodiments, but rather that various changes or modifications thereof are possible without departing from the spirit of the invention. Accordingly, the scope of the invention shall be determined only by the appended claims and their equivalents.
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A liquid crystal display module is disclosed that has an optical sheet supported by a main support. In the module, the optical sheet is secured to a main support through a first securing point close to one corner at one side and secured to the main support through a second securing point close to each corner at the opposing side. In this liquid crystal display module, deformations in the optical sheet caused by applied heat from the light source is reduced or eliminated.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part application of Patent Cooperation Treaty Patent Application Number PCT/JP2010/072004 (filed on Dec. 8, 2010), which claims priority from Japanese patent application JP 2009-281010 (filed on Dec. 10, 2009), all of which are hereby incorporated by reference herein in their entirety.
TECHNICAL FIELD
The instant application relates to reducing possibility of short-circuit in a display device.
BACKGROUND
The display device may include a display panel and a cabinet for accommodating the display panel. In usage, the display device may be placed on a wall of an indoor room by fixing the backside of the cabinet to the wall. Alternatively, the display device may be standalone display device. See e.g., JP2005-286987A1.
The display device may also include a socket configured to receive a power supply cord for supplying an electric power to the display panel and a connector configured to receive a cable for receiving and/or transmitting image and audio signals. The socket and/or cable may be arranged in the rear wall of the cabinet, facing toward the back side.
As long as the display device is installed indoor, the socket and/or connector may not get exposed to water or dust, and therefore they may be configured such that they are exposed from the back of the cabinet. In recent years, it is expected to install such display device outdoors since the display device may have a small thickness. The small thickness may be advantageous for installing the display device in narrow locations, for example.
However, in the outdoor-use display devices, if the socket or plug is exposed from the back side of the cabinet, the socket or plug may get exposed to water or dust, resulting in a short-circuit or fire from the circuit. To prevent such short-circuit or fire, one idea is to utilize a dedicated cord having a sealed structure in order to protect the plug and the socket from the dust and water. Such dedicated cord is expensive, however, and increases the manufacturing cost of the display device. Another idea is to form a sealing structure in an accommodation unit, which accommodates the socket and the connector. The sealing structure may be formed by jointing the concave portion provided on the back wall of the cabinet and a lid which covers the opening of this concave portion. The sealing structure may protect a socket and a connector from water or dust. However, such sealing structure may reduce operating convenience because the lid may have to be frequently removed to connect or disconnect the cable to the connector.
Accordingly, there is a need for a display device that can reduce or eliminate short-circuit or fire in the display device installed outdoors while preventing an increase in manufacturing cost and decrease operating convenience.
SUMMARY
In one general aspect, the instant application describes a display apparatus that includes a display panel; a cabinet configured to accommodates the display panel; a first concave portion defining a first opening in a back wall of the cabinet; a first lid configured to cover the first opening; a second concave portion defining a second opening in the back wall of the cabinet; a second lid configured to cover the second opening; a plurality of first fastening elements configured to connect the first concave portion and the first lid; and a plurality of second fastening elements configured to connect the second concave portion and the second lid. A distance between adjacent first fastening elements and a distance between adjacent second fastening elements are different.
In the above general aspect, the second concave portion may be provided on the first lid.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view showing an exemplary display device of the instant application;
FIG. 2 is a perspective view of the exemplary display device shown in FIG. 1 when viewed from its back side;
FIG. 3 is a rear view of the exemplary display device shown in FIG. 1 ;
FIG. 4 is a plan view showing a first lid which forms a first accommodation unit provided in the exemplary display device shown in FIG. 1 ;
FIG. 5 is an enlarged perspective view of a second concave portion which forms a second accommodation unit provided in the exemplary display device shown in FIG. 1 ;
FIG. 6 is a sectional view along the A-A line shown in FIG. 3 ;
FIG. 7 is a bottom view of the exemplary display device shown in FIG. 1 ;
FIG. 8 is an enlarged view of the B area shown in FIG. 7 ;
FIG. 9 is a sectional view showing the state where a plug of a power cord is inserted to the socket provided in the exemplary display device shown in FIG. 1 ;
FIG. 10 is a perspective view showing a seal structure associated with a second accommodation unit of the exemplary display device shown in FIG. 1 ; and
FIG. 11 is another perspective view showing a seal structure associated with a second accommodation unit of the exemplary display device shown in FIG. 1 .
DETAILED DESCRIPTION
In the following detailed description, numerous specific details are set forth by way of examples in order to provide a thorough understanding of the relevant teachings. However, it should be apparent to those skilled in the art that the present teachings may be practiced without exemplary details. In other instances, well known methods, procedures, components, and/or circuitry have been described at a relatively high-level, without detail, in order to avoid unnecessarily obscuring aspects of the present concepts.
FIG. 1 is a perspective view showing an exemplary display device of the instant application. The display device includes a LCD (Liquid Crystal Display) panel ( 1 ) and a cabinet ( 2 ) for accommodating the panel ( 1 ). In the front wall ( 21 ) of the cabinet ( 2 ), a display window ( 20 ) is provided so as to make a screen ( 10 ) of the panel ( 1 ) viewable from the outside.
FIG. 2 is a perspective view of the exemplary display device shown in FIG. 1 when viewed from its back side. As shown in FIG. 2 , a first concave portion ( 61 ) is provided in the back wall ( 22 ) of the cabinet ( 2 ). The first concave portion ( 61 ) has a rectangular shaped opening having four sides. The opening of the first concave portion ( 61 ) is covered by a first lid ( 62 ), which is a portion of the back wall ( 22 ), and in this state, the lid ( 62 ) is jointed to the first concave portion ( 61 ).
Specifically, the first concave portion ( 61 ) has four edges surrounding the opening of the first concave portion ( 61 ). The first lid ( 62 ) has a rectangular shape with four sides. The rectangular shape of the first lid ( 62 ) may be substantially same as the perimeter edge of the edge surrounding the opening of the first concave portion ( 61 ). By covering the opening with the first lid ( 62 ), the surface of the edge portion of the first concave portion ( 61 ) contacts the back side of the first lid ( 62 ). In this state, the first concave portion ( 61 ) may be connected to the first lid ( 62 ) by, for example, screwing the first lid ( 62 ) to the edge of the first concave portion ( 61 ).
Thereby, as shown in FIG. 2 , in the back wall ( 22 ) of a cabinet ( 2 ), a first accommodation unit ( 63 ) constituted by jointing the first lid ( 62 ) and the first concave portion ( 61 ) is formed. Among the back side of the first lid ( 62 ), the jointing surface of the first lid ( 62 ) is formed by an area which contacts edges of the first concave portion ( 61 ). In order to connect the first lid ( 62 ) to the edges of the first concave portion ( 61 ), a screw component may be utilized To this end, as shown in FIG. 3 , in the first lid ( 62 ) plurality of penetration holes ( 621 ) are provided. The plurality of penetration holes may be configured to receive the screw components. Specifically, as shown in FIG. 4 , in the edges of the first lid ( 62 ), eight penetration holes ( 621 a )-( 621 h ) are formed aligned in the portion along the upper side from the right side to the left side. Five penetration holes ( 621 i )-( 621 m ) are formed aligned in the portion along the left side from the top to the bottom. Eight penetration holes ( 621 n )-( 621 u ) are formed aligned in the portion along the lower side from the left to the right. Five penetration holes ( 621 v )-( 621 z ) are formed aligned in the portion along the right side from the bottom to the top.
Among the jointing surfaces of the first concave portion ( 61 ) and the first lid ( 62 ), in the concave portion ( 61 ) side jointing surface, screw holes may be provided in a plurality of places along the inner edge of the jointing surface. Each of the screw holes may be arranged in the position that faces the corresponding penetration holes ( 621 ), when the opening of the first concave portion ( 61 ) is covered by the first lid ( 62 ). In one implementation, when joining the first lid ( 62 ) to the first concave portion ( 61 ), a plurality of penetration holes ( 621 ) are selected for penetrating a screw component among holes ( 621 a )-( 621 z ). In each of the selected holes ( 621 ), a screw component is penetrated, and the screw component is screwed to the corresponding screw holes. Thereby, the first lid ( 62 ) is screwed to the edge of the first concave portion ( 61 ).
Between the jointing surface of the first concave portion ( 61 ) of the first accommodation unit ( 63 ) and the first lid ( 62 ), a seal component which surrounds the space inside the accommodation unit ( 63 ) may be placed. The sealing component may prevent or reduce intrusion of the water and dust inside the first accommodation unit ( 63 ) from between the jointing surfaces of the first lid ( 62 ) and the first concave portion ( 61 ). Hence, the first accommodation unit ( 63 ) has a sealed structure which prevents or reduces the intrusion of water or dust inside the first accommodation unit ( 63 ). In the first accommodation unit ( 63 ), a circuit board for controlling the LCD panel ( 1 ) is accommodated, for example.
In one implementation, the jointing strength between the first concave portion ( 61 ) and the first lid ( 62 ) may be increased by making distance between the neighboring screw components small. To this end, the sealing performance of the first accommodation unit ( 63 ) may be improved. In one specific example, when a relatively high sealing performance equivalent to IP66 (here, IP is a code indicating the degrees of protection provided by enclosures in the IEC 60529 of an IEC (International Electro-technical Commission) standard) is required in the first accommodation unit ( 63 ), the screw components may be penetrated into all or substantially all of the penetration holes ( 621 a )-( 621 z ), and the screw components may be screwed to the screw holes provided in the first concave portion ( 61 ) side of the jointing surface. As a result, the distance between the adjacent screw components becomes small.
In another example, when a higher sealing performance equivalent to IP 33 in the IEC standard is used, the screw components may be penetrated into less than all the penetration holes ( 621 a )-( 621 z ). To this end, the distance between the neighboring screw components can be set larger compared with the case of IP 66. In one specific example, the screw components are inserted only in the penetration holes ( 621 a ) ( 621 c ) ( 621 f ) ( 621 i ) ( 621 k ) ( 621 n ) ( 621 p ) ( 621 s ) ( 621 u ) ( 621 x ) ( 621 z ) out of the penetration holes ( 621 a )-( 621 z ). As for rest of the penetration holes, in which the screw components are not inserted, they are covered by the sealing component. Widening the distance between the screw components can reduce the number of the screw components necessary for joining the first lid ( 62 ) and the first concave portion ( 61 ). As a result, it becomes easier to remove the first lid ( 62 ) from the first concave portion ( 61 ). In one implementation, the screw components are waterproofing screws which can be expensive. Therefore, reducing the number of the screw components can help in reducing the manufacturing cost.
The first lid ( 62 ) of the first accommodation unit ( 63 ) may be seldom removed except for repairing circuit board accommodated in the first accommodation unit ( 63 ) or for maintenance. Thus, it may not be necessary to remove the first lid ( 62 ) of the first accommodation unit ( 63 ) frequently. As a result, even when the required sealing level is IP33, the screw components may be inserted in all of the penetration holes ( 621 a )-( 621 z ) provided on the first lid ( 62 ).
Since the first lid ( 62 ) may be seldom removed, the screw components of the first accommodation unit ( 63 ) can be screwed with a large torque to the screw hole provided on the first concave portion ( 61 ) side so that the jointing strength between the first concave portion ( 61 ) and the first lid ( 62 ) may be increased. Thereby, high sealing performance in the first accommodation unit ( 63 ) may be realized.
As shown in FIG. 2 , in the back wall ( 22 ) of the cabinet ( 2 ), a second concave portion ( 4 ) is provided. The second concave portion ( 4 ) is provided on the first lid ( 62 ) which constitutes the first accommodation unit ( 63 ). The second concave portion ( 4 ) is substantially rectangular and includes an opening ( 40 ) having four sides. As shown in FIG. 5 , a plurality of connectors ( 60 ) configured to receive cables for receiving or transmitting video or audio signal is attached in the bottom wall ( 41 ) of the second concave portion ( 4 ) facing backward.
In the upper wall ( 42 ) of the second concave portion ( 4 ), a socket ( 6 ) for inserting a plug ( 71 ) (see FIG. 9 ) of a power cord ( 7 ) is attached facing downward. The power cord ( 7 ) is configured to supply power to the LCD panel ( 1 ) is attached. In detail, in the upper wall ( 42 ), a rectangular shaped mounting unit ( 421 ) for attaching the socket ( 6 ) is formed. The socket ( 6 ) is attached downward to the lower wall of the unit ( 421 ) so as to penetrate the lower wall, as shown in FIG. 6 .
As shown in FIG. 6 , the opening ( 40 ) of the second concave portion ( 4 ) is covered by a second lid ( 5 ) which is jointed to the second concave portion ( 4 ). In detail, as shown in the FIG. 5 , the second concave portion ( 4 ) has an edge portion ( 401 ) stretching along the four sides of the opening ( 40 ) of the second concave portion ( 4 ) such that the edge portion ( 401 ) surrounds the opening ( 40 ). The second lid ( 5 ) has a board ( 50 ), having four sides and substantially rectangular shape as shown in FIG. 3 .
The second lid ( 5 ) also includes four side walls ( 51 ). The four side walls ( 51 ) extend from the four sides of the board ( 50 ) and are substantially perpendicular to the board ( 50 ) as shown in FIG. 6 . By covering the opening ( 40 ) of the second concave portion ( 4 ) by the second lid ( 5 ), forefront surface of the side walls ( 51 ) of the second panel ( 5 ) contacts the edge portion ( 401 ). Under this condition, by screwing the second lid ( 5 ) to the edge portion ( 401 ) of the second concave portion ( 4 ), the second lid ( 5 ) connects to the second concave portion ( 4 ).
As shown in FIG. 6 , in the back wall ( 22 ) of the cabinet ( 2 ), a second accommodation unit ( 3 ) constituted by jointing the second concave portion ( 4 ) and the second lid ( 5 ) is formed. In the accommodation unit ( 3 ), a connector ( 60 ) and a socket ( 6 ) are accommodated. The jointing surface of the second concave portion ( 4 ) and the second lid ( 5 ) is formed by edge portion ( 401 ) of the second concave portion ( 4 ) and forefront surface of the side walls ( 51 ) of the second lid ( 5 ) which contacts the edge portion ( 401 ).
The cable may be connected to or removed from the connector ( 60 ) frequently. Thus, the second lid ( 5 ) of the second accommodation unit ( 3 ) may have to be removed frequently. However, when relatively high sealing performance such as equivalent to IP66 is required in the second accommodation unit ( 3 ), it may not be so desirable to harm the sealing structure in the second accommodation unit ( 3 ) even temporarily. Thus, it may be preferable to limit the frequency of removing the second lid ( 5 ) in such case.
As for connecting the second lid ( 5 ) to the edge portion ( 401 ) of the second concave portion ( 4 ), screw components may be used. Here, as shown in FIG. 3 , a plurality of penetration holes ( 404 ) configured for receiving the screw components are provided on the second lid ( 5 ). In one specific example, as shown, five penetration holes ( 404 a )-( 404 e ) are formed along the upper side portion of the edge of the second lid ( 5 ) from the right to the left. Three penetration holes ( 404 f )-( 404 h ) are formed along the left side of the second lid ( 5 ) from the top to the bottom. Three penetration holes ( 404 i )-( 404 k ) are formed along the right side of the second lid ( 5 ) from the bottom to the top. In the center part of the lower side of the second lid ( 5 ), a pair of penetration holes ( 404 l ) is provided in a vertical (up and down) direction. In the left side of the holes ( 404 l ), a pair of penetration holes ( 404 m ) is provided in vertical direction, and in the right side of the holes ( 404 l ), a pair of penetration holes ( 404 n ) is provided in vertical direction.
As shown in FIG. 5 , among the jointing surface of the second concave portion ( 4 ) and the second lid ( 5 ), in the second concave portion ( 4 ) side, screw holes ( 402 ) are provided on the plurality of places along the edge portion ( 401 ) of the second concave portion ( 4 )). Each of the screw holes ( 402 ) may be located on the position where it faces the corresponding penetrating holes ( 404 ) when the opening ( 40 ) is covered by the second lid ( 5 ).
When connecting the second lid ( 5 ) with the second concave portion ( 4 ), the plurality of penetration holes ( 404 ) for penetrating the screw components may be selected among the holes ( 404 a )-( 404 n ) provided in the second lid ( 5 ). In the selected penetrating hole ( 404 ), a screw component may be inserted, and the screw component may be screwed to a screw hole ( 402 ) corresponding to the penetrating hole ( 404 ). Thereby, the second lid ( 5 ) is fixed to the edge portion ( 401 ) of the second concave portion ( 4 ).
Here, as shown in FIGS. 3 , 5 , and 6 , the edge portion ( 401 ) of the second concave portion ( 4 ) protrudes backward from the back wall ( 22 ) of the cabinet ( 2 ) in the area along the lower side ( 403 ), which is one of the four sides of the opening ( 40 ) of the second concave portion ( 4 ), thereby, forming the protruding portion ( 43 ) is formed. As shown in FIG. 8 , among the four side walls ( 51 ) of the second lid ( 5 ), the side wall ( 51 ) extending along the lower side ( 503 ) (see FIG. 3 or 6 also) of the top plate ( 50 ) includes a concave portion ( 511 ). The concave portion ( 511 ) conforms to the shape of the portion ( 43 ) and is configured to receive the protruding portion ( 43 ). To this end, when the second concave portion ( 4 ) and the second lid ( 5 ) are jointed, the tip side ( 431 ) of the protruding portion ( 43 ) contacts the bottom surface ( 512 ) of the concave portion ( 511 ). Thereby, among the second accommodation unit ( 3 ), the second lid ( 5 ) and the protruding portion ( 43 ) protrudes backward from the back wall ( 22 ) of the cabinet ( 2 ).
As shown in FIG. 8 , among the jointing surface of the second concave portion ( 4 ) and the second lid ( 5 ), in the jointing surface of the protruding portion ( 43 ) and the side wall portion ( 51 ), a plurality of pair of concave grooves ( 31 ) and ( 32 ) is formed. Specifically, the plurality of pair of concave grooves ( 31 ) and ( 32 ) are formed in the forefront surface ( 431 ) of the portion ( 43 ) and in the bottom surface ( 512 ) of the portion ( 511 ), respectively. Among each of the pair of the grooves ( 31 ) and ( 32 ), groove ( 31 ) faces groove ( 32 ) in a state the second concave portion ( 4 ) and the second lid ( 5 ) are jointed, thereby forming a penetrating hole ( 30 ). The penetrating hole ( 30 ) enables communication from the inside of the second accommodation unit ( 3 ) to the outside of the second accommodation unit ( 3 ) and vice versa. In the penetrating hole ( 30 ), the power cord ( 7 ) or the cables may be penetrated as shown in FIG. 9 .
Thereby, in the above-described display device, in the lower surface wall of the second accommodation unit ( 3 ), the penetration hole ( 30 ) for penetrating a power cord ( 7 ) or a cable is formed in the area outside the area intersecting the back wall ( 22 ) of the cabinet ( 2 ).
As shown in FIG. 5 , among the jointing surface of the protruding portion ( 43 ) and the side wall portion ( 51 ), in the forefront surface ( 431 ) of the portion ( 43 ), a second concave groove ( 33 ) crossing the plurality of grooves ( 31 ) is formed (see also FIG. 6 ). As shown in FIGS. 6 and 11 , the first sealing component ( 81 ) is fitted to the second concave groove ( 33 ). Similarly, as shown in FIG. 6 , in the bottom surface ( 512 ) of the portion ( 511 ) of the side wall ( 51 ), a second concave groove ( 34 ) crossing the plurality of grooves ( 32 ) is formed. To the second concave groove ( 34 ), a second sealing component ( 82 ) is fitted. The second sealing component ( 82 ) is different from the first sealing component ( 81 ) fitted to the second concave groove ( 33 ) in the portion ( 43 ).
The seal components ( 81 ) and ( 82 ) contact each other when the second concave portion ( 4 ) and the second lid ( 5 ) are jointed. Thus, the penetrating hole ( 30 ) formed by jointing the second concave portion ( 4 ) and the second lid ( 5 ) is covered by the seal components ( 81 ) and ( 82 ) as shown in FIG. 6 . As a result, intrusion of the water or dust from the hole ( 30 ) into the second accommodation unit ( 3 ) is prevented by the seal components ( 81 ) and ( 82 ).
As shown in FIG. 5 , in the edge portion ( 401 ) of the second concave portion ( 4 ), a third groove ( 35 ) surrounding the space inside the second accommodation unit ( 3 ) is formed so as to overlap the second groove ( 33 ) in a concave manner. To this third groove ( 35 ), a ring shaped third sealing component ( 83 ) is fitted as shown in FIG. 10 .
In detail, the third groove ( 35 ) is formed along the four sides of the opening ( 40 ) of the second concave portion ( 4 ) which contacts the four side walls ( 51 ) of the second lid ( 5 ) when the second lid ( 5 ) is jointed to the second concave portion ( 4 ). The third groove ( 35 ) has a smaller width in the upper side, left side, and/or the right side of the opening ( 40 ) of the second concave portion ( 4 ) than the width of the second groove ( 33 ) in the bottom side of the opening ( 40 ). The third sealing component ( 83 ) contacts the first sealing component ( 81 ) in a portion along the bottom side ( 403 ) out of the four sides of the opening ( 40 ) when the second concave portion ( 4 ) and the second lid ( 5 ) are jointed. At the same time, the third sealing component ( 83 ) contacts the upper side, left side, and/or right side of the side walls ( 51 ) of the second lid ( 5 ). Thereby, intrusion of water and/or dust between the jointing surfaces may be prevented by the third sealing component ( 83 ).
Here, the jointing strength between the second concave portion ( 4 ) of the second accommodation unit ( 3 ) and the second lid ( 5 ) may be increased by making the distance between adjacent screw components arranged in the circumference of the second accommodation unit ( 3 ) small. As a result, the sealing performance in the second accommodation unit ( 3 ) may be improved. When a relatively high sealing performance IP66 is required in the second accommodation unit ( 3 ), the screw components may be penetrated in all the penetration holes ( 404 a )-( 404 n ) provided in the plurality of places in the second lid ( 5 ).
The screw components may be screwed to the screw holes ( 402 ) provided on the edge portion ( 401 ) of the second concave portion ( 4 ). When a relatively high sealing performance is required, the screw components of the second accommodation unit ( 3 ) may be screwed with large torque to the screw holes ( 402 ) provided on the edge portion ( 401 ) of the second concave portion ( 4 ). By penetrating screw components in all of the penetration holes ( 404 a )-( 404 n ) and screwing the screw components by large torque, although the removal of the second lid ( 5 ) may become difficult, seal structure may be deteriorated.
When the required sealing performance level for the second accommodation unit ( 3 ) is IP33, compared with the case of IP66, the distance between the adjacent screw components may be made larger. In such case, out of the penetration holes ( 404 a )-( 404 n ) provided in plurality of places in the second lid ( 5 ), the screw components may be penetrated in three of the holes ( 404 c ), ( 404 g ), and ( 404 j ) along the top, left, and right sides of the second lid ( 5 ) respectively and in a pair of the holes ( 404 l ) along the bottom side of the second lid ( 5 ). These screw components are screwed to the screw holes ( 402 ) provided on the edge portion ( 401 ) of the second concave portion ( 4 ). Furthermore, the remaining penetration holes, in which the screw components are not penetrated, may be covered by seal materials. In this case, distances between the adjacent screw components are different between two accommodation units ( 63 ) and ( 3 ).
Specifically, the distance becomes larger in the second accommodation unit ( 3 ) compared to that in the first accommodation unit ( 63 ). When this distance becomes larger in the second accommodation unit ( 3 ), the number of the utilized screw components decreases. Therefore, it may become easier to remove the second lid ( 5 ) in the second accommodation unit ( 3 ), where the distance between the adjacent screw components is large, compared to the first lid ( 62 ) in the first accommodation unit ( 63 ), where the distance between the adjacent screw components is small. Furthermore, in case of IP33, the screw components of the second accommodation unit ( 3 ) may be screwed to the screw holes ( 402 ) with a smaller torque, when compared with the case in the first accommodation unit ( 63 ). This may further enhance ease of removal of the second lid ( 5 ) in the second accommodation unit ( 3 ) compared to the first lid ( 62 ) in the first accommodation unit ( 63 ).
If the torque for screwing the screw components is large, the crushing amount of the seal component may become large. Thereby, when the lid is opened, the seal component may remain crushed. Thus, it may become difficult to use the same seal component when covering the lid again. On the other hand, if the torque for screwing the screw components is small, the crushing amount may become smaller. In this case, it may be easier for the seal component to recover to its original state. Therefore, it may be possible to use the same seal component again when covering the lid. By making torque at the time of screwing smaller, it may be possible to prevent the second accommodation unit ( 3 ) from decreasing its sealing performance due to the repetitive uncovering and covering of the second lid ( 5 ).
In the above-mentioned display device, at the plurality of places in the first lid ( 62 ) of the first accommodation unit ( 63 ), the penetration holes ( 621 a )-( 621 z ) are formed. In the first concave portion ( 61 ) screw components are screwed, penetrating the respective penetration holes ( 621 ) chosen from the penetration holes ( 621 a )-( 621 z ). Therefore, according to the usage of the display device, the number of the screw components used for connecting the first concave portion ( 61 ) and the first lid ( 62 ) can be changed. As a result, the distance between the adjacent screw components can also be adjusted.
At plurality of places in the second lid ( 5 ) of the second accommodation unit ( 3 ), penetration holes ( 404 a )-( 404 n ) are formed. In the second concave portion ( 4 ) screw components are screwed penetrating the respective penetration holes ( 404 ) chosen from the penetration holes ( 404 a )-( 404 n ). Therefore, according to the usage of the display device, the number of the screw components used for connecting the second concave portion ( 4 ) and the second lid ( 5 ) can be changed. As a result, the distance between the adjacent screw components can also be adjusted.
Therefore, between the display devices having different usage, the first lid ( 62 ) and the second lid ( 5 ) can be used commonly.
In the above-described display device, by opening the second lid ( 5 ), the plug ( 71 ) of the power cord ( 7 ) can be inserted in the socket ( 6 ). Here, the socket ( 6 ) is provided facing downward. Thus, the plug ( 71 ) inserted in the socket ( 6 ) protrudes downwards from the socket ( 6 ) as shown in FIG. 9 , and the power cord ( 7 ) extends downward from the socket ( 6 ). Thereby, when installing the display device facing its back side to the wall, the display device may require smaller space (room) in the back side of the display device, compared to the display device in which the plug protrudes backwards from the socket ( 6 ) toward the wall.
After inserting the plug ( 71 ) in the socket ( 6 ), by closing the second lid ( 5 ) while fitting the power cord ( 7 ) to the pair of the grooves ( 31 ) and ( 32 ), the cord ( 7 ) stretching downward from the socket ( 6 ) can be drawn downward from inside the second accommodation unit ( 3 ) to the outside of the cabinet ( 2 ) through the penetrating hole ( 30 ). Similarly, the cable connected to the connector ( 60 ) is drawn downward from inside the second accommodation unit ( 3 ) to the outside of the cabinet ( 2 ) through the hole ( 30 ). Thereby, the display device may require small space in the back side of the display device when installing the display device facing its back side to the wall.
By closing the second lid ( 5 ) while fitting the power cord ( 7 ) and the cable to the pair of the grooves ( 31 ) and ( 32 ), the cord ( 7 ) and the cable may be sandwiched without a gap by the sealing components ( 81 ) and ( 82 ) as shown in FIG. 9 . Thus, intrusion of water or dust from the hole ( 30 ) may be prevented by the sealing components ( 81 ) and ( 82 ) when the cord ( 7 ) and/or the cable are penetrated through the hole ( 30 ).
Thus, according to the above-described display device, the socket ( 6 ), the plug ( 71 ), and the connector ( 60 ) inside the second accommodation unit ( 3 ) may be prevented from exposure to the water and/or dust even when the display device is installed outdoor. In other words, the second accommodation unit ( 3 ) formed by the second concave portion ( 4 ) and the second lid ( 5 ) has a sealed structure which may prevent or reduce the water and/or dust from intruding inside from the hole ( 30 ) or from the jointing surface. Furthermore, in the above-described display device, the width of the third groove ( 35 ) may be made smaller for the portion in the upper side, left side, and/or right side of the opening ( 40 ) of the second concave portion ( 4 ) compared to the width of the second groove ( 33 ) in the lower side of the opening ( 40 ) of the second concave portion ( 4 ). This can improve the waterproofing or dust-proofing structure of the second accommodation unit ( 3 ).
Other implementations are contemplated. For example, when forming the first accommodation part ( 63 ) by connecting the first lid ( 62 ) with the first concave portion ( 61 ), the screw components may be penetrated in other penetration holes ( 621 ) compared to the example described above. According to the frequency of the removal of the first lid ( 62 ), required sealing performance for the first accommodation unit ( 63 ), or the usage of the display device, penetrating holes ( 621 ) to which the screw components are penetrated can be selected. This is the same for the case when forming the second accommodation unit ( 3 ) by connecting the second lid ( 5 ) with the second concave portion ( 4 ).
With respect to the above-described display device, the third groove ( 35 ) may be provided on the jointing surface of second lid ( 5 ) instead of on the jointing surface of the second concave portion ( 4 ). The penetrating hole ( 30 ) may be arranged only in one place.
In the above-described display device, the penetrating hole ( 30 ) may be provided on the lower wall of the second accommodation unit ( 3 ). In another example, the hole ( 30 ) may be provided on the other inner walls of the second accommodation unit ( 3 ), (the upper wall, left side wall, or right side wall). In such case, the hole ( 30 ) is formed outside the area intersecting the back wall ( 22 ) of the cabinet ( 2 ). Thereby, the power cord ( 7 ) or the cable can be drawn outside from the second accommodating unit ( 3 ) not only downward but also upward, leftward or rightward depending on how the display device is installed. Thereby, optimum wiring of the cord or the cable depending on the installing place of the display device may be realized. Further, the above-described structures may be applied not only to the display device having the LCD panel ( 1 ), but also to the display device having a plasma display panel, OLED display panel, or Electro-Luminescence panels etc.
While the foregoing has described what are considered to be the best mode and/or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that they may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim any and all modifications and variations that fall within the true scope of the present teachings.
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An image display device which is provided with an image display panel, and a housing which houses the image display panel. In the front wall of the housing, an image display window makes the screen of the image display panel viewable from the outside. In the rear wall of the housing are two housing sections, each being configured by connecting together a recessed section provided in the rear wall, and a cover which covers the opening of the recessed section. On the recessed section-side connecting surface from the surfaces on which the recessed section and the cover of each housing section are connected, screw members are screwed at a plurality of areas along the inner circumference of the connecting surface by penetrating the cover. The distances between the adjacent screw members in the two housing sections are different from each other.
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GOVERNMENT RIGHTS
The U.S. Government has a paid-up license to this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms.
This application is a continuation of application Ser. No. 08/598,781, filed Feb. 5, 1996, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention (Technical Field)
The present invention relates to methods for production of nanophase dispersion-strengthened materials, including plasma-based processes which produce a wide range of products, including thin layers and complete articles made of a composite comprising metal and metal-ceramic particles.
2. Background Art
Aluminum alloys are used in numerous commercial and industrial applications requiring high strength and light weight. Their range of applicability, however, is often limited by their limited tribological properties. Much effort, therefore, has gone into the development and deposition of hard, wear-resistant coatings to extend the use of Al alloys,
High strength has recently been achieved for aluminum-oxygen alloy films of varying stoichiometries and microstructure ranging from hard, dispersion-strengthened layers to Al 2 O 3 layers that are expected to be hard and resistant.
Dispersion-strengthened AlO x layers are comprised of an fcc Al matrix containing finely dispersed γ-Al 2 O 3 precipitates (nanophase precipitates) which strengthen the film by blocking dislocation motion. (The AlO x nomenclature arises as an attempt to stress the non-stoichometric nature of the film as a whole.) The yield stress in such a film is approximately given by 2 Gb/L, where G is the shear modulus of the Al matrix, b is the Burgers vector of the dislocations, and L is the inter-particle spacing. Thus, as precipitate density increases, L decreases, and the yield stress increases.
Such materials have been synthesized in the past, primarily using sintering, but these materials have low precipitate density and large precipitates. Such sintered materials hence do not exhibit the strengths achieved by materials produced using the new method described in this patent. Another method is ion implantation of O into Al to produce nanophase Al 2 O 3 in the Al matrix. (The term nanophase is defined here as a nanometer-size cluster embedded in a matrix, wherein said cluster is composed of a different material than the surrounding matrix. An example of this usage is to refer to the nanometer-size Al 2 O 3 precipitates in an Al matrix as nanophase Al 2 O 3 .) However, the thickness of dispersion-strengthened layer which can be produced using implantation is limited to the depth of ion implantation (typically less than 1 μ). Such ion-implanted layers exhibit yield stress of as high as 2.9 GPa, which is much greater that the yield stress for conventional high-strength aerospace alloys such as 7075 Al, which has a yield stress of 0.5 GPa. This factor of six increase in strength, and the corresponding decrease in friction and wear exhibited by O-implanted Al, suggests a host of potential uses. However, practical use of this ion implantation-based synthesis technique is restricted by high cost and the limitation of the thickness of the final film to ˜1 μ or less.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method for manufacture of dispersion-strengthened Al-O alloys, where said alloys have flow stresses approaching those of high strength steel, and said alloys comprise a continuous Al matrix containing nanophase particles with a nominal composition of Al 2 O 3 .
Another object of the present invention is to provide such a technique having properties compatible with large-scale commercial application of dispersion-strengthened Al-O alloys.
Yet another object of the present invention is to provide a method for making objects comprising dispersion-strengthened Al-O alloys with a thickness reatly in excess of 1 μ.
Still another object of the present invention is to provide a method for synthesizing dispersion-strengthened Al-O alloys which exhibit high strength at elevated temperatures.
It is also an object of the present invention to provide a method for manufacture of dispersion-strengthened Al-O alloy layers having greatly reduced friction and wear relative to Al and currently existing Al alloys.
These and other objects are achieved by providing a method of producing a composite material, comprising a continuous metallic matrix containing a fine dispersion of nanophase precipitates. In one set of implementations, the continuous metallic matrix comprises Al and the nanoscale precipitates have a nominal composition of Al 2 O 3 . This is accomplished by using deposition techniques which include a plasma-based step. These techniques include Pulsed Laser Deposition (PLD) and conventional deposition in the presence of an oxygen plasma source, such as an Electron Cyclotron Resonance (ECR) plasma.
DETAILED DESCRIPTION
The present invention is based on supplying simultaneous fluxes of Al and O atoms, with excess excitation energy, impinging on a growth surface. (The choice of Al and O atoms are a specific implementation, not intended to limit the scope of the present invention.) The effect is to causing growth of nanophase precipitates having a nominal composition of Al 2 O 3 within an Al matrix. These precipitates will have a size and separation which depends largely on the nominal composition and the growth rate of the growing film. Growth in the presence of an energetic plasma has been found to be effective to form such materials.
The desired effect, that of strengthening the material being grown by introducing precipitates into the basic matrix of the material, is most significant for a very dense dispersion of small precipitates (a rather narrow range of composite structures). Dispersion strengthening can only be effective if the particles are spaced closely enough, and have the size and strength to pin the dislocations locally, so that further yielding forces the growth of large loops of dislocation. In a simple approximation, the yield stress in a material containing particles capable of pinning dislocations is approximately 2 Gb/L, where G is the shear modulus of the matrix, b is the Burgers vector of the dislocation, and L is the separation between the particles. A conventional high strength aerospace Al alloy will have a yield stress of about 0.5 GPa, whereas a dispersion-strengthened Al film can have a yield stress up to about 5.0 GPa. The 5.0 GPa figure suggests a particle separation of about 30 Å. It is difficult to speak of continuous dislocations on size scales much less than this, which may suggest a limit on strength enhancement using dispersion strengthening. However, these numbers also suggest that any dispersion having separation greater than about 300 Å would have little effect on the strength of an Al film. It appears that obstacles in an Al body (grain and subgrain boundaries, other dislocations, work hardening, spatial variance in alloy concentration, etc.) serve to inhibit dislocation motion as well as a dispersion with 300 Å particle separation. Dispersion strengthening thus appears to occur only over a factor of ten or so in particle separation.
The size and density of the nanophase particles making up the dispersion can be greatly affected by the average composition of the material. The nanophase particles making up the dispersion must be large enough to pin the dislocations moving through the matrix. Experiment suggests that a size of ˜10 Å is sufficient to effectively pin dislocations, at least in the Al-O system. However, the dislocations must run into the particles as they move through the matrix in order to be pinned. Particles very much smaller than the particle separation tend to be less effective, as significant motion of the dislocations will occur before effective pinning occurs. Increasing the oxygen content of the composite can help to increase the density of the nanophase particles. When the composition of the composite approaches Al 2 O 3 , the properties of the composite become more nearly those of the Al 2 O 3 (high-strength but brittle), rather than those of the Al matrix (lower-strength but ductile). For dispersion-strengthening to be useful, it seems necessary for both the size of the particles making up the dispersion and the separation of those particles to be within fairly narrow values.
As mentioned above, we have found that the application of an oxygen plasma during growth from an Al deposition source produces films and thicker structures having the correct nanostructure to produce significant dispersion-strengthening. This procedure is now described.
In demonstration of this procedure, electron-beam deposition of Al combined with an oxygen plasma from an Electron Cyclotron Resonance (ECR) source is used to deposit the Al matrix containing Al 2 O 3 precipitates. The general method, however, is not dependent on either the use of an electron-beam source or the ECR plasma source. Other deposition sources, e.g., resistively heated or gas sources, could be used to provide Al atoms at the growth surface. Similarly, other plasma sources, e.g., RF, DC, and remote-plasma sources, would provide a similar oxygen plasma at the growth surface. The present example is thus of an implementation of the invention, but is not intended to limit the scope of the claims in any way.
A beam of Al atoms and a beam of O 2 + plasma are directed simultaneously on the surface of the growth substrate. The oxygen plasma is accelerated toward the substrate by a bias acting between the plasma source and the substrate. (The bias between the plasma and the substrate may either by a self bias or a bias applied through the use of power supplies external to the source of generation of the plasma.) Average layer compositions ranging from Al 0 .9 O 0 .1 to Al 2 O 3 have been grown under a wide range of deposition conditions, including variations of Al deposition rate (2-30 Å/sec), of O 2 flow rate (0.7-2.5 sccm), pressure (2-7.5×10 -5 Torr), applied DC bias (0 to -300 V), microwave power (35-150 W), and growth temperatures from 35° C. to 150° C. Note that many of these numbers pertain primarily to the deposition chamber used in our experiments, and may vary significantly in other systems. However, suitable growth conditions for other chambers can be determined without undue experimentation using methods well known in the art.
Layer compositions, thickness, and nanostructure are characterized using techniques well known in the art. The nanostructure characteristic of dispersion-strengthened films having average composition up to about 33% oxygen, or Al 2 O, is very fine grained fcc Al (grain size about 200 Å), which grains contain a fine dispersion of γ-Al 2 O 3 precipitates with an average size of 10-30 Å. The average spacing of the precipitates is about 40-50 Å (generally greater for smaller oxygen concentrations). Such dispersion-strengthened samples have been prepared on Si, Al, or SiO substrates.
A specific set of growth conditions which produce yield strengths of 1.3 GPa follow.
______________________________________Substrate temperature 100° C.Deposition rate 10-25 Å/secDC bias voltage 0 vOxygen flow rate Sufficient to grow films with 20% O content______________________________________
The oxygen flow rate and Al source conditions will have to be adjusted for each deposition system. The key is to provide a large enough flux of aluminum atoms incident on the growth surface that an acceptable deposition rate is obtained, and then to provide a sufficiently large flux of oxygen plasma at the growth surface to produce films having the desired average composition. All other parameters can be varied widely, save that the deposition temperature should not greatly exceed 150° C.
The plasma-assisted growth of Al-O alloys offers an approach to the synthesis of thick, high-strength Al-based layers. Such alloy films have a yield strength as much as 3 times that of high-strength bulk Al alloys, approaching the hardness of high-strength steel alloys while retaining much of the elasticity and light weight of the Al metal matrix.
A technique for synthesis of such alloys which is closely related in principle to the oxygen plasma source technique described above, but operates rather differently in detail is the Pulsed Laser Deposition (PLD) technique. In this method, the materials to be deposited are ablated from ablation sources by pulses of high energy laser light, producing short bursts of plasma that in turn impinge on a substrate where they quench and form the deposited layer. The high energy of the atoms in these plasma bursts distinguishes PLD from purely thermal deposition techniques such as e-beam deposition.
To grow dispersion-strengthened Al-O alloy films, a pair of ablation targets is used, specifically Al and Al 2 O 3 . Deposition is done at room temperature in ultrahigh vacuum, so that a very low deposition pressure (˜10 -9 Torr) can be used. The Al-O alloy layers are formed by ablating Al for x laser shots, switching to the Al 2 O 3 target for y shots, then back to Al and repeating until the film is grown. The ratio x:y controls the atomic composition of the film, while the total number of shots determines the final thickness. Techniques for setting these growth parameters are known in the state of the art. The geometry of the sources and substrate is defined so that each laser pulse deposits a small enough amount of material (sometimes less than one atomic layer per shot) that the final material is uniform in composition. Note that gradients in composition may be obtained by slow variation of the x:y ratio during growth.
A further set of implementations of this class of techniques for producing dispersion-strengthened films would use, e.g., a nitrogen plasma together with a Ti or Al film to form a suitable dispersion of nanophase particles. The principle of growth and formation are essentially the same, thus very similar techniques for film growth may be applied.
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A process for fabricating dispersion-strengthened ceramic-metal composites is claimed. The process comprises in-situ interaction and chemical reaction of a metal in gaseous form with a ceramic producer in plasma form. Such composites can be fabricated with macroscopic dimensions. Special emphasis is placed on fabrication of dispersion-strengthened aluminum oxide-aluminum composites, which can exhibit flow stresses more characteristic of high strength steel.
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FIELD OF THE INVENTION
[0001] The invention relates to a method of producing mixtures of polyvinyl chloride and polymers based on conjugated dienes and acrylonitrile.
BACKGROUND OF THE INVENTION
[0002] Mixtures of polyvinyl chloride and, for example, copolymers of acrylonitrile and butadiene (NBR rubbers) are known and are valued in the rubber-processing industry because vulcanates thereof exhibit very good ozone or weathering resistance, coupled with high resistance to swelling in oils or benzene and good flame resistance. In addition, the blends of nitrile rubber (NBR) with polyvinyl chloride (PVC) are distinguished by better processing properties as compared with pure nitrile rubber mixtures. Moreover, the vulcanates exhibit increased tensile strength and tear strength. Reference is made in this connection to corresponding comments in the “Handbuch für die Gummiindustrie” from Bayer AG, 2nd edition of 1991, page 90 ff.
[0003] Two different methods are employed in the rubber industry for producing the mentioned mixtures of NBR and PVC, the so-called dry blend method and the latex blend method.
[0004] In the dry blend method, the bales of NBR are comminuted and mixed with PVC powder by the batch method. The mixture is homogenized in a kneader or in a screw, the PVC component being distributed in the NBR phase to such an extent that no areas of PVC are discernible in the NBR phase. Gelling is then also referred to.
[0005] In the latex blend method, the NBR latex is blended with a corresponding PVC latex before being worked up to the solid. The mixture is then coagulated, gelled and thus worked up continuously to the solid product.
[0006] A disadvantage of the latex blend method is that the PVC latex that is used still contains a considerable amount of monomeric vinyl chloride. For reasons of environmental protection and safety in the workplace (with regard to vinyl chloride see: 1st Hazardous Substances Directive, 19th adaptation, 2nd Römpp Chemielexikon, Thieme Verlag), it is, therefore, desirable to use PVC components in which the content of monomeric vinyl chloride is less than 1 ppm. Moreover, the use of a PVC latex for producing the mentioned blends is less economical owing to the high water content of the latex, which has a negative effect on transport and on processing (removal of the aqueous phase).
[0007] Disadvantages of the dry blend method are, in particular, that the NBR and PVC components that are used must be distributed homogeneously in the blend, that the NBR and PVC components must be thoroughly distributed prior to the gelling, and that the bales of NBR that are used must be thoroughly comminuted beforehand. Those factors are all associated with a high technical outlay, so that the dry blend method is less economical than the latex blend method.
SUMMARY OF THE INVENTION
[0008] The object of the present invention was to provide an inexpensive and environmentally friendly method of producing mixtures of polyvinyl chloride and polymers based on conjugated dienes and acrylonitrile, such method avoids the above-described disadvantages of the mixing methods hitherto employed in rubber technology.
DETAILED DESCRIPTION OF THE INVENTION
[0009] Accordingly, the present invention provides a method of producing mixtures of polyvinyl chloride and polymers based on conjugated dienes and acrylonitrile, wherein the method is characterized in that powdered polyvinyl chloride is mixed with NBR latexes based on conjugated dienes and acrylonitrile, and the mixture is then coagulated.
[0010] It is important for the method according to the present invention that polyvinyl chloride in powdered form is blended with the latex based on conjugated dienes and acrylonitrile. According to the present invention, powdered polyvinyl chloride is to be understood as being homopolymers based on the emulsion or suspension or microsuspension process as well as graft copolymers and copolymers according to the suspension process having a mean particle diameter in the range from 5 to 200 μm and K values (DIN 53726 or ISO 1628) of from 40 to 90. Preference is given to powdered homopolymers based on the emulsion or, especially, the suspension process having mean particle diameters of from 40 to 150 μm and K values of from 55 to 75.
[0011] There is usually used in the method according to the present invention commercially available polyvinyl chloride having the typical residual vinyl chloride content (<1 ppm vinyl chloride), provided it meets the above-indicated specification.
[0012] There may be used as latexes based on conjugated dienes and acrylonitrile all latexes typical for NBR production that have a polymer content, by weight, in the range from 10 to 50 wt. %, with contents of from 15 to 30 wt. % being preferred.
[0013] The amount of conjugated dienes and acrylonitrile in the polymers to be used may vary within wide limits; for example, it is possible to use polymers in which the content of conjugated dienes is in the range from 40 to 90 wt. %, preferably from 55 to 75 wt. %, and the content of acrylonitrile is in the range from 10 to 60 wt. %, preferably from 25 to 45 wt. %.
[0014] Examples of conjugated dienes that come into consideration for the polymers that are to be used are especially 1,3-butadiene and isoprene as well as other conjugated dienes such as 2,3-dimethyl-1,3-butadiene, 1,3-pentadiene and piperylene, with 1,3-butadiene being preferred.
[0015] In addition to acrylonitrile, it is also possible to use its known derivatives, such as α-chloroacrylonitrile and/or methacrylonitrile.
[0016] Of course, in addition to the mentioned conjugated dienes and the acrylonitrile, it is also possible to use further monomers known to the person skilled in the art for constructing the polymers that are to be used. Mention may be made in this connection of, for example, α,β-unsaturated carboxylic acids and α,β-unsaturated carboxylic acid esters. Preference is given to fumaric acid, maleic acid, acrylic acid, methacrylic acid, as well as butyl acrylate and butyl methacrylate, as well as ethylhexyl acrylate and ethylhexyl methacrylate.
[0017] Furthermore, crosslinking polyfunctional monomers known to the person skilled in the art may be used for constructing the polymers that are to be used. Such monomers are especially di- and tri-functional monomers. Examples which may be mentioned here are divinylbenzene, diethylene glycol dimethacrylate and trimethylolpropane trimethylacrylate.
[0018] The additional monomers for construction of the polymers based on the mentioned conjugated dienes and the acrylonitriles may be present in amounts of from 0.1 to 40 wt. %, preferably from 1 to 30 wt. %, based on the total polymer.
[0019] The latexes based on conjugated dienes and acrylonitriles that are to be used according to the present invention, optionally, with addition of the additionally mentioned polymerizable monomers, are described in the specialist literature known to the person skilled in the art, as is their method of preparation (e.g. Ullmann's Encyclopedia of Industrial Chemistry, Vol. A23, p. 239-364).
[0020] By the process according to the present invention, mixtures of polyvinyl chloride and polymers based on conjugated dienes and acrylonitriles, optionally with addition of the additionally mentioned monomers, are produced in which the amount of polyvinyl chloride in the mixtures is in the range from 10 to 95 wt. %, preferably from 25 to 45 wt. %, and the amount of the described rubber polymers is from 90 to 5 wt. %, preferably from 55 to 75 wt. %.
[0021] Mixing of the two components may be carried out in many different mixing devices. Examples which may be mentioned are stirrer vessels of variable vessel geometry with single- and multi-shaft stirrers and different mixing tools as well as rotor-stator mixers, mixing by circulating by pumping with and without the use of rotor-stator dispersing machines or mixing nozzles, jet suction devices, injectors, tumbler mixers, planetary mixers, plough blade mixers with and without blade stirrers, preferably mixing in stirrer vessels or jet suction devices, injectors, guide beam mixers, especially mixing in stirrer vessels.
[0022] According to the present invention, mixing of the mentioned components takes place at temperatures in the range of approximately from 10 to 100° C., preferably at from 15 to 30° C.
[0023] It is, of course, possible to carry out mixing of the components used in the presence of stabilizers. Stabilizers, according to the present invention, can be substances and mixtures of substances conventionally employed for stabilizing PVC, such as, preferably organotin compounds, metal soaps, lead compounds and organic nitrogen compounds, with more preference being given to mixtures of calcium and zinc stearate.
[0024] The stabilizers are usually used in amounts of from 0.2 to 5 wt. %, preferably from 0.4 to 2 wt. %, based on the rubber PVC mixture.
[0025] The method according to the present invention may, for example, be carried out in such a manner that the latex based on conjugated dienes and acrylonitrile is placed in a vessel and the polyvinyl chloride in powdered form is mixed therewith, with intensive thorough mixing by means of stirrer vessels, until a homogeneous mixture of polyvinyl chloride and the mentioned polymers has formed.
[0026] In the method according to the present invention, after mixing of the powdered polyvinyl chloride with latexes based on conjugated dienes and acrylonitrile, the suspension so obtained is coagulated. To that end, known precipitating agents are added to the suspension in the conventional manner (see in this connection Ullmann's Encyclopedia of Industrial Chemistry, Vol. A23, p. 260 to 261).
[0027] There is obtained a mixture of polyvinyl chloride and the polymers based on conjugated dienes and acrylonitrile in solid form, which can be processed further in the conventional manner for the production of vulcanates of all kinds, for example, for use, in hoses.
[0028] It is surprising that it has been possible by the method according to the present invention to produce mixtures of polyvinyl chloride and polymers based on conjugated dienes and acrylonitrile simply by mixing powdered polyvinyl chloride with the mentioned latexes, since it was to be expected that, on stirring the PVC powder into the latex, coagulation of the latex would occur so that it would not be possible to obtain the desired homogeneous mixture of the two components. Furthermore, the analytical determination of the organic chloride content in the blend indicates that the PVC powder has been completely coagulated together with the NBR latex. There is no loss of PVC as a result of washing operations during the working-up process. Moreover, it was surprising that, under the mixing conditions, no separation of the components occurs and that mixtures are obtained that do not differ in terms of physical behaviour from the corresponding mixtures produced by the dry blend method or the latex blend method.
[0029] The invention is further illustrated but is not intended to be limited by the following examples in which all parts and percentages are by weight unless otherwise specified.
EXAMPLE
[0030] With stirring, 30 parts of a suspension PVC powder having a K value of 71 (Solvin) and 1 part of a calcium-zinc stearate mixture (Ciba) are added to 70 parts of a Perbunan NT 2830 (Bayer AG) latex. Stirring is continued for a further one hour before the mixture is precipitated by addition of a calcium chloride solution at 70° C. The rubber is filtered off and washed with water. The rubber is then dried. Examination under a microscope shows uniform distribution of the PVC powder in the rubber, and chlorine determination yields the theoretically calculated Cl content, which confirms complete precipitation of the PVC powder with the rubber.
[0031] Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims.
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The invention relates to a method of producing mixtures of polyvinyl chloride and polymers based on conjugated dienes and acrylonitrile, by mixing powdered polyvinyl chloride with latexes based on conjugated dienes and acrylonitrile and then coagulating the mixture. The method according to the present invention represents an inexpensive and environmentally friendly method of producing the mentioned mixtures, the physical behavior of the resulting mixtures being no different to that of corresponding mixtures produced by the dry blend method or the latex blend method.
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FIELD OF INVENTION
[0001] The present invention generally relates to the field of processes and apparatus for converting carbonaceous materials such as biomass, waste, coal, organic materials etc. to product gas which is one of either producer gas, typically obtained from air-blown gasification, or syngas, typically obtained from indirect or oxygen-blown gasification that is essentially free of tar or tar forming compounds and wherein carbon conversion and yield of product gas in increased.
BACKGROUND
[0002] When carbonaceous materials are heated during a gasification process, gaseous species of varying molecular weights are released as product gas. Production of product gas via gasification of renewable resources has been a focus for researchers for decades. For this purpose, carbonaceous materials include but are not limited to biomass, waste, coal, etc.
[0003] Product gas as used herein is a mixture of hydrogen (H2), carbon monoxide (CO) and other combustible and non-combustible gases whereas the hydrogen and carbon monoxide concentrations are maximized, and can be considered as either a fuel gas where it is typically burned directly as fuel to produce heat and/or electric power or as an intermediate for multiple uses, such as synthesis of liquid fuels, chemicals, or other materials.
[0004] Carbonaceous species in product gas with molecular weights greater than benzene (MW=78) are generally classified as tars. As initially produced, these tars are reactive or problematic due to their chemical functional groups including but not limited to: hydroxyls, aldehydes, ketones, carboxylic acids, alkenes, alkynes, heterocyclic structures, in any combination, which can allow them to polymerize and thereby cause plugging, form coke or other solid deposits, cause equipment to seize, or have other deleterious effects. The presence of these reactive or problematic tars in product gas has plagued most gasification projects and has been the Achilles heel of gasification.
[0005] Capital needs for conversion of carbonaceous materials to product gas are substantial and available processes and equipment still leave much to be desired by way of efficiency of production and ease of operation and maintenance. Although the process of gasification has been practiced for decades, and many, many gasifier designs have been invented, no gasifier exists that can produce a product gas free of tar at commercial scales appropriate for economically compelling conversion of carbonaceous materials into liquid fuels, electric power, or chemicals.
[0006] What was needed was a method and apparatus that performs tar conversion to a large extent, would increase product gas production, and would increase carbon conversion, and could do so under conditions that would prevent melting, slagging, clinkering, or agglomeration of char-ash particles, and can be built at an economically viable scale and cost. As used herein, “tar conversion” or “conversion of tar” means removal, modification, or transformation of chemical functional groups within the tar species, including but not limited to: deoxygenation, hydrogenation, reforming, cracking, depolymerization, or other chemical reactions that result in less problematic tar species and/or lower molecular weight species including gases such as H2 and/or CO.
[0007] As is known in the art, Ziad Abu El-Rub, Biomass Char as an In - situ Catalyst for Tar Removal in Gasification Systems , PhD thesis dissertation, Twente University, Enschede, The Netherlands, March 2008, char-ash (also known as biochar, char, fly ash, or simply ash) can be used as a catalyst to convert tars produced in the gasification of carbonaceous material. It would be desirable to partially oxidize the residual carbon in the char-ash while avoiding oxidation of hydrogen or other valuable constituents in the product gas to generate additional CO in the product gas, generate enough heat to support/enable endothermic tar conversion reactions, enhance or improve the catalytic activity of the char-ash for tar conversion reactions, and maximize carbon conversion while simultaneously enabling smaller reactor volumes or reduced reactor temperatures, all leading to lower cost and more robust operations.
SUMMARY OF INVENTION
[0008] It is the first objective of the present invention to increase product gas yield;
[0009] It is a second objective of the present invention to increase the activation of the surface of char-ash in order to increase its catalytic activity;
[0010] It is a third objective of the present invention to “hold up” char-ash to increase the ratio of char-ash to product gas in the process and to enhance product gas and-char-ash contacting;
[0011] It is a fourth objective of the present invention to provide the heat needed for tar conversion without causing or requiring the oxidation of product gas;
[0012] It is a fifth objective to convert tar under conditions where that reaction is favored and under conditions that result in increased yield of product gas;
[0013] It is a sixth objective of the present invention to increase carbon conversion but simultaneously control the temperature during carbon partial oxidation by providing an excess of char-ash and multiple opportunities for the partial oxidation of the char-ash; and
[0014] It is a seventh objective of the present invention to utilize any of multiple oxygen sources including air, enriched oxygen air (mixtures of air and oxygen), or pure oxygen with varying amounts of steam, carbon dioxide, or other gases as reaction constituents and/or ballast.
[0015] It is an eighth objective of the present invention to reduce the residence time of tar-laden product gas after it is initially produced in an environment of low char-ash concentration to prevent reactions of tar which may form refractory tars of higher molecular weight.
[0016] The present invention comprises a method for converting tars and increasing efficiency of product gas production. The invention provides means to separate and then hold up char-ash from product gas for the purpose of performing tar conversion reactions. The invention also provides a means of increasing product gas yield by partially oxidizing elutriated char-ash to enhance the amount of CO produced while preventing combustion of hydrogen or other desired gases from the product gas.
[0017] Many other methods of producing product gas exist and gasifier inventions are almost as numerous as the number of gasifiers built. Gasifiers can generally be classified by how heat is applied to the process—either direct or indirect. Examples of direct gasifiers include fixed bed, fluid bed, or entrained flow. Examples of indirect gasifiers include plasma or allothermal.
[0018] Allothermal systems rely on combustion of char-ash in a separate reactor from where the gasification reactions take place in order to produce heat. The heat is then circulated back into the gasifier via some heat transfer medium (usually a granular solid such as sand or granular catalyst material) and char-ash and flue gas from char-ash combustion are removed from the combustion reactor. By employing an allothermal reaction and not allowing char-ash to contact product gas to any great extent, these methods are unable to take advantage of the catalytic effect of char-ash, and the resulting increase in product gas production. Plasma systems rely on electricity to form a plasma arc which provides the energy required to volatilize gases and raise the gaseous mixture to a temperature at which all gases are reduced to low molecular weight. While many plasma gasifiers are able to produce a product gas with low tar content, they suffer from very low thermodynamic efficiency, are difficult to scale up, and are typically very expensive.
[0019] Direct gasifiers are also unable to take advantage of the catalytic effect of char-ash without a corresponding destruction of product gas or creating a high temperature zone that leads to ash melting problems previously described, unless, as provided for in the description of the present invention, a zone is provided to separate char-ash from syngas where the partial oxidation of the char-ash can take place without simultaneously combusting product gas.
[0020] Methods for managing tar in direct gasifiers often employ high temperatures to thermally convert tar and/or scrubbers/absorbers/condensers, etc. to remove tar. The high temperatures can create melting or softening of ash components and this can create slagging and/or agglomeration which, in turn, requires maintenance and/or specific processes for removal of agglomerates in order to retain the reactor's ability to produce product gas.
[0021] For example, downdraft gasifiers use high temperature and holdup of char-ash to take advantage of the catalytic effects of the char-ash to reduce tars. Downdraft gasifiers are known to those skilled in the art as low tar-producing gasifiers due to this effect. The problem with these fixed-bed gasifiers, however, is that they can not be scaled up to very large size or large throughput units since the fixed bed of char-ash can develop preferential flow patterns (known as channeling or rat-holing) that can cause bypassing of the char-ash bed, stoppage of char-ash flow, or other problems.
[0022] Gasifier systems that employ liquid-based scrubbing of tar from product gas suffer thermodynamic efficiency losses, may create a waste water stream, may contaminate equipment with hazardous compounds, and require additional, expensive, and energy intensive unit operations to achieve a low tar concentration.
[0023] The method of the present invention addresses the shortcomings of other methods. The present invention comprises separating a first stage of gasification from a second stage of tar conversion and char-ash heating. Char-ash particles are elutriated from the first stage of gasification. These particles are most preferred to be finely divided and of a size range that enables them to move from the first stage to the second stage. By avoiding the larger particles of char-ash, the catalytic effect of char-ash is enhanced since the effect of diffusion which is expected with larger particles and which typically poses limitations on reaction rates, is reduced. The method optionally uses an external or internal heat source to provide the heat needed to convert tar. As used herein, “external” heat source means a source of energy other than the chemical energy available in the char-ash or product gas, including, but not limited to electricity, electromagnetic radiation, combustion of fuels inside or outside the char-ash heating zone boundary, thermal fluids, and so forth. One particular method of providing an internal heat source is to partially oxidize char-ash in the heating zone which, in this method, is a char-ash rich, product gas lean zone. This controlled char-ash oxidation provides the heat necessary for tar conversion while increasing production of CO and preventing combustion of hydrogen or other desirable constituents from the product gas, thereby resulting in an increase in product gas yield. In this particular method, the creation of a separate char-ash rich zone is necessary, because otherwise the product gas will tend to oxidize first and to a greater extent due to the faster kinetics of gas combustion compared to the oxidation of solid carbon in char-ash.
[0024] The present invention includes but is not limited to two stages of gasification, delivery of first stage tar-laden and char-ash laden gasification product gas to a second stage of gasification where the tars are provided adequate space, contact with char-ash, time, and temperature for conversion of tars in the product gas occurring as a result of the hold up of the char-ash, and the resulting higher char-ash/product gas ratio possible in the second stage of gasification. The second stage of gasification may be comprised of one or more zones: one or more tar conversion zone(s) where a high char-ash/product gas ratio is employed to convert tars, and optionally one or more char-ash heating zone(s) where the char-ash undergoes heating via an internal or external heat source.
[0025] In embodiments of the method that utilize char-ash heating zone(s), char-ash oxidation may be used as an internal source of heat. In this case, in the char-ash heating zone partially oxidizes char-ash which produces heat and activates the carbon at the surface of the char-ash particles. The oxidized carbon surface is expected to have an activity for tar conversion that is significantly greater than expected for a carbon surface in a reduced state, especially for the conversion of the most problematic refractory tars such as poly-aromatic hydrocarbons including naphthalene, anthracene, coronene, and so on. The carbon surface serves as a site for adsorbed oxygen and therefore can act as an oxygen transfer catalyst, which can also enhance the selectivity of tar conversion over gas-phase oxidation of CO or H2, owing to the solid-phase adsorption characteristic of heavy tars being preferred over light gases. This oxygen adsorption effect may also significantly reduce the temperatures required in the tar conversion zone to achieve the desired tar conversion.
[0026] Hot, activated char-ash and product gas containing tar are contacted in the tar conversion zone(s) which allows tar conversion to occur on the surface of the char-ash. Tar-free product gas is separated from char-ash by cyclones where most of the char-ash is delivered back to the char-ash oxidation zone, and product gas exits the reactor.
[0027] In methods employing char-ash oxidation in the char-ash heating zone, the temperature in the char-ash heating zone is kept below the temperature threshold that would result in ash melting or slagging. The char-ash circulation rate in the tar conversion zone(s) should be maximized. A higher char-ash/gas ratio in the tar conversion zone(s) reduces the temperature needed to achieve beneficial rates of tar conversion. Maximizing the char-ash circulation rate increases the ratio of char-ash to oxygen in the char-ash oxidation zone, thereby increasing the yield of CO relative to carbon dioxide (CO2) produced in the char-ash oxidation zone. Also, maximizing the char-ash circulation rate increases the mass rate through the char-ash heating zone, which increases the char-ash to incoming product gas ratio and thereby reduces the char-ash heating zone temperature needed to achieve the desired temperature in the tar conversion zone.
[0028] The method may be accomplished via several alternative apparatus assemblies. At its simplest, a first embodiment includes a second reactor separate from the first stage gasifier, having only a tar conversion zone. Product gas and char-ash suspended in the product gas from a separate first stage gasifier enters a char-ash heating zone and the bottom of the tar conversion zone in the second reactor; char-ash is separated from product gas after exiting the second reactor in a single or series of cyclone(s); char-ash is returned to the tar conversion zone and product gas exits the reactor.
[0029] Another embodiment includes a second reactor separate from a first stage gasifier, the second reactor having a char-ash heating zone and a tar conversion zone. Product gas and char-ash suspended in the product gas from the separate first stage gasifier enters the bottom of a tar conversion zone in the second reactor; char-ash is separated from product gas after exiting the second reactor in a single or series of cyclone(s); char-ash is returned to the char-ash heating zone via at least one standpipe for heating by external means to a desired outlet temperature. This provides heat to drive the endothermic tar conversion reactions in the tar conversion zone.
[0030] Another embodiment includes a second reactor separate from the first stage gasifier, having a char-ash heating zone and a tar conversion zone. Product gas and char-ash suspended in the product gas from a separate gasifier enters the bottom of a tar conversion zone in the second reactor; char-ash is separated from product gas after exiting the second reactor in a single or series of cyclone(s); char-ash is returned to the char-ash heating zone via at least one standpipe where an oxidizing agent is introduced and the char-ash is partially oxidized to a target outlet temperature with no oxygen in the gas exiting the char-ash oxidation zone. This provides heat to drive the endothermic tar conversion reactions in the tar conversion zone. Partial oxidation leaves the surface of the char-ash in an activated state and thus improved catalytic activity for tar conversion.
[0031] Another arrangement employs a split standpipe, where the lower leg delivers char-ash to the char-ash heating zone. The upper leg operates in a streaming flow regime and most of the product gas entrained with the char-ash solids therefore is returned to the tar conversion zone, so less entrained product gas is delivered to the char-ash heating zone. The char-ash heating zone can operate in an overflowing bubbling fluidized bed, fast fluidized bed, or entrained flow regime
[0032] Still another embodiment employs a series of cyclones. A first cyclone or first series of cyclones recycles char-ash back to a tar conversion zone through a standpipe or series of standpipes located internally in the reactor and a second cyclone, which may be internal or external to the reactor, recycles char-ash back to the char-ash heating zone. This arrangement preferentially delivers lower carbon-content char-ash to the char-ash heating zone and may result in improved overall carbon conversion.
[0033] In another embodiment, a single vessel houses both stages of gasification (both reactors). This arrangement positions the first stage gasifier below the char-ash heating zone. The char-ash heating zone includes within it overflow standpipes for returning any entrained bed media (typically, but not limited to sand, limestone, dolomite, olivine, aluminum oxide, silicon carbide, or other granular solids) back to the first stage gasifier. Product gas and tar and char-ash from the first stage gasifier bypasses the char-ash heating zone via product gas transfer pipes which deliver them to the tar conversion zone. At the top of the tar conversion zone, internal cyclones and standpipes (char-ash standpipes) are present for delivering char-ash back to the char-ash heating zone which operates in overflowing bubbling fluidized bed regime. Char-ash disengages from product gas entrained by char-ash at the outlet of the char-ash standpipes allowing that entrained product gas to travel back up the tar conversion zone to the cyclone inlet, and allowing the char-ash to return to the oxidation zone. The char-ash oxidation zone may be operated in bubbling, turbulent or fast fluidization, or entrained flow regimes. The product gas from the first stage gasifier is blended with product gas from the char-ash heating zone; the char-ash heating zone when operated to cause partial oxidation of char-ash provides the necessary heat and activated char-ash catalyst for tar conversion reactions to take place within the tar conversion zone. This embodiment provides a broader scope of scalability than the aforementioned embodiments and is amenable to increasing the vessel diameter without detriment to good flow distribution. A smaller, shorter freeboard, or a smaller volume provided in the first reactor may be employed in this, or other embodiments which in turn, allows more vessel volume to be applied or utilized for conversion. This may lower vessel fabrication costs, but also may provide less residence time for the product gas to exist in a low char-ash/product gas ratio environment, which may reduce the extent of maturation of less refractory tars into more refractory tars.
[0034] Other modifications and embodiments also exist. For example but not for limitation, the following modifications and embodiments may be considered within the purview of this invention: swaged sections may be employed to adjust diameters, effect the desired residence times and solid holdup in the fluidized beds, riser, standpipes or other sections of the process. Heat exchangers may be added to remove from or transfer heat to: the tar conversion zone, standpipes, char-ash heating zone, or other portions of the system, which may have application for startup, shutdown, or operational conditions for enhancing selectivity, conversion, or protection of metallurgy or materials of construction. Variations in materials of construction of the vessel shell or internals and variations in refractory design are also possible and may include enhancements to enhance or reduce heat transfer, reduce erosion, corrosion, or provide other vessel shell protection or protection for internal structures. Addition of sorbents, minerals, or other catalysts to the process to enhance tar conversion or to effect stability or selectivity of the process may be used. Addition of chemicals (such as but not limited to sulfur) to the feedstock, in order to improve the life of the metallurgy of the internals or enhance catalytic activity of the char-ash can be considered. Liquids, solid or gaseous sorbent to act as getters for process contaminants may be employed to address the presence of heavy metals, toxic metals, halides or other undesired species. Finally, internals may be added to the riser section or the reactor may be inverted so that the tar conversion zone is operated in down flow mode to improve gas/solid contact and/or flow distribution by increasing solids holdup, turbulence, or by reducing the gas/solids separating effects. Many of these variations may be used as described in Wen-Chin Yang, Handbook of Fluidization and Fluid-Particle Systems, CRC Press, 2003 and/or Fluidization engineering, Chemical Engineering Series, Daizo Kunii, Octave Levenspiel, Edition 2, Publisher Butterworth-Heinemann, 1991, ISBN 0409902330, 9780409902334.
[0035] These, and other considerations, may be used in combination with or as augmentations to the present invention.
[0036] Other objects, features, and advantages of the present invention will be readily appreciated from the following description. The description makes reference to the accompanying drawings, which are provided for illustration of the preferred embodiment. However, such embodiment does not represent the full scope of the invention. The subject matter which the inventors do regard as their invention is particularly pointed out and distinctly claimed in the claims at the conclusion of this specification.
DRAWINGS
[0037] FIG. 1 a prior art gasification assembly;
[0038] FIG. 2 an embodiment of the present invention comprising a tar conversion zone, external cyclone, and standpipe in a separate reactor vessel from the first stage gasifier;
[0039] FIG. 3 an embodiment of the present invention comprising a tar conversion zone, external cyclone, and split standpipe;
[0040] FIG. 4 an embodiment of the present invention comprising a tar conversion zone, at least one internal cyclone and associated standpipe(s), and an external cyclone and associated standpipe in a separate reactor vessel; and
[0041] FIG. 5 an embodiment of the present invention comprising a single vessel where both first stage gasification and second stage tar conversion reactions take place.
DETAILED DESCRIPTION OF THE INVENTION
[0042] Prior art gasification assemblies can include one or several types of gasification processes. As an example, FIG. 1 shows an apparatus that includes a vessel 1012 comprising a char-ash oxidation zone 1014 where char-ash 1020 is partially oxidized and a tar conversion zone 1016 having an exit 1028 . Said exit 1028 is fluidly connected to a cyclone 1022 for separating particulates from the gas which gas is then collected. The separated particulate matter is then discarded or may be sent to the bed below the char-ash oxidation zone. Gasifiers of this nature are disclosed and described in such texts as Handbook of Biomass Gasification, edited by H.A.M. Knoef, BTG Biomass Technology Group, Krukkerij Giethoorn ten Brink, Meppel, the Netherlands, 2005, ISBN 90-810068-1-9 and Combustion and Gasification in Fluidized Beds, Prabir Basu, CRC Press, 2006, ISBN 0-8493-3396-2 and Biorenewable Resources Engineering new Products from Agriculture, Robert Brown, Iowa State Press, 2003, ISBN 0-8138-2263-7.
[0043] The present invention comprises a method for gasifying carbonaceous material, which includes two stages of gasification. Product gas and char-ash from the first stage is delivered to a second stage where it is mixed with a hot char-ash stream exiting either a char-ash oxidation zone which provides heat and char-ash with an activated carbon surface or a char-ash heating zone which provides heat. This increases catalytic action necessary for adequate tar conversion, lessens the oxidation of CO and H2 resulting in increased product gas yield, and reduces temperature required for the desired tar conversion. The method may also include any of the aforementioned augmentations.
[0044] Various apparatus assemblies may be employed. A first embodiment of such an assembly shown in FIG. 2 includes a first stage gasifier vessel 210 and a separate vessel 212 wherein said separate vessel 212 further comprises a char-ash oxidation zone 214 where char-ash 220 is partially oxidized with an oxidizer 238 (such as but not limited to air, enriched oxygen (air and oxygen mixture), or any gas containing oxygen) and a riser comprising tar conversion zone 216 having an exit 228 . Said exit 228 is fluidly connected to a cyclone 22 which, in turn, is fluidly connected to a standpipe 218 having a first end 218 a and a second end 218 b . The second end 218 b is fluidly associated with the char-ash oxidation zone 214 of the separate vessel 212 . Char-ash and tar laden product gas 234 from the first stage gasifier vessel 210 enters the separate vessel 212 above the char-ash oxidation zone 214 . Char-ash 220 is partially oxidized in the char-ash oxidation zone 214 and then contacts the incoming char-ash and tar laden product gas 234 . Both travel up the separate vessel 212 to the exit 228 to the cyclone 222 where the char-ash laden, tar free product gas 238 exits and the separated char-ash 220 is returned through the standpipe 218 to the char-ash oxidation zone 214 . While char-ash and tar laden product gas 234 and partially oxidized char-ash 220 are present in the tar conversion zone 216 , tar is converted to low molecular weight product gas products by catalytic action of the char-ash 220 . The conditions are such that the tar conversion reactions are selected over the gas-phase oxidation of CO or H2 thereby resulting in a higher yield of tar free product gas 238 .
[0045] A second embodiment shown in FIG. 3 includes the first stage gasifier vessel 310 , the separate vessel 312 , the char-ash oxidation zone 314 , the tar conversion zone 316 having exit 328 connected to the cyclone 322 in turn fluidly connecting to standpipe 318 . Here, said standpipe 318 is split to comprise an upper leg 330 and a lower leg 332 . The upper leg 330 operates in streaming flow as does the remainder of the standpipe 318 above the upper leg 330 , but the lower leg 332 operates in a stick-slip or packed bed flow regime. The effect of the split standpipe 318 is to reduce the amount of entrained product gas delivered to the char-ash heating zone 314 since most of the entrained product gas going down the standpipe 318 will move through upper leg 330 and bypass the char-ash heating zone 314 and be, instead, delivered to the separate vessel 312 in the tar conversion zone 316 and, in another embodiment where char-ash is partially oxidized, avoiding contact with the oxidizer 338 in the char-ash heating zone 314 .
[0046] A third embodiment in FIG. 4 includes a gasifier vessel 410 , a separate vessel 412 , a char-ash heating zone 414 , a riser comprising a tar conversion zone 416 having an exit 428 and a first stage cyclone or a plurality of first stage cyclones 440 . Said exit 428 and a second stage cyclone 430 external to the separate vessel 412 are fluidly associated with a standpipe 418 . The standpipe 418 returns char-ash 20 to the char-ash heating zone 414 . Char-ash laden, tar free product gas 436 is allowed to exit from the tar conversion zone 416 at exit 428 . Said first stage cyclone or plurality of first stage cyclones 440 are each comprised of a solids exit via a char-ash standpipe 445 , and a gas outlet fluidly connected to exit 428 . Each said standpipe 445 includes an outlet 445 a providing space enough for most of the char-ash 20 to disengage from any entrained char-ash laden, tar free product gas 436 that also flows down the standpipe 445 , such that the entrained char-ash laden, tar free product gas 36 is allowed to go back up the tar conversion zone 416 and some of the char-ash 20 can mix into the char-ash heating zone 414 . The standpipe 445 recycles char-ash 20 back to the lower portion of the tar conversion zone 416 but above the char-ash heating zone 414 . The second stage cyclone 430 serves to provide improved capture efficiency of char-ash 20 . Due to the lower solids loading in the second stage cyclone 430 , the amount of char-ash laden, tar free product gas 436 that is entrained in the second stage standpipe 418 is reduced, such that this standpipe can operate in packed bed or stick-slip regime, reducing the amount of product gas 436 that enters the char-ash heating zone 414 . Char-ash laden, tar-free product gas 436 exits the system at the product gas outlet 424 .
[0047] A fourth embodiment in FIG. 5 comprises a single vessel 512 having a first stage gasifier 510 , a char-ash heating zone 514 where char-ash is partially oxidized with an oxidizer 538 , and a tar conversion zone 516 where tar conversion reactions take place. This embodiment is enabled by placement of two separate categories of standpipes which provide a means for char-ash 20 to be returned to the heating zone, product gas 34 from the first stage gasifier 510 to be transferred through and thus bypass the char-ash heating zone 514 and entrained bed media to be returned to the dense phase of the first stage gasifier 510 . Specifically, the vessel 512 further includes one or a series of cyclones 540 . Each said cyclone is comprised of a char-ash laden, tar free product gas 36 outlet fluidly connected to the vessel gas outlet 528 and to a standpipe(s) 545 for allowing char-ash 20 to be transported to the char-ash oxidation zone 514 . At the outlet of the standpipe(s) 545 entrained product gas 36 is allowed to disengage from char-ash 20 to rise back through the tar conversion zone 516 . The char-ash 20 from the standpipe(s) 545 mixes with the char-ash 20 in the char-ash oxidation zone 514 . The vessel 512 also includes at least one or a plurality of bed media standpipes 550 for returning any entrained bed media to the first stage gasifier 510 . The vessel further includes at least one or a plurality of product gas transfer pipes 560 for allowing char-ash and tar laden product gas 34 to pass directly from the first stage gasifier 510 to the tar conversion zone 516 , bypassing the char-ash oxidation zone 514 .
[0048] Thus, the present invention has been described in an illustrative manner. It is to be understood that the terminology that has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the present invention may be practiced otherwise than as specifically described.
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A method and assembly for producing substantially tar free product gas from gasification of carbonaceous material. The assembly preferably includes a first stage gasifier to produce char-ash and tar laden product gas and a second stage gasifier which has a char-ash heating zone, at least one cyclone, and at least one standpipe for the purpose of allowing selective delivery of char-ash to the char-ash heating zone. A char-ash heating zone that utilizes oxidation of char-ash is preferred and this results in the heat required to convert tar, additional yield of product gas, and an oxidized, activated carbon surface to facilitate tar conversion in the riser, thereby reducing the temperature required to achieve the desired tar conversion. Alternatively, external heat is supplied to the heating zone.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a regular application claiming priority from provisional patent application Ser. No. 60/792,821 and 60/792,822 both filed 18 Apr. 2006.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] None
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON COMPACT DISC
[0003] None
BACKGROUND OF THE INVENTION
[0004] (1) Field of the Invention
[0005] The present invention relates to compounds used to label biomolecules for diagnostic and therapeutic purposes. In particular, it relates to fluorescent, chromophoric, pro-fluorescent and pro-chromophoric compounds that may be conjugated to biomolecules such as proteins and nucleic acids. Such compounds may be incorporated into linkers that may be used to link a ligand to a biomolecular probe allowing quantitation of the ligand bound to that molecular probe.
[0006] (2) Description of Related Art
[0007] Methods to detect interactions between biomolecules continues to be an area of active research as new and more sensitive methods are required to increase sensitivity, reduce costs and enable new detection methods. One of the most widely used methods is to directly label a biomolecule with a fluorescent molecule that fluoresces at a desired frequency. For example, a fluorescent molecule is modified with a thiol- or amino-reactive moiety such as succinimidyl esters or maleimides that form a covalent bound in the presence of a sulhydryl or amine group of a desired protein. The modified fluorescent molecule is isolated and reacted with the desired protein. The fluorescently labeled protein is then used to detect a desired target by monitoring the unique fluorescent frequency of the fluorophore. A variety of fluorophores have been modified with these moieties including fluorescein, rhodamine, Texas Red and cyanine dyes, Cy3 and Cy5. Unfortunately, the conjugation methods often cause quenching and photobleaching of the fluorophore and there can be interference with the observed signal if the unbound labeled biomolecule is not removed from the reaction mixture.
[0008] Other biolmolecules such as nucleic acids such as DNA, RNA, polynucleotide and oligonucleotides have been labeled with fluorophores is commonly accomplished by incorporating a fluorophore on the base moiety of a nucleoside triphosphate. These fluorescently labeled triphosphates are added to the polymerase chain reaction (PCR) or reverse transcription reaction wherein the labeled nucleoside is incorporated in the amplicon yielding a fluorescently labeled polynucleotide. These fluorescently labeled polynucleotides are probed using oligonucleotide microarrays identifying sequences present in the target. Unfortunately, the fluorophores used for labeling these biomolecules are not often stable to these synthesis conditions. In addition, the long-term stability of conjugates are low due to photobleaching, consequently, retention of the fluorescent signal is difficult when archiving microarrays.
[0009] A variety of references cite the use of fluorescent hydrazides, thiosemicarbazides and hydrazides to react with aldehydes on biological molecules for the detection of the aldehydes. For example Ahn et al. (B. Ahn, S. G. Rhee and E. R. Stadtman, Anal. Biochem. 161:245 (1987) describe the use of fluorescein hydrazide and fluorescein thiosemicarbazide for the fluorometric determination of protein carbonyl groups and for the detection of oxidized proteins on polyacrylamide gels. Proudnikov and Mirzabekov (Nucl. Acids Res. 24:4535 (1996)) describe labeling of DNA and RNA to identify acid-induced depurination that results in production of aldehyde moieties detected by reaction of fluorescent labels containing hydrazide groups in the presence of sodium cyanoborohydride. Others have labeled the reducing end of polysaccharides with fluorescent hydrazides. These methods are used to detect aliphatic aldehyde groups on biomolecules. In each of the references the fluorescent moiety is incorporated on the hydrazine or hydrazide that forms a hydrazone on reaction with the aldehyde present on the biomolecule.
[0010] It has been documented that hydrazones formed between certain aromatic aldehydes and aromatic hydrazines and not aromatic hydrazides or aromatic thiosemicarbazides form fluorescent molecules (J. Wong and F. Bruscato, Tet. Lett. 4593, 1968). It has also been reported that hydrazones formed specifically from 2-substituted aldehyde heterocycles and 2-substituted hydrazine heterocycles become fluorescent on chelation to zinc (D. E. Ryan, F. Snape and M. Winpe, Anal. Chim. Acta 58:101, 1972).
[0011] Schwartz et al. (U.S. Pat. No. 5,420,285; U.S. Pat. No. 5,753,520; U.S. Pat. No. 5,420,285; J. Nucl. Med. 31(12):2022, 1990 and Bioconjug. Chem. 2(5):333, 1991) describe the preparation of succinimidyl 6-hydraziniumnicotinate hydrochloride for the one-step modification of amino groups on proteins and other molecules to incorporate pyridylhydrazine moieties on proteins for the specific purpose of binding technetium-99m for in vivo diagnostic purpose. Subsequently Schwartz (U.S. patent application, titled: Functional Oligonucleotide Modification Reagents and Uses Thereof, filed Aug. 1, 2000) describe novel oligonucleotide aldehyde and hydrazine phosphoramidite reagents for incorporation of aldehydes and hydrazines on synthetic oligonucleotides including aromatic and heteroaromatic aldehydes and hydrazines. Triphosphates incorporating both aromatic hydrazine and aromatic aldehydes have been described by Schwartz and Hogrefe (U.S. Pat. No. 6,686,461).
[0012] Cytidine and deoxycytidine moieties in polynucleotides can be transformed into 4-N-aminocytidine (4-hyd-C), an aromatic hydrazine, by treatment with hydrazine/bisulfite at neutral pH. Nitta et al. Eur. J. Biochem. 157(2):427, 1986 has described crosslinking between 16S ribosomal RNA and protein S4 in E. coli ribosomal 30S subunits effected by treatment with bisulfite/hydrazine and bromopyruvate. Also Musso et al., (U.S. Pat. No. 5,130,466) describe labeling of 4-N-aminocytidine moieties on hydrazine/bisulfite treated DNA to yield a fluorescently labeled polynucleotide. Bittner et al. (U.S. Pat. No. 5,491,224) also describe the labeling of transaminated DNA with fluorescent moieties possessing moieties that react with the transaminated cytosine such as fluorophores possessing succinimidyl esters.
[0013] In all of the aforementioned references the biomolecule is fluorescently labeled with a fluorescent molecule. Unfortunately as previously stated the processes or methods used to prepare the conjugate can often times cause quenching or photobleaching of the fluorophore. In addition, during use the unbound fluorescently labeled conjugate must be removed to obtain an accurate fluorescent signal.
[0014] Therefore, there is a need in the field for a fluorescent label that is resistant to reaction conditions necessary for producing a labeled biomolecule and does not require removal of the unbound fluorescently labeled biomolecule from the detection reaction mixture to obtain a accurate and/or quantitative signal. There is also a need for fluorophores that may be formed under standard assay conditions from pro-fluorophores which, are stable under various laboratory conditions and by a reaction that is highly specific and efficient.
[0015] To date the most commonly used method to link, immobilize and detect biomolecules is the biotin/streptavidin ligand/receptor couple. Biotin ( FIG. 1 ) is a small molecule, MW 250, that binds to streptavidin with an association constant of 10 15 . The extremely high binding constant and fast kinetics of binding and the stability of avidin under a variety of conditions make this an ideal ligand/receptor pair for these purposes. Biotin has been modified to include amino, thiol and carbohydrate reactive moieties, i.e. succinimidyl ester, maleimido and hydrazide respectively, to allow easy incorporation into a large variety of biomolecules. To accomplish detection of an analyte, biotin is conjugated to a probing biomolecule such as an antibody or an oligonucleotide. Following binding of the biotinylated biomolecule to its receptor or complement, an avidin/reporter conjugate such as an avidin/fluorophore conjugate or a avidin/reporter enzyme conjugate is added and allowed to bind to biotinylated probe and visualized by fluorescence detection or addition of a substrate that emits light or precipitates a colored insoluble product on enzymatic processing (Heitzmann H., Richards F. M., Proc. Natl. Acad. Sci. USA 71:3537-3541, 1974; Diamandis E. P., Christopoulos T. K., Clin. Chem. 37:625-636, 1991; Wilchek M. Methods Enzymol Vol. 184, 1990; Savage, M. D. et al., 1992 Avidin-Biotin Chemistry: A Handbook. Rockford, Ill.: Pierce Chemical Co.).
[0016] Following conjugation it is important to determine that the probe molecule has been biotinylated and to quantify the number of biotins now conjugated to the probe molecule. To this end two multi-step indirect assays have been developed. The first assay is the HABA ([2-(4′-hydroxyazobenzene)] benzoic acid) assay developed by Green (Green, N. M. Biochem. J., 94, 23c-24, 1965). To quantify biotin label incorporation, a solution containing the biotinylated protein is added to a mixture of HABA and avidin. Because of its higher affinity for avidin, biotin displaces the HABA from its interaction with avidin and the absorption at 500 nm decreases proportionately. By this method, an unknown amount of biotin present in a solution can be evaluated in a single cuvette by measuring the absorbance of the HABA-avidin solution before and after addition of the biotin-containing sample. The change in absorbance relates to the amount of biotin in the sample.
[0017] The second more sensitive fluorescence-based multi-step assay developed by Molecular Probes (recently acquired by Invitrogen Corporation in Carlsbad, Calif.) is the ‘Fluoreporter Biotin Quantitation Assay’ that is based on fluorescence resonance energy transfer (FRET) quenching wherein an avidin molecule is labeled with a fluorophore and its binding sites are occupied with a fluorescent molecule that quenches the covalently linked fluorophore until the quencher in the binding site is displaced by a higher binding biotin molecule resulting in fluorescence of the covalently attached fluorophore. While this assay is sensitive to 50-100 ρmol range it requires many processing steps and a fluorimeter or multi-well fluorimeter. It is also recommended to digest the biotinylated protein prior to the assay to expose any sterically encumbered biotins.
[0018] Consequently there is a need in the field for a assay wherein the number of biotins covalently linked to a biomolecule could be determined by direct methods such as spectroscopic means.
BRIEF SUMMARY OF THE INVENTION
[0019] The present invention provides profluorescent/prochromophoric hydrazine and aldehyde reagent compounds for preparing novel hydrazone-based fluorescent molecules. More specifically conjugationally extended profluorescent/prochromophoric hydrazine compounds of the formula (RR 2 )N(H) n (NH 2 ) n , wherein R is independently a substituted or unsubstituted conjugationally extended moiety wherein the unsubstituted conjugationally extended moiety is an alkenyl, alkynyl, aromatic, polyaromatic, heteroaromatic or polyheteroaromatic moiety and wherein the substituted conjugationally extended moiety may be substituted with any combination of one or more of the groups hydroxy, alkoxy, alkene, alkyne, nitro, carboxy, sulfo, unsubstituted amine and substituted primary, secondary, tertiary and quaternary amine; R 2 is independently a hydrogen, a straight chain aliphatic moiety of 1-10 carbon atoms, a branched aliphatic moiety of 1-10 carbon atoms, a cyclic aliphatic moiety of 1-10 carbon atoms, a substituted or unsubstituted conjugationally extended moiety wherein the unsubstituted conjugationally extended moiety is an alkenyl, alkynyl, aromatic, polyaromatic, heteroaromatic or polyheteroaromatic moiety and wherein the substituted conjugationally extended moiety may be substituted with any combination of one or more of the groups hydroxy, alkoxy, alkene, alkyne, nitro, carboxy, sulfo, unsubstituted amine and substituted primary, secondary, tertiary and quaternary amine; n is 0 when m is 2 and n is 1 when m is 1 may be combined with conjugationally extended profluorescent/prochromophoric carbonyl compounds of the formula O═C(R 1 R 2 ) wherein: R 1 is independently a substituted or unsubstituted conjugationally extended moiety wherein the unsubstituted conjugationally extended moiety is an alkenyl, alkynyl, aromatic, polyaromatic, heteroaromatic or polyheteroaromatic moiety and wherein the substituted conjugationally extended moiety may be substituted with any combination of one or more of the groups hydroxy, alkoxy, alkene, alkyne, nitro, carboxy, sulfo, unsubstituted amine and substituted primary, secondary, tertiary and quaternary amine; R 2 is independently a hydrogen, a straight chain aliphatic moiety of 1-10 carbon atoms, a branched aliphatic moiety of 1-10 carbon atoms, a cyclic aliphatic moiety of 1-10 carbon atoms, a substituted or unsubstituted conjugationally extended moiety wherein the unsubstituted conjugationally extended moiety is an alkenyl, alkynyl, aromatic, polyaromatic, heteroaromatic or polyheteroaromatic moiety and wherein the substituted conjugationally extended moiety may be substituted with any combination of one or more of the groups hydroxy, alkoxy, alkene, alkyne, nitro, carboxy, sulfo, unsubstituted amine and substituted primary, secondary, tertiary and quaternary amine; n is 0 when m is 2 and n is 1 when m is 1 to form fluorescent hydrazone compounds of the formula (RR 2 )NN═C(R 1 R 2 ).
[0020] In one embodiment the hydrazone compound has the formula:
[0000]
[0000] wherein R 1 (which is R 2 ) is independently a substituted or unsubstituted conjugationally extended moiety wherein the unsubstituted conjugationally extended moiety is an alkenyl, alkynyl, aromatic, polyaromatic, heteroaromatic or polyheteroaromatic moiety and wherein the substituted conjugationally extended moiety may be substituted with any combination of one or more of the groups hydroxy, alkoxy, alkene, alkyne, nitro, carboxy, sulfo, unsubstituted amine and substituted primary, secondary, tertiary and quaternary amine; R 2 (which is R 3 ) is independently a hydrogen, a straight chain aliphatic moiety of 1-10 carbon atoms, a branched aliphatic moiety of 1-10 carbon atoms, a cyclic aliphatic moiety of 1-10 carbon atoms, a substituted or unsubstituted conjugationally extended moiety wherein the unsubstituted conjugationally extended moiety is an alkenyl, alkynyl, aromatic, polyaromatic, heteroaromatic or polyheteroaromatic moiety and wherein the substituted conjugationally extended moiety may be substituted with any combination of one or more of the groups hydroxy, alkoxy, alkene, alkyne, nitro, carboxy, sulfo, unsubstituted amine and substituted primary, secondary, tertiary and quaternary amine; R 3 (which is R 4 ) is H or OH; R 4 (which is R 6 ) is H or a nucleic acid moiety; and R 5 (which is R 7 ) is PO 3 or a nucleic acid moiety.
[0021] In another embodiment these novel profluorophore hydrazine and carbonyl compounds may further comprise a linkable moiety at one of the R or R 2 positions wherein the linkable moiety is selected from the group consisting of an amino reactive moiety, a thiol reactive moiety, an ester moiety and a modified carbohydrate monomer moiety.
[0022] In yet another embodiment a biomolecule such as for example a nucleic acid, a nucleotide, a protein, an amino acid, a carbohydrate monomer or a polysaccharide is linked to the profluorescent/prochromophoric hydrazine and/or profluorescent/prochromophoric carbonyl by a linkable moiety. If the biomolecule is a nucleic acid it may be DNA, cDNA, RNA, or PNA and can comprise natural or unnatural bases or internucleotide linkages selected from the group consisting of phosphodiesters, phosphorothioates, phosphoramidites and peptide nucleic acids.
[0023] In still another embodiment one or more of the profluorescent/prochromophoric hydrazine or carbonyl compounds may be bound to a polymer such as poly-lysine, poly-ornithine or polyethyleneglycol by one or more linkable moieties.
[0024] In another aspect of the present invention methods of forming a hydrazone compound are provided by combining the conjugationally extended profluorescent/prochromophoric hydrazine of formula (RR 2 )N(H) n (NH 2 ) with conjugationally extended profluorescent/prochromophoric carbonyl of the formula O═C(R 1 R 2 ) for a time and under conditions that allow hydrazone formation.
[0025] In one embodiment of this aspect of the invention the conjugationally extended profluorescent/prochromophoric hydrazine and/or the conjugationally extended profluorescent/prochromophoric carbonyl may further comprise a linkable moiety at either the R 1 or R 2 position.
[0026] In yet another aspect of the invention a method for labeling a biomolecule with a fluorescent hydrazone compound is provided.
[0027] In still another aspect the present invention provides oxyamine and aldehyde reagent compounds for preparing novel oxime-based fluorescent molecules. More specifically conjugationally extended profluorescent/prochromophoric oxyamine compound of formula: (R 1 R 2 )ONH 2 are provided wherein: R 1 is a substituted or unsubstituted conjugationally extended moiety wherein the unsubstituted conjugationally extended moiety is an alkenyl, alkynyl, aromatic, polyaromatic, heteroaromatic or polyheteroaromatic moiety and wherein the substituted conjugationally extended moiety may be substituted with any combination of one or more of the groups hydroxy, alkoxy, alkene, alkyne, nitro, carboxy, sulfo, unsubstituted amine and substituted primary, secondary, tertiary and quaternary amine; and R 2 is a hydrogen, a straight chain aliphatic moiety of 1-10 carbon atoms, a branched aliphatic moiety of 1-10 carbon atoms, a cyclic aliphatic moiety of 1-10 carbon atoms, a substituted or unsubstituted conjugationally extended moiety wherein the unsubstituted conjugationally extended moiety is an alkenyl, alkynyl, aromatic, polyaromatic, heteroaromatic or polyheteroaromatic moiety and wherein the substituted conjugationally extended moiety may be substituted with any combination of one or more of the groups hydroxy, alkoxy, alkene, alkyne, nitro, carboxy, sulfo, unsubstituted amine and substituted primary, secondary, tertiary and quaternary amine.
[0028] In one embodiment a profluorescent/prochromophoric oxyamine compound is provided wherein R 1 or R 2 further comprise a linkable moiety selected from the group consisting of an amino reactive moiety, a thiol reactive moiety, an ester moiety and a modified carbohydrate monomer moiety.
[0029] In another embodiment a profluorescent/prochromophoric oxyamine compound is provided wherein the linker further comprises a biomolecule selected from the group consisting of a nucleic acid, a nucleotide, a protein an amino acid, a carbohydrate monomer and a polysaccharide. The nucleic acid may be selected from the group consisting of DNA, cDNA, RNA and PNA and may comprise natural or unnatural bases or internucleotide linkages selected from the group consisting of phosphodiesters, phosphorothioates, phosphoramidites and peptide nucleic acids.
[0030] In another aspect of the invention a spectrophotometrically quantifiable linker is provided comprising of formula: A-B-C-D wherein A is an amino, thiol or carbohydrate reactive moiety; B is a chromophoric or fluorescent moiety; C is a flexible linker; and D is biotin or a receptor ligand. When A is an amino reactive moiety it may be selected from the group consisting of N-hydroxysuccinimidyl, p-nitrophenyl, pentafluorophenyl and N-hydroxybenzotriazolyl. When A is a thiol reactive moiety it may be selected from the group consisting of maleimido, α-haloacetamido and pyridylsulfides. When A is a carbohydate reactive moiety it may be aminooxy. B may be a compound that fluoresces, emits light or precipitates a colored insoluble product on enzymatic processing. C is a flexible linker and may be a PEG flexible linker having no less than 8 carbon atoms and no more than 34 carbon atoms. D is a receptor ligand selected from the group consisting of receptor ligand pairs biotin/avidin, peptide S/ribonuclease, complimentary oligonucleotide pairs or antibody/ligand pairs, and digoxigenin/anti-digoxigenin antibody.
[0031] In one embodiment of the present invention wherein the spectrophotometrically quantifiable linker is bound to a biomolecule via a amino, thiol or carbohydrate reactive moiety and wherein the biomolecule is selected from the group consisting of a protein, a peptide, an oligonucleotide and a polynucleotide. Alternatively the spectrophotometrically quantifiable linker may be bound to a biomolecule via receptor ligand pairs such as biotin/avidin, peptide S/ribonuclease, digoxigenin/anti-digoxigenin antibody complimentary oligonucleotide pairs or antibody/ligand pairs. Correspondingly, a first biomolecule may be bound via an amino, thiol or carbohydrate reactive moiety and a second biomolecule may be bound via a receptor ligand pair to the spectrophotometrically quantifiable linker.
[0032] In another aspect of the present invention a method of preparing a spectrophotometrically quantifiable linker is provided by the steps of preparing a first conjugate of a first biomolecule bound to one profluorescent/prochromophoric compound of a fluorescent pair via an amino, thiol or carbohydrate reactive moiety and preparing a second conjugate of a second biomolecule bound to a flexible linker via a biotin or a receptor ligand and the other profluorescent/prochromophoric compound of a fluorescent pair and combining the first conjugate with the second conjugate for a time thereby forming a hydrazone bond between the profluorescent/prochromophoric compound pair forming a fluorescent moiety.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0033] FIG. 1 : A diagrammatic representation of the chemistry for the formation of fluorescent hydrazones from conjugationally extended aldehydes and hydrazines;
[0034] FIG. 2 : A diagrammatic representation of the tautomerization of bis-(2-heteroaromatic)hydrazone chelates;
[0035] FIG. 3 : Hydrazine and aldehyde succinimidyl ester reagents, SANH and SFB respectively, developed for modification of amino moieties on biomolecules and a diagrammatic representation of the conjugation of a hydrazine-modified biomolecules with a benzaldehyde-modified biomolecule;
[0036] FIG. 4 : (A) PAGE gel of the results of the conjugation of a 5′-benzaldehyde-modified oligonucleotide to a hydrazine-modified antibody visualized by coomassie blue (CB) staining; (B) the same gel visualized by UV backshadowing to visualize the oligonucleotide conjugated to the protein; (C) nitrocellulose membrane of the blotted conjugate following hybridization of the fluorescein-labeled complementary oligonucleotide demonstrating retention of hybridization functionality of conjugated oligonucleotide;
[0037] FIG. 5 : A diagrammatic representation of fluorescent hydrazone (3) formed from 6-hydrazinonicotinic acid (1; R═OH) and 4-dimethylaminocinnamaldehyde (2);
[0038] FIG. 6 : (A) Chemical structure of benzaldehyde phosphoramidite used to incorporate benzaldehyde moieties on the 5′-terminus of oligonucleotides during their solid phase synthesis; (B) PAGE gel of purified oligonucleotide (Lane 1) and the product of the reaction of the oligonucleotide with trans-4-hydrazinostilbazole (1; Fluka Chemical Co.);
[0039] FIG. 7 : Absorbance and emission spectra of a 22 mer oligonucleotide modified on the 5′-end with the hydrazone formed from the reaction of benzaldehyde and, trans-4′-Hydrazino-2-stilbazole;
[0040] FIG. 8 : Chemical structure of bifunctional hydrazido amine modification reagent SHTH;
[0041] FIG. 9 : A diagrammatic representation showing hydrazones prepared from conjugationally extended hydrazines and aldehydes form fluorescent species while hydrazones prepared from conjugationally extended hydrazides and aldehydes do not form substantially fluorescent species. 5′-(6-Hydrazinylpyridine)-modified oligonucleotide is reacted with 4-dimethylaminocinnamaldehyde (Reaction A) and naphthalene-1,2-dicarboxaldehyde (Reaction B) form fluorescent species. The hydrazone formed from the reaction of 5′-(6-hydrazidoterephalate)-modified oligonucleotide with 4-dimethylaminocinnamaldehyde is not fluorescent and the product with NDA forms a weakly fluorescent species based on the pyrollo-fused naphthalene product without conjugation through hydrazide moiety;
[0042] FIG. 10 : A diagrammatic representation of the conversion of cytidine to 4-N-aminocytidine with hydrazine/bisulfite;
[0043] FIG. 11 : A diagrammatic representation of the incorporation of fluorescence into DNA wherein salmon sperm DNA was treated with hydrazine/bisulfite to convert cytidine moieties to 4-aminocytidine, an aromatic hydrazine. The modified DNA was treated with dimethylaminocinnamaldehyde (DAC; top reaction; Lane 2) or naphthalene-1,2-dicarboxladehyde (NDA; bottom reaction; Lane 4) and visualized following electrophoresis on an agarose gel (at left). Control reactions wherein untreated DNA was reacted with DAC and NDA were not fluorescent (Lanes 1 and 3 respectively);
[0044] FIG. 12 : Chemical structure of commercially available aromatic hydrazines;
[0045] FIG. 13 : Chemical structure of commercially available aldehydes;
[0046] FIG. 14 : Chemical structure of cyanine dyes Cy3 and Cy5;
[0047] FIG. 15 : Chemical structure of cyanine profluors and their parent fluorophores targeted for synthesis;
[0048] FIG. 16 : A diagrammatic representation of the synthetic methods for the preparation of hydrazinoheterocyles; and
[0049] FIG. 17 : Chemical structure of benzimidazole profluors and synthesis schemes of their parent fluorophores targeted for synthesis.
[0050] FIG. 18 : Chemical structure of biotin;
[0051] FIG. 19 : A diagrammatic representation showing hydrazones prepared from conjugationally extended hydrazines and aldehydes that form fluorescent species while hydrazones prepared from conjugationally extended hydrazides and aldehydes do not form substantially fluorescent species. 5′-(6-Hydrazinylpyridine)-modified oligonucleotide is reacted with 4-dimethyl-aminocinnamaldehyde (Reaction A) and naphthalene-1,2-dicarboxaldehyde (Reaction B) form fluorescent species. The hydrazone formed from the reaction of 5′-(6-hydrazidoterephalate)-modified oligonucleotide with 4-dimethylaminocinnamaldehyde is not fluorescent and the product with NDA forms a weakly fluorescent species based on the pyrollo-fused naphthalene product without conjugation through hydrazide moiety;
[0052] FIG. 20 : A schematic representation of the synthesis of amino-reactive biotin/hydrazone chromophore 6;
[0053] FIG. 21 : A graph showing amino-reactive biotin/hydrazone chromophore 6 and overlaid spectra of equivalent amounts (20 μg) native bIgG and bIgG modified with 5×, 10× and 15× amino-reactive biotin/hydrazone chromophore 6 demonstrating the incorporation of chromophore/PEG4/biotin moiety by their absorbency at A354.
[0054] FIG. 22 : Structure of a thiol-reactive chromophore linker of the present invention (7), aldehyde-reactive chromophore linker of the present invention (8) and an oxidized carbohydrate-reactive chromophore linker of the present invention (9);
[0055] FIG. 23 : A schematic representation of the incorporation of a conjugationally extended aldehyde cytosine triphosphate 10 in a DNA amplicon (R═H) or RNA amplicon (R═OH) and labeling the modified amplicon with a linker of the present invention 11 and
[0056] FIG. 24 : Schematic representation of the synthesis of a linker of the present invention (11).
DETAILED DESCRIPTION OF THE INVENTION
[0057] Unless defined otherwise, all terms used herein have the same meaning as are commonly understood by one of skill in the art to which this invention belongs. All patents, patent applications and publications referred to throughout the disclosure herein are incorporated by reference in their entirety. In the event that there is a plurality of definitions for a term herein, those in this section prevail.
[0058] The term “biomolecule” as used herein refers to a compound of biological origin, or of biological activity, that may have, or may be modified to have, an amine group or carbonyl group that may be harnessed in the formation of a hydrazone bond with a novel carbonyl profluorophore or novel hydrazine profluorophore of the present invention. Biomolecules include for example a nucleic acid, a nucleotide, a protein, an amino acid, a carbohydrate monomer and a polysaccharide. If the biomolecule is a nucleic acid it may be DNA, cDNA, RNA, or PNA and may comprise natural or unnatural bases or internucleotide linkages such as for example phosphodiesters, phosphorothioates, phosphoramidites or peptide nucleic acids.
[0059] The term “profluorophore” as used herein refers to a compound that may, or may not fluoresce, but when joined with its corresponding profluorophore pair compound produces a fluorescent hydrazone compound that has a peak emission wavelength substantially separate from the peak emission wavelength of either of the profluorophores that they may that make up the fluorescent hydrazone compound. A profluorophore pair comprises a hydrazine-based profluorophore and a carbonyl-based profluorophore that when combined form a fluorescent hydrazone compound.
[0060] The term “pro-chromophore” as used herein refers to a compound that may, or may not produce a visible color, but when joined with its corresponding pro-chromophoric pair compound produces a chromophoric compound that has a peak observable wavelength substantially separate from the peak observable wavelength of either of the prochromophores that make up the chromophoric hydrazone compound. A pro-chromophoric pair comprises a hydrazine-based pro-chromophore and a carbonyl-based pro-chromophore that when combined form a chromophoric hydrazone compound.
[0061] The term “reactive linking moiety” as used herein refers to molecules used commercially for binding one molecule to another based on the presence of a particular chemical group on the molecule of interest. Some commercially sold molecules referred to herein as linking moieties include those that react with free amines on the target molecule, such as N-hydroxysuccinimidyl, p-nitrophenyl, pentafluorophenyl and N-hydroxybenzotriazolyl ester and those that react with free sulfhydryls present on the target molecule such as maleimido, α-haloacetamido and pyridyldisulfides.
[0062] The term “ligand/receptor couple” as used herein refers to a pair of molecules having a substantially high affinity of binding specifically to one another. One example of such a binding pair would be a receptor on a cell and the ligand that binds that receptor. Another example would be biotin and avidin, which are two molecules that have a strong affinity for binding each other having an association constant of around 10 15 . Other pairs include Peptide S and ribonuclease A, digoxigenin and it receptor and complementary oligonucleotide pairs.
[0063] To achieve the optimal signal from a fluorescent label it is important that the structural integrity of the fluorophore is retained throughout processing of the labeled reporter molecule. A disadvantage with commercially available fluorophores is their propensity to be hydrolytically unstable or photobleach. The ability to efficiently form fluorescent species in situ in biological media in contrast to present methods wherein a labile fluorescent species is present throughout all protocols would be extremely advantageous in yielding products with fully retained fluorescence for improved limits of detection. In one current example in DNA microarays, fluorescently labeled triphosphates, e.g. Cy3 and Cy5 triphosphosphates (Amersham Biosciences, Piscataway, N.J.), are incorporated during PCR or reverse transcriptase amplification however quenching of the fluorophores through photobleaching or hydrolysis occurs during the many manipulations required to isolate the desired fluorescently labeled polynucleotide. To overcome this problem a less than ideal two-step method has been developed wherein a 3-aminoallylcytidine triphosphate is incorporated during polynucleotide amplification with subsequent purification, labeling with fluorescent succinimidyl esters and final purification to remove excess unincorporated fluorescent molecules. This chemistry is based on a amino/succinimidyl ester reaction that requires large excess of succinimidyl ester due to its instability in water and steps to remove the excess hydrolyzed reagent. This reaction proceeds over a small pH range, i.e. 7.2-8.0 and is concentration dependent.
[0064] It would be advantageous to have a method wherein a stable non-fluorescent species is used to label a biomolecule that following all required processing in techniques such as PCR, 2-dimensional electrophoresis or immunohistochemistry can be reacted efficiently with a second non-fluorescent molecule to form a fluorescent species. The present invention describes a chemistry wherein a conjugationally extended hydrazine reacts with a conjugationally extended carbonyl in situ in aqueous media to form a fluorescent molecule ( FIG. 1 ). Both aldehydes and hydrazines are stable in aqueous media and react efficiently to form stable hydrazones. The hydrazone formation is acid catalyzed and has an optimum pH of 4.7 but proceeds up to pH 8.0. This methodology could be extended to use with biosensors for biowarfare and pathogen detection, brand security and Near-IR products. These fluorophores may also be engineered for use in laser and photonics applications.
[0065] D. E. Ryan, F. Snape and M. Winpe (Ligand Structure and Fluorescence of Metal chelates; N-Heterocyclic Hydrazones with Zinc, Anal. Chim. Acta 58:101, 1972) described a series of hydrazone chelates (Table 1) and that upon addition of Zn 2+ the chelates complex the metal yielding a fluorescent metal chelate ( FIG. 2 ). It was postulated how the non-complexed chelate can exist in two different tautomers that have different fluorescent properties due to disrupted aromatic bonding. The addition of the zinc ion ‘locks in’ the tautomer with better conjugation and higher fluorescence. These authors further described the use of these chelates as analytical tools for determination of trace amounts, i.e. parts per million and parts per billion, of zinc.
[0000] Abbreviated Relative Full Name Form λ excitation λ emission Fluorescence* Pyridine-2-aldehyde-2-pyridyl hydrazone PAPH 455 515 1 Quinoline-2-aldehyde-2-pyridylhydrazone QAPH 490 540 2 Phenanthridine-2-aldehyde-2-pyridylhydrazone PDAPH 490 545 7 Pyridine-2-aldehyde-2-quinolylhydrazone PAQH 470 535 660 Quinoline-2-aldehyde-2-quinolylhydrazone QAQH 495 595 30 Phenanthridine-2-aldehyde-2- PDAQH 525 610 16 quinolylhydrazone Pyridine-2-aldehyde-2- PAPDH 450 540 100 phenanthrdinylhydrazone Quinoline-2-aldehyde-2- QAPDH 510 600 110 phenanthrdinylhydrazone Phenanthridine-2-aldehyde-2- PDAPDH 580 620 230 phenanthrdinylhydrazone Benzimidazole-2-aldehyde-2-pyridylhydrazone BAPH 440 510 140 470B550enzimidazole-2-aldehyde-2- BAQH 470 520 2000 quinolylhydrazone Benzimidazole-2-aldehyde-2- BAPDH 480 530 440 phenanthrdinylhydrazone Phenyl-2-pyridylketone-2-pyridylhydrazone PPKPH 420 470 8 Phenyl-2-pyridylketone-2-quinolylhydrazone PPKQH 470 550 450 Phenyl-2-pyridylketone-2-phenanthrdinylhydrazone PPKPDH 490 575 1520
Table 1 lists the bis-(2-heteroaromatic)hydrazones prepared by Ryan et al, supra. and including their excitation and emission wavelengths and relative fluorescence properties.
[0066] Bifunctional hydrazine and carbonyl reagents to modify biomolecules have been prepared. FIG. 3 outlines this chemistry. The hydrazine/carbonyl bioconjugation couple has significant advantages over currently used maleimido/thiol couple in that both the aldehyde and hydrazine moieties are stable following incorporation on biomolecules, simple addition of an aldehyde-modified biomolecule to a hydrazine-modified biomolecule yields a stable hydrazone without the requirement of a reduction reaction to stabilize the bond, the stability of the functional groups allows conjugations to be performed at low concentrations, i.e. <100 microgram/mL and the chemistry has been engineered to prepare conjugates from all biomolecules.
[0067] FIG. 4 shows the conjugation of an 5′-[4 formalbenzamide]-modified oligonucleotide to a hydrazine-modified antibody. The results demonstrate complete conversion of modified protein to conjugate by the simple addition of the stable 5′-[4 formalbenzamide]-modified oligonucleotide to the modified-hydrazine modified protein forming a stable hydrazone mediated conjugate.
[0068] The linkers have been prepared as reagents for the solid phase syntheses of peptides (hydrazino carboxylic acids) and oligonucleotides (aldehyde phosphoramidites). Aldehyde-modified deoxy and ribo-triphosphates have also been prepared and demonstrated to be incorporated into polynucleotide amplicons.
[0069] In the initial demonstration of the fluorescence of conjugationally extended hydrazones, 6-hydrazinonicotinic acid (1) (Solulink Biosciences, San Diego, Calif.) was reacted with 4-dimethylcinnamaldehyde (2) (Aldrich Chemical Co., Milwaukee, Wis.) to yield fluorescent hydrazone (3) ( FIG. 5 ). Hydrazone (3) absorbed at 397 nm and emitted at 508 nm a Stokes shift of 109 nm. Other hydrazones prepared from commercially available conjugationally extended hydrazines and aldehydes were prepared and their respective excitation and emission wavelengths are presented in Table 2 below. It should be noted that the Stokes shifts for hydrazones 2, 3 and 4 all are 100 nm or greater.
[0000] absorbance emission nm nm 385 407 355 472 397 508 450 550
Table 2 shows the fluorescent hydrazones and their absorbance and emission maxima.
[0070] In another demonstration benzaldehyde phosphoramidite has been prepared that is used to incorporate benzaldehyde moieties directly on the 5′-end of oligonucleotides during solid phase oligonucleotide synthesis. The incorporation of this moiety is accomplished with similar identical procedures and yields as incorporation of DMT-amino modified phosphoramidites. Reaction of an oligonucleotide with trans-4′-hydrazino-2-stilbazole dihydrochloride quantitatively yields a fluorescent oligonucleotide ( FIG. 6 ). The emission and absorbance spectra of hydrazone (4) (see Table 2 above) linked to a 22 mer oligonucleotide are presented in FIG. 7 .
[0071] Methods have been developed to prepare both hydrazino- and hydrazido-modified oligonucleotides. Hydrazinopyridine-modified oligonucleotides can be prepared by the reaction of amino-modified oligonucleotides with SANH and hydrazido-modified oligonucleotides can be prepared using SHTH ( FIG. 8 ). To demonstrate that hydrazones prepared from conjugationally extended hydrazines but not conjugationally extended hydrazides both oligonucleotides were reacted with 4-dimethylaminocinnamaldehyde ( FIG. 9 , reactions A and C) but only the hydrazine derived hydrazone was fluorescent. In another demonstration both hydrazino- and hydrazido-modified oligonucleotides were reacted with 1,2-naphthalene-dicarboxaldehyde (NDA; reactions B and D). It is known that amines react with NDA yield a fluorescent species. The products from the reaction of these oligonucleotides were both fluorescent however the hydrazine derived product absorbed and emitted qualitatively more intensely and at longer wavelengths than the hydrazido-modified oligonucleotide.
[0072] In another demonstration salmon sperm DNA was treated with hydrazine/bisulfite to convert cytidine moieties to 4-N-aminocytidine, an aromatic hydrazine ( FIG. 10 ; Negishi, K., Harada, C., Ohara, Y., Oohara, K., Nitta, N. and Hayatsu, H., 4-N-aminocytidine, a nucleoside analog that has an exceptionally high mutagenic activity, Nucleic Acids Res. 1983, 11, 5223-33)). The reaction of the modified DNA with both 4-dimethylaminocinnamaldehyde and naphthalene-1,2-dicarboxaldehyde (NDA) yielded fluorescent DNA. ( FIG. 11 ).
[0073] It should be noted that the hydrazine-modified cytidine is a component of the fluorophore and not solely a linkage point. It is anticipated that conjugationally extended aldehydes that yield hydrazones with more intensely fluorescent properties can be developed to convert reverse transcribed DNA to fluorescent species thereby using all natural triphosphates in the reverse transcription reaction and not substituted triphosphates whose incorporation is random and not quantitatively reproducible batch to batch.
[0074] A library of hydrazone fluorophores may be prepared from commercially available aromatic hydrazines and aldehydes using the methods described. FIG. 12 below presents structures of commercially available hydrazines that will be purchased to be reacted to form hydrazone fluorophores.
[0075] FIG. 13 presents structures of commercially available aldehydes that will be purchased to be reacted to form hydrazone fluorophores.
[0076] The initial pro-fluorophore structures targeted for syntheses in this program are based on cyanine dyes. These dyes are extremely sensitive and have been developed for a variety of commercial uses including life sciences applications as well as photographic uses (A. Mishra, R. K. Behera, P. K. Behera, .K. Mishra and G. B. Behera, Cyanines during the 1990's: A Review, Chem. Rev., 100:1973, 2000). FIG. 14 below presents the structures of the most used cyanine dyes, Cy3 and Cy5, for life science applications. These dyes are routinely used as reporter molecules in both gene and protein microarrays.
[0077] FIG. 15 presents aldehyde and hydrazine cyanine-based profluorophores and their parent fluorophores targeted for synthesis.
[0078] Two methods have been developed for the preparation of hydrazino-substituted aromatic compounds ( FIG. 16 ). The classical method for the synthesis of 2-hydrazinoheteroaromatic compounds is direct nucleophilic aromatic substitution of 2-chloro-heterocycles with hydrazine. Arterburn et al. (J. B. Arterburn, K. V. Rao, R. Ramdaa and B. R. Dible, Org. Lett. 2001, 3, 1351 and J. B. Arterburn, B. D. Bryant and D. Chen, Chem. Comm. 2003, 1890) have developed palladium-catalyzed protocols to convert 2-substituted bromo, chloro and trifloro substituted pyridines to 2-hydrazinylpyridines.
[0079] Aromatic aldehydes can be prepared by a variety of methods including direct oxidation of methyl-substituted aromatic moieties and reduction of aromatic nitrites. Aromatic aldehydes can be conjugationally extended using the Mannich reaction.
[0080] Due to the fluorescence of benzimidazole-quinoline hydrazone (5) a variety of pro-fluorophores based on this parent core structure have been investigated. FIG. 17 presents target pro-fluorophores and their respective parent fluorophores.
[0081] Diverse libraries with varying fluorescent properties can be readily prepared as any carbonyl and any hydrazine prepared or commercially available can be combined to yield a fluorescent hydrazone. The excitation and emission characteristics desired can be tailored by incorporation of substituents such as dimethylamino, alkoxy and nitro groups.
[0082] The photophysical characteristics of the fluorophores may be observed using a QM-2 Spectrofluorimeter (Photon Technologies International, Inc.), with a nitrogen-dye laser/second harmonic generator excitation source. A Xe arc lamp may be utilized having excitation that allows for the collection of steady state excitation and emission spectra, the characterization of quantum yield, photo-bleaching, and an degradation of fluorescence from these species. The response of this instrument may be characterized by fluorescence quantum yield standards (i.e. quinine sulfate) to determine the quantum yield of the various fluorophores. The laser system with the laser-strobe detection attachment allows for the collection of sub nanosecond time-decays. The time decay curves may be analyzed to determine the excited-state lifetimes of these fluorophores.
[0083] In addition a Nd:YAG laser pumped OPO system, will allow for tunable excitation between 400 nm and 3000 nm. The detection system includes a Jobin-Yvon 0.5 m monochromator with both PMT and CCD detection. The CCD camera is sensitive in the visible and Near Infrared regions of the electromagnetic spectrum. This system may be used for the characterization of fluorophores in the far-red region of the visible spectrum and in the NIR region. The tunable excitation will provide a means to excite fluorophores, regardless of their absorption spectra in the visible/NIR regions
[0084] The stability of the commercially available fluorophores has limited the full range of development of a variety of applications. The advantageous characteristics of this technology includes: elimination of the need to remove the excess second moiety from the in situ formed fluorescent species as it is either not fluorescent or has completely different fluorescent properties that do not interfere with detection of the new fluorescent species; increased efficiency of the formation of the fluorescent species >90%, in buffered aqueous media, pH 5.0-8.0; the ability to prepare a wide variety of fluorophores of different absorbance and emission wavelengths by varying the structures of the two moieties of the final fluorescent molecule; utilizing a linker moiety that may be incorporated on either of the pro-fluorescent species for covalent linking to a biomolecule or a surface; significant reduction in photobleaching or increased hydrolytic stability of the initial pro-fluorophore as has it will be in a lower energy state than fully conjugated fluorophores currently employed; and the development of fluorescent species having well separate spectral absorbance and emission properties, i.e. a Stoke's shift>100 nm.
[0085] U.S. patent application Ser. No. 60/546,104 to Schwartz incorporated herein in its entirety has described the in situ preparation of hydrazone fluorophores by the reaction of a conjugationally extended aldehyde with a conjugationally extended hydrazine one of which is linked to biomolecular probe such as an antibody or an oligonucleotide. FIG. 19 presents the reaction scheme for the reaction of a conjugationally extended hydrazine with a conjugationally extended aldehyde linked to an oligonucleotide forming an oligonucleotide linked fluorescent hydrazone. The scheme also presents results that demonstrated that the reaction is specific for a conjugationally extended hydrazine and not a hydrazide. In contrast to forming chromophore/fluorophores in situ the present invention incorporates a pre-formed chromophoric/fluorescent hydrazone into the linker comprising the ligand for direct spectrophotometric quantitation of the level of incorporation of the ligand when bound to a biomolecule such as a protein or nucleic acid.
[0086] FIG. 20 presents the construction of an amino-reactive biotin moiety that has incorporated in its chain a chromophoric hydrazone for spectrophotometric quantitiation and a short PEG linker that is required to retain the binding affinity of biotin to streptavidin. This tri-functional molecule can be readily quantified spectrophotometrically following conjugation to a biomolecule because of its unique molar extinction coefficient (generally >20000) and its unique absorbance or fluorescence (generally at wavelengths greater than 300 nm and at frequencies having no, or only minimal, observable signals prior to conjugation). It is anticipated that more highly conjugated systems than presented in FIG. 20 will absorb at longer wavelengths with greater extinction coefficients or fluorescence allowing even greater sensitivity. FIG. 21 presents constructions of thiol and oxidized carbohydrate-reactive linkers of the present invention.
[0087] The incorporation of labels into nucleic acids such as cDNA or cRNA using polymerases and reverse transcriptases respectively for gene expression analysis by microarrays is a multi-step procedure that requires high levels of reproducibility so results can be reliably compared between experiments. One current method for labeling cDNA or cRNA is the use of a nucleoside modified to incorporate a biotin molecule on the minor groove side. One of the most commonly used methods to label and detect labeled cDNA and cRNA is using a biotinylated nucleoside triphosphate (NTP). As there are only labor-intensive methods to quantitate the level of biotin incorporation in the amplicon, the biotin-modified amplicon is used directly without quantitation. It would be extremely advantageous to be able to directly quantitate the level of biotin incorporated into cDNA or cRNA. FIG. 22 is a schematic diagram of the synthesis of a nucleoside triphosphate modified with a conjugationally extended aldehyde such as a benzaldehyde moiety and to label the amplicon after elongation by reaction with a biotinylated conjugationally extended hydrazine. U.S. Pat. No. 6,686,461 to D. Schwartz and R. Hogrefe which is incorporated herein by reference in its entirety more fully discloses this synthesis. The chemistry described herein is advantageous in that the formation of the hydrazone is high yielding at near stoichiometric amounts, a chromophore is formed that will allow batch-to-batch quantitiation of levels of incorporation of biotin and a short polyethylene linker is incorporated is necessary to retain the affinity of the biotin to its cognate receptor avidin.
[0088] In another protocol the amplicon may be hybridized prior to reaction with the biotin hydrazide and subsequently detected with a fluorescently-labeled avidin or anti-biotin antibody. The benzaldehyde-labeled amplicon can be quantitated by removing an aliquot and treating it with a hydrazide pro-fluorophore to form a fluorescent hydrazone and spectrophotometrically quantitating the level of aldehyde incorporation. This may be advantageous as the hybridization reaction will have minimal modification resulting in less sterically encumbered hybridization.
[0089] In use the linker moiety reacts with a biomolecule such as an antibody under appropriate reaction conditions. The conjugate is then purified and the protein concentration determined. The number of biotin molecules/protein molecule is determined by observing the absorbance of a known concentration of the conjugate in solution at a wavelength>300 nm. The concentration of the chromophore and therefore the biotin is determined by dividing the absorbance reading by the extinction coefficient of the chromophore incorporated in the chain. This concentration is divided by the mM concentration of the protein and the number of biotin molecules per conjugated is determined.
EXAMPLES
Example 1
Synthesis of Biotin/PEG/hydrazone succinimidyl ester 6
FIG. 20
[0090] PMR spectra were obtained on a Bruker 500 MHz NMR at NuMega Laboratories (San Diego, Calif.) and electrospray mass spectral data was obtained at HT Laboratories (San Diego, Calif.).
1. Synthesis of Mono-Boc-1,13-diamino-4,7,10-trioxatetradecane (1; (3-{2-[2-(3-Amino-propoxy)-ethoxy]-ethoxy}-propyl)-carbamic acid tert-butyl ester), Amine 1
[0091] To a solution of 4,7,10-trioxa-1,13-tridecanediamine ( FIG. 20 ) (30 g; mmol) in dichloromethane (1000 mL) was added a solution of di-t-butyl dicarbonate (10 g; mmol; Aldrich Chemical Co., Milwaukee, Wis.) in dichloromethane (200 mL) over 2 h. The reaction mixture was stirred at room temperature for 4 hours. Thin layer chromatography (TLC, silica gel) using dichloromethane/methanol/triethylamine (90/10/1); ninhydrin development) indicated the presence of two new spots, a minor spot at Rf 0.8 ascribed to the bis-BOC product and a major spot at Rf (0.2) for the desired product. The reaction mixture was washed with water (4×500 mL) to remove the excess diamine and the organic phase was dried over magnesium sulfate, filtered and concentrated to give a viscous oil that was purified by flash chromatography over silica gel using DCM/MeOH/TEA (95/5/1) to give 10.5 g of desire Amine 1 as an oil.
2. Synthesis of ((3-{2-[2-(3-{[6-(N′-Isopropylidene-hydrazino)-pyridine-3-carbonyl]-amino}-propoxy)-ethoxy]-ethoxy}propyl)-carbamic acid tert-butyl ester), Hydrazone 2
[0092] To a solution of Amine 1 (1.05 g; 3.28 mmol) in DCM (20 mL) was added a solution of succinimidyl 6-hydrazinonicotiniate acetone hydrazone (0.951 g; 3.28 mmol; Solulink Biosciences, Inc., San Diego, Calif.) in DCM (10 mL). The reaction mixture was stirred at room temperature for 6 hours. Subsequently the reaction mixture was washed with water and brine. The organic phase was dried (magnesium sulfate), filtered and concentrated to give 1.2 g of Hydrazone 2 as a colorless thick oil.
3. Synthesis of (4-{[5-(3-{2-[2-(3-tert-Butoxy-carbonylamino-propoxy)-ethoxy]-ethoxy}-propylcarbamoyl)-pyridin-2-yl]-hydrazonomethyl}-benzoic acid), Hydrazone 3
[0093] To Hydrazone 2 (0.405 g: 0.81 mmol) in MeOH (5 mL) and 100 mM MES, 150 mM NaCl (5 mL) was added a solution of 4-carboxybenzaldehyde (0.121; 0.81 mmol) in MeOH (3 mL). The reaction mixture is allowed to stir at room temperature overnight. Copious precipitate formed. The reaction mixture was centrifuged and the solids were washed with a 1/1 solution of MeOH/MES. The solids were dried under vacuum to yield 0.42 g of Hydrazone 3 as a pale yellow solid and used directly in the next step.
4. Synthesis of (4-{[5-(3-{2-[2-(3-Amino-propoxy)-ethoxy]-ethoxy}-propylcarbamoyl)-pyridin-2-yl]-hydrazonomethyl}-benzoic acid hydrochloride salt), chromophore Hydrazone 4
[0094] A solution of Hydrazone 3 (0.388 g; 0.66 mmol) in dioxane (15 mL) was prepared with heating. The solution was cooled to room temperature and 4 N HCl in dioxane (4 mL; Aldrich Chemical Co., Milwaukee, Wis.) was added succinimidyl and the reaction was stirred at room temperature for 16 h. A precipitate formed on stirring. The reaction mixture was centrifuged and the solids were washed with dioxane (3×10 mL). The solids were resuspended in dioxane and concentrated under vacuum to yield 240 mg of amino/PEG4/Hydrazone 4 as a pale yellow solid. Electrospray mass spec: expected m/e 487; found positive mode 488 (M+H), negative mode 486 (M−H) and 522 (M+Cl − ).
5. Synthesis of Biotin/PEG4/chromophore succinimidyl ester 6 (5-(N′-{4-[2-(2,5-Dioxo-pyrrolidin-1-yl)-2-oxo-acetyl]-benzylidene}-hydrazino)-pyridine-2-carboxylic acid {3-[2-(2-{3-[5-(2-oxo-hexahydro-thieno[3,4-d]imidazol-4-yl)-pentanoylamino]-propoxy}-ethoxy)-ethoxy]-propyl}-amide)
[0095] To a solution of amino/PEG4/hydrazone 4 (0.780 g; 1.60 mmol) in DMF (25 mL) was added biotin succinimidyl ester (0.546 g; 1.60 mmol) followed by the addition of triethylamine (0.726 mL; 4.80 mmol). The solution was stirred at room temperature until complete as determined by silica gel TLC using DCM/MeOH/TEA (90/10/1) as eluant (developed by UV to visualize the pyridine chromophore and dimethylaminocinnamaldehyde/sulfuric acid/ethanol spray followed by heating to visualize the biotin moiety). To the reaction mixture N-hydroxysuccinimide (0.184 g; 1.60 mmol) and DCC (0.330 g; 1.60 mmol) were added and stirred at room temperature for 16 hours. The reaction mixture was concentrated to dryness and partitioned between DCM and water. The organic phase was further washed with brine, dried (magnesium sulfate), filtered and concentrated to give a yellow sticky solid. The solids were triturated with ethyl acetate. The solids were isolated by filtration to give 830 mg of a yellow solid. TLC (DCM/MeOH/TEA (90/10/1) indicated one major spot (visualized by UV and dimethylaminocinnamaldehyde/sulfuric acid/ethanol solution) and HPLC analysis (YMC C-18, 150×4.6 cm; 5 □m; 120 A; gradient mobile phase A: water/acetonitrile/trifluoroacetic acid (20/80/0.1), mobile phase B: 0.1% TFA in water; gradient 10% A/90% B to 100% A over 20 min; retention time 8.8 min, detection @A254 and A350. PMR (DMSO-d 6 ) δ: 11.64, s (1 H), 8.65, d, (1H), 8.37 t, (1H) N H , 8.12 dd (1H), 7.95 and 8.11 ab system (4H), 7.73 t (1H) N H , 7.36 d (1H), 6.41 s (1H), 6.35 s (1H), 5.57 d (1H), 4.29 br. t (1H), 4.11 br. t (1H), 3.3-3.55 m (12H), 3.08 m (4H), 2.90 s (4H), 2.88 dd (1H), 2.57 d (1H), 2.03 t (2H), 1.75 m (2 H), 1.59 m (2H), 1.2-1.5 m (8H). The extinction coefficient of Biotin/PEG4/chromophore succinimidyl ester 6 was determined by dissolving Biotin/PEG4/chromophore succinimidyl ester 6 (1.0 mg) in DMF (1 mL) and diluting into PBS. The absorbance maximum was A354 and the molar extinction coefficient was determined to be 23,250.
Example 2
Protein labeling with Biotin/PEG4/chromophore/succinimidyl ester 6
[0096] Bovine immunoglobulin (bIgG; Sigma Chemical Co., St. Louis, Mo.) was dissolved in modification buffer (100 mM phosphate, 150 mM NaCl, pH 7.2) to prepare a 5 mg/mL solution. A solution of Biotin/PEG4/chromophore/succinimidyl ester 6 (1 mg) dissolved in DMF (100 mL) was prepared. Three separate reactions were performed wherein 5 mole equiv., 10 mol equiv. and 15 mol equiv. of Biotin/PEG4/chromophore/succinimidyl ester 6 (1.3, 2.6 and 3.9 μL,) respectively were added to 0.5 mg bIgG solution. The reaction was allowed to incubate at room temperature for 2 hours. The reaction mixtures were desalted into PBS using Biomax diafiltration apparatuses (Millipore, Inc., Bedford, Mass.). Protein concentrations of all the modified proteins were determined using the BCA assay (Pierce Chemical Co., Rockford, Ill.). Spectral analyses of each product were performed by diluting 20 mg of modified protein to 100 mL in PBS. The number of moles of chromophore incorporated was calculated by determining the absorbance of the protein at A354 dividing by the molar extinction coefficient, i.e. 29000, of the chromophore. The overlaid spectra of the products as well as unmodified IgG are present in FIG. 21A . The number of incorporated biotins in the modified proteins was further analyzed by the HABA assay (Pierce Chemical Co., Rockford, Ill.). The results, both tabular and graphically, from both the UV spectral assay and the HABA assay are presented below.
[0000] IgG/HABA IgG/A354 5X 1.03 2.45 10X 1.60 4.71 15X 2.22 6.25
A further experiment to demonstrate retention of binding activity of the chromophore/biotinylated bIgG the modified proteins were incubated with streptavidin and the reaction products were analyzed by PAGE gel electrophoresis. FIG. 21B presents the results.
Example 3
Synthesis of Biotin/PEG/hydrazone 10
FIG. 24
1. Synthesis of ({3-[2-(2-{3-[5-(2-Oxo-hexahydro-thieno[3,4-d]imidazol-4-yl)-pentanoylamino]-propoxy}-ethoxy)-ethoxy]-propyl}-carbamic acid tert-butyl ester),1-biotinamido/PEG/BOC-amino 14.
[0097] To a solution of Amine 1 (0.544 g; 1.70 mmol) in DMF (15 mL) was added a solution of biotin succinimidyl ester (0.580 g; 1.70 mmol) in DMF followed by the addition of TEA (0.75 mL; 5.09 mmol). The reaction mixture was stirred at room temperature for 16 h. The solvent was removed on the rotavap and the residue was partitioned between DCM and water. The organic phase was further washed with brine, dried (magnesium sulfate), filtered and concentrated to give 415 mg of 1-biotinamido/PEG/BOC-amino 14 as an amorphous solid. The product was a single spot by TLC (DCM/MeOH/TEA (90/10/1); developed by dimethylcinnamaldehyde/ethanol/sulfuric acid/heat to visualize the biotin moiety). The product was used directly in the next step.
2. Synthesis of (5-(2-Oxo-hexahydro-thieno[3,4-d]imidazol-4-yl)-pentanoic acid (3-{2-[2-(3-amino-propoxy)-ethoxy]-ethoxy}-propyl)-amide), 1-biotinamido/PEG/amino 15
[0098] To a solution of 1-biotinamido/PEG/BOC-amino 14 (400 mg; 0.73 mmol) was dissolved in dioxane (20 mL) with mild heating. The solution was cooled to room temperature and a solution of 4 N HCl in dioxane (10 mL; Aldrich Chemical Co., Milwaukee, Wis.) was added. The reaction was stirred for 14 h. The solvent was removed on the rotavap and the residue was co-evaporated twice from dry dioxane. The product, 1-biotinamido/PEG/amino 15, was used directly without purification.
3. Synthesis of (5-(N′-Methylene-hydrazino)-pyridine-2-carboxylic acid {3-[2-(2-{3-[5-(2-oxo-hexahydro-thieno[3,4-d]imidazol-4-yl)-pentanoylamino]-propoxy}-ethoxy)-ethoxy]-propyl}-amide), 1-biotinamido/PEG/amido-6-hydrazino-4-nicotinamide 11
[0099] To a solution of 1-biotinamido/PEG/amino 15 (0.375 g; 0.78 mmol) in DMF (25 mL) was added a solution of SANH (0.225 g; 0.78 mmol) and triethylamine ((0.645 mL; 4.66 mmol)). The reaction mixture was stirred at room temperature for 16 h. The solvent was removed on the rotavap and the residue was partitioned between DCM and water. The organic phase was further washed with brine, dried (magnesium sulfate), filtered and concentrated to give 290 mg of 1-biotinamido/PEG/amido-6-hydrazino-4-nicotinamide 11 as an amorphous solid. The product was a single spot, Rf 0.33, by TLC (DCM/MeOH/TEA (90/10/1) developed by dimethylcinnamaldehyde/ethanol/sulfuric acid/heat to visualize the biotin moiety). Mass spectral data: exptd m/e 621; pos mod exptd m/e 622 (M+H); found 622 and exptd 644 (M+Na); found 644; neg mode exptd m/e (M−H) 620; found 620 and (M+Cl − ) 656; found 656
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Conjugationally extended hydrazine compositions of the formula (RR 2 )N(H) n (NH 2 ) n , fluorescent hydrazone compositions of the formula (RR 2 )NN═C(R 1 R 2 ), methods of the formation of hydrazones from the reaction of conjugationally extended hydrazines with conjugationally extended carbonyls and methods of their use in assays systems are described. Use of these conjugationally extended hydrazine and oxime compositions for direct calorimetric and fluorometric assays wherein a chromophore or the fluorophore is incorporated into the linker that is positioned between a reactive linking moiety and a biotin molecule. More specifically the linker comprises one molecule of a high affinity binding pair such as for example biotin of the biotin/avidin high affinity binding pair, connected to a spacer molecule such as for example a length of polyethyleneglycol followed by a pro-chromophoric, chromophoric, pro-fluorescent or fluorescent moiety connected to an amino-, thiol- or carbohydrate-reactive moiety such as for example succinimidyl, maleimido or aminoxy group respectively, that may covalently link to a biomolecule.
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This application claims the benefit of U.S. Provisional Application No. 60/217,790 filed Jul. 12, 2000 entitled “One (1) Piece Tubular Doorbeam”.
BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention relates to the forming of a tubular beam and more particularly to a one-piece tubular beam.
II. Description of the Art
Vehicle doorbeams are widely used in the automotive industry to enhance the impact strength of vehicle doors and thereby to enhance passenger safety. Typically these beams are fabricated from multiple pieces including a metal tube and brackets welded on the opposite ends of the tube. The brackets are used in securing the beam within the door frame. Such beams are not without their drawbacks. First, the multi-piece beams require numerous manufacturing steps, and therefore are relatively labor-intensive and expensive. Second, the structural integrity of these doorbeams greatly depends on weld consistency and weld quality. Third, any welding splatter left on the beam may cause a squeak if the splatter contacts another interior door component.
The doorbeams also can be manufactured as a single-piece or one-piece beam. A method for roll-forming such a beam is illustrated in U.S. Pat. No. 5,756,167 issued May 26, 2998 to Tamura et al. The Tamura process rollforms continuous strip stock into one-piece beams using specially designed rollers. The rollers have a circumference that corresponds to the length of the beam. The rollers create alternating rolled body portions and flat end brackets joined together by curving transition portions. This process also is not without its drawbacks. First, the tooling is extraordinarily expensive. Second, the separate set of tooling is required for each doorbeam. Third, extensive set up time is required when a new/different doorbeam is to be manufactured. As part of the set up, different circumference rollers require different distances between the axes of opposing and adjacent rollers.
One-piece beams also can be manufactured using stamping or pressing methodologies. Examples of such processes are illustrated in U.S. Pat. No. 5,183,718 issued Sep. 29, 1998 to Masuda et al and Japanese Patent Publication 4-238725 published Aug. 26, 1992. These methods form individual metal blanks into beams, and also are not without their drawbacks. First, these methods are relatively labor intensive resulting in relatively high manufacturing costs because individual blanks must be press formed. Second, stamping often utilizes less of the sheet than rollforming, thereby creating more waste. Third, different doorbeams require different tooling.
SUMMARY OF THE INVENTION
The aforementioned problems are overcome in the present application wherein a one-piece doorbeam is rollformed from continuous stock using relatively simple tooling and producing relatively little waste. More specifically, the process includes the steps of removing material from the edge of a continuous metal stock at spaced locations, rollforming the entire stock into a tubular shape so that the opposite edges engage one another except where material has been removed, welding the engaged edges, severing the tubular shape in the area where material was removed to create a rollformed piece having two ends, and opening at least one of the ends to create an end bracket.
The present invention has a variety of advantages over the prior techniques. First, highly specialized and unique tooling is not required. Second, virtually any length doorbeam can be created using a single set of tooling. Third, the integral end brackets can be uniquely shaped and processed following the basic forming steps. Consequently, the present invention is relatively labor efficient and inexpensive. Further, the quality and consistency of the tubular beam is improved.
These and other objects, advantages and features of the invention will be more fully understood and appreciated by reference to the detailed description of the preferred embodiment and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow diagram of the process of the present invention;
FIG. 2 is a schematic view of the process;
FIG. 3 is a block diagram of four different processing options all using the process;
FIG. 4 is a perspective view of a door beam formed using the process and broken to show indeterminate length;
FIG. 5 is a top view of a portion of the continuous metal strip showing the area of the pierced indentations;
FIG. 6 is a view of a portion of the continuous rolled tube showing the area of pierced indentations;
FIG. 7 is a view of the individual door beam cut to length in the area of cut-outs, broken to show indeterminate length;
FIG. 8 is an end view of the beam in FIG. 7;
FIG. 9 is a perspective view of the beam pre-forms in a progressive press in which the ends of the pre-forms are opened and flattened;
FIG. 10 is a perspective view of the end of a door beam with reinforcement gussets; and
FIG. 11 is a perspective view of the end of a door beam with rolled-in reinforcements in the transition area.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The manufacturing process of the present invention is illustrated in FIGS. 1-3; and a tubular doorbeam fabricated using the process is illustrated in FIG. 4 and generally designated 10 . The beam 10 is a single piece and includes a tubular body 12 , a transition area 14 , and end brackets 16 .
I. Manufacturing Process
As illustrated in FIGS. 1-3 the tubular beam starts as a continuous web of flat stock drawn from a coil. As seen in FIG. 5 (which shows the stock after the pre-piercing step), the stock includes a pair of opposite edges 24 . In the preferred embodiment, the edges as the stock are linear and uniformly spaced from one another so that the stock has a uniform width. In the preferred embodiment, the material is martinsitic steel (i.e. Martinsite) such as Inland M 220 ultra high strength low alloy steel. Of course, other materials could be used that have suitable properties for the performance requirements of the doorbeam.
The first step 101 is the feeding of the continuous metal stock into a pre-piercing press.
The second step 102 is the trimming of the opposing linear edges 24 by the pre-piercing press at regularly spaced or period intervals forming indentations or cut-outs 22 (see FIG. 5 ). The pre-pierced, but still flat, stock is designated 20 . The spaced points 25 define the opposite ends of each indentation 22 . The distance between the points 25 corresponds to the length L of the tubular body 12 of the finished beam 10 . Depending on the implementation of the fourth step 104 of welding, this second step may be omitted.
The third step 103 is the rollforming of the pre-pierced stock 20 within a tube rolling mill. The flat stock 20 is rollformed into a tubular shape generally designated 30 (see FIG. 6 ). In the continuous tubular shape 30 , the opposite edges 24 of the stock engage one another in areas other than the cut-outs 22 . Preferably, the edges 24 abut one another, but they also could overlap one another. The cut-outs 22 create elongated gaps or spaces 32 . The edges of the cut-outs 22 do not engage one another. The rolling mill operates at a speed at which the subsequent steps are able to accept material.
The fourth step 104 is to weld the lateral edges 24 together between the elongate spaces 32 . The welding apparatus may operate continuously as the stock moves through the welder (because the spaced cut-outs 22 will not be joined), or the welding apparatus may be operated only in the areas between the elongate spaces 32 (i.e. only where the edges 24 engage one another. Further, if the second step 102 of pre-piercing has been omitted, the welding apparatus must be operated intermittently to create areas of joined edges separated by areas of unjoined edges. The preferred welder is a laser welder to obtain high weld quality. Any suitable welding technique, such as induction welding, also could be used. The welding seam 36 results from the welding (see FIG. 7 ).
The fifth step 105 is to size and straighten the welded tubular shape to increase the uniformity of the final beams 10 .
The sixth step 106 is to anneal the continuous stock. In the preferred embodiment, annealing performed only in the approximate area of the elongate spaces 32 . Annealing also can be performed before or after other steps in the process depending on the desired qualities and characteristics to be imparted to the doorbeam both for processing (e.g. pre-piercing) and/or as a final product.
The seventh step 107 is to cut the continuous tubular form into lengths creating individual items or pre-forms 40 (see FIGS. 7 - 8 ). This step occurs at the end of the rollforming line. The cuts occurs in the area of the elongate spaces 32 (if the stock has been pre-pierced) or in the area of unjoined edges (if the stock has not been pre-pierced), so that an unwelded portion remains at each end of the pre-form 40 .
In the eighth step 108 , the end of each pre-form 40 is opened to create a relatively flat end. The progressive press used to perform this step is illustrated in FIG. 9 . Preferably, the opening step includes a plurality of forming steps but may be done with only one step. In the preferred embodiment the elongate space 32 is initially opened as illustrated at 42 and is further opened as illustrated at 44 , 45 , and 46 . After stamping in the final die, the end bracket 48 is fully formed.
The subsequent steps (i.e. those after the opening step 108 ) occur on various lines to perform different processes as illustrated in FIGS. 2 and 3. The particular processes or steps 110 utilized in each line will depend on the desired shape and features to be imparted to the ultimate doorbeam. The four process options illustrated in FIG. 3 are exemplary, and other process options can be readily developed depending on the desired result.
One alternative forming step 111 is to pierce at least one hole 52 (see FIG. 4) in the end bracket 16 . As many holes as are needed may be pierced. A second alternative forming step 112 is to add bends or angles 54 (see FIGS. 4 and 10 - 11 ) to the end bracket 16 . The angles 54 can be any one of a variety of shapes, and the angle may vary greatly depending upon the installation needs of the tubular beam 10 . A third alternative forming step 113 is to add reinforcement gussets 56 (see FIG. 10) to the angles 54 on the end bracket 16 to strengthen the bracket 16 . A fourth alternative forming step 114 is the rolling in of reinforcements 58 (see FIG. 11 ). In this step the edges of the trimmed cut-outs 22 are rolled over and into the center of the transition area 14 . This doubling back of the edges of the cut-outs 22 strengthens the transition area 14 . This rolling may also be done to reduce the profile of the transition area 14 to enable installation in areas with little clearance. A fifth alternative step 115 is to trim the end bracket 16 to a final shape and size. The trimming of the edges after all forming steps have completed provides improved consistency of the resulting doorbeams 10 . The alternative steps may be preformed in virtually any order or in any combination.
After all forming, shaping and trimming steps have been completed the door beam may be laser marked with the company name, date, shift, customer part number, or bar code to identify and track the beam for quality control reasons. Preferably each doorbeam is inspected 116 to confirm that has been made to specification. After the doorbeam is inspected 116 it is packaged 118 for shipment.
Four exemplary process options 201 , 202 , 203 , and 204 are illustrated in FIG. 3 . Each includes a various combination of the above-described steps, as well as other steps that will be recognized and understood by those skilled in the art.
The invention can be used to create a wide, and indeed limitless, variety of one-piece tubular doorbeams 10 wherein the tubular body 12 is integral with the end brackets 16 through a transition area 14 . The present invention results in an improved product at a lower cost.
The above descriptions are those of preferred embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents.
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A method of rollforming one-piece tubular doorbeams. The method includes the steps of drawing a continuous metal strip, creating cut-outs in the edges of the strip at spaced locations, rollforming the strip into a tube so that the unindented edges engage one another, welding the engaged edges together, cutting the tube in the areas of the cut-outs to create pre-forms, and opening the ends of the pre-forms to create end brackets. Additional optional steps provide customization of the end brackets.
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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to a method for super-resolution microscopy and, more particularly, to a method for non-fluorescence higher harmonic generation ground state depletion super-resolution microscopy.
[0003] 2. Description of Related Art
[0004] The recently developed high-resolution STED (stimulated emission depletion) microscopes and STED microscopy have overcome the 200-nm upper limit of resolution imposed by diffraction on the conventional fluorescence microscopes. Using the innovative point-spread function technique, STED microscopes have a resolution more than ten times as high as that of their traditional counterparts and can therefore provide much finer microscopic images.
[0005] One major limitation on the application of STED microscopy, however, is that the STED technique can only be used to modulate, and form microscopic images with, fluorescence signals. The conventional STED ultra-resolution microscopy is used mainly in fluorescence-related applications and achieves ultra-high resolution by modulating fluorescence intensity with STED; it does not work or cannot offer any help when it is desired to modulate, or form microscopic images with, non-fluorescence signals.
[0006] In view of this, it has been a common goal of development and innovation in the fields of cell analysis, spatial domain analysis, and microscopy to extend the currently limited use of STED ultra-resolution microscopy in modulating fluorescence signals alone, and to create a useful and easy-to-implement method for non-fluorescence STED microscopy that features fast and accurate detection, stable imaging, and high spatial domain resolution, thereby expanding the application of STED to the modulation and detection of non-fluorescence signals.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention provides a method for non-fluorescence higher harmonic generation ground state depletion ultra-resolution microscopy, and the method includes the steps of: providing an organic material unit, focusing excitation light and ground state depletion light, generating a higher harmonic signal, performing ground state depletion, and performing microscopic imaging. The present invention expands the application of STED ultra-resolution microscopy to modulating, and forming microscopic images with, non-fluorescence signals and increases the image resolution of microscopic imaging.
[0008] More particularly, the present invention provides a method for non-fluorescence higher harmonic generation ground state depletion ultra-resolution microscopy, and the method includes the steps of: providing an organic material unit, wherein the organic material unit includes a plurality of molecules, each of the molecules has a plurality of electrons, and each of the electrons has an energy band with energy of hv such that, when excited by hv, the electrons jump from the ground state to the singlet state and undergo inter-system crossing from the singlet state to the triplet state, with h being the Planck constant (6.626×10̂−34) and v being a frequency expressed in the unit of hertz (Hz); focusing excitation light and ground state depletion light by collimating excitation light projected by a long-wavelength ultrafast pulse laser and ground state depletion light projected by a short-wavelength continuous-wave laser, combining the collimated excitation light with the collimated ground state depletion light, and focusing the combined light onto a plurality of test positions of the organic material unit sequentially; generating a higher harmonic signal by irradiating and exciting the test positions of the organic material unit with the focused excitation light such that the electrons of the molecules at the test positions are excited and jump to the singlet state and the molecules induce the higher harmonic generation signal; performing ground state depletion by irradiating with the focused ground state depletion light, and thus depleting, the electrons at the test positions that are in the ground state such that the electrons are excited and jump to the singlet state and undergo inter-system crossing to the triplet state; and performing microscopic imaging by receiving the higher harmonic generation signal of the test positions of the organic material unit and generating an ultra-resolution microscopic image corresponding to the organic material unit, with a STED system.
[0009] Implementation of the present invention at least provides the following advantageous effects:
[0010] 1. The application of STED microscopy is expanded to modulating, and forming microscopic images with, non-fluorescence signals.
[0011] 2. With ground state depletion, non-linear absorption is reduced, and higher harmonic generation signals are suppressed in strength to facilitate the modulation of spatial distribution of such signals.
[0012] 3. The method of the present invention can be directly applied to cell analysis and microscopic imaging and is useful, easy to implement, fast and accurate in detection, and stable in terms of imaging.
[0013] The features and advantages of the present invention are detailed hereinafter with reference to the preferred embodiments. The detailed description is intended to enable a person skilled in the art to gain insight into the technical contents disclosed herein and implement the present invention accordingly. In particular, a person skilled in the art can easily understand the objects and advantages of the present invention by referring to the disclosure of the specification, the claims, and the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0014] The invention as well as a preferred mode of use, further objectives and advantages thereof will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:
[0015] FIG. 1 is the flowchart of the method in an embodiment of the present invention for non-fluorescence higher harmonic generation ground state depletion super-resolution microscopy;
[0016] FIG. 2 schematically shows how an electron changes through the ground state, the singlet state, and the triplet state;
[0017] FIG. 3 is a schematic diagram of the optical system in an embodiment of the present invention;
[0018] FIG. 4A schematically shows how a second harmonic generation signal is generated in an embodiment of the present invention;
[0019] FIG. 4B schematically shows how a third harmonic generation signal is generated in an embodiment of the present invention; and
[0020] FIG. 5 is a schematic diagram of the optical system in another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Referring to FIG. 1 , the method S 100 in an embodiment of the present invention for non-fluorescence higher harmonic generation ground state depletion super-resolution microscopy includes the steps of: providing an organic material unit (step S 10 ), focusing excitation light and ground state depletion light (step S 20 ), generating a higher harmonic signal (step S 30 ), performing ground state depletion (step S 40 ), and performing microscopic imaging (step S 50 ).
[0022] Referring to FIG. 1 and FIG. 2 , the step S 10 of providing an organic material unit uses an organic material unit 10 which includes a plurality of molecules each having a plurality of electrons e. Each electron e has an energy band with energy of hv, wherein h is the Planck constant (6.626×10̂−34) and v is a frequency expressed in the unit of hertz (Hz). When excited by energy of hv, the electrons e jump from the ground state S 0 to the singlet state S 1 .
[0023] As shown in FIG. 2 , once the electrons e in the ground state S 0 are excited and jump to the singlet state S 1 , some of the electrons e in the singlet state S 1 are transferred from the singlet state S 1 to the triplet state T 1 through inter-system crossing (ISC).
[0024] More specifically, some of the electrons e in the singlet state S 1 undergo inter-system crossing from the singlet state S 1 to the triplet state T 1 due to the fact that the orbitals in which the electrons e revolve about the atom's nucleus overlap, or that the spin directions of the electrons e are non-conservative or unstable. There is significant inter-system crossing in the organic material unit 10 .
[0025] Referring to FIG. 1 and FIG. 3 , the method S 100 for non-fluorescence higher harmonic generation ground state depletion ultra-resolution microscopy can be carried out via an optical system 100 . The optical system 100 may include a long-wavelength ultrafast pulse laser 20 , a short-wavelength continuous-wave laser 30 , two laser collimation units A 1 , a light combining unit A 2 , an objective lens A 3 , and a photodetector DR.
[0026] The step S 20 of focusing excitation light and ground state depletion light is now described with reference to FIG. 1 and FIG. 3 . To begin with, the laser collimation units A 1 respectively collimate the excitation light 21 projected by the long-wavelength ultrafast pulse laser 20 and the ground state depletion light 31 projected by the short-wavelength continuous-wave laser 30 . Then, the collimated excitation light 21 and the collimated ground state depletion light 31 are combined by the light combining unit A 2 , in order for the objective lens A 3 to focus the combined excitation light 21 and ground state depletion light 31 onto a plurality of test positions 11 of the organic material unit 10 sequentially. The test positions 11 are located on the surface of the organic material unit 10 that is irradiated by the focused excitation light 21 and the focused ground state depletion light 31 .
[0027] The term “ultrafast pulse” means that the pulse width of the long-wavelength ultrafast pulse laser 20 is selected to be less than 1 picosecond.
[0028] Referring to FIG. 1 , FIG. 3 , FIG. 4A , and FIG. 4B , the step S 30 of generating a higher harmonic signal involves irradiating the test positions 11 of the organic material unit 10 with the focused excitation light 21 . As a result, the electrons e of the molecules at the test positions 11 are excited and jump from the ground state S 0 to the singlet state S 1 , and the molecules induce a higher harmonic generation signal whose frequency is a multiple of v.
[0029] Referring to FIG. 1 , FIG. 3 , and FIG. 4A , if the wavelength of the excitation light 21 emitted by the long-wavelength ultrafast pulse laser 20 is selected to be twice as long as the wavelength corresponding to the frequency v, the sum of the energy of a biphoton (two photons) of the excitation light 21 will be hv, which is sufficient to excite the electrons e at the test positions 11 from the ground state S 0 to the singlet state S 1 and cause the molecules of the organic material unit 10 to induce a second harmonic generation signal F 2 whose frequency is twice that of the excitation light 21 .
[0030] Referring to FIG. 1 , FIG. 3 , and FIG. 4B , if the wavelength of the excitation light 21 emitted by the long-wavelength ultrafast pulse laser 20 is selected to be three times as long as the wavelength corresponding to the frequency v, the sum of the energy of a triphoton (three photons) of the excitation light 21 will be hv, which is sufficient to excite the electrons e at the test positions 11 from the ground state S 0 to the singlet state S 1 and cause the molecules of the organic material unit 10 to induce a third harmonic generation signal F 3 whose frequency is three times that of the excitation light 21 .
[0031] In the following step S 40 of performing ground state depletion, referring to FIG. 1 to FIG. 3 , the focused ground state depletion light 31 of the short-wavelength continuous-wave laser 30 is projected to the electrons e at the test positions 11 that are in the ground state S 0 , with a view to depleting the electrons e. The electrons e will be excited and jump to the singlet state S 1 , and some of the electrons e will undergo inter-system crossing to the triplet state T 1 .
[0032] According to physics, the time it takes for an electron e in the triplet state T 1 to return to the ground state S 0 (i.e., the lifetime of the electron) is much longer than the time it takes for an electron e in the singlet state S 1 to return to the ground state S 0 (i.e., the lifetime of the electron). Moreover, as previously mentioned, there is significant inter-system crossing in the organic material unit 10 .
[0033] Therefore, irradiating the organic material unit 10 with the focused ground state depleting light 31 will cause the irradiated electrons e to stay in the triplet state T 1 most of the time such that ground state depletion (GSD) is achieved.
[0034] When the organic material unit 10 undergoes ground state depletion, the depletion of ground-state electrons e reduces non-linear absorption of the organic material unit 10 , thus allowing modulation of strength of the higher harmonic generation signal induced by the organic material unit 10 .
[0035] Herein, the term “short wavelength” means that the wavelength of the short-wavelength continuous-wave laser 30 is selected to be a wavelength corresponding to the frequency v.
[0036] To carry out the step S 50 of performing microscopic imaging, referring back to FIG. 1 to FIG. 3 , the higher harmonic generation signal induced by the molecules at the test positions 11 of the organic material unit 10 is received by the photodetector DR in order for a microscopic imaging device of the STED system to generate an ultra-resolution microscopic image corresponding to the organic material unit 10 .
[0037] Modulation of the higher harmonic generation signal helps enhance the resolution of the image of the organic material unit 10 obtained from the step S 50 of performing microscopic imaging, and this contributes to expanding the applicability of STED microscopy substantially.
[0038] Referring to FIG. 5 , the optical system 100 implementing the method S 100 for non-fluorescence higher harmonic generation ground state depletion ultra-resolution microscopy may further include a spiral phase plate 50 provided between the short-wavelength continuous-wave laser 30 and the light combining unit A 2 .
[0039] Once the collimated ground state depletion light 31 passes through the spiral phase plate 50 , the center of the light is twisted like eccentric spirals that meet in opposite directions every 180 degrees. When subsequently focused by the objective lens A 3 , the spirals at the center of the ground state depletion light 31 cancel each other due to their difference in phase, forming an annular distribution of light.
[0040] On the other hand, referring to FIG. 3 or FIG. 5 , the light combining unit A 2 can be a dichroic mirror for combining the collimated excitation light and the collimated ground state depletion light. The selection of the dichroic mirror is based mainly on the mirror's permeability to the excitation light. The higher the permeability to the excitation light is, the better the microscopic imaging result will be.
[0041] As shown in FIG. 5 , the excitation light 21 , the ground state depletion light 31 , and the signal light 80 in the optical system 100 lie on the same optical axis (optical path). Hence, a band pass filter 60 can be provided upstream of the photodetector DR, which serves to receive the signal light 80 . The band pass filter 60 will filter out the excitation light 21 and the ground state depletion light 31 so that the photodetector DR receives only the higher harmonic generation signal.
[0042] Since higher harmonic generation signals are difficult to obtain, the photodetector DR in the optical system 100 can be a photomultiplier tube (PMT) for receiving the signal light 80 , converting the received signal light 80 into an electrical signal, and then increasing the strength of the electrical signal with an amplifier to facilitate subsequent imaging.
[0043] The embodiments described above are intended only to demonstrate the technical concept and features of the present invention so as to enable a person skilled in the art to understand and implement the contents disclosed herein. It is understood that the disclosed embodiments are not to limit the scope of the present invention. Therefore, all equivalent changes or modifications based on the concept of the present invention should be encompassed by the appended claims.
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The present invention discloses a method for non-fluorescence higher harmonic generation ground state depletion super-resolution microscopy, it includes the following steps: providing an organic material unit, focusing excitation light and ground state depletion light, generating a higher harmonic signal, performing ground state depletion and performing microscopic imaging. With the implementation of the present invention, the stimulated electrons of the organic material remains majorly on the singlet (S 1 ) state or the triplet (T 1 ) state, instead of the ground (S 0 ) state, to provide modulation of the spatial distribution of the non-fluorescence signal, and make STED microscopy applicable to non-fluorescence signals to promote the resolution of the images.
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BACKGROUND OF THE INVENTION
The present invention relates to a receiver or chucking device for the interchangeable attachment of a work-contacting probe pin or probe-pin combination to the probe head of a coordinate-measuring instrument. Such devices are intended to permit the fastest and easiest possible chucking of the probe-pin combination necessary for a specific measurement task.
Until now, it has been customary, in a manual operation, to screw or clamp the probe pin into the probe head. However, this manual operation is disadvantageous in the case of large-scale automatically controlled measurement processes, since it requires an operator whose sole purpose is to replace probe pins at relatively long intervals of time.
A measurement method is known from "American Machinist", October 1982, pages 152-153, in which the measurement machine itself changes the probe, under computer control. However, that reference does not show how to provide a chucking device for fastening the probe to the machine; in any event, this known automatic change method requires calibration of probe pins after each change, thereby slowing the measurement process.
British Pat. No. 1,599,751 discloses a receiver for replaceable attachment of a complete probe head to the measuring spindle of a measurement machine. This receiver consists of a three-point support on the measurement spindle, and the feeler head is drawn against the three-point support by means of a clamping lever. The support unequivocally determines the position in space of the probe pins with a high degree of accuracy. But again, in the case of this instrument, replacement of probe heads is effected by an operator, who must actuate the clamping lever. There is also the disadvantage that, as a result of changing the complete probe head, a large number of different electrical connections to the measurement machine must be interrupted.
West German Gebrauchsmuster No. 7,400,071 discloses a probe head wherein a probe pin is removably secured to the probe head by means of several permanent magnets. Here, the magnet attachment serves to protect against collision damage. When the pin falls off, in the case of an excessive load, the pin must be reinserted by hand. This solution is not suitable for effecting an automatic change of the probe pin.
BRIEF STATEMENT OF THE INVENTION
The object of the present invention is to provide a receiver or chuck for the interchangeable attachment of a probe pin or probe-pin combination in such manner as to permit a change that is automatically controlled from the machine.
This object is achieved by providing an electrically operated clamping device which draws the connecting member of a probe pin or probe-pin combination against a support which unequivocally determines its position in the receiver of the probe head.
Actuation of the electromagnetic clamping device can be effected automatically by a computer which controls the path of probe-head movement in the measuring machine and the detection of the measurement value. The computer need merely be so programmed that it brings the probe head of the machine to a magazine, which illustratively is provided at a margin of the measurement region and in which different probe pins or probe-pin combinations are stored; the program causes the clamping device to deposit, in the magazine, probe-pin combinations which are no longer required and/or to pick up a new probe-pin combination. Thus, in a probe-pin change, all manual operations are eliminated.
With sufficiently large dimensioning of the support against which the connecting member is drawn, it is in most cases possible to dispense with calibration of the probe ball after introducing a new probe-pin combination, such calibration being necessary only at longer intervals, i.e., probe-pin calibration is not necessary after each change. As a result, measurement time is saved.
The clamping device may illustratively comprise an electric motor having a self-locking transmission which draws the probe pin against its support. In the simplest case, this transmission consists of a threaded spindle on the axis of the motor, the spindle being engaged to a corresponding mating thread in the connecting member.
However, it is particularly advantageous if the clamping device comprises a permanent magnet and an electromagnet, wherein the field of the electromagnet can be superposed on the field of the permanent magnet. With this embodiment, the number of moving parts is minimized and nevertheless the receiver, as in the case of the embodiment involving a motor with self-locking transmission, does not consume any current during intervals between changes.
The permanent magnet is advisedly displaceable against spring force in the direction toward the support for the probe pin. By means of this spring, a reliable separation of the probe pin from the probe head is assured at all times, so that the danger of "sticking" due to an imperfectly compensated or compensatable residual magnet field is avoided.
It is advisable to install the clamping device in the receiver of the probe head, since then only one clamping device is required for each measuring instrument. However, it is also possible to install the clamping device in the connecting member of the probe pin as long as reliable electric switching of the clamping device is assured by the provision of protruding contacts and of corresponding mating contacts on the involved probe-pin magazine. It is also possible to arrange only the permanent magnet or transmission in the connecting member and to associate the electromagnet or motor with the magazine.
The support of the probe head preferably consists of three cylindrical bodies, and the mating support on the probe-pin side comprises three pairs of balls which nest (via their V-shaped spaces) against the cylindrical bodies. By means of such an arrangement, which is already well known to establish the connection point (Knickstelle) for probe heads, the position of the probe-pin combination relative to the coordinate system of the measuring instrument, is clearly determined within an angle of 120°. In order to assure lack of ambiguity over the entire angular range of 360°, an off-axis groove (or locating pin) can be provided in the support, this groove enables angularly unambiguous reception of an off-axis locating pin (or groove) on the connecting member of the probe-pin combination.
The receiver or chuck of the invention is suitable (a) for switch-type probe heads which produce a pulse-like signal when contact is made and (b) for probe heads of the so-called measuring type which contain measurement-value transmitters which, starting from a zero or reference position, supply a signal proportional to the deflection of the movable probe-head part. Probe heads of the last-mentioned type, such as, for instance, the probe device described in U.S. Pat. No. 3,869,799, as a rule include motorized weight balancing to equalize deflections of the probe chuck after insertion of probe-pin combinations of different weight or weight distribution. With the present invention, it is advisable to provide within the probe chuck a switch which signals the presence of a correctly inserted probe pin and which electrically certifies correct reception of the probe pin, the operation of said switch being an interlock function for controlling automatic weight equalization of the probe head.
The connecting member of the probe-pin combination advantageously consists of two parts which are relatively rotatable and can be locked in position, so that the probe-pin combination can be rotated into any desired angular position, as dictated by the workpiece and the specific measurement task.
DETAILED DESCRIPTION
The invention will be illustratively described for two embodiments, in conjunction with the accompanying drawings, in which:
FIG. 1a is a first longitudinal sectional view through a first embodiment, taken along the line I--I of FIG. 3;
FIG. 1b is a fragmentary detail of one of the three groups of bearings (14/15) of FIGS. 1a and 3;
FIG. 2 is a second longitudinal section through the embodiment of FIG. 1, in a 90°-displaced plane indicated by the line II--II of FIG. 3;
FIG. 3 is a transverse section, taken at line III--III of FIG. 1 and FIG. 2, with the probe-pin carrier removed;
FIG. 4 is a view similar to FIG. 1, for a second embodiment of the invention; and
FIG. 5 is a perspective view of a magazine adapted to store probe-pin carriers of the embodiment of FIG. 1.
In FIGS. 1 to 3, the receiver or chuck for a probe-pin combination 21 comprises a cylindrical housing 1 having a flange 2 via which housing 1 is mounted to the deflectable part of a probe head (not shown), as for example to the part 1 of the probe head described in U.S. Pat. No. 3,869,799.
An annular ring 3 has threaded engagement to the bore of housing 1, and ring 3 engages one end of a set of cup springs (Belleville washers) 5. This set of springs 5 is preloaded to urge a retaining plate 6 in the direction toward the upper housing wall 8 of the receiver 1.
The housing 9 of a structural unit consisting of an electromagnet 10 and a permanent magnet 11 is secured to plate 6 by means of a screw 7.
As can be noted from FIGS. 1a, 2 and 3, housing 1 has three radial openings 23a, b and c which are covered by a sleeve 22. A bore 24a extends to opening 23a, from the upper end 8 of housing 1. Bore 24a accommodates connecting cable 25 for electromagnet 10, and cable 25 will be understood to be connected to controls of the measurement machine via the probe head (not shown).
At its lower end, the receiver housing 1 includes probe-supporting means comprising three cylindrical bodies 14a, 14b and 14c which are arranged within the wall of the housing and are located 120° apart. The radially oriented arrangement of these cylindrical bodies can be noted from FIG. 3. A ring 16 has referencing engagement to said supporting means via three pairs of circumferentially spaced balls 15a, b, c; as shown in FIG. 1a for the engaged support elements 14a/15a, each pair of balls forms a V-shaped groove for nested location of a cylindrical body 14. In addition a pin 27 carried by housing 1 engages within a local cutout 26 of ring 16, thus unequivocally determining the spatial position of ring 16 relative to receiver 1 (which is connected to the probe head); pin 27 will be understood to assure the unequivocal character of the seating of ring over the entire circular circumference of 360°.
A first or upper circular plate 18 is seated in a counterbore of ring 16, and a flanged second or lower plate 19 is located to the underside of ring 16, being secured to plate 18 by three screws 17. The second plate 19 has a central thread 20 into which the probe-pin combination 21 is removably engaged. Ring 16 is clamped by the two plates 18 and 19 upon the setting of screws 17, thus securely connecting the probe-pin combination 21 to ring 16. By loosening of screws 17, plates 18 and 19 can be rotated with respect to ring 16, thus enabling angular adjustment of a generally asymmetrical probe-pin combination 21.
The plates 18 and 19, the ring 16 and the pairs of balls 15 form the connecting member of the probe-pin combination. Plate 18 is made of steel, so that the connecting member is drawn by the permanent magnet 11 against the cylindrical bodies of the supporting means 14a, b, c. For an automatically controlled probe-pin change, the electromagnet 10 is so energized by direct current as to produce an additional magnetic field of magnitude approximating but directionally opposed to that of permanent magnet 11, so that the net resultant field is substantially zero. In this circumstance, the holding force between magnet 10 and plate 18 disappears, and the spring 5 presses the magnet combination 9 upward until the plate 6 abuts the upper end 8 of the housing. The involved displacement of the structural part 9 develops a gap between plate 18 and the upper end of magnet 11; the axial extent of this gap corresponds to the distance shown in FIGS. 1a and 2 between the plate 6 and the housing cover 8. The connecting member (16-17-18-19), together with the probe-pin combination mounted thereto, then drops out of the supporting means by its own weight, and is stored in one of the holders of the magazine shown in FIG. 5 for example.
Another probe-pin combination provided with a similar connecting member can then be removed from such a magazine when the measurement machine, under the control of a suitable program, moves the receiver 1 (mounted to the probe head) to another magazine location and positions it above the connecting member of the desired probe-pin combination. Removal of the combination from the magazine can be effected, in principle, without actuation of the electromagnet 10, since the connecting member is automatically drawn against its supporting means, upon sufficient approach of the permanent magnet 11, depending upon the weight of the combination. It is advisable, however, to more positively effect removal of the combination from the magazine by also energizing the electromagnet 10 with such polarity that its field reinforces the field of the permanent magnet 11; this assures a dependable take up of the combination, for even larger gap widths between plate 18 and the magnet 11. It will be understood that upon take up of a new combination (with probe-pin) from the magazine, the structural part 9 (with plate 6) is drawn downward against action of spring set 5 and into the axial offset from the upper end 8 of the housing, as shown in FIG. 1a.
A microswitch 13 is shown mounted by two screws 12a, 12b, to the lower edge of the bore of housing 1. This microswitch is actuated by ring 16 as soon as the latter engages the supporting means 14. Automatic weight compensation of the probe head, as described in U.S. Pat. No. 3,869,799, can therefore be initiated by switch 19, the connecting cable for microswitch 19 being shown passing through bore 24b (FIG. 3).
FIG. 4 shows another embodiment of a receiver or chuck for the replaceable attachment of a probe-pin combination. This receiver again consists of a cylindrical housing 101 provided with a flange 102. By means of the flange 102 the receiver can be fastened, for example, to the movable part 3 of the probe head described in U.S. Pat. No. 4,177,568. On the bottom of the housing are three cylindrical bodies 114 which form the supporting means for a connecting member comprising a ring 116, pairs of balls 115, and plates 118 and 119. A probe-pin combination 121 (not fully shown) can be securely engaged to plate 119 via thread 120. As in the previous embodiment, the plates 118 and 119 are connected to each other by three screws 117 and, after the loosening of said screws, plates 118-119 can be rotated with respect to ring 116. In this case also, a pin 127 in the housing 1 serves, in combination with a cutout 126 in ring 116, for the unequivocal orientation of the position of ring 116 with respect to the probe head.
In contrast to the embodiment shown in FIGS. 1 to 3, the connecting member 115-116-117-118-119 of FIG. 4 is drawn against the supporting means 114 not by a permanent magnet but, rather, by a threaded spindle 111, with the aid of an electric motor 109. For this purpose, plate 118 is provided with a concentric mating thread 131 engaged to spindle 111.
The housing of the electric motor 109 has an annular collar 108 and is fastened, by means of three screws 107 and clamp washers which clamp said collar to a support ring 104. Seated in this support ring 104 is a thrust bearing 112 for relieving the shaft 110 of motor 109. A set screw 113 secures the threaded spindle 111 to the motor shaft 110. Support ring 104 and the motor 109 mounted thereto will be seen as a completely assembled unit inserted into housing 101. And the support ring 104 is fixed in housing 101 by three stud bolts 103 having conical ends to locate against the upper flank of a V-shaped annular groove 105, thus pressing the support ring 104 against the locating rim 106 of a counterbore within housing 101. The threaded bores for bolts 103 are covered by a sleeve 122.
Upon a change of the probe-pin combination, motor 109 will be understood to be activated by the program control of the measurement machine, to drive spindle 111 out of engagement with the thread 131 of plate 118. After suitably controlled repositioning of the probe head and reversal of the direction of rotation of motor 109, the motor-driven spindle engages and draws another connecting plate (having a different probe-pin combination) against the supporting means 114. Motor 109 is disconnected by an electronic control system (not shown) when a predetermined torque has been reached, thus determining the force of application of ring 116 and its pairs of balls 115 against the supporting means 114. The thread pitch of spindle 111 is preferably small, so that self-locking occurs, whereby the probe-pin combination remains fastened in the receiver 1 with constant holding force even when the motor is no longer energized.
The isostatic three-point supports (14/15 and 114/115) in the two embodiments of FIGS. 1 to 3 and FIG. 4 determine the position in space of the probe-pin combination relative to the probe head with such a high precision of reproducibility that it is possible to dispense with a separate calibrating process after changes of probe-pin combination. This being the case, the workpiece to be measured can be immediately contacted by a newly mounted probe-pin combination whose geometry (relative to the machine coordinate system) is stored in the computer. This leads to a considerable reduction in measurement time, particularly in measurement jobs which require frequent probe replacement.
The magazine shown in FIG. 5 consists of several holder-plates slidably mounted to a rail 30. Two of these plates, designated 31 and 41, are shown in the drawing. These holder-plates 31 and 41 are adapted to store probe-pin combinations for the holding device shown in FIG. 1a to FIG. 3.
Holder-plates 31 and 41 are provided with fork like recesses 37 and 47, respectively, enabling horizontal movement of the probe-pin combinations to their storing place at plates 31 and 41.
Additional cover plates 33 and 44 are pivotably mounted to holder-plates 37 and 47, the pivot axes being designated 32 and 42. Plates 33 and 44 cover the support side of the connecting member 15-16-17-18-19 of stored probe-pin combinations from dust exposure, thereby preventing a misadjusted attachment of probe-pin 21 and the probe head. The bottom surfaces of cover plates 33 and 44 carry velvet layers 34 and 43. These layers 34 and 43 serve to smoothly clean support members 15a in the course of pivoted displacement of cover plates 33 and 44 about their axes 32 and 42.
Under "normal" conditions, i.e., during the measuring procedure between probe-pin changes, cover plates 33 and 44 are biased into the position shown for plate 33 by a spring (not shown). If a probe-pin is stored in recess 37 of plate 31, its support side also would be covered by velvet layer 34 of plate 33.
A single block 35 (45) is fixedly mounted to the upper side of each plate 33 (44). When the probe head is to be provided with a probe pin stored in the magazine, the probe head is driven by the measuring machine, under computer control, against one of these blocks 35 or 45, thereby causing the involved plate 33 (44) to pivot and thus to be removed from the support end of the involved probe pin. At this juncture, electrical excitation of electromagnet 10 of the receiver or chuck of FIG. 1a is operative to automatically take the probe pin from its holder plate.
A magnet 36 (46) on each of the holder plates 31 (41) enables magnet-retention of the open condition of recesses 37 (47) when one or more of the plates 33 (44) is retracted, so that unobstructed access is available for the measuring machine to establish and store spatial coordinates applicable to the probed recess 37 (or 47). It will be understood that such measurement is necessary when the magazine has just been installed with respect to the measuring machine, so that stored data as to each recess 37 (47) can then be available for subsequent program-controlled storage or pick-up of probe pins.
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The invention concerns a receiver (1) in the probe head of a multiple-coordinate measuring machine in which probe-pin combinations (21) can be replaceably chucked with high precision with respect to their position in space. The receiver contains an isostatic three-point support (14) against which the base (15, 16, 17, 18, 19) of the probe-pin combination is drawn by an electrically operated clamping device. The clamping device is coupled with the control computer of the measuring machine so that a probe change can be effected automatically.
In a preferred embodiment, the clamping device consists of a permanent magnet (11) and of an electromagnet (10) by which the field of the permanent magnet (11) can be selectively counteracted or increased to achieve pick-up and release functions. In another embodiment, a motor-driven screw thread performs the pick-up and release functions, and assures that the picked-up probe will unambiguously be drawn into correct isostatic engagement with the three-point support.
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CROSS REFERENCE
[0001] This application is a divisional of U.S. patent application Ser. No. 13/960,308 filed on Aug. 6, 2013. The entire contents of U.S. patent application Ser. No. 13/960,308 are hereby incorporated by reference.
BACKGROUND
[0002] The present disclosure relates to door catches, and more particularly door catches utilizing a ball catch mechanism.
[0003] Door catches can generally be utilized to hold doors or similar structures in either an open or closed position. In addition, door catches used to hold a door or the like in an open position can be configured to prevent the door from hitting and damaging a wall and therefore can also perform the function of a doorstop.
[0004] Door catches come in a variety of different types. For example, roller catches, magnetic catches, hinge pin doorstops, kick down holders, j-hook catches, strike and catch automatic wall holders, and ball catches. One class of door catches relies on tension between two portions of the door catch to hold the door open.
[0005] One of the challenges in door catch design, is adjustment of catch tension, particularly for door catches that can be utilized to hold a door in the open position by relying on tension between two portions of the door catch. For example, catch tension adjustment sometimes requires that one of the mounting members be moved relative to the mounting surface. Alternatively, catch tension adjustment may require removal of one of the mounting members from the mounting surface. Either of these can be inconvenient for the installer or maintainer of the door. In many door catch designs, the installer or maintainer is required to drill new holes in order to adjust the position or catch tension. In these designs, micro-adjustments are not possible. Micro-adjustment of catch tension may be particularly important over time, as the door or doorframe shift and settle or as the door sags.
SUMMARY
[0006] Doors often sag under their own weight over time. This can damage the hinges or cause the door not to close properly when the door is no longer in alignment with the door opening. This problem is particularly exasperated for heavy or tall residential or commercial doors. The inventor recognized that a door catch could be devised that helps to prevent door sag in addition to solving the problem of providing for micro-adjustments of catch tension while the door catch is mounted to the door.
[0007] Disclosed is a door catch that can help to prevent door sag, and provide for post-installation catch tension adjustment without removal or adjustment of mounting members. In one aspect, the door catch includes a ball plunger assembly, a catch bar bracket, and a ball catch base. The ball plunger assembly includes a ball captive within the body of the ball plunger assembly. The exterior of the ball plunger body is threaded. The bottom surface of the ball plunger assembly includes a tool-receiving pattern, such as a slot head, Philips, hex head, or Torx head pattern. The catch bar bracket includes a mounting portion for mounting the catch bar to a door, wall, or doorframe. A catch bar includes a detent on the side facing the ball catch base. The catch bar projects away from the mounting base of the catch bar bracket. The ball catch base also includes a mounting portion for mounting the ball catch base to a door, wall, or wall frame. The ball catch base also includes a base portion that projects away from the ball catch mounting portion. The base portion includes a threaded aperture and the ball plunger assembly is threaded into the threaded aperture with the ball facing and aligned with the detent when the catch is engaged.
[0000] The catch bar bracket and the ball catch base are mountable on opposing surfaces of a wall structure and the door so that the ball and detent frictionally engage to hold the door open when the door is in an extended position. The frictional force impinging the ball against the detent is adjustable by rotatably engaging the tool-receiving pattern causing the ball to raise or lower with respect to the detent.
[0008] In order to ensure that the door catch can properly sustain the downward force of the door and help keep if from sagging, it is helpful to make sure that door catch components are designed to sustain the force without slippage. One way to help assure this is to provide apertures on the mounting portions that are shaped to hold the fastener in a fixed and non-adjustable position, for example, a recessed aperture with corresponding complementary fastener head.
[0009] The catch bar bracket and or corresponding mounting portion in one aspect, can be fabricated from a single piece of metal or otherwise made as a non-separable unit. Alternatively, in another aspect, the catch bar can be separable from the rest of the catch bar bracket. This allows for the possibility of creating a catch bar bracket where the distance between the downward facing detent and its corresponding mounting portion is adjustable.
[0010] One example of a catch bar bracket where the distance between the downward facing detent and its corresponding mounting portion is constructed with an integrated base portion projecting away from the mounting portion that includes a serrated top surface. The catch bar includes a serrated bottom surface configured to engage the serrated top surface of the base portion. In combination, they adjust a distance of the detent with respect to the mounting portion of the catch bar bracket. The base portion can include a fastener receiving threaded aperture through the serrated top surface and the catch bar bracket, a slot for receiving and securing a threaded fastener to the fastener receiving threaded aperture.
[0011] Another aspect of the disclosed door catch that allow for distance adjustment of the detent with respect to the catch bar mounting portion separates the catch bar bracket into a mounting portion and a catch bumper portion where the catch bumper portion includes the downward facing detent. The two portions are separated by a rod. If the rod is threaded, the distance between the catch bumper portion and the mounting portion may be adjusted by screwing the threaded rod into the mounting portion or the bumper portion. Alternatively the rod may allow for distance adjustment by a securing a pin between the bumper portion or the mounting portion and one of several holes mounted at various distances along the rod.
[0012] In another aspect, the disclosed door catch can be adapted to work on a pivot door. In this aspect, the catch bar is formed in the shape of a downward facing L-bracket and the mounting portion of the catch bar bracket is configured as a planar back with respect to the downward facing L-bracket.
[0013] This Summary has introduced a selection of concepts in simplified form that are described the Description. The Summary is not intended to identify essential features or limit the scope of the claimed subject matter.
DRAWINGS
[0014] FIG. 1 shows a door catch of the present disclosure mounted near the top of a door and corresponding wall.
[0015] FIG. 2 shows a portion of FIG. 1 detailing the door catch in relation to the door and corresponding wall.
[0016] FIG. 3 shows a portion of the door and frame in the open position of FIG. 1 with corresponding door catch.
[0017] FIG. 4 shows the door catch of FIG. 1 in top perspective view.
[0018] FIG. 5 shows a sectional view of the door catch of FIG. 4 shown along section lines 5 - 5 .
[0019] FIG. 6 shows a top perspective exploded view of the ball catch base and the ball plunger of the door catch of FIG. 4 .
[0020] FIG. 7 shows a top assembled view of the ball catch base and ball plunger assembly of FIG. 6 .
[0021] FIG. 8 shows a sectional view of the FIG. 7 shown along section lines 8 - 8 .
[0022] FIG. 9 shows a front view of the ball catch base and ball plunger assembly of FIG. 7 .
[0023] FIG. 10 shows a bottom view of the ball catch base and ball plunger assembly of FIG. 7 .
[0024] FIG. 11 shows the ball plunger assembly of the door catch of FIG. 4 in top view.
[0025] FIG. 12 shows a cross sectional view of the ball plunger assembly of FIG. 11 taken along section lines 12 - 12 .
[0026] FIG. 13 shows a side view of the ball plunger assembly of the door catch of FIG. 4 .
[0027] FIG. 14 shows a bottom view of the ball plunger assembly from the door catch of FIG. 4 .
[0028] FIG. 15 shows a front top perspective view of the catch bar bracket of the door catch of FIG. 4 .
[0029] FIG. 16 shows a front bottom perspective view of the catch bar bracket of FIG. 15 .
[0030] FIG. 17 shows a top view of the catch bar bracket of FIG. 15 .
[0031] FIG. 18 shows a sectional view of FIG. 17 taken along section lines 18 - 18 .
[0032] FIG. 19 shows a top view of a door catch with alternative catch bar bracket and alternative ball catch base construction.
[0033] FIG. 20 shows a sectional view of the catch bar bracket of FIG. 19 taken along section lines 20 - 20 .
[0034] FIG. 21 shows a bottom view of the catch bar bracket of FIG. 19 .
[0035] FIG. 22 shows a bottom view of the ball catch base of FIG. 19 .
[0036] FIG. 23 shows a top perspective view of a door catch with an alternative catch bar bracket and catch bar base where the position of the catch bar detent from the wall or doorframe is adjustable.
[0037] FIG. 24 shows a cross sectional view of the door catch of FIG. 23 taken along section lines 24 - 24 .
[0038] FIG. 25 shows a cross sectional view of the door catch of FIG. 23 taken along section lines 24 - 24 with an optional spacer.
[0039] FIG. 26 shows a top view of the catch bar of FIG. 23 .
[0040] FIG. 27 shows a bottom view of the catch bar of FIG. 23 .
[0041] FIG. 28 shows a side view of the catch bar of FIG. 23 .
[0042] FIG. 29 shows a top view of the catch bar base of FIG. 23 .
[0043] FIG. 30 shows a sectional view of FIG. 29 taken along section lines 30 - 30 .
[0044] FIG. 31 shows a top perspective view of the catch bar base of FIG. 29 .
[0045] FIG. 32 shows a top view of an alternative door catch where the position of the catch bar detent from the wall or doorframe is adjustable by a threaded rod.
[0046] FIG. 33 shows a sectional view of FIG. 32 taken along section lines 32 - 32 .
[0047] FIG. 34 shows a side exploded view of catch bar assembly of FIG. 32 .
[0048] FIG. 35 shows a top view of an alternative door catch where the position of the catch bar detent from the wall or doorframe is adjustable by a rod and pin arrangement.
[0049] FIG. 36 shows a sectional view of FIG. 32 taken along section lines 36 - 36 .
[0050] FIG. 37 shows a side exploded view of the catch bar assembly of FIG. 35 .
[0051] FIG. 38 shows a bottom exploded view of the catch bar assembly of FIG. 35 .
[0052] FIG. 39 shows an upper portion of a partially open pivot door in top front perspective view illustrating an alternative door catch.
[0053] FIG. 40 shows a bottom view of the pivot door and door catch of FIG. 39 with the pivot door in the closed position.
[0054] FIG. 41 shows a bottom view of the pivot door and door catch of FIG. 39 with the pivot door in the open position and with the door catch fully engaged.
[0055] FIG. 42 shows a front perspective view of the catch bar bracket of the door catch of FIG. 39 .
[0056] FIG. 43 shows a front view of the catch bar bracket of FIG. 42 .
[0057] FIG. 44 shows a side view of the catch bar bracket of FIG. 43 .
[0058] FIG. 45 shows a bottom view of the catch bar bracket of FIG. 44 .
[0059] FIG. 46 shows a front detail view of the door catch assembly mounted to the door and door frame in closed position.
[0060] FIG. 47 shows an alternative door catch in top perspective view mounted to the bottom of a door and wall.
[0061] FIG. 48 shows a sectional view of the door catch of FIG. 47 shown along section lines 48 - 48 .
DESCRIPTION
[0062] The following description is made with reference to figures, where like numerals refer to like elements throughout the several views, FIG. 1 shows a door catch 10 of the present disclosure mounted near the top of a door 11 and corresponding wall 13 . FIG. 2 shows a portion of FIG. 1 detailing the door catch 10 in relation to the door 11 and corresponding wall 13 . FIG. 3 shows a portion of the door 11 in the open position where the catch portions are separate and not engaged. Referring to FIGS. 2-3 , the door catch 10 of FIG. 2 includes a catch bar bracket 15 secured to the door and a ball catch base 17 secured to the wall. Referring to FIG. 3 , the catch bar bracket 15 includes a detent 19 in the lower surface of the catch bar portion of the catch bar bracket 15 . The door catch 10 holds the door 11 in place through friction. When the door 11 is in the fully open position, the detent 19 aligns a ball plunger assembly 21 in order to create a friction force that holds the door open. One of the utilities of the door catch 10 of this disclosure is the ability to adjust the frictional force that holds the door in place without removing or moving the catch bar bracket 15 or ball catch base 17 . The friction between the ball plunger assembly 21 and the detent 19 can be adjusted by moving the ball plunger assembly 21 up and down relative to the top of the ball catch base 17 . The ball plunger assembly 21 is shown from the bottom with a slot 27 for engaging a screwdriver or similar tool for adjusting the height of the ball plunger assembly 21 relative to the ball catch base 17 .
[0063] In FIGS. 1-3 , the catch bar bracket 15 and ball catch base 17 are shown as mounted between a door 11 and a wall 13 . It should be understood by the reader, that in FIGS. 1-3 , and throughout this disclosure, that the catch bar bracket 15 and ball catch base 17 can be mounted between the door 11 and other mounting surfaces that can be intersected by a door when open; for example, a folding door panel.
[0064] FIG. 4 shows the door catch 10 of FIG. 1 in top perspective view showing the relationship between the catch bar bracket 15 and the ball catch base 17 when frictionally engaged; for example, when the door 11 is open and proximate to the wall 13 . FIG. 5 shows a sectional view of the door catch 10 of FIG. 4 shown along section lines 5 - 5 . Referring to FIGS. 4-5 , the catch bar bracket 15 and ball catch base 17 are secured respectively to the door 11 and wall 13 by apertures 23 and corresponding threaded fasteners 25 through the apertures 23 through the surface of the catch bar bracket 15 and the ball catch base 17 . The catch bar bracket 15 and the ball catch base 17 need to be mounted in a way to withstand the rotational torque of the door 11 with respect to its hinges in order prevent the door 11 from sagging over time. One way to assure this is to provide mounting holes where the fastener is mounted in fixed mounting holes without any possibility for vertical or horizontal movement within the hole. As an example, the apertures 23 in FIGS. 4-5 are round and countersunk.
[0065] In FIG. 5 , the ball plunger assembly 21 is shown threaded into the ball catch base 17 and can be rotated to increase or decrease friction between the ball plunger assembly 21 and the catch bar bracket 15 . A slot 27 is provided to engage a screwdriver or other similar tool. When the ball plunger assembly 21 is rotated upward into the ball catch base, the friction between the ball plunger assembly 21 and the catch bar bracket 15 is increased. As the ball plunger assembly 21 is rotated downward out of the ball catch base, the friction between the ball plunger assembly 21 and the catch bar bracket 15 is decreased.
[0066] The door 11 is illustrated in FIG. 5 as being made of wood. The wall 13 is illustrated as having a drywall outer surface with the threaded fasteners 25 engaging drywall anchors or the like. The door catch 10 can be mounted on most common commercial or residential door materials. For example, the door material can be steel, steel over foam core, metal, wood, or fiberglass framed-glass.
[0067] FIG. 6 shows a top perspective exploded view of the ball catch base 17 and the ball plunger assembly 21 of the door catch of FIG. 4 . FIG. 7 shows a top assembled view of the ball catch base 17 and ball plunger assembly 21 of FIG. 6 . FIG. 8 shows a sectional view of the FIG. 7 shown along section lines 8 - 8 . FIG. 9 shows a front view of the ball catch base 17 and ball plunger assembly 21 of FIG. 7 . FIG. 10 shows a bottom view of the ball catch base 17 and ball plunger assembly 21 of FIG. 7 . Referring to FIGS. 6-10 , a bumper 29 is shown optionally attached to the ball catch base 17 . Depending on the whether the ball catch base 17 is secured to the door 11 , wall 13 of FIG. 1 for example, or a doorframe, the bumper 29 can be used to protect the opposing surface from damage. The bumper 29 can be made generally of a pliant material such a soft plastic or an elastomer such as silicone rubber or butyl rubber. Those skilled in the art will readily recognize materials suitable for the bumper 29 .
[0068] Referring to FIG. 6 , the ball catch base 17 is illustrated in the shape of a bracket. The ball catch base 17 includes a base portion 31 that when mounted to a wall or door projects approximately perpendicularly away from the door. If the door is mounted vertically, as in the door 11 illustrated in FIGS. 1-3 , then a top surface 33 of the base portion 31 lies substantially in the horizontal plane. The ball catch base 17 includes a mounting portion 35 that lies in the same plane as the mounting surface of the door, wall, or doorframe. The mounting portion 35 projects approximately perpendicularly away from the plane of the top surface 33 of the base portion 31 of the ball catch base 17 . While the mounting portion 35 is shown projecting upward from the base portion 31 , the mounting portion 35 can optionally be constructed to project both upward and downward with respect to the base portion 31 for additional support.
[0069] FIGS. 6-10 all show the mounting portion 35 in various views. FIGS. 6 , 8 , and 9 show the apertures 23 for mounting the ball catch base 17 to the wall or door in relation to the mounting portion 35 . FIGS. 6 and 8 shows the apertures 23 as countersunk. As previously described, the aperture 23 is shaped so that threaded fastener 25 of FIGS. 4-5 is fixed in position without the opportunity to slide or move under the downward torque of the open door.
[0070] FIG. 6 shows a threaded aperture 37 sized and threaded to receive the ball plunger assembly 21 . FIG. 8 shows the ball plunger assembly 21 threaded inside the threaded aperture 37 . The ball plunger assembly 21 can be moved up and down with respect to the top surface 33 of the base portion 31 of the ball catch base 17 by rotationally engaging the slot 27 with a screwdriver or similar tool. Referring to FIGS. 6-9 , the ball plunger assembly 21 includes a tension ball 39 . Referring to FIGS. 8-10 , the ball plunger assembly 21 includes a tool-engaging plunger base 41 with a slot 27 or other shape for engaging a tool in rotational motion.
[0071] FIG. 11 shows, in top view, the ball plunger assembly 21 of the door catch 10 of FIG. 4 . FIG. 12 shows a cross sectional view of the ball plunger assembly 21 of FIG. 11 taken along section lines 12 - 12 . FIG. 13 shows a side view of the ball plunger assembly 21 . FIG. 14 shows a bottom view of the ball plunger assembly 21 . FIGS. 11-13 show the tension ball 39 . The tension ball 39 is shown in cross section in FIG. 12 . The tension ball 39 generally has a circular profile or spherical shape. Other shapes can be used to produce specific frictional profiles. For example, an elliptical shape with the top of the tension ball 39 along the major axis of the elliptical shape, assuming uniform deformation of the tension ball 39 , the force at the point of contact with the detent 19 of FIG. 3 would tend to be concentrated over less of an area than a tension ball 39 that is spherically shaped. The door would tend to release more abruptly as the force of friction would be overcome over less surface area than the tension ball 39 of spherical shape. Similarly, an elliptical shape with the top of the tension ball 39 along the minor axis of the elliptical shape, assuming uniform deformation of the tension ball 39 , would tend to release less abruptly than a tension ball 39 with a corresponding spherical shape.
[0072] FIG. 12 shows the internal construction of ball plunger assembly 21 including the tension ball 39 , the threaded ball plunger body 43 , tool-engaging plunger base 41 , and the slot 27 . The ball plunger assembly 21 is similar in construction to spring plungers used in the art for positioning fixtures, punch presses, or forging dies. The tension ball 39 is typically installed through the top opening using a plunger wrench. The plunger wrench typically includes projections that are complementary to rectangular insertion points 45 shown in FIG. 11 .
[0073] Referring again to FIG. 12 , the ball plunger assembly 21 includes a spring 47 . The spring provides compression force, and thereby holding friction, when the tension ball 39 makes contact with the detent 19 of FIG. 3 . In FIGS. 13-14 , the ball plunger assembly 21 , when rotated, moves linearly as an integrated unit within the threaded aperture 37 of ball catch base 17 of FIG. 6 . The slot 27 of the tool-engaging plunger base 41 is a typical tool-engaging screw drive. Alternatively, other tool-engaging screw drives may be used, for example, Phillips, Frearson, Cross, Robertson (square shaped), Allen (hex shaped), Torx, or TTAP, as long as they are able to engage the ball plunger assembly 21 with sufficient force and grip to prevent stripping.
[0074] FIG. 15 shows a front top perspective view of the catch bar bracket 15 of the door catch 10 of FIG. 4 . FIG. 16 shows a front bottom perspective view of the catch bar bracket 15 . FIG. 17 shows a top view of the catch bar bracket 15 . FIG. 18 shows a sectional view the catch bar bracket 15 of FIG. 17 taken along section lines 18 - 18 . Referring to FIGS. 15-18 , the catch bar bracket 15 includes an integrated catch bar/base 49 and a mounting portion 51 . The mounting portion 51 projects approximately perpendicularly away from integrated catch bar/base 49 . In FIGS. 15-16 and 18 , the mounting portion 51 is shown projecting perpendicularly away from both above and below both the integrated catch bar/base 49 . With a typical vertically mounted door, wall, and doorframe, the mounting portion 51 would be oriented vertically and the integrated catch bar/base 49 would be projecting horizontally away from the door. The mounting portion 51 includes apertures 23 . The apertures 23 of the catch bar bracket 15 are round and countersunk to prevent any possibility of vertical or horizontal movement within the hole so as to withstand the rotational torque of the door 11 with respect to its hinges in order prevent the door 11 from sagging over time as previously described.
[0075] FIGS. 17 and 18 show the detent 19 for frictionally engaging the tension ball 39 of FIGS. 11-14 . The detent 19 is shown having a circular profile that is complementary to the spherical shape of the tension ball 39 of FIGS. 11-14 . Other arcuate shapes can be used to adjust the frictional force of engagement or disengagement. For example, given the same spherically shaped tension ball, an elliptical shaped with the center line along its minor axis would tend to more gradually disengage and engage but potentially provide a weaker frictional holding force than a comparable spherical shaped detent.
[0076] FIG. 19 shows a top view of a door catch 10 with alternative construction of the catch bar bracket 15 and alternative construction of the ball catch base 17 . FIG. 20 shows a sectional view of the door catch 10 of FIG. 19 taken along section lines 20 - 20 . FIGS. 19-20 show the alternatively constructed versions of the catch bar bracket 15 , ball catch base 17 , the ball plunger assembly 21 , and an alternatively shaped version of the bumper 29 , in engaged cooperation as previously described. A catch stop 53 projects downward from the catch bar bracket 15 and functions to horizontally limit the motion of the ball catch base 17 when frictionally engaged with the catch bar bracket 15 . The bumper 29 , here shown as hemi-spherically shaped, dampens the force between the catch stop 53 and the ball catch base 17 .
[0077] FIG. 21 shows a bottom view of the catch bar bracket 15 of FIG. 19 . FIG. 22 shows a bottom view of the ball catch base 17 of FIG. 19 . FIG. 21 shows in the detent 19 and the catch stop 53 . FIG. 22 shows bumper 29 and the bottom of the ball plunger assembly 21 . The ball plunger assembly 21 is shown with the slot 27 for rotationally engaging the ball plunger assembly 21 , as previously described.
[0078] FIGS. 23-38 show several configurations of door catches 10 where the catch bar is horizontally adjustable with respect to its mounting surface. This may be desirable when a specific distance between the open door and wall needs to be maintained. FIGS. 23-31 illustrate horizontal adjustment using a serrated catch bar and catch bar base with complementary serrations. FIG. 23 shows a top perspective view of a door catch with a catch bar 55 and catch bar base 57 where the position of the detent 19 from the wall 13 or doorframe is adjustable. The ball catch base is shown secured to a door 11 . The detent 19 is shown in hidden lines. FIG. 24 shows a cross sectional view of the door catch 10 of FIG. 23 taken along section lines 24 - 24 with the catch bar base secured to the wall 13 and the ball catch base secured to the door 11 . The door 11 is illustrated as having a fiberglass or metal frame, and the wall including a wood member. As previously described, the door catch 10 can be mounted to most common residential door and wall materials. FIG. 25 shows a cross sectional view of the door catch 10 of FIG. 23 taken along section lines 24 - 24 with a spacer 59 . FIG. 26 shows a top view of the catch bar 55 of FIG. 23 . FIG. 27 shows a bottom view of the catch bar 55 of FIG. 23 . FIG. 28 shows a side view of the catch bar 55 of FIG. 23 . FIG. 29 shows a top view of the catch bar base 57 of FIG. 23 . FIG. 30 shows a sectional view of the catch bar base 57 of FIG. 29 taken along section lines 30 - 30 . FIG. 31 shows a top perspective view of the catch bar base 57 of FIG. 29 .
[0079] Referring to FIG. 23 , the door catch 10 includes the ball catch base 17 previously described for FIGS. 6-10 , the catch bar 55 and catch bar base 57 . Referring to FIGS. 27-28 , the catch bar 55 includes a detent 19 that frictionally engages the ball plunger assembly 21 ; the ball plunger assembly 21 is illustrated frictionally engaging the catch bar 55 in FIGS. 24-25 . The force of friction between the ball plunger assembly 21 and the catch bar 55 is adjustable by rotationally engaging the ball plunger assembly 21 causing it to move up or down depending on the direction of rotation as previously described. The distance between the catch bar base 57 and the ball catch base 17 can be adjusted by extending the catch bar 55 along the catch bar base 57 . A slot 61 , shown in FIGS. 23 , and 26 - 27 , can adjustably secure the position of the catch bar 55 relative to the catch bar base 57 . Complementary serrations on the bottom surface of the catch bar 55 , shown in FIGS. 23-25 , and 27 - 28 , and the catch bar base 57 , shown in FIGS. 23-25 , and 29 - 31 ensure that the when secured, slippage may not occur between the catch bar 55 and catch bar base 57 under the forces exerted by the door. The threaded fastener 25 is illustrated in FIGS. 23-25 . FIGS. 29-30 show the threaded aperture 37 for receiving the threaded fastener 25 .
[0080] The catch bar 55 of FIGS. 23-28 can be manufactured in different standard lengths to accommodate various distance ranges between the door and wall/doorframe. Alternatively, a universal catch bar can be supplied that can be designed to be cut to length to accommodate a specific installation requirement. In FIG. 25 a spacer 59 secured to the front of the catch bar base 57 to provide a bumper surface between the catch bar base 57 and the ball catch base 17 . The spacer 59 is shown secured to the catch bar base 57 by a threaded fastener 25 . The spacer 59 can similarly be secured by a spring-loaded snap fit fastener.
[0081] FIGS. 30-31 show the mounting portions 51 projecting perpendicularly upwardly and downwardly away from the horizontal plane of the catch bar base 57 . As previously discussed, the mounting portion 51 includes apertures 23 . The apertures 23 of the catch bar bracket 15 are round and countersunk to prevent any possibility of vertical or horizontal movement within the hole so as to withstand the rotational torque of the door with respect to its hinges in order prevent the door from sagging over time as previously discussed.
[0082] FIG. 32 shows a top view of the door catch 10 alternatively constructed where the position of the detent from the door 11 or alternatively the wall is adjustable by a threaded rod 63 . FIG. 33 shows a sectional view of FIG. 32 taken along section lines 32 - 32 showing the door catch assembly in the catch position between the door 11 and wall 13 . FIG. 34 shows a side exploded view of catch bar assembly 65 of FIG. 32 showing the detent 19 in broken lines representing hidden lines. Referring to FIGS. 32-34 , the catch bar assembly 65 includes the threaded rod 63 , a mounting base 67 , jamb nut 69 , and a catch bumper 71 . Referring to FIG. 34 , the mounting base 67 and the catch bumper 71 include a threaded aperture 37 for receiving the threaded rod 63 . The jamb nut 69 locks the threaded rod 63 in place once the distance is adjusted. The threaded rod 63 can come in a variety of standard lengths to accommodate specified distances between the door 11 and wall 13 of FIGS. 32-33 . Optionally, a universal length version of the threaded rod 63 can provided and cut to length by the door installer. The ball catch base 17 of FIGS. 32-33 and the ball plunger assembly 21 of FIG. 33 can be the same ball catch base 17 and ball plunger assembly 21 as previously described in FIGS. 6-10 . The apertures 23 of the mounting base 67 are round and countersunk to prevent any possibility of vertical or horizontal movement within the hole so as to withstand the rotational torque of the door with respect to its hinges in order prevent the door from sagging over time as previously discussed.
[0083] FIG. 35 shows a top view of the door catch 10 of alternative construction where the position of the catch bar detent from the wall or doorframe is adjustable by a rod and pin arrangement. FIG. 36 shows a sectional view of the door catch 10 of FIG. 32 taken along section lines 36 - 36 . FIG. 37 shows a side exploded view of the catch bar assembly 65 of FIG. 35 . FIG. 38 shows a bottom exploded view of the catch bar assembly 65 of FIG. 35 showing the detent 19 . Referring to FIGS. 35-37 , the catch bar assembly 65 includes a non-threaded rod 73 , a mounting base 67 , holding pins 75 , and a catch bumper 71 . Referring to FIG. 37 , the mounting base 67 and the catch bumper 71 each include an aperture 23 for receiving the non-threaded rod 73 . Each of the apertures 23 is indicated by broken lines. FIG. 38 shows a series of apertures 23 in the non-threaded rod 73 and a corresponding apertures 23 in the mounting base 67 and the catch bumper 71 for receiving the holding pin 75 of FIG. 37 . In FIG. 36 , the holding pins 75 are inserted in place in the non-threaded rod 73 once the distance is adjusted. The non-threaded rod 73 of FIGS. 35-38 can come in a variety of standard lengths to accommodate specified distances between the door and the wall. Optionally, a universal length version of the non-threaded rod 73 can provided and cut to length by the door installer. The ball catch base 17 of FIGS. 35-36 and the ball plunger assembly 21 of FIG. 36 can be the same ball catch base 17 and ball plunger assembly 21 as previously described in FIGS. 6-10 . The apertures 23 of the mounting base 67 are round and countersunk to prevent any possibility of vertical or horizontal movement within the hole so as to withstand the rotational torque of the door with respect to its hinges in order prevent the door from sagging over time as previously discussed.
[0084] The door catch of this disclosure may readily be adapted for use with a pivot door. FIG. 39 shows an upper portion of a pivot door 77 in a partially open position in top front perspective view. An alternative version of the door catch 10 is shown mounted to the top of the pivot door 77 with respect to a doorframe 79 . FIG. 40 shows a bottom view of the pivot door 77 , the door catch 10 of FIG. 39 , the doorframe 79 , and the wall 13 with the pivot door 77 in the closed position. FIG. 41 shows a bottom view of the pivot door 77 and door catch 10 of FIG. 39 with the pivot door 77 in the open position and with the door catch 10 fully engaged. FIG. 41 shows the pivot door 77 in relation to the doorframe 79 and the wall 13 . In FIGS. 39-40 , the door catch 10 includes a ball catch base 17 and a catch bar bracket 15 . The same ball catch base 17 can be used as previously described, for example, in FIGS. 6-10 , 23 - 25 , and 32 - 33 . Using the same ball catch base 17 across multiple applications simplifies manufacturing, forecasting, and inventory management.
[0085] FIGS. 42-46 shows the catch bar bracket 15 of FIGS. 39-40 in several views. FIG. 42 shows the catch bar bracket 15 in a front perspective view, FIG. 43 in front view, FIG. 44 in side, and FIG. 45 in bottom view. Referring to FIGS. 42-45 the catch bar bracket 15 of FIGS. 39-40 includes a downward facing L-bracket portion 81 and a planar-back mounting portion 83 . The planar-back mounting portion 83 is shown with apertures 23 for mounting the planar back to doorframe 79 of FIGS. 39-41 . The apertures 23 of the catch bar bracket 15 of FIGS. 42-43 , and 46 are round and countersunk to prevent any possibility of vertical or horizontal movement within the hole so as to withstand the rotational torque of the door with respect to its hinges in order prevent the door from sagging over time as previously discussed. In FIG. 46 the catch bar bracket 15 is shown secured to the doorframe 79 with threaded fasteners 25 . A metal stiffener plate 85 is shown to provide added support if needed. In FIG. 44-45 , the bottom the downward facing 1 -bracket portion 81 includes the detent 19 for frictionally engaging the top of the ball plunger assembly 21 of FIG. 46 . Note that in FIG. 46 , the ball plunger assembly 21 and the corresponding ball catch base 17 is mounted in the opposite direction as in FIG. 6-10 . This reversible configuration allows the ball catch base 17 to be used in a variety of different applications. In FIG. 46 , the ball catch base 17 is shown mounted to the door 11 with the mounting portion 35 facing downward. As in the other disclosed configurations, the ball plunger assembly 21 is rotationally adjustable from below.
[0086] FIG. 47 shows an alternative door catch in top perspective view mounted to the bottom of a door 11 and wall 13 . FIG. 48 shows a sectional view of the door catch of FIG. 47 shown along section lines 48 - 48 . Referring to FIGS. 47-48 , the door is shown with the catch bar bracket 15 frictionally engaged with the ball plunger assembly 21 of the ball catch base 17 to hold the door open. The ball catch base 17 is shown with mounting portion extending perpendicularly upward and downward for additional support. This configuration allows the ball catch base 17 to be fully supported in either the upward facing or downward facing direction. In FIGS. 47-48 , where the door catch 10 is mounted at the bottom of the door, the slot 27 of the ball plunger assembly 21 is facing upward for easy adjustment with a screwdriver or the like from above. As the ball plunger assembly is rotated so it screws downward and into the ball catch base 17 , the ball plunger assembly 21 and catch bar bracket 15 become more frictionally engaged. As the ball plunger assembly is rotated so it screws upward and out of the ball catch base 17 , the ball plunger assembly 21 and the catch bar bracket 15 become less frictionally engaged. Also shown in FIGS. 47-48 are the threaded fasteners 25 and aperture 23 for receiving the threaded fasteners 25 into either the door 11 or wall 13 . In FIG. 48 , both the wall 13 and the door 11 are shown as wood. The door 11 or wall 13 can also be any combination of standard door and wall materials. For example, the wall 13 can be drywall, metal, or concrete or a fiberglass frame and the door can include a fiberglass or metal frame structure in addition to the illustrated wood structure. Those skilled in the art will readily recognize other suitable door and wall materials.
[0087] The door catch thus far described has been applied to frictionally hold a door in an open position. It may also be desirable to frictionally hold a door in a closed position. For example, local fire and safety codes may require certain exit door include a crash bar or “panic bar” where a simple push on the bar releases the door for easy egress during an emergency. Many historical buildings require that their facade be maintained including the original doors and these may not suitable or adaptable for integration of a panic bar. In this situation it may be possible to adapt the door catch 10 described thus far to function in the closed position. For example by extending perpendicular brackets outward from the inside of the door and the wall to provide suitable mounting surfaces for the catch bar bracket 15 and ball catch base 17 while the door is in the closed position.
[0088] A novel door catch has been described. It is not the intent of this disclosure to limit the claimed invention to the examples, variations, and exemplary embodiments described in the specification. Those skilled in the art will recognize that variations will occur when embodying the claimed invention in specific implementations and environments. As an example, while the catch bar bracket is shown in specific examples mounted to a door and in others mounted to a wall, those skilled in the art will readily recognize from the disclosure that the catch bar bracket can be mounted on either the door or the wall in any of the examples. The same can be said for the ball catch base. In addition, various materials, for example, wood, metal, fiberglass, or drywall has been shown for the wall material in specific examples. Similarly, various material variations have been shown for the door. It should be understood, that the choice of material is simply as an aid in understanding the broad scope for which the disclosed door catch can be utilized. In each example, any of the other disclosed materials as well as any standard material for commercial or residential door and wall construction can be used to mount the door catch.
[0089] It is possible to implement certain features described in separate embodiments in combination within a single embodiment. Similarly, it is possible to implement certain features described in single embodiments either separately or in combination in multiple embodiments. It is the intent of the inventor that these variations fall within the scope of the claimed invention. While the examples, exemplary embodiments, and variations are helpful to those skilled in the art in understanding the claimed invention, it should be understood that, the scope of the claimed invention is defined solely by the following claims and their equivalents.
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Disclosed is a door catch that can help to prevent door sag, especially for heavy or tall residential or commercial doors, and provides for post-installation catch tension adjustment without removal or adjustment of mounting members. In one aspect, the door catch can include a ball catch base, a threaded ball plunger assembly, a catch bumper, and a bumper base. In another aspect, the catch bumper and the bumper base can optionally be combined into a single catch bar bracket. The ball plunger assembly is adjustably mounted within a threaded aperture of ball catch base. A ball captive in one end of the ball plunger assembly engages a detent in the catch bumper, or catch bar bracket, providing friction to hold the door open. The position of the ball plunger assembly can be adjusted vertically to increase or decrease the tension between the detent and the ball plunger assembly.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent application Ser. No. 12/401,381, filed Mar. 10, 2009, which claims the benefit of Provisional Application Ser. No. 61/035,227, filed on Mar. 10, 2008, the entire contents of which are hereby incorporated by reference.
GOVERNMENT SUPPORT
[0002] This invention was supported in part with funding provided by NIH Grant No. K08HL74512 and HL090991awarded by the National Institutes of Health. The government has certain rights to this invention.
FIELD OF THE INVENTION
[0003] The field of the present invention is identification of genetic markers for assessing therapeutic responses in diseases associated with pulmonary inflammation.
BACKGROUND
[0004] Cystic fibrosis (CF) is the most common lethal inherited disease in the western world. While life expectancies have increased to nearly 40 years, respiratory failure still accounts for >80% of deaths from the disease, usually in young adults in the third or fourth decade of life. The triad of airway obstruction with mucus, chronic endobronchial infection with pathogens such as Pseudomonas aeruginosa, and severe airway inflammation, are the major pathogenic factors in CF lung disease (Konstan, 1998, Clin Chest Med 19(3):505-13, vi). Given the shortage of solid organs for transplantation in end stage lung disease, there is a critical need for effective anti-microbial and anti-inflammatory therapies to mitigate progression of disease in this young population.
[0005] However, the rendering of rapid and efficient clinical trials in CF and other diseases associated with airway inflammation, is hampered, in part, by the lack of sensitive measures of treatment response. Currently, spirometry is the most common pulmonary function test for measuring lung function. Specifically, Forced Expiratory Volume in 1 second or FEV 1 is the established standard for assessing pulmonary treatment response. When FEV 1 measurements are decreased, treatment is initiated. Following two to three weeks of IV antibiotic therapy, FEV 1 measurements are typically repeated as a quantitative measure of clinical response. Similarly, FEV 1 measurements are utilized as the gold standard measurement for treatment response in clinical trials.
[0006] Airway remodeling, driven by inflammatory cells, most directly impacts progressive decline in lung function, and ultimately survival in CF. While novel anti-inflammatory therapies seek to target this decline, fibrosis and remodeling occur slowly and progressively, and may not be detected in a typical month-long Phase 2 trial. Thus, a beneficial effect of an anti-inflammatory treatment, which slows decline in lung function via reduced fibrosis and remodeling, could be missed with monitoring of lung function by FEV1 alone.
[0007] At present, there are no known reliable and sensitive molecular markers which can be used to quantify pulmonary inflammation and assess therapeutic responses against diseases associated with such inflammation. Thus, there exists a need for development of reliable and sensitive markers of airway or pulmonary inflammation that would allow testing of therapeutics against such diseases.
SUMMARY OF THE INVENTION
[0008] In one embodiment, the present invention comprises a method for assessing response to a treatment of a disease that is associated with pulmonary inflammation in a subject, comprising the steps of detecting the expression of one or more genes selected from the group consisting of CD64, ADAM9, CD36, IL32, HPSE, PLXND1, HCA112, CSPG2, TLR2, and CD163 in a sample taken from the subject before administering the treatment; detecting the expression of one or more genes selected from the group consisting of CD64, ADAM9, CD36, IL32, HPSE, PLXND1, HCA112, CSPG2, TLR2, and CD163 in a sample taken from the subject after administering the treatment; and comparing the level of the expression of the genes from step (a) in the sample taken from the subject before administering the treatment to the level of the expression of the genes from step (b) in the sample taken from the subject after administering the treatment. In preferred embodiments, the present invention comprises detecting the expression of one or more genes from the group consisting of CD64, ADAM9, CD36 and TLR2.
[0009] In some embodiments, the present invention further comprises the step of measuring FEV 1 in the subject before and after administering the treatment.
[0010] In some embodiments, the sample taken from the subject is blood, sputum, bronchoalveolar lavage or urine. In some embodiments, the sample comprises cells selected from the group consisting of: leukocytes, lymphocytes, monocytes, basophils, and eosinophils.
[0011] In some embodiments, the disease associated with the pulmonary inflammation is selected from the group consisting of cystic fibrosis, asthma, chronic obstructive pulmonary disease, emphysema, interstitial lung disease, bronchitis, acute respiratory distress syndrome, and pneumonia. In a preferred embodiment, the disease is cystic fibrosis lung disease.
[0012] In some embodiments, detecting the expression of genes comprises detection of RNA transcripts of the gene. In some embodiments, detecting the expression of genes comprises detection of the protein encoded by the gene.
[0013] In another embodiment, the present invention comprises a method to identify agents that inhibit the progression of a disease that is associated with pulmonary inflammation, comprising identifying agents that alter the expression or activity of one or more genes selected from the group consisting of CD64, ADAM9, CD36, IL32, HPSE, PLXND1, HCA112, CSPG2, TLR2, and CD163. In some embodiments, the disease associated with the pulmonary inflammation is selected from the group consisting of cystic fibrosis, asthma, chronic obstructive pulmonary disease, emphysema, interstitial lung disease, bronchitis, acute respiratory distress syndrome, and pneumonia. In a preferred embodiment, the disease is cystic fibrosis lung disease.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 shows a schematic diagram of the design and execution of the study.
[0015] FIGS. 2A and 2B shows the comparison of median expression values of the CF gene signature in pre-antibiotic (Pre-Rx) and post-antibiotic (Post-Rx) PBMC samples versus age-and gender-matched normal controls and stable CF controls. Whiskers on boxplots represent range of expression values between patient samples for each individual gene. Median is represented within each box whose boundaries represent 25 th -75 th quartiles. Differences in transcript abundance between pre-versus post-therapy CF patients were significant (p<0.05) for all genes, except for HCA112.
[0016] FIG. 3 shows the clinical outcomes as represented by changes in FEV 1 % predicted and CRP pre-and post-antibiotic therapy in the development cohort. FEV 1 figure represents changes in FEV 1 % predicted at initiation (Pre-Rx) and termination (Post-Rx) of antibiotics. Boxplot boundaries represent 25 th -75 th quartiles of values, with median line within box, and whiskers representing FEV 1 % predicted ranges. CRP values in mg/dL are also depicted in pre and post therapy groups, with normal standard range. P=0.02 for differences between FEV 1 % predicted pre and post therapy, by paired t-test. P=0.09 for differences in pre and post therapy CRP values, by paired t-test.
[0017] FIGS. 4A and 4B show the Receiver-operating-characteristic (“ROC”) curves of gene combinations and FEV 1 . ROC curves depict the fraction of true positive (Sensitivity) and false positive (1 minus specificity) values plotted for RNA transcripts and FEV 1 % predicted. A perfect test is indicated by AUC=1. A test with no discriminatory value has an AUC=0.50. FIG. 4A shows the ROC curves for the development cohort depicting discriminatory capacity of FEV 1 % predicted alone versus FEV 1 with CD64 and ADAM9 transcripts (C statistic=0.88). FIG. 4B shows the ROC curves for validation group comparing FEV 1 % predicted alone to FEV 1 plus CD64 and CD36 transcripts (C statistic=0.80).
DETAILED DESCRIPTION
[0018] The present invention relates to novel methods for assessing therapeutic responses in the treatment of a disease that is associated with pulmonary inflammation. These methods are based on the discovery of gene biomarkers whose expression patterns correlate with resolution of pulmonary infection and inflammation. The markers of the present invention represent a novel noninvasive tool to quantify therapeutic responses and to predict resolution of pulmonary exacerbations. The methods of the present invention provide greater sensitivity, specificity and discriminatory capacity than the existing methods that are based on measurements of FEV 1 alone and when used in conjunction with measurements of FEV 1 enhance the predictive power of FEV 1 .
[0019] This is believed to be the first report to utilize gene expression patterns to assess response to therapy in a disease involving pulmonary inflammation. The terms pulmonary inflammation and airway inflammation are synonymous and are used interchangeably in this application. As described herein, the gene expression changes demonstrated reproducibility across two patient groups and discriminatory capacity to differentiate between acutely ill and subsequently treated patients.
[0020] Furthermore, the regression model described herein demonstrated that the information related to changes in gene expression add meaningful diagnostic information to FEV 1 in assessing treatment response in acute pulmonary exacerbations. The independent, significant explanatory power contributed by these genes demonstrates that gene expression values from the CF therapeutic signature enhance the predictive discriminating value of FEV 1 alone.
[0021] More specifically, as described herein, the present invention comprises a group of ten genes (CD64, ADAM9, CD36, IL32, HPSE, PLXND1, HCA112, CSPG2, TLR2, and CD163) whose expression patterns were found to correlate with resolution of pulmonary infection and inflammation in cystic fibrosis (CF) lung disease. The list of these genes is shown in Table 3b. Seven of the 10 genes and the proteins they encode (IL32, HPSE, ADAM9, PLXND1, HCA112, CSPG2, and CD163) have not previously been linked to CF lung disease. It is noted that these genes are not specific to CF and have varying roles in other conditions characterized by pathologic pulmonary inflammation, including without limitation, cystic fibrosis, asthma, chronic obstructive pulmonary disease, emphysema, interstitial lung disease, bronchitis, acute respiratory distress syndrome and pneumonia (Wu et al., 2008, Am J Respir Crit Care Med 177(7):720-9; Moller et al., 2006, Crit Care Med 34(10):2561-6). The fact that these genes encode for proteins implicated in inflammatory processes, lends biologic plausibility to naming them as potential markers of resolution of CF airway infection and inflammation, as well as other diseases associated with airway infection and inflammation.
[0022] As a group, these genes represent functions of immune recognition and response, phagocytosis, and matrix degradation. TLR2 represents a central pattern recognition receptor for the innate response against bacterial infection. IL-32 is a newly described TNF-inducible intracellular cytokine (Kim et al., 2005, Immunity 22(1):131-42). An inducer of proinflammatory cytokines, IL-32 induces blood monocyte differentiation to macrophages, with subsequent phagocytic activity for live bacteria (Netea et al., 2008, Proc Natl Acad Sci USA 105(9):3515-20). Expression of IL-32 by inflamed luminal epithelia, may facilitate differentiation of blood monocytes infiltrating infected lung (Kim et al., 2005, Immunity 22(1):131-42). Three surface receptor genes participate in phagocytosis. CD64, or FcγRIA, mediates receptor mediated endocytosis of IgG-antigen complexes in macrophages (Rodrigo et al., 2006, J Virol 80(20):10128-3). CD36, a scavenger receptor, mediates macrophage uptake of oxidized LDL, as well as serving as a surface receptor for thrombospondin-1 (Kwok et al., 2006, Am J Physiol Endocrinol Metab.; Ferreira et al., 2006, Atherosclerosis; Doyen et al., 2003, J Exp Med 198(8):1277-83). CD163 serves as a macrophage cell surface hemoglobin scavenger receptor, and was recently shown to be highly predictive of mortality in pneumococcal bacteremia (Moller et al., 2006, Crit Care Med 34(10):2561-6; Weiss and Schneider, 2006, Crit Care Med 34(10):2682-3). Degradative enzymes, including heparanase, ADAM9 and versican, facilitate extravasation of leukocytes to inflamed tissues. In persistent airway inflammation, this process may culminate in marked and irreversible structural injury to lung parenchyma, by modification of extracellular matrix architecture (Vaday and Lider, 2000, J Leukoc Biol 67(2):149-59).
[0023] The study described herein was designed to measure markers that change with aggressive treatment of a pulmonary exacerbation, the current best therapy for reduction of acute increases in airway infection and inflammation in lung diseases. This design had several advantages. First, the design closely paralleled a clinical trial sequence, in which a treatment would be tested for its effect on decreasing inflammation. Second, the gene signature was not pathogen limited. The patient populations used in this study suffered from infection with a representative variety of bacterial pathogens. When patients were treated for pulmonary exacerbations, expression of most of the candidate genes more closely resembled the normal controls ( FIGS. 2A and B), supporting biological roles of these genes as markers of decreased infection and inflammation. Furthermore, half the genes were specific for exacerbation amongst CF patients, meaning values differed significantly prior to treatment versus stable CF patients, but not following treatment compared to stable CF patients. This included the three genes (CD64, ADAM9, and CD36) which were most highly diagnostic of therapeutic response. One of the genes which added significant explanatory power to the regression model in both patient groups, ADAM9, was highly representative of immediate post-exacerbation transcriptional changes, since its post-exacerbation expression remained significantly different from both normal and stable CF controls.
[0024] Simultaneous measurements of respiratory physiology and plasma markers allowed for statistical comparisons of multiple outcomes measures. The significant correlation of over half of the genes in the CF therapeutic signature with changes in CRP, a well characterized serum marker of inflammation, in addition to correlations to neutrophil counts, further strengthened the association of these genes with inflammatory processes.
[0025] The identification of biomarkers has more immediate clinical implications for several large sub-populations of CF patients. In children, airway infection and inflammation can occur as early as four weeks of age (Khan et al., 1995, Am J Respir Crit Care Med 151(4):1075-82). CT radiographic studies have demonstrated considerable bronchiectasis and parenchymal abnormalities in children with normal lung function (de Jong et al., Eur Respir J 23(1):93-7). Sensitive markers allow for a personalized strategy of anti-infectious and anti-inflammatory treatment in young children, with the ability to rapidly monitor outcomes from these interventions. Conversely, in patients with severe lung destruction and multiple antibiotic drug resistant organisms, assessment of response to a particular treatment is often difficult, given day-to-day variability in disease and the degree of irreversibility in airway damage. A sensitive measure of leukocyte activities can be used to gauge response to therapeutics when clinical response lags far behind.
[0026] In one embodiment, the present invention comprises a method to assess response to a treatment of a disease that is associated with pulmonary inflammation in a subject. The method includes detecting the expression of one or more genes selected from the group consisting of CD64, ADAM9, CD36, IL32, HPSE, PLXND1, HCA112, CSPG2, TLR2, and CD163 in a sample taken from the subject before administering the treatment. The method also includes the step of detecting the expression of the selected genes in the sample taken from the subject after administering the treatment. The method also includes comparing the expression levels of the genes before administering the treatment to the expression levels after administering the treatment. In preferred embodiments, the method includes detecting the expression of one or more genes selected from CD64, ADAMS, CD36 and TLR2.
[0027] In some embodiments, the method of the present invention further comprises measuring FEV 1 in the subject.
[0028] The methods of the present invention can be used to assess therapeutic responses in the treatment of any disease that is associated with pulmonary inflammation. The diseases contemplated herein include, without limitation, cystic fibrosis, asthma, chronic obstructive pulmonary disease, emphysema, interstitial lung disease, bronchitis, acute respiratory distress syndrome and pneumonia. In a preferred embodiment, the disease is cystic fibrosis.
[0029] A patient sample can include any bodily fluid or tissue from a patient that may contain the RNA or protein encoded by the genes contemplated here. The term “sample” or “patient sample” can be used generally to refer to a sample of any type which contains products that are to be evaluated by the present method, including but not limited to, a sample of isolated cells, a tissue sample and/or a bodily fluid sample. According to the present invention, a sample of isolated cells is a specimen of cells, typically in suspension or separated from connective tissue which may have connected the cells within a tissue in vivo, which have been collected from an organ, tissue or fluid by any suitable method which results in the collection of a suitable number of cells for evaluation by the method of the present invention. The cells in the cell sample are not necessarily of the same type, although purification methods can be used to enrich for the type of cells that are preferably evaluated. Cells can be obtained, for example, by scraping of a tissue, processing of a tissue sample to release individual cells, or isolation from a bodily fluid.
[0030] In some embodiments, the sample may comprise blood, sputum, bronchoalveolar lavage or urine. In a preferred embodiment, the patient sample comprises blood.
[0031] In some embodiments the sample may comprise Peripheral Blood Mononuclear Cells (PBMCs), leuokocytes, monocytes, lymphocytes, basophils, or eosinophils.
[0032] A systemic marker of lung inflammation has many advantages, as blood can be obtained from subjects of any age and disease severity, and may reflect the status of inflammation throughout the lung, rather than one segment. This analysis is sensitive, inexpensive, and obtained from tissue that is easily accessible in pediatric and adult populations, and has the potential to be performed in a clinical laboratory.
[0033] As used herein, the term “expression”, when used in connection with detecting the expression of a gene, can refer to detecting transcription of the gene (i.e., detecting mRNA levels) and/or to detecting translation of the gene (detecting the protein produced). To detect expression of a gene refers to the act of actively determining whether a gene is expressed or not. This can include determining whether the gene expression is upregulated as compared to a control, downregulated as compared to a control, or unchanged as compared to a control. Therefore, the step of detecting expression does not require that expression of the gene actually is upregulated or downregulated, but rather, can also include detecting that the expression of the gene has not changed (i.e., detecting no expression of the gene or no change in expression of the gene).
[0034] Expression of transcripts and/or proteins is measured by any of a variety of known methods in the art. For RNA expression, methods include but are not limited to: extraction of cellular mRNA and Northern blotting using labeled probes that hybridize to transcripts encoding all or part of the gene; amplification of mRNA using gene-specific primers, polymerase chain reaction (PCR), and reverse transcriptase-polymerase chain reaction (RT-PCR), followed by quantitative detection of the product by any of a variety of means; extraction of total RNA from the cells, which is then labeled and used to probe cDNAs or oligonucleotides encoding the gene on any of a variety of surfaces; in situ hybridization; and detection of a reporter gene.
[0035] Methods to measure protein expression levels generally include, but are not limited to: Western blot, immunoblot, enzyme-linked immunosorbant assay (ELISA), radioimmunoassay (RIA), immunoprecipitation, surface plasmon resonance, chemiluminescence, fluorescent polarization, phosphorescence, immunohistochemical analysis, matrix-assisted laser desorption/ionization time-of-flight (MALDI-TOF) mass spectrometry, microcytometry, microarray, microscopy, fluorescence activated cell sorting (FACS), and flow cytometry, as well as assays based on a property of the protein including but not limited to enzymatic activity or interaction with other protein partners. Binding assays are also well known in the art. For example, a BIAcore machine can be used to determine the binding constant of a complex between two proteins. The dissociation constant for the complex can be determined by monitoring changes in the refractive index with respect to time as buffer is passed over the chip (O'Shannessy et al., 1993, Anal. Biochem. 212:457; Schuster et al., 1993, Nature 365:343). Other suitable assays for measuring the binding of one protein to another include, for example, immunoassays such as enzyme linked immunoabsorbent assays (ELISA) and radioimmunoassays (RIA); or determination of binding by monitoring the change in the spectroscopic or optical properties of the proteins through fluorescence, UV absorption, circular dichroism, or nuclear magnetic resonance (NMR). A preferred method is an immunoassay, wherein an A 2Λ -specific antibody (an antibody that selectively binds to A 2Λ ) is used to detect the expression on tumor cells.
[0036] A patient sample can include any bodily fluid or tissue from a patient that may contain tumor cells or proteins of tumor cells. More specifically, according to the present invention, the term “test sample” or “patient sample” can be used generally to refer to a sample of any type which contains cells or products that have been secreted from cells to be evaluated by the present method, including but not limited to, a sample of isolated cells, a tissue sample and/or a bodily fluid sample. According to the present invention, a sample of isolated cells is a specimen of cells, typically in suspension or separated from connective tissue which may have connected the cells within a tissue in vivo, which have been collected from an organ, tissue or fluid by any suitable method which results in the collection of a suitable number of cells for evaluation by the method of the present invention. The cells in the cell sample are not necessarily of the same type, although purification methods can be used to enrich for the type of cells that are preferably evaluated. Cells can be obtained, for example, by scraping of a tissue, processing of a tissue sample to release individual cells, or isolation from a bodily fluid.
[0037] In another embodiment, the present invention includes a method to identify agents that inhibit the progression of a disease that is associated with pulmonary inflammation, comprising identifying agents that alter the expression or activity of one or more genes selected from the group consisting of CD64, ADAM9, CD36, IL32, HPSE, PLXND1, HCA112, CSPG2, TLR2, and CD163. The diseases contemplated herein include, without limitation, cystic fibrosis, asthma, chronic obstructive pulmonary disease, emphysema, interstitial lung disease, bronchitis, acute respiratory distress syndrome and pneumonia. In a preferred embodiment, the disease is cystic fibrosis.
[0038] The following examples are provided for illustrative purposes, and are not intended to limit the scope of the invention as claimed herein. Any variations which occur to the skilled artisan are intended to fall within the scope of the present invention. All references cited in the present application are incorporated by reference herein to the extent that there is no inconsistency with the present disclosure.
EXAMPLES
Example 1
[0039] This example illustrates the overall design and step-wise execution of the study described herein.
[0040] The design of the study is shown in FIG. 1 . Peripheral blood mononuclear cells (PBMCs) were isolated from 10 CF patients in the Development Cohort with acute pulmonary exacerbations before and after therapy, as well as healthy non-CF control subjects and stable CF patients matched in age and sex to the patients of Development Cohort. Gene expression profiling was performed by utilizing gene microarray technique to identify genes whose expression significantly changed with treatment. Thus, candidate gene markers, differentially regulated before and after antibiotic therapy were identified. These genes were independently confirmed in the same set of samples, utilizing quantitative RT-PCR.
[0041] Further, these markers were tested for their ability to classify therapeutic response in an independent Validation Cohort of 14 acutely ill CF patients, utilizing reverse transcription-PCR amplification technique. The gene expression data from patients who responded to therapy from development and validation cohorts were subjected to statistically analyzed using methods of multiple logistic regression/receiver operating characteristic (ROC) analysis.
[0042] Table 1 summarizes measurement distributions performed for all 24 CF patient samples, including 10 from the Development Cohort and 14 from the Validation Cohort.
[0000]
TABLE 1
Analysis performed on CF patient samples in
development and validation cohorts
Plasma
PBMC
cytokine
Logistic
gene
Quantitative
measure-
regression
Patient
microarray
RT-PCR
ments
FEV1
CRP
model
1
x
x
x
x
x
2
x
x
x
x
x
3
x
x
x
x
x
x
4
x
x
x
x
x
x
5
x
x
x
x
x
x
6
x
x
x
x
x
x
7
x
x
x
x
x
x
8
x
x
x
x
x
x
9
x
x
x
x
non-
responder
10
x
x
x
x
x
V11
x
x
non-
responder
V12
x
x
x
V13
x
x
x
V14
x
x
x
V15
x
x
x
V16
x
x
x
V17
x
x
x
V18
x
x
non-
responder
V19
x
x
x
V20
x
x
x
V21
x
x
x
V22
x
x
x
V23
x
x
x
V24
x
x
x
*V indicates validation cohort population
Nonresponders were not included in logistic regression model
Example 2
[0043] This example describes the initial study performed with patients in the development cohort for identification of the genetic markers.
[0044] Patient recruitment was done as follows. Subjects >18 years of age with CF (based on sweat chloride testing and genotype) were enrolled at the time of admission or home IV antibiotic initiation for a clinically diagnosed pulmonary exacerbation at a large Cystic Fibrosis Foundation accredited adult CF clinic, following obtainment of informed consent from the study subject. All study participants were monitored by the National Jewish Health and University of Colorado Institutional Review Boards. Patients identified for enrollment met CF Foundation Clinical Practice Guidelines of at least 3 of 11 criteria for an acute pulmonary exacerbation (Foundation, C. F. Clinical Practice Guidelines for Cystic Fibrosis).
[0045] All patients were treated with at least 2 antibiotics targeting their specific bacterial pathogens for a minimum of 2 weeks and a maximum of three weeks. The study design utilized within subject comparisons, such that each study subject served as their own control, following treatment with antibiotics. Blood was drawn at the initiation (±2 days) and the completion (±1 week) of intravenous antibiotic therapy. At each timepoint, the following were collected or measured: 1) blood for PBMC isolation 2) sputum for microbiologic analysis 3) simple spirometry for FEV 1 determination according to American Thoracic Society guidelines and 4) plasma isolation from the blood preparation for cytokine measurements.
[0046] The baseline demographics, severity of airflow limitation, genotype, and sputum microbiology for the development and validation cohorts are shown in Table 2. As shown in table 2, both groups had moderate to severe airways disease by ATS criteria, based on FEV 1 % predicted measured at the completion of IV antibiotic therapy (Pellegrino et al., 2005, Eur Respir J 26(5):948-68). Ninety percent of patients in both groups grew Pseudomonas aeruginosa on sputum culture at the time of therapy. Staphylococcus aureus was commonly isolated in both groups, though only 1 strain was methicillin resistant. While no patients were treated with steroids in the development cohort, over half of the validation cohort received steroids (p=0.002). The median pre-treatment FEV 1 % was lower in the validation group (p=0.04); however, post-treatment FEV 1 % predicted did not significantly differ between groups. All patients exhibited FEV 1 increases at the conclusion of therapy except for one single patient in the development cohort, whose FEV 1 % predicted declined by 26% after therapy. This patient concomitantly suffered a severe flare of CF-related arthritis at the end of her antibiotic therapy. Given the drop in FEV 1 , this patient was considered a non-responder, and her gene copy changes were not utilized in the regression analyses for genes with FEV 1 .
[0000]
TABLE 2
Base-line characteristics of study population.
Development
Validation
group
group
Characteristic
(n = 10)
(n = 14)
Age* (mean) - yr
26 ± 5.7
27 ± 3
Gender - no. (%)
Male
3 (30)
9 (64)
Female
7 (70)
5 (42)
Genotype - no. (%)
DF508/DF508
8 (80)
9 (64)
Other
2 (20)
5 (36)
FEV1* (median % predicted)
Pre
44 ± 19
31.5 ± 18‡
Post
51 ± 18
44 ± 20
Sputum culture - no. (%)
Pseudomonas aeruginosa
9 (90)
13 (93)
Staphylococcus aureus (methicillin
7 (70)
8 (57)
sensitive)
Staphylococcus aureus (methicillin
1 (10)
0
resistant)
Other ( B. cepacia , A. xylosoxidans ,
1 (10)
4 (29)
A. fumigatus )
Systemic antibiotic therapy- no. (%)
APAG + 4th gen Ceph or Carbapenem
7 (70)
10 (71)
or Monobactam**
Other combination{circumflex over ( )}
3 (30)
4 (29)
Systemic steroid use - no (%)
0
8 (57)‡
CFRD - no. (%)
4 (40)
5 (36)
*Plus-minus values indicate ± SD.
**APAG represents anti-pseudomonal aminoglycoside, and 4th gen Ceph represents fourth generation cephalosporin
{circumflex over ( )}Other therapy includes vancomycin, nafcillin, cefazolin, levofloxacin and carbapenem/monobactam combinations
‡p < 0.05
B. cepacia indicates Burkholderia cepacia
A. xylosoxidans indicates Alcaligenes xylosoxidans
A. fumigatus indicates Aspergillus fumigatus
CFRD represents CF- related diabetes mellitus as diagnosed by CF Foundation guidelines
[0047] PBMC isolation was performed as follows. Four ml of peripheral blood was collected into sodium citrate tubes (BD Vacutainer® CPT™, BD Biosciences, Franklin Lakes, N.J.) utilizing a Ficoll Hypaque density gradient. PBMC's were isolated via density gradient centrifugation (1650 RCF, 30 minutes, 18° C.). Furthermore, cytospins with H&E staining verified that all cells from which RNA was extracted were mononuclear and fewer than 1% neutrophils were identified from the interphase.
[0048] The RNA was isolated by Trizol method, and purified using the Rneasy Mini Kit (Qiagen) according to manufacturer's protocol. cDNA was reverse transcribed from total RNA using the Superscript II Reverse Transcriptase™ Kit (Invitrogen, Carlsbad, Calif.). Complete blood counts were done to quantify cell numbers. Additionally, cell counts were done after each isolation in order to insure that differences in transcript abundance were not due to differences in cell counts, PBMC's were counted at the time of each isolation, and absolute numbers between timepoints evaluated by paired t tests.
[0049] Microarray hybridization and data analysis was performed as follows. PBMC RNA isolated from the development cohort, containing 10 patients representing 10 pulmonary exacerbations, was utilized for microarray analysis, in order to identify PBMC transcriptional changes before and after antibiotic therapy. All raw microarray data is available on the NCBI Gene Expression Omnibus Database. Prior to microarray, all RNA was evaluated with an Agilent 2100 Bioanalyzer to confirm high grade RNA quality. PBMC gene expression analysis was performed with Hu133 Plus 2.0 gene chips. Samples were prepared for Affymetrix arrays using 2.5 μg of total RNA. First and second strand complimentary DNA was synthesized using standard techniques. Biotin-labeled antisense complimentary RNA was produced by an in vitro transcription reaction. Target hybridization, washing, staining, and scanning probe arrays were done following manufacturer's protocol as described in the Affymetrix GeneChip Expression Analysis Manual. Affymetrix CEL files were loaded into dChip 2005 array analysis software (Li C, Wong W H 2001), normalized to median brightness, and expression modeled using the perfect match/mismatch (PM/MM) algorithm.
[0050] Beginning with microarrays containing over 35,000 sequences from 10 patients before and after antibiotic treatment, sequences assigned to known genes with a minimum expression threshold (Affymetrix “present call”) were focused upon. The study design utilized “within subject comparisons”, such that each study subject served as their own control. From these genes, differentially expressed genes were identified in pairwise comparisons between pre-and post-treatment groups, using a non-parametric Wilcoxon signed rank test, with a minimum of 1.4-fold change. Analysis of microarray data using the dChip analysis program yielded 32 candidate genes with both significant expression and significant change (p<0.05) between pre-and post-treatment. These genes are listed below in Table 3a.
[0000]
TABLE 3a
Transcripts changed in PBMC's pre- and post- antibiotic therapy.
fold
p
Gene name
probe set
change
value
ADAM metallopeptidase domain 9 (meltrin gamma)
202381_at
−2.5
0.004
Fc fragment of IgG, high affinity Ia, receptor (CD64)
214511_x_at
−2.4
0.004
Kruppel-like factor 9
203542_s_at
−2.4
0.001
Charcot-Leyden crystal protein
206207_at
−2.3
0.018
histocompatibility (minor) 13
232209_x_at
−2.1
0.014
chondroitin sulfate proteoglycan 2 (versican)
204619_s_at
−1.9
0.001
tweety homolog 3 ( Drosophila )
224674_at
−1.8
0.019
hepatocellular carcinoma-associated antigen 112
218345_at
−1.8
0.004
Potassium inwardly-rectifying channel, subfamily J, member 2
231513_at
−1.8
0.014
alanyl (membrane) aminopeptidase (CD13, p150)
202888_s_at
−1.7
0.009
CD36 antigen (thrombospondin receptor)
228766_at
−1.7
0.001
osteoclast-associated receptor
1554503_a_at
−1.7
0.007
C-type lectin domain family 4, member D
1552772_at
−1.7
0.006
plexin D1
212235_at
−1.7
0.005
Trypsin domain containing 1
231422_x_at
−1.7
0.003
CD163 antigen
203645_s_at
−1.6
0.003
ADP-ribosylation factor-like 11
1552691_at
−1.6
0.006
toll-like receptor 2
204924_at
−1.6
0.003
ST8 alpha-N-acetyl-neuraminide alpha-2,8-sialyltransferase 4
230836_at
−1.5
0.003
Regulatory factor X-associated ankyrin-containing protein
1560034_a_at
−1.5
0.001
glucosidase, alpha; acid
202812_at
−1.5
0.011
J-type co-chaperone HSC20
223647_x_at
−1.5
0.026
Dmx-like 2
212820_at
−1.5
0.010
CCAAT/enhancer binding protein (C/EBP), alpha
204039_at
−1.4
0.002
BRI3 binding protein
225716_at
−1.4
0.002
heparanase
219403_s_at
−1.4
0.017
Splicing factor, arginine/serine-rich 3
232392_at
1.4
0.057
interleukin 32
203828_s_at
1.4
0.033
Formin binding protein 4
239469_at
1.5
0.000
villin 2 (ezrin)
208621_s_at
1.6
0.005
dehydrogenase/reductase (SDR family) member 3
202481_at
1.9
0.011
chemokine (C-C motif) receptor 5
206991_s_at
2.4
0.007
Genes listed in this table meet criteria for differential expression in a paired t-test between log transformed values of pre- and post- antibiotic circulating samples (n = 10) (p < 0.05).
[0051] Gene ontology analysis was utilized to determine biologic plausibility and the gene list was narrowed to 19 genes. The false discovery rate was computed from the gene-wise p values according to Benjamini-Hochberg.
[0052] Further, high quality PBMC microarray data from 8 normal and 6 stable CF matched controls was utilized to assess baseline transcripts of the gene signature. Relationships between CF pre-and post-antibiotic genes, normal and stable CF PBMC controls were evaluated with ANOVA, with post-hoc testing determined by Fisher's PLSD (StatView, SAS Institute Inc., Cary, N.C.). Statistical significance was assigned for p-values<0.05.
[0053] Microarray expression data from 19 genes in the development cohort were secondarily confirmed by real-time polymerase chain reaction (RT-PCR), utilizing all sufficient remaining RNA for analysis (6 of 10 total patients had sufficient RNA from both pre-and post-therapy PBMC RNA samples). First strand cDNA was made from 1 μg total RNA using a QuantiTect Reverse Transcription Kit (Qiagen, Valencia, Calif.). Quantitative real-time PCR was performed using a total reaction volume of 25 μl, containing 5 μl of diluted cDNA, 10 μl H20, 9.94 μl of the fluorescent indicator Sybrgreen® and 0.03 μl of each nucleotide primer (250 μM) PCR was carried out in a 7300 Real Time PCR System (Applied Biosystems, Foster City, Calif.), using 40 cycles of 95° C. for 15 seconds, followed by 60° C. for 1 minute, with a 10 minute 95° C. initial soak. Each measurement was made in triplicate and expressed relative to the detection of the housekeeping gene, hypoxanthine guanine phosphoribosyl transferase (HPRT). For quantitative RT-PCR, statistics were performed in StatView (SAS, Cary, N.C.), utilizing paired t-tests, and significance at P<0.05.
[0054] Of 19 genes, 10 genes were significantly changed when measured by both methods. Table 3b lists ten genes significantly changed (p<0.05) by both microarray and quantitative RT-PCR analysis in the development cohort of CF patients. Of note, the RT-PCR validation occurred in 6 pairs of RNA samples, since the other samples did not have sufficient remaining RNA after microarray to evaluate by PCR. We designated these 10 PBMC genes, reflecting treatment of CF pulmonary exacerbations, the “CF Therapeutic signature.” The vast majority of genes (nine of ten) were downregulated after resolution of the acute pulmonary exacerbation. Only IL-32 increased transcription after treatment, suggesting suppression during the acute exacerbation, with a return to normal baseline after treatment, as indicated by transcripts in normal controls.
[0000]
TABLE 3b
Classification of 10 genes in the CF therapeutic gene signature
Fold
p
Fold
p
change
values
change
values
Gene
Description
array a
array
PCR b
PCR
Cell membrane molecules and receptors
CD64
Fcg Receptor IA
−2.4
0.004
−2.1
0.007
CD36
collagen type 1 receptor/thrombospondin receptor
−1.7
<0.001
−1.6
<0.001
CD163
hemoglobin scavenger receptor
−1.6
0.003
−1.7
0.024
TLR2
toll-like receptor 2
−1.6
0.003
−1.7
0.011
HCA112
hepatocellular carcinoma-associated antigen 112
−1.8
0.004
−1.6
0.012
PLXND1
plexin D1
−1.7
0.005
−1.3
0.083
Immune response
IL32
interleukin 32
1.4
0.033
1.4
0.001
Matrix degradation/Extravasation
HPSE
heparanase
−1.4
0.017
−1.6
0.004
ADAM9
a disintegrin & metalloproteinase, meltrin gamma
−2.5
0.004
−1.7
0.016
CSPG2
versican, chondroitin sulfate proteoglycan 2
−1.9
<0.001
−1.9
0.015
a Mean fold changes depicted compare pre and post antibiotic therapy expression values from oligonucleotide arrays
P values calculated by paired t-test following log transformation.
b Mean fold changes depicted compare pre and post antibiotic therapy real time PCR gene expression values as copies/1000 copies housekeeping gene, hypoxanthine-phosphoribosyl transferase (HPRT).
(n = 6 patients' pre and post samples from development cohort). P values calculated by paired t-test following log transformation.
[0055] FIGS. 2A and B shows the comparison between pre-and post-antibiotic therapy median values and distribution for CF genes in the development cohort, to array data from eight age- and gender-matched normal controls, as well as six stable CF controls. Before antibiotic therapy, expression of all genes, except for TLR2, significantly differed from expression in normals (ANOVA, p<0.05; pairwise comparison with Fisher's PLSD, p<0.05) and expression of 5 of 10 genes (PLXND1, ADAM9, CSPG2, CD64 and CD36) differed from stable CF (ANOVA, p<0.05; pairwise comparison with Fisher's PLSD, p<0.05). Following treatment of the acute pulmonary exacerbation, none of the 10 genes differed significantly between post-therapy patients and stable CF controls. The following genes were significantly different between pre-antibiotic CF and stable CF and unchanged between post-antibiotic CF and stable CF: PLXND1, ADAM9, CSPG2, CD64, and CD36 (by ANOVA and pairwise comparison with Fisher's PLSD). In post-therapy CF patients, expression of three genes, CD64, ADAM9 and PLXND1, remained significantly different in CF compared to normal controls (ANOVA, p<0.05; pairwise comparison with Fisher's PLSD, p<0.05).
[0056] Associations between the ten candidate genes and common clinical outcome measures were investigated. Measurements of C-reactive protein (CRP) and FEV1 were performed simultaneously with PBMC isolation in the development cohort. CRP assays were measured utilizing nephelometry of the Dade Behring BNII. Improvement in FEV1% predicted was statistically significant after treatment, (p=0.02 by paired t test, 95% confidence intervals −1.8 to −15.78). The change in plasma CRP levels between pairs did not reach statistical significance (p=0.09). These data are shown in FIG. 3 .
[0057] The correlations between gene expression values and both FEV1 and CRP levels were evaluated with Spearman's rank order correlation coefficient (rs) in Table 4 below. A significant correlation exists between the development cohort expression values and CRP values for seven of the ten genes: TLR2, CD64, CSPG2, HPSE, IL-32, CD163, and ADAM9. No correlation was noted between FEV1 change and the 10 gene CF signature.
[0000]
TABLE 4
Spearman's rank correlation coefficients (rs) for
genes, FEV1 and CRP pre- and post- antibiotic therapy
FEV1
CRP
Variable
rs
p value
rs
p value
FEV1
1.00
−0.45
0.05*
CRP
−0.44
0.05*
1.00
PLXND1
−0.38
0.10
0.42
0.07
HCA112
0.42
0.07
0.21
0.38
ADAM9
−0.35
0.13
0.57
0.01*
HPSE
0.08
0.72
0.54
0.01*
CSPG2
−0.31
0.18
0.45
0.05*
IL32
0.09
0.71
−0.47
0.04*
CD64
0.03
0.88
0.49
0.03*
CD36
−0.25
0.30
0.31
0.18
CD163
−0.42
0.06
0.48
0.03*
TLR2
−0.18
0.44
0.49
0.02*
[0058] Correlations were also conducted between the ten genes and circulating cellular markers of inflammation, namely neutrophil counts and total white blood cell counts. Results are shown in Table 5. Four genes were highly correlated (p<0.05) to circulating neutrophil counts before and after therapy: ADAM9, CSPG2, IL32, and CD163.
[0000]
TABLE 5
Spearman's rank correlation coefficients (rs) for
genes, PMNs and WBC pre- and post- antibiotic therapy
PMNS
WBC
Variable
rs
p value
rs
p value
PMNS
1.00
0.87
<0.01*
WBC
0.87
<0.01*
1.00
PLNX
0.42
0.07
0.39
0.09
HCA112
−0.04
0.89
−0.25
0.29
ADAM9
0.47
0.04*
0.28
0.23
HPSE
0.25
0.31
−0.02
0.93
CSPG2
0.54
0.02*
0.31
0.19
IL32
−0.60
<0.01*
−0.31
0.18
CD64
0.13
0.61
−0.08
0.75
CD36
0.42
0.07
0.21
0.37
CD163
0.50
0.03*
0.36
0.12
TLR2
0.24
0.32
0.21
0.37
[0059] Additionally, cytokines were measured in the aliquots of plasma taken from the same blood specimens from which PBMCs were isolated before and after antibiotic therapy. The cytokine measurements were performed as follows. Plasma collected at the time of PBMC isolation was processed at The Children's Hospital, University of Colorado GCRC Core laboratory. Multiple cytokine measurements were done using the Fluorokine® MAP Cytokine assay (R&D systems, Minneapolis, Minn.) on the Luminex 100 system (a dual laser, flow-based sorting and detection platform) to quantify the following cytokines at each blood draw: IL-1α, IL-1β, IL-1RA, IL-2, IL-4, IL-5, IL-6, IL-8, IL-10, IL-17, TNFα, IFNγ, G-CSF, GM-CSF, MIP-1β, MCP-1, VEGF, RANTES, and IL-13. All analyses were performed according to manufacturer's protocols. The mean minimal detectable doses for cytokines are as follows: IL-1α (0.39 pg/ml), IL-1β, (0.27 pg/ml), IL-1ra (2.06 pg/ml), IL-2 (0.89 pg/ml), IL-4, (1.75 pg/ml), IL-5 (0.33 pg/ml), IL-6 (0.36 pg/ml), IL-8 (0.39 pg/ml), IL-10 (0.13 pg/ml), IL-17 (0.39 pg/ml), TNFα (0.47 pg/ml), IFNγ (0.31 pg/ml ), G-CSF (0.57 pg/ml), GM-CSF (1.05 pg/m1), MIP-1β (2.12 pg/ml , MCP-1 (0.95 pg/ml), VEGF (0.81 pg/ml), RANTES (1.08 pg/ml), and IL-13 (6.0 pg/ml). Univariate analysis with paired t-tests was performed to compare pre-and post-antibiotic values. The concomitant evaluation of plasma cytokines in the development cohort did not demonstrate statistical significance. Post-treatment cytokine measurements were lower than pre-treatment measurements, however, specific cytokines reduced differed from patient to patient, making none of them broadly applicable as a marker for exacerbation resolution, in a cohort of this size. Table 6 depicts mean cytokine measurements at both timepoints and associated p values. After the Bonferroni's correction for multiple tests, the change in G-CSF failed to reach significance at the p<0.05 level.
[0000]
TABLE 6
CF plasma cytokine levels (mean ± SEM) pre
and post antibiotic therapy in development group
CYTOKINE
(pg/ml)
PRE-RX
POST-RX
P VALUE*
IL-1α
0.15 ± 0.15
<0.01
0.30
IL-1β
1.09 ± 0.41
0.88 ± 0.50
0.60
IL-1RA
2608 ± 1412
1637 ± 667
0.20
IL-2
0.95 ± 0.34
0.45 ± 0.29
0.30
IL-4
<0.01
0.78 ± 0.40
0.08
IL-5
0.93 ± 0.64
0.20 ± 0.11
0.08
IL-6
7.34 ± 3.39
3.57 ± 2.03
0.10
IL-8
5.37 ± 2.25
2.56 ± 1.31
0.10
IL-10
3.24 ± 2.74
1.50 ± 0.55
0.90
IL-13
1118 ± 388
1539 ± 495
0.30
IL-17
2.38 ± 1.36
0.15 ± 0.15
0.08
TNFα
2.99 ± 0.83
3.04 ± 0.68
0.80
IFNγ
0.04 ± 0.04
0.37 ± 0.20
0.80
G-CSF
29.50 ± 10.30
12.27 ± 4.96
0.02
GM-CSF
0.14 ± 0.08
0.45 ± 0.33
0.06
MIP-1β
39.10 ± 13.50
31.51 ± 8.83
0.20
VEGF
10.75 ± 2.82
10.57 ± 2.76
0.50
RANTES
3216 ± 433
4268 ± 776
0.30
*P values calculated by paired t-test on log transformed values
[0060] The primary endpoints of the study were lung function (FEV 1 ) and gene transcript abundance changes after treatment of an acute pulmonary exacerbation. All patients were evaluated with testing as described above as well as clinical evaluation at the onset and completion of therapy. Patients who responded to therapy by manifesting improvement in FEV 1 % predicted at the completion of antibiotic therapy and not requiring rehospitalization within 1 week with a diagnosis of pulmonary exacerbation were analyzed such that changes in FEV 1 % predicted were regressed with transcript changes. Pulmonary function testing was performed in compliance with American Thoracic Society standards [E4]. The statistical methods used in the study were as follows. Comparison of gene expression values pre-and post-antibiotic therapy were initially performed by paired univariate analyses: t test and the Wilcoxon signed rank test.
[0061] Validation Study
[0062] Following the initial study with the Development Cohort, a validation study was performed in an independent population of CF patients made up of 14 adult CF patients suffering from an acute pulmonary exacerbation using RT-PCR.
[0063] All procedures including patient recruitment, antibiotic treatment as well as blood, microbiology, and spirometry analysis were the same as described above for the Development Cohort. PBMC isolation and FEV1 measurements were performed on adult CF patients, at the initiation and at the termination of antibiotic therapy for acute pulmonary exacerbations, using identical methods to the development cohort. This validation group of patients was heterogeneous in terms of sputum microbiology, variable use of systemic steroids, and ultimately, more representative of a realistic clinical setting. (See Table 2.)
[0064] While many patients in the Validation Cohort were treated with steroids, as opposed to none in the initial study group, the presence of steroids did not significantly alter gene expression between steroid-treated and steroid-naive patients, for nine of the ten genes (by multi-way ANOVA). Only transcript changes in HPSE significantly differed between steroid-treated and steroid naive patients (p=0.03). FEV1 improved significantly between pre-and post-measurements in this cohort (p=0.003 by paired t test). All patients in the validation cohort had a higher FEV 1 % predicted at the second measurement. However, two patients in this cohort with severe airway limitation (FEV 1 <25% predicted at both measurements) manifested <100 ml improvement in FEV 1 % predicted and were considered non-responders based on clinical parameters. Both patients had poor outcomes: one was readmitted with recurrent pulmonary symptoms in 6 days and the second never was discharged due to persistently poor clinical response to antibiotics and underwent lung transplant 43 days later. These “non-responders” were not included in the logistic regression analysis of the validation cohort, since the model was predicated on identifying genes associated with therapeutic response.
[0065] In univariate analysis of individual gene changes within the validation cohort, five genes were significantly changed in responders after antibiotic therapy, based on log transformed gene expression values measured by RT-PCR: CD36 (p=0.002), CD64 (p=0.007), PLXND1 (p=0.01), CSPG2 (p=0.002), and TLR2 (p=0.05).
Example 3
[0066] This example illustrates the diagnostic value of the CF therapeutic signature in association with % change in FEV 1 and demonstrates that the gene expression values from the CF therapeutic signature enhance the predictive discriminating value of FEV 1 alone.
[0067] In a multivariate analysis, the combined explanatory power of FEV 1 in combination with gene expression values was evaluated. Utilizing Generalized Estimating Equations, multivariate logistic regression models were constructed predicting resolution of acute pulmonary exacerbations as a function of FEV 1 % predicted, and the discriminative value of combinations of genes identified by the development cohort (SAS, SAS Institute Inc., Cary, N.C.). An unstructured correlation structure between time points was utilized, and a stepwise selection procedure chose the most significant combination of FEV 1 improvement and transcript changes. FEV 1 % predicted was forced into modeling due to its known clinical reliability, as a standard assessment for response to therapy. To identify the most frugal combination of predictors to predict resolution of inflammation, a p value <0.05 was required for entry into the model, which also allowed for determination of the unique contribution of the genes over and above FEV 1 alone. Finally, receiver operating characteristic (ROC) analyses reflected the overall diagnostic value of the gene markers, in terms of enhanced sensitivity and specificity over FEV 1 alone.
[0068] The addition of two gene measurements to the regression substantially increased the explanatory power of the model. As shown in FIGS. 4A and 4B , the ROC curves demonstrated the sensitivity and specificity of gene expression values for assessing treatment response. Juxtaposition of ROC curves demonstrated the additional discriminatory capacity of gene measurements in comparison to FEV1 alone, to diagnose resolution of airway inflammation.
[0069] In the development cohort, 4 different pairs of genes combined with FEV1 (C-statistic=0.75, 0.85, and 0.88 respectively) to give an overall better diagnostic performance in comparison to FEV1 alone (C-statistic=0.58). In the validation cohort, four different pairs of genes in combination with FEV 1 (C-statistic ranging from 0.73 to 0.80) demonstrated a more robust performance than did FEV 1 alone (C statistic =0.69). Table 7 demonstrates diagnostic values (area under ROC curves) for pairs of PBMC gene markers and their independent association with improvement in FEV 1 , in both development and validation groups.
[0000]
TABLE 7
Diagnostic value of CF therapeutic signature
for resolution of airway inflammation
p values
Area under
(logistic regression)
Markers
ROC curve
Gene 1
Gene 2
FEV1
Dev. Cohort
CD64 ADAM9
0.88
0.0003
0.03
0.89
CD64 PLXND1
0.85
0.003
0.01
0.19
CSPG2 ADAM9
0.85
0.01
0.005
0.85
CSPG2 CD163
0.75
0.008
0.03
0.64
FEV1 alone
0.58
0.004
Valid.
CD64 CD36
0.8
0.02
0.03
0.5
Cohort
CD64 CSPG2
0.77
0.02
0.004
0.6
CD64 IL32
0.76
0.03
0.02
0.5
CD36 ADAM9
0.73
0.02
0.03
0.4
FEV1 alone
0.69
0.25
[0070] As demonstrated by p values<0.05 for each gene in the model, the genes contributed meaningful diagnostic information not available from FEV 1 alone. The use of 2 gene markers combined with FEV 1 was an optimal pairing, as less than two lost significance and greater than two did not improve significance by logistic function. From the 10 gene signature, 7 genes were strong independent predictors for treatment response in the regression model for the 2 groups. Three genes significantly improved diagnostic value (p<0.05) in both cohorts. In the first cohort, the gene pair with the highest predictive accuracy, based on C statistic, as well as statistical significance for each gene in the model, consisted of CD64 and ADAM9 (C=0.88). In the validation cohort, the best predictive pair, in terms of C statistic and significance in all genes, was represented by CD64 and CD36 (C=0.80). The independent, significant explanatory power contributed by these genes to both patient groups demonstrates that gene expression values from the CF therapeutic signature enhance the predictive discriminating value of FEV 1 alone.
[0071] The foregoing description of the present invention has been presented for purposes of illustration. The description is not intended to limit the invention to the form disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and the skill or knowledge of the relevant art, are within the scope of the present invention. The embodiments described hereinabove are further intended to explain the best mode known for practicing the invention and to enable others skilled in the art to utilize the invention in such, or other, embodiments and with various modifications required by the particular applications or uses of the present invention. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art. Each publication and reference cited herein is incorporated herein by reference in its entirety.
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The present invention is related to the novel discovery of a number of genes that were identified as systemic markers of pulmonary inflammation. This discovery allows for development of a novel tool for reliable, rapid and efficient assessment of therapeutic responses and enables design of novel therapies targeted against diseases associated with pulmonary inflammation. In one embodiment, the present invention allows quantification of therapeutic response in patients who have a disease associated with pulmonary inflammation. In preferred embodiments, the genes are CD64, ADAM9, CD36, IL32, HPSE, PLXND1, HCA 112, CSPG2, TLR2, and CD163.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to single lens reflex cameras and viewfinders for single lens reflex cameras in which data images are displayed with the image of a scene by passing data light into the camera's pentaprism, and more particularly to display changing devices for such viewfinders.
2. Description of the Prior Art
In general, automatic exposure cameras may operate in one of two modes, namely a shutter time priority mode or an aperture priority mode. In so-called dual priority cameras, operable in either one of these modes, the display of exposure information in the camera's viewfinder must be switched depending upon the selected exposure mode. That is, in the shutter time priority mode, it is necessary to display the preset value of the shutter time and an aperture value computed on the basis of the object brightness. Conversely, in the aperture priority exposure mode, the viewfinder must display the preset aperture value and the shutter time computed on the basis of the object brightness. However, such data may each be displayed by using a meter with a scale. In the shutter priority mode, the exposure data may be displayed at one side margin of the field of view image. In the aperture priority mode, the exposure data may be displayed in the lower margin of the field of view image. If both exposure data appear simultaneously, the displayed data may be confusing to the photographer. In other words, when the exposure data are to be displayed in such a manner, it is desirable to control the presentation so that one set of data is displayed and the other is extinguished.
Various types of display switchover devices for presenting and cancelling exposure data are known. These may use a changeover mechanism which is actuated by an operating member provided in the camera body for extinguishing the displayed data. However, conventional switchover devices generally involve placing a shutter member in the data light path to make the displayed information disappear, and by operatively connecting the operating member to the shutter by means of wire or other device. Therefore, conventional switchover devices in a finder raise the problem of increasing the size of the finder to allow for space in which the shutter member may move. This complicates the mechanism. Furthermore, because the operative connection between the shutter member and the operating member in such switchover devices must be established with the use of a wire or the like, it cannot be used with interchangeable finders decoupleable from single lens reflex cameras. In prior single lens reflex cameras using interchangeable viewfinders, such display switchover devices had to be located entirely within the camera body, thereby sacrificing the simplicity of the latter.
SUMMARY OF THE INVENTION
With the foregoing in mind, an object of the present invention is to provide a display changeover device for a single lens reflex camera which has achieved the possibility of including a changeover mechanism for extinguishing the display of exposure information in the finder and which even when applied to an interchangeble finder, can change the display depending upon the position of the operating member that is included in the camera body.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an example of application of the display changeover device of the invention to a single lens reflex camera.
FIG. 2 is a perspective view of one embodiment of a display changeover device according to the present invention.
FIG. 3 is a sectional view of the finder optical system in the single lens reflex camera of the invention.
FIG. 4 is a perspective view of the finder optical system of FIG. 3.
FIGS. 5 and 6 are plan views of a field of view of the finder with respective differing displays of exposure information.
FIGS. 7 and 8 are perspective views of the operative connection of FIG. 2 in two positions.
FIG. 9 is a fragmentary perspective view of another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will next be described in greater detail in connection with embodiments thereof by reference to the drawings.
In FIG. 1, the camera is composed of a camera body 1, is an objective lens 2, a shutter dial 3 forming part of a shutter time presetting mechanism, an actuator pin 4 mounted on the shutter dial 3, an interchangeable finder 5 for attachment to the camera body 1 and a sensor member 6 to react to the actuator pin 4 when the information display is changed.
FIG. 2 illustrates a practical example of the mechanical structure of the interchangeable finder 5 attached to the camera body 1. The shutter dial 3, actuator pin 4 and sensor member 6 are those illustrated in FIG. 1. A slide 7, fixedly carrying the sensor member 6 and having elongated slots 7a which respective pins 8 mounted on a base plate 9 penetrate, is slidably movable on the surface of the base plate 9 and guided by the pins 8.
The slide plate 7 has an extension 7b engaging a lever 10. A lever 10 is pivotally mounted on a pin 11 on the base plate 9. A resilient member 12 (for example, torsion coil spring) urges the lever 10 clockwise. The lever 10 while, on one hand, engaging the extension 7b, on the other hand, engages a radial extension 13a of a rocking member 13 which fixedly carries a flat mirror 23 (see FIGS. 7 and 8). The rocking member 13 is pivotally mounted at stubs 14a on a support member 14. Again the support member 14 has an extension 14b on which is movably mounted an adjusting member (for example, a set screw).
Further provided in the above-described rocking member 13 is a cutout portion 13b at which is connected one end of a resilient member 16 (for example, a coil spring) which urges the rocking member 13 counterclockwise. The opposite end of the resilient member 16 is connected to the base plate 9. A meter 17 receives a lead wire 17b electrically connected through a terminal (not shown) to the camera body. A display member 18 with a shutter time scale rests on supporting legs therefor. An adjusting member 19 for a flat mirror 27 (see FIG. 3) adjusts the angle of the flat mirror 27 to correctly direct data light to a pentaprism 21.
In FIGS. 3 and 4, the pentaprism 21 directs, rays of light radiated from an image of an object to be photographed on a focusing screen (not shown) to a sub-prism 22 and is therefrom directed to an eyepiece 24. The sub-prism 22 has parallel flat permeable surfaces 22a and 22b, downwardly of which are reflection surfaces 22c and 22d, and has an upper permeable surface 22e. And, these reflection surfaces 22c and 22d are mirrored by a reflection coating of, for example, aluminum. The permeable surface 22a is cemented to the rear or exit face 21a of the pentaprism 21. This permeable surface 22a may be otherwise spaced from the exit face 21a a small distance, but the cemented form has the advantage that handling of both the prisms becomes easier. Member 23 is the above-described rockingly mounted flat mirror with its reflection surface 23a mirrored by depositing a reflection coating of aluminum or the like. A triangular prism 25 has permeable surfaces 25a and 25c and a reflection surface 25b. The triangular prism 25 is cemented with its permeable surface 25a to the front upper slant face 21b of the pentaprism 21 at almost the center of the area thereof. Displays 17a and 18 are means for displaying information representing the above-described shutter time, and a warning of whether or not the exposure adjustment is out of range. The information display means 17a and 18 gives off light L which after having passed through the permeable surface 25a of the triangular prism 25 is then reflected by the reflection surface 25b to the permeable surface 25c and from there is directed through the front upper slant face 21b of the penta-prism 21 to the lower margin of the exiting face 21a. After having emerged from this exiting face 21a, the light L enters the sub-prism 22 at the permeable surface 22a and is then reflected from the reflection surface 22c to the permeable surface 22e. After having emerged from this surface 22e, it is reflected by the reflection surface 23a of the flat mirror 23 which is positioned to face at the surface 22e, and then again enters the sub-prism 22 at the surface 22e. After that, it is reflected by the reflection surface 22d to the permeable surface 22b and is therefrom directed to the eye-piece 24. A concave lens 28 has its second surface 28b cemented to the front upper slant face 21b of the pentaprism at the side thereof. The concave lens 28 and the preceding triangular prism 25 are arranged in a row in a direction perpendicular to a plane including an edge line of division of the roof faces of the pentaprism 21, i.e., perpendicular to the paper of FIG. 3. In the illustrated embodiment, a reflection member 27 is in the form of a flat mirror, and a reflection member 26 in the form of a rhombic prism mirror. The rhombic prism 26 has two reflection surfaces 26a and 26b and two permeable surfaces 26c and 26d and is positioned near the front upper slant face 21b of the penta-prism 21 at a location such that one of the reflection surfaces 26a occupies almost the center of the length in the lateral direction. Data 2a on the outer periphery of the barrel of the objective lens 2 is in the illustrated embodiment in the form of an aperture scale on the diaphragm presetting ring. Display information light M from the aperture scale 2a enters the rhombic prism 26 at the permeable surface 26c as shown in FIG. 4 and is then reflected sidewards by one of the reflection surfaces 26a of this prism. After that, the information light M is reflected upwards by the other reflection surface 26b, and exits from the permeable surface 26d of this prism. Then, it is reflected by the reflection surface 27a of the flat mirror 27 to the concave lens 28. After having been refracted by this concave lens 28, it enters at the front upper slant face 21b of the penta-prism 21 and is directed therethrough to the lower margin of the exit face 21a thereof at almost the same angle as the other display information light L. Thus, the information light M emerging from the rear face 21a of the prism 21 travels in a path similar to that of the display information light L before reaching the eye-piece 24. Hence, as shown in FIG. 6, data 2a appear as displayed information 2a ', and the data 17a, 18 appear as displayed information 17a', 18' in side-by-side relation in predetermined positions below the image F in the field of view.
In FIG. 3, a phantom outline 23' indicates a turned position of the flat mirror 23. As the flat mirror 23 is turned from the solid line position, the information bearing light beam is deflected so as not to proceed to the reflection surface 22d of the sub-prism 22. Then the display of data 2a' and 17a', 18' is extinguished before the photographer looking through the eye-piece.
Also the above-described pentaprism 21 as shown in FIG. 4 is slanted in one side of the bottom entrance face thereof to form a pearmable surface 21c. A triangular prism 29 has permeable surfaces 29a and 29b and a reflection layer-coated surface 29c and is positioned with its permeable surface 29b opposite to the permeable surface 21c of the pentaprism at a small separation therefrom. Members 33, 34, 31a are information display arrangement such as a shutter scale, diaphragm scale, out-of-range warning, and meter needle. In the illustrated embodiment, 33 is a diaphragm scale; 34 is shutter time; and 31a is a meter needle.
The information display members 33, 34, 31a together give off light N which passes enters the triangular prism 29 through a permeable surface 29a to enter this prism. Then, it is totally reflected by the permeable surface 29b and then once more by the reflecting surface 29c through the permeable surface 29b. After having emerged from that surface 29b, it enters the above-described pentaprism 21 and passes therethrough in a path similar to that in which the finder image forming light passes until it reaches the eye-piece 24. Thus, the light N bearing data to be displayed presents itself as a display of informations 33', 34' and 31a' at the right hand side of the viewfinder image F as shown in FIG. 5. A shutter arrangement 32 cooperates with the shutter dial 3 and, as far as the illustrated embodiment is concerned, upon selection of the aperture priority exposure mode places a symbol "A" on the shutter dial 3 in registry with an index to block the light N as shown by dashed lines in FIG. 6. The members 33, 34 and 31a and the shutter arrangement 32 are included in the interior of the camera body. It is further noted that the operative connection between the shutter arrangement 32 and the shutter dial 3 is known and constructed as follows: The shutter dial 3 fixedly carries a first pulley rotatable along therewith, and the shutter arrangement 32 is provided with an actuator which is driven by a second pulley. The first and second pulleys are constrained by an endless wire to transmit motion of the first pulley to the second one, so that the shutter dial 3 is drivingly connected to the shutter arrangement 32.
The operation of the embodiment of such construction is as follows.
FIG. 7 illustrates the elements' positions where the display of informations appears below the field of view of the finder as shown in FIG. 6. The shutter dial 3 may be set in a position (in this instance, "A" position) where the camera is switched to the aperture priority exposure mode, and where the actuator pin 4 acts on the sensor member 6. As the slide 7 is moved to the left, the lever 10 is turned counterclockwise against the force of the bias spring 12, so that rocking member 13 its extension engaging with the lever 10 is freed therefrom to turn counterclockwise by the spring member 16. Such movement goes on until the extension 13a abuts the above-described adjusting member 15. Thus, the flat mirror 23 is oriented such that the information light from the reflection surface 22c of sub-prism 22 is returned to the prism at its reflection surface 22d. Therefore, the information light from the reflection surface 22c of sub-prism 22 is directed to the eye-piece 24 when the shutter dial 3 is set in the aperture priority mode position ("A" position), and the information light is recognized within the finder as shown in FIG. 6. Also, at this time, the shutter means 32 blocks the triangular prism 29 from the information light so that the display of exposure information which is significant in the shutter priority exposure mode is not presented. In connection with the adjusting member 15, it need scarcely be said that it is better to carry out an adjusting operation of the member 15 during assembly with the resulting position of the displayed data 2a', 17a' and 18' optimum relative to the field of view of the finder.
FIG. 8 illustrates another operative position where the shutter dial 3 is turned to move the symbol "A" representing the aperture priority exposure mode out of registry with the index. In this case, the actuator pin 4 is moved away from the sensor 6 to permit clockwise movement of the lever 10 by the spring 12 as the slide 7 moves in the direction reverse of that described in connection with FIG. 7. In this case, the force of the spring 12 which overcomes the force of the spring 16 turns the rocking member 13 clockwise, so the flat mirror 23 is turned to a position where the information light from the reflection surface 22c of sub-prism 22 is not directed to the reflection surface 22d of said prism. Therefore, the display of data 2a', 17a' and 18' which occurs in the aperture priority exposure mode is extinguished from the vicinity of the field of view of the finder. On the other hand, at this time, the shutter arrangement 32 is retracted from the light path to the position shown in FIG. 4 so that when in the shutter priority exposure mode or the manual exposure mode, the display of informations 31a', 33' and 34 is presented.
FIG. 9 illustrates another embodiment of the invention where a reversible opaque mask 41 (for example in the form of a thin plate with a light shielding property) is arranged to advance into and be drawn from the light path between the sub-prism 22 and flat mirror 23. This embodiment though capable of reducing ghost as compared with the first embodiment has a problem of requiring additional space.
As described in greater detail above, according to the present invention, setting the shutter dial on the camera suffices either to readily extinguish the display of informations unnecessary to the selected exposure mode, or to present this display as need arises. Further, the device for switching between the presentation and extinction of the display of information can be constructed in a simple form that does not require a very large space, thus avoiding any increase in the bulk and size of the camera and finder. Furthermore, according to the present invention, even interchangeable finder type single lens reflex cameras, the selecting the presentation and extinction of a display data can be achieved with ease. This contributes to a simple operation of the camera.
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The disclosed single lens reflex camera includes a shutter dial and a pentaprism as well as an eyepiece, and forms an image of a scene in the camera's field of view and a data image near the scene image through the eyepiece by passing data light from the vicinity of the pentaprism into the interior of the pentaprism. A display switchover device includes a transmission arrangement on the shutter dial for transmitting the motion of the dial, a linkage arrangement engageable with the transmission arrangement to be actuated on the basis of the selected position of the shutter dial, and a display selector between the pentaprism and the eyepiece and actuated by the linkage arrangement to control the direction of the data light to the eyepiece. According to an embodiment, the selector includes a subprism having a surface from which the data light from the pentaprism is reflected and another surface for directing the data light to the eyepiece, and a reflector that faces the two subprism surfaces for changing the reflecting position in response to the linkage arrangement.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to plumbing fixtures. More particularly, it relates to a flush valve that includes a height-adjustable overflow tube to allow for proper setting of the overflow tube in relation to the height of the water contained within a toilet tank, which height varies between products and designs.
BACKGROUND OF THE INVENTION
[0002] A conventional gravity operated flush toilet has several basic components. The china components include a porcelain bowl and a porcelain tank mounted on top of the bowl. The bowl and tank may either be separate pieces or may be molded as a single unitary piece of china. The plumbing components of a conventional gravity operated flush toilet include a fill valve in the tank that is connected to a water supply line, a flush valve mounted in a hole in the bottom wall of the tank that communicates with the bowl, a flapper valve that normally closes the flush valve, and a lever or push button on the outer wall of the tank that is connected with a chain or other mechanical linkage for momentarily lifting of the flapper valve. This allows water stored in the tank to flow rapidly through the flush valve into the bowl to carry waste along with the water through a trap connected to the underside of the bowl and into a waste pipe connected to a sewer line, septic tank or other waste reservoir.
[0003] Conventional flush valves for gravity operated toilets are generally cylindrical and provide a round valve seat for the flapper valve. They are secured in a drain hole in the bottom wall of the toilet tank from underneath the bottom wall. Typically a large nut is screwed over a male threaded lower portion of the cylindrical flush valve body, on the underside of the bottom wall of the tank. Extending upwardly from the flush valve body is a cylindrical overflow tube. The purpose of the overflow tube is to ensure that a proper water level is maintained within the toilet tank. Ideally, the inlet of the overflow tube is set at a point where it is slightly above normal water level but below the bottom of the flush lever nut that is located on a vertical wall of the tank for actuation of the flushing cycle.
[0004] In the United States, there are two basic markets for toilet flush valves, namely, the original equipment manufacturer (OEM) market and the after-installation market. The former consists of large toilet manufacturers that assemble and sell complete gravity operated flush toilets including flush valves. The latter consists of hardware and plumbing supply stores that sell to plumbers and home owners for repair and replacement in toilets already installed in residences.
[0005] Every gravity operated flush toilet has an optimum fill level that ensures that enough water is in the tank for proper flushing without wasting water or risking incomplete waste carry out. For many years, gravity operated flush toilets in the United States had tanks with capacities of three and one-half, five gallons, or more. More recently, the Environmental Protection Agency (EPA) has mandated that low water consumption toilets be installed in all new construction and during all re-models, with a maximum water usage of 1.6 gallons per flush. Both the older high volume gravity operated flush toilets and the newer low volume gravity operated flush toilets come in a wide range of tank configurations with different optimum fill levels. Because of this, installation of after-installation market flush valves, which are manufactured in a pre-determined height to accommodate the deepest tank depth likely to be found, typically requires the installer to hand cut the overflow tube of the flush valve to fit. In the experience of this inventor, it would be unduly expensive to manufacture a variety of different overflow valves, each having an overflow tube of different height, to satisfy the configurations of the various gravity operated flush toilets manufactured in the United States and abroad. It is, therefore, advantageous to provide an after-installation flush valve having an adjustable overflow tube that permits plumbers and do-it-yourself homeowners to install the flush valve and to quickly, easily, and without tools, adjust the height of its overflow tube as necessary.
SUMMARY OF THE INVENTION
[0006] Accordingly, a primary objective of the device of the present invention is to provide an improved flush valve for the after market that can be readily adapted to the tank profile of a wide variety of gravity operated flush toilets. A further object of the invention is to provide an increase in the surface area of the opening of the overflow tube by flaring the upper end of the overflow tube such that the overflow tube permits 10 or more gallons/minute. It is an additional object of the present invention to provide a clip mechanism that cooperates with a plurality of ribs on the flared end of the overflow tube. In accordance with the aforementioned objectives of the present invention, there is provided a flush valve having an overflow tube that is adjustable in height. The foregoing and other features of the apparatus of the present invention will be apparent from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is front elevational view of the flush valve with an adjustable overflow tube of the present invention shown installed in a toilet tank.
[0008] FIG. 2 is an enlarged front exploded elevational view of the flush valve illustrated in FIG. 1 .
[0009] FIG. 3 is top perspective view of the valve body of the flush valve of the present invention.
[0010] FIG. 3A is a cross-sectional view of the valve body of the flush valve along line A-A of FIG. 3B .
[0011] FIG. 3B is a top elevational view of the valve body of the flush valve.
[0012] FIG. 3C is a side elevational view of the valve body of the flush valve.
[0013] FIG. 3D is a top elevational view of the valve body of the flush valve.
[0014] FIG. 3E is a front elevational view of the valve body of the flush valve.
[0015] FIG. 3F is a cross-sectional view of the valve body of the flush valve along line B-B of FIG. 3C .
DETAILED DESCRIPTION
[0016] Referring now to the drawings in detail, wherein like-numbered elements refer to like elements throughout, FIG. 1 illustrates the flush valve 1 of the present invention as it would be installed in a toilet tank 31 . Specifically, FIG. 1 shows a toilet tank 31 mountable to the rearward portion of a toilet seat (toilet seat is shown in phantom view). The toilet tank 31 is mounted to the toilet seat using mounting bolts 47 and the flush valve 1 is inserted through the drainhole 7 of the toilet tank 31 into the toilet seat. FIG. 1 also shows the water level 49 in a toilet tank 31 , which is below the top of the overflow tube 15 . In normal operation, to flush the toilet, the lever on the outside of the toilet tank 31 would be moved, typically downwardly, thus actuating the lever 25 in the toilet tank 31 and lifting the flapper chain 27 and flapper valve 21 , thereby emptying the contents of the toilet tank 31 and flushing the toilet. After a flush occurs, the flapper valve 21 closes permitting the toilet to fill. Normally, the flow of water into the toilet is governed by a toilet fill valve or ballcock (not shown). In the event the toilet fill valve malfunctions and fails to shut off the flow of water to the toilet tank 31 , the overflow tube 15 provides an outlet for the excess water in the tank by providing passage down the overflow tubes, 15 , 11 (i.e. the upper tube 15 and lower tube 11 ) and through the passage through the valve body 9 .
[0017] FIG. 2 shows an exploded view of the assembly of the adjustable-height flush valve 1 . Referring back to FIG. 1 , and starting from the base of the toilet and moving upwardly, items that may be included in the commercial embodiment of the replacement flush valve include a sponge gasket 3 , a mounting nut 5 , a chipboard washer 23 between the toilet tank 31 and the mounting nut 5 , and a rubber seal 29 between the valve body 9 and the toilet tank 31 .
[0018] The washer 23 is a donut-shaped piece of elastomeric material which is both resilient and deformable. Suitable materials for the washer 23 include, but are not limited to, chipboard or polyethylene. The chipboard washer 23 is used to reduce the friction between the mounting nut 5 and the toilet tank 31 , making it easier to tighten the mounting nut 5 by hand.
[0019] The valve body 9 is formed with a passage (not shown) adjacent to the aperture 39 . The valve body 9 includes flapper valve mounts 35 situated on either side of the valve body 9 for mounting the rubber flapper valve 21 . The flapper valve 21 also includes a flapper chain eyelet 37 . The flapper chain eyelet 37 permits attachment of a flapper chain 27 , attached to lever 25 . The rubber flapper valve 21 covers the aperture 39 in the valve body 9 when the toilet is not being flushed. The lever 25 is actuated by the toilet handle (not pictured) to pull the flapper chain 27 and open the flapper valve 21 and evacuate the contents of the toilet tank 31 , thus flushing the toilet.
[0020] The valve body 9 also has a first length of overflow tube 11 and a second length of overflow tube 15 . The first length 11 may be an integral part of the valve body 9 or may be a separate part that attaches to the valve body 9 . The first length of overflow tube 11 has been shown in FIG. 2 as a separate part. In this case, the overflow tube 11 would fit into the complimentary aperture of the passage through the valve body 9 . A simple press fit would be acceptable, although other types of retaining means could also be used. Water entering the upper end of the overflow tube 15 can flow through the passage to the drain hole 7 while the flapper valve 21 is in its closed position sealing the central aperture 39 . In a first embodiment, an adjustable overflow tube 15 fits into the first overflow tube 11 and the top of the first overflow tube 15 is externally threaded 33 . A locknut 13 having complimentary internal threads (not shown) threads onto the threaded portion 33 of the first overflow tube 11 . The first overflow tube 11 also includes an internal retaining ring (not pictured), which is merely a narrowing of the inside of the overflow tube 11 so as to provide a “catch” or retaining means for the adjustable overflow tube 15 .
[0021] The second, or adjustable overflow tube 15 has a notched bottom 41 and a retaining ring 43 . The retaining ring 43 is intended to “catch” the retaining ring on the inside of the first overflow tube 11 such that the adjustable overflow tube 15 cannot easily be pulled out of the first overflow tube 11 .
[0022] Additionally, the adjustable overflow tube 15 of the present invention has one end having a notched appearance 41 . The notches 41 provide a degree of flexibility in the overflow tube 15 which permits the user of the of the overflow tube 15 to insert it into the first overflow tube 11 and move it within the tube so as to adjust the height of the overflow tube 15 . When the adjustable overflow tube 15 is located at the desired height, the locknut 13 is tightened. Tightening or turning the locknut clockwise locknut 13 compresses the radial seal 12 against the outside of the overflow tube 15 , thus locking the overflow tube 15 to the first overflow tube 11 to hold the adjustable overflow tube 15 in relative position to the first overflow tube 11 .
[0023] The upper end of the adjustable overflow tube 15 is flared 51 such that it provides a larger surface area to admit water in the event of an overflow of water. Additionally, the upper end of the overflow tube provides a gap 49 in the flared overflow tube 15 that provides a latching point for the refill tube clip 19 , discussed below. The gap 49 provides, in general, a flat surface 53 interrupted by a ridge 55 . The ridge provides a surface for attaching the refill tube clip 19 .
[0024] Preferably, the various parts of the flush valve 9 and the overflow tubes 11 , 15 are injection molded using a suitable plastic such as ABS (Trademark) plastic or glass filled polypropylene. However, none of the above materials are considered a limitation of the invention. A wide variety of other suitable, durable and low cost materials for injection molding are also available.
[0025] The present invention also provides a method for fitting any sized toilet tank 31 with a universal flush valve 1 having an adjustable height overflow tube 15 . In general, the water supply to the toilet should be turned off and the toilet tank 31 should be emptied. Secondly, the tank should be unbolted form the toilet bowl. Continuing, the existing flush valve should be removed and the new flush valve installed. First a rubber seal 29 is placed over the threaded end of the valve body 9 . The threaded end of the valve body 9 is then inserted through the drainhole 7 in the toilet tank 31 . A friction reducing washer 23 is then placed over the threaded end of the valve body 9 and a mounting nut 5 is threaded onto the valve body 9 to secure the valve body 9 to the toilet tank 21 . A sponge gasket 3 is then placed over the mounting nut 5 . The toilet tank 31 is then reattached to the bowl. Importantly, the height of the adjustable overflow tube 15 is then adjusted relative to the toilet tank. To adjust the height of the flush valve overflow tube 15 , loosen the locknut 13 and extend the adjustable overflow tube 15 to the appropriate level. Next, tighten the locknut 13 and attach the refill tube 17 to the top of the adjustable overflow tube 15 using the refill tube clip 19 . The refill tube clip 19 can take a variety of forms, but in one particular embodiment features a plurality of prongs which extend downwardly on the inside and the outside of the overflow tube 15 in the gap 49 of the flare 51 of the overflow tube 15 . The prongs on the outside of the overflow tube 15 further have a notch slightly larger than the ridge 55 in the gap 49 such that the clip 19 is securely attached to the overflow tube 15 .
[0026] Although the foregoing has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made by way of example only and that numerous changes in the construction and the arrangement of components, some of which have been alluded to, may be resorted to without departing from the spirit and scope of the invention as it is described.
[0027] From the foregoing detailed description of the illustrative embodiment of the invention set forth herein, it will be apparent that there has been provided a new, useful and uncomplicated toilet flush valve having a variably adjustable overflow tube.
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The present invention provides an improved top mounted toilet flush valve and a method for installing the flush valve that can be readily adapted to the tank profile of a wide variety of gravity operated flush toilets. More specifically, in accordance with the objectives of the present invention, there is provided a flush valve having an overflow tube that is adjustable in height and a method for adjusting the overflow tube.
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PRIORITY APPLICATION
[0001] This application is based upon Provisional Patent Application No. 60/889,592 filed Feb. 13, 2007, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention is directed to the field of watercraft, and in particular to an improved tunnel for housing surface piercing propellers.
BACKGROUND OF THE INVENTION
[0003] The use of surface piercing propellers to increase the efficiency of watercraft is known in the industry. Inventor Small adapted such use into a tunnel design, as disclosed in U.S. Pat. Nos. 4,689,026; 6,045,420; 6,193,573; and 6,213,824, all of which are incorporated herein by reference. These patents claim various tunnel configurations for the use of such propellers in shallow draft vessels. Specifically U.S. Pat. No. 6,213,824 teaches a tunnel that raises the propeller vertically to reduce draft. This patent has an inlet ramp or chute that feeds water flow to the propeller when the craft is moving forward on plane.
[0004] Surface piercing propellers operate efficiently when a portion of the blade breaks the surface of the water. Shallow draft vessels that employ these propellers housed within a tunnel rely upon a configuration that allows air to be placed in a position directly before the propellers. Through proper tunnel design, the propellers operate as an air pump drawing the air through a conduit. The shape of the tunnel is calculated to provide efficient operation at cruising and/or top speed.
[0005] In the teachings of Small, the shape of the tunnel around the surface piercing propeller is just slightly larger in width than the propeller diameter. If the tunnel width is too wide then the ability of the propeller to act like a pump begins to decrease. If the tunnel width is too narrow, inadequate water may lead to excess propeller ventilation. Unique to the tunnel shape of Small is an inlet ramp, or chute, along the leading edge which directs water up to meet the propeller. While the prior art tunnels allow for very efficient vessel operation while on plane, the tunnel design does not provide efficient operation when the vessel is traveling beneath planning speeds or transitioning from off plane to on plane operation. More specifically, the tunnel design of Small fails to provide adequate water flow to the propeller during acceleration.
[0006] When forward motion is inadequate for the chute to direct water into the tunnel, the required water must come from in front of and below or in front of and from the sides of the propeller. The current tunnel design inhibits the flow of water during a transition stage from idle to planning, resulting in poor acceleration. The result is known as propeller blow out, or excess propeller slip.
[0007] Thus, what is needed is a tunnel configuration that employs the benefits of the surface piercing propellers for shallow draft vessels but addresses the problem of propeller slip.
SUMMARY OF THE INVENTION
[0008] The present invention is an improvement upon the prior art shallow draft configurations such as those set forth in U.S. Pat. Nos. 4,689,026; 6,045,240; 6,193,573; and 6,213,824. The shallow draft configuration employs the use of a surface piercing propeller placed in a tunnel that runs longitudinally in the bottom of the watercraft. The placement effectively eliminating the likelihood of underwater impact and improving shallow water operation without encountering the high efficiency loses normally associated with other shallow draft drive systems or water jets.
[0009] The improvement of the instant invention is directed to the shaping of the tunnel and in particular to the forming of a chamfered or radiused corner that improves water flow before the watercraft is on plane. The chamfered corner design allows water to flow into the flow field of the propeller disk providing smooth acceleration.
[0010] An objective of this invention is to teach the use of a tunnel mounted surface piercing propeller wherein the tunnel has a stepped side wall. Above the step the tunnel is 3-10% larger than the diameter of the propeller; below the step the tunnel can widen to any size without affecting operation efficiency.
[0011] Another objective of this invention is to teach the use of a tunnel mounted surface piercing propeller wherein the tunnel has a generally vertical side wall. The width of the tunnel above and below the centerline of the propeller is about 3-10% larger than the diameter of the propeller. At the intersection of the vertical side wall of the tunnel and the planning surface of the hull we place a radius or a chamfer that is larger than that required to accommodate manufacturing considerations.
[0012] Another objective of this invention is to teach the use of a tunnel mounted surface piercing propeller wherein the width of the tunnel above and below the centerline of the propeller is about 3-10% larger than the diameter of the propeller and the width of the tunnel aft of the propeller widens to improve the flow of water into the propeller disk when in reverse.
[0013] Still another objective of this invention is to teach the use of a tunnel mounted surface piercing propeller wherein the roof of the tunnel aft of the propeller slopes down until the trailing edge of the roof is at or below the free surface of the water when the vessel is at rest. The roof serving to stop air from entering the propeller when the vessel is operating in reverse.
[0014] Still another objective of this invention is to teach the use of a tunnel mounted surface piercing propeller wherein the roof of the tunnel aft of the propeller slopes down until the trailing edge of the roof is at or below the free surface of the water when the vessel is at rest, the tunnel roof being formed by a hinged panel that drops down in reverse and lifts up when the vessel is going forward. The hinged roof serving to stop air from entering the propeller when the vessel is operating in reverse and swings up to reduce drag when the vessel is moving forward.
[0015] Still another objective of the invention is to teach an improvement to tunnel configuration that allows water entry to the propeller in reverse by adding a second chamfer to the side walls of the tunnel aft of the propeller disk.
[0016] Still another objective of this invention is to increase reverse thrust by shaping the tunnel roof so as to greatly reduce the amount of air being introduced into the propeller disk when operating in reverse.
[0017] Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a pictorial end view of a prior art tunnel configuration;
[0019] FIG. 1A is a bottom view of FIG. 1 ;
[0020] FIG. 2 is a pictorial end view of the improved design tunnel configuration;
[0021] FIG. 2A is a bottom view of FIG. 2 ;
[0022] FIG. 3 is a pictorial end view of a prior art tunnel configuration illustrating water flow at acceleration;
[0023] FIG. 3A is a bottom view of FIG. 3 ;
[0024] FIG. 4 is a pictorial end view of the improved tunnel design illustrating water flow at acceleration;
[0025] FIG. 4A is a bottom view of FIG. 4 ;
[0026] FIG. 5 is a pictorial end view of a prior art tunnel configuration illustrating water flow at top speed;
[0027] FIG. 5A is a bottom view of FIG. 5 ;
[0028] FIG. 6 is a pictorial end view of the improved tunnel design illustrating water flow at top speed;
[0029] FIG. 6A is a bottom view of FIG. 6 ;
[0030] FIGS. 7 A, 7 B, 7 C and 7 D are various views of the tunnel showing the hull, and vessel propulsion system;
[0031] FIGS. 8A , 8 B, 8 C and 8 D are various views of the improved tunnel showing the hull and vessel propulsion system with the chamfered corner design;
[0032] FIGS. 9A , 9 B, 9 C, and 9 D are various views of the improved tunnel design showing the hull and vessel propulsion system with a radiused corner design;
[0033] FIGS. 10A , 10 B, 10 C, and 10 D are various views of the improved tunnel design showing the hull and vessel propulsion system with a stepped side wall design;
[0034] FIG. 11A is a prospective view of the tunnel roof that includes a fixed downwardly sloping tunnel roof aft of the propeller.
[0035] FIG. 11B is a prospective view of a hinged panel that drops down when the vessel is operated in reverse.
[0036] FIG. 12 is a graph of acceleration improvement versus tunnel width.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] The instant invention is directed to the shaping of the tunnel used in housing surface piercing propellers to enable water flow into the tunnel during acceleration and reverse. In particular, there are three ways to achieve the required flow improvement to the propeller disk during acceleration: chamfering, radiusing or stepping the side walls of the tunnel starting at a point that is approximately level with the center line of the propeller. This allows the surface piercing propeller to function well when on plane and moving forward at speed as an air pump, with all the same advantages as described by the prior art. In addition, since the preferred embodiment of the shallow draft tunnel configuration can result in the propeller blades actually being out of the water when the craft is at rest there is a need to find a way to reduce the flow of air into the propeller disk. The instant invention teaches a tunnel roof that can be either fixed or pivotal in nature and extends below the static waterline of the vessel.
[0038] Referring now to the Figures, FIG. 1 depicts a vessel ( 10 ) having a surface piercing propeller ( 12 ) placed within a tunnel having a width X as disclosed in the prior art. “X” varies from a few percent larger than the diameter of the propeller to approximately 10 percent larger than the diameter of the propeller. Conduit air vents ( 14 ) extend from the transom ( 16 ), or any other suitable location on a vessel, to a position in front of the propeller effectively filling the vacuum formed in front of the propeller allowing the water level in the tunnel to drop so the propeller can operate in the surface piercing mode where it is most efficient. The side walls ( 18 ) of the tunnel extend in a straight and approximately vertical wall along each side of the propeller. FIG. 1A is a bottom view further depicting the side wall ( 18 ) as a straight side wall, the propeller ( 12 ) coupled to a drive source by shaft ( 20 ).
[0039] FIG. 2 depicts the use of a vessel ( 30 ) having a surface piercing propeller ( 32 ) placed within a tunnel having width D of the improved design where the side air vents are “stepped”. It has been found that the width of the tunnel in a plane above the centerline of the propeller should be 3 to 10 percent larger than the diameter of the propeller. The width of the tunnel in a plane below the center line of the propeller can also be 3 to 10 percent larger than the diameter of the propeller or even larger dependent on desired performance characteristics. In this configuration, a shortened air vent conduit ( 34 ) again draws air from the transom ( 36 ) of a vessel to a position before the propeller in a similar manner to the prior art. As shown in this embodiment the tunnel has a width located in a plane beneath the center line of the propeller X as disclosed, where “X” varies from ten percent larger than the diameter of the propeller to approximately two times larger than the diameter of the propeller. The propeller ( 32 ) continues to operate as an air pump in a similar manner as disclosed in the prior art. However, the disclosed shape further allows water to be drawn to the propeller by use of the stepped wall depicted by width D. In this configuration there is no need to chamfer or radius the lower corner of the tunnel side wall because the widened tunnel alone is sufficient to provide water flow to the propeller during acceleration. A disadvantage of this embodiment however is that the stepped air vents reduce planning surface in the aft section of the hull and while this may not be a detriment, and may even be an advantage on some hulls, other hull shapes may find this loss of planning area unacceptable and so in those cases it is preferable to bring the lower surface of the air vent down to the planning surface of the hull and chamfer or radius its' inside edge.
[0040] FIG. 2A depicts the position of the stepped wall through radius ( 38 ) with the upper side position of the tunnel conforming to the teaching of the prior art and depicted by wall ( 40 ). The propeller ( 32 ) remains within the tunnel, the upper portion of the propeller surrounded by the tunnel shape disclosed in the prior art with a modification to the air vent conduit and stepping of the walls along the lower portion of the propeller. The result has been proven to provide the water flow necessary to provide smooth acceleration, and lessen the planning transition period.
[0041] FIGS. 3 and 3A depict a tunnel of the prior art with an illustration of water flow during acceleration. Water flow blockage ( 13 ) results in turbulence to the propeller ( 12 ) as a result of the straight vertical side wall ( 18 ) inhibiting water flow. At the lower speed, the chute forming along the leading edge of the tunnel is ineffective, the hull design actually prohibiting debris, as well as water, from reaching the propellers. The lack of water resulting in a turbulent flow along the tips of the propeller, resulting in slippage and poor acceleration.
[0042] As depicted in FIGS. 4 and 4A , the use of the stepped tunnel allows water flow to carry past the corner radius ( 38 ) and flood the tunnel with sufficient water to eliminate the turbulent flow area caused by the sharp tunnel walls.
[0043] FIGS. 5 and 5A depict the efficiency of the invention of the prior art at speeds where a flow of water is delivered through the chute ( 19 ) directly to the propeller ( 12 ) and the efficiency of the super cavitating propeller is allowed to operate accordingly.
[0044] Similarly, as depicted in FIGS. 6 and 6A the water to the propeller ( 32 ) of the instant invention tunnel shape provides the same efficiency, wherein the upper portion of the tunnel maintains the shape necessary for the propellers to operate as an air pump.
[0045] FIG. 7A is a rear view of a marine vessel having a surface piercing propeller 32 mounted on a unit 31 . The unit is positioned aft an angled front wall 33 which extends to a fixed tunnel roof 35 . Depicted is a transom 36 , with the tunnel 42 further formed by opposition vertical side walls 37 & 37 ′ and angled transition walls 39 & 39 ′. FIG. 7B shows a side view of the marine vessel 30 showing the relationship between the propeller 32 and the tunnel 42 . FIG. 7C is a bottom view of the vessel showing the propeller 32 the tunnel 42 and the transom 36 of the vessel 30 . FIG. 7D is a perspective view of the hull bottom showing the relationship between the hull bottom the tunnel 42 , the propeller 32 , and the transom 36 . The exact positioning of the propeller in relation to the top and each side wall is dependent upon the size of the vessel and the power plant. It has been discovered that optimum efficiency is possible when the tunnel is 3-10% larger than the diameter of the propeller.
[0046] FIG. 8A is a rear view of the marine vessel showing the transom 36 , the tunnel 50 and the propeller 32 . The tunnel 50 has opposing side walls 52 and chamfered transition sections 54 that extend from the side walls 52 to the hull bottom. As shown at 56 the tunnel is widened aft of the propeller to facilitate the flow of water to the propeller disk when operating in reverse. FIG. 8B shows a side view of the marine vessel 30 , shown in FIG. 8A , showing the relationship between the propeller 32 , and the tunnel 50 with the chamfered transition section 54 . FIG. 8C is a bottom view of the vessel showing the propeller 32 the tunnel 50 with the chamfered transition section 54 . FIG. 8D is a perspective view of the hull bottom showing propeller 32 , and the tunnel 50 with the chamfered transition section 54 . Optimum efficiency is possible when the tunnel is 3-10% larger than the diameter of the propeller, or expressed in the range of in the range of 1.03 to 1.1 times the diameter of the propeller.
[0047] FIG. 9A is a rear view of the marine vessel showing the transom 36 , the tunnel 60 and the propeller 32 . The tunnel 60 has opposing side walls 62 and curved or radiused transition sections 64 that extend from the side walls 62 to the hull bottom. As shown at 66 the tunnel is widened aft of the propeller to facilitate the flow of water to the propeller disk when operating in reverse. FIG. 9B shows a side view of the marine vessel 30 , shown in FIG. 9A , showing the relationship between the propeller 32 , and the tunnel 60 with the curved or radiused transition section 64 . FIG. 9C is a bottom view of the vessel showing the propeller 32 the tunnel 60 with the curved or radiused transition section 64 . FIG. 8D is a perspective view of the hull bottom showing propeller 32 , and the tunnel 60 with the curved transition section 64 . Optimum efficiency is possible when the tunnel is 3-10% larger than the diameter of the propeller.
[0048] FIG. 10A is a rear view of the marine vessel showing the transom 36 , the tunnel 70 and the propeller 32 . The tunnel 70 has opposing side walls 72 and stepping transition sections 74 that extend from the side walls 72 to the hull bottom. FIG. 10B shows a side view of the marine vessel 30 , shown in FIG. 10A , showing the relationship between the propeller 32 , and the tunnel 70 with the stepped transition section 74 . FIG. 10C is a bottom view of the vessel showing the propeller 32 the tunnel 70 with the stepped transition section 74 . FIG. 10D is a perspective view of the hull bottom showing propeller 32 , and the tunnel 70 with the stepped transition section 74 . Optimum efficiency is possible when the tunnel is 3-10% larger than the diameter of the propeller.
[0049] FIG. 11A shows a fixed slopping tunnel roof section 80 located aft of the propeller. The trailing edge of section 80 is at or below the free surface of the water when the boat is at rest. This roof section 80 stops air from entering the propeller when operating in reverse.
[0050] FIG. 11B shows an alternative embodiment to the tunnel roof section shown in 11 A. In this embodiment the roof section aft of the propeller includes a hinged roof panel 82 that is pivotally coupled to the roof 81 by a hinge. The hinged roof panel drops down when the vessel is operated in reverse and is lifted up when the vessel is operated in the forward direction. This hinged roof panel 82 serves to stop air from entering the propeller when reversing and swings up to reduce drag when going forward. In the preferred embodiment, the hinged roof panel operates under water pressure provided as the vessel moves forward, forcing the hinged panel upward or when the vessel is moved backward, forcing the hinged panel downward. Alternatively the hinged roof panel can be operated by an electric or hydraulic ram.
[0051] FIG. 12 is a graph of the acceleration improvement of the instant invention versus tunnel width. As the tunnel is widened, acceleration begins to improve. The improvement continues with increasing tunnel widths until the width increase of approximately 70% is reached.
[0052] It is to be understood that while I have illustrated and described certain forms of my invention, it is not to be limited to the specific forms or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown in the drawings and described in the specification.
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An improved tunnel configuration for tunnel mounted surface piercing propellers. The improved tunnel configuration provides a flooding suction to the tunnel to allow flooded propeller operation at speeds below planning. The tunnel is stepped whereby an upper portion of the tunnel is sized to allow the propeller to draw air at high speeds. The lower portion of the tunnel is sized to allow the propeller to be flooded resulting in smooth acceleration, improved handling in forward and reverse and a reduction of the transition period.
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This is a continuation of application Ser. No. 879,373 filed Jun. 27, 1986, now abandoned.
TECHNICAL FIELD
This invention relates generally to a magnetic head supporting device for supporting a magnetic head for recording and reproducing, for example, in a floppy disk player. More specifically, this invention relates to an improved flat spring member and oil retaining bearing sleeves.
BACKGROUND OF THE INVENTION
Magnetic recording and reproducing requires that the magnetic head contact the recording medium, e.g. a floppy disk, very accurately in order to maximize track density. Variations introduced by dimensional and positional errors result in mistracking and increased access time. A conventional magnetic head supporting device for a floppy disk player will be described with reference to FIGS. 1 and 2.
A carriage 1, namely a supporting member, is made of a synthetic resin substantially in the form of a rectangular plate. A front bearing arm 2 and a rear bearing arm 3 are formed integrally with the carriage 1 so as to project from one side surface of the carriage 1. Oil retaining bearings 4 and 5 are force fitted in the front and rear bearing arms 2 and 3, respectively. A guide shaft 7, horizontally mounted on a chassis 6 (see FIG. 2), is received through the oil retaining bearings 4 and 5 to guide the carriage 1 for horizontal movements in directions indicated by a double-headed arrow a. A lower magnetic head 8 is attached, adhesively or likewise, to the upper surface of the front end of the carriage 1.
A hinge 10, made of a flat spring, is fixed to the upper surface of the rear end wall of the carriage 1 with screws. An arm 11 is fixed at its rear end to the hinge 10. Thus, the arm 11 is supported on the carriage 1 by the hinge 10 so as to be swingable in a vertical plane as indicated by arrows b and c in FIG. 2. The arm 11 is made of a synthetic resin in the form of a rectangular plate. Projection 12 is integral with the arm 11 and projects from one side surface thereof. At the rear end of the carriage 1 is a torsion coil spring 13 which applies pressure through one end 13a to the arm 11, biasing arm 11 downward (i.e. direction C) on the hinge 10.
A magnetic head 15 is held elastically on a magnetic head holding member 14 made of a flat spring and attached to the lower surface of the front end of the arm 11. The magnetic head holding member 14 is designated generally as a gimbal and is typically formed by punching a rectangular shape into a flat, phosphor-bronze spring or stainless spring. As illustrated in FIG. 1, the magnetic head holding member 14 consists integrally of a magnetic head holding part 16, a fixing part 17 formed in the shape of a rectangular frame surrounding the holding part 16, and an elastic functional part 18, which interconnects the holding part 16 and the fixing part 17. Holding part 16 and the elastic functional part 18 are connected by a pair of connecting parts 19 on a line X'. The elastic functional part 18 and the fixing part 17 are connected by a pair of connecting parts 20 on a line Y' extending at right angles to the line X'. The magnetic head 15 is attached adhesively or likewise to the underside (as viewed in the figures) of the holding part 16 with the head's center on the center 0 of the holding part 16. The fixing part 17 is fixed adhesively or likewise to the lower surface of the front end of the arm 11.
Referring now to FIG. 2, a floppy disk 22 is contained within a cartridge 23. The floppy disk 22 is a recording medium made of a magnetic sheet. The cartridge 23 is mounted horizontally on the chassis 6 with the floppy disk 22 placed horizontally on a turntable 24. Then, upper and lower magnetic heads 15 and 8 engage the cartridge 23, entering the cartridge through upper and lower openings 25 and 26 to contact with the respective upper and lower sides of the disk 22. The cartridge 23 is adapted to be inserted into a cartridge holder, not shown in this figure. The projection 12 (FIG. 1) rests on part of the upper surface of the cartridge holder. Accordingly, when the cartridge 23 is lowered in a direction indicated by arrow d, from an upper position indicated by alternate long and short dashed lines to a working position indicated by continuous lines, arm 11 is turned by the torsion coil spring 13, in the direction indicated by arrow c, from an upper position indicated by alternate long and short dashed lines to a lower position indicated by continuous lines.
After the cartridge 23 has thus been loaded on the chassis 6, a motor for driving the turntable 24 is actuated to rotate the floppy disk 22 within the cartridge 23. The carriage 1 is moved horizontally by a carriage driving mechanism, not shown, in a direction indicated by the arrow a to move the upper and lower heads 15 and 8 radially with respect to the disk 22, enabling the desired recording or reproducing operation. Since the magnetic head 15 is held on the magnetic head holding member 14 so as to be tiltable in directions indicated by double-headed arrows X and Y and so as to be moveable in directions indicated by a double-headed arrow Z (FIG. 1), the magnetic head 15 is held very satisfactorily in elastic contact with the flexible floppy disk 22.
As noted above, high quality recording and reproducing require that dimensional and positional errors in the contact between the magnetic head and the recording medium be minimized. However, the conventional supporting device described above is inherently inaccurate, permitting dimensional variations in assembly and in ambient temperature and humidity conditions to adversely affect the contact and positioning of the magnetic head and the recording medium. The difficulty of the conventional device is more fully described with reference to FIGS. 1 and 2.
The hinge 10 is screwed to the upper surface of the rear end wall of the carriage 1. The arm 11 is screwed at its rear end to the hinge 10. The magnetic head holding member 14 is attached adhesively or likewise to the lower surface of the front end of the arm 11. All of these fastening steps result in troublesome assembly work. Furthermore, as is well known, since the magnetic head 15 needs to be positioned with respect to the floppy disk 22 highly accurately, the hinge 10, the arm 11 and the magnetic head holding member 14 need to be assembled highly accurately, a troublesome and difficult requirement. Also, since it is inevitable that there will be both dimensional and positional errors between these parts in their assembly, a troublesome adjustment is required.
Conventionally, the arm 11 is formed by molding a synthetic resin. As a result, the arm 11 is liable to expand or to contract due to variations in temperature and/or the humidity. This expansion and contraction is likely to cause variations in dimensions which require high accuracy such as, for example, the distance L 1 , between the center of the magnetic head holding member 14 and the center line of the bolt holes for receiving the screws for fastening the arm 11 to the hinge 10, and the distance W 1 between the respective centers of the bolt holes (FIG. 1). These variations cause problems in the tracking of the floppy disk 22 magnetic tracks by the head 15. These tracking variations reduce the interchangeability characteristics of the floppy disk 22.
Thus, in the conventional magnetic head supporting device of the type having upper and lower magnetic heads, as described above, the condition of contact of the upper and lower magnetic heads 15 and 8 with the floppy disk 22 is deteriorated by the relative positional variation (offset) between the upper and lower magnetic heads 15 and 8 due to the expansion or contraction of the arm 11.
Another aspect of the conventional magnetic head supporting device which contributes to undesirable variations in position involves the motion of the carriage 1 along guide shaft 7, best seen with reference to FIG. 1. In this conventional design, carriage front bearing arm 2 and rear bearing arm 3 are force-fitted with oil retaining bearings 4 and 5, respectively. The guide shaft 7, horizontally mounted on the chassis 6 (FIG. 2), is received through the oil retaining bearings 4 and 5 to guide the carriage 1 for horizontal movement in directions indicated by a double-headed arrow a. As shown in FIG. 1, the conventional shaft-bearing relationship permits undesirable movement in the directions indicated by arrows e and f. These positional variations, which result from bearing-insertion error and subsequent bearing wear, produce tracking errors which reduce signal reproduction quality and which restrict floppy disk 22 interchangeability.
SUMMARY OF THE INVENTION
The above and other problems are overcome by the present invention which provides an improved magnetic recording device in which a magnetic head for reproducing and recording is elastically maintained in contact with a recording medium. One improvement specifically comprises combining an arm swingably supported on a support member or carriage, a hinge and a magnetic head holding member in a unitary flat spring member. Another improvement comprises an elongate oil retaining bearing sleeve which is configured to receive a guide shaft which enables a carriage driven mechanism to move the carriage supported magnetic heads in the horizontal, or radial, direction necessary to record or to reproduce signals on the recording medium.
By integrating the hinge, the arm and the magnetic head holding member of a magnetic head supporting device into a single member, the troublesome work of assembling a plurality of parts is unnecessary. The magnetic head supporting device can be simply assembled for accurate contact of the magnetic heads with a recording medium, hence remarkably improving the assembly efficiency. Furthermore, since the hinge, the arm and the magnetic head holding member are formed in a single member and need not be assembled together, errors accompanying the assembly work are eliminated completely. Also, the adjustment of the magnetic head supporting device after assembly is remarkably facilitated.
Still further, since the expansion and contraction of a single flat spring member due to temperature and/or humidity variations is very small, those dimensions of the arm which require high accuracy vary only scarcely. Resultantly, the variation of the magnetic head in tracking position relative to the floppy disk magnetic tracks is prevented. This, in turn, provides signals which can be recorded and reproduced surely and accurately.
As applied to those devices described above as having two magnetic heads disposed one over the other, the present invention improves the reliability of recording and reproducing performance of the associated apparatus remarkably. The arm expands and contracts only scarcely so there is no possibility of the dislocation (offset) of the upper and lower magnetic heads relative to each other.
Furthermore, since according to the present invention, the magnetic head is brought elastically into contact with a recording medium by the intrinsic resilience of the flat spring member, the torsion coil spring, which is necessary in the conventional magnetic head supporting device, is unnecessary, thereby reducing the number of parts required.
Another, significant improvement of the invention relates to the longitudinal slide bearings for moving the assembly radially with respect to the disk. As described above, with reference to the conventional device, forced-fit oil retaining bearings are used to horizontally move the carriage along a chassis supported guide shaft. The present invention eliminates assembly error and wear difficulties caused by the forced-fit oil retaining bearings. The present invention provides at least one elongate oil retaining bearing sleeve which does not require "force-fitting" and which sleeved bearing is longer than the conventional bearings. These characteristics of the bearings contribute to improved carriage positioning and reduce variations introduced by assembly and wear.
In a particularly preferred embodiment, a single elongate bearing made from oil impregnated, sintered metal is provided. This embodiment completely eliminates assembly error and wear difficulty.
The foregoing and other objectives, features and advantages of the invention will be more readily understood upon consideration of the following detailed description of certain preferred embodiments of the invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of a prior art magnetic head supporting device for a floppy disk player.
FIG. 2 is a vertical, enlarged, cross-sectional view of the prior art magnetic head supporting device of FIG. 1.
FIG. 3 is an exploded perspective view of a magnetic head supporting device, according to the present invention, in a preferred embodiment as applied to a floppy disk player.
FIG. 4 is a perspective view of the magnetic head supporting device of FIG. 3, in which the device is assembled.
FIG. 5 is a vertical, enlarged, cross-sectional view of the magnetic head supporting device of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
A magnetic head supporting device, in a preferred embodiment, according to the present invention as applied to a floppy disk player will be described with reference to FIGS. 3 through 5. In these figures, parts which are similar to those previously described with reference to FIGS. 1 and 2 are denoted by the same reference numerals and the description of similar parts will be omitted to avoid duplication.
While the preferred embodiment described below applies to a double head type magnetic head supporting device provided with upper and lower magnetic heads, it is intended that the present invention is applicable also to a single head type magnetic head supporting device provided with one magnetic head on the flat spring member. It is also intended that the present invention is not limited to the magnetic head supporting device for a floppy disk player, but it is intended that the present invention is applicable also to the transducing head supporting device of various recording and reproducing apparatus in which various recording and reproducing heads are to be brought into elastic contact with various recording media, respectively.
Referring now to FIG. 3, according to the present invention, a single flat spring member 30 has sections which correspond to the hinge 10, the arm 11 and the magnetic head holding section 14 of the previously described, conventional magnetic head supporting device. The flat spring member 30 is formed in a rectangular shape by punching a phosphor-bronze spring plate or a stainless steel spring plate. The flat spring member 30, moving from the rear end toward the front end as viewed in the figures, has a hinge section 31, an arm section 32 and a magnetic head holding section 33. The magnetic head gimbal mounting section 33 is the same as the magnetic head gimbal mounting 14 of the prior art in construction except that gimbal mounting 33 is integral with the flat spring 30. This is accomplished, for example, by stamping out the gimbal from the flat spring. A magnetic head 15 is attached adhesively or likewise to the magnetic head holding part 16 of the magnetic head holding section 33.
A reinforcement 34 made of a synthetic resin is molded around the flat spring member 30. In FIG. 3, the reinforcement 34 is separated from the flat spring member 30 to facilitate an understanding of the construction. The side edges of the arm section 32 and the magnetic head holding section 33, and the upper surface of the arm section 32 of the flat spring member 30 are covered with the side sections 34a and the central sections 34b, respectively. Grooves 34c of the reinforcement 34 allow the hinge section 31 and the magnetic head holding section 33 of the flat spring member 30 to flex and also restrict the waving and flexure of the arm section 32. The upper and lower parts of the reinforcement 34 are joined together through a plurality of holes 35 formed in the arm section 32. The reinforcement 34 has, as the integral parts, a protrusion 36 for providing a pivot point support which lightly depresses the magnetic head holding part 16 and a projection 12 similar to that of the prior art. The flat spring member 30 is screwed at the rear end thereof to the upper surface 40a of the rear end wall of a carriage 40.
The carriage 40 of this embodiment is formed in a rectangular shape by pressing a metal plate. The rear portion of the carriage 40 is bent substantially in an L-shape. The upper surface 40a of the rear end wall of the carriage 40 is declined slightly toward the front. A magnetic head 8 is attached adhesively or likewise to the upper surface of the front end of the carriage 40. Plates of various metals can be used to form the carriage 40, however, a thick plate of the same material as that of the flat spring member 30, such as a thick phosphor bronze plate or a thick stainless steel plate, is preferable since then the upper and lower head supports will have the same linear coefficients of thermal expansion. Similarly to the flat spring member 30, a part of the carriage 40, such as the rear end wall to which the flat spring member 30 is attached, may be provided with a reinforcement by encasement in a synthetic resin.
An oil retaining bearing in the form of a sleeve 41 is secured to one side edge of the carriage 40. The oil retaining bearing 41 is a single member formed of a sintered metal and is provided with a bore 41b having a predetermined length L 4 . The oil retaining bearing 41 receives one side edge of the carriage 41 in a groove 41a formed therein and is fixed to the carriage 41 with rivets 42. Note that the length L 4 of the bearing sleeve 41 is greater than one half of the length L 3 , thus minimizing the undesirable movements of prior art bearing mounts referenced as e and f in FIG. 1. As illustrated in FIG. 5, a guide shaft 7 is inserted through the bore 41b of the oil retaining bearing 41 to guide the carriage 40 for movement in directions indicated by a double-headed arrow a.
The upper and lower magnetic heads 15 and 8 supported on the magnetic head supporting device thus constructed are operated in the same manner as that of the prior art for recording and reproducing operation.
Since the hinge section 31, the arm section 32 and the magnetic head holding section 33 are formed integrally in the unitary flat spring member 30, the magnetic head supporting device can be easily and very accurately assembled by simply attaching the flat spring member 30 at the rear end (hinge section 31) thereof to the upper surface 40a of the rear end wall of the carriage 40. Furthermore, since the hinge section 31, the arm section 32 and the magnetic head holding section 33 need not each be assembled, errors in assembling the individual parts are eliminated. Hence, the adjustment of the magnetic head supporting device after assembly is greatly facilitated.
Since the arm section 32, as well as the hinge section 31 and the magnetic head holding section 33, is a part of the unitary flat spring member 30, there are only slight variations in dimension due to the changes in temperature and/or humidity. For example, the dimensions of the arm section 32 which require high accuracy, such as the distance L 2 between the center line of holes formed in the rear end of the flat spring member 30 for fixing the same to the carriage 40 and the center line of the magnetic head holding part 16, and the distance W 2 between the same holes formed in the rear end of the flat spring member 30 (FIG. 3), are now scarcely variable. Accordingly, undesired variation of the magnetic head 15 in tracking position relative to the magnetic tracks of the floppy disk 22 is prevented.
Referring now to FIG. 5, since the upper surface 40a of the rear end wall of the carriage 40 is declined slightly toward the front and since the flat spring member 30 is attached at the rear end thereof to the upper surface 40a of the rear end wall of the carriage 40, the unitary flat spring member 30 turns of its own resilience from an upper position indicated by alternate long and short dash lines to a lower position in a direction indicated by an arrow c. So, when a cartridge 23 is lowered from an upper position indicated by alternate long and short dash lines to its working position indicated by full lines in a direction indicated by an arrow d in FIG. 5 the unitary flat spring member 30 is biased in the direction indicated by arrow c of its own resilience. Therefore, the torsion coil spring 13 which is an integral part of the conventional magnetic head supporting device is unnecessary, thereby reducing the number of parts required. Furthermore, since the hinge section 31, the arm section 32 and the magnetic head holding section 33 are integrated into the unitary flat spring member 30, the load is not concentrated only on the hinge section 31, thereby extending the life of the hinge section 31.
Since the carriage 40 is formed by pressing a metal plate, preferably of the same material as the spring 30, the expansion and contraction of the carriage 40 attributable to changes in temperature and/or humidity is very small. Accordingly, the dimensions of the carriage 40 which require high accuracy, such as the horizontal distance L 3 between the center of the magnetic head 8 attached to the front end of the carriage 40 and the center line of holes formed in the upper surface 40a of the rear end wall of the carriage 40 (FIG. 1), vary only scarcely. Consequently, undesired variation of the magnetic head 15 in tracking and positioning relative to the magnetic tracks of the floppy disk 22 is prevented.
Since the individual oil retaining bearing 41 is secured to the carriage 40, the oil retaining bearing 41 also is affected scarcely by the variation of temperature and/or humidity, and hence the oil retaining bearing 41 is never deformed and the axis of the oil retaining bearing 41 is never dislocated. Accordingly, the carriage 40 is able to move always smoothly and accurately along the guide shaft 7 when the oil retaining bearing 41 is formed and secured to the carriage 40 accurately.
Although the invention has been described with particular reference to a preferred embodiment thereof, the present invention is not limited thereto and many changes and variations are possible in the invention without departing from the scope and spirit thereof.
For example, the shape of the unitary flat spring member integrally having the hinge section, the arm section and the magnetic head holding section may be any suitable shape including the rectangular shape of the flat spring member employed in the above-described preferred embodiment. The shape of the magnetic head holding part also may be any suitable shape, such as a circular shape.
In this embodiment, the flat spring member is urged downward of its own resilience, however, an additional torsion coil spring or extension coil spring may be provided for urging the flat spring member downward.
Although the present invention has been shown and described with respect to preferred embodiments, various changes and modifications which are obvious to a person skilled in the art to which the invention pertains are deemed to lie within the spirit and scope of the invention.
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In a magnetic recording device wherein a magnetic head is maintained in elastic contact with a recording medium, an improved magnetic head supporting device integrates a hinge, a swingably supported arm and a magnetic head holding member into a unitary flat spring member. Further, an elongate oil retaining bearing sleeve is provided to guide the magnetic head cartridge in the horizontal or radial direction relative to the recording medium.
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REFERENCE TO RELATED APPLICATION
This application is a division of my copending application Ser. No. 53,898, filed July 10, 1970, now U.S. Pat. No. 3,842,596 which is incorporated herein by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to rotating heat pipes and more particularly to air conditioning apparatus incorporating a rotary heat pipe for transferring heat from a heat source to a heat sink.
The term "heat pipe" as used herein refers to any device that transfers heat by means of evaporation and condensation of a fixed amount of fluid within a sealed cavity of any shape formed in the device. In the operation of a heat pipe, a quantity of liquid locates in the relatively hot region of the cavity (the "evaporator" region) where it absorbs heat from the cavity walls in that region causing it to evaporate. The vapor flows to the cooler region of the cavity where it gives off heat to the walls of the cavity in that region (the "condenser" region) and condenses into a relatively cool liquid. The condensed, cooled liquid is then returned to the hotter zone of the cavity to repeat the cycle.
In my invention, I provide the rotating body with an interior sealed cavity which has a certain diameter at the hotter (evaporator) end of the body tapering up to a slightly smaller diameter at the cooler (condenser) end as, for example, is shown in FIG. 1.
I locate a small inventory of liquid in the cavity and rotate the body at high speed. At high speed, the liquid inventory forms a uniform annulus at the evaporator end. Heat transferred through the evaporator portion of the body wall vaporizes some of the liquid and the vapor so formed flows toward the axis of rotation and axially toward the condenser end. Here the vapor condenses on the cooled walls and the liquid condensate is pumped back along the tapered cavity walls by the small component of centrifugal acceleration tangential or parallel to the taper of the wall (hereinafter sometimes referred to as "centrifugal pumping acceleration" or "CPA"). The speed at which I rotate the body is sufficiently great to produce a component of centrifugal acceleration in the condensate parallel to the tapered cavity wall which is in excess of 1G acceleration at essentially all points on the condenser walls, and often preferably many times greater.
Accordingly, I provide a self-contained, vapor cycle heat transfer device which returns the condensate from the condenser region to the evaporator region at a relatively high velocity even against gravity or in the absence of gravity, and which can provide heat transfer ability which is greatly improved over that of conventional heat pipes and the like.
My invention is particularly well suited to provide substantial heat transfer between two ends of rotating body having a relatively long axial dimension and a relatively small diameter, since I can generate fairly large return pumping acceleration along a very small angle slope.
The benefits of my invention are obtainable only in a vapor cycle or two-phase system, and only in such a system where the cool condensing surface is kept relatively free of liquid.
It should be noted that at horizontal attitude under the influence of gravity, the liquid in the evaporator forms a non-uniform annulus when centrifugal acceleration of the liquid just exceeds 1G. As centrifugal acceleration in the liquid approaches the relatively high levels required to produce centrifugal pumping acceleration in excess of 1G according to the present invention, the liquid annulus becomes highly uniform and the pressure of the liquid increases substantially. This provides highly efficient boiling and vaporization effects since it greatly increases the convection of vapor bubbles and liquid in the annulus, and also provides a smooth interface at relatively high heat fluxes. By contrast, when boiling occurs at 1G, the interface is distorted and turbulent and tends to disperse relatively large droplets into the vapor which reduces the heat transfer effectiveness of the system. Accordingly, a device constructed in accordance with the principles of my invention may accommodate relatively high levels of heating without causing undue surface turbulence.
Because of the tendency of centrifugal acceleration to increase convection, the denser, cooler liquid flows away from the axis and quickly displaces the less dense heated liquid near the hot evaporator wall which, in turn, flows rapidly toward the axis. This prompt movement from the evaporator wall to the interface enhances evaporation, suppresses boiling and improves the heat transport capabilities of the system as a whole.
The present invention involves use of the heat pipe in an air conditioning apparatus. The heat pipe is part of a unique air conditioner having a hollow shaft extending through a small hole in the building wall and having a rotating refrigerant compressor at the end of the shaft.
In each of the embodiments of the invention herein described, the condenser surface is preferably curved in axial cross section to provide uniform pumping acceleration.
In the embodiment of the invention claimed herein an air conditioning unit is provided comprising a tapered hollow heat pipe projecting through an opening in a building wall. The heat pipe contains an inventory of liquid including a reservoir in an evaporator region at the inside of the wall and has a condenser region at the outside of the wall. Means are provided for transferring heat from the heat pipe to the outside air to condense the vapors in the condenser region, and means are provided for compressing a gaseous refrigerant at the outer surface of the heat pipe in the evaporator region. A hollow air impeller is preferably provided to receive the refrigerant and to rotate in unison with the heat pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a longitudinal sectional schematic view of a rotating heat pipe constructed in accordance with the principles of the present invention;
FIG. 2 is a longitudinal sectional schematic view of an electric motor according to the invention;
FIG. 3 is a longitudinal sectional schematic view of a drill bit assembly constructed according to the invention;
FIG. 3A is a transverse section taken along line 3A-3A of FIG. 3;
FIG. 4 is a longitudinal sectional schematic view of an alternate rotating heat pipe construction according to the invention;
FIG. 5 is a longitudinal sectional schematic view of a turbine engine constructed according to the invention; and
FIG. 6 is a longitudinal sectional schematic view of an air conditioning unit constructed according to the invention.
While many of the drawings are schematic and not exactly to scale, the relative dimensions of the heat pipe may be as shown.
DETAILED DESCRIPTION
Referring to the drawings in greater detail, FIG. 1 is a schematic view showing a centrifugal pumping heat pipe 1 constructed in accordance with the principles of the present invention. The heat pipe 1 has a generally cylindrical body portion 2 with an axial shaft 3 extending from one end. The shaft 3 is journalled for rotation in a bearing 4. An elongated cavity 5 is formed coaxially in the body portion 2. The cavity is generally frusto-conical with curved or substantially parabolic side walls 6. At the large end of the cavity, there is a cylindrical reservoir 7 which has a slightly larger diameter than the large diameter of the frustum. A small inventory of liquid is sealed in the cavity. The amount of liquid employed is such that when the pipe is rotated during operation, the liquid forms a uniform annulus which fills the reservoir 7 but does not overflow onto the parabolic walls 6. The amount of liquid may be less than the amount required to fill the reservoir 7 completely, but should be great enough that the reservoir 7 does not boil dry during operation.
In operation, the end of the pipe 1 wherein the reservoir 7 is located (the "evaporator" end) is subjected to heat which causes the liquid in the reservoir to vaporize. The vapor tends to fill the central empty space in the cavity. The opposed end of the pipe (the "condenser" end) is subjected to relatively cooler temperatures so that when the vapor encounters the walls 6 in the condenser end, it condenses. The pipe is rotating at a very high rate so that the condensate which forms on the walls 6 will be subjected to a radial or centrifugal acceleration which is great enough that the component of that acceleration parallel to the wall 6 at any point on the wall (the CPA) will be in excess of 1G.
The CPA or centrifugal pumping acceleration of a body at a point on a sloped wall in a direction parallel to the wall at that point is equivalent to ω 2 r sin θ, where ω = the angular velocity of the body, θ = the angle of a tangent to the surface of the wall at that point relative to the axis, and r = the distance from the axis. It will be seen that centrifugal acceleration tends to increase as r increases, so that the slope of the wall may be decreased as r increases without decreasing the tangential component of centrifugal acceleration. For this reason, in each embodiment of the invention shown herein, the walls in the condenser portion of the cavity are preferably curved as shown in FIG. 1, FIG. 3 or FIG. 5.
In most applications of the present invention, the outer diameter of the rotating body will be limited as, for example, in the case of a drill for drilling a hole of a particular size. For this and other reasons, it will be desirable to determine what cavity wall curvature will produce the optimum pumping acceleration. In the usual case, this will be where the net pumping acceleration is relatively uniform at all points on the slope.
Accordingly, I have calculated the relationship of the radius, surface taper, and angular velocity to one another when it is desired to obtain a uniform centrifugal pumping acceleration at all points on the slope. In these calculations, it is necessary to take into account both the presence (or absence) of actual gravity and the attitude of the axis of the rotating body to the direction of actual gravity. The general equation is as follows:
r = 0.816 (n + M cos θ cos β)/(rev./sec.) 2 (sin θ)
where
r = the distance of the wall from the axis, expressed in feet;
n = the no. of G's desired for net pumping (including the effect of actual gravity);
m = the acceleration of actual gravity in G's, (m = 0 in outer space, m = 1 on earth);
θ = the angle formed by the axis of rotation and a straight line drawing parallel to the surface of the wall at a particular point on the wall; and
β = the angle of the axis of rotation relative to the direction of actual gravity, where β = 180° when the axis of rotation is vertical with the evaporator end down. 0° ≦ β ≦ 180°.
The general equation assumes that the body is rotating at a rate sufficient to produce a centrifugal acceleration normal to the axis which is much greater than the actual ambient gravity.
I have also calculated the following simplified equations for special cases:
CASE I
Axis of rotation vertical, condenser end down, actual gravity = 1G. r = 0.816(n + cos θ)/(rev./sec.) 2 (sin θ), ft.
CASE II
Axis of rotation vertical, condenser end up, actual gravity = 1G.
r = 0.816(n - cos θ)/(rev./sec.) 2 (sin. θ), ft. This equation is meaningless where n < 1.
CASE III
Axis of rotation horizontal, actual gravity between 0 and 1G; also axis at any angle with actual gravity = 0.
r = 0.816(n)/(rev./sec.) 2 (sin θ), ft.
From the above four equations, it is possible to generate ideal curves for the wall of the heat pipe. Very good approximate curves may be drawn by beginning at either end of the condenser wall and plotting values for r and θ at small regular increments along axis of the pipe (Δ L). This generates a stepped slope which can be smoothed out by drawing a curve through the intersection of the taper and the radius for each value of Δ L. If desired, more accurate slopes can be generated from the above formulae by iteration.
In generating approximate curves for small taper portions of the wall (i.e., where θ < 6°), one may assume that sin θ = tan θ. Accordingly, the following equations may be employed.
IN CASE I
tan θ = 0.816(n+1)/r(rev./sec.) 2
IN CASE III
n = 1, tan θ = 0.816/r(rev./sec.) 2
Since tan θ = Δr/ΔL, one may generate the curve by determining the value of θ and r for the wall at one point on the axis and then plotting subsequent points on the wall by inserting values for ΔL and solving for the corresponding values of Δr.
The curved condensing surface of the heat pipe is important in the drill, electric motor, gas turbine and air conditioner shown herein by way of example and in other applications as disclosed in said U.S. application Ser. No. 53,898. This is explained in more detail in NASA Contractor Report CR-130373 dated September 1973 and entitled "An Analytical and Experimental Investigation of Rotating Noncapillary Heat Pipes."
In the evaporator end, it is important to maintain heat flux below levels where critical nucleate boiling ("burn-out") occurs. This critical level tends to increase at high accelerations. For example, water boiled at 400G's and 815,000 BTU/hour, ft 2 is below the burn-out level, yet this heat flux is approximately double the normal critical value at 1G. Generally speaking, burn-out heat flux varies with the one-fourth power of acceleration in excess of 1G, and at multiple G levels, it is necessary to produce high levels of radial centrifugal acceleration on the wall and in the evaporator (since centrifugal pumping acceleration at any point on the taper is equal to centrifugal acceleration at that point times the sine of the slope angle at that point, and since the slope angle is typically quite small). Accordingly, the high levels of acceleration produced in the evaporator tend to raise the heat flux capacity of the evaporator.
For example, in a 2-inch diameter evaporator cylinder turning at about 6000 revolutions per minute, the centrifugal acceleration of the liquid is about 1000G's. The heat flux capacity of this evaporator with water is about 1,800,000 BTU/hour, ft 2 . This is about 10 times greater than the highest capillary heat pipe heat flux reported prior to this invention.
At the condenser end, it is important to pump the condensate off the walls and back to the evaporator since any buildup of condensate reduces the condensing effectiveness of the walls. For this reason, it is preferable to produce relatively high levels of centrifugal pumping acceleration in the practice of my invention. Since, typically, centrifugal pumping acceleration equivalent to dozens of G's can be produced in devices constructed according to my invention, such devices can operate with much less thermal resistance in the condensate layer than devices with equivalent vertical condensing surfaces at 1G.
The thermal resistance of the condensate layer can be reduced still further by plating the condenser walls with noble metals.
Turning to FIG. 2 of the drawings, there is shown a schematic drawing of an electric motor constructed in accordance with the principle of the present invention. The motor has a housing 10, a stator 11, and a rotor 12. The rotor core 13 has an axial drive shaft 14 extending from one end, and an auger-like portion 19 extending from the other end which serves as a fluid pump. The rotor core is further provided with a coaxial sealed cavity 15, which has cylindrical walls 16 adjacent the rotor windings (defining the evaporator region) and tapered walls 17 adjacent the auger portion 19 (defining the condenser region). The cylindrical walls 16 in the evaporator region have a slightly larger diameter than the largest diameter of the condenser walls 17 so that the evaporator walls are recessed to form a well-defined reservoir for the liquid 18. The rotor is shown rotating at a speed sufficient to form a substantially uniform liquid annulus in the reservoir. The liquid inventory is small enough that it does not overflow the reservoir to cover any appreciable portion of the condenser walls 17 during operation.
The importance of minimizing the amount of liquid on the condenser walls of devices constructed according to my invention has been discussed and, for this reason, a recessed, well-defined reservoir is preferred in this and most other embodiments of my invention as will be readily apparent to persons or ordinary skill in the art.
In the operation of the electric motor shown in FIG. 2, the rotor 12 develops localized heat in the rotor windings and at the bearings upon which the rotor is journalled in the housing 10. The heat is conducted through the cylindrical walls 16 of the core 13, where it is transferred to the liquid 18 in the reservoir. The liquid 18 is vaporized and the vapor flows radially toward the axis and axially to the condenser end where it condenses on the tapered walls 17. This condensate is subjected to centrifugal pumping acceleration to return it to the reservoir. When the vapor condenses on the walls 17, it gives off heat which is conducted through the walls 17 and into the auger blades 19. The motion of the auger blades 19 in the ambient air (entering the housing through an air inlet screen 20) enhances cooling of the condenser walls 17. Moreover, the auger 19 acts as a blower, forcing air through apertures 21, across the rotor and stator windings, and out the opposite side of the housing 10 via vents 22. This assists cooling of both the rotor 12 and stator 11.
FIGS. 3 and 3A provide schematic illustrations of a drill bit assembly constructed in accordance with the principles of the present invention. The assembly consists essentially of a drill bit 30 and a non-rotating sleeve 31. The bit 30 has conventional helical cutting blades 32 formed at one end and is provided with a coaxial sealed cavity 33 with a length many times its diameter. The cavity has an enlarged reservoir portion adjacent the blades 32. The reservoir is defined by the cavity walls 34 which extend into the cutting blades 32. Liquid inventory 35 locates in the reservoir during rotation to form a substantially uniform annulus during operation, as shown. The cavity 33 tapers gradually from the reservoir to a smaller diameter at the opposite end. In operation, localized heat buildup in the evaporator region at the blades 32 is transferred away according to principles already discussed, as will be apparent. In addition, the sleeve 31 enhances heat transfer by flowing coolant (from the pipes 38) over the outer surface of the shank of the bit 36 and adjacent the condenser walls 37. Rotational flow in the coolant is minimized by locating one or more apertured baffles 39 on the inner surface of the sleeve 31.
FIG. 4 of the drawings shows a schematic representation of an alternate form of heat pipe 40 embodying features which may be employed together or singly in the embodiments of FIGS. 1 through 6 or other specific applications as desired. As shown, the pipe 40 is being employed to transfer heat away from a fluid 43 supplied to the evaporator end of the pipe in a non-rotating jacket 42. The pipe 40 is provided with coaxial sealed cavity 44 having a cylindrical evaporator wall 45 at the evaporator end, a conically tapered condenser wall 41 at the condenser end, and circumferentially spaced, generally axial submerged channels 46 extending between the evaporator wall 45 and the condenser wall 41 beneath a conically tapered wall 47 mounted in the pipe on radially outwardly extending posts or ribs (not shown).
The submerged passages 46 and conical wall 47 are provided between the condenser and evaporator regions because, in the central regions of a heat pipe, there is usually an adiabatic zone in which the vapor and liquid flows are transferred countercurrently. This is a zone of annular flow with the vapor at the center moving at much higher velocities than the liquid along the wall which creates the possibility that the vapor will blow the returning condensate film into waves or mist.
To solve this problem, if it occurs, one may employ submerged condensate passages as shown at 46 in FIG. 4.
A further feature illustrated in FIG. 4 of the drawings is that the transverse end of the condenser region is folded inwardly to accomplish one or more of several objectives, as follows: (a) to increase the area available for cooling when overall length is limited; (b) to increase the condensing heat-transfer coefficient by causing the condensate, as soon as it is formed, to be centrifuged off the convex inner surface 48 of the in-folded wall and collect on the larger diameter tapered surface 41 for centrifugal pumping back to the evaporator region; and (c) to provide a concave outer surface opposite convex inner condensing surface 48, in which coolant is directed as a jet from a pipe 49 against the concave surface which, because of its shape, causes the coolant to flow back along the wall to conduct heat through the wall away from the inner condenser surface 48. It will be noted that in (b) above, this feature permits one to increase the condensing surface area without increasing the return surface area. Such feature may be incorporated, for example, in the embodiments of FIGS. 2, 5 and 6.
FIG. 5 is a schematic drawing of a turbine-type engine which incorporated features of the present invention. The turbine is claimed in said copending application Serial No. 53,898, the entire disclosure of which is incorporated herein by reference. In FIG. 5 the turbine rotor 50 on shaft 56 has a plurality of radially outwardly projecting turbine blades 51 which are hollow. A housing 52 encloses the rotor 50 and hot combustion gases blow into the housing via passages 54, past the blades 51, and out of the housing via outlet passages 55. The flow of hot combustion gases against the blades 51 imparts angular velocity or acceleration to the rotor 50 and, at the same time, heats the hollow blades 51. The rotor 50 is provided with a sealed partially liquid-filled cigar-shaped coaxial cavity 57 communicating with the hollow blade cavities 58 via small tubes 59. Heat in the liquid in the blade is transferred either by small vapor bubbles or very strong liquid natural convection current in the connecting tubes 59 to the interface in the central cavity 57.
Heat transferred from the vapor to the tapered concave condensing surface 62 of the rotor is conducted away from opposed convex outer surface 66 of the rotor by the flow of fuel or other coolant over that rotating surface 66 through a stationary jacket 63 which surrounds the exterior of the rotor 50 at the condenser end. Fuel enters the jacket 63 from the fuel tanks via inlet pipe 64 and leaves the jacket, preheated for combustion, on its way to the combustors via outlet pipe 65. The condensing surface 62 is curved in axial cross section to provide the desired pumping acceleration.
FIG. 6 is a schematic drawing of a novel air conditioning unit constructed according to my invention. This unit essentially comprises a rotor generally indicated by the numeral 70, and a housing generally indicated by the numeral 71. An electric motor 72 drives the rotor 70 in rotation in the housing 71, the motor's rotor windings wound on the rotor 70, and the motor's stator windings fixed in the housing 71. Hollow fan blades 73 are fixedly mounted at one end of the rotor 70 and partially filled with a conventional liquid refrigerant, such as freon. A hollow tube 74 communicates between each hollow blade tip and one end of the compressor passage 75 in the compressor. The other end of the compressor passage 75 communicates with each hollow blade cavity near the hub of the blade at compressor passage inlet 82. When the motor drives the rotor 70 in rotation, the refrigerant is compressed in the compressor passages 75 where it gives off heat of compression to liquid 77 in the evaporator region of heat pipe cavity 76. The compressed, liquefied refrigerant flows from the compressor into the tubes 74 toward the tips of the hollow blades 73 where, upon leaving the tubes 74 through orifices near the blade tips, it expands to fill the blades with cold vapor. Room air, induced to circulate past the exterior surfaces of the blades 73, gives off heat, cooling the room air and heating the cold vaporized refrigerant. The warmed vaporized refrigerant flows through the hollow blades 73 toward the axis where it re-enters the compressor at compressor passage inlet 82, where it is compressed, liquefied, and the cycle repeated.
When the compressed refrigerant gives off heat of compression to the liquid 77 in the evaporator end of the rotor cavity 76 (note the hollow interior surface 78 of the rotor compressor vanes forming a part of the total evaporator surface in the evaporator region), the vapor flows to the condenser end of the cavity 76, where it condenses on tapered surface 79 giving off heat to the outside air through the rotating tapered conductive disc 80 (constructed of aluminum or other good heat conductor). The surface 79 may be shaped so that the condensate is returned to the evaporator region under uniform centrifugal pumping acceleration according to the principles of the present invention discussed previously.
It will be noted that an insulating sleeve 83 is applied to the outer surface of the rotor 70 at the point where the rotor passes through the wall 81. This sleeve substantially prevents condensation on the conical interior rotor walls in that region so that heat is not given off into the inside air, but only into the outside air.
It will be apparent that relatively low temperature levels will be encountered at both ends of the rotor 70 (on exterior surfaces), and that the rotor liquid inventory must either have a relatively low boiling point at normal pressure, or the pressure in the rotor cavity must be relatively low.
The air conditioning unit shown in FIG. 6 has several advantages, including (a) that it can provide superior cooling in a compact unit; and (b) that it requires a very small hole in the wall (e.g., 3 or 4 inches) by comparison to conventional units which require large vents.
In addition, cooling can be further improved by providing a stationary shroud ring to collect condensation of room air moisture on the blades as it sprays off the blades, and this moisture can be ducted to the outside rotating disc 80 near its hub so that the moisture can be centrifuged radially outwardly over the rotating disc surfaces to help cool them.
As in the embodiment of FIG. 2, the electric motor 72 develops localized heat in the rotor windings and at the bearings upon which the rotor is journalled. In the construction of FIG. 6, the motor and the bearings at the evaporator region are effectively cooled by the heat pipe.
It will be appreciated that several of the devices illustrated herein, for example in FIGS. 2 and 4, show conical return walls that are not curved to produce uniform net pumping acceleration at all points along the walls. These illustrations were not intended to show optimum wall configuration for the devices shown, and it will be understood that properly curved return walls are preferred for all of the embodiments of FIGS. 1 through 6. The invention may be practiced less effectively with straight conical return walls.
Many different liquids are suitable for use in devices constructed according to the present invention. Preferred liquids for specific applications will be readily apparent to persons of ordinary skill in the art. For many applications, it will be preferable, or even essential, to utilize a liquid metal (such as liquid sodium, for example). One benefit of liquid metals is that they conduct heat readily (about 100 times faster than water) so that the condensate that forms on the condenser walls does not slow subsequent condensation while it is being pumped back to the evaporator region.
Similarly, the pipe may be constructed of many different materials as will be apparent to persons of ordinary skill, although it is usually preferably formed of a highly conductive, non-corrosive metal such as stainless steel, molybdenum, nickel, or their alloys. It is essential, however, that the pipe be constructed to withstand the substantial internal pressures that may be developed during operation.
As should be apparent to those skilled in the art, means of cooling the external surfaces of the condenser may be used other than those described herein such as water sprayed onto the rotating condenser with slinger rings mounted on the outside of the condenser, or wiping the condenser surface with liquid-saturated cloth type material.
It will be understood that, in accordance with the patent laws, further changes and modifications may be made without departing from the spirit of the invention as set forth in the claims appended hereto.
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A unique rotary hermetic heat pipe is disclosed for transferring heat from an external source to an external heat sink. The heat pipe has a tapered condensing surface which is curved preferably to provide uniform pumping acceleration, the heat pipe being rotated at a velocity such that the component of centrifugal acceleration in an axial direction parallel to the tapered surface is greater than 1G and so that the condensing surface is kept relatively free of liquid at any attitude. The heat pipe may be incorporated in an air conditioning apparatus so that it projects through a small wall opening. In the preferred air conditioning apparatus, a hollow hermetic air impeller is provided which contains a liquefied gaseous refrigerant, such as freon, and means are provided for compressing the refrigerant in the evaporator region of the heat pipe.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a printing head for a dot printer.
2. Related Art And Prior Art Statement
A printing head for a general dot printer comprises a plurality of needles arranged in a retractable manner within a tubular needle holder, swingable armatures connected respectively to rearward ends of the respective needles, an armature stopper arranged rearwardly of the armatures for regulating backward positions of the respective armatures, springs for biasing respectively the armatures rearwardly, and solenoids provided correspondingly to the armatures. When any one of the solenoids is energized, the corresponding armature is attracted to move the needle forwardly. A forward end of the needle projects from the needle holder to perform printing. When energization of the solenoid is released, the armature is moved backwardly and impinges against the armature stopper. Noises are generated by an impact at the time the armature impinges against the armature stopper.
In view of the above, in order to solve the above-discussed problem, a printing head is disclosed in Japanese Patent Laid-Open No. 62843/1991 in which a resilient or elastic element is provided for being abutted against rearward ends of respective wires to absorb the impact. However, the printing head is such that, when the wires are repeatedly abutted, the elastic element is abraded or worn off by the impact, and the wires are cut into the elastic element so that the printing head is difficult to operate normally when the wires are again released from the elastic element.
Further, an impact dot head is disclosed in Japanese Patent Laid-Open No. 231765/1987 in which a metallic spacer and a rubber spacer which are polymerized to each other are arranged as a buffer material on lever abutting portions.
The above-described impact dot head has the following problems. That is, it is possible to absorb the impact by the rubber spacer, and the metallic spacer is provided on the surface of the rubber spacer. Accordingly, there is no case where returned levers cut into the rubber spacer. Printing can normally be performed even after stoppage for a long period of time. The impact dot head is rich in durability. However, since the rubber spacer is provided on a rear surface of the metallic spacer, the number of parts increases. Not only this forms a primary factor of an increase in cost, but also it is difficult to produce thickness accuracy of the rubber space. Thus, if the accuracy of this portion is poor, variation is apt to occur in printing performance.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the invention to provide a printing head which is simple in structure, which is low in cost, in which variation in printing performance is low, in which impact at the time an armature is returned to a waiting or stand-by condition is relieved, and in which generation of noises is prevented from occurring.
According to the invention, there is provided a printing head in which armature abutting portions have high elasticity, and an impact at the time armatures impinge against an armature stopper is absorbed by the fact that the armature abutting portions are flexed or deflected and are displaced toward a gap therebehind. Thus, noises are restrained or suppressed, and the durability of the armature stopper is considerably improved.
Furthermore, since armatures are positioned only by the armature abutting portions of the armature stopper, other inclusions such as an elastic element, a damper and the like are not required. A structure is simple. Precision processing or working of the inclusion is not required. Thus, the cost is reduced, and the accuracy can easily be raised. Variation is difficult to occur in printing performance.
The printing head according to the invention is arranged such that the plurality of armatures are positioned under a waiting condition at a position at the back of the plurality of armatures which are arranged radially and which are swingably supported, an armature stopper is provided which has armature abutting portions which are displaceable by impingement of the armatures, the armature abutting portions project toward a center in a radial direction, a gap is defined at the back of the armature stopper, and the armature abutting portions are supported such that inward ends of the respective armature abutting portions are displaceable toward the gap.
When excitation of a coil stops, and when the armatures are returned to the original condition and impinge respectively against the armature abutting portions, the armature abutting portions are displaced toward the Cap by resiliency or elasticity of the armature abutting portions and presence of the gap at the back of the armature abutting portions, to absorb the impact upon the impingement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially broken side elevational view of a printing head, which shows an embodiment of the invention;
FIG. 2 is an enlarged side elevational cross-sectional view of a principal portion shown in FIG. 1;
FIG. 3 is a top plan view of an armature stopper base according to the embodiment of the invention;
FIG. 4 is a top plan view of an armature stopper according to the embodiment of the invention;
FIG. 5 is a top plan view of an armature base and an armature stopper according to another embodiment of the invention;
FIG. 6 is a cross-sectional view taken along a line A--A in FIG. 5; and
FIG. 7 is a top plan view of the armature stopper according the embodiment of the invention illustrated in FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, a printing head 1 comprises a plurality of electromagnets 3 arranged within a solenoid base 2 along a periphery of the printing head 1 concentric with the solenoid base 2, a plurality of needles 6 extending through a tubular needle holder 4 so provided as to project from a center of a front surface of the solenoid base 2 and arranged in a retractable manner from openings 5 at a forward end of the needle holder 4, armatures 7 connected respectively to rearward ends of the respective needles 6, an armature base 8 provided rearwardly of the armature 7, an armature stopper table 16 mounted on a front surface of the armature base 8, and an armature stopper 9 provided on an entire surface of the armature stopper table 16 for regulating backward positions of the respective armatures 7.
The armatures 7 are confronted respectively against rearward portions of the respective electromagnets 3 and are arranged radially along a radial direction of the printing head 1. The armatures 7 are supported by a rearward edge 2a of the solenoid base 2 so as to be swingable in a longitudinal direction with inner corners 7a adjacent to the outer periphery of the printing head 1 serving respectively as fulcrums.
Further, the needles 6 have respective rearward ends thereof which are fixedly mounted respectively on ends 2b of the respective armatures 7 adjacent to a center of the printing head 1. Compression springs 10 which are provided at the center of the printing head 1 are abutted respectively against front surfaces of the respective armatures 7. Under a condition that the electromagnets 3 are not energized or deenergized, the armatures 7 are moved rearwardly by biasing forces of the respective compression springs 10. The armatures 7 are abutted against the armature stopper 9, and the forward ends of the respective needles 6 plunge into the needle holder 4.
Moreover, when any one of the electromagnets 3 is energized, the armature 7 corresponding to the energized electromagnet 3 is attracted so that the needle 6 moves forwardly. The forward end of the needle 6 projects from the opening 5 at the forward end of the needle holder 4. Thus, printing is performed.
A material of the armature stopper table 16 is a plastic material which is the same in material as the armature base 8. A material of the armature stopper 9 is that high in wear and abrasion resistance such as a cobalt-group alloy or the like. As shown in FIG. 3, the armature stopper table 16 has a through bore 19 which is formed through a center of a board 18. An annular projection 11 is provided along an outer periphery of the annular stopper 10 at a front surface of the board 18. A convexity 20 projecting from a center of a front surface of the armature base 8 is inserted into the through bore 19, whereby the armature stopper table 16 is mounted on the center of the front surface of the armature base 8.
The armature stopper 9 is made of a plate element having a top plan configuration which is substantially the same as that of the armature stopper table 16. As shown in FIG. 4, a through bore 13 is formed at a center of a central board 21 which is abutted against the front surface of the convexity 20 on the armature base 8. An annular portion 22 is provided along the outer periphery of the annular stopper 9 in spaced relation to the central board 21. Armature abutting portions 12 each in the form of a tongue piece, which position respectively the armatures 7 under the waiting condition, are so formed as to project toward the center of the armature stopper 9 in a radial direction at positions which are confronted against the rearward portions of the respective armatures 7 on the inner periphery of the annular portion 22. The central board 21 and the annular portion 22 are integrally arranged by connections 23.
Moreover, a projection 15 provided at the center of a front surface of the convexity 20 on the armature base 8 is inserted into the inserting bore 13, whereby the armature stopper 9 is mounted on the front surface of the armature stopper table 16. At this time, since the projection 11 on the armature stopper table 16 is abutted against the rear surface of the annular portion 22, a gap 14 is defined between the annular stopper 9 and the base 18 of the armature stopper table 16 at the back of the armature abutting portions 12.
When energization of the electromagnets 3 is released, and when the armatures 7 are moved rearwardly so as to impinge against the armature abutting portions 12 of the armature stopper 9, the armature abutting portions 12 are flexed or deflected toward the gap 14 to absorb the impact, and the armatures 7 are positioned.
In the embodiment, since the armature abutting portions 12 are partially formed, the embodiment has high elasticity or resiliency, is apt to be flexed or deflected by the impact, and is high in impact absorbing effects.
FIGS. 5 and 6 show another embodiment of the invention. The convexity 20 and the projection 15 in the first embodiment are not provided on a center of a front surface of an armature base 80. However, an annular standing wall 81 is integrally formed in substitution for the armature stopper table 16. An armature stopper 90 is directly mounted on a forward end surface of the standing wall 81.
The armature stopper 90 is made of a plain plate having a top plan configuration which is substantially the same as a space surrounded by an outer edge of the standing wall 81. As shown in FIG. 7, a window bore 91 is formed at a center. An integral armature abutting portion 120 is formed along a periphery of the window bore 91.
The armature stopper 90, as best seen in FIG. 6, is abutted against the front end surface of the standing wall 81, and projections indicated by the broken line and beforehand formed respectively at a plurality of locations on an outer peripheral edge portion of the standing wall 81 are dissolved by ultrasonic waves, to thereby form inhibit or suppression portions 92. By the suppression portion 92, the outer edge portion of the armature stopper 90 is restrained or pressed down. Thus, the armature stopper 90 is mounted on the armature base 80.
Then, a gap 140 corresponding to the height of the standing wall 81 is defined at the back of the armature abutting portion 120 of the armature stopper 90.
In the present embodiment, since the armature stopper 90 is formed by the simple annular planar plate, it is not required to apply complicated or complex processing. Thus, it is possible to keep the cost of the device correspondingly low.
In this disclosure, there are shown and described only the preferred embodiments of the invention, but, as aforementioned, it is to be understood that the invention is capable of use in various other combinations and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein.
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A printing head comprising a plurality of armatures which are arranged radially and which are swingable before and behind, an armature stopper having armature abutting portions of cantilever type provided in projection toward a center in a radial direction at respective locations at the back of the armature for positioning the armatures under a waiting condition, the armature stopper being displaceable by impingement of the armatures, and a gap defined at the back of the armature abutting portions.
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RELATED APPLICATION
[0001] This application is claiming the benefit, under 35 U.S.C. §119(e), of the provisional application filed Jul. 30, 2008 titled Catheter System under 35 U.S.C. §111(b), which was granted Ser. No. 61/137,344. This provisional application is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a catheter system designed to provide a quickly made but secure connection between the system and any liquid receiving container.
BACKGROUND OF THE INVENTION
[0003] A catheter is a tube that can be inserted into a body cavity, duct or vessel. Catheters allow drainage, injection of fluids or access by surgical instruments. In most uses a catheter is a thin, flexible tube (“soft” catheter), although in some uses it is a larger, solid tube (“hard” catheter). The catheter may be left inside the body either temporarily or permanently.
[0004] Frequently, catheters are used to drain urine from a bladder. The process of inserting one end of the catheter in one's body, while maintaining the other end in a container for receiving the urine, can be difficult for one person to do on their own. Even when the catheter is already inserted in a patient's body, the inserted end may fall out of the container as the patient moves, the container moves, the tube moves or when catheterized fluid begins to flow through the tube. Typically, this is because there is no mechanism for maintaining the container end of the catheter in the container. When the container end leaves the container, urine, or other fluids, spill in beds, on cloths, on the patient and on health care providers. Such spills are highly undesirable as they can lead to bacterial contamination of sterile environments or urine specimens and patient embarrassment.
[0005] In view of the above disadvantages of permitting the end of the catheter to remain unsecured in the container, it would be advantageous to have the end secured. It would be further advantageous for a catheter security device to be easy to use, inexpensive, capable of being used by a single person and readily adaptable to current bodily fluid containers.
SUMMARY OF THE INVENTION
[0006] In one embodiment, a catheter retaining system comprises a container for receiving catheterized fluids. A conical end piece receiving portion is located on an inside surface of a mouth portion of the container. The end piece receiving portion has an inner surface shaped to selectively secure an end piece of a catheter therein. The conical end piece receiving portion may be also located on alternative containers, as described herein.
[0007] In another embodiment, a flexible hook-like structure is located on the inside surface of the mouth portion. The structure selectively extends at least partially about an end piece of a catheter to selectively secure the catheter within the mouth portion. The structure may be also located on alternative containers, as described herein.
[0008] In yet another embodiment, the system comprises a lid that at least partially selectively closes a fluid collection portion of a container. An aperture is located through the lid where the aperture selectively secures an end piece of a catheter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description when considered in the light of the accompanying drawings in which:
[0010] FIG. 1A is a schematic depiction of a front view of the present invention located in a urinal bottle;
[0011] FIG. 1B is a schematic view of the present invention;
[0012] FIG. 2 is a schematic, partial, cut-away side view of the invention of FIG. 1 ;
[0013] FIG. 3 is a schematic, partial, cut-away side view of the invention of FIG. 2 ;
[0014] FIG. 4 is a schematic depiction of a front view of another embodiment of the present invention;
[0015] FIG. 5 is a plan, schematic view of another embodiment of the invention;
[0016] FIG. 6 is a plan, schematic view of a variation on the invention of FIG. 5 ;
[0017] FIGS. 7A and 7B are schematic front and side views of another embodiment of the invention;
[0018] FIGS. 8A and 8B are schematic front and side views of another embodiment of the invention;
[0019] FIGS. 9A and 9B are schematic front and side views of another embodiment of the invention; and
[0020] FIGS. 10A and 10B are schematic front and side views of another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] It is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined herein. Hence, specific dimensions, directions or other physical characteristics relating to the embodiments disclosed are not to be considered as limiting, unless expressly stated otherwise.
[0022] Turning now to FIGS. 1 , 2 and 3 , one embodiment of the present invention is depicted. This embodiment comprises a catheter system 10 having a drain tube 12 , an end piece 14 and an end piece receiving portion 16 located within a container. The container may be, but is not limited to, a bottle-type urinal 18 . A bottle-type urinal 18 is used herein merely for illustrative purposes.
[0023] The container may comprise any receptacle capable of collecting and holding a fluid. Containers within the scope of the invention may comprise, but are not limited to, bottles, plastic urinals, cups, or trays. As can be appreciated herein, the invention may work with containers without further modification or the container may be adapted for convenient use with the invention.
[0024] The fluid may comprise any known fluid but is likely to be bodily fluids, such as urine or blood, whether from a human or an animal.
[0025] The drain tube 12 may be such as surgical tubing which typically is both relatively small in diameter and flexible. A channel 20 extends continuously from a first end 22 of the tube 12 to a second end 24 of the tube 12 .
[0026] At, or proximate, the first end 22 of the tube 12 , at least one aperture (not shown) is provided. There may be more than one aperture at the first end 22 and the aperture or apertures may be oriented and located about the first end 22 as known by those skilled in the art.
[0027] The end piece 14 is attached to the second end 24 of the tube 12 . Preferably, the end piece 14 is securely attached to the second end 24 such that it will not easily become detached from the tube 12 . Alternatively, the end piece 14 may be unitary and one-piece with the tube 12 . The tube 12 may terminate anywhere within the end piece 14 .
[0028] It is preferred that the end piece 14 has a means for permitting fluid to flow through it. Such means may comprise, but are not limited to, a hollow channel 26 substantially coaxial with the tube 12 . The hollow channel 26 may have a design complimentary to an exterior surface 28 of the end piece 14 , or it may have a different design.
[0029] The exterior surface 28 of the end piece 14 may be such as a frusto conical design, such as a tapered cone. In this embodiment, a first end 30 having a smaller diameter is connected to a second end 32 having a larger diameter. A continuous body portion 34 connects the first end 30 with the second end 32 .
[0030] The end piece 14 may be constructed of a plastic or rubber-like material that is preferably somewhat elastic, although rigid designs are also permissible.
[0031] While one shape of the end piece 14 has been described, the present invention is not limited to such shapes and others may be within the scope of the present invention. By way of example only, the continuous body portion 34 may be substantially uninterrupted, as shown, or it may have steps or grooves. Further, the end piece may also comprises a body portion with a substantially constant outer diameter.
[0032] The end piece receiving portion 16 is preferably located within a mouth portion 36 of the bottle urinal 18 . While the figures depict one bottle urinal design, those skilled in the art will readily appreciate that there are numerous other types of such designs, all of which are within the scope of the present invention. Further, the present invention is not limited to locating the end piece receiving portion 16 in a bottle-type urinal; instead, it may be used in conjunction with any container, such as those mentioned above.
[0033] Preferably, the end piece receiving portion 16 is located on an upper portion 38 of the mouth portion 36 as this may assist in maintaining the end piece receiving portion 16 out of fluid collected in the bottle 18 . While one location of the end piece receiving portion 16 is shown in the figures, it can be appreciated that other locations are permissible. For example, the end piece receiving portion 16 might be located on a side wall 40 of the mouth portion 36 or on a bottom portion 42 of the mouth portion 36 . It is also permissible for the mouth portion 36 to have one or more end piece receiving portions 16 adjacent one another or spaced apart from one another about the mouth portion 36 .
[0034] In one embodiment of the end piece receiving portion 16 depicted in FIGS. 1 , 2 and 3 , the end piece receiving portion 16 is of a frusto-conical, or tapered cone, design that is complimentary to the shape of the end piece 14 . More specifically, the end piece receiving portion 16 may have a first end 44 , a second end 46 , an inner surface 48 and an outer surface 50 . The inner surface 48 defines a substantially hollow interior portion 52 . A slot 54 may be located from the first end 44 to the second end 46 .
[0035] The first end 44 has a diameter that is smaller than a diameter of the second end 46 . The inner and outer surfaces 48 , 50 may be parallel to one another, but need not be. In the preferred embodiment, the end piece receiving portion 16 defines a gradually and continuously expanding inner and outer surfaces 48 , 50 from the first end 44 to the second end 46 . It is also within the scope of the present invention for the end piece receiving portion to have a substantially constant outside diameter.
[0036] The end piece receiving portion 16 may be separately formed from and then selectively attached to the mouth portion 36 of the bottle 18 . By way of example only, the end piece receiving portion 16 may be selectively secured to the mouth portion 36 by tape, adhesive, hook and loop type fasteners, complimentary male and female connectors, clips or clamps and/or mechanical fasteners or it may be made part of the collection device itself.
[0037] In the depicted embodiment, the end piece 14 has a complimentary shape to the end piece receiving portion 16 . More specifically, the frusto-conical shape of the exterior surface 28 of the end piece 14 is slightly smaller than, but in the same shape as, the frusto-conical shape of the inner surface 48 of the end piece receiving portion 16 . Thus, it can be appreciated that the end piece receiving portion 16 may selectively receive the end piece 14 therein.
[0038] Preferably, the end piece receiving portion 16 is shaped so as to selectively lock the end piece 14 therein, thus portion 16 and end piece 14 selectively interlock with one another. The design of the end piece 14 described above, thus permits it to be located securely within the end piece receiving portion 16 but also permits it to be released from the end piece receiving portion 16 .
[0039] In the depicted embodiment, the frusto-conical design of the end piece receiving portion 16 is oriented such that the first, smaller end 44 is adjacent the mouth portion 36 opening and the second, larger end 46 is adjacent the more significant volume of the bottle. Therefore, the smaller end 30 of the end piece 14 can be located into the smaller end 44 of the end piece receiving portion 16 and the larger end 32 of the end piece 14 can be located within the larger end 46 of the end piece receiving portion 16 .
[0040] It can be appreciated that the tube 12 can be located through the slot 54 of the end piece receiving portion 16 such that it can then extend through the open end of the larger end 46 of the end piece receiving portion 16 .
[0041] FIG. 4 depicts yet another embodiment of a catheter system 55 within the scope of the present invention. In one embodiment, an end piece receiving portion 56 is integrally formed and unitary with a mouth portion 58 of a bottle 60 . This end piece receiving portion 56 forms a slot 62 within the mouth portion 58 for receiving a drain tube end piece, which is not shown but it is as depicted and described above. The slot 62 connects with a substantially continuous hollow interior 64 of the portion 56 to accept the end piece.
[0042] The portion 56 is depicted as being located at a top portion 66 of the bottle 60 , however, the portion 56 may be located anywhere in the mouth portion 58 . Further, more than one portion 56 may be located in the mouth portion 58 for receiving more than one end piece.
[0043] FIG. 5 depicts yet another embodiment of the present invention wherein the end piece 14 described above is inserted into an end-piece receiving portion 68 located on another type of fluid container. In this case, the fluid container is a tray 70 . The tray 70 of FIG. 5 is substantially rectangular, but it may be of any design, including oval, circular, rectangular and/or about any other geometric design without limitation.
[0044] The end-piece receiving portion 68 is preferably of a frusto-conical, or tapered cone, design that is complimentary to the shape of the end piece 14 . More specifically, the end piece receiving portion 68 may have a first end 74 , a second end 76 , an inner surface 78 and an outer surface 80 . The inner surface 78 defines a substantially hollow interior portion 82 in the shape of a channel. A slot 84 may be located from the first end 74 to the second end 76 . The slot 84 may define the portion 68 in to two upstanding walls 85 ′ and 85 ″.
[0045] The first end 74 has a diameter that is smaller than a diameter of the second end 76 . The inner and outer surfaces 78 , 80 may be parallel to one another, but need not be. In the preferred embodiment, the end piece receiving portion 68 defines a gradually and continuously expanding inner and outer surfaces 78 , 80 from the first end 74 to the second end 76 .
[0046] The end-piece receiving portion 68 may be separate from the tray 70 . The portion 68 may be selectively attached to the tray 70 by tape, adhesive, hook and loop type fasteners, complimentary male and female connectors, clips or clamps and/or mechanical fasteners. Alternatively, portion 68 may be integrally formed and unitary with a portion of the tray 70 . By way of example, the portion 68 may be integrally formed from and unitary with a side 72 of the tray 70 , as shown in FIG. 5 .
[0047] The portion 68 may be located anywhere on or in the tray 70 . In addition, while only a single portion 68 is depicted in FIG. 5 , it can be appreciated that more than one portion 68 may be located on or in the tray 70 . Regardless of its location on or in the tray 70 , the end piece, such as item 14 described above and depicted in FIGS. 1-3 , may be engaged with the portion 68 to selectively secure the end piece 14 to the portion 68 .
[0048] FIG. 6 depicts another embodiment of the present invention. In this embodiment, a curvilinear end piece receiving portion 86 is utilized to secure the end piece 14 of a catheter. As in FIG. 5 , the portion 86 is depicted located on a tray 88 , however, the present invention also includes locating the portion 86 on trays of various sizes and shapes (as stated above) as well as on bottle-type urinals, such as that described and depicted above, any other fluid collection devices (also mentioned above).
[0049] The portion 86 may be separate from the tray 88 . The portion 88 may be selectively attached to the tray 88 by tape, adhesive, hook and loop type fasteners, complimentary male and female connectors, clips or clamps and/or mechanical fasteners. Alternatively, portion 86 may be integrally formed and unitary with any portion of the tray 88 . By way of example, the portion 86 may be integrally formed from and unitary with a side 90 of the tray 88 , as shown in FIG. 6 .
[0050] The portion 86 may be located anywhere on or in the tray 88 . In addition, while only a single portion 86 is depicted in FIG. 6 , it can be appreciated that more than one portion 86 may be located on or in the tray 88 . Regardless of its location on or in the tray 88 , the end piece, such as item 14 described above and depicted in FIGS. 1-3 , may be engaged with the portion 86 .
[0051] The portion 86 is preferably substantially curvilinear such that it forms a curlicue-type design. Preferably, the portion 86 curls in on itself so that it forms a selectively openable, central aperture 92 for receiving and retaining the end piece 14 . The portion 86 may be formed of any material, but preferably it is a flexible material than can be urged open, the end piece 14 can be inserted in the aperture 92 and then the portion 86 substantially returns to its original curvilinear design about the end piece 14 to secure the end piece 14 therein.
[0052] The curlicue portion 86 may have a connection portion 87 adjacent the container it is attached to. The portion 86 may or may not gradually taper to an end portion 89 .
[0053] The portion 86 may extend entirely about the end piece 14 one or more times, or the portion 86 may extend only partially about the end piece 14 . Regardless, the portion 86 may take on other forms as well with a more geometric design. For example, the interior and exterior surfaces may be substantially planar so as to form a J-shape or hook-type design.
[0054] FIGS. 7A and 7B depict the portion 86 ′ within a bottle type urinal 98 , which has been described above. The portion 86 ′ is substantially similar to portion 86 described above.
[0055] Preferably, portion 86 ′ is located on an upper portion 94 of the mouth portion 96 as this may assist in maintaining the portion 86 ′ out of fluid collected in the bottle 98 . While one location of the portion 86 ′ is shown in the figures, it can be appreciated that other locations are permissible. For example, the portion 86 ′ might be located on a side wall 100 of the mouth portion 96 or on a bottom portion 102 of the mouth portion 86 ′. It is also permissible for the mouth portion 96 to have one or more portions 96 adjacent one another or spaced apart from one another about the mouth portion 96 .
[0056] The portion 86 ′ may be separately formed from and then selectively attached to the mouth portion 96 of the bottle 98 . By way of example only, the portion 86 ′ may be selectively secured to the mouth portion 96 by tape, adhesive, hook and loop type fasteners, complimentary male and female connectors, clips or clamps and/or mechanical fasteners or it may be made part of the collection device.
[0057] FIG. 7B depicts an end piece 14 , such as described above, engaged with the portion 86 ′. The end piece 14 is inserted into a central aperture 92 ′, and the portion 86 ′ wraps at least partially about the end piece 14 . The portion 86 ′ selectively holds the end piece 14 so that fluid can be drained into the bottle 98 .
[0058] FIGS. 8A and 8B depict yet another embodiment of the present invention, wherein a selectively removable lid 104 is provided on a bottle 106 , such as a bottle type urinal described above. The lid 104 may be securely, but removably, engaged with the bottle 106 . The lid 104 may be formed of a polymeric material that preferably has both resilience and flexibility.
[0059] An aperture 108 may be located within the lid 104 . The aperture 108 is depicted as being located substantially centered in the lid 104 , but it may be located anywhere in the lid 104 . The aperture 108 may be comprised of two portions—a main portion 110 and a minor portion 112 . In this embodiment, the main portion 110 and the minor portion 112 are connected to one another and share a common perimeter 111 .
[0060] The main portion 110 may have a larger diameter D than a diameter d of the minor portion 112 . The larger diameter D of the main portion 110 facilities locating the end piece 14 of the catheter into the aperture 108 . Once the end piece 14 is located within the lid 104 , the drain tube 14 may be dropped down into the minor portion 112 . The end piece 14 can then be partially withdrawn through the minor portion 112 so that the exterior surface 28 of the end piece 14 can be selectively secured by inner circumference 114 of the minor portion 112 .
[0061] To withdraw the end piece 14 from the minor portion 112 , the end piece 14 may be urged slightly into the bottle 106 so that the inner diameter 114 is no longer in gripping contact with tapered exterior surface 28 of the end piece 14 . The end piece 14 may then be lifted out of the aperture 108 .
[0062] FIGS. 9A and 9B depict yet another embodiment of the present invention. In this embodiment, at least one aperture 116 is provided in a lid 118 . The lid 118 may be substantially as disclosed above, except for the cited differences. While the aperture 116 may be located anywhere in the lid 118 , in the depicted embodiment, the aperture 116 is located in a lower portion 120 of the lid 118 .
[0063] The aperture 116 has a diameter d′ that approximates the outer diameter of the exterior surface 28 of the end piece 14 . As shown in FIG. 9B , the end piece 14 may be selectively inserted into the aperture 116 to be secured within the lid 118 . The flexible nature of the lid 118 permits the end piece 14 to be removed therefrom by pulling the end piece 14 through the lid 118 . The aperture 116 expands as the larger end of the end piece 14 is withdrawn through it. The aperture 116 then returns substantially to its original size.
[0064] FIGS. 10A and 10B depict yet another embodiment of the present invention wherein a selectively removable lid 122 is provided on a container, such as a bottle type urinal described above. The lid 122 may have two apertures 124 , 126 . A first aperture 124 may have a larger diameter 128 than a diameter 130 of the second aperture 126 , however, this is not a requirement of the present invention. Further, FIG. 10A depicts the second aperture 126 above the first aperture 124 . Again, this is not a requirement of the present invention and the second aperture 126 may be located in any relationship about the first aperture 124 .
[0065] Preferably, a slot 132 connects the first aperture 124 and the second aperture 126 . The slot 132 may have a width W that is less than both of the diameters 128 , 130 of the apertures 124 , 126 .
[0066] The end piece 14 described above may interlock with the lid 122 by locating it initially through the larger diameter aperture 124 . The tube 12 may be slid up the slot 132 until it is located in the aperture 126 . Next, the end piece 14 may be withdrawn from the bottle through the aperture 126 until the diameter 130 of the second aperture 126 securely retains the end piece 14 therein.
[0067] In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiments. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.
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A catheter retaining system for a container is disclosed. The system may be utilized with a wide variety of containers for receiving catheterized fluids. Each embodiment of the system includes a structure for selectively securing at least one catheter to the container. The structure assists in maintaining the catheter in the proper location with respect to the container to minimize or eliminate spills, prevent contamination of sterile environments or the specimen, facilitate the catheterization process for patients and prevent patient embarrassment.
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BACKGROUND OF THE INVENTION
The invention relates to a roll manufactured with a light waveguide conductor (LWG-conductor), in particular for the transmission of optical signals from and to, respectively, a moving body.
In an arrangement known form DE-OS 20 12 293 a coil wound with an LWG-conductor is accommodated in a rocket-driven missile. On such coils, a large supply length of the LWG-conductor must be wound with a minimum volume, and it must be possible to unreel said conductor at high speed without loops or knots being formed.
The coil must be wound with extreme care so that an interference-free rapid unreeling process is possible. Neither in the wound condition, nor during unreeling may the optical properties of the LWG-conductor be adversely influenced. For conventionally used LWG's the radius of curvature may not be smaller than approximately 15 mm.
SUMMARY OF THE INVENTION
It is the object of the invention to ensure in a coil of the type mentioned in the opening paragraph a perfect construction of the roll and an interference-free unreeling operation. The additional attenuations resulting from the winding operation of the LWG-conductor must be as small as possible.
This object is achieved in that the LWG-conductor is wound to form a self-supporting cross-roll without a winding core.
In the arrangement according to the invention the LWG-conductor can be unreeled particularly rapidly from the inner layers of the non-rotating roll. The self-supporting cross-roll according to the invention without a winding core is a firm assembly also without a coil former. The cross-roll can be manufactured with a particularly well arranged build-up, when the LWG of the LWG-conductor comprises a sheath which in the bond of the cross-roll, in particular at the cross-points of the turns, has a flattened cross-sectional contour which is widened in the direction of the winding plane.
According to a simple solution it is ensured that the sheath of the LWG-conductor in the starting position has an elongate cross-sectional shape. A widened cross-sectional shape is automatically obtained with an additional element of approximiately the same cross-section, in particular a further LWG, is provided beside the LWG and may then also be used for the data transmission. An additional element could also consist of a particularly tension-proof synthetic resin or of a metal. Advantageously such a material is chosen which has at least approximately the same physical characteristics (E-modulus, temperature behaviour and dimensions) as the LWG.
Bulges of the wider side faces of the LWG-conductor which are directed outwards too considerably can be avoided in that the sheath is extruded with underpressure.
A simple solution is characterised in that the roll is wound with an LWG-conductor whose circular sheath has an E-modulus of smaller than 1 GPa. The originally circular sheath is deformed to the desired flat shape during the winding operation. Suitable for this purpose are materials having a low E-modulus of less than 1 GPa, for example, in particular thermoplastic polyurethane or soft polyvinylchloride.
According to a very advantageous solution it is ensured that the LWG is enveloped by a hose-like sheath with some intermediate space. The desired flat cross-sectional contour is then obtained during the winding operation even when harder materials are used for the sheath. It is to be preferred that a gel-like material should be provided between the hose-like sheath and the LWG. A gel-like mass having the known advantages permits the desired deformation of the hose-like sheath to a flat cross-sectional contour. In contrast with a fixed envelope of the LWG, smaller damping increases are caused by the last-mentioned solution. Comparatively hard materials may be used for the synthetic resin envelope, in particular, for example, polybutylene terephthalate and elastomer-modified polybutylene terephthalate. Polymides have also proved to be advantageous.
It is possible as such to additionally accomodate inside the envelope at least one pull-relief element, in particular in the form of at least one fibre-like element.
An advantageous possiblity of fixing the LWG-conductor in its position in the roll consists in that a metal wire plastically deforming during the winding operation is accomodated additionally inside the sheath.
Securing the position of the LWG-conductors in the roll is further improved in that the coefficient of friction of the sheath exceeds μ+=0.3. Moreover, the holding forces of polar materials (for example, polyurethane) may contribute to maintaining the shape of the roll.
Particularly small increases in damping of the wound LWG-conductor are obtained in that the inside spacing between two adjacent turns of LWG-conductors is the 1- to 4-fold, preferable the 1- to 2-fold of the average diameter of the LWG-conductor.
It has been found that the angle of inclination α of the LWG-conductor relative to a cross-sectional plane of the cross-roll should, for reasons of stability, be as large as possible, but on the other hand it should be as small as possible to avoid impermissible increases in damping of the LWG-conductor. It is therefore ensured that the angle of inclination α of an LWG-conductor turn relative to a cross-sectional plane of the cross-roll in each winding layer lies in the range from 2° to 30°, preferably in the range from 4° to 10°.
A manufacturing method which is advantageous for this embodiment is characterised in that, depending on the diameter of the cross-roll each time occurring during the winding operation, the angle of inclination α is adjusted as to be in the range from 2° to 30°, preferably in the range from 4° to 10°.
By means of the adjustment of the angle of inclination t is possible to manufacture also coils having a high number of layers while maintaining the above mentioned limits for the angle of inclination α. In this manner it is prevented that the angle of inclination α constantly decreases with increasing diameter of the roll so that the roll might become unstable. In the unreeling operation of the LWG-conductor from a non-rotating roll, torsions are formed in the LWG-conductor. It is therefore ensured that the LWG-conductor in the roll is wound with a torsion throughout its length. In manufacturing the roll a counter-compensating torsion is provided. Advantageously, the torsion of the roll is produced with such a small amount that the torsion produced on the LWG-conductor during the unreeling operation is compensated for only partly so that neither the wound, nor the unreeled conductor has too high a torsion.
It has further been found advantageous that the torsion is different in various radial winding layers or areas of winding layers. The angle of torsion per unit of length of the LWG-conductor decreases with increasing diameter of a winding layer.
BRIEF DESCRIPTION OF THE DRAWING
The invention will now be described in greater detail with reference to advantageous embodiments shown in the drawing, in which:
FIG. 1 is a side elevation of a cross-coil according to the invention, cut in two halves;
FIG. 2 is a sectional view of an LWG-conductor which in the initial position has a widened sheath;
FIG. 3 is a cross-sectional view of an LWG-conductor which in the initial position has a circular sheath of a soft synthetic resin;
FIG. 4 shows a cross-sectional shape adjusting in the wound condition of an LWG-conductor eneloped by a gel intermediate layer and a synthetic resin envelope.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the cross-roll shown diagramatically and not to scale in FIG. 1, the lower half shows the variation of the turns which are typical of a cross-roll of an LWG-conductor 1 which are wound with an anle of inclination α. In the longitudinal sectional view of the upper half of the broken lines denote winding planes of a multiplicity of winding layers lying radially one over the other. Cross-sectional shapes 3 of the LWG-conductor of the outermost winding layer are shown. The wider cross-sectional sides extend in the diretion of the planes of their winding layer.
When the cross-roll is accomodated in a moving body, the end 4 of the optical conductor 1 is optically coupled to a transmitter and/or receiver of the body. The end 5 is coupled, for example, to a stationary transmitter/receiver unit. The LWG-conductor is unreeled from the interior of the cross-roll in accordance with the speed of the moving body.
Particularly low dampings are obtained when a spacing of the 1-fold to 2-fold of the average conductor diameter is maintained between the two adjacent LWG-conductor turns. Values exceeding the 4-fold of the average conductor diameter do not provide any note-worthy advantage in this respect.
The angle of inclination α of the conductor turns with respect to a cross-sectinal plane of the cross-roll was adjusted in all layers at a value which differed only little from 8°. The ratio of the speed ofwinding and the speed of the axial guiding of the LWG-conductor was constantly adapted so that the angle α was kept in the range from 4° to 10°. Such adaptation may be done constantly. In the preferred embodiment it was done step-wise after the manufacture of each time a few winding layers, since a certain fluctuation range of the angle of inclination α is allowed.
FIGS. 2, 3 and 4 show on an enlarged scale various cross-sectional shapes of an LWG-conductor with respect to position 3 in FIG. 1. The LWG's 6, 7 and 8, respectively, have a diameter of approximately 250 μm, the synthetic resin coating included. They are enveloped by extruded sheaths 9, 10 and 11, respectively.
In the embodiment shown in FIG. 2 an element 13 of the same cross-sectional shape is provided in the synthetic resin sheath 11 parallel to the LWG 8. A flattened cross-sectional shape is obtained which facilitates the winding of a similar cross-roll.
This element may be a further LWG by which additional information transmission is possible. However, a glass fibre which is only tension-proof and is not suitable as a waveguide may also be used, as well as other strain relief elements, for example, Kevlar-Roings or also metal wires. Preferably elements should be used the physical characteristics of which (E-modulus, temperature behaviour and dimensions) differ from those of the LWG 8 as little as possible.
A plastically deformable metal wire has proved to be particularly suitable. Said wire maintains the winding layer of the conductor shown in FIG. 2 against the elastic recoil forces of the LWG 8 also at reversal points of the winding inclination, even when the surface of the synthetic resin sheath 11 is comparatively smooth and free of adhesive.
In order that during the extrusion of the sheath the wider side faces thereof do not arch so much outwards, it is advantageous in the embodiment of FIG. 2 to extrude with underpressure. Even inwardly directed arches may then be produced which are favourable for winding the cross-roll.
In the embodiment of an LWG-conductor shown in FIG. 3 the LWG 6 is enveloped only by a particularly soft and not too thin synthetic resin sheath which during winding the cross-roll is deformed to an elongate cross-section similar to FIGS. 2 and 4, so that at least approximately equally good winding results are obtained as in an elongate cross-sectional shape present already originally.
Synthetic resins having an E-modulus of less than 1 GPa have proved to be particularly suitable for the sheath 9. Therefore, in particular thermoplastic polyurethane or soft polyvinyl chloride was used.
Outside diameters of less than 1 mm are to be preferred for the sheath 9. Of course, when the LWG-conductors are too thick, the length of the conductor to be provided in a unit by volume of a cross-roll is small.
In the FIG. 4 embodiment more rigid sheaths 10 may be used, since the flexibility of the cross-sectional shape is achieved by a gel-like intermediate layer 12 which additionally prevents the damping increases of the LWG.
FIG. 4 shows the resulting cross-sectional shape in the cross-roll. Originally, a circular synthetic resin sheath 12 concentrically enveloping the LWG 7 was provided around the said LWG by extrusion.
When the coefficient of friction of the sheath 9 of the sheath 10 exceeds μ=0.3, the cross-roll also coheres readily without a coating of adhesive on the conductors and can be unreeled without disturbances at high speed.
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The invention relates to a roll manufactured with a light waveguide conductor (LWG-conductor), in particular for the transmission of optical signals from and to, respectively, a moving body. A perfect winding construction from which the conductor can be unreeled without interference is obtained in that the LWG-conductor (1) is wound to form a self-supporting cross-roll without a winding core.
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BACKGROUND
[0001] The production of electrical energy from electrical energy from the surroundings without utilizing a utilization of a battery is a form of energy harvesting. Energy harvesting also known as power harvesting or energy scavenging is a process by which energy is captured and stored. Energy harvesting makes it possible to drive electrical systems without the necessity of battery or a more restrictive accumulator. Energy harvesting systems conventionally use thermal electricity or mechanical vibrations which are converted to electric energy.
[0002] Some electrical generating systems make use of reciprocating magnet movement through one or more coils. The movement of a magnet through a conductive coil induces a current flow in the coil. The coupling of the mechanical energy through an inert mass is usually done by means of a mechanical feather or spring. If the magnet is moved back and forth in a reciprocating motion, the direction of current flow in the coil will be reversed for each successive traverse, yielding an AC current.
[0003] Another form of energy harvesting systems is provided for harvesting energy from the environment or other remote surfaces and converting it electrical energy. This type of harvester relies on another source of the magnetic field or the earth's magnetic field that is external to the harvester. The harvester in this case does not contain a permanent magnetic or other local magnetic field source. Harvesters of this type may be smaller and lighter than an energy harvester that contains the magnet. Additionally, by having an external magnetic field they do not require vibrational energy.
[0004] For these and other reasons, there is a need for the present invention.
SUMMARY
[0005] An energy harvesting system in accordance with disclosed embodiments includes a rotatable member with an electrically conductive coil mounted to the rotatable member and adapted to move with the rotatable member such that the movement of the coil through a magnetic field induces a voltage in the coil. An energy storage device is coupled to the coil.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification. The drawings illustrate the embodiments of the present invention and together with the description serve to explain the principles of the invention. Other embodiments of the present invention and many of the intended advantages of the present invention will be readily appreciated as they become better understood by reference to the following detailed description. The elements of the drawings are not necessarily to scale relative to each other. Like reference numerals designate corresponding similar parts.
[0007] FIG. 1A is a block diagram conceptually illustrating an embodiment of an energy harvesting system.
[0008] FIG. 1B is a block diagram conceptually illustrating an embodiment of an energy harvesting system.
[0009] FIG. 1C is a block diagram conceptually illustrating an embodiment of an energy harvesting system.
[0010] FIG. 2 is a block diagram conceptually illustrating aspects an embodiment of a tire system including an energy harvesting device.
[0011] FIG. 3 is diagrammatic representation illustrating aspects an embodiment of a tire system including an energy harvesting device.
[0012] FIG. 4 is a diagrammatic representation illustrating aspects an embodiment of a tire system including an energy harvesting device.
DETAILED DESCRIPTION
[0013] In the following Detailed Description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the Figure(s) being described. Because components of embodiments of the present invention can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.
[0014] FIGS. 1A-1C are block diagrams illustrating aspects of an energy harvesting system in accordance with embodiments of the invention. The system for which energy is supplied may be any device which requires energy and is subject to some degree of movement and rotation, for example, a tire sensor mounted inside a tire. The disclosed energy harvester may be applicable in situations where it is not easy to access other types of power, although its application can be anywhere energy harvesting is sought. The energy harvester provides for conversion of magnetic energy to electrical energy.
[0015] FIG. 1A is a block diagram illustrating an implementation of an energy harvesting system 10 in accordance with embodiments of the invention. FIG. 1A illustrates a magnetic field 12 , such as the Earth's magnetic field, applied to an energy harvester 14 . Electrical energy generated by the energy harvester may be applied to an electronic device or system 16 to be powered and/or an energy storage device 18 . The energy harvester 14 provides electrical energy to the system 16 such as a tire pressure gauge mounted to a tire, for example. The energy storage device 18 stores the electrical energy generated by the energy harvester 14 . The energy storage device 14 may be a capacitor or battery, for example. The energy storage device 18 stores energy for future use by the system 16 .
[0016] FIGS. 1B and 1C illustrate further embodiments. In FIG. 1B , the energy harvester 14 is connected to the energy storage device 18 , which supplies power to the system 16 . FIG. 1C illustrates a diagrammatic representation of an energy harvesting system according to another embodiment. An outside magnetic field source is applied to the energy harvester. Electrical energy generated is then sent to the system for use.
[0017] FIG. 2 is a block diagram illustrating an energy harvesting system, similar to that illustrated in FIGS. 1A-1C , where the energy harvesting system is implemented with a tire. Many different types of wheeled vehicles use pneumatic tires (in this specification, the term tire generally refers to a pneumatic tire). Typically, a tire is mounted on the rim of a wheel, which is mounted to a vehicle.
[0018] Sensor devices exist for providing information about the tires of a wheeled vehicle. Features such as automatic stability and traction control in cars have made it necessary to obtain information about the interaction between the tires and the road surface. Such information is available from several sources, including ABS sensors, tire pressure measurement systems, and accelerometers and gyros located in the vehicle. Such sensors require an energy source to power the device, which is typically a battery. Eliminating the battery as the energy source for tire-mounted sensors, or providing an energy source for charging the battery is desirable from cost, reliability and environmental standpoints.
[0019] FIG. 2 conceptually illustrates the system 100 implemented with a tire 110 . The magnetic field 12 is applied to the tire system 110 inclusive of the energy harvester 14 . Energy generated by the tire's energy harvester 14 is supplied to an energy storage device 18 and/or the system 16 being powered, such as a tire sensor device. As illustrated in FIGS. 1A-1C , the harvested energy can be applied both the storage device 18 and powered system 16 , serially to the energy storage device 18 and then to the system 16 , or applied directly to the system 16 , for example.
[0020] FIG. 3 illustrates further aspects of an embodiment of the system 100 . Energy harvester 14 includes an electrically conductive coil 114 situated inside the tire 110 . The coil 114 is connected to the system to be powered 16 (such as a tire sensor) and/or an energy storage device 18 as illustrated in FIGS. 1 and 2 . The tire 110 containing the electrically conductive coils 114 rotates as indicated by the arrow 120 .
[0021] As the tire 110 rotates relative to the magnetic field source 12 , which is the earth's magnetic field or other suitable magnetic field source, the coil 114 cuts through the magnetic field 12 as the orientation of coil 114 changes from vertical to horizontal and horizontal to vertical, inducing an electrical current in the coil 114 . The magnetic flux Φ created as the tire rotates can be calculated by
[0000] Φ=BA
[0000] where B is the strength of the magnetic field 12 and A is the cross-sectional area defined by the coil 114 . As the tire 110 rotates, the cross-sectional area A as a function of time is
[0000] A=nr o 2 cos φ=A o cos ωt
[0000] where r o is the radius of the coil 114 (which is about equal to the cross-sectional radius of the tire 110 depending on the manner in which the coil 114 is mounted to the tire 110 ), φ is the change in angular position of the coil 114 , and φ is the angular velocity of the tire. The driving speed v of the tire 110 having a radius r is
[0000] v=ωr
[0000] and thus, the induced voltage V ind as a function of time is
[0000]
V
ind
=
-
n
/
t
Φ
=
-
n
B
/
t
A
(
t
)
=
nBA
o
v
/
r
sin
(
tv
/
r
)
[0000] where n is the number of turns in the coil 114 . For example, if the Earth's magnetic field is estimated at 30 μT and the following values are assumed:
r o =0.1 m r=0.2 m v=60 km/h≈20 m/s n=100 turns
a voltage having an amplitude of about 100 mV with a frequency of 100 Hz is induced. The energy generated in this manner is supplied to the energy storage device 18 and/or directly to the system 16 .
[0026] The conductive coil 114 can be mounted on the inside surface of the tire 110 , or even embedded into the material of the tire 110 . In the embodiment illustrated in FIG. 3 , the coil 114 defines an axis that is generally parallel to a line tangent to the tire 110 —the coil 114 is generally coaxial with the cross-section of the tire 110 . The coil 114 includes a predetermined number of turns based on the particular device or system 16 to be powered.
[0027] FIG. 4 is another embodiment of a tire system 100 including an energy harvesting device 14 , similar to FIG. 3 . In this embodiment, the energy harvester 14 includes an electrically conductive coil 214 with an axis 228 generally radial to an axis of rotation 218 of the tire 110 . The tire 110 , containing the coils 214 , rotates as indicated by the arrow 120 , relative to the magnetic force 12 . The induced voltage V ind is a function of time, as previously described and illustrate with reference to FIG. 3 .
[0028] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof.
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An energy harvesting system and method includes a rotatable member with an electrically conductive coil mounted to the rotatable member and adapted to move with the rotatable member such that the movement of the coil through a magnetic field induces a voltage in the coil. An energy storage device is coupled to the coil.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional application No. 60/258,395 filed Dec. 27, 2000.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to railroad cars and, more particularly, to jackets for tank cars and roofs for hopper cars.
[0003] Rail car fabrication is a labor intensive process and generally requires numerous weld operations. While at least some welding processes are now automated, e.g., for welding sheets, even automated welding processes require proper set-up of numerous sheets of steel and experienced operators to ensure high quality welds are made by the automated equipment.
[0004] Components for rail cars such as tank cars and hopper cars are fabricated by welding steel plates together into a desired configuration. For example, some tank cars require insulation on an outer surface of the tank, and an outer jacket is utilized to contain and protect the insulation. The outer jacket typically is fabricated by welding numerous steel plates together. Although the actual welding is performed by automated machinery, the set-up operations are labor intensive. In addition, experienced welders typically must closely supervise the automated weld process to ensure proper welding.
[0005] Similarly, for a hopper car, the hopper car roof is formed by welding a plurality of steel plates together. The sides are then welded to a car cylindrical body, and the roof is located over the sides and welded thereto. Again, the extensive welding required to form the hopper car roof is time consuming and labor intensive.
BRIEF DESCRIPTION OF THE INVENTION
[0006] Methods and systems for fabricating spiral welded cylinders that are particularly well suited for rail car components are described herein. In an exemplary embodiment, a method for fabricating a cylindrical body utilizing a continuous weld includes the steps of feeding a source material including a first edge and a second edge from a coil and straightening at least a portion of the source material. The first edge is offset and the material is fed into a spiral mill so that the material forms a cylinder, or a cylindrical body. The material second edge is positioned adjacent the first edge, and a continuous weld at the interface maintains the material in the formed cylinder. The weld is sometimes referred to herein as a spiral weld because the continuous weld extends along the cylinder in a spiral path.
[0007] To fabricate a jacket for a tank car, for example, a longitudinal cut is made in the cylindrical body so that the cut ends can be spread apart. Additionally, a plurality of jackets can be fabricated from a single cylindrical body by making a plurality of longitudinal cuts. The body, or jacket, is then positioned over and secured to the tank. To fabricate a roof for a hopper car, two longitudinal cuts are made to the cylindrical body at select location to provide an arc shaped roof. The roof is then secured to side walls of the hopper car.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a side plan view of a system for forming a cylindrical body using a continuous weld.
[0009] [0009]FIG. 2 is a top plan view of the system shown in FIG. 1.
[0010] [0010]FIG. 3 is a perspective plan view of one embodiment of a spiral welder.
[0011] [0011]FIG. 4 is a perspective top view of a jacket for a tank car.
[0012] [0012]FIG. 5 is a front view of the jacket shown in FIG. 4.
[0013] [0013]FIG. 6 is a perspective view of a spiral welded roof for a hopper car.
[0014] [0014]FIG. 7 is an end view of the roof shown in FIG. 6.
[0015] [0015]FIG. 8 is an exploded detailed view of the spiral welded roof and hopper car shown in FIGS. 6 and 7.
DETAILED DESCRIPTION OF THE INVENTION
[0016] [0016]FIG. 1 is a side plan view and FIG. 2 is a top plan view of a system 10 for forming a cylindrical body using a continuous weld. System 10 includes a peeler 12 in series configuration with a coil 14 of a metal source material 16 . Peeler 12 prevents coil 14 from freely unwrapping. System 10 further includes a first drive roller 18 in series configuration with peeler 12 , a straightener 20 in series configuration with roller 18 , and a splicing assembly 22 also in series configuration with roller 18 . System 10 further includes an offsetter 24 in series configuration with roller 18 , and a second drive roller 26 in series configuration with offsetter 24 . Coil 14 , peeler 12 , roller 18 , straightener 20 , splicing assembly 22 , offsetter 24 , and roller 26 are mounted on a pivoting mounting surface 28 . System 10 further includes a spiral welder 30 in series configuration with roller 26 , a cylinder fixture 32 in series configuration with welder 30 , and a cutter 34 in series configuration with fixture 32 . Material 16 includes a first edge 36 and a second edge 38 .
[0017] During operation of system 10 , material 16 is fed through peeler 12 to first drive roller 18 and first drive roller 18 is engaged such that first drive roller 18 can drive or push material 16 . First drive roller 18 pushes material 16 through straightener 20 and splicing assembly 22 to offsetter 24 . Offsetter 24 offsets at least one of first edge 36 and second edge 38 before material 16 is pushed to second drive roller 26 . Second drive roller 26 is engaged such that second drive roller 26 can drive or push material 16 to spiral welder 30 which welds material 16 into a cylinder 40 and cylinder fixture 32 supports and transports cylinder 40 . Cutter 34 cuts cylinder 40 when a length (not shown) of cylinder 40 is at a desired length.
[0018] In an exemplary embodiment, cutter 34 is a plasma torch, such as, for example, a Hypertherm Max 100 system, available from Hypertherm Inc. of Hanover N.H. In an alternative embodiment, cutter 34 is a metal cutting laser. It is contemplated that the benefits of the invention accrue to systems utilizing all methods of cutting metal, including metal cutting bandsaws and metal cutoff wheels.
[0019] In an exemplary embodiment, offsetter 24 utilizes a joggle joint die to offset at least one of first edge 36 and second edge 38 . When material 16 reaches second drive roller 26 , first drive roller 18 is disengaged and not utilized to push material 16 further. Additionally, straightener 20 is typically utilized only at the beginning and the ending portions (not shown) of coil 14 . Accordingly, straightener 20 can be disengaged. In an exemplary embodiment, straightener 20 is a three over two straightening table that utilizes three rollers above material 16 and two rollers below material 16 and second drive roller 26 pushes material 16 to spiral welder 30 at a helix angle (not shown) from 90° to a longitudinal axis 42 of cylinder 40 . The helix angle is between approximately 6.5° and approximately 13.3° to provide a diameter (not shown) of between approximately 96″ and approximately 132″ for cylinder 40 utilizing material 16 having a width (not shown) between approximately 48″ and approximately 64″. The helix angle is adjusted by pivoting surface 28 along an arc 44 .
[0020] [0020]FIG. 3 is a perspective plan view of one embodiment of spiral welder 30 including an automatic submerged arc welder 50 including a weld head 52 , a flux dispenser 54 , a flux supply 56 , and a movable mount 58 . Spiral welder 30 further includes a seam tracker 60 in series configuration with arc welder 50 . Seam tracker 60 is electrically connected to a controller 62 that controls arc welder 50 . Spiral welder further includes a vacuum 64 in series configuration with arc welder 50 opposite seam tracker 60 . Vacuum 64 includes a vacuum nozzle 66 to vacuum loose flux (not shown) from weld 68 . A scraper 70 to scrap hardened flux (not shown) from weld 68 is in series configuration with vacuum nozzle 66 . Spiral welder 30 further includes monitor 72 in series configuration with seam tracker 60 . Monitor 72 monitors a width (not shown) of a gap 74 between first edge 36 and second edge 38 . In addition, monitor 72 controls the helix angle such that the width of gap 74 is substantially uniform. Also, in an exemplary embodiment, a person, i.e., an operator, watches the width of gap 74 and manually actuates a gap control for swing arm 44 and makes active adjustments to the welding process.
[0021] Spiral welder 30 includes a spiral mill (not shown) that material 16 passes through. Because of the helix angle and the spiral mill, material 16 is wrapped in a helix and first edge 36 is positioned next to second edge 38 as best seen in FIG. 2. In an exemplary embodiment, the spiral mill is a spiral mill from the PRD Company of Hayward Calif. and automatic submerged arc welder 50 is an automatic submerged arc welder available from the Lincoln Electric Company of Cleveland Ohio. Seam tracker 60 is a Cyclomatic seam tracker from ITW Welding Automation of Appleton Wis. Vacuum 64 is a vacuum from the American Vacuum Company of Skokie Ill.
[0022] During operation of spiral welder 30 , a portion 76 of gap 74 rotates beneath monitor 72 which monitors the width of portion 76 and transmits a signal to a motor 78 configured to pivot mounting surface 28 (shown in FIG. 1) about arc 44 (shown in FIG. 2) such that the width of gap 74 is substantially uniform. Portion 76 then rotates beneath seam tracker 60 which tracks a seam (gap 74 ) and transmits a weld location signal to controller 62 which positions arc welder 50 accordingly. In an exemplary embodiment, arc welder 50 is mounted with a plurality of orthogonal sliding members 78 providing a two dimensional positioning capability. Portion 76 then rotates under flux dispenser 56 which dispenses an amount of flux (not shown) such that weld head 52 is submerged in flux and weld held 52 fabricates weld 68 . Portion 76 then rotates under vacuum nozzle 66 which vacuums loose flux. Portion 76 then rotates under scraper 70 which scraps hardened flux from weld 68 . The hardened flux falls into a chute leading to a trash dumpster (not shown). Accordingly, cylinder 40 is fabricated until the length is at a desired length and second drive roller 26 (shown in FIG. 2) is stopped while cutter 34 (shown in FIG. 2) rotates around cylinder 40 cutting cylinder 40 . In an exemplary embodiment, cylinder 40 is cut in a plane normal to cylinder 40 . In an alternative embodiment, cylinder 40 is cut in a plane other than normal to cylinder 40 . Accordingly, a cylindrical body is formed with a continuous weld.
[0023] After forming a plurality of bodies with continuous welds, coil 14 is exhausted of material 16 . Material 16 is pulled from coil 14 until an end portion (not shown) is positioned at splicing assembly 22 . A new coil (not shown) of material 16 replaces coil 14 and a beginning end (not shown) is fed through peeler 12 to first drive roller 18 and first drive roller 18 is engaged such that first drive roller 18 can drive or push the beginning end through straightener 20 to splicing assembly 22 . The beginning end is then joined to the end portion providing a continuous source of material 16 . In an exemplary embodiment, splicing assembly 22 includes a plasma torch (not shown) and a clamp welder (not shown). The plasma torch is utilized to trim the beginning end and the end portion. The trimmed beginning end is butted against the trimmed end portion and both are clamped down and welded together. Accordingly, a continuous source of material 16 is provided.
[0024] In an exemplary embodiment, material 16 is flexible gauge 11 steel, such as, for example, American Society for Testing and Materials (ASTM) A607 grade 50, ASTM A569 grade 50, ASTM A36, and ASTM A570 grade 50. Accordingly, cylinder 40 is deformable under its own weight and fixture 32 (shown in FIG. 1) includes a plurality of side supports 80 to limit the deformation of cylinder 40 while supported in fixture 32 .
[0025] [0025]FIG. 4 is a perspective top view of a jacket 90 for a tank car (not shown). Jacket 90 is fabricated by making a cylindrical body 92 with a continuous weld 94 , as explained above, and cutting a longitudinal cut 96 and at least one cutout 97 in cylindrical body 92 . In an exemplary embodiment, continuous weld 94 is an outer fillet weld and an automated plasma torch (not shown) traverses a longitudinal path underneath cylindrical body 92 cutting longitudinal cut 96 . Longitudinal cut 96 allows a radius 98 to be increased, as explained below, to facilitate applying jacket 90 to the tank car. In an exemplary embodiment, an interior surface (not shown) is painted except for an approximately three foot wide longitudinal strip in a bottom portion (not shown) of cylindrical body 92 .
[0026] [0026]FIG. 5 is a front view of jacket 90 lifted in an anti-overspread beam 110 including a plurality of restricting arms 112 . Anti-overspread beam 110 further includes a plurality of chain mounts 114 for mounting a plurality of chains 116 including chain hooks 118 that hook on a plurality of edges 120 of jacket 90 .
[0027] During operation, two beams 110 are positioned over jacket 90 and chain hooks 118 are attached to edges 120 , beams 110 are placed one at each end (not shown) of jacket 90 . When beams 110 are raised, hooks 118 apply a force to edges 120 that causes radius 98 to distort from a normal state 122 to an enlarged state 124 . Restricting arms 112 contact jacket 90 in enlarged state 124 at contact points 126 preventing jacket 90 from inverting to an inside out state (not shown). Enlarged state 126 has a radius 98 greater than a radius (not shown) of the tank car including a layer of insulation (not shown).
[0028] An angle (head angle) is applied to a head (not shown) of the tank car to align jacket 90 with a first half (not shown) of the tank car and then jacket is positioned on the first half. Beams 110 are lowered allowing jacket 90 to return to normal state 122 and hooks 118 are removed from edges 120 . Accordingly, edges 120 are free to wrap around the tank car. After jacket 90 is applied to the tank car, jacket 90 is tightened around the tank car and a second jacket (not shown) is applied to a second half (not shown) of the tank car similarly. In an exemplary embodiment, second jacket overlaps jacket 90 . After the second jacket is tightened around the tank car, jacket 90 and the second jacket are fillet welded together and edges 120 are welded together on both jacket 90 and second jacket with an outer fillet weld. Jacket 90 and the second jacket are then welded to the tank car at a plurality of inlet nozzles (not shown), a plurality of attachment flashings (not shown), and a plurality of tank car heads (not shown). In an exemplary embodiment, jacket 90 is a jacket for a train tank car. In an alternative embodiment, jacket 90 is a jacket for a truck tank car.
[0029] [0029]FIG. 6 is a perspective view of a spiral welded roof 140 for a hopper car (not shown in FIGS. 1 - 6 ). Roof 140 is fabricated by making a cylindrical body 142 with a continuous weld 144 , as explained above, and cutting a plurality of longitudinal cuts 146 on both sides 148 of roof 140 . In an exemplary embodiment, cylindrical body 142 has four longitudinal cuts 146 and, accordingly, four roofs 140 are fabricated from cylindrical body 142 . Continuous weld 144 is an inner butt weld and an outer butt weld. Roof 140 includes at least one cutout 150 for hatch rings (not shown).
[0030] [0030]FIG. 7 is an end view of roof 140 attached to a hopper car 160 including a plurality of wheels 162 , two bulkheads 164 (one shown in FIG. 7), and two sidewalls 166 . To attach roof 140 to car 160 , roof 140 is positioned over bulkheads 164 and extending over sidewalls 166 creating an extension area 168 . Roof 140 is then welded to bulkheads 164 and sidewalls 166 . More specifically, and referring to FIG. 8, hopper car 160 includes a side wall 170 with a top chord 172 attached at a top portion 174 of side wall 170 . Roof 140 attaches to hopper car 160 via top chord 172 . In other words, top chord 172 is attached to side wall 170 and then roof 140 is also attached to top chord 172 . Accordingly, a roof for a hopper is fabricated from a cylindrical body using a continuous weld and the roof is attached to a hopper car.
[0031] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
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A method for forming a cylindrical body utilizing a continuous weld is provided. The method includes feeding a source material including a first edge and a second edge from a coil and offsetting at least one of the first edge and the second edge. The method further includes spiraling the material to form a cylinder, welding the first edge and the second edge together forming a continuous weld, and cutting the cylinder to a selected length. To fabricate a jacket, a longitudinal cut is made in the cylindrical body, at least one cutout is cut, and the continuous weld is an outer fillet weld.
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BACKGROUND OF THE INVENTION
This invention relates to a wire enclosure and in particular to a lockable wire enclosure and a locking mechanism therefor.
Lockable wire enclosures are well known in the prior art and are conventionally used for securely storing valuable materials, such as packages, tools, valuable parts, medicines, and the like.
Conventionally, wire enclosures have been used for such storage since the stored items are fully visible so that inventory control is facilitated. Additionally, the stored items are accessible to airflow and to light for improved storage. Such secure storage prevents pilferage of the stored items, while still enabling authorized persons to access the materials. Many of such prior art wire enclosures are mounted on wheels or casters for ease of movement of the materials from place to place. Conventionally, the walls of such enclosure are made of a heavy-duty gauge wire mesh. While some prior art enclosures include a slidable front door, the more common arrangement is to have two hinged front doors. Conventionally also, the enclosures are provided with one or more wire mesh shelves.
Such prior art enclosures or security carts have used a variety of locking mechanisms to securely lock the doors in order to prevent access except to authorized persons. In some prior art enclosures, heavy-duty metal frames are provided, including conventional catalog locking arrangements for locking the door to the frame of the enclosure. A problem with such arrangements has been that the door is not securely locked to either the bottom wall nor to the top wall of the enclosure. This creates a problem in that the door may be forced away from the top wall or the bottom wall whereby unauthorized persons have access to the contents of the enclosure, while the door is still locked.
In other prior art arrangements, the doors have been made of solid metal or other solid materials such as wood. While this creates a more secure enclosure, the disadvantage of this arrangement is that visibility of the contents of the enclosure has been sacrificed to greater security.
Other prior art locking arrangements have also been used but these all have the disadvantage that the arrangements are expensive and therefore less desirable.
It is therefore desired to provide a wire mesh enclosure and a secure locking arrangement therefor.
In particular, it is desired to provide a wire mesh enclosure which may be securely locked while at the same time securing the doors to both the wire mesh top wall and the wire mesh bottom wall of the enclosure.
SUMMARY OF THE INVENTION
The present invention provides a wire mesh enclosure wherein the door or doors may be locked and, at the same time, securing the door(s) to both the top wall and the bottom wall of the enclosure by means of a locking mechanism.
The invention further comprises a wire enclosure which may be securely locked by means of a locking mechanism which includes a latch. A rod-like member is rotatably attached to one of the doors and is also slidable in a vertical direction relative to the door. The rod-like member includes hook members at both its top and bottom. The top wall and the bottom wall of the enclosure both include engaging hooks. The rod-like member, in the closed position of the door, may be rotated whereby the hook members engage the hook engaging members of the top and bottom enclosure walls and securely lock the door to the top wall and bottom wall. The rod-like member may also be raised to place the rod-like member in a latched position. The rod-like member may then be locked in position by means of a padlock or the like.
The invention also comprises a top wall, a bottom wall, first and second walls, and a door hingedly secured to the first side wall. A locking member is movably secured to the door. The locking member has one end. The engagement member is disposed on either the top wall or the bottom wall. Therefore, when the door is closed, the locking member may be moved to a locking position so that the end of the locking member engages with the engagement member and secures the door to one of the top wall and the bottom wall.
The invention still further comprises a wire enclosure having a top wire mesh wall, a bottom wire mesh wall, first and second wire mesh side walls, and first and second doors. The doors are hingedly secured to respectively the first and second side walls. A locking member is rotatably secured to the first door. The locking member has two ends. First and second engagement members are disposed respectively on the top wall and the bottom wall. When the door is closed, the locking member may be rotated to a locking position so that the two ends of the locking member engage with respectively the first and second engagement members and thereby secure the doors to both the top wall and the bottom wall.
The invention also comprises a latching mechanism for a wire enclosure. The wire enclosure includes a top wall, a bottom wall, and first and second hinged doors. A locking member is rotatably secured to the first door. The locking member includes two hooks. First and second engagement members are secured to both the top and bottom walls so that, when the door is closed, the locking member may be rotated and the hooks engage with the engagement member so thereby secure the door to both the top wall and the bottom wall.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent, and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a perspective view of a security cart according to the invention;
FIG. 2 shows the cart of FIG. 1 with the doors in the open position and the top wall hinged upwardly;
FIG. 3 is a perspective view of a wire enclosure according to the invention showing one of the doors in the open position;
FIG. 4 shows the wire enclosure of FIG. 3 with both doors closed and the locking mechanism in the latched position;
FIG. 5 shows an enlarged partial view of the locking mechanism according to the invention; and
FIG. 6 shows an enlarged top view of the front area of the wire enclosure of FIG. 3 with the top hook member engaged with the top engaging hook.
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one preferred embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , a wire enclosure 10 is shown which includes a top wall 12 , a bottom wall 14 , side walls 16 and 18 , and a back wall 20 . Two doors are shown hingedly respectively connected to the two side walls by means of six hinges, three of which are shown on each side of the enclosure. The enclosure is also provided with a bottom frame 28 and four casters so that the enclosure is a security cart. Casters 26 are optional for a stationary enclosure. Each of the walls and doors of the enclosure comprises a tubular steel frame and a heavy wire mesh which is welded to the frame. In the preferred embodiment, the round frame tubing is 1¼″ 11 gauge, and the wire mesh is made of 1″ 16 gauge wire. The base frame square tube is 1¼″ 16 gauge steel with 1″×4″ reinforced steel rod.
Referring to FIG. 2 , two shelves 38 are shown. The shelves may also be made of heavy wire mesh or may be made of other materials such as wood. As further shown in FIG. 2 , the top wall 12 is hingedly connected to the back wall by means of two hinges 36 . These hinges may be loops at the ends of two wire members of the top wall wire mesh.
While each of the walls of the enclosure are made of a wire mesh material, it should be understood that any one or more of these walls may be constructed of a solid material such as, for instance, sheet steel material or wood. However, for ease in conducting a visual inventory of the contents of the enclosure, it is preferable that the walls are made of a wire mesh.
Referring now to FIGS. 1 , 2 , 5 and 6 , a locking member 44 is provided on door 22 . The locking member is shown as a rod-like member 44 which has hooks 50 and 52 , respectively, at its top and bottom. Locking member 44 is rotatably secured to door 22 by means of three ferrules 46 . Member 44 is not only rotatable in ferrules 46 but can also be moved up and down with respect to those ferrules, as seen in FIG. 2 . By referring to FIG. 5 , it can be seen that member 44 includes a handle 58 which is welded at 60 to member 44 . Further, it can be seen that the top portion of the handle 64 , in the position of FIG. 5 , rests on ferrule 46 while the bottom portion of the handle 72 is located at a distance 62 below ferrule 46 . Locking member 44 can therefore not only rotate relative to ferrule 46 but can also be moved up a distance 62 relative to ferrule 46 . As best seen in FIG. 5 , door 24 includes a latch holder 68 which is welded to tubular member 32 b of door 24 . A latch 66 is welded to latch holder 68 . It should also be noted that, while two doors are shown in the embodiment of FIGS. 1-6 , one door could be used.
In operation, as best seen by referring to FIGS. 3 , 4 and 6 , the two doors are shown in the open position of FIG. 3 . It should be noted that for the sake of simplicity the mesh of the walls and doors of the enclosure is not illustrated in either FIGS. 3 and 4 . Further, it can be seen that the enclosure of FIGS. 3 and 4 does not include casters. Top wall 12 includes a hook 54 which is formed from the end of a wire member of the top wall wire mesh. Similarly, bottom wall 14 includes a hook 56 , shown here as a wire loop. Hook 56 is shown as a loop but may be an open hook similar to hook 54 . Similarly, hook 54 may be a closed loop similar to hook 56 .
FIG. 4 shows the doors 22 and 24 in the closed and latched position. To achieve this latched position, door 24 is closed, door 22 is closed, and thereafter locking member 44 is lifted a distance equal to or smaller than distance 62 , while handle 58 is rotated, so that hook 50 engages hook 54 , and hook 52 engages hook 56 . Thereafter, handle 58 is moved downwardly into the position of FIG. 5 , assisted by gravity, whereby handle 58 will be latched behind latch 66 . In this position, it can be seen that locking member 44 securely engages top wall 12 and bottom wall 14 , thereby securing the bottom wall 14 and the top wall 12 to door 22 and latching door 22 to door 24 by means of latch member 66 . As shown in FIG. 6 , a padlock 70 can then be used to lock latch holder 68 and handle 58 together so that doors 22 , 24 and walls 12 and 14 are all securely locked together. The enclosure is now securely locked. To open doors 22 and 24 , the procedure is reversed.
While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
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A lockable wire mesh security and closure including a locking member which engages and locks to both the top wall and the bottom wall of the enclosure. The locking member can be latched into position and locked in place to securely lock the enclosure.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a data input apparatus, and more particularly, to a position coordinates signal detecting circuit of a sensor panel for sensing position coordinates at which contacts occur.
2. Description of the Related Art
As information terminals become smaller in size and larger in functional complexity, the types of input devices for providing data And information to the information terminals become more varied. For example, one input apparatus that is widely used for providing input commands or characters is a sensor panel coated with a resistance component. In such a device, characters and information are entered by pressing on the sensor panel at particular predefined locations. By detecting the position at which a contact is made on the panel, the system can determine the desired input. To that end, sensor panels typically include detection circuitry for detecting the locations of contacts.
In one example of such a position coordinates signal detecting circuit of a sensor panel, the position at which a contact occurs is detected by detecting the pairs of voltages at both ends of series resistances connected to the four edges of the sensor panel. The sensor panel resistances are driven by applying a driving signal of the same level through the connected resistors. Since the pairs of voltages on both sides of the contact point change according to the position of the contact point, it is possible to display the position of the point at which the contact occurred as coordinates by detecting the pairs of voltages at both ends of the resistors.
In conventional technology, four differential amplifiers are used for a position coordinates signal detecting circuit in order to separately amplify the pairs of voltages at the ends of the resistors connected to the respective edges. Also, variable resistors are generally used for the resistors connected to the respective edges of the sensor panel in order to correct internal impedance mismatching at the respective corners of the sensor panel.
In the position coordinates signal detecting circuit using four differential amplifiers, it is desirable that the characteristics of the differential amplifiers connected to the respective edges be identical to provide accurate position detection in the sensor panel of the location at which a contact occurred. That is, the respective differential amplifiers should generate the same level of output signals in a common mode and the amplification of the respective differential amplifiers should be the same. However, it is difficult to make the characteristics of the differential amplifiers identical, due to manufacturing processes. Accordingly, position coordinates of the point at which contacts occur may not be precisely detected due to the difference between the characteristics of the differential amplifiers.
FIG. 1 contains two waveforms labelled (a) and (b) which illustrate a signal output by differential amplifiers when there is no contact in the sensor panel i.e., in the common mode, under two conditions. For these waveforms, it is assumed that the impedances at the respective edges of the sensor panel are the same. Waveform (a) is an output waveform showing output characteristics of the four differential amplifiers in the common mode when the amplifier characteristics are different. Waveform (b) is an output waveform showing the output characteristics of the four differential amplifiers in the common mode when the amplifier characteristics are identical.
In a conventional position coordinates detecting circuit of a general sensor panel using four differential amplifiers, the output signals of the four differential amplifiers are multiplexed so that the output signal of the differential amplifier corresponding to a selecting signal is generated. For example, in one general conventional sensor panel, the output signals of the differential amplifiers connected to the left upper edge, the left lower edge, the right upper edge, and the right lower edge of the sensor panel are output from sections T 1 , T 2 , T 3 , and T 4 , respectively, in response to a selecting signal. When the output characteristics of the four differential amplifiers are identical in the common mode, signals having the same levels are output from the sections T 1 through T 4 , in which the output signals of the respective differential amplifiers are selectively output as shown in waveform (b) of FIG. 1 .
In actuality, because of fabrication process deviations, it is very difficult to achieve the desired result that the output characteristics of the differential amplifiers are identical in the common mode. Accordingly, the levels of the output signals of the four differential amplifiers selectively output from the sections T 1 through T 4 are different from each other as shown in waveform (a) of FIG. 1 . Therefore, in a conventional position coordinates signal detecting circuit, it is difficult to precisely detect position coordinates of the point on the sensor panel at which contacts occur.
Also, in a conventional position coordinates signal detecting circuit, not only the output characteristics in the common mode, but also the amplifying degrees of the differential amplifiers may be different from each other due to the process deviation. In this case, since the signals output from the respective edges of the sensor panel are amplified to different amplifications, the position at which the contact actually occurred cannot be precisely detected.
SUMMARY OF THE INVENTION
To solve the above problems, it is an object of the present invention to provide a position coordinates signal detecting circuit of a sensor panel having a simplified structure and correctly sensing coordinates using only one differential amplifier.
Accordingly, to achieve the above and other objects, there is provided a position coordinates signal detecting circuit of a sensor panel for detecting a position coordinates signal of a contact point in a sensor panel coated with a resistance component. The circuit includes a plurality of e.g., first through fourth, resistors one end of each of which is connected to an edge of the sensor panel, e.g., the left upper-most edge, the left lower-most edge, the right upper-most edge, and the right lower-most edge of the sensor panel, respectively. The circuit also includes a plurality, e.g., first through fourth, driving signal generators respectively connected to the other side of the resistors for generating a driving signal so as to drive the sensor panel. The circuit also includes an analog switching means for receiving a plurality, e.g., first through fourth pairs of voltages respectively generated at both ends of the resistors, multiplexing the pairs of voltage in response to a plurality of e.g., first through fourth, selecting signals and providing a multiplexed signal. The circuit also includes a differential amplifier for inputting and amplifying the multiplexed signal.
The position coordinates detecting circuit of the sensor panel according to the present invention makes it possible to amplify the voltage difference between both ends of the variable resistor. Thus, the characteristics mismatching between amplifiers is reduced, and the position coordinates are detected accurately.
BRIEF DESCRIPTIONS OF THE DRAWINGS
The foregoing and other objects, features, and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
FIG. 1 contains waveforms showing the output signals of differential amplifiers according to the characteristics of differential amplifiers in a position coordinates signal detecting circuit of a sensor panel using four differential amplifiers.
FIG. 2 is a schematic block diagram of one embodiment of a position coordinates signal detecting circuit of a sensor panel according to the present invention.
FIG. 3 contains waveforms showing first through fourth selecting signals for controlling the output of an analog switching unit shown in FIG. 2 and the output signal of a differential amplifier.
FIG. 4 is a block diagram showing an analog switching unit of a circuit shown in FIG. 2 .
FIG. 5 is a circuit diagram of a first switch shown in FIG. 4 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 is a schematic block diagram of one embodiment of a position coordinates signal detecting circuit of a sensor panel 21 according to the present invention. The position coordinates signal detecting circuit of the sensor panel 21 according to the present invention includes first through fourth driving signal generators 11 , 13 , 15 , 17 , first through fourth variable resistors VR 1 , VR 2 , VR 3 and VR 4 , an analog switching unit 31 , and a differential amplifier 41 .
The first through fourth driving signal generators 11 , 13 , 15 , 17 shown in FIG. 2, which are voltage generators for driving the senior panel 21 , transmit analog driving signals having predetermined voltages (1V˜4V) to the sensor panel 21 through the resistors VR 1 through VR 4 , respectively. The resistors VR 1 , VR 2 , VR 3 and VR 4 are connected to the four edges UL, LL, UR, and LR, respectively, of the sensor panel 21 , which is coated with a resistance component. When a contact occurs at an arbitrary point 43 of the sensor panel 21 , the first through fourth voltages are generated from both ends of each respective resistor VR 1 through VR 4 , corresponding to the point at which the contact occurred. The voltages generated from both ends of the respective resistors VR 1 through VR 4 are input to the analog switching unit 31 as shown.
The analog switching unit 31 receives the voltages generated from the ends of the resistors VR 1 through VR 4 . The analog switching unit 31 sequentially outputs the voltages of both ends of the first through fourth resistors VR 1 through VR 4 to the differential amplifier 41 by multiplexing the voltages input in response to first through fourth selecting signals S 1 through S 4 . The differential amplifier 41 amplifies a difference between the voltages of the first through fourth resistors VR 1 through VR 4 sequentially received from the analog switching unit 31 and generates the amplified voltages as the position coordinates signal of the contact point 43 generated in the sensor panel 21 . That is, the contact point generated in the sensor panel 21 can be indicated by coordinates by detecting and amplifying the difference of the voltages of the first through fourth resistors VR 1 through VR 4 .
In the present embodiment, when there is no contact in the sensor panel 21 , variable resistors can be used as the first through fourth resistors VR 1 through VR 4 in order to control the input impedances of the respective edges UL, LL, UR, and LR of the sensor panel 21 to be the same. However, when there is no processing deviation in the sensor panel 21 , namely, when there is no contact in the sensor panel 21 fixed resistors can be used when the maximum level and the minimum level of the output signal of the differential amplifier 41 are under a predetermined level (for example, 80 mV). When the fixed resistors are used instead of the variable resistors, it is possible to reduce time required for testing the position coordinates signal detecting circuit shown in FIG. 2 .
FIG. 3 contains waveforms labelled (a) through (e) which illustrate the first through fourth selecting signals S 1 through S 4 in Waveforms (a) through (d), respectively, for controlling the output of the analog switching unit 31 shown in FIG. 2 and the output signal of the differential amplifier 41 in waveform (e). Waveform (a) shows the first selecting signal S 1 for controlling the analog switching unit 31 to select the voltage of both ends of the first resistor VR 1 . Waveform (b) shows a second selecting signal S 2 for controlling the analog switching unit 31 to select the voltage of both ends of the second resistor VR 2 . Waveform (c) shows a third selecting signal S 3 for controlling the analog switching unit 31 to select the voltage of both ends of a third resistor VR 3 . Waveform (d) shows a fourth selecting signal S 4 for controlling the analog switching unit 31 to select the voltage of both ends of a fourth resistor VR 4 . Waveform (e) shows position coordinates signal of the contact point 43 output by the differential amplifier 41 .
The operation of the position coordinates detecting circuit of the sensor panel according to the present invention will be described ii detail with reference to FIGS. 2 and 3. The respective edges UL, LL, UR, and LR of the sensor panel 21 are driven by alternating current voltages having predetermined voltage levels (1V through 4V) and input to the respective edges UL, LL, UR and LR through the respective registers VR 1 , VR 2 , VR 3 and VR 4 .
As mentioned above, after controlling the first through fourth resistors VR 1 through VR 4 so that the level of the voltage of the output of the differential amplifier 41 is uniform in an initial state in which the contact does not occur in the sensor panel 21 , when the contact by a finger occurs at an arbitrary point of the sensor panel 21 coated with the resistance component, the finger functions as a condenser. Therefore, the amount of current flow through the both ends of the first through fourth resistors VR 1 through VR 4 are different from each other. Accordingly, the voltage differences are generated in the both ends of the first through fourth resistors VR 1 through VR 4 . The difference of the pair of voltages is generated in the both ends of the first through fourth resistors VR 1 through VR 4 . The pairs of voltage are respectively input to the analog switching unit 31 .
The pairs of voltage of the both ends of the first through fourth resistors VR 1 through VR 4 input to the analog switching unit 31 are sequentially output in response to the first through fourth selecting signals S 1 through S 4 which have a predetermined duty cycle (for example, T 5 , T 6 , T 7 and T 8 are all 1.25 ms) and are sequentially enabled, as shown in waveforms (a) through (d) of FIG. 3 . The differential amplifier 41 receives the pairs of voltages of the both ends of the first through fourth resistors VR 1 through VR 4 sequentially generated from the analog switching unit 31 , amplifies the voltage differences, and provides the amplified signal to an output terminal OUT as the position coordinates signal as shown in waveform (e) of FIG. 3 .
As shown in waveforms (a) through (e) of FIG. 3, since the pairs of voltages of both ends of the first through fourth resistors VR 1 through VR 4 connected to the respective edges of the sensor panel 21 are input to the differential amplifier 41 in response to the first through fourth selecting signals S 1 through S 4 which have a predetermined duty, for example, 1.25 ms and are sequentially enabled, the position coordinates signal of the contact point generated in the sensor panel 21 can be output in a period of 5 ms in this particular exemplary embodiment.
For example, as shown in FIG. 2, when the contact point 43 is generated in the sensor panel 21 , capacitances are formed between the contact point 43 and the respective edges of the sensor panel 21 and the capacitances of the capacitor vary according to a distance between the respective edges and the contact point 43 . As a result, the pairs of voltage of the both ends of the first through fourth resistors VR 1 through 4 connected to the respective edges UL, LL, UR, and LR may be different. To the contact paint 43 shown in FIG. 2, the nearest edge is the left upper UL, and the furthest edge is the right lower edge LR. And the contact point 43 is located at the almost same distance from the left lower edge LL and the right upper edge UR. In this case, the capacitance between the left upper edge UL and the contact point 43 is smallest. The capacitance between the right lower edge LR and the contact point 43 is largest. The capacitances between the left lower edge LL and the right upper edge UR are almost same.
The capacitances between the contact point 43 and the respective edges UL, LL, UR, and LR of the sensor panel 21 are respective serially connected to the first through fourth resistors VR 1 through VR 4 and change the pairs of voltages of both ends of them. In the case of the contact point 43 shown in FIG. 2, since the capacitance of the capacitor serially connected to the resistor VR 1 among the first through fourth resistors VR 1 through VR 4 is the smallest value, the pairs of voltages at the ends of the first resistor VR 1 are the largest among the pairs of voltage at the ends of the first through fourth resistor VR 1 through VR 4 . Also, since the capacitance of the capacitor serially connected to the fourth resistor VR 4 is the largest value, the pairs of voltages at the ends of the fourth resistor VR 4 is the smallest. Therefore, the differential amplifier 41 generates the output signal having the largest level as shown in waveform (e) of FIG. 3 in the section T 5 in which the analog switching unit 31 selectively outputs the pair of voltages at the ends of the first resistor VR 1 , in response to the first selecting signal S 1 shown in waveform (a) of FIG. 3 . Also, as shown in waveform (e) of FIG. 3, the differential amplifier 41 generates an output signal. The level of the output signal in sections T 6 and T 7 is lower than that of the output signal in section T 5 . In sections T 6 and T 7 , the analog switching unit 31 selectively generates the pairs of voltage received from the second and third resistors VR 2 and VR 3 , in response to the second and third selecting signals S 2 and S 3 shown in waveforms (b) and (c) of FIG. 3 . Also, as shown in waveform (e) of FIG. 3, the differential amplifier 41 generates an output signal having the lower level in a section T 8 . In the section T 8 , the analog switching unit 31 selectively generates the voltage received from the fourth resistor VR 4 , in response to the fourth selecting signal S 4 shown in waveform (d) of FIG. 3 . The position coordinates of the contact point 43 are detested by the output signals of the differential amplifier 41 , generated in the sections T 5 , T 6 , T 7 , and T 8 .
In the present invention, since the pars of voltage at the ends of the first through fourth resistors VR 1 through VR 4 are transferred the input terminal of the differential amplifier 41 the analog switching unit 31 , one differential amplifier is sufficient. Therefore, using the position coordinates signal detecting circuit of the invention, the problem of inaccurate position coordinates found in prior systems due to amplifier mismatch, i.e., output level differences between the amplifiers and amplifying degree differences between the amplifiers in the common mode, are virtually eliminated.
FIG. 4 contains a schematic block diagram illustrating the analog switching unit 31 of the circuit shown in FIG. 2 . The analog switching unit 31 according to the present invention includes first through fourth switching units 81 , 83 , 85 and 87 . Each switching unit includes two switches.
The first switching unit 81 shown in FIG. 4 respectively receives the pair of voltages at the ends of the first resistor VR 1 shown in FIG. 2 at a first input terminal IN 1 and a second input terminal IN 2 and selectively generates and outputs the pair of voltages at the ends of the first resistor VR 1 in response to the first selecting signal S 1 . The second switching unit 83 receives the pair of voltages at the both ends of the second resistor VR 2 shown in FIG. 2 through a third input terminal IN 3 and a fourth input terminal IN 4 . The second switching unit 83 selectively generates and outputs the pair of voltages at the ends of the second resistor VR 2 in response to the second signal S 2 . Also, the third switching unit 85 receives the pair of voltages at the ends of the third resistor VR 3 shown in FIG. 2 through a fifth input terminal IN 5 and a sixth input terminal IN 6 . The third switching unit 85 selectively generates and outputs the pair of voltages at the ends of the third resistor VR 3 in response to the third selecting signal S 3 . The fourth switching unit 87 receives the pair of voltages at the ends of the fourth resistor VR 4 shown in FIG. 2 through a seventh input terminal IN 7 and an eighth input terminal IN 8 . The fourth switching unit 87 selectively generates and outputs the pair of voltages at the ends of the fourth resistor VR 4 in response to the fourth selecting signal S 4 .
A first switch 51 included in the firs switching unit 81 receives the voltage level of a terminal of the first resistor VR 1 through the input terminal IN 1 as a first voltage level and selectively generates and forwards the first voltage level to the output terminal OUT 1 in response to the first selecting signal S 1 . A second switch 53 inputs the voltage level of the other terminal of the first resistor VR 1 as a second voltage level and selectively generates the second voltage level to the output terminal OUT 2 in response to the first selecting signal S 1 . Since the operations of third through eighth switch 55 , 57 , 59 , 61 , 63 and 65 included in the second through fourth switching units 83 , 85 ant 87 are the same as those of the first and second switches 51 and 53 included in the first switching unit 81 , descriptions thereof will be omitted.
FIG. 5 is a circuit diagram of one embodiment of each of the switches 51 , 53 , 55 , 57 , 59 , 61 , 63 and 65 shown in FIG. 4 . The switch 51 includes an inverter 71 including a first PMOS transistor MP 1 and a first NMOS transistor MN 1 and a transfer gate 73 including second and third PMOS transistors MP 2 and MP 3 and a second NMOS transistors MN 2 .
The inverter 71 receives the first selecting signal S 1 through the gates of the first PMOS transistor MP 1 and the first NMOS transistor MN 1 and generates the inverted first selecting signal to a drain. The transfer gate 73 outputs the first voltage level which is voltage level of the terminal of the first resistor VR 1 input to the sources of the respective transistors MP 2 , MP 3 and MN 2 through the drain, in response to the inverted first selecting signal received through the gates of the second and third PMOS transistors MP 2 and MP 3 and the first selecting signal S 1 received through the gate of the second NMOS transistor MN 2 .
For example, when the first selecting signal S 1 of a “high” logic level is input through the inverter 71 , the second and third PMOS transistors MP 2 and MP 3 and the second NMOS transistor MN 2 of the transfer gate 73 are timed on by an inverted first selecting signal of a “low” logic level and the first selecting signal S 1 of the “high” logic level. Accordingly, the first voltage level received through the input terminal IN 1 is transmitted to the output terminal OUT 1 . When the first selecting signal S 1 of the “low” logic level is received, the second and third PMOS transistor MP 2 and MP 3 and the second NMOS transistor MN 2 of the transfer gate 73 are turned off by the inverted first selecting signal of the “high” logic level and the first selecting signal S 1 of the “low” logic level. Accordingly, the first voltage level received the input terminal IN 1 is not transmitted to the output terminal OUT 1 .
While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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A position coordinates signal detecting circuit of a sensor panel is provided. The position coordinates signal detecting circuit of the sensor panel according to the present invention includes first through fourth resistors each of which has one end connected to one of the left upper-most edge, the left lower-most edge, the right upper-most edge, and the right lower-most edge of the sensor panel. First through fourth driving signal generators are respectively connected to the other side of the first through fourth resistors for generating a driving signal so as to drive the sensor panel. Analog switches receive first through fourth pairs of voltages respectively generated at both ends of the first through fourth resistors. The first through fourth pairs of voltage are multiplexed in response to first through fourth selecting signals to provide a multiplexed signal, and a differential amplifier for amplifies the multiplexed signal. The position coordinates detecting circuit of the sensor panel according to the present invention makes it possible to amplify the voltage difference between both end of the variable resistors. Thus, the characteristics mismatching between different amplifiers is reduced, and the position coordinates are detected accurately.
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[0001] Oral intubation is a procedure by which a tube is inserted through the mouth down into the trachea, the large airway from the mouth to the lungs. The tube is often inserted with the a laryngoscope, an instrument that permits the person inserting the tube to see the upper portion of the trachea, just below the vocal cords. During the procedure, the laryngoscope is used to hold the tongue to the side while the tube is inserted into the trachea. Critical to the procedure is that the head of the patient be positioned in the appropriate manner to allow for proper visualization. Additionally, pressure is typically applied to the thyroid cartilage (or Adam's apple) to allow better visualization of the trachea and to prevent possible aspiration.
[0002] Oral intubation is often a difficult medical procedure because the anatomy of some patients makes it difficult to view the patient's vocal chords, which is essential for successful intubation. Examples of patients where oral intubation is difficult include overweight patients, patients with an anterior placed trachea, patients with a short neck such as pediatric patients, and/or patients requiring intubation out in the field in an emergency situation. The existing methods of oral intubation involve prying forward on the patient's upper lip and teeth with the standard laryngoscope blade which often causes injury and, most importantly, results in an unsuccessful intubation or view of the patient's vocal chords. When the laryngoscope blade is tilted back into the upper lip and teeth, injury to the patient, such as broken teeth and lacerations to the interior of the mouth, may occur.
[0003] A device for oral intubation that may be easily used to provide successful oral intubation to difficult-to-intubate patients is needed. A device that uses a hard palate pivot support as a safe anchor point to push against the roof of a patient's mouth and consequently open the airway (or oropharynx) in order to visualize the vocal chords is needed.
[0004] A laryngoscope for use in pre-hospital and hospital situations is disclosed. The device is designed to increase the success rate of oral intubation of adult and pediatric patients. The device utilizes unique features that allow for one handed operation and use. The one-handed operation allows the healthcare worker performing the intubation to hold the device in one hand and free up the other hand for insertion of the endotracheal tube. The purpose of the device is to overcome obstacles that present themselves in any intubation situation. This device eliminates the requirement of physical arm strength by utilizing an anatomically friendly design and easy to use handle. The device allows for direct visualization of the vocal chords and will increase the success rate of intubations while decreasing the risk of injury to patients.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The present disclosure will be better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
[0006] FIG. 1 is a perspective view of the intubation device. In such depiction, the device is in the depressed state as the lever is pulled down.
[0007] FIG. 2 is a partial back perspective view of the intubation device in FIG. 1 .
[0008] FIG. 3 is a side perspective view of the intubation device. In such depiction, the device is in not in the depressed state as the lever is not depressed or pulled down.
[0009] FIG. 4 is a right side perspective view of the intubation device of FIG. 1 .
[0010] FIG. 5 is a left side perspective view of the intubation device of FIG. 1 .
[0011] FIG. 6 is a top perspective view of the intubation device in use. Such depiction portrays a view of a perspective airway provided by the intubation device.
[0012] FIG. 7 is a side perspective view of the intubation device inserted into the mouth of a patient.
[0013] FIG. 8 is a front perspective view of the intubation device of FIG. 6 .
[0014] FIG. 9 is a perspective view of the handle of the intubation device of FIG. 1 .
[0015] FIG. 10 is a perspective view of the laryngoscope blade of the intubation device of FIG.
[0016] FIG. 11 is a perspective view of the actuating lever of the intubation device of FIG. 1 .
[0017] FIG. 12 is a perspective view of the hard palate pivot support of the intubation device of FIG. 1 .
[0018] FIG. 13 is a perspective view of a first actuating arm of the intubation device of FIG. 1 . Such first actuating arm has two points of connection. It is connected to the actuating lever and a second actuating arm.
[0019] FIG. 14 is a perspective view of the second actuating arm of the intubation device of FIG. 1 . Such second actuating arm has three points of connection. It is connected to the first actuating arm. Additionally, such second actuating arm is connected to the laryngoscope blade and the hard palate pivot support.
[0020] FIG. 15 is a perspective view of the third actuating arm of the intubation device of FIG. 1 . Such third actuating arm is connected to the laryngoscope blade and the hard palate pivot support.
DETAILED DESCRIPTION
[0021] Referring to FIGS. 1 to 15 , a device for oral intubation is disclosed. In one example embodiment, the device utilizes a laryngoscope blade 2 and hard palate pivot support 3 that is positioned into the airway (or oropharynx) through the opening in the mouth. The device is unlike any other device in that it is utilizes a spring activated lever 4 on the handle 1 that is designed to be easily operated with one hand. In addition to ease of use, the device's design benefits the patient by protecting the patient's teeth, gums, palate and all other soft tissue in the mouth and oropharynx from injury that commonly occurs with the current intubation method. The blade 2 and hard palate pivot support 3 may be collapsed together via the spring (best shown in FIG. 3 ) for easy insertion; once the device is in the proper position inside a patient's mouth, the lever 4 may be depressed or pulled down spreading the laryngoscope blade 2 and the hard palate pivot support 3 apart at a specific angle and distance from each other. In one embodiment, the device is designed with the proper distance and opening angle to allow for a wide open view of the vocal chords 10 and adequate room for visualization and insertion of a endotracheal tube (best shown in FIGS. 6 to 8 ).
[0022] Referring now to FIG. 3 , in one example embodiment, the device is collapsed in its resting state (or non depressed state) making insertion of the device easier. Referring now to FIGS. 1-15 , the anatomical design is designed to protect the patient from injury. The laryngoscope blade 2 and hard palate pivot support 3 are offset and positioned for optimal utilization meaning it will open and provide the widest view possible of the trachea. The device is designed to release automatically and pressure is easily controlled by the provider. The handle 1 and lever 4 are designed for easy one handed operation requiring minimal physical strength. The hard palate pivot 3 has two apertures (shown in FIG. 12 ) and is attached to the blade 2 having two apertures (see FIG. 10 ) with actuating arms 5 B and 5 C on the side of the blade 2 to allow for direct visualization and easy insertion of an endotracheal tube.
[0023] In one example embodiment, laryngoscope blade 2 has a proximal end and a distal end. The proximal end of the blade 2 attached to handle 1 . The distal end of blade 2 in inserted into the mouth of a patient. In one example embodiment, the blade 2 has two apertures for attaching to actuating arms 5 B and 5 C. The size and the length of blade 2 may vary as desired by one of skill in the art. In one example embodiment, laryngoscope blade 2 has a tip on the distal end. Actuating arm 5 A has two apertures on each distal end. Arm 5 A is connected to lever 4 at one end and actuating arm 5 B at the opposite end. Actuating arm 5 B is substantially L-shaped and three points of attachment. At each distal end of actuating arm 5 B, an aperture exists to allow attachment to the pivot support 3 and the actuating arm 5 A. Actuating arm 5 B is also attached to blade 2 at the perpendicular junction of actuating arm 5 B. Actuating arm 5 C has two apertures on each distal end. Arm 5 C is connected to blade 2 at one end hard palate pivot support at the opposite end. Actuating arms 5 A, 5 B and 5 C allow movement between the lever 4 and hard palate pivot support 3 .
[0024] A method of using the device to provide oral intubation to a patient comprises positioning the laryngoscope blade 2 and the hard palate pivot support 3 into the oropharynx through the opening of a patient's mouth. Handle 1 is used to guide the blade 2 into the proper positions. The blade 2 and the hard palate pivot support 3 may be collapsed together to allow them to be inserted between the tongue 16 and the hard palate 14 of the patient 12 (best shown in FIGS. 7 and 8 ). Once the device is positioned inside the patient's mouth, the actuating lever 4 may be depressed which moves the actuating arms 5 A, 5 B and 5 C, wherein such actuating arms cohesive work together to spread apart the laryngoscope blade 2 and hard palate pivot support 3 . This action opens the oropharynx for the necessary view of the vocal chords 10 . The endotracheal tube may then be placed through the vocal chords and into the trachea for a successful intubation.
[0025] In one embodiment, the device may be made of surgical steel, except for the hard palate pivot support 3 , which may be made of a softer synthetic plastic or rubber. The device may be made of other materials as desired by one of skill in the art. Referring to FIGS. 1-15 , the hard palate pivot support 3 may be shaped or curved to protect the patient's hard palate 12 from injury. In one example embodiment, the material used may be easily sterilized to allow for multiple uses.
[0026] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the disclosure may occur to persons skilled in the art, the disclosure should be construed to include everything within the scope of the disclosure and equivalents thereof.
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A device used for oral intubation on a patient having a mouth and airway (or oropharynx) is disclosed. The device comprises a hard palate pivot support attached to a laryngoscope blade by a plurality of actuating arms, wherein the hard palate pivot support is used to push against the roof of a patient's mouth and consequently open a patient's airway in order to visualize the vocal chords. A method of use is further disclosed.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to cable support systems for suspending an object from an overhead structure by means of cables. The cable support systems include novel clamps that clamp to the overhead structure and support the cable that suspends from them to secure the object to be suspended.
[0003] 2. Prior Art
[0004] Various cable support systems have been described and utilized in the prior art to suspend objects from overhead beams. The purposed of such systems is to suspend items such as conduit, heating and air conditioning ducts, piping, and other objects from overhead structures such as beams or roofs. The earlier cable suspension systems did not provide adequate methods of adjusting the height of the objects suspended precisely so as to equalize the weight on several cables that might be suspending the same object. Further, the earlier systems did not provide a simple and easy way of connecting the cables that suspend an object to the overhead structures. The present invention provides a cable system that may precisely control the height of an object suspended from an overhead structure and also form a ready and easy connection to the overhead structure by novel clamps.
BRIEF SUMMARY OF THE INVENTION
[0005] A clamp for a cable support system is provided that includes a generally “C” shaped clamp body with a threaded fastener threadingly received within one leg of the “C” shaped body to clamp the “C” shaped body onto an overhead beam. A vertical bore through the clamp body receives a cable to be suspended from the overhead beam and there are various devices within the clamp body to restrict the downward vertical movement of the cable relative to the clamp body. One of the arrangements for restricting the downward movement of the cable within the clamp body is to provide a annular shoulder within the bore that cooperates with an oversized end portion on the cable and thereby restricts downward movement of the cable.
[0006] Another arrangement for restraining the cable within the “C” shaped body of the clamp includes providing a conical end portion at the lower part of the vertical bore through the body. A wedge retainer is movable vertically within the bore. Wedges retained by the wedge retainer contact the cable within the bore and force the wedges against the cable by contact with the conical end portion of the bore when the retainer is at the lower part of the bore. A spring urges the wedge retainer downwardly relative to the bore so that when the cable is forced upwardly through the wedges, the cable is restricted from downward movement.
[0007] Still another arrangement for restraining the cable within the “C” shaped body of the clamp includes providing a passage extending downwardly at an acute angle to the vertical bore with a wedge within the passage that is urged into the bore by a spring. The wedge prevents the cable from moving downwardly unless it is released by release levers that extend out from the wedge through slots in the “C” shaped body.
[0008] Cable support systems are also provided which utilize the novel clamps and suspend an object from the cable with the use of cable clamps or by providing fixed loops at the end of the cable to secure an object to the cable.
[0009] Accordingly, it is an object of the present invention to provide a novel clamp for securing a cable to an overhead beam.
[0010] Another object of the present invention is to provide systems for securing objects to overhead beams which permit the height to be precisely regulated.
[0011] Another object of the present invention is to provide a system for securing an object to an overhead beam by means of suspension cables that is readily installable by workmen.
[0012] These and other objects of the present invention all become readily apparent as this description proceeds in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a perspective view of one embodiment of the clamp of the present invention clamped to a section of “I” beam.
[0014] [0014]FIG. 2 is an elevational view of the clamp of FIG. 1 clamped to the “I” beam.
[0015] [0015]FIG. 3 is a sectional elevation of the clamp of FIGS. 1 and 2 showing the internal arrangement of the clamp.
[0016] [0016]FIG. 4 is a perspective view of a clamp similar to that of FIG. 1.
[0017] [0017]FIG. 5 is a sectional elevation of the clamp of FIG. 4.
[0018] [0018]FIG. 6 is a sectional elevation of another form of clamp.
[0019] [0019]FIG. 7 is an end elevation of the clamp of FIG. 6.
[0020] [0020]FIG. 8 is a system for suspending an object from an overhead beam shown schematically.
[0021] [0021]FIG. 9 is a system similar to that of FIG. 6.
[0022] [0022]FIG. 10 is another system similar to those of FIGS. 6 and 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Referring to FIGS. 1 - 3 , there is shown a clamp generally indicated at 10 clamped to an overhead beam 12 . The overhead beam 12 is depicted as an “I” beam but it could be a beam or support of any shape that would accept the clamp 10 . The clamp 10 has a generally “C” shaped body 14 with a threaded fastener 16 threaded through one leg of the “C” shaped body 14 . A lock nut 18 is included on the threaded fastener 16 to lock the fastener in place after the clamp 10 is secured to beam 12 . A vertical bore 20 (FIG. 3) is provided through the body 14 of clamp 10 . The vertical bore 20 has a conical end 22 at the lower end of the clamp 10 . Within the vertical bore 20 is positioned a wedge retainer 24 which is generally conical in shape with an extended cylindrical end portion 24 a and which has a bore extending through the length of the wedge retainer 24 to accept a cable. The wedge retainer 24 retains wedges 26 about its periphery. The wedges 26 are depicted as balls but they could also be wedges of other shapes without departing from the spirit of this invention. The wedge retainer 24 is urged downwardly relative to the clamp body 14 by a spiral spring 28 that is secured at the upper end of the body 14 by a spring cap 30 fixed to the body 14 .
[0024] A retainer lock nut 32 is threaded onto the outer extension of the wedge retainer 24 for a purpose to be described. A cable 34 is positioned within the body 14 of clamp 10 . The cable 34 may be moved upwardly in the direction shown by the arrow A in FIG. 3. If cable 34 is attempted to be moved downwardly against the direction of arrow A, the wedges 26 within the wedge retainer 24 are wedged against the cable as the wedge retainer 24 moves downwardly and the wedges 26 enter the lower conical portion 22 of vertical bore 20 . It will be seen that the position of the cable 34 relative to the clamp body 14 may be adjusted by moving the cable 34 upwardly in the direction of arrow A. Once the cable 34 is positioned in the desired location, the retainer lock nut 32 is threaded upwardly against the body 14 of clamp 10 to prevent movement of the wedge retainer 24 relative to the body 14 and thereby lock the cable 34 in place.
[0025] Referring to FIGS. 4 and 5, there is shown a second embodiment of a clamp adapted to fix a cable to an overhead beam. The clamp shown generally at 40 has a generally “C” shaped body 44 with a threaded fastener 46 threaded through one leg of the body 44 . A lock nut 48 is positioned on the threaded fastener 46 to lock it in place once the threaded fastener 46 clamps the body 44 of clamp 10 onto an overhead beam (not shown). Referring to FIG. 5, there is shown a vertical bore 50 that has an oversized portion 52 at the top of the body of clamp 10 . The oversized portion 52 forms an annular shoulder 54 around the top of the smaller vertical bore 50 . A cable 56 is shown within the vertical bore 50 and cable 56 has an oversized end 58 which prevents the cable 56 from moving downwardly relative to the clamp body 44 when the oversized end 58 contacts the annular shoulder 54 within the clamp body 44 .
[0026] Referring to FIGS. 6 and 7, there is shown a third embodiment of a clamp adapted to fix a cable to an overhead beam. The clamp shown generally at 80 has a generally “C” shaped body 84 with a threaded fastener 86 through one leg of the body 84 . A lock nut 88 is positioned on the threaded fastener 86 to lock it in place once the threaded fastener 86 clamps the body 84 of clamp 10 onto an overhead beam (not shown). A vertical bore 90 is provided through the body 84 of clamp 80 .
[0027] The vertical bore 90 has a passage 92 communicating with it. Passage 92 extends downwardly at an acute angle to bore 90 and contains a wedge 94 that slides within passage 92 . The wedge 94 is urged toward bore 90 by a spring 96 that is retained by a spring cap 98 fixed to the upper end of passage 92 . The wedge 94 has release levers 100 fixed to it that extend outwardly from wedge 94 through slots 102 formed into each side of “C” shaped body 84 . The slots 102 extend generally parallel to passage 92 and permit the wedge 94 to be moved against the urging of spring 96 .
[0028] It will be seen that cable 104 can be inserted upwardly into bore 90 and that the wedge 94 will move against the urging of spring 96 to permit passage of cable 104 . If there is an attempt to move cable 104 downwardly, it will be wedged against bore 90 by wedge 94 . If it is desired to move cable 104 downwardly, release levers 100 are moved against the urging of spring 96 to move wedge 94 away from cable 104 .
[0029] [0029]FIGS. 8, 9, and 10 show systems for supporting objects below overhead beams by means of cable supported from the novel clamps shown in FIGS. 1 - 7 . FIG. 8 shows a clamp 40 having the “C” shaped body 44 with the threaded fastener 46 and lock nut 48 clamped to an overhead beam (not shown). The cable 56 that suspends from clamp 40 is utilized to support an object 60 at a desired distance below the clamp 40 . The object 60 as shown in FIG. 6 has an eye through which cable 56 passes. It should be understood that the shape and size of object 60 form no part of the present invention and the object 16 may be a pipe, a heating or air conditioning vent, or any other object which is encircled by cable 56 .
[0030] As shown in FIG. 8, the cable 56 passes through a cable grip 64 and then encircles the object 60 and is returned back through cable grip 64 where the free end 66 of cable 56 protrudes above the cable grip 64 .
[0031] The cable grip 64 is a device shown and described in my copending patent application Ser. No. 10/029,087 entitled “Releasable Cable Grip” and filed in the United States Patent and Trademark Office on Dec. 20, 2001. The cable grip 64 consists generally of a housing that has twin bores through the housing. One bore permits the cable to pass freely through the housing without being restricted. The other bore contains wedges and retainer elements that permit the cable to pass in only one direction through the housing and restrict the cable from being removed from the housing in the opposite direction. As shown in FIG. 6, the cable 56 suspends from the clamp 40 and passes through the passage within cable grip 64 which does not restrict it. The cable 56 is passed around object 60 and is then passed upwardly through cable grip 64 until the end portion 66 of the cable 56 protrudes above the cable grip 64 . The precise height of object 60 relative to clamp 40 will depend upon the amount of the free end 66 of cable 56 that extends above the cable grip 64 .
[0032] Referring to FIG. 9, the clamp 10 of the type shown in FIGS. 1 - 3 is attached to an overhead beam (not shown) when the threaded fastener 16 in the clamp body 14 is threaded against the beam and the lock nut 18 is secured. In clamp 10 , the retainer lock nut 32 will hold the cable 34 a in place. In the embodiment of FIG. 9, the cable 34 a has a permanent loop 68 formed on the end of cable 34 a by means of a crimped retainer 70 that secures the end of cable 34 a and forms the loop 68 . In FIG. 9, the object 72 is encircled by cable 34 a and then cable 34 a passes back through its own loop 68 to secure the object. The cable 34 a is then passed upwardly into clamp 10 with the retainer lock nut 32 loosened to permit free movement of cable 34 a through the clamp body 14 . The height of object 72 relative to clamp 10 is adjusted by adjusting the amount of cable 34 a that protrudes above the body 14 of the clamp 10 . It will be appreciated that the system of FIG. 9 may also be practiced with the clamp 80 of FIGS. 6 and 7 since the amount of cable protruding above clamp 80 is adjustable.
[0033] [0033]FIG. 10 also shows a system which utilizes the clamp 10 of FIGS. 1 - 3 . Here again, a cable 34 is secured by clamp 14 as described in conjunction with the description of clamp 10 . The cable 34 passes through a cable grip 64 as described in conjunction with the configuration of FIG. 8 herein. The cable 34 passes through the free passage of cable grip 64 , encircles the object to be retained, and then passes back up through the restrained passage of cable grip 64 so that the free end 74 of cable 34 extends above the cable grip 64 . In the configuration of FIG. 10, the height of object 72 relative to clamp 10 may be adjusted by the amount of cable that is moved above clamp 10 by loosening retainer lock nut 32 and thereafter tightening it. The height of object 72 relative to clamp 10 may also be adjusted by the amount of the free end 74 of cable 34 that is permitted to protrude above the cable grip 64 . Thus FIG. 8 has two separate and distinct adjustment means for adjusting the height of the object 72 relative to the clamp 10 . Again, it will be appreciated that the clamp 80 of FIGS. 6 and 7 may be substituted in this system of FIG. 10 since it operates in a manner similar to the clamp 10 of FIGS. 1 - 3 .
[0034] In accordance with the provisions of the patent statutes, I have described the principle, mode of operation and the preferred embodiments of my invention. It should be understood that the invention may be practiced otherwise than as specifically illustrated and described herein in accordance with the claims affixed hereto.
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Cable Support Systems for supporting an object at a desired distance below an overhead beam or other overhead structure are provided. Novel clamps for clamping to the overhead structure are fitted to support cables that encircle objects to be supported by the cable support systems. The novel clamps have internal methods to support the cables. The cables are then encircled around the objects and fixed relative to the clamp. The distances between the object and the clamps may be precisely controlled.
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BACKGROUND OF THE INVENTION
Metal lead frames used in the production of plastic encapsulated electrical components are usually made with temporary metal bars connected between each adjacent pair of leads. The bars are integral with the lead frame and are referred to by a variety of terms such as tie strips, stabilizer bars, dam bars, spacer bars, etc. They serve usually two functions: they hold the leads in proper spaced relationship during processing and they restrict the outward flow of fluid plastic during the molding operation. Both functions are completed when processing is complete. The bars, which we refer to here as spacer bars, are punched out with a die stamp after the molding operation is complete.
STATEMENT OF THE INVENTION
I propose an alternative to the conventional spacer bars. The alternative is to form the spacer bars from a material different than the material of the lead frame. In a preferred embodiment the material is low melting, allowing it to be selectively removed by heating. An advantageous low melting material is solder. Removal of the spacer bar by heating eliminates the need for the die stamp operation referred to earlier.
DETAILED DESCRIPTION
These and other aspects of the invention will become evident from the following detailed description and the accompanying drawing in which:
FIG. 1 is a lead frame typical of the prior art with spacer bars integral with the lead frame.
FIGS. 2a and 2b show two exemplary forms of lead frames constructed according to the invention with the spacer bars and the lead frame formed of different materials.
FIG. 1 depicts the conventional approach to lead frame design with spacer bars 11 formed integrally with lead frame 12. After completion of the molding operation, the spacer bars and the frame (13) are removed by severing the bars at the locations indicated by dashed lines 14.
FIGS. 2a, 2b and 2c show the alternative approach of the invention. In FIG. 2a the spacer bars 21, formed from a low melting material such as solder, are shown connected between leads 22. These bars serve effectively as mechanical supports and to restrict the flow of molten plastic during the molding operation. It has been demonstrated that conventional solder (e.g. 60-40) bars maintain their physical integrity during standard molding operations. FIG. 2b shows an arrangement wherein a frame 24 of low melting material such as solder is pressed around the series of leads 22. The frame may be applied with or without heating forming either a cold compression or thermocompression bond. The frame may be applied in two halve-like sections affixed from opposite sides of the series of leads 22, as shown in FIG. 2c, in which case the two sections of the frame 24 and 24 1 weld or otherwise attach together.
FIG. 3 shows the assembly after application of heat. The spacer bars, shown in phantom at 22, have melted and the material, 25, e.g. solder, may (as shown) or may not adhere to the leads. In some cases it is desirable to "solder coat" the leads to aid in subsequent assembly operations. This solder coating operation can be accomplished conveniently in conjunction with the spacer bar technique as just described. Heat for melting the spacer bars may be applied to the whole part in e.g. a furnace, or may be applied selectively to the bars or the regions of the assembly containing the bars by using a laser, an electron beam or other appropriate directed source of radiant energy. Selective heating allows greater latitude in the choice of the material for the spacer bars, as long as the bar melts preferentially to the adjacent leads. For example the spacer bars may be made from a material with a relatively high melting point but with a surface that couples more energy from the laser beam than the leads 22. Leads 22 are typically specular. It is possible therefore to construct the spacer bars of the same bulk material as the lead frame if the surface of the spacer bars is so modified to couple radiation selectively with respect to the remainder of the lead frame. The term "lower melting" as used herein is intended to include materials that melt preferentially due to a variety energy absorbing effects, as for example anti-reflection coatings, energy absorbing coatings, chemically reactive coatings (e.g. exothermic compound formers). However in each case the spacer bars are designed to melt preferentially with respect to the leads 22. It is to be understood that this is in contrast with conventional laser machining where the laser beam melts material where the beam is directed but there is no inherent selectivity. In the conventional processs the address of the beam must be precisely controlled. According to this invention the beam is scanned over the leads 22 as well as the spacer bars and selectivity is inherent. Alteratively high intensity lamps may be used in the manner of well known rapid thermal annealing processes.
A further alternative is to melt the spacer bars using hot air leveling or hot liquid leveling. (See. H. W. Markstein, Electronic Packaging and Production, December, 1982, pp. 30-35.) Both of these techniques are well known and well developed for applications similar to the one described here, and the former was used to demonstrate the effectiveness of solder spacer bar technology. The hot air knives are effective not only for melting the solder spacer bars but also enhance the solder coating operation mentioned earlier. Similar results can be expected using liquid leveling. Both of the approaches are attractive for packages with small pitch leads. The gas or liquid serves a dual role, i.e. it provides the requisite thermal energy while also imparting a physical scrubbing action that insures removal or distribution of molten material so that secondary bridging does not occur.
Various additional modifications and extensions of this invention will become apparent to those skilled in the art. All such variations and deviations which basically rely on the teachings through which this invention has advanced the art are properly considered to be within the spirit and scope of this invention.
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Fabricating spacer bars or dam bars in conventional lead frames of a low melting material, e.g. solder, permits facile removal of the bar after molding. The low melting bars can be removed by furnace heating, localized radiant energy heating, exposure to rapid thermal annealing (RTA), hot air or hot liquid leveling, etc.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to an apparatus and method for compensating image blocking artifacts, and more particularly to an apparatus and a method for compensating image blocking artifacts occurring in display systems like Liquid Crystal Displays (LCD). The present application is based on Korean Patent Application No. 2001-65226, which is incorporated herein by reference.
[0003] 2. Description of the Prior Art
[0004] Generally, display devices like liquid crystal displays (LCD), plasma display systems, and light-emitting diodes (LED) display images by controlling on/off of a plurality of pixels arranged in matrixes. Such display devices, which perform the on/off control on the respective pixels, are only capable of displaying images in two ways, namely light on/light off or transparent/nontransparent.
[0005] [0005]FIG. 1 is a view schematically showing a cell structure of a general LCD. Referring to FIG. 1, a plurality of pixels are arranged in a 4×9 matrix. Each pixel is categorized into a major pixel 11 and a minor pixel 13 . The ratio of the major pixel 11 to the minor pixel 13 in regard to the intensity of radiation is 8:1, and the major pixel 11 and the minor pixel 13 are driven in time series by the expression of gradation. For example, if the gradation is fifteen (15), the minor pixel 13 is driven fifteen ( 15 ) times. If the gradation is sixteen (16), the major pixel 11 is driven two (2) times. In the example shown in FIG. 1, minor pixels 13 are driven from the first to third columns, the major pixels 11 are driven from the fourth to the sixth columns, and the minor pixels 13 are driven from the seventh to the ninth columns.
[0006] Conventionally, each pixel is driven in time series, and occasionally, a situation occurs in which the consecutively driven pixels are perceived by the user's eyes with a gradation that is different from the actual gradation. Such a situation will be called ‘image blocking artifacts’ hereinbelow. When the image blocking artifacts happen, the user may perceive two consecutive columns as one column. And he/she may perceive the respective columns of pixels by the order of 15 gradation, 15 gradation, 31 gradation, 16 gradation, 0 gradation, 15 gradation and 15 gradation. Accordingly, from the user's view, the user will perceive dark 31 gradation at an instance when the major pixel 11 is driven after the minor pixel 13 is driven. Then, at the instance when the minor pixel 13 is driven after the major pixel 11 is driven, the user will perceive 0 gradation, which will cause the interruption between lines.
SUMMARY OF THE INVENTION
[0007] The present invention has been made to overcome the above-mentioned problems of the prior art. Accordingly, it is an object of the present invention to provide an apparatus and a method for compensating image blocking artifacts, which are caused due to the structure of a display device like a liquid crystal display.
[0008] The above object is accomplished by an apparatus for compensating image blocking artifacts according to the present invention, including a video signal comparing unit for comparing gradation values of video signals which are consecutively input at a predetermined time interval, the signal comparing unit determining if the difference between the gradation values meets a certain condition, as the image blocking artifacts occur in the consecutively input video signals; and an operation processing unit for removing the image blocking artifacts by adding/subtracting the gradation values of the input video signals when it is determined that the image blocking artifacts occur.
[0009] The video signal comparing unit comprises an index generating unit for generating an index for commanding an adding/subtracting of the gradation values of the video signals that are input to the operation processing unit when it is determined that the image blocking artifacts occur.
[0010] The operation processing unit comprises a video signal modulating unit for modulating the input video signals, so that resultant gradation values of adding/subtracting can be output.
[0011] When a gradation value of a preceding video signal of the consecutively input video signals meets a certain condition, the video signal comparing unit compares the gradation values of the consecutively input video signals.
[0012] When a remainder of dividing the gradation value of the preceding video signal by a predetermined number equals a predetermined value, the video signal comparing unit compares the gradation values of the consecutively input video signals.
[0013] According to the present invention, the apparatus for compensating image blocking artifacts compares gradation values of sequentially input video signals. When there is a possibility of having image blocking artifacts, the apparatus minimizes the image blocking artifacts by adding or subtracting a predetermined gradation value with respect to the gradation value of the input signals.
[0014] According to the present invention, a method for compensating image blocking artifacts comprises the steps of comparing gradation values of video signals that are consecutively input at a predetermined time interval; determining when a difference between the gradation values meets a certain condition, as the image blocking artifacts occur in the video signals; and when determining that the image blocking artifacts occur, removing the blocking artifacts by adding/subtracting the gradation values of the consecutively input video signals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The above-mentioned object and the feature of the present invention will be more apparent by describing the preferred embodiment of the present invention by referring to the appended drawings, in which:
[0016] [0016]FIG. 1 is a view schematically showing the cell structure of a conventional liquid crystal display;
[0017] [0017]FIG. 2 is a block diagram schematically showing an apparatus for compensating image blocking artifacts according to the present invention;
[0018] [0018]FIG. 3 is a view showing a variable region of a gradation that is displayable in pixels; and
[0019] [0019]FIG. 4 is a flowchart for illustrating a process of compensating image blocking artifacts of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] From now on, the present invention will be described in greater detail by referring to the appended drawings.
[0021] [0021]FIG. 2 schematically shows the apparatus for compensating the image blocking artifacts according to the present invention. As shown in FIG. 2, the image blocking artifacts compensating apparatus includes an image delay unit 21 , a video signal comparing unit 23 and an operation processing unit 25 . The video signal comparing unit 23 has an index generating unit 23 a . Also, the operation processing unit 25 has a video signal modulating unit 25 a.
[0022] The image delay unit 21 delays an input video signal by a predetermined time period. The predetermined delay time made by the image delay unit 21 is preferably set to be as much as the time interval at which each frame of the video signal is input. Further, it is preferred that the image delay unit 21 be constructed in a first-in first-out type buffer, in which the image delay unit 21 temporarily stores the input video signal for a predetermined time before outputting the signal.
[0023] The video signal comparing unit 23 compares the gradation values of the video signals that are consecutively input at a predetermined time interval. The video signal comparing unit 23 determines if the difference between the compared video signals meets a certain condition, as there are image blocking artifacts occurring between the consecutively input video signals.
[0024] When it is determined by the video signal comparing unit 23 that there are image blocking artifacts occurring in the consecutively input video signals, the index generating unit 23 a generates an index that gives a command to add/subtract the gradation values of the video signals that are input to the operation processing unit 25 , to eliminate the possibility of having the image blocking artifacts.
[0025] When it is determined that there is a possibility of having image blocking artifacts in the consecutively input video signals, the operation processing unit 25 adds/subtracts the gradation values of the input video signals, to thereby eliminate the possibility of having the image blocking artifacts.
[0026] When it is determined that there is a possibility of having image blocking artifacts in the consecutively input video signals, the video signal modulating unit 25 a modulates the input video signals so that the input video signals can be output with the resultant gradation values of adding or subtracting by the operation processing unit 25 . FIG. 3 shows the available range of gradation values that can be added/subtracted to modulate the input video signals, when it is determined that there is a possibility of having the image blocking artifacts in the consecutively input video signals. The general range of gradation is between 14 and 241 .
[0027] [0027]FIG. 4 is a flowchart showing the process of compensating the image blocking artifacts of FIG. 2. Referring to FIG. 4, first, video signals in a frame unit are input to the image blocking artifact compensating apparatus consecutively (step S 103 ). As mentioned above, the input video signals have the gradation value ranging from 14 to 241. Among the input video signals, the preceding input signals are delayed for a predetermined time so that the preceding signals can be input to the video signal comparing unit 23 together with the following input signals.
[0028] The image delay unit 21 delays the input video signals for a predetermined time (step S 103 ). The image delay unit 21 can be achieved by a first-in/first-out type buffer. The video signals, which are delayed by the image delay unit 21 , are input to the video signal comparing unit 23 together with the following input signals that are not delayed. The delayed input video signals and non-delayed input video signals are input to the video signal comparing unit 23 together with each other. Alternatively, once-delayed and twice-delayed input video signals can be input to the video signal comparing unit 23 . The video signals, which are consecutively input to the video signal input unit 23 , have to be input to the video signal comparing unit 23 at the same time.
[0029] The video signal comparing unit 23 determines whether the remainder of dividing the gradation value of the preceding input video signal corresponds to a certain value or not (steps S 105 , S 113 , S 119 , S 125 ). If the remainder of dividing the gradation value of the preceding input video signal corresponds to the certain value, the video signal comparing unit 23 determines whether the resultant gradation value of adding or subtracting a certain gradation value with respect to the gradation value of the following input video signal corresponds to the gradation value of the preceding input video signal or not (steps S 107 , S 115 , S 121 , S 127 ). In other words, the video signal comparing unit 23 determines whether the difference between the gradation value of the preceding input video signal and the gradation value of the following input video signal meets a certain condition or not.
[0030] When it is determined that the resultant gradation value of adding or subtracting a certain gradation value with respect to the gradation value of the following input video signal corresponds to the gradation value of the preceding input video signal, i.e., when it is determined that the difference between the gradation value of the preceding input video signal and the gradation value of the following input video signal corresponds to a certain value, the index generating unit 23 a generates the respective indexes (steps S 109 , S 117 , S 123 , S 129 ). The indexes generated by the index generating unit 23 a are transmitted to the operation processing unit 25 . The video signal comparing unit 23 transmits the preceding input video signal and the following input video signal to the operation processing unit 25 so that the image blocking artifacts occurring in the consecutively input video signals can be compensated.
[0031] The operation processing unit 25 receives the indexes from the index generating unit 23 a , and adds/subtracts the gradation value of the input video signal to eliminate the possibility of having the image blocking artifacts in the input video signals. At this time, based on the received indexes, the operation processing unit 25 determines whether to add or subtract the gradation value of the input video signals. Also, the video signal modulating unit 25 a of the operation unit 25 modulates the input video signals so that the input video signals can be output with the gradation values of the video signals that are added/subtracted by the operation processing unit 25 (step S 111 ). Either the preceding input video signal or the following input video signal can be modulated. Alternatively, both of the preceding and following input video signals can be modulated.
[0032] When it is determined that the resultant gradation value of adding or subtracting a certain gradation value with respect to the gradation value of the following input video signal does not meet the gradation value of the preceding input video signal, the video signal comparing unit 23 terminates the image blocking artifact compensating process, and stands by for the process of compensating the image blocking artifacts of the next input video signals.
[0033] When it is determined that the remainder of dividing the gradation value of the preceding input video signal by a predetermined value does not correspond to any of the preset values, the video signal comparing unit 23 terminates the process of compensating the image blocking artifacts of the input video signal, and stands by for the process of compensating the image blocking artifacts with respect to the next input video signals.
[0034] [0034]FIG. 4 shows an example of image blocking artifact compensation, which is performed when the remainder of dividing the gradation values of the input video signal by sixteen (16) corresponds to any of 14, 15, 0 and 1. It is based on the fact that there is a high possibility of having the image blocking artifacts when the remainders of dividing the gradation values of the consecutively input video signals by sixteen (16) falls into the range of +2˜−2. However, it does not necessarily mean that the image blocking artifacts are compensated only when the remainder of dividing the gradation value of the input video signal by sixteen (16) corresponds to any of 14, 15, 0 and 1.
[0035] As described above, whether the difference between the gradation values of the consecutively input video signals is two (2) or three (3) is determined according to the remainder of dividing the gradation values of the input video signals by sixteen (16). However, it should be noted that it is just based on the fact that the difference of 2 or 3 between the gradation values of the consecutively input video signals indicates a high possibility of having the image blocking artifacts. Accordingly, one does not necessarily have to use certain limited figures to compensate the image blocking artifacts.
[0036] As described above, the image blocking artifact compensating apparatus according to the present invention reduces occurrence of image blocking artifacts by compensating to prevent occurrence of the image blocking artifacts between the video signals that are consecutively input in a frame unit.
[0037] Although the preferred embodiment of the present invention has been described, it will be understood by those skilled in the art that the present invention should not be limited to the described preferred embodiment, but various changes and modifications can be made within the spirit and scope of the present invention as defined by the appended claims.
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An apparatus and a method for compensating image blocking artifacts are capable of eliminating image blocking artifacts occurring in consecutively input image signals, in advance. The apparatus for compensating image blocking artifacts has a video signal comparing unit for comparing gradation values of video signals which are consecutively input at a predetermined time interval, the video signal comparing unit determining if the difference between the gradation values meets a certain condition, as the image blocking artifacts occur in the consecutively input video signals; and an operation processing unit for removing the image blocking artifacts by adding/subtracting the gradation values of the input video signals when it is determined that the image blocking artifacts occur. By eliminating the image blocking artifacts occurring in the consecutively input image signals, the image blocking artifact compensating apparatus can provide a clearer video on the liquid crystal display.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a §371 of International PCT Application PCT/EP2014/062712, filed Jun. 17, 2014, which claims the benefit of DE 10 2013 106 382.9, filed Jun. 19, 2013, both of which are herein incorporated by reference in their entireties.
FIELD OF THE INVENTION
[0002] Embodiments of the invention relate to a process for obtaining fatty alcohols by catalytic hydrogenation of fatty acid methyl ester. In particular, embodiments of the invention relate to the use of novel catalysts for the production of fatty alcohols, wherein as compared to the production methods known from the prior art less undesired by-products are obtained.
BACKGROUND
[0003] According to the prior art, the production of biodegradable fatty alcohols as raw material for example for the detergent industry is effected either by catalytic hydrogenation of breakdown fatty acids in a discontinuously operated reactor with catalyst slurry or continuously in a trickle-bed reactor with solid catalyst bed on the basis of methyl esters or wax esters of the corresponding fatty acids.
[0004] In the production of fatty alcohols by hydrogenation of methyl esters, fractions of non-converted methyl ester still are present in the produced fatty alcohol. During the hydrogenation, the throughput through the shaft or tubular reactor therefore already is adjusted such that only traces of methyl ester can be found in the exiting product stream, which ultimately limits the maximum possible throughput at the reactor. This procedure is necessary, since methyl esters of a certain C chain length n form azeotropes with the associated alcohols of the C chain length n−1, and the remaining methyl esters in the fatty alcohol mixture therefore cannot be separated completely by distillation.
[0005] In the patent EP 0 454 720 B1 of Davy McKee Ltd. a process is described, with which a large amount of the fatty alcohol can be recovered from a mixture of fatty alcohols (FA) and fatty acid methyl esters (ME). For this purpose, the FA/ME mixture initially is mixed with a homogeneous catalyst, preferably an alkyl titanate, and a transesterification of the ME to wax esters (WE) and methanol (MeOH) is carried out. After reaching the chemical equilibrium, the product mixture which now contains FA, WE, MeOH and small traces of ME is liberated from MeOH by distillation. The residue of FA, WE and small traces of ME obtained by distillation subsequently is liberated from a large amount of the contained FA in a further distillation. The residue of the second distillation now is again mixed with MeOH and subjected to a second transesterification, in which FA and ME again are obtained from the contained WE together with MeOH. The used excess of MeOH is separated from the obtained reaction product by evaporation, and the latter is fractionated in a further distillation into a distillate comprising FA and ME as well as a distillation residue, which also contains the homogeneous catalyst used in the first step and is partly recirculated and partly disposed of. Thus, two reaction and four fractionation steps must be carried out in this process.
[0006] The unexamined German application DE 10 2007 033 636 A1 describes a production process for fatty alcohols by hydrogenation of fatty acid methyl esters and the separation of the fatty alcohol mixtures thus produced into individual fractions after the hydrogenation by distillation. In particular, there is taught a process for separating a lower alkyl ester of a fatty acid from a fatty alcohol fraction or from a fatty alcohol mixture. This object is solved in that the fatty alcohol fraction or the fatty alcohol mixture is transesterified to fatty alcohol (FA), wax ester (WE) and the lower alkyl alcohol and at the same time the lower alkyl alcohol is discharged from the reaction mixture substantially completely and the wax ester is separated from the obtained product. In particular, it is proposed to carry out the transesterification in the presence of a heterogeneous transesterification catalyst. In contrast to the homogeneous catalyst which is used in the process according to EP 0 454 720 B1, there is not obtained a catalyst-containing residue. The wax ester obtained is pure and free from catalyst and therefore can be recirculated to the hydrogenation of fatty acid alkyl ester without further purification or processing. In DE 10 2007 033 636 A1, there was preferably used a titanium silicalite catalyst.
SUMMARY OF THE INVENTION
[0007] Our own experiments have shown that the use of acidic catalysts on the basis of titanium silicalite leads to the formation of undesired by-products during the transesterification. These are high-boiling, still unidentified products which cannot be separated from the wax esters by distillation. It is assumed that these are di-fatty alcohol ethers. Furthermore, when carrying out the transesterification in the presence of catalysts on the basis of titanium silicate, olefins also were observed as disturbing by-products.
[0008] Therefore, it is the object underlying embodiments of the present invention to indicate a rather simple process for obtaining fatty alcohols (FA) from fatty acid methyl ester (FAME), in which by-products as described above do not occur or only to a small extent.
[0009] The object is solved by a process according to the embodiments disclosed herein. In one embodiment, the following process steps are carried out in detail:
(a) supplying a feed stream containing fatty acid methyl ester to a hydrogenation stage, conversion of the feed stream in the presence of hydrogen under hydrogenation conditions on a bed of solid, granular hydrogenation catalyst, discharging a first material stream containing fatty alcohol, methanol and non-converted FAME, (b) supplying the first material stream to a distillation stage, separating the methanol as top product of the distillation, and discharging the bottom product of the distillation as second material stream comprising fatty alcohol and FAME, (c) supplying the second material stream to a transesterification reactor filled with a bed of solid, granular catalyst, transesterification of the second material stream under transesterification conditions to a third material stream comprising fatty alcohol and wax ester (WE) in counterflow with an inert gas stream as stripping gas stream, wherein the methanol produced during the transesterification is separated with the stripping gas as top product and the third material stream comprising fatty alcohol and wax ester is discharged, (d) supplying the third material stream to a separation stage operating by a thermal separation process, separating a fourth material stream enriched in wax ester, discharging a fifth material stream depleted of wax ester and enriched in fatty alcohol as fatty alcohol product stream, (e) recirculating the fourth material stream enriched in wax ester to the hydrogenation stage (a),
wherein the process according to the invention is characterized in that in process step (c) a transesterification catalyst on the basis of magnesium oxide or hydrotalcite is used.
[0015] Further advantageous aspects of the invention can be found in the dependent claims.
[0016] Hydrogenation conditions or transesterification conditions are understood to be reaction conditions which effect at least a partial conversion, preferably an extensive conversion of the FAME to fatty alcohol or to wax ester. The conversion conditions required for the hydrogenation or transesterification, in particular suitable reaction temperatures, pressures and space velocities, are known in principle to the skilled person from the prior art, for example from the documents discussed above. Necessary adaptations of these conditions to the respective operating requirements, for example to the composition of the feed stream or to the type of catalysts used, will be made on the basis of routine experiments. Conversion conditions particularly suitable in connection with the process according to the invention will be disclosed in the following exemplary embodiment.
[0017] Wax ester is understood to be the product of the esterification of the obtained fatty alcohols with the corresponding fatty acids.
[0018] As stripping gas stream, there can be used any gas which shows an inert behavior with respect to the components present in process step (c). For this purpose, nitrogen preferably is used.
[0019] Surprisingly, it has been found that when carrying out the transesterification process by using a basic catalyst on the basis of magnesium oxide or hydrotalcite, the above-mentioned impurities resulting from by-products such as olefins and probably di-fatty alcohol ethers only are observed in a very low concentration or even are not detectable, wherein the FAME conversion to wax ester is at least just as good as, in part even better than with the titanium-silicate-based catalysts used according to the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Further developments, advantages and possible applications of the invention can also be taken from the following description of an exemplary embodiment and the drawings. All features described and/or illustrated form the invention per se or in any combination, independent of their inclusion in the claims or their back-reference.
[0021] FIG. 1 shows a process of the invention according to a first embodiment,
[0022] FIG. 2 shows a process of the invention according to a second embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0023] A preferred aspect of the invention provides that the separation stage in process step (d) is designed as distillation stage, wherein the fourth material stream enriched in wax ester is obtained as bottom product and the fifth material stream depleted of wax ester and enriched in fatty alcohol is obtained as top product. In this way, the target product fatty alcohol can be obtained in high purity.
[0024] In an alternative aspect, the thermal separation stage in process step (d) can be designed as winterization stage. The fourth material stream depleted of wax ester, which then has been deposited under winterization conditions, can be separated by means of a mechanical separation process. Winterization is understood to be the cooling of a material stream to below the crystallization temperature of the wax ester, wherein the latter is deposited in solid form. Due to the great difference in the melting points of fatty alcohol and wax ester, a particularly easy and efficient separation is possible in this way. In contrast to other thermal separation processes like the distillation, the products are not subjected to a thermal load. This is advantageous in particular when separating wax esters whose fatty alcohol or fatty acid component is thermally unstable. It is particularly advantageous when the sedimentation, decantation, filtration or combinations thereof are used as mechanical separation process.
[0025] FIG. 1 shows a schematically represented basic flow diagram of one aspect of the process according to the invention, which will be explained in detail below.
[0026] Via conduit 1 , a liquid educt stream which contains fatty acid methyl ester (FAME) is supplied to the hydrogenation reactor 2 . The hydrogenation reactor contains a bed of a commercially available hydrogenation catalyst in tablet form. Via conduit 3 , hydrogen furthermore is supplied to the top of the hydrogenation reactor. The conversion is effected in the hydrogenation reactor in the trickle bed. Non-converted hydrogen is separated at the outlet of the hydrogenation reactor by means of a separating device not shown in the Figure and via conduits 4 , 6 and 3 and the compressor 5 recirculated to the top of the hydrogenation reactor. During the hydrogenation, the FAME space velocity typically is between 0.1 to 5 l/(l cat h), preferably 0.5 to 1.5 l/(l cat h), particularly preferably 0.75 l/(l cat h). The temperature typically is between 100 and 300° C., preferably between 120 and 250° C., particularly preferably 180° C. The hydrogen pressure preferably is 50 to 300 bar, absolute, preferably either 50 to 75 bar, absolute, or alternatively roughly 250 bar, absolute (high-pressure hydrogenation).
[0027] At the lower end of the hydrogenation reactor a liquid material stream is discharged, which beside non-converted FAME also contains the hydrogenation products fatty alcohol (FA) and methanol. Via conduit 7 , this substance mixture is supplied to the distillation column 8 . As top product of the distillation column 8 methanol is withdrawn via conduit 9 and supplied to the disposal, processing or direct reuse, for example for the production of FAME. As bottom product of the distillation column 8 a liquid material stream is discharged via conduit 10 , which substantially contains FA and FAME. This material stream is charged to the top of the transesterification reactor 11 which is filled with a bed of coarsely porous magnesium oxide granules with a grain size of 2 to 3 mm as transesterification catalyst. The transesterification in turn is carried out in the trickle bed at a temperature of 100 to 300 ° C., preferably 150 to 250 ° C., particularly preferably 240 ° C. and at a pressure of 0.1 to 5 bar, absolute, preferably 0.5 to 2 bar, absolute, particularly preferably at 1 bar, absolute, and at a space velocity of the liquid phase of 0.1 to 5 l/(l cat h), preferably 0.5 to 2 l/(l cat h), particularly preferably 0.75 to 1 l/(l cat h). In counterflow to the liquid phase, nitrogen gas is passed through the transesterification reactor with a space velocity of 2 to 3 l/(l cat h). During the transesterification, FAME is reacted with excess fatty alcohol to obtain wax ester (WE), wherein methanol is released.
[0028] At the top of the transesterification reactor, a nitrogen stream loaded with methanol is withdrawn via conduit 12 , which in the cooler 13 is cooled to below the dew point of methanol. Via conduit 14 , the two-phase mixture gas/liquid is supplied to the separator 15 , at the top of which a nitrogen stream liberated from methanol is withdrawn and via conduit 16 and condenser 17 charged to the bottom side of the transesterification reactor 11 . Via conduit 18 , a further fraction of methanol is withdrawn and supplied to the disposal, processing or direct reuse, for example for the production of FAME.
[0029] At the lower end of the transesterification reactor 11 a liquid material stream is discharged, which substantially consists of fatty alcohol (FA) and wax ester (WE). Via conduit 19 , the same is charged to a distillation column 20 . As top product of the distillation column 20 a material stream containing the target product fatty alcohol is discharged via conduit 21 and supplied to the further processing or direct further use.
[0030] As bottom product of the distillation column 20 a liquid material stream is discharged via conduit 22 , which substantially contains wax ester beside traces of FA. This material stream is recirculated to the hydrogenation reactor 2 via conduit 22 and again charged at the top of the reactor.
[0031] FIG. 2 shows a schematically represented basic flow diagram of a further aspect of the process according to the invention. The material stream substantially containing FAME and wax ester, which is discharged from the transesterification reactor 11 via conduit 19 , is supplied to a cooler 23 via conduit 19 and cooled there to below the crystallization temperature of the wax ester. This procedure also is referred to as winterization. The resulting two-phase mixture of solid wax ester and liquid fatty alcohol subsequently is charged to a centrifuge 25 via conduit 24 . The clear supernatant obtained during the centrifugation contains the target product fatty alcohol already in high purity and is supplied to the further processing or direct further use. Beside wax ester as main constituent the crystal mash obtained during the centrifugation also contains fatty alcohol. This material stream is recirculated to the hydrogenation reactor 2 via conduit 22 and again charged at the top of the reactor. The possibly required additional process steps, for example the redissolution of the wax ester to a pumpable solution, are not represented in FIG. 2 , but are well-known to the skilled person.
NUMERICAL EXAMPLE
[0032] In the following Table, the results of transesterification experiments by using various titanium silicate catalysts, as they were described in the prior art (comparative experiments), are compared with the test results obtained when using magnesium oxide granules (invention). All transesterification experiments were carried out in the trickle bed in a tubular reactor filled with a bed of the respective catalyst, wherein a nitrogen stream constant in all cases was countercurrently passed through the reactor. The composition of the feed mixture each was 95 wt-% of fatty alcohol +5 wt-% of methyl ester. The reactor temperature each was 240° C., the space velocity LHSV constantly was 1 l/(l cat h). All experiments were carried out at ambient pressure.
[0000]
TABLE
Results of the transesterification experiments with
titanium silicate catalysts (comparative experiments)
and magnesium oxide catalyst (invention)
Products/GC area percentage
Catalyst
FA
FAME
WE
Olefins
X #)
Comp. ex-
Ti-silicate
90
3
2
4
1
periment
1
Comp. ex-
Ti-silicate
93
0
5
2
0
periment
2
Comp. ex-
Ti-silicate
94
0
1
1
4
periment
3
Comp. ex-
Ti-silicate
93
2
3
0
2
periment
4
Comp. ex-
Ti-silicate
91
4.5
0.5
1
3
periment
5
Comp. ex-
Ti-silicate
93
4
1
1
1
periment
6
Invention
MgO
95
0
5
0
0
#) X: probably di-FA ether
[0033] As can distinctly be seen with reference to the test results shown in the Table, a quantitative conversion of FAME to wax ester is effected in the transesterification process according to the invention by using magnesium oxide granules as catalyst, without disturbing impurities being produced. When using titanium-silicate catalysts according to the prior art, a less quantitative conversion to wax ester and the formation of impurities (olefins and/or component X) is observed under the same reaction conditions.
INDUSTRIAL APPLICABILITY
[0034] The invention provides a process with which fatty alcohols can be obtained in high purity as highly desired base chemicals. The catalysts are commercially available and therefore easy to obtain. The hydrogenation catalyst can be exploited better than in the processes known from the prior art; the catalyst costs per ton of produced fatty alcohol thereby are reduced. Furthermore, the process according to the invention leads to an increase of the product yield by better utilization of raw materials.
[0035] While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims. The present invention may suitably comprise, consist or consist essentially of the elements disclosed and may be practiced in the absence of an element not disclosed. Furthermore, if there is language referring to order, such as first and second, it should be understood in an exemplary sense and not in a limiting sense. For example, it can be recognized by those skilled in the art that certain steps can be combined into a single step.
[0036] The singular forms “a”, “an” and “the” include plural referents, unless the context clearly dictates otherwise.
[0037] “Comprising” in a claim is an open transitional term which means the subsequently identified claim elements are a nonexclusive listing (i.e., anything else may be additionally included and remain within the scope of “comprising”). “Comprising” as used herein may be replaced by the more limited transitional terms “consisting essentially of” and “consisting of” unless otherwise indicated herein.
[0038] “Providing” in a claim is defined to mean furnishing, supplying, making available, or preparing something. The step may be performed by any actor in the absence of express language in the claim to the contrary.
[0039] Optional or optionally means that the subsequently described event or circumstances may or may not occur. The description includes instances where the event or circumstance occurs and instances where it does not occur.
[0040] Ranges may be expressed herein as from about one particular value, and/or to about another particular value. When such a range is expressed, it is to be understood that another embodiment is from the one particular value and/or to the other particular value, along with all combinations within said range.
[0041] All references identified herein are each hereby incorporated by reference into this application in their entireties, as well as for the specific information for which each is cited.
LIST OF REFERENCE NUMERALS
[0000]
[ 1 ] conduit
[ 2 ] hydrogenation reactor
[ 3 ] conduit
[ 4 ] heat exchanger
[ 5 ] compressor
[ 6 ] conduit
[ 8 ] distillation column
[ 9 ] conduit
[ 10 ] conduit
[ 11 ] transesterification reactor
[ 12 ] conduit
[ 13 ] cooler
[ 14 ] conduit
[ 15 ] conduit
[ 16 ] conduit
[ 17 ] condenser
[ 18 ] conduit
[ 19 ] conduit
[ 20 ] distillation column
[ 21 ] conduit
[ 22 ] conduit
[ 23 ] cooler
[ 24 ] conduit
[ 25 ] centrifuge
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Subject-matter of the invention is a process for producing fatty alcohols by catalytic hydrogenation of fatty acid methyl ester (FAME), in which the FAME initially is hydrogenated to fatty alcohol (FA). The fractions of non-converted FAME remaining in the hydrogenation product are converted to wax ester and methanol in a succeeding transesterification step with FA. According to the invention, catalysts on the basis of magnesium oxide or hydrotalcite are used. After separating the methanol and the FA as target product, a stream enriched in wax ester is recirculated to the hydrogenation reactor.
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This is a continuation of application Ser. No. 07/680,678 filed Apr. 4, 1991 now U.S. Pat. No. 6,017,722.
BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention relates generally to the field of methods for identifying toxicants and/or isolated component substances in a sample. The types of samples which may be analyzed include either a solid sample, a liquid sample or a gaseous sample. The present invention also relates to the field of biological toxicant identification agents, as a particularly described luminescent biological reagent, for example the luminescent bacteria, are employed in the claimed isolation, identification and quantitation methods and techniques disclosed herein. The present invention also relates to the field of toxicant detecting kits, as a kit for the identification of toxicants is described employing a luminescent biological reagent.
II. Description of the Related Art
When grown in appropriate liquid culture or on semi-solid culture media, suspensions of luminescent bacteria emit a constant level of light for extended periods. Luminescent bacteria are bacteria which emit light without excitation, (i.e., they glow in the dark). The origin of the emission is biochemical, and organisms which demonstrate this characteristic are described as exhibiting the phenomenon of bioluminescence. Most known examples of luminescent bacteria are marine. Two major subclasses of the luminescent organisms are 1) free living ( Vibrio harveyl ) and 2) symbiotic ( Vibrio fischeri, Photobacterium phosphoreum, Photobacterium leiognathi ). Other major bioluminescent organisms include fire flies ( Photinus pyralis ), crustaceans ( Cyridina hilgendorfi ), dinoflagellates ( Gonyaulax polyhedra, Notiluca militaris ), fungi ( Omphalia flavida ) and the sea pansy ( Renilla reniformis ).
The luminescence of bacteria has long been known to be sensitive to a wide variety of toxic substances (e.g., heavy metals, pesticides, etc.). The exquisite sensitivity of luminescent bacteria to a variety of substances has made them a popular choice in methods for the gross detection of the presence of toxic materials. For example, the use of luminescent bacteria has been discussed for the detection of toxins on solid surfaces, such as soil 5 , and in liquid substances, such as in the analysis of waste water 3 , as well an in the detection of toxins in gaseous samples 6 .
Luminescent bacteria have also been employed in the detection of toxicants in marine environments. 2 For example, Vasseur et al. describe a Microtox luminescent bacterial assay for the detection of toxicants in water ( Photobacterium phosphoreum ) 2 .
Another variety of luminescent bacteria used in the analysis of industrial waste water is described in the Baher patent. 3 Specifically, the Klebsiella planticola bacteria has been used to detect the presence of substances toxic to particular microorganisms (used to purify industrial chemical plant waste waters) indicated through monitoring the luminescence of the Klebsiella.
Luminescent bacteria have also been used for detecting the presence of specific substances in a sample, including antibiotics, heavy metals, enzyme inhibitors, pesticides, microbial toxins, volatile hydrocarbons, disinfectants, and preservatives. 6 For example, the Siemens patent describes the use of a luciferase-gene-transformed microorganism for detecting the presence of a toxicant in a sample through a demonstrated reduction in the luminescent signal emitted by the luminescent bacteria in the presence of a toxic substance 6 .
Others have reported the ability to detect the presence of particular classes of chemical toxicants using luminescent bacteria, particularly phenolic compounds. 7 For example, in Strom et al., the relative toxicity of a variety of particularly defined phenolic compounds, including hydroquinone, is described using a luminescent bacterium 7 .
Thus, some species and components of luminescent bacteria have been adapted for use to simply detect the general presence of a toxic substance in a sample. In the presence of toxicants, detection of the toxins is provided by an observed diminution in luminescent emission and intensity in a variety of luminescent bacteria. However, the value of the “detection” techniques currently available is limited by an inability to identify, in an isolatable form, the substance which constitutes the “detected” toxicant or foreign substance.
No methods have been described wherein a generically “detected” toxicant may be identified in an isolatable form using a luminescent bacteria. The ability to actually identify an isolated substance as a potential “toxicant” in a sample would provide a powerful industrial and research tool. Moreover, the ability to distinguish, by positive chemical analysis, the chemical structure of an isolated toxicant (using various chemical separation techniques known to those of skill in the art) would find great potential application in research, diagnostic medicine and industrial manufacturing processes.
Standard chemical visualization techniques for the localization of separated substances employ a variety of stains and staining procedures known to those skilled in the art (i.e., coomassie brilliant blue for gel electro-phoresis of proteins; 2-Naphthol or Resoranol for paper chromatography of sugars inhydrin for amino acid analysis with TLC). However, these techniques do not identify the potential toxicity of any visualized substance in the sample. No system has been proposed wherein a reagent may be used to provide a system wherein the potential toxicity of isolated substance in a sample may also be visualized and thereby identified.
Such a novel method for the simple, inexpensive and sensitive identification of a substance(s) in a sample or product which may be potentially lethal to an organism would also facilitate the further chemical elucidation of the chemical identity of the proposed toxicant through the subsequent use of various well known chemical analysis strategies available to those of skill in the art (such as mass spectrometry, nuclear resonance spectroscopy, infrared spectroscopy, x-ray crystallography, and chromatographic analysis). Thus, the complete chemical structure and identity of the potential toxicant could be determined if such a method, capable of identifying in an isolatable form the potential toxicant, were available. Such a system would be particularly valuable in the development of strategies to remove such identified toxicants from products intended for consumer use, and also in the development of procedures to render chemically identified toxicant(s) innocuous to animals and humans.
SUMMARY OF THE INVENTION
The present invention provides a rapid and accurate method for identifying a component substance (such as a toxin/toxicants) in a sample through the use of a luminescent biological agent employed together with chromatographic resolution techniques.
While any of a variety of luminescent bacteria may be used, those species found to be most particularly preferred for use in the practice of the present invention include Photobacterium phosphoreum, Vibrio fischeri, Vibrio harveyi and Photobacterium leiognathi . However, it is to be understood that the present inventive methods, reagents and kits may be practiced using any luminescent organism whose luminescence is specifically inhibited by an isolated component substance (for example, a potential toxicant) in a sample.
The present methods, reagents and kits may be used to isolate and identify a single toxicant, a number of individual toxicants, or a group of toxicants in or on a sample in the solid, liquid, or gaseous phase.
In part, the point of novelty of the present invention resides in the ability to identifiably isolate a component substance (for example, a toxicant) contained in a sample rapidly, and without the necessity of a separate biosensitivity assay of test sample. This is accomplished, for example, by applying a potentially toxicant-containing sample to a separation phase matrix, such as a chromatography paper sheet or a thin layer chromatography plate. The sample-exposed sheet is then exposed to a luminescent biological agent (i.e., the luminescent bacteria) according to the claimed method to accomplish, in one step, both the isolation of each distinct component substance of the sample and the potential toxicity of each of the distinct components in the test sample.
For example, according to the claimed invention, an unknown sample (for example a liquid unknown sample or a concentrated extract of a larger sample which potentially contains toxicants) may be spotted or streaked near one edge of a chromatography paper sheet at several points.
Most preferably, the sample “spots” or “streaks” are air dried to eliminate the carrier solvent in which the sample was dissolved. More applications of sample(s) can be overlaid onto the respective sample spots, if necessary, and dried. The end of the chromatography sheet closest to the spotted sample edge is then placed in contact with the solvent system of choice.
In the usual situation, the solvent of the solvent system will migrate through the “spotted” sample and through the length of the chromatography paper via capillary action and along the length of the chromatography sheet, thus separating the sample into its component parts onto particular locations or “segments” on the separation phase matrix (i.e., chromatography paper).
These locations or “segments” of the separation phase matrix (which provide the isolated components of the sample) are then exposed to a luminescent biological agent, and provide for the visualiation and identification of a distinct zone of luminescent inhibition” at locations or “segments” where luminescent inhibitory components of the sample are located.
Alternatively (to the above paper chromatography method), an unknown sample could be separated using TLC by spotting the sample on a thin layer chromatography plate. Thus, the sample would be spotted, and air dried analogously to that procedure followed for paper chromatography. However, the solvent in a TLC chamber is at the bottom of the chamber and therefore the solvent migration will be upward through the TLC plate separation phase matrix.
Depending on a variety of factors, including molecular polarity, the isolatable components in the sample will resolve, on the separation phase matrix, being more soluble in the solvent than having affinity for the silica gel or other separation phase matrix.
Resolution of the components in the mixture will depend on the polarity of the molecules in the sample verses the polarities of the stationary (e.g. paper, silica or alumina) and mobile (solvent) phases. The end result in the one dimensional TLC described is a linear array of components at different locations along the length of the chromatogram. The component substances of the sample thus migrate to isolatable locations or “segments” on the plate.
Vertical sections along one side or portion of the TLC plate may be sprayed with the luminescent biological agent to visualize toxicant location. Corresponding unsprayed zones of the plate may then be scraped off and eluted with an appropriate solvent or solvent mixture. In this manner, individual toxicants may be obtained for further separation, chemical identification, or quantitation using those laboratory techniques well known to those of skill in the art.
More toxicant may be obtained for specific chemical analysis of the thus “identified” locations or segments (areas of luminescent inhibition on the chromatogram) of the separation phase matrix by eluting identical segments from a second run selected separation phase matrix (TLC or chromatography paper) that has not been exposed to the luminescent biological agent. The chemical structural identity of the toxicant or isolated component substance of the sample may be elucidated according to standard laboratory techniques well known to those skilled in the art, such as mass spectroscopy (MS) 22 ; high performance liquid chromatography (HPLC) 10,11,12,28 ; infrared spectroscopy (IR) 23 ; nuclear magnetic resonance (NMR) 22,24 ; thin layer chromatography (TLC) 9,26 ; x-ray crystallography 22,23 and the like.
As used in the present application, the term “luminescent” biological agent is defined as an organism or an extract of an organism, which emits heatless light under appropriate conditions. Most luminescent systems involve the use of molecular oxygen. Luciferin (a pigment) and a specialized form of a luciferase enzyme are included in many luminous organisms and enables these organisms to emit a heatless light in the presence of oxygen. Cypridina is an example of a marine organism which contains the luciferin pigment. For example, Cypridina contains a luciferin which, when reacted with the Cypridina luciferase enzyme in the presence of oxygen, emits a heatless bioluminesence. Vibrio fischeri 16 and Vibrio harveyil 7 contain an enzyme necessary to make light, a well as two reagent compounds (a long-chained aliphatic aldehydes and a vitamin derivative, which is a yellow pigment flavin mononucleotide. In reduced form (i.e., in the presence of oxygen) the pigment glows and allows the organism to emit a heatless light. For example, Cypridina contains a luciferin which, when reacted with the Cypridina luciferase enzyme in the presence of oxygen, emits a heatless bioluminescence. Similarly, fire flies possess a luciferin pigment which in the presence of the firefly luciferase and oxygen, provides a bioluminescence suitable for use in the practice of the present invention. Photobacterium leiognathia is a bacteria which is strongly bioluminescent. All organisms and plants which possess a luciferin/luciferase system would be included among those luminescent biological agents which could be used in the practice of the claimed invention.
The present invention also provides a kit for the identification of a toxicant in a sample, which includes a luminescent biological (for example, bacterial) agent. In a particularly preferred embodiment, the kit comprises a carrier means adapted to receive at least two container means and at least one separation phase matrix in close confinement therewith; at least one separation phase matrix; a first container means comprising a luminescent biological agent; and a second container means comprising a diluent for the luminescent biological agent.
Most preferably, the luminescent biological agent is a luminescent bacteria, such as Vibrio fischeri (ATCC No. 7744), Photobacterium phosphoreum, Photobacterium leiognathi , or Vibrio harveyi (ATCC No. 33843). In a most preferred embodiment of the kit, the luminescent biological agent is in a lyophilized form. Where the luminescent biological agent is in a lyophilized or dried form, the kit will include a diluent suitable for reconstituting the particular biological agent into its “glowing” form.
By way of example, where the luminescent biological agent is a luminescent bacterial agent, and the particular luminescent bacterial agent is a marine bacteria, a suitable diluent would comprise a salt solution of at least 1% by weight NaCl. A saline solution between 1% to 4% NaCl is even more particularly preferred. Most preferably, the diluent should constitute 3% by weight NaCl.
The diluent of the kit most preferably is a buffering agent which includes an NaCl concentration of the diluent should be a concentration which maximizes the luminescent characteristics of the particular marine bacterial species employed. The salt concentration of the diluent has been observed by the Inventors to affect the intensity of the bacteria's luminescence, and thus the bacteria's suitability as a “visualizing” agent for the described method. For example, where the luminescent bacteria is Vibrio fischeri , a marine luminescent bacteria, the diluent is most preferably about 0.5 M NaCl. Other diluents for marine luminescent bacteria may comprise a saline solution between 0.6-0.66 M NaCl (1%-4% by weight NaCl).
The separation phase matrix may comprise a chromatography paper sheet, a TLC plate, a Sepharose matrix, or virtually any matrix which is capable of separating a mixed sample into discernable, at least partially isolated, components. The separation phase matrix most preferred for use in the described kit is a TLC plate.
Most preferably, where the method to be used to isolate the components of the sample is paper chromatography, the chromatography paper sheet is most preferably Whatman chromatography paper 1M or 3M. Where the method for separation is TLC, the most preferred TLC plates are Whatman adsorption plates flexible backed aluminum or polyester #4410-222 plates.
The luminescent bacterial agent is to be suspended in a saline solution diluen. Where the bacteria is stored in lyophilized form, the lyophilized bacterial agent is reconstituted in the referenced saline diluent to regain its luminescent form prior to use.
Attempts by the Inventors of directly laying a TLC plate on the luminescent bacteria provided relatively low-sensitivity (i.e., a large amount of inhibitor substance or toxicant needed to be present to demarcate the presence of any isolated substance) for detection, as the discernable “zones” of luminescent inhibition were relatively faint. Therefore, most preferably, the reconstituted bacterial agent is placed into an aspirator spray bottle and sprayed onto sample-exposed separation phase matrix, (for example, the sample-exposed chromatography paper sheet or TLC plate).
The method of directly spraying a TLC plate with a suspension of the luminescent bacteria was demonstrated to provide the best results, with clearly defined “zones of luminescent inhibition” and wherein even minor (less distinct) zones of luminescent inhibition are discernable. At this time, spray application of the luminescent biological reagent thus constitutes the best mode for practicing this aspect of the invention.
However, other methods for achieving contact of the luminescent biological agent to a test sample may be employed to identify substances and/or toxicants in a sample. For example, a sheet of film with an agarose or acrylamide layer, or other solid surface or gel containing a rehydratable material therein capable of being stored in sheet form and rehydratable prior to use, are contemplated by the Inventors as constituting equally usable methods for practicing the claimed invention.
In such an embodiment, a dehydrated form of the luminescent biological agent would be incorporated into a porous or water permeable material which was amenable to being formed into a sheet form. The sheet, so impregnated with a dehydrated form of the luminescent biological agent, would be stored in dry form until needed for use. For use, the sheet with the bacterial agent in it should be rehydrated in a suitable rehydrating agent, such deionized water or a saline solution. Where the luminescent biological agent is a marine luminescent bacteria, such as Vibrio fischeri , the rehydrating agent would most preferably be a saline solution of at least 1% NaCl. Most preferably, the saline solution should be between 1-4% NaCl. A 3% NaCl solution is most preferred.
After the sheet has been rehydrated, the now “glowing” sheet would be laid over a sample of isolated component substances/toxicants to render the luminescent biological agent in contact with the test sample component substances. The existance of zones of luminescent inhibition could then be examined to identify potential toxicants of the sample.
The claimed invention also comprises a luminescent bacterial agent which is capable of identifying in isolatable form a component or mixture of components, substances or a toxicant in a sample. The presence of isolatable component substances or toxicants in a sample is visualized through the presence of discernable zones of inhibition surrounding the applied luminescent bacterial reagent (i.e., termed “zones of luminescent inhibition”).
Any luminescent bacteria may be employed in the practice of the present invention. However, those luminescent bacterial agents preferred in the practice of the invention include Photobacterium phosphoreum, Photobacterium leiognathi, Vibrio fischeri , (ATCC Acc. 7744) and Vibrio harveyi (ATCC Acc. 33843). Among these exemplary bacteria, the Vibrio fischeri and Vibrio harveyi bacteria embody the even most preferred luminescent bacterial agents of the invention. The Vibrio fischeri (ATCC Acc. No. 7744) constitute the most particularly preferred embodiment of the claimed luminescent bacterial agent of the present invention.
As a method for identifying component substances in a sample, using a luminescent biological agent, the claimed method comprises: preparing a luminescent biological agent; obtaining a sufficient volume of the sample to provide a test sample; separating the component substances of the test sample by applying the test sample to a separation phase matrix to provide isolated component substances; and exposing the isolated component substances to a volume of the luminescent biological agent in a concentration sufficient to identify the isolated component substances of the sample. One or more zones of luminescent inhibition will become apparent on the luminescent biological agent-exposed separation phase matrix, and thus identify the isolated component substances in the sample. The concentration of luminescent biological agent sufficient to identify the isolated component substances of a sample is referred to as a “substance indicating amount”. Where the test sample is being analyzed to identify potential toxicant(s), the amount of luminescent biological agent is defined as “toxin indicating amount”. The necessary concentrations to provide this “indicating” effect is between 10 8 -10 9 bacterial cells/ml of diluent where the bacterial agent is contacted with the sample in the form of a liquid suspension.
Where paper chromatography is the technique used to separate component substances or toxicants in a test sample, chromatography paper (as the separation phase matrix) and an appropriate solvent system are used. Corresponding segments on a separate chromatogram (sample plus chromatography sheet) not exposed to luminescent bacteria may be used to obtain additional volumes of the component substances/toxicants of the sample, or where desired, to further chemically identify the isolated component substances of the sample. Additional sample or chemical analysis of the sample in purer form may be accomplished for example, by cutting out the chromatography paper segments (not exposed to luminescent bacteria) which correspond to the identified “zones of luminescent inhibition”; and eluting the isolated substances from the cut out chromatography paper segments with an appropriate solvent.
The isolated component substances or potential toxicants of the sample may then be analyzed using standard chemical and spectral means to chemically identify the isolated substances of the sample. If necessary, the eluate of the isolated components of the sample may be concentrated by techniques well known to those skilled in the art prior to chemical and spectral analysis to chemically identify the isolated substance or toxicant of the sample.
The luminescent biological agent of the claimed method may comprise a luminescent bacteria, a luminescent fungi, a luminescent fish extract, a luminescent dinoflagellate, a luminescent firefly extract, luminescent anthrogans, luminescent earthworm extract, luminecent coelenterate extract or a luminescent crustacean. ( Cypridina organisms ).
Most preferably, the luminescent biological agent is a luminescent bacteria, such as Vibrio fischeri (ATCC acc. 7744) Vibrio harveyi (ATCC Acc. 33843), Photobacterium phosphoreumi , or Photobacterium leiognathi . The term “luminescent biological agent” as used in the present application may include an organism which has been modified to possess luminescence such as an organism genetically engineered to include the luciferase gene. According to the claimed methods, the test sample may comprise a liquid sample, a solid sample, or a gaseous sample. Most preferably, the sample is to be prepared as a liquid test sample for separation via a TLC plate separation phase matrix.
While the present methods may be used to isolate and identify virtually any substance(s) or toxicant(s) in a sample which is capable of inhibiting the luminescence of a luminescent biological agent (for example, a luminescent bacterial agent), preferred applications of the present method include the identification of isolated substances such as pesticides, herbicides, heavy metals and their salts, and plant extracts, from a sample. By way of example, pesticides which may be identified according to the present methods include DIAZANON®, LINDANE® and SEVIN®. By way of example, herbicides which may be identified according to the present methods include ROUNDUP® and WEED-B-GON®. Heavy metals which may potentially be identified according to the present methods include the identification of mercury, lead, cadmium and their respective salts.
According to the present method, the isolated substance or toxicant(s) in the sample may be chemically analyzed by any combination of laboratory techniques well known to those of skill in the art for the chemical characterization of an isolated or partially isolated substance. For example, MS, IR, NMR, HPLC, thin layer chromatography, etc are standard techniques which may be used to further chemically define an isolated substance in a sample. Any of these common laboratory techniques may be used alone or in combination to identify the chemical structure of substantially purified component substances or potential toxicants in a sample.
According to one preferred embodiment of the present method, wherein the separation technique is paper chromatography (separation phase matrix is chromatography paper), the developed chromatogram (having thereupon any isolatable component substances or toxicants of the sample) may be exposed to the luminescent bacterial agent by spraying a suspension of the luminescent bacterial agent, most preferably suspended in a saline solution, onto the developed chromatogram.
As the agent used to visualize the components/toxicants of a sample is of a biological nature, and therefore potentially sensitive (i.e., inhibited by chemicals) to components of a desired solvent to be used, failure to remove solvent could in itself cause nonspecific inhibition of luminescence. Thus, application of the luminescent bacterial suspension should be done after the complete evaporation of carrier solvent from the chromatogram. In addition, the developed chromatogram should also be allowed to dry a second time, after the separation solvent has passed through the sample “streaked” or “spotted” chromatogram, before the luminescent biological (for example, luminescent bacterial agent) is applied (for example sprayed) to the chromatogram.
Observation of a chromatogram exposed to the luminescent agent (the “sprayed” chromatogram) should be made while the chromatogram is still wet or at least moist with the suspension of luminescent biological reagent applied thereto. For example, luminescent bacteria are very sensitive to dehydration, and thus luminescence would be lost everywhere if the investigator does not examine the chromatogram within at least 1 hour of exposing the bacteria to the chromatogram. In practice, a bacteria-sprayed chromatogram remains moist and glowing from the luminescent biological agent for as long as 45 minutes to one hour, depending on the humidity of the environment.
The Inventors herein demonstrate that the inhibition of luminescence of particular species of luminescent bacteria employed according to the methods described herein, is discriminating as among potential toxicants and/or isolated component substances of a test sample. For example, the Inventors have found that the luminescence of one particular species of luminescent bacteria, Vibrio fischeri , is not inhibited by the pesticide, VOLCK oil spray. Neither does the luminescence of the Vibrio fischeri appear to be immediately inhibited by calcium ion. Moreover, all of the luminescent inhibition effects demonstrated through the use of luminescent bacteria, particularly Vibrio fischeri , are concentration dependent.
The methods of the present invention may be adapted for use in the identification of closely related components which may be present together in a test sample. For example, selective sensitivities as between different luminescent biological agents, particularly as between luminescent bacteria, may be used to tailor the disclosed method for use in a particular industry, or to test specific product lines. For example, the luminescence of the bacterial agent Vibrio fischeri is more sensitive to the pesticide DIAZANON® than to the pesticide LINDANE®. Similarly, the luminescence of this particular bacterial agent is more sensitive to the inhibitory action of SEVIN® as compared to LINDANE®. Selection of Vibrio fischeri bacteria would thus be indicated as particularly suitable for use in the described method where a sample is suspected to contain pesticides, such as in a pesticide production facility, or perhaps where foodstuffs are stored.
Thus, the particular species of luminescent bacteria may be selected on the basis of the specific use for which it is intended (i.e., for the identification of a particular class of related substances). For example, where an Investigator wishes to isolate and identify particular pesticides, he/she may select a luminescent bacteria which demonstrates a particular sensitivity to pesticides in general, over another, perhaps less sensitive, luminescent bacteria, for the analysis of a sample which may likely include pesticides. Therefore, a hierarchy of relative toxicant sensitivity, in regard to both the class of toxicant and particular luminescent bacteria, can be established.
The present invention provides a rapid (about 35 minutes) technique that can potentially identify a wide variety of environmentally and biologically harmful substances.
The Inventors have found that the methods described herein are capable of identifying herbicides and pesticides at their working strengths, (i.e., DIAZANON®, LINDANE®, ROUNDUP® AND WEED-B-GON® diluted 1/150). Therefore, herbicides, pesticides and other environmental pollutants and contaminants may be identified according to the present method with the described kits as they occur in the environment in the air, in lakes, streams, ground water and in run-off from fields, for example, in relatively dilute form (for example diluted 1/1,000 from commercial stock concentration).
As used in the present disclosure, the term “toxicant” and “identified isolated component substance” of a sample is defined as a substance which is capable of inhibiting the luminescence of a luminescent biological agent, such as a luminescent bacteria, Vibrio fischeri.
Even more specifically, the term “toxicant” is broadly defined as a substance which is capable of inhibiting or potentially lethal to, a virus or a living organism, such as a plant, animal or microorganism. Even more specifically a toxicant potentially toxic to an animal such as a human may be identified using the described method. Toxicity to bacteria is recognized as an indication of toxicity of a substance to higher organisms, including humans. The Inventors hypothesize that forms of the biological agents which are represented by whole organisms, rather than extracts of whole organisms, will be both more sensitive and also be capable of identifying a broader range of substances and toxicants in a sample in smaller concentrations than with luminescent extracts from an organism.
As used in the present application, the term bioluminescence more specifically refers a living organism or from extracts of a living organism when combined under appropriate conditions. Lack of luminescence refers to the lack of light emission not necessarily related to the expiration of the organism.
The following abbreviations are used throughout the Specification:
ECD
=
Electron Capture Detection
TLC
=
Thin Layer Chromatography
NMR
=
Nuclear Magnetic Resonance Spectroscopy
M
=
Molar
HPLC
=
High Performance Liquid Chromatography
IR
=
Infra-Red Spectroscopy
MS
=
Mass Spectroscopy
D
=
Dimension
THF
=
Tetrahydrofuran
UV
=
Ultraviolet
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 -
TLC plate with garlic extract sample in H 2 O.
Not exposed to luminescent bacteria. TLC
Plate identified those components which are
ultraviolet light-absorbing. If compound
absorbs the 254 nM light, then area where
compound is located will not glow, and appears
as a dark spot (V shape) in a garlic extract
using fluorescent detection (254 nM
excitation). Solvent used is 80:8:12 mixture
of (H 3 CCN:H 2 O:NH 3 ). The V-shaped areas are not
indicative of a bacteriotoxic agent. Results
from these analysis indicate a compatible
system for resolving ultraviolet absorbing and
thereby identifiable components in a sample.
FIG. 2 -
TLC plate with garlic extract sample exposed
to luminescent bacteria, Vibrio fisheri, same
solvent as FIG. 1. Bioluminescence
inhibition is evident as a dark circular
region (about 10.5 cm from bottom of plate).
This circular region is hypothesized to
constitute allicin in the garlic extract.
FIG. 3 -
TLC plate with DIAZANON ® and LINDANE ® by
fluorescence.
FIG. 4 -
TLC plate DIAZANON ® and LINDANE ® by
bioluminescence.
FIG. 5 -
TLC for DIAZANON ® dilution series. Plates
demonstrate a dilution series of DIAZANON ®.
The presence of DIAZANON ® is demonstrated at
dim areas defining the “zone of luminescent
inhibition” of the luminescent bacteria,
Vibrio fischeri, in response to the pesticide.
Dilutions employed of the pesticides were full
strength, 1:128; 1:256; 1:512 and 1:1024.
FIG. 6 -
TLC for DIAZANON ® dilution series with the
luminescent bacteria, Vibrio fischeri (same
dilutions as for FIG. 5).
FIG. 7 -
TLC of DIAZANON ® with either UV 254
fluorescence or bioluminescence inhibition
with luminous bacteria, Vibrio fischeri in a
sample.
FIG. 8 -
TLC of DIAZANON ®, ROUNDUP ® and WEED-B-
GON ® identified at a dilution of 1/150 (working
strength). Luminescent bacteria exposure time
prior to examining the bacteria-sprayed plates
was 35 minutes.
FIG. 9 -
TLC plates of two pesticides, DIAZANON ® and
LINDANE ® and two herbicides, ROUNDUP ® and
WEED-B-GON ®, taken in room lighting. Dilution
of pesticides and herbicides = 1/150.
FIG. 10 -
TLC plates of two pesticides, DIAZANON ® and
LINDANE ® and two herbicides, ROUNDUP ® and
WEED-B-GONE ® viewed by bioluminescence showing
zones of luminescent inhibition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides methods, kits and luminescent biological (for example, bacterial) agents which are demonstrated to be surprisingly advantageous for the identification of specific toxicants or component substances in a sample. Moreover, techniques are proposed wherein the identified component substances of a sample may subsequently be chemically characterized or additional volumes of the isolated component ingredient (i.e., toxicant) be obtained employing a variety of chemical techniques in conjunction with the teachings of the present disclosure.
The novel use of a luminescent biological agent together with a separation phase matrix provides a unique method for the rapid and simple identification of potentially toxic (isolated) substances in a sample. The Inventors foresee the application of the present invention in the laboratory as well as in industry for the detection of environmental pollutants, particularly in water resources. Additionally, use of the described methods in the development and identification of therapeutically valuable components in plants and organisms, such as in garlic, is also considered an important application of the described invention.
Luminescent Bacteria as the Luminescent Biological Agent
Where the luminescent biological agent to be used is a luminescent bacterial agent, such as the luminescent bacteria Vibrio fischeri , the bacteria should constitute a suspension of bacteria at a final concentration of about 10 8 -10 9 bacteria cells/ml in the suspension to be used, for example, where the luminescent bacterial agent is sprayed onto a chromatogram.
A preferred method whereby the luminescent bacteria are prepared for use in the presently described invention is as follows. The bacteria must first be allowed to become fully “induced” in their luminescent system, i.e., the luminescent system of the bacteria should be allowed to reach complete development prior to harvesting of the bacteria from the culture. Determination of at what point a bacteria has reached full luminescent system development is well known to those of skill in the art 30,31 .
Upon full development of the luminescent system of the bacteria, the bacteria should be harvested and then placed in a centrifuge tube. The bacteria are then to be centrifuged at a speed of 10,000×G for 30 minutes at room temperature. Thus centrifuged, the bacteria will form a pellet of cell “paste” at the bottom of,the tube. About 1 gram of this cell paste (about 12 ml of cell “paste”=1 gram) of glowing bacteria is then to be diluted to a volume of 20 ml, by adding 20 ml of a diluent of choice. Where the luminescent bacteria is a marine bacteria, for example, the diluent is most preferably a buffered saline solution of between 1-4% NaCl. As diluted to 20 ml, the cell suspension constitutes a concentration of 10 10 -10 12 bacteria cells/20ml (or 10 8 -10 9 cells/ml).
The following Examples are presented only to describe preferred embodiments and utilities of the present invention, and to satisfy best mode requirements. The examples are not meant to limit the scope of the present invention unless specifically indicated otherwise in the claims appended hereto. The following Examples are provided to demonstrate various aspects of the present invention.
EXAMPLE 1—Isolation of Identifiable Luminescent Inhibitory Toxicant In Garlic Extract Using Luminescent Bacteria.
PROPHETIC EXAMPLE 2—Proposed Chemical Identification of Toxicants in a Garlic Extract.
EXAMPLE 3—Identification of Pesticides in Sample With Luminescent Bacteria.
EXAMPLE 4—Dilution Series of DIAZANON® or TLC with Vibrio fischeri.
EXAMPLE 5—Solvent Polarity and Fluorescent and Bioluminescent Detection of DIAZANON®.
EXAMPLE 6—Identification of Pesticides and Herbicides in a Sample with Luminescent Bacteria.
EXAMPLE 7—Identification of Herbicides and Pesticides.
PROPHETIC EXAMPLE 8—Proposed Identification of Heavy Metals In a Sample with Luminescent Bacteria.
PROPHETIC EXAMPLE 9—Proposed Chemical Identification of a Toxicant In a Sample Isolated With Bioluminescence Methods.
EXAMPLE 10—Identification of Toxicant in a Gaseous Phase Sample with Luminescent Bacteria.
PROPHETIC EXAMPLE 11—Proposed Identification of a Toxicant on a Solid Surface Sample with Luminescent Bacteria.
PROPHETIC EXAMPLE 12—Proposed Test Kits for Identifying Toxicants in a Sample.
EXAMPLE 1
Isolation of Identifiable Luminescent Inhibitory Toxicant in Garlic Extract using Luminescent Bacteria
The present example is presented to describe a method by which components of a substance which inhibit luminescent bacteria may be isolated. The sample analyzed in the present example is a garlic extract. For this experiment, the Inventors first prepared a garlic extract from garlic powder. The garlic powder was processed so as to form a liquid garlic extract. One (1) gram of garlic powder was blended with 5 ml. H 2 O. Other solvents such as ethanol, chloroform, or acetone may be used to blend the sample, but H 2 O was found to be the best solvent for the garlic.
A 5 ml. volume of the garlic extract was first applied (“spotted”) to TLC plates at several points equidistant from one edge of the plate. The plate was inverted in a sealed TLC solvent container with a small amount of solvent in the bottom such that spotted samples were parallel to and above the solvent interface.
As the solvent (acetonitrile:water:aqueous ammonia, 8:1.5:0.5) migrated up the TLC plate, the individual components in the garlic extract were sufficiently separated to detect separate zones of luminescent inhibition upon exposing the developed chromatogram to a suspension of luminescent bacteria, Vibrio fischeri applied in a suspension of 0.5 M NaCl (See FIG. 1 - 2 ).
The Inventors applied the luminescent bacteria, Vibrio fischeri to the chromatogram specifically by spraying the described suspension of bacteria (contained in a buffered salt solution of 3% (0.5 M) NaCl at a pH of about 7) onto the developed chromatogram after the solvent in which the sample was contained had evaporated. Zones of luminescent inhibition were located prior to the dehydration of the bacteria on the chromatogram, i.e., at least within 1 hour after application of the bacteria.
The inhibition of bioluminescence of the bacteria caused by the presence of toxicants in isolated components of the garlic extract was then visualized. The bioluminescent inhibition effect of any toxicant in the garlic extract became apparent generally within a few minutes in the form of a clearly demarcated zone of bioluminescent inhibition (See FIG. 2 ). These zones of bioluminescent inhibition are areas on the chromatogram which were dimmer (i.e., less brightly emissive) than the more brightly emissive surrounding areas on the chromatogram (which did not include isolated components of the garlic extract which were capable of inhibiting the luminescence of the Vibrio fischeri ). The areas wherein the chromatogram demonstrated greatest amounts and intensity of blue bioluminescence from the applied Vibrio fischeri bacteria identified areas of no component substances or instead isolated components of the garlic extract which were not toxic to the bioluminescence of the bacteria, and therefore according to the described method were considered not to constitute toxicants.
As stated, the inhibition of bacterial luminescence which occurs when a toxicant is detected, becomes apparent very soon, often within a few minutes, and grows more distinct with time and reaching a pronounced peak effect in the minutes before the chromatogram dries out, i.e., the zones of decreased luminescence show more contrast relative to the surrounding luminescence with time, prior to the chromatogram drying out. When the chromatogram is dried out, of course, all the luminescence of the bacteria on the chromatogram will be extinguished with the dehydration of the bacteria.
Curiously, with the described methods, those positions on the chromatogram to which the toxicants have migrated (i.e., the “zones of inhibition”) appear to dry out faster than the remainder of the chromatogram which, for example, remains highly luminescent.
Alternatively, the identification of the different individual components of the garlic extract could have been accomplished using paper chromatography as the separation phase matrix for the sample or other such techniques well known to those of skill in the art.
FIG. 1 —TLC Plate of Garlic Extract
This is a photograph of a TLC plate viewed by fluorescence. The actual plate was 20 cm by about 4.5 cm. In the photograph the plate is seen reduced to 13.0 cm by 2.95 cm. Dimensions below refer to dimensions of the photograph not of the original plate.
Sample: Aqueous Garlic Extract. Preparation: 1.0 g of powdered garlic suspended in 5.0 ml of H 2 O. Mixed with Vortex mixer for 1 minute. Centrifuged in table top centrifuge on high (about 1-2000 rpm, 60 seconds) to obtain straw yellow supernatant: the sample. Five μl applied at origin of plate: pencil lines seen near 1.7 cm from bottom of plate. The application zone is seen as a circle (faint) of about a 6 mm diameter centered on the line.
Development: The solvent system used was acetonitrile:water:25% ammonia (aqueous); 80:8:12. The sample was chromatographed in a closed chamber for approximately 20 minutes. The solvent front traveled about ⅘ of the distance of the plate. A faint demarkation line is seen at about 10.5 cm from the bottom of the plate showing the location of this solvent front.
Results:
Major features of the chromatogram viewed by fluorescence excitation are a pronounced dark line at about 7.9 cm from the bottom of the plate several chevron or V-shaped dark areas in the 5.8-7.7 cm from the bottom region and a faint roughly circular shaped zone centered at about 8.8 cm from the bottom. The chevron shaped darkenings represent chemical components in the garlic resolved by the chromatographic process. The more or less circular zone at 8.8 cm (which can be more dramatically revealed by moving the photograph back and forth about 2 cm in the plane of the photograph) is the zone or near the zone of bioluminescence inhibition seen in photograph 2.
FIG. 2 —TLC Plate of Garlic Extract
This is a photograph of a TLC plate (not the same one as in photograph 1, but a plate developed in an identical fashion except for a longer time) viewed by the emission of Vibrio fischeri luminous bacteria. The actual plate was 20 cm by about 4.2 cm. In the photograph the plate dimensions are 12.9 cm by 2.8 cm.
Sample: Aqueous garlic extract: the identical sample used in chromatogram of photo 1.
Development: same as in photo 1 except chromatogram ran longer, front reaching near the end of plate, near 12.5 cm in photograph. The origin was centered on the pencil line visible at about 2.4 to 2.5 cm from bottom of plate.
Results:
A very dark, nearly circular zone is seen centered at about 10.5 cm from bottom of plate. A faint second zone is seen at about 6.7 cm from the bottom. Several darkened regions can be seen at the edges of the plate. The dark areas which appear at the edges are artifacts, and represent places on the chromatogram sheet which were not adequately sprayed with the luminous bacterial suspension. The zone at 10.5 cm represents the lumotox effect i.e., the determination of the location of the component in garlic which inhibits the luminous bacteria.
Routinely, for preliminary analysis of the chromatograms, the plates were irradiated with a lamp emitting UV (254 nm) radiation. The TLC plate used had the F 254 backing and were therefore fluorescent everywhere that no UV absorbing samples or components existed. This preliminary detection system also revealed component substances as dark spots on a light background where heterocyclic or other UV absorbing compounds were present. However, fluorescent extinction and luminescence inhibition were often not in parallel. For example, some samples presented as very dark zones, as viewed by fluorescence (for example, garlic), had little or no bioluminescence inhibition, while other zones presented very faint or non-existent fluorescence extinction but had substantial ability to inhibit (extinguish) bioluminescence (e.g., garlic, LINDANE®, ROUNDUP®).
Particular sources of TLC plates and chromatography sheets include Sargent Welch (No. S18953-10-TLC plate with F 254 fluorescent material), Analtech (uniplate taperplate silica gel G-F, No. 81013), and Eastman-Kodak (Kodak chromatogram sheets silica gel absorbent with fluorescent indicator, catalog no. 122-4294) and Whatman (absorbent plates flexible-backed aluminum polyester, catalog no. 4410-22 (contains fluorescent indicator)).
The Albert et al. article 22 provides a description of analyzing mevinolin, a fungal metabolite employing standard laboratory techniques such as mass spectroscopy, nuclear magnetic resonance and x-ray analysis. These alternative standard laboratory techniques could be utilized to analyze eluted components from an unknown sample.
Upon isolation/separation of the various components in the garlic extract sample by a chromatography method, the inventors then applied the luminescent bacteria to the developed chromatogram. Most preferably, the luminescent bacteria is applied to the developed chromatogram in the form of a suspension contained in a buffered salt solution (about 0.3 M Na + /K + phosphate buffered saline (3% NaCl by weight) pH 7.0).
PROPHETIC EXAMPLE 2
Proposed Chemical Identification of Toxicants in a Garlic Extract
The present prophetic example is provided to outline one proposed method by which the toxicant(s), as identified according to the method of the procedure outlined in Example 1 may be further characterized to identify the chemical structure of the isolated toxicant(s). This method may also be used where additional amounts of the isolated substance are desired or where the purity of the isolated substance is to be determined.
The particular “zones of luminescent inhibition” described above, which provide for the isolation of the component substances (i.e., toxicant) in the test sample, are used as reference points to isolate each component substance from an adjacent spotted sample which was run on the same or a separate TLC plate with the same sample. Unsprayed sections of the TLC plate, which correspond to zones of luminescent inhibition on the sprayed portion, may be scraped off and added to a sufficient volume of an appropriate solvent (i.e., distilled water, acetone, ethanol, ether, ethyl acetate-chloroform or other solvent mixtures) such that the isolated component substance of the sample may become dissolved in the solvent.
Subsequent removal of the solid TLC scrapings from the liquid eluate can be accomplished by various methods known in the art such as centrifugation or filtration. If necessary, the eluates containing dissolved toxicants may then be concentrated using standard techniques. These separated, (and in some cases, concentrated) isolated substances of the sample may be further resolved in other TLC solvent systems (or HPLC, paper chromatography, and the like) to verify purity or to obtain suitably pure isolated substances. These substantially pure isolated substances can then be identified using standard chemical and spectral methodologies. For example, such standard chemical and spectral methodologies include as HPLC, MS, IR, NMR, and the like.
Alternatively, two dimensional (2D) thin layer (TLC) can be run for higher resolution of the sample for more explicit identification of components therein. In the 2D method, a sample is spotted near one corner of the TLC sheet or plate, and run A successively in two, usually perpendicular, directions, using different solvent systems or conditions. For example, the sample is chromatographed in the usual way (described above) on the TLC medium in the first direction using solvent system No. 1 (e.g., a basic non-polar system, ammonia:butanol:hexane in a 5:20:75 ratio). The chromatogram, containing components resolved in a linear fashion in this solvent system No. 1, is then to be removed from the chromatography chamber, dried fully to remove solvent molecules of this system No. 1 solvent, and then the thus dried chromatogram is rotated 90° to the orientation first used and chromatographed in the new orientation using a solvent system No. 2 (e.g., a polar, acetic system, such as acetic acid, acetone, ethanol in a 10:50:40 ratio). The components resolved into a linear array by system No. 1 move in the perpendicular direction with the solvent system 2 to provide even greater resolution of individual component substances in the sample.
This same basic approach can be utilized where luminescent bacteria are used to identify isolated component substances of a sample separated by paper chromatography systems, either 1D or 2D. As those in the art will appreciate, in using such systems, there are various ways to achieve separation such that toxicants can be obtained in relatively pure form. For example, another version of 2D paper chromatography may employ electrophoresis in one dimension and gravitational flow paper chromatography or isoelectric focussing in another dimension, or other two-dimension combination thereof (i.e., 1st D=paper chromatography, 2sn D=isoelectric focusing, etc.)
EXAMPLE 3
Identification of Pesticides in Sample with Luminescent Bacteria
The present example is provided to demonstrate the use of the claimed methods and reagents for the identification of a pesticide in a sample of known substances. In this example, the pesticides identified were DIAZANON®, LINDANE® and SEVIN®. The luminescent bacteria used in the present example was Vibrio fischeri (ATCC 7744).
Identification of these individual pesticides and herbicides was achieved essentially according to the same methods described in Example 1. A suspension of Vibrio fischeri in a saline diluent was sprayed, using an aspirator bottle, on the developed chromatograms. Zones of luminescent inhibition appeared surrounding those areas on the plate where the DIAZANON® had migrated. Similar, less dim zones of inhibition, where LINDANE® had migrated (See FIGS. 6 and 7 ). In a similarly run TLC with SEVIN®, the chromatogram also demonstrated zones of luminescent inhibition at those areas on the chromatogram where SEVIN® had migrated.
FIGS. 3 and 4
These are photographs of the same TLC plate taken by two different conditions: Fluorescence and Bioluminescence, respectively.
Samples: 5 μl samples of (1/32 by DIAZANON®) and (1/8 LINDANE®). The DIAZANON® sample was produced by serial dilution of the commercial diagram (25% w/v) 0,0, diethyl-O-[2-isopropyl-6-methyl-≮-pyrimidinyl] phosphorsthionate, Ortho Products. The DIAZANON® was diluted with ethanol by factors of 2 until a dilution of 1/32 commercial strength was reached. The LINDANE® (Ortho Products) was diluted in ethanol from the commercial 20% (w/v) gamma isomer of benzene hexachloride, until a final strength of 1/8 was reached.
Development: Acetonitrile: 25% Aqueous ammonia, 75:25
Results: FIG. 3 represents the results from this study using DIAZANON® and LINDANE® on a TLC plate viewed by 254 nm excitation. A prominent dark zone for DIAZANON® is located at 8.8 cm from bottom of FIG. 3 . About 3 quite faint zones for LINDANE® at 8.2, 9.2, and 10.3 cm from bottom of FIG. 3 are demonstrated. DIAZANON® origin (application spot) at 2.5 cm from bottom of photo, LINDANE® origin at 3.0 cm.
FIG. 4 viewed by bioluminescence from vibrio fischeri . Dark zone for DIAZANON® very close to zone for fluorescence extinction (at about 8.1 cm from photobottom). Several very dark zones for LINDANE® at about 8.0, 8.8, and 10.0 from photobottom. Also seen is slight inhibition zone at origin of LINDANE® sample. The several zones for LINDANE® indicate that several isomers or different inhibition compounds are present in the LINDANE® sample.
EXAMPLE 4
Dilution series of DIAZANON® on TLC with Vibrio fischeri
The present example is provided to demonstrate the sensitivity of the claimed invention to detect relatively low concentrations of a pesticide. An exemplary pesticide for demonstrating the sensitivity of the assay used here is DIAZANON®.
FIGS. 5 AND 6
Spot tests of DIAZANON® at several dilutions were performed at the following strengths: full strength (25% w/v DIAZANON®), 1:128; 1:256; 1:512; and 1:1024. No chromatography was done. 5 μl samples of the various DIAZANON® dilutions were applied to TLC plate material, sprayed with a suspension of Vibrio fischeri in a saline solution (3% NaCl WT/VOL.) and photographed. Marked inhibition occurred up to and including the D/256 dilution (D/252 appears by clerical mistake on sheet instead of D/256 which was used) of full strength (25% w/v) DIAZANON®. Faint inhibition is seen at dilution 1:512 and dilution 1:1024 (See FIG. 6, R).
The TLC plates with DIAZANON® demonstrate that the methods described herein are sufficiently sensitive to identify a pesticide in a sample at concentrations in which they are likely to occur in a land or water sample obtained in the environment.
EXAMPLE 5
Solvent Polarity and Fluorescent and Bioluminescent Detection of DIAZANON®
The present example is presented to demonstrate the effect of varying the solvent polarity on the detection patterns, or “zones of inhibition” of Vibrio fischeri in the presence of DIAZANON®, a pesticide.
FIGS. 7 and 8 provide photographs of TLC plates viewed by 254 nm irradiation (FIG. 7) and by bioluminescence (FIG. 8 ).
Samples: In each case, 5 μl of (DIAZANON®/8) was applied at origin on left and 5 μl of LINDANE®/8 was applied at right origin.
Development: Three solvent systems used. All composed of Hexane: THF mixtures. In FIG. 7 the left chromatogram was Hex:THF, 70:30 the middle chromatogram was Hex:THF, 80:20 the right chromatogram was Hex:THF, 90:10. (middle chromatogram contains clerical labeling error of 80 THF:20 HEX, which should be 80 HEX:20THF)
Results: FIG. 7 shows the decrease in polarity as the proportion of THFs lowered causes the DIAZANON® and faint LINDANE® spots or zones to be progressively diminished in mobility; to have smaller R f values; to migrate shorter distances from the origin.
FIG. 8 shows only the left-hand and right-hand TLC plates seen in FIG. 9 . Dark bioluminescence zones of inhibition are seen in Photo 8 for DIAZANON® and LINDANE® samples.
EXAMPLE 6
Identification of Pesticides and Herbicides in a Sample with Luminescent Bacteria
The present example is provided to demonstrate the use of the claimed methods and reagents for the identification of pesticides and herbicides in a known test sample using a luminescent biological agent.
In this example, the herbicides ROUNDUP® and WEED-B-GON® and the pesticides DIAZANON® and LINDANE® are identified in a test sample with the luminescent bacteria, Vibrio fischeri (ATCC 7744).
EXAMPLE 7
Identification of Herbicides and Pesticides
Each sample was run on an individual TLC sheet. Photographs of the resulting 4 individual chromatograms are presented at FIG. 9 (room light) and FIG. 10 (Bioluminescence—chromatogram with luminescent bacteria).
Two solvent systems were used. The solvent systems used to identify the herbicides (ROUNDUP® and WEED-B-GONE®) was 100% ethanol. A 5 ml sample of an 8-fold dilution of these commercially available herbicides was used in the spotting of the TLC plates.
The solvent system used for the pesticides DIAZANON® and LINDANE® was Hexane:THF, 90:10. The pesticides were spotted at a concentration of 1.8. A 5 ml sample of an 8-fold dilution of these commercially available pesticides was used in the spotting of the TLC plates.
Two solvent systems were employed as no single system has yet been found to adequately resolve all compounds (i.e., the two pesticides and the two herbicides). Use of 100% ethanol causes DIAZANON® and LINDANE® to run at the front of the solvent system. Use of 90% Hexane, 10% THF causes ROUNDUP® and WEED-B-GONE® to stay at the origin. The TLC plates photographed are in the following order (left to right) (one sample per plate): DIAZANON®, LINDANE®, ROUNDUP®, and WEED-B-GONE®. In each case, the commercial strength was diluted by a factor of 8.
Results:
a. Pesticides
The DIAZANON® sheet did present an entirely distinct “zone of inhibition” , but the FIG. 10 only marginally indicates this characteristic, perhaps due to partial bacteria dehydration. The LINDANE® chromatogram presented as a distinct zone of inhibition culminating in a dark spot center about 2.9 cm from the bottom of the plate.
The ROUNDUP® chromatogram presented a clear zone of inhibition as seen at the origin, and at least one other inhibition zone centered at 4.5 cm from the bottom of the plate. The WEED-B-GONE® chromatogram presented as a large oval zone of luminescent inhibition (perhaps comprised of several components) starting at about 1.8 cm from the bottom of the TLC plate and stretching to beyond 6 cm from the bottom of the plate.
EXAMPLE 7
Identification of Herbicides and Pesticides
The following example presents the results of three separately run experiments by the Inventors. These data demonstrate the reliability of the described methods for consistently identifying a component substance in a sample. The following list represents a description of the particular herbicides and pesticides, and the percent dilutions used thereof, in the described 3 separately run TLC plates.
WEED-B-GON®
10.8% w/v dimethylamino salt of 2,4 dichlorophenoxyacetic acid 11.6% w/v dimethylamino salt of 2-(2-methyl-4 chlorophenoxy) propionic acid
DIAZANON®
25% w/v O,O,diethyl-O-[2-isopropyl-6-methyl-4-pyrmidinyl] phosphorothio(n)ate
ROUNDUP®
41% w/v isopropylamino salt of glycophosphate N-(phosphoromethyl)glycine
LINDANE® (bark and leaf mineral spray)
20% w/v gamma isomer of benzene hexachloride liquid
LIQUID SEVIN® CARBAMYL
27% w/v 1-naphthyl-N-methyl carbamate
The following table presents the results obtained for identifying DIAZANON®, LINDANE®, ROUNDUP®, and WEED-B-GON® in three different tests conducted by the Inventors. These data demonstrate that the described method provides a system which possesses the ability to detect, with varying sensitivity, a variety of herbicides or pesticides in a sample on a consistent and reliable basis, as demonstrated by the closely corresponding “spots” for each run of the same component substance between the three separately run chromatograms.
TABLE 1
Dis-
Ratio of
Herbicide/
tance
Spot
Spot
Spot
Front
Stan.
Pesticide
of Front
1
2
3
Fluor
Biolu
Dev.
Test 1
DIAZANON ®
2.38
0.63
—
—
0.26
0.26
0.02
LINDANE ®
2.38
.88
1.38
1.66
0.37
0.37
0.02
0.58
0.57
0.00
0.70
—
ROUNDUP ®
2.36
0.00
0.13
1.38
0.00
0.00
0.00
0.06
—
—
0.58
—
—
WEED-B-GON ®
2.36
0.66
1.64
1.88
0.28
0.28
0.02
0.69
0.69
0.04
0.80
—
—
Test 2
DIAZANON ®
2.75
0.68
—
—
0.26
0.25
0.01
LINDANE ®
2.19
0.83
1.23
1.55
0.38
0.35
0.03
0.56
0.57
0.00
0.70
—
—
ROUNDUP ®
2.00
0.00
0.12
1.22
0.00
0.00
0.00
0.06
—
—
0.61
—
—
WEED-B-GON ®
2.25
0.65
1.35
1.79
0.28
0.28
0.020
0.66
0.66
.01
0.80
—
—
Test 3
DIAZANON ®
2.79
0.68
—
—
0.24
0.24
0.00
LINDANE ®
2.09
0.83
1.23
1.59
0.39
0.40
0.01
0.58
0.60
0.03
0.73
—
—
ROUNDUP ®
2.13
0.00
0.21
1.29
0.00
0.00
0.00
0.10
—
—
0.60
—
—
WEED-B-GON ®
1.84
0.38
1.17
1.55
0.21
0.21
0.05
0.64
0.63
0.02
0.84
—
—
R f Values Represented in the Reported Values in the Table; R f = relative to the front; a fractin of the total distance which the solvent front migrated.
PROPHETIC EXAMPLE 8
Proposed Identification of Heavy Metal Salts in a Sample with Luminescent Bacteria
The present prophetic example is provided to present a use of the claimed methods and reagents for the identification of a heavy metal in a sample. Specifically, the Inventors hypothesize that the described methods would be useful in the identification of the heavy metals such as mercury, lead and cadmium using the described luminescent biological reagents, such as the bacteria, Vibrio fischeri (ATTC Acc. No. 7744).
In the present example, the Inventors spotted the various metals on to a chromatography paper sheet, but did not run them through a chromatography separation process. Upon spotting of the various metals along one side of a chromatography paper sheet, the sample spots were allowed to dry. Upon drying, the spotted sheets were exposed to the luminescent bacteria Vibrio fischeri . Employing this method, the Inventors were able to visualize the presence of the heavy metal salts of mercury, lead, and cadmium.
To isolate the heavy metal spotted on the chromatography paper, the paper edge at which the sample was spotted should be exposed to a solvent system, most preferably an acidic solvent system.
Specific reference is made here to the RAININ® catalog 29 , wherein a standard technique (for the separation of heavy metals) is described using an ion chromatography metals column. Resolution of Pb ++ and Cd ++ is demonstrated in the reference RAININ® catalog.
Successive equal volumes of a heavy metal could be eluted using the HPLC procedure from the HPLC machine and spotted in an array or in a linear fashion on a sheet of (Whatman) chromatography paper. After the carrier solvent is evaporated or otherwise removed by drying, the sheet could be sprayed with a suspension of luminescent bacteria, such as Vibrio fischeri , as described. Zones of bioluminescent inhibition could be similarly visualized to identify the metal.
PROPHETIC EXAMPLE 9
Proposed Chemical Identification of a Toxicant in a Sample Isolated with Bioluminescence Methods
The present prophetic example is provided to outline a proposed method whereby the identified region provided on a chromatography sheet with the described luminescent agent, particularly a luminescent bacteria may be analyzed to ascertain the chemical identity of an isolated component substance of a sample.
A volume of sample containing sufficient concentration of toxicants would be applied to a chromatography paper, such as Whatman 1M or 3M and chromatographed using a solvent system which provides maximum separation of the sample components. Various solvent systems may be utilized and tested for separation efficiency as well understood by those skilled in the art. Small amounts of sample may be used to test for improved resolution in one dimensional (1D) chromatography solvent systems. Those solvents found most effective may then be utilized for larger scale separation on large sheets of chromatography paper for two-dimensional chromatography (2D).
Two dimensional chromatography may be necessary to resolve sample ingredients for subsequent identification of substantially pure compounds. By determining a combination of two solvent systems which effectively resolve the component toxicants, 2D chromatography can be run in duplicate.
Following the chromatography, the luminescent bacteria may be sprayed onto one of two identical sample sheets. Areas on the sheet which demonstrate a decreased luminescence would then be used to mark the corresponding areas of the unsprayed sheet. The corresponding areas on the unsprayed sheet are cut out and eluted with distilled water, appropriate solvents such as acetone or ethanol or a solvent mixture to provide individual, substantially pure toxicants for identification. This procedure can be repeated, and/or multiple 2D sheets may be run simultaneously, in order to accumulate sufficient quantities of various substantially pure toxicants.
In this manner, appropriate amounts of toxicants in a sample may be separated and then identified using standard chemical procedures. For example, small amounts of the purified component substances may be run on high pressure liquid chromatography (HPLC) and compared to known standards for identification 15 . As will be appreciated by those skilled in the art, additional standard techniques used for chemical identification may be employed such as spectral analysis: Mass spectra, infrared spectra (IR), nuclear magnetic resonance (NMR), and the like.
It will understood by those skilled in the art that multiple 2D chromatography sheets can be run simultaneously in which different sheets are sprayed with different luminescent bacteria. This would provide a more thorough analysis of toxicants which may be detectable by one luminescent bacterium, but not by another. Additionally, combinations of different luminescent bacteria in one spray solution may facilitate the thorough identification of most or all of the detectable isolated component substances in a sample. In this manner, a thorough analysis and identification of toxicants in a sample may be undertaken.
Essentially this same approach can be taken using thin layer chromatography (TLC), instead of paper chromatography as described above, for the initial separation and identification of toxic substances in a sample. Multiple TLC plates (e.g., Whatman 4856-840 with 1,000 μM silica layer) may be run simultaneously in the same solvent system utilizing 1D or 2D runs, as described above, for paper chromatography. In such a TLC approach to toxicant identification, toxicants would be identified by spaying the plates with luminescent bacteria, marking the zones of decreased luminescence, and scraping off the corresponding areas on the unsprayed portions of plates. The scrapings are then eluted with an appropriate solvent, such as distilled water, acetone or ethanol or a solvent mixture, concentrated (if required), and identified using HPLC, MS, IR, NMR, and the like.
By following either of the above procedures, the separation and identification of toxicants in a sample can be accomplished simply and rapidly. The standardization of this method to be used for the identification of toxicants in certain types of samples will be appreciated by those skilled in the art as providing simple, rapid, and inexpensive methodologies for toxicant identification. For example, certain types of samples (i.e., industrial effluent) could be tested to determine the initial separation system, the solvent systems, the luminescent bacteria (or combinations of luminescent bacteria), the elution protocol, and any subsequent techniques for quantitation and/or identification.
Through the use of standard curves of easily quantitated known compounds, the percent recovery in a given separation system can be determined. In this manner, amounts of identified toxicants can be quantitated and extrapolated back to the original sample volume applied. For example, the use of radiolabeled compounds, of known specific activity, which are separated by paper or TL chromatography, eluted, and counted for radioactivity, would provide an indication of the percentage recovery of a given compound. By comparing various radiolabeled chemical compounds in a given identification system (paper or TLC with different solvents and the like), one could correct for recovery losses of a given identification system.
When the separated toxicants are quantitated by certain chemical and spectral methods, the quantities may then be extrapolated to determine the quantities of individual toxicants present in the original sample. Thus, this method, in many cases, would allow for toxicant quantification.
These steps could be standardized into kits tailored for the analysis of specific types of samples (i.e., a kit for a certain industrial effluent or certain biological samples, such as foodstuffs, pharmaceuticals, and the like). These kits would comprise certain solvents and luminescent bacteria which would effectively resolve specific sample types thereby greatly simplifying and reducing the cost of toxicant detection, identification, and quantitation.
Alternatively, an unknown sample may be processed by the above procedure for identification and quantitation.
PROPHETIC EXAMPLE 10
Identification of Toxicant in a Gaseous Phase Sample with Luminescent Bacteria
The present prophetic example is provided to outline a proposed method whereby an investigator may identify a toxicant present in a gaseous phase sample employing the methods with luminescent bacteria described herein.
As an initial step, the gaseous sample would be collected by techniques known to those skilled in the art. For example, a gas sample might be collected by filtration through a solid filter such that toxicants deposit onto the filter or by aspiration into a liquid such that toxicants dissolve in the liquid. In the case of a solid filter, the filter could then be eluted with distilled water or a suitable solvent, concentrated, chromatographed by paper or thin layer chromatography, and identified using certain luminescent bacteria as described in Example 6.
PROPHETIC EXAMPLE 11
Identification of a Toxicant on a Solid Surface Sample with Luminescent Bacteria
The present prophetic example is provided to outline a proposed method whereby a toxicant on a solid surface sample may be identified with the described luminescent bacteria.
As in Example 7, methods for removing a toxicant from a solid surface so that it is collected in a concentrated liquid form will vary depending on the nature of the solid surface. Techniques for such removal will be apparent to those skilled in the art. Using the procedures outlined in Example 6, one skilled in the art would be capable of identifying and quantifying toxicants which were eluted from or removed from the solid surface. Alternatively, for direct detection of toxicants, the solid surface could be sprayed with a certain luminescent bacteria, or mixture of more than one luminescent bacteria, such as Vibrio fischeri and the surface observed for zones of decreased luminescence (i.e., zones of luminescent inhibition) substantially as has already been outlined in Example 1. of course, these isolated component substances of the sample (potential toxicants) could then be chemically analyzed according to laboratory techniques well known to those of skill in the art to identify the chemical structure of the isolated component. By way of example, such laboratory techniques for determining the chemical structure of an isolated component substance include HPLC, MS, IR, NMR, and the like.
PROPHETIC EXAMPLE 12
Proposed Test Kits for Identifying Toxicants in a Sample
The present prophetic example is provided to define those components which would comprise a proposed test kit useful for the identification of toxicants in a sample. Such a kit most preferably would comprise a carrier means adapted to receive at least two container means and at least one chromatography paper sheet in close confinement therewith. The kit should also include at least one chromatography paper sheet and a first container means comprising a luminescent bacterial agent. While any luminescent bacterial agent may be used in conjunction with the described kit, that bacterial agent most preferred is the Vibrio fischeri (ATTC Acc. No. 7744). Most preferably, the luminescent bacterial agent should be in lyophilized form in the container means. The lyophilized bacteria would then be suspended in a diluent solution. For example, where appropriate NaCl concentrations are within the lyophilized sample, deionized water may be employed as the diluent solution without any expected deleterious effects to the luminescence of the bacteria.
In a second container means, the kit should further comprise a diluent for a luminescent bacterial agent. Most preferably, the diluent should comprise a 0.5 M NaCl buffered saline solution at pH 7 where the bacteria is a marine bacteria and has not been lyophilized to include NaCl. The kit may optionally also include a separation solvent, such as acetonitrile, deionized water, or aqueous ammonia.
In other proposed forms of the presently proposed kit, the kit may further comprise an aspirator spray bottle to facilitate the easy application of suspended luminescent bacteria to a separation phase matrix such as a TLC plate or chromatography paper, chromatogram. In addition, the kit may comprise several vials of lyophilized luminescent bacteria. In other proposed forms of the presently proposed kits, the kit may further comprise instructions for the suspension and application of the luminescent bacteria to facilitate visualization of the isolated component substances of the test sample, and also in regard to the reaction time to be allowed and at what point the luminescent bacteria-exposed separation phase matrix should be read.
BIBLIOGRAPHY
The following references are specifically incorporated herein by reference in pertinent part.
1. Drucker et al. (1984) E.P. 153366.
2. Vasseur et al. (1983), presented at the International Symposium on Ecotoxicological Testing for Marine Environment, Belgium, pp. 12-14.
3. Baher (1988)—WPI 88-308491 (884).
4. Liebowitz (1984), Anal. Biochem ., 137(1):161-163.
5. Gu, Z. (1987), Turangxue Jinzhan 15 (3):48-51).
6. Siemens (1990)—WO 88 DE 626—; WPI ACC No. 90-116654(9016)—Genlux Fursch. Biol. Verfahren.
7. Strom et al. (1986), ACTA Hydro Chim Hydrobiol ., 14 (3):283-292.
8. Ugarova et al. (1987), Appl. Biochem. Biotechnical ., 15(1):35-51.
9. Thin Layer Chromatography: A Laboratory Handbook 2nd ed, E. Stahl, Ed., Springer-Varlag, New York, N.Y., (1967).
10. HPLC of Small Molecules: A Practical Approach C. K. Lim; Ed., IRL Press, Oxford England (1986).
11. HPLC of Macromolecules: A Practical Approach R. W. A. Oliver, Ed., IRL Press, Oxford, England (1989).
12. Plant Drug Analysis: A Thin-Layer Chromatography Atlas , H. Wagner, S. Bladt, E. M. Zgainski, Springer-Verlag (eds.), New York, N.Y. (1984).
13. Alltech Bulletin, (1991) #183 , Gas Chromatography Apparatus , p. 11.
14. Thompson, B. C., Kugmack, J. M., Law, D. W., Winslow, J. J., eds. (1989), “Copolymeric Solid Phase Extraction for Quantitating drugs of Abuse in Urine by Wide-Bore Capillary Gas Chromatography” L C - G - C 7(10):846-850.
15. Merck Index, 11th ed. (1989), p. 878-879.
16. Johnson, F. H., (1972) J. Bact ., 109:1101-1105.
17. Hastings, J. W., MAV (1973) Arch. Mikrobiol ., 94:283-330.
18. Yetison, T., (1978) Appl. Environ. Microbio ., 36:11-17.
19. Williamson, K. L., (1989), Macroscale and Microscale Organic Experiments , D.C. Heath and Company, Lexington, Mass. ISBN 0-669-19429-8.
20. Shriner, R., Fuson, R., Curtin, D., The Systematic Identification of Organic Compounds , John Wiley and Sons, Inc., New York, Fifth Edition, (1964).
22. Alberts et al. (1980) Proc. Natl. Acad. Sci., U.S.A ., 77(7):3957-3961.
23. Pannell et al. (1990) Organometallics , 9(9):2454-2462.
24. Hertel et al. (1991) J. Am. Chem. Soc ., 113:657-665.
25. Fischer Scientific Catalog (1991-1992), p. 483.
26. Kamminga, D., (1985), J. Chromatog . 330:375-378.
27. Günther, K., (1988) J. Chromatog ., 448:11-30.
28. Armstrong, D. W., 91984) J. Liquid Chromatography , 7:353-376.
29. Rainin Scientific Catalog (1991-1992), p. 3-38.
30. Bioluminescence and Chemiluminescence: Basic Chemistry and Analytical Applications , Marlene A. DeLuca and William D.
McElroy, eds., Academic Press (1981).
31. Bioluminescence and Chemiluminescence, In: Methods in Enzymology , Marlene A. DeLuca, eds., Academic Press, Vol. 57 (1978).
32. G. W. Mitchell and J. W. Hastings (1971) Analytical Biochemistry 39:243.
33. J. W. Hastings and G. Weber (1963), J. Opt. Soc. Am ., 53:1410.
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Methods for the isolation and identification of a toxicant in a sample are disclosed. Luminescent biological agents (i.e., bacteria) having sensitivity to a toxicant or an isolatable component in a sample are used to provide visually discernable zones of luminescent inhibition in the presence of a toxicant (or) in the presence of an isolatable sample component as separated by paper or thin layer chromatography. Kits for use in conjunction with the identification of a toxicant in a sample are also described, which include a luminescent biological reagent as the visualizing agent. Particular examples of luminescent bacterial agents useful in the practice of the present invention include Photobacterium leoganthi, Photobacterium phosphoreum, Vibrio fischeri, Vibrio harveyi a luminescent fungi, a luminescent fish extract, a luminescent dinoflagellate and fluorescent microorganisms, such as Cypridina. Potential toxicants in a liquid sample, a solid sample, or in a gaseous sample may be identified and further chemically characterized using the described methods. The isolation of potential toxicants in a sample through the processing of a sample through a separation phase matrix such as chromatography paper or TLC plate, followed by exposure to luminescent biological agent, provides for a rapid and inexpensive method for identifying pesticides, herbicides and heavy metals in a known or unknown sample.
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BACKGROUND OF THE INVENTION
Many of the prior art methods and combinations of apparatus which are designed to accomplish optical waveguide amplitude modulation have intrinsically and inherently involved the reliance upon additional polarizer/analyzer devices for their operation. Generally, it may be said that many of such prior art methods and arrangements have relied upon giving effect to a polarization of light energy change which is induced in transmitted light in an optical waveguide or a bulk crystal device by either acousto-optic, magneto-optic, or electro-optic effects.
For example, optical waveguide switching and modulation has been proposed in the prior art as exemplified by U.S. Pat. No. 3,589,794 issued in the name of Enrique A. J. Marcatili on June 29, 1971. The optical waveguide amplitude modulation and switching functions achieved in this patent and many related prior art concepts was realized by the modification of resonant optical coupling between two parallel or closely contiguous optical waveguides.
Despite the fact that analogous coupled devices have been well known to operate satisfactorily in microwave technology applications, coupled optical waveguides depending upon resonance conditions inherently involve dimensional tolerances which are extremely critical for an efficient and effective operation at most optical wavelengths.
Although resonant coupling optical waveguide switching and modulation is relatively quite simple in concept, it's implementation is extremely difficult to realize through fabrication by practical and convenient techniques due to the extremely stringent tolerances required for it to function as a wholly effective device.
Accordingly, it is highly desirable that an optical waveguide interferometer modulator/switch be devised which inherently does not require the severely critical dimensional tolerances of prior art concepts and arrangements designed to be functionally equivalent in performing optical modulation and switching operations.
SUMMARY OF THE INVENTION
The present invention is based on the concept of giving effect to constructive and destructive optical interference of light energy through the means of mode shifting in waveguides which are fabricated in optically active material. Such optically active material may comprise acousto-optic, magneto-optic or electro-optic responsive materials, though the latter has been found to be much the best in performance and ease of controlling the desired effects. Though the concept of the present invention inherently involves the use of optically active materials which are controlled in a particular manner in optical waveguides or particular requisite configurations, there is some analogy of the interferometric phenomena involved to certain well known classical optical interferometers such as the Mach-Zehnder interferometer.
In accordance with the concept of the present invention the optical waveguide interferometer modulator switch may comprise an optical waveguide for transmitting single mode optical energy originating at the suitable source. First and second single mode optical waveguide branches as defined by electro optically responsive material converge at a common connection to the optical waveguide transmitting the single mode optical energy. The first and second single mode optical waveguide branches diverge along a substantially coextensive distance to reconverge for providing first and second single mode light paths of identical optical length. As is well known and will be appreciated by those thoroughly skilled and knowledgeable in the pertinent optical arts, identical optical length may or may not coincide with identical physical dimensional length and in accordance with the concept of the present invention the optical length of one of the single mode optical waveguide branches may be modified to bring about the identical optical length as desired between the two single mode optical waveguide branches.
A light path is connected with the first and second single mode optical waveguide branches at their reconvergence and appropriate control means are arranged relative to the first and second single mode optical waveguide branches for modifying their optical properties. Such control means may comprise acoustic transducers, magneto transducers, or conductive electrodes depending upon whether the optically active material of the first and second single mode optical waveguide branches is acousto optically responsive, magneto optically responsive, or electro optically responsive, respectively.
In a preferred embodiment of the present invention it has been found that electro optically responsive material employed to define the first and second single mode optical waveguide branches is readily controllable to the degree of response necessary to provide most desirable results in its operation. Accordingly, conductive electrodes are disposed contiguous to at least one of the optical waveguide branches defined by electro optically responsive material and a source of suitable electrical energy is arranged to be connected through controlling switch means to selectively change the optical properties of at least one of the optical waveguide branches by impressing an electrical field thereacross. Such electric field causes phase differences in the optical energy transmitted by the two single mode light paths of identical optical length and produces consequent destructive optical interference at the reconvergence of the first and second optical waveguide branches into a single mode waveguide.
Where the amplitude of the electrical energy which is selectively connected to the electrodes is sufficient to cause πradians phase difference in the optical energy transmitted by the first and second single mode optical waveguide branches, the destructive interference is virtually complete, causing maximum depth of modulation at the single mode waveguide reconvergence of the two single mode optical waveguide branches.
On the other hand, when the reconvergence of the first and second single mode optical waveguide branches is connected to a multi-mode optical path, waveguide, i.e., two modes can be supported, multi-mode optical energy will be transmitted along such path having components of first order mode light energy and second order mode light energy, as well.
The optical waveguide interferometer modulator as previously described can be rendered operative as a switch by the addition of two diverging optical waveguides connected to the multimode optical path in which the two diverging optical waveguides have different dimensions such that one of the diverging optical waveguides has a propagation velocity characteristic which is selectively conducive to the transmission of first order mode light energy, while the other of the diverging optical waveguides has a propagation velocity which is selectively conducive to the transmission of second order mode light energy received from the multi mode optical path.
As a result light energy will be propagated along one or the other of the two diverging optical waveguides in accordance with the instantaneous condition of whether or not electrical energy has been applied to the electrodes contiguous to the first and second single mode optical waveguide branches which is determinative of whether first order or second order light energy is developed at the reconvergence of the first and second single mode optical waveguide branches. Thus, the application or lack of application of electrical energy to the previously described electrodes will determine which of the two diverging optical waveguides will transmit light energy and effectively provide a switch for optical energy.
As will be appreciated readily by those knowledgeable and skilled in the pertinent optical arts, the identical optical length of the two single mode optical waveguide branches can be achieved by the application and maintenance of a suitable dc bias potential to correct for slight dimensional differences in the physical configuration of the two single mode optical waveguide branches.
Further, in accordance with the concept and teaching of the present invention, either a dc or an ac potential may be employed to provide the requisite electro optical effect in changing the phase of the light energy propagating along one or both of the two single mode optical waveguide branches of identical optical length to cause optical interference and produce the desired ultimate results at the reconvergence of the two single mode optical waveguide branches.
Accordingly, it is a primary object of the present invention to provide an optical modulator-switch employing optical interferometer principles.
Another most important object of the present invention is to provide such an optical waveguide modulator switch which employs optical interferometric principles to perform mode converter functions.
A further important object of the present invention is to provide such an optical waveguide modulator in which the modulating-switching function is performed by asymmetric divergent optical waveguides operating as mode selectors.
Another most important object of the present invention is to provide an optical waveguide modulator-switch inherently having significantly less stringent dimensional tolerance requirements as compared to functionally equivalent optical modulator switches known in the prior art.
A concomitant object of the present invention is to provide an optical waveguide switch which is adaptable to control the amount of light switched as a function of a controllable applied electrical potential as may be desired in picking off a small fraction of light energy from an optical data bus line, for example.
A further object of the present invention is to provide such an optical switch which may be operated in reverse to function as a controllable light insertion unit.
And an overall prevading objective of the present invention is to provide an optical waveguide modulator switch which can be fabricated to reasonably attainable dimensional tolerances from readily available materials by known techniques affording a broad variety of suitable combinations of materials and techniques.
These and other features, objects, and advantages of the present invention will be better appreciated from an understanding of the operative principles of a preferred embodiment as described hereinafter and as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIGS. 1a and 1b are greatly enlarged illustrations of an embodiment of the present invention;
FIGS. 2a and 2b are schematic graphical illustrations of the operative conditions prevailing in two different states of an embodiment of the present invention such as that shown in FIGS. 1a and 1b;
FIG. 3 is an illustration of the propagation constants calculated for a channel optical waveguide of a type which may be employed in the present invention;
FIGS. 4 and 5 are illustrations of the propagating characteristics of two different embodiments of the present invention; and
FIGS. 6a, 6b, and 6c are illustrations of several spatial arrangements employing multiple embodiments of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1a illustrates an embodiment of the present invention in which a single crystal ZnSe may be employed together with diffusion techniques which are known to the art and as has previously been disclosed and discussed in a publication by the inventor herein which appeared in the Journal of Applied Physics, Volume 44, at page 3703.
Sputtered silicon dioxide may be employed as a diffusion mask with conventional photolithographic techniques using commercially available photo resist to define the optical waveguide pattern of the device. Cadmium diffusion into the etched pattern in the silicon dioxide mask produces controllable refractive index increases in the ZnSe substrate 10. The optical waveguides produced by diffusion are not precisely rectangular in cross-section as illustrated in the drawing of FIG. 1a but contain some refractive index gradients as has been pointed out by the inventor herein in a disclosure which appeared in Volume 13 of Applied Optics, page 2112. However, waveguide calculations made for diffused channel waveguides indicate that the mode structure is not significantly different from calculations made assuming a rectangular cross-section channel waveguide so that very close approximations are valid.
In FIG. 1a an embodiment of the present invention is illustrated in which an incoming single mode optical waveguide 11 diverges at 12 into two single mode optical waveguides 13 and 14. The single mode optical waveguide branches 13 and 14 diverge along a substantially coextensive distance to reconverge for providing first and second single mode light paths of identical optical length.
Conductive electrodes 15 and 17 are disposed substantially parallel to, and outside, the first and second optical waveguide branches 13 and 14, respectively. A third electrode 16 is disposed between the two optical waveguide branches 13 and 14.
In the particular embodiment illustrated in FIG. 1a, at the reconvergence 18 of the first and second single mode optical waveguide branches 13 and 14, a multi mode waveguide 19 is formed. The multi mode optical waveguide 19 diverges at 20 into two optical waveguides 21 and 22 having different dimensions.
In operation of the embodiment illustrated in FIG. 1, when no potential is applied to the electrodes 15, 16, and 17, light in the single mode waveguide 11 propagates with a mode velocity β 1 and is divided equally at 12 into the two optical waveguide branches 13 and 14. When the light energy thus propagated reaches the point 18, it has travelled the same distance in each optical waveguide branch since they are substantially of identical optical length and therefore the reconverging light is in phase and combines constructively, producing the lowest order mode which propagates with velocity β 1 ' in the optical waveguide section 19.
The light energy propagates in the optical waveguide section 19 to the point 20 where it will continue to propagate in either the optical waveguide section 21 or the optical waveguide section 22 depending on which of the mode propagation constants in the two optical waveguide sections 21 or 22 most closely matches the propagation and velocity constant β 1 '.
However, when an electrical potential V is applied to electrodes 15, 16, and 17 through a suitable ganged switch means schematically represented in an open condition in FIG. 1a, and in closed condition in FIGS. 2a and 2b such that the polarity of electrode 16 is opposite the polarity of electrodes 15 and 17, a change is caused in the optical properties of the optical waveguide branches 13 and 14 depending upon the electro optical responses of the type of material employed, its orientation, and the magnitude of the applied electric field as well.
In typical operation, the applied electrical potential V will produce an electric field E between electrodes 15 and 16 which is opposite in sense to the electric field developed between electrodes 16 and 17. In the optical waveguide branch 13 the applied electric field produces a small change of refractive index for TE (polarized parallel to the plane of the device) modes which may be expressed as ##EQU1## where δ TE and δ TM are found from the specific type and orientation of the crystal. In general δ TE ≠ δ TM except in certain orientations.
For simplicity and clarification of explanation it may be assumed that δ TE = δ TE = δ. The phase shift induced in the light by this small change of refractive index may be expressed as ##EQU2## where λ is the wavelength of the light and l is the length of the waveguide over which the electric field is applied.
In the optical waveguide branches 13 and 14 the phase shift is equal but opposite in sense so that the phase difference between light propagated along the two optical waveguide branches 13 and 14 is ##EQU3##
Those skilled and knowledgeable in the pertinent arts will appreciate that the concept of the present invention does not require that equal and opposite electric fields be applied to the two optical waveguide branches 13 and 14 to produce the desired phase difference but approximately twice the electric potential could be applied to the pair of electrodes 15 and 16 or the other pair 16 and 17 to produce substantially the same phase difference as is given effect by generating equal and opposite electric fields. However, it will be equally well appreciated that in practice it is generally desirable to employ minimum operational electric potentials; thus, the equal and opposite electric field technique is generally preferred.
If the applied electrical potential is such that Δφ=π the light in optical waveguide branches 13 and 14 will be out of phase and thus destructively interfere. Stated in a different way, the application of an appropriate electrical potential causes the light propagating in the optical section 19 to shift from the lower order mode with propagation constant β 1 ' to the second order mode (which has a null at its center) with propagation constant β 2 '.
FIGS. 2a and 2b illustrate the mode profiles as a function of distance along the optical paths of the embodiment of FIG. 1a when it is operated as a switch. Such operation results from the choice of dimensions of the optical waveguide section 21 and 22 to be such that the propagation constant, β 1 ', of the lowest mode in optical waveguide section 21 matches the lowest mode in optical waveguide portion 19, i.e., β 1 ' = β 1 ''.
The propagation constant of the lowest mode β 1 ''' of waveguide 22 is chosen to be the same as the second mode of the waveguide section 19, i.e., β 2 ' = β 1 '''.
It should be noted that the embodiment of the present invention illustrated in FIG. 1 may be operated as an amplitude modulator. In such operation the waveguide sections 21 and 22 are not required, and the optical waveguide portion 19 need not only be single mode in character.
As indicated schematically in FIGS. 2a and 2b, the application of a voltage to the electrodes of the embodiment of the present invention illustrated in FIG. 1a causes variation in the effective optical length of the two optical waveguide branches so that interferometer type performance is realized by utilization of the electro optic properties of the optical waveguide material. Accordingly, the optical waveguide interferometer modulator-switch of the present invention may be considered to be a mode converter, ideally with substantially equal optical length of the two optical waveguide branches 13 and 14 of FIG. 1a, the light propagating along the two optical guide branches being recombined as shown in FIG. 2a to produce the lowest order mode.
However, upon the application of an electric field so as to cause a phase shift or πradians between the two optical waveguide branches 13 and 14, the recombination of the propagated light results in a light field distribution having a value of zero at the center of the recombined light energy, i.e., the second order mode as shown in FIG. 2b. Accordingly, the present invention will operate as an amplitude modulator requiring no external polarizers with the only requirement being that the exit optical waveguide where the propagated light is recombined be of single mode character and far from the second mode cut-off. Applying the electric field therefore causes the light in the exit optical waveguide to be extinguished since the mode produced is not confined.
For the present invention to operate in the manner of a switch requires that the exit optical waveguide be multi mode in character and also the addition of optical waveguide portions of different dimensions as previously described.
FIG. 3 illustrates propagation constant calculations for a channel optical waveguide with fixed depth and varying width. The ratio y/x is that of the depth of the waveguide to the width of the waveguide as shown by the enlarged illustration of FIG. 1b.
Three modes are plotted in FIG. 3 with the desired operating widths "a", "b", "c", and "d" referring to FIG. 1a. The width indicated as "a" in FIG. 1a ensures single mode operation of the interferometer section. The exit optical waveguide portion with an operating width `b` propagates two modes only.
The width "c" is chosen such that the lowest mode of "b" has nearly the same propagation constant as the lowest mode in "c" and is as far as possible from the second mode "b". The width "d" is chosen to match the propagation constant of the second order mode of "b".
It has been found that in fabricating operative embodiments of the present invention there is considerable latitude in choosing the various optical waveguide widths and that, moreover, the individual width tolerances are not extremely stringent to produce satisfactory operative results.
Waveguide mode calculations on diffused channel waveguides indicate a mode structure that is not significantly different from the calculations for rectangular channel waveguides illustrated graphically in FIG. 3 if the dimensions and normalizations are well chosen. In the implementation of the present invention, it has been found that for a branching angle of 1° the power divides equally into branches of the same dimensions within 0.1 db if the waveguides contain less than 3 modes.
In FIG. 1 the branching angles of the illustrated embodiment were chosen unsymmetrically with respect to the center line of the structure which is an indication of the large tolerances that are acceptable for satisfactory operation employing the teaching of the present invention.
The operation of the interferometer concept of the present invention involves several important considerations. The crystal orientation of the ZnSe substrates, for example, is not a usual one even for bulk crystal electro optic modulators. The crystal orientation was chosen to maximize the useable substrate area in a crystal which twins perpendicular to the [111] direction. The entrance and exit phases are (110) cleavage planes which give the devices an unusual orientation. The TE and TM phase shifts in a cubic bulk crystal having the described orientation may be expressed by the approximations ##EQU4## With l the device length, r 41 the electro-optic coefficient, and E the applied field. Thus, it may reasonably be expected that TE and TM modes would behave quite differently in the interferometer section.
FIGS. 4 and 5 illustrate the operative characteristics of two different embodiments of the present invention propagating light of 0.63 μm wavelength. The operative characteristics illustrated in FIG. 4 indicate a slightly higher surface index than the operative characteristics of the embodiment illustrated in FIG. 5.
Operation of embodiments of the present invention does not appear to be strongly dependent upon the input light polarization if the interferometer section optical waveguides are far from the second mode cut-off. TE, TM, and elliptically polarized light were used with only small changes from the circularly polarized light performance characteristics illustrated in FIGS. 4 and 5. The changes were primarily in the overall output intensity and not in the magnitude of the switching operation.
If the interferometer section of an embodiment of the present invention is made to be multi mode in character, the TE modes are affected by a given applied electric field much more strongly than are the TM modes. This demonstrated behavior is in agreement with the expected results of a bulk crystal modulator having this orientation.
The waveguide dimensions of the embodiments whose characteristics are graphically presented in FIGS. 4 and 5 are not optimum terms of the parameters illustrated in FIG. 3 with the exception of single mode waveguides in the interferometer section. It is also reasonable to expect that with improved design experience, significant reductions in crosstalk can be realized.
The length of the interferometer region and the affect of mode propagation velocity changes induced by the electric field determine the required operating voltage. A [100] ZnSe crystal offers a factor of two reduction in the required voltage for a given length and will have equal TE and TM operating voltage, while an interferometer switch in other materials such as ZnTe or LiNbO 3 will offer corresponding reduction in either the length or operating voltage of the embodiment of the present invention.
The capacitance of the embodiment whose characteristics are represented in FIG. 4 is about 0.6pf, but may be reduced somewhat by implementation of optimum electrode configurations. Electronics limited rise times of 1nsc have been realized in both the modulator and switch embodiments of the present invention. Additionally, the modulator and the switch embodiments of the present invention have both demonstrated suitability for use in a 1GHz optical communication system, confirming their ready adaptability to high speed optical systems.
One of the principal advantages of the modulator-switch of the present invention is that it has reasonable dimensional tolerances which can readily be met by fabrication techniques which are presently well known. By contrast, directional coupler types of devices having comparable operational objectives are severely limited in the realization of their full capabilities because of extremely stringent dimensional tolerances which are most difficult to meet in the manufacture of practical devices by known presently available fabrication techniques.
Moreover, if small dimensional differences occur, such as a difference in the length of the two optical waveguide branches which cooperate to perform in the manner of an interferometer, the lack of precisely identical optical length may be corrected with a small dc static electrical potential bias applied to the electrodes of the modulator switch as is exemplified by the graphical illustration of FIG. 5, for example.
Due to the relative simplicity of the basic concept of the present invention, there are numerous alternatives and variant configurations in which it may be embodied. The two most basic configurations are (1) the interferometer with the single mode output optical waveguide for use as a modulator, and (2) the interferometer with a multiple mode output optical waveguide and mode selective branching optical waveguides for use as a switch. FIG. 1a, for example, illustrates the basic one input-two output optical switch.
FIGS. 6a, 6b, and 6c illustrate several multi pole type switch embodiments of the present invention. In FIG. 6a the optical waveguide section 30 propagates three modes and thus is operationally functional as a 1×3 optical switch. FIG. 6a illustrates a 2×2 switch configuration with the optical waveguides 31 and 32 and 33 propagating two modes. FIG. 6c illustrates a 4×4 switch configuration employing two 2×2 switching elements. In this latter configuration of FIG. 6c, any one of four inputs can be switched to any one of four outputs.
Those skilled and knowledgeable in the pertinent arts will understand from the teaching of the present invention that many desired extension of its concepts may be realized to provide a N×N switching network of any number of inputs and outputs which may be desired.
Additionally, since the amount of light energy which is switched in the embodiment illustrated in FIG. 1a varies with the amplitude of the applied electrical potential, it may be used in a partial switching mode to pick off a specified fraction of light such as 10%, for instance, from an optical data bus line. Moreover, by operating the switch in reverse (that is to say, that the light would enter from the right in FIG. 1a) the device can be made to perform in the manner of a controllable light insertion unit.
Further, by choosing appropriate crystal materials, the phase shifts are defined in equations (1) and (2) can be made non-identical. This type of operation would then result in a polarization selective modulator or switch which may be used as a low loss polarizing element.
Also since both the induced phase shifts and the mode propagation characteristics are wavelength dependent, a switching device which is wavelength (i.e., color selective) is inherently possible within the concept and teaching of the present invention.
The embodiments of the present invention may be fabricated in both channel waveguides such as illustrated in FIG. 1a, or in epitaxial configuration where the plane of FIG. 1a would represent a cross-section through the device which would have no lateral confinement.
Materials suitable to fabricating embodiments of the present invention by known techniques include diffusion in II-VI compound, epitaxy and chemical etching in III-V compounds, and diffusion in ferro electric crystals, though the concept and teaching of the present invention is not limited to the use of these materials or techniques but may be extended to other suitable materials and techniques which are particularly adaptable to the requisites of specific applications of the invention.
Obviously many modifications and variations of the present invention are possible in the light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
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An optical waveguide arrangement operates in the manner of an interferometer to provide modulator and/or switching functions. Two optical waveguide branches having a common connection diverge along a substantially coextensive distance and reconverge to provide first and second light paths of identical optical length. Conductive electrodes are disposed contiguous to at least one of the optical waveguide branches and are connectable through a controlling switch to a source of electrical energy for producing an electric field across the energized electrodes. In the absence of such electric field, light energy entering the two optical waveguide branches will propagate along identical optical path lengths and recombine constructively at the reconvergence of the waveguide branches. However, a selectively applied electrical energy changes the optical property of at least one of the optical waveguide branches causing phase differences in the optical energy transmitted by the branches and producing destructive interference at the reconvergence of the optical waveguide branches. The addition of two optical waveguide sections having different dimensions provides a switch function when one of such additional waveguides is dimensioned to be conducive to the propagation of first order mode light energy while the other waveguide is dimensioned to be conducive to the propagation of second order mode light energy.
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REFERENCE TO RELATED APPLICATIONS
This application is a division of application Ser. No. 06/894,372 filed Aug. 6, 1986, now abandoned, which is a continuation of Ser. No. 474,930 filed mar. 14, 1983, now abandoned, which is a continuation-in-part of Ser. No. 368,773 filed Apr. 15, 1982, now abandoned.
FIELD OF THE INVENTION
The present invention relates to human urokinase, to novel forms and compositions thereof and particularly to means and methods for the preparation in vitro of functional protein species of human urokinase.
The present invention is based in part on the discovery of the DNA sequence and deduced amino acid sequence of native urokinase as well as associated portions of the urokinase molecule found to be the functional bioactive moieties. This discovery enabled the production of urokinase in various forms via the application of recombinant DNA technology, in turn enabling the production of sufficient quality and quantity of materials with which to conduct requisite biological testing identifying the biologically functional, hence useful moieties of the molecule. Having determined such, it was possible to tailor-make functional species of urokinase via genetic manipulation and in vitro processing, arriving efficiently at hitherto unobtainable commercially efficacious amounts of active products. This invention is directed to these associated embodiments in all respects.
The publications and other materials hereof used to illuminate the background of the invention, and in particular cases, to provide additional details concerning its practice are incorporated herein by reference, and for convenience, are numerically referenced in the following text and respectively grouped in the appended bibliography.
BACKGROUND OF THE INVENTION
A. Human Urokinase
The fibrinolytic system is in a dynamic equilibrium with the coagulation system, maintaining an intact, patent vascular bed. The coagulation system deposits fibrin as a matrix serving to restore a hemostatic condition. The fibrinolytic system removes the fibrin network after the hemostatic condition is achieved. The fibrinolytic process is brought about by the proteolytic enzyme plasmin that is generated from a plasma protein precursor plasminogen. Plasminogen is converted to plasmin through activation by an activator.
Urokinase is one such activator. It and another activator, streptokinase, are currently commercially available. Both are indicated for the treatment of acute vascular diseases such as myocardial infarct, stroke, pulmonary embolism, deep vein thrombosis, peripheral arterial occlusion and other venous thromboses. Collectively, these diseases account for major health hazards and risks.
The underlying etiological basis for these diseases points to either a partial, or in severe cases, total occlusion of a blood vessel by a blood clot--thrombus or thromboembolus. Traditional anticoagulant therapy, as with heparin and coumarin, does nothing to directly enhance dissolution of thrombi or thromboemboli. Streptokinase and urokinase have enjoyed practical and effective use as thrombolytic agents. Until now, however, each has suffered from severe limitations. Neither has demonstrated a high affinity for fibrin; consequently, both activate circulating and fibrin-bound plasminogen relatively indiscriminately. The plasmin formed in circulating blood is neutralized rather quickly and lost for useful thrombolysis. Residual plasmin will degrade several clotting factor proteins, for example, fibrinogen, Factor V and Factor VIII, causing a hemorrhagic potential. In addition, streptokinase is strongly antigenic and patients with high antibody titers respond inefficiently to treatment and cannot remain on continuous treatment. Urokinase therapy is expensive, owing to its involved isolation from human urine or tissue culture, and it therefore is not generally accepted in clinical practice. Urokinase has been the subject of numerous investigations--See, for example, references 1-9. Presently available urokinase, as defined, is isolated from human urine or tissue culture, e.g. kidney cells (9A,9B).
The urokinase molecule exists is several biologically active forms--high molecular weight (ca. 54000 daltons) and low molecular weight (ca. 33000 daltons), each composed of single chain or two chain material. The low molecular weight form is derived from the high molecular weight form by enzymatic cleavage. Biologically active material contains the so-called serine protease portion linked, in active form, to a second chain via a disulfide bond. Any activity ascribed to the high molecular weight material is believed to be due to the similar presence of these two connected chains, the strategic disulfide bond and interruption in the sequence doubtless being located in the serine protease portion of the overall molecules (See FIG. 1). In any event, until the present invention, the identity, and hence function, of the ca. 21000 dalton residue was unknown and the assignment of activity to one or another of the known moieties of urokinase was not uncontrovertedly possible.
Recently, there was a report of another form of urokinase peptide having low, but specific activity (10, 10A). It was speculated that this material corresponds to native urokinase, a preform of the previously isolated active species described above, most probably consisting of a single chain.
Previous attempts to clone the requisite gene for urokinase with attendant hopes of attaining expression in a microbial host were not believed successful (11, 11A). See also (6).
It was perceived that the application of recombinant DNA and associated technologies, after all, would be a most effective way of providing the requisite large quantities of high quality, bioactive human urokinase, essentially free of other human protein, and derivatives thereof that retain functional bioactivity, thus admitting of the use of such materials clinically in the treatment of various vascular conditions or diseases.
B. Recombinant DNA/Protein Biochemistry Technology
Recombinant DNA technology has reached the age of some sophistication. Molecular biologists are able to recombine various DNA sequences with some facility, creating new DNA entities capable of producing copious amounts of exogenous protein product in transformed microbes and cell cultures. The general means and methods are in hand for the in vitro ligation of various blunt ended or "sticky" ended fragments of DNA, producing potent expression vehicles useful in transforming particular organisms, thus directing their efficient synthesis of desired exogenous product. However, on an individual product basis, the pathway remains somewhat tortuous and the science has not advanced to a stage where regular predictions of success can be made. Indeed, those who portend successful results without the underlying experimental basis, do so with considerable risk of inoperability.
DNA recombination of the essential elements, i.e., an origin of replication, one or more phenotypic selection characteristics, an expression promoter, heterologous gene insert and remainder vector, generally is performed outside the host cell. The resulting recombinant replicable expression vehicle, or plasmid, is introduced into cells by transformation and large quantities of the recombinant vehicle obtained by growing the transformant. Where the gene is properly inserted with reference to portions which govern the transcription and translation of the encoded DNA message, the resulting expression vehicle is useful to actually produce the polypeptide sequence for which the inserted gene codes, a process referred to as expression. The resulting product may be obtained by lysing, if necessary, the host cell, in microbial systems, and recovering the product by appropriate purification from other proteins.
In practice, the use of recombinant DNA technology can express entirely heterologous polypeptides--so-called direct expression--or alternatively may express a heterologous polypeptide fused to a portion of the amino acid sequence of a homologous polypeptide. In the latter cases, the intended bioactive product is sometimes rendered bioinactive within the fused, homologous/heterologous polypeptide until it is cleaved in an extracellular environment. See references (12) and (13).
Similarly, the art of cell or tissue cultures for studying genetics and cell physiology is well established. Means and methods are in hand for maintaining permanent cell lines, prepared by successive serial transfers from isolate normal cells. For use in research, such cell lines are maintained on a solid support in liquid medium, or by growth in suspension containing support nutriments. Scale-up for large preparations seems to pose only mechanical problems. For further background, attention is directed to references (14) and (15).
Likewise, protein biochemistry is a useful, indeed necessary, adjunct in biotechnology. Cells producing the desired protein also produce hundreds of other proteins endogenous products of the cell's metabolism. These contaminating proteins, as well as other compounds, if not removed from the desired protein, would prove toxic if administered to an animal or human in the course of therapeutic treatment with desired protein. Hence, the techniques of protein biochemistry come to bear, allowing the design of separation procedures suitable for the particular system under consideration and providing a homogeneous product safe for intended use. Protein biochemistry also proves the identity of the desired product characterizing it and ensuring that the cells have produced it faithfully with no alterations or mutations. This branch of science is also involved int he design of bioassays, stability studies and other procedures necessary to apply before successful clinical studies and marketing can take place.
SUMMARY OF THE INVENTION
The present invention is based upon the discovery that recombinant DNA/protein biochemistry technology can be used to successfully produce human urokinase in the form of biologically functional, tailored species. This invention provides active urokinase protein suitable for use, in all of its forms, in the prophylactic or therapeutic treatment of human beings for various vascular conditions or diseases. Each of its forms includes the bioactive moiety, to wit, the enzymatic portion of native material believed to reside in a 2-chain region comprising the serine protease portion. In accordance with this invention, a series of urokinase active products can be prepared, either directly in bioactive form or notably in a form available for in vitro processing to result in bioactive product. This invention also provides the means and methods for producing full length native urokinase molecules particularly in bioactive or bioactivatable form, having the potential added advantage of specific affinity for fibrin not demonstrated until now with any urokinase product isolated from natural sources. Thus provided is human urokinase product having the potential new property of specific activity toward tangible, extant thrombi. The products being produced by cell culture harboring recombinant DNA encoding respective product entity, the facilities are now at hand to produce human urokinase in a much more efficient manner than has been possible and in forms exhibiting enhanced biologically significant properties. In addition, depending upon the host cell, the urokinase activator hereof may contain associated glycosylation to a greater or lesser extent compared with native material.
The present invention comprises the human urokinase products thus produced and the means and methods of production. The present invention is further directed to replicable DNA expression vehicles harboring gene sequences encoding the enzymatic portion of human urokinase in expressible form. Further, the present invention is directed to microorganism strains or cell cultures transformed with the expression vehicles described above and to microbial or cell cultures of such transformed strains or cultures, capable of directing production of the human urokinase products hereof. In still further aspects, the present invention is directed to various processes useful for preparing said urokinase gene sequences, DNA expression vehicles, microorganism strains and cell cultures and to specific embodiments thereof. Still further, this invention is directed to the preparation of fermentation cultures of said microorganisms and cell cultures.
Reference herein to the expression "human urokinase" connotes polypeptide in bioactive form, produced by microbial or cell culture or optional in vitro processing and comprising the enzymatic portion corresponding to native material. Human urokinase, according to the present invention, is thus provided 1) in full length, in contradistinction to material hitherto isolated from natural sources or 2) in other, bioactive forms bearing the sites of the enzymatic portion found essential for plasminogen activation or 3) having a methionine first amino acid or a signal polypeptide or conjugated polypeptide other than the signal polypeptide fused at the N-terminus of the enzymatic potion, the methionine, signal or conjugate polypeptide being specifically sleavable in an intra- or extracellular environment (See reference 12). In any event, the thus produced human urokinase polypeptides are recovered and purified to levels fitting them for use in the treatment of various cardiovascular conditions or diseases.
DESCRIPTION OF PREFERRED EMBODIMENTS
A. Microorganisms/Cell Cultures
1. Bacterial Strains/Promoters
The work described herein was performed employing, inter alia, the microorganism E. coli K-12 strain GM 48 (thr - , leu - , B 1 - , lacY1, gal K12, gal T22, ara 14, ton A31, tsx 78, Sup E44, dam 3, dcm 6) deposited with the American Type Culture Collection on Apr. 9, 1982 (ATCC No. 39099) and E. coli K-12 strain 294 (end A, thi - , hsr - , k hsm + ), described in reference (16), deposited with the American Type Culture Collection, ATCC Accession No. 31446, on oct. 28, 1978. However, various other microbial strains are useful, including known E. coil strains such as E. coli B, E. coil X 1776 (ATCC No. 31537, deposited Jul. 3, 1979) and E. coli W 3110 (F - , λ - , protrophic) (ATCC No. 27325 deposited Feb. 10, 1972), or other microbial strains many of which are deposited and (potentially) available from recognized microorganism depository institutions, such as the American Culture Collection (ATCC)--cf. the ATCC catalogue listing. See (17), These other microorganisms include, for example, Bacilli such as Bacillus subtilis and other enterobacteriaceae among which can be mentioned as exampled Salmonella typhimurium, Serratia marcesans, and Pseudomonas. utilizing plasmids that can replicate and express heterologous gene sequences therein.
As examples, the beta lactamase and lactose promoter systems have been advantageously used to initiate and sustain microbial production of heterologous polypeptides. Details relating to the make-up and construction of these promoter systems can be had by reference to (18) and (19). More recently, a system based upon the tryptophan pathway, the so-called trp promoter system, has been developed. Details relating to the make-up and construction of this system can be had by reference to (20) and (21). Numerous other microbial promoters have been discovered and utilized and details concerning their nucleotide sequences. Enabling a skilled worker to ligate them functionally within plasmid vectors, have been published.--See (22).
2. Yeast Strains/Yeast Promoters
The expression system hereof may also employ a plasmid which is capable of selection and replication in either or both E. coli and/or yeast, Saccharomyces cerevisiae. For selection in yeast the plasmid may contain the TRP1 gene (23, 24, 25) which complements (allows for growth in the absence of tryptophan) yeast containing mutations in this gene found on chromosome IV of yeast (26). A useful strain is strain RH218 (27) deposited at the American Type Culture Collection without restriction on Dec. 8, 1980. (ATCC No. 44076). However, it will be understood that any Saccharomyces cerevisiae strain containing a mutation which makes the cell trp1 should be an effective environment for expression of the plasmid containing the expression system, e.g., strain pep4-1 (28). This tryptophan auxotroph strain also has a point mutation in TRP1 gene.
When placed on the 5' side of a non-yeast gene the 5'-flanking DNA sequence (promoter) from a yeast gene (for alcohol dehydrogenase 1) can promote the expression of a foreign gene in yeast when placed in a plasmid used to transform yeast. Besides a promoter, proper expression of a non-yeast gene in yeast requires a second yeast sequence placed at the 3'-end of the non-yeast gene on the plasmid so as to allow for proper transcription termination and polyadenylation in yeast. In the preferred embodiments, the 5'-flanking sequence of the yeast 3-phosphoglycerate kinase gene (29) is placed upstream from the structural gene followed again by DNA containing termination--polyadenylation signals, for example, the TRP1 (23-25) gene or the PGK (29) gene.
Because yeast 5'-flanking sequence (in conjunction with 3' yeast termination DNA) (infra) can function to promote expression of foreign genes in yeast, it seems likely that the 5'-flanking sequences of any yeast gene could be used for the expression of important gene products, e.g., glycolytic genes such as e.g., enolase, glyceraldehyde - 3-phosphate dehydrogenase, hexokinase, pyruvate decarboxylase, phosphofructokinase, glucose - 6-phosphate isomerase, 3-phosphoglycerate mutase, pyruvate kinase, triosephosphate isomerase, phosphoglucose isomerase, and glucokinase. Any of the 3'-flanking sequences of these genes could also be used for proper termination and mRNA polyadenylation in such an expression system.
Finally, many yeast promoters also contain transcriptional control so they may be turned off or on by variation in growth conditions. Some examples of such yeast promoters are the genes that produce the following proteins: Alcohol dehydrogenase II, acid phosphatase, degradative enzymes associated with nitrogen metabolism, glyceraldehyde -3-phosphate dehydrogenase, and enzymes responsible for maltose and galactose utilization (30). Such a control region would be very useful in controlling expression of protein product--especially when their production is toxic to yeast. It should also be possible to combine the control region of one 5'-flanking sequence with a 5'-flanking sequence containing a promoter from a highly expressed gene. This would result in a hybrid promoter and should be possible since the control region and the promoter appear to be physically distinct DNA sequences.
3. Cell Culture Systems/Cell Vectors
Propogation of vertebrate cells in culture (tissue culture) has become a routine procedure in recent years. (See 31). A useful host for the production of heterologous protein is the COS-7 line of monkey kidney fibroblasts (32). However, the present invention could be practiced in any cell line that is capable of the replication and expression of a compatible vector, e.g., WI38, /BHK, 3T3, CHO, VERO, and HeLa cell lines. Additionally, what is required of the expression vector is an origin or replication and a promoter located in front of the gene to be expressed, along with any necessary ribosome binding sites, RNA splice sites, polyadenylation site, and transcriptional terminator sequences. It will be understood that this invention, although described herein in terms of a preferred embodiment, should not be construed as limited to these sequences. For example, the origin of replication of other viral (e.g., Polyoma, Adeno, VSV, BPV, and so forth) vectors could be used, as well as cellular origins of DNA replication which could function in a nonintegrated state.
In such vertebrate cell hosts, the genetic expression vector for a urokinase produce polypeptide hereof may also contain a secondary genetic coding sequence under the control of the same promoter. The secondary sequence provides for a convenient screening marker, both for transformants in general, and for transformants showing high expression levels for the primary sequence, as well as serving as a control device whereby the expression of the desired urokinase polypeptide can be regulated, most frequently enhanced.
This is particularly significant as the two proteins are produced separately in mature form. While both DNA coding sequences are controlled by the same transcriptional promoter, so that a fused message (mRNA) is formed, they are separated by a translational stop signal for the first and start signal for the second, so that two independent proteins result.
It has been recognized that environmental conditions are often effective in controlling the quantity of particular enzymes that are produced by cells under certain growth conditions. In a preferred embodiment, advantage is taken of the sensitivity of certain cells to methotrexate (MTX) which is an inhibitor of dihydrofolate reductase (DHFR). DHFR is an enzyme which is required, indirectly, in synthesis reactions involving the transfer of one carbon units. Lack of DHFR activity results in inability of cells to grow except in the presence of those compounds which otherwise require transfer of one carbon units for their synthesis. Cells lacking DHFR, however, will grow in the presence of a combination of glycine, thymidine and hypoxanthine.
Cells which normally produce DHFR are known to be inhibited by methotrexate. Most of the time, addition of appropriate amounts of methotrexate to normal cells will result int he death of the cells. However, certain cells appear to survive the methotrexate treatment by making increased amounts of DHFR, thus exceeding the capacity of the methotrexate to inhibit this enzyme. It has been shown previously that in such cells, there is an increased amount of messenger RNA coding for the DHFR sequence. This is explained by assuming an increase in the amount of DNA in the genetic material coding for this messenger RNA. In effect, apparently the addition of methotrexate causes gene amplification of the DHFR gene. Genetic sequences which are physically connected with the DHFR sequence although not regulated by the same promoter are also amplified. Consequently, it is possible to use the amplification of the DHFR gene resulting from methotrexate treatment to amplify concomitantly the gene for another protein, in this case, the desired urokinase polypeptide.
Moreover, if the host cells into which the secondary sequence for DHFR is introduced are themselves DHFR deficient, DHFT also serves as a convenient marker for selection of cells successfully transfected. If the DHFR sequence is effectively connected to the sequence for the desired peptide, this ability serves as a marker for successful transfection with the desired sequence as well.
B. Vector Systems
1. Expression in Bacterial Systems
Expression plasmids for bacterial use, e.g., E. coli are commonly derived using BR322 (37) as vector and appropriately inserting the heterologous gene sequence together with translational start and stop signals in operable reading phase with a functional promoter, taking advantage of common or synthetically created restriction sites. The vector will carry one or more phenotypic-selection characteristic genes and an origin of replication to insure amplification within the host. Again, the heterologous insert can be aligned so as to be expressed together with a fused presequence, derivable for example from the trp system genes.
2. Expression in Yeast
To express a heterologous gene such as the cDNA for human urokinase in yeast, it is necessary to construct a plasmid vector containing four components. One component is the part which allows for transformation of both E. coli and yeast and thus must contain a selectable gene from each organism. This can be the gene for ampicillin resistance from E. coli and the gene TRP1 from yeast.) This component also requires an origin of replication from both organisms to be maintained as a plasmid DNA in both organisms. This can be the E. coli origin from pBR322 and the ars1 origin from chromosome III of yeast.)
A second component of the plasmid is a 5'-flanking sequence from a yeast gene to promote transcription of a downstream-placed structural gene. The 5'-flanking sequence can be that from the yeast 3-phospho- glycerate kinate (PGK) gene. The fragment is constructed in such a way so as to remove the ATG of the PGD structural sequence, replaced with a sequence containing alternative restriction sites, such as XbaI and EcoRI restriction sites, for convenient attachment of this 54'-flanking sequence to the structural gene.
A third component of the system is a structural gene constructed in such a manner that it contains both an ATG trranslational start and translational stop signals.
A fourth component is a yeast DNA sequence containing the 3'-flanking sequence of a yeast gene, which contains the proper signals for transcription termination and polyadenylation.
3. Expression in Mammalian Cell Culture
The strategy for the synthesis of heterologous peptide in mammalian cell culture relies on the development of a vector capable of both autonomous replication and expression of a foreign gene under the control of a heterologous transcriptional unit. The replication of this vector in tissue culture is accomplished by providing a DNA replication origin (such as from SV40 virus), and providing helper function (T antigen) by the introduction of the vector into a cell line endogenously expressing this antigen (33, 34). The late promoter of SV40 virus precedes the structural gene and ensures the transcription of the gene.
A useful vector to obtain expression consists of pBR322 sequences which provides a selectable marker for selection in E. coli (ampicillin resistance) as well as an E. coli origin of DNA replication. These sequences are derivable from the plasmid pML-1. The SV40 origin is derivable from a 342 base pair PvuII-HindIII fragment encompassing this region (35, 36) (both ends being convertable to EcoRI ends). These sequences, in addition to comprising the viral origin of DNA replication, encode the promoter for both the early and late transcriptional unit. The orientation of the SV40 origin region is such that the promoter for the late transcriptional unit is positioned proximal to the gene encoding interferon.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of urokinase polypeptides. Low molecular weight urokinase begins at amino acid 136 and ends at amino acid 412. High molecular weight urokinase starts at amino acid 1 and terminates at amino acid 412. Conversion of the one chain form of both high and low molecular weight urokinase to the bioactive two-chain form occurs by proteolytic cleavage between amino acid 158 and 159. Pre-urokinase begins at amino acid-20. The depicted conformational positioning o the disulfide bonds is based on analogy with other serine proteases.
FIGS. 2A to 2C depict the nucleotide sequence and restriction endonuclease map of the plasmid pD2 cDNA insert for low molecular weight 33000 dalton urokinase bioactive protein. The nucleotide portion of the synthetic deoxyoligonucleotide CG6B probe is underlined.
FIGS. 3A,B depict the deduced amino acid sequence of the cDNA sequence of FIG. 1, the amino acids of the cDNA insert portion being numbered 1 to 279.
FIGS. 4A to 4C depict the nucleotide sequence and restriction endonuclease map of the cDNA for full length human urokinase protein. The CB6B probe is likewise underlined.
FIGS. 5A,B depict the deduced amino acid sequence for full length urokinase from the cDNA sequence of FIG. 3.
FIG. 6 illustrates the construction of plasmid pUK33trpLE L for expression of long fusion -33000 dalton protein.
FIG. 7 illustrates the construction of plasmid pUK33trpLE S for expression of short fusion -33000 dalton protein.
FIG. 8 shows the construction of the plasmid for direct expression of the 33000 dalton protein.
FIG. 9 illustrates another construction of a plasmid for direct expression of the 33K dalton protein.
FIGS. 10 and 11 illustrate the construction of plasmids for the direct expression of 54K urokinase and a precursor form of 54K urokinase.
FIG. 12 shows the construction of a plasmid (p-pEH3-Bal14 preUK54) for the expression of 54K urokinase in eukaryotic cells.
FIG. 13 illustrates the time dependent activation of, and the requirement for, plasminogen in a plasmin assay by urokinase produced as described herein.
FIG. 14 illustrates the plasminogen activating activity of the urokinase extracts hereof and the inhibition of that activity by antibodies raised against natural urokinase.
DETAILED DESCRIPTION
A. Source of Urokinase mRNA
Detroit 562 (human pharangeal carcinoma) cells (38)(ATCC No. CCL 138) were cultured to confluency in Eagle's minimal essential medium (39) supplemented to contain 3 percent sodium bicarbonate (pH 7.5), 1 percent L-glutamine (Irvine), 10 percent fetal bovine serum, 1 percent sodium pyruvate (Irvine), 1 percent non-essential amino acids (Irvine), 2.4 percent HEPES (pH 7.5), 50 μg/ml Garamycin, and incubated at 37° C. in a 5 percent CO 2 atmosphere. Confluent cells were harvested by centrifugation after treatment with 0.25 percent trypsin for 15 minutes at 37° C.
B. Messenger RNA Isolation
Total RNA from Detroit 562 cells was extracted essentially as reported by Lynch et al. (40). Cells were pelleted by centrifugation and approximately one gram of cells was then resuspended in 10 ml of 10 mM NaCl, 10 mM Tris·HCl (pH 7.4), 1.5 mM MgCl 2 . Cells were lysed by the addition of non-ionic detergent NP-40 to a final concentration of 1 percent. Nuclei were removed by centrifugation and the RNA was further purified by two successive phenol (redistilled)/chloroform: isoamyl alcohol extractions at 4° C. The aqueous phase was made 0.2M NaCl and total RNA was precipitated by addition of two volumes of b 100 percent ethanol and overnight storage at -20° C. Following centrifugation polyA mRNA was purified from total RNA by oligo-dT cellulose chromatography (41). Yields from 1 gram of cells were typically 10-15 mg of total RNA and ˜2 percent of that was polyA mRNA.
C. Size Fractionation of polyA mRNA
Size fractionation of 200 μg polyA mRNA was achieved by electrophoresis through an acid-urea gel composed of 1.75 percent agarose, 25 mM sodium citrate (pH 3.8) and 6M urea (40,42). Electrophoresis was performed for 7 hours at 25 mA and 4° C. The gel was then fractionated manually with a razor blade. Individual slices of the gel were melted at 70° C., diluted into 12 mls 10 mM NaCl, 10 mM Tris·HCl (H 7.4), 1.5 mM MgCl 2 , 0.1 percent SDS and extracted twice with water saturated, redistilled phenol and once with chloroform. Fractions were then ethanol precipitated and subsequently translated in vitro (43) in order to determine the affected size fractionation and integrity of the polyA mRNA.
D. Preparation of Oligo-dT Primed Colony Library Containing Urokinase DNA Sequences
Poly A mRNA was size-fractionated on acid urea gels. mRNA fractions greater than 12S were pooled and used as template for oligo-dT primed preparation of double stranded cDNA by standard procedures (44,45). The cDNA was size fractionated on 6 percent polyacrylamide gel electrophoresis and 132 ng of ds cDNA greater than 350 basepairs in length was obtained by electroelution. A 30 ng portion of ds cDNA was extended with deoxy C residues using terminal deoxynucleotidyl transferase (46) and annealed with 200 ng of the plasmid pBR322 (37) which had been similarly tailed with deoxy G residues at PstI site (46). Each annealed mixture was then transformed into E. coli K12 strain 294 (ATCC No. 31446). Approximately 10000 ampicillin sensitive, tetracycline resistant transformants were obtained.
E. preparation of Synthetic DNA Oligomers for Use as Urokinase Screening Probes
Eight synthetic DNA oligomers 14 bases long were designed complementary to mRNA based on the Met-Tyr-Asn-Asp-Pro amino acid sequence of a urokinase cyanogen bromide polypeptide fragment designated CB6. These eight deoxyoligonucleotides were synthesized by the phosphotriester method (17) in the following pools of two: (CB6A) 5' GGGTCGTTA/GTACAT 3', (CB6B) 5' GGATCGTTA/GTRACAT 3', (CG6C) 5' GGGTCATTA/GTACAT 3', (CB6D) 5' GGATCATTA/GTACAT 3'. Each pool of two oligomers was then radioactively phosphorylated as follows: 250 ng of deoxyoligonucleotide were combined in 25 μl of 60 mM Tris·HCl (pH 8), 10 mM MgCl 2 , 15 mM beta-mercaptoethanol, and 100 μCi (γ- 32 P) AT) (Amersham, 5000 Ci/mMole). 5 units of T4 polynucleotide kinase were added and the reaction was allowed to proceed at 37° C. for 30 minutes and terminated by addition of EDTA to 20 mM.
F. Screening of Oligo dT Primed Colony Library for Urokinase Sequences
˜10000 colonies were individually inoculated into wells of microtitre dishes containing LB (48)+5 μg/ml tetracycline and stored at -20° C. after addition of DMSO to 7 percent. Individual colonies from this library were transferred to Schleicher and Schuell BA85/20 nitrocellulose filters and grown on agar plates containing LB+5 μg/ml tetracycline. After ˜10 hours growth at 37° C. the colony filters were transferred to agar plates containing LB+5 μg/ml tetracycline and 12.5 μg/ml chloramphenicol and reincubated overnight at 37° C. The DNA from each colony was then denatured and fixed to the filter by a modification of the Grunstein-Hogness procedure (49). Each filter was floated for 3 minutes on 0.5N NaOH, 1.5M NaCl to lyse the colonies and denature the DAN then neutralized by floating for 15' on 3M NaCl, 0.5M Tris·Hcl (pH 7.5). The filters were then floated for an additional 15 minutes on 2XSSC, and subsequently baked for 2 hours in an 80° C. vacuum oven. The filters were prehybridized for ˜2 hours at room temperature in 0.9M NaCl, 1× Denhardst, 100 mM Tris·HCl (pH 7.5), 5 mM Na-EDTA, 1 mM ATP, 1M sodium phosphate (dibasic), 1 mM sodium pyrophosphate, 0.5 percent NP-40, and 200 μg/ml E. coli t-RNA, and hydrodized in the same solution overnight essentially as described by Wallace et al. (50) using ˜40×10 6 cpm of each kinased CB6 deoxyoligonucleotide pool of 2. After extensive washing at 37° C. in 6X SCC, 0.1 percent SDS, the filters were exposed to Kodak XR-5 X-ray film with DuPont Lighting-Plus intensifying screens for 16-24 hours at -80° C. Two colonies indicated hybridization with the mixture of eight probes: UK513dT69D2 (pD2) and IK513dT73D12 (pD12).
G. Characterization of pD2 and pD12 Plasmid DNA
Plasmid DNA isolated from E. coli colony UK513dT69D2 and UK513dT73D12 by a rapid miniscreen method (51) was subjected to PstI restriction endonuclease analysis. This analysis strongly suggested that pD2 and pD12 are identical. Each plasmid DNA has 3 PstI restriction fragments that comigrate when electrophoresed through a 6 percent polyacrylamide gel. The complete nucleotide sequence of the plasmid pD2 cDNA insert was determined by the dideoxynucleotide chain termination method (52) after subcloning the PstI restriction fragments into the M13 vector mp7 (53). FIG. 1 presents the nucleotide sequence and FIG. 2 presents the translated nucleotide sequence of the cDNA insert fragment of pD2. The entire coding region of low molecular weight (33KL) urokinase was isolated on this one large fragment of pD2. The nucleotide sequence of the CB6B (50' GGATCGTTA/GTACAT) deoxyoligonucleotide includes nucleotides 466 through 479 according to this map. A typical serine protease active site (gly asp ser gly gly pro) is present between amino acids 222 and 227. The coding region consists of 838 basepairs or 279 amino acids of the carboxy terminal portion of high molecular weight (54K) urokinase. The stop codon UGA at amino acid position 280 begins ca. 935 nucleotides of 3' untranslated sequence up to the poly A sequence. Because only 31413 daltons of full length urokinase were encoded by the cDNA insert of pD2 it was necessary to construct additional colony banks containing urokinase sequences in order to identify high molecular weight urokinase.
H. Construction of Two Different Specifically Primed Colony Banks for Amino Terminal Extension of the Existing Urokinase Clone
The first specifically primed cDNA bank utilized a 45 basepair urokinase DNA restriction endonuclease fragment beginning with HaeII in position 225 and ending with AccI in position 270 (FIG. 1) as a primer rather than oligo dT 12-18 . This fragment was heat denatured in the presence of 20 μg unfractionated Detroit 562 polyA mRNA and cDNA was prepared according to procedures referenced in Section D. 11.5 ng of double-stranded cDNA greater than 200 bp were electroeluted from a 6 percent polyacrylamide gel, and used to generate approximately 6000 clones in E. coli 294.
A second specifically primed cDNA bank called UK89CB6 of about 4000 colonies was constructed using a pool of 4 μg polyA mRNA acid-urea agarose gel fraction 8 and 4 μg polyA mRNA from fraction 9 (Section C). 250 ng of each CB6 deoxyoligo-nucleotide pool (Section E) were used as primer rather than oligo dT 12-18 .
I. Screening of Full Length Colony Bank
Full length cDNA containing colonies were transferred directly to nitrocellulose filters then grown at 37° C. The colonies were lysed and the DNA was denatured and fixed to the filters as described in Section F (49). A 32 P-labelled DNA probe was prepared (54) from a 143 basepair HinfI to HaeII restriction endonuclease fragment from the cDNA insert of pD2 and hybridized (55) with the filter fixed full length cDNA. 8×10 6 CPM of the probe was hybridized for 16 hours then washed as described (55) and exposed to X-ray film. Two colonies demonstrated strong hybridization: A3 and E9.
J. Characterization of Full Length Urokinase cDNA's pA3 and pE9
PstI restriction analysis of A3 plasmid DNA showed cDNA insert fragments of ˜360 bp and ˜50 bp, and of E9 plasmid DNA, one fragment at ˜340 bp. PstI EcoRI double restriction of each plasmid DNA revealed a common cDNA insert fragment of ˜190 bp as predicted where each plasmid DNA encoded urokinase sequence information 5' to the HaeII AccI primer fragment. Plasmid pA3 has an additional PstI EcoRI cDNA insert fragment of 185 bp and E9 a 160 bp additional fragment. The larger ˜360 bp PstI cDNA insert fragment of pA3 was subcloned into the M13 vector mp7 (53) and sequenced by the dideoxynucleotide chain termination method (52). The urokinase coding sequence of pA3 is located from approximately position 405 to position 785 in the cDNA sequence for full length urokinase protine in FIG. 3.
K. Screening of Urokinase Colony Bank UK89CB6
DNA from ˜1900 UK89CB6 cDNA insert containing colonies was denatured and fixed to nitrocellulose filters as previously described in Section F. A 32 P-labelled DNA probe was prepared (54) from the 146 bp PstI HinfI fragment of the cDNA inset fragment of pA3. 40×10 6 CPm of this probe was then hybridized to the filter bound DNA of UK89CB6 colonies for 16 hours then washed as described (55) and exposed to X-ray film. Two colonies demonstrating positive hybridization were UK89CB6F 1 (pF1) and UK89CB6H10 (pH10).
L. Characterization of pFI and pH10 Urokinase cDNAs
PstI restriction of pF1 demonstrates cDNA insert fragments of ˜450 bp and ˜125 bp, and pH10 shows one PstI cDNA insert fragment of ˜500 bp. PstI EcoRI double restriction of pF1 indicates no EcoRI restriction site and has cDNA insert fragments identical to those of the PstI restriction alone. pH10 does demonstrate an EcoRI restriction site, producing cDNA insert fragments of ˜375 bp and ˜220 bp. This EcoRI site of pH10 is probably the same EcoRI site as noted at position 627 (FIG. 3). The pF1 cDNA insert does not contain this EcoRI restriction site.
pF1, having a cDNA insert fragment longer than that of pH10, was selected for sequencing. Both PstI restriction fragments of the pF1 cDNA insert were sequenced by M13 subcloning and dideoxy sequencing. The composite nucleotide sequence of UK cDNA inserts from pF1, pA3 and pD2 encoding the entire amino acid sequence of high molecular weight full length urokinase is shown in FIG. 3. The urokinase coding sequence of pF1 is depicted from position 1 approximately to position 570. The urokinase coding sequence of pD2 is located from position 532 to position 2304 in FIG. 3.
The amino terminal serine at amino acid position one as determined by amino acid sequence analysis is shown in FIGS. A and 4. The preceding 20 amino acids at the amino terminus beginning with met and ending with gly probably serves as a signal sequence for the secretion of the remaining 411 amino acids of high molecular weight urokinase. This putative signal sequence has features, such as size and hydrophobicity (56,57), in common with other characterized signal sequences.
Trypsin cleavage sites rendering 33K two-chain low molecular weight urokinase from high molecular weight urokinase are as follows: lys at position 136 is the amino terminal amino acid of the short chain and ile at position 159 is the amino terminus of the long chain (FIGS. A, 4).
M. Expression of Low Molecular Weight Derivatives of Urokinase in E. coli
1. Long trp LE fusion (FIG. 5)
A plasmid (pNCV, 58) was constructed which has the following properties: 1) the plasmid is a derivative of pBR322 and is present in about 20 copies per cell. 2) the plasmid makes its E. coli host resistant to tetracycline. 3) the plasmid contains an inducible tryptophan promoter, which directs the synthesis of a protein consisting of a fusion between the trp leader peptide and the trp E structural gene (Le fusion gene). 4) A unique PstI restriction site was constructed in the trp E gene, which can be used to clone PstI DNA fragments, by converting the EcoRI site at the distal end of the LE gene in plasmid pSOM7Δ1Δ4 to a PstI site flanked by two EcoRI sites using a synthetic sequence: ##STR1## The DNA fragment containing the trp promoter and LE gene was then introduced into plasmid pBR322 to give plasmid pNCV (47A).
The urokinase PstI fragment from nucleotide position 5 (the Pst I 5',cleavage site) to nucleotide position 1130 (FIG. 1) was cloned into the PstI site of pNCV in such a way that a fusion protein is made upon induction of the trp promoter. The N-terminal part is trp LE and the C-terminal part is low molecular weight urokinase.
With reference to FIG. 5, 5 μg of plasmid pUK513dT69D2 (pD2) was digested with 20 units PstI and the 1125 bp cDNA insert fragment encoding low molecular weight urokinase was isolated by 6 percent polyacrylamide gel electrophoresis. ˜1 μg of this insert was electroeluted from the gel, phenol/chloroform extracted and ethanol precipitated. 1 μg of the vector plasmid pNCV (58) was digested with 10 units PstI and ethanol precipitated after phenol/chloroform extraction. ˜100 ng of this 1125 bp fragment was combined with ˜100 ng PstI digested pNCV in 20 μl of 20 mM Tris·Ncl (pH 7.5), 10 mM MgCl 2 , 10 mM DTT, 2.5 mM ATP and 30 units of T4 DNA ligase. After overnight ligation at 14° C. one half of the mixture was transformed in E. coli K12 strain 294. BamI digestion of the DNA from twelve transformants showed 23 with the proper orientation. Expression of this plasmid (pUK33trpLE L ) (FIG. 5) in E. coli yielded a long trp LE fusion protein including 33000 urokinase. The 33000 urokinase is activated by cleavage with a trypsin-like active enzyme between positions 3 and 4 and positions 26 and 27 (see FIG. 2).
2. Short trp LE fusion (FIG. 6)
Plasmid pINCV was constructed. It is similar to pNCV (see supra.) in every respect except that the majority of the trp E gene is deleted. In this plasmid the BglII site was converted to a PstI site and the region between this new PstI site and the original PstI site was deleted. ˜100 ng of pINCV was digested with PstI and HindIII then phenol/CHCl 3 extracted and ethanol precipitated. ˜3 μg of pUK33trpLE L (FIG. 6) was digested to completion with HindIII and partially digested with PstI to yield a PstI HindIII DNA fragment of 1150 bp which was purified by electroelution after electrophoresis on a 6 percent polyacrylamide gel. The PstI site within the structural UK gene was spared from digestion. All of the PstI HindIII digested pINCV was mixed with ˜50 ng of the 1150 bp HindIII, partial PstI fragment of pUK33trpLE L and ligated overnight at 14° C. This mixture was then transformed in E. coli K12 strain 294. BamHI digestion confirmed the proper construction of this plasmid (pUK33trpLE X ) (FIG. 6). Expression of this plasmid in E. coli yielded a fusion protein from which 33,000 urokinase is activated, as described supra.
3. Direct Expression of 3K Urokinase (FIGS. 7 and 9)
A urokinase DNA fragment beginning with nucleotide 16 (FIG. 1), was cloned into a pBR322 derivative resulting in a construction in which the trp promoter is positioned directly in front of this urokinase fragment encoding low molecular weight urokinase. The plasmid pLeIFAtrp103 (FIG. 7) is a derivative of the plasmid ;LeIFA25 (58) in which the Eco RI site distal to the LeIFA gene has been removed (59). 10 μg of pLeIFAtrp103 (FIG. 7) was digested with 20 units EcoRI phenol/CHCl 3 extracted and ethanol precipitated. The EcoRI cohesive ends of the plasmid DNA molecules were extended to flush ends using 12 units of DNA Polymerase I in a 50 μl reaction containing 60 mM NaCl, 7 mM MgCL 2 , 7 mM Tris·HCl (pH 7.4) and 1 mM in each ribonucleotide triphosphate. The reaction was incubated at 37° C. for 1 hour, extracted with phenol/CHCl 3 and precipitated with ethanol. The DNA was then resuspended in 50 μl of 10 mM Tris·HCl (pH 8), 1 mM EDTA and treated with 500 unites Bacterial Alkaline Phosphatase for 30 minutes at 65° C., twice extracted and ethanol precipitated. After digestion with PstI the mixture was electrophoresed on a 6 percent polyacrylamide gel and the ˜3900 bp vector fragment was electroeluted.
The plasmid pUK33trpLE L was transformed in E. coli K12 strain GM48 (deoxyadenosine methylase - ) in order that DNA purified from this E. coli strain could be digested with restriction endonuclease BclI (60). 4 μg of this DNA were treated for 1 hour at 50° C. with 6 units of BclI (in 75 mM Kcl, 6 mM Tris·HCl (pH 7.4), 10 mM MgCl 2 , 1 mM DTT), then made 50 mM NaCl and digested with 10 units PstI. 6 percent gel electrophoresis was performed and the 914 bp fragment was electroeluted.
A 14 nucleotide DNA primer encoding the amino acid sequence met lys lys pro was synthesized by the phosphotriester method (47) and has the following sequence: ##STR2## 500 ng of this primer were phosphorylated at the 5' end with 10 units T4 DNA Kinase in a 20 μl reaction containing 0.5 mM ATP. The 264 bp PstI AccI cDNA insert fragment of pUK33trpLE L (grown in E. coli GM48)) was isolated. ˜500 ng of this fragment resuspended in 10 μl of deionized water were mixed with the 20 μl of the phosphorylated primer, heated to 95° C. for 3 minutes and quick frozen in a dry-ice ethanol bath. The denatured DNA solution was made 60 mM NaCl, 7 mM MgCl 2 , 7 mM Tris·HCl (pH 7.4), 1 mM in each deoxy ribonucleotide triphosphate and 12 units DNA polymerase I large fragment was added. After 2 hours incubation at 37° C. this primer repair reaction was phenol/CHCl 3 extracted and ethanol precipitated and digested to completion with BclI at 50° C. The reaction mixture was then run on a 6 percent polyacrylamide gel and ˜50 ng of the 200 bp amino-terminal blunt-end to BclI fragment was electroeluted. Subsequently, ˜50 ng of the blunt-BclI primer-repair fragment, ˜100 ng of the BclI PstI carboxy-terminal fragment and ˜100 ng of the ˜3900 bp vector fragment were ligated overnight at 14° C. and transformed into E. coli 294. EcoRI digestion of a number of transformants indicated the proper construction and DNA sequence analysis proved the desired sequence through the initiation codon of this new plasmid, pUK33trp103 (FIG. 7). In this construction, the N-terminal methionine is followed by two lysines which in turn are followed by the amino acid sequence 5 through 279 as depicted in FIG. 2A. Expression of this plasmid in E. coli resulted in the synthesis of low molecular weight urokinase. This protein was activated with a trypsin-like active enzyme as described supra which serves to cleave the N-terminal lysine pair and cleaves between lysine in position 26 and isoleucine in position 27 (FIG. 2A).
We found it desirable to construct a derivative plasmid of pUK33trp103 that would confer tetracycline resistance to its host cell. FIG. 8 depicts the following construction of pUK33trp103Ap R- Tc R . 5 μg of pHGH207-1 (See infra) was digested with HpaI and PvuII. The vector fragment was isolated and purified. 5 μof pUK33trp103 was digested with HpaI and BamH1, electrophoresed on 6 percent polyacrylamide and the 836 bp DNA fragment was purified. A second 5 μg aliquot of pUK33trp103 was digested with BamH1 and PvuII for isolation and purification of the 119 bp DNA fragment. Equal molar amounts of each of these three DNA fragments were ligated overnight at 14° C. and used to transform E. coli 294. Restriction endonuclease analysis of plasmid DNA from several ampicillin resistant transformants verified the proper construction of pUK33trp103Ap R and the reversal in orientation of the trp promoter/UK33 encoding DNA.
˜5 μg pBR322 DNA was digested with EcoR1 and the cohesive ends were filled in with Klenow Pol1. After Pst1 digestion, the large vector fragment containing the DNA that encodes tetracycline resistance, the origin of replication, and a portion of the ampicillin resistance gene was isolated and purified. ˜5 μg of pUK33trp103 Ap R was digested with BamH1 and Pst1. The DNA fragment encoding the remaining portion of the ampicillin resistance gene, the trp promoter and most of low molecular weight urokinase was purified. Approximately equal molar amounts of these two DNA fragments and the 119 bp BamH1-PvuII DNA fragment from pUK33trp103Ap R was ligated overnight at 14° C. to complete the construction of pUK33trp103Ap R Tc R . This plasmid was employed in the construction of a plasmid designed to express high molecular weight full length urokinase (see Section N and FIG. 9).
N. Expression of High Molecular Weight Derivatives of Urokinase
1. Direct Expression of 54K Urokinase
FIG. 10 illustrates construct for full length urokinase. Plasmid pHGH20701, having a single trp-promoter, was obtained by removal of the double lac-promoter from pHGH 207 that has a double lac-promoter followed by a single trp-promoter. This was done as follows: The trp-promoter 310 b; DNA fragment was obtained from pFIF trp 69 (20) by digestion with EcoRI. This fragment was inserted into pHGH 107 (44) that had been opened with EcoRI. Thus, a plasmid was obtained (pHGH 207) that has a double lac promoter followed by the trp-promoter, flanked by EcoRI sites. The thus obtained pHGH 207 was digested with BamHI; this was partially digested with EcoRI and the largest fragment was isolated. This fragment therefore has the entire trp-promoter. From pBR322 the largest EcoRI-BamHI fragment was isolated. Both fragments were ligated and the mixture was used to transform E. coli 294. Tet r , Amp r colonies were isolated and most of them had the plasmid with the structure as shown for pHGH207-1. Plasmid pHGH207-1 is thus a derivative of the plasmid pHGH107 (44) and has the following properties: 1) the human growth hormone gene is flanked by the tryptophan promoter rather than the lac promoter as with pHGH107, 2) the plasmid confers ampicillin and tetracycline resistance when expressed in E. coli. (See also 47A).
20 μg of pHGH207-1 was partially digested with EcoRI and totally digested with BglII. Purification of the large vector fragment was achieved by 5 percent polyacrylamide gel electrophoresis, electroelution, phenol/CHCl 3 extraction and ethanol precipitation. 14 μg of pF1 was digested with BglII and TaqI and the 236 bp DNA fragment was isolated and purified from a 6 percent polyacrylamide gel. The following complementary DNA fragments were synthesized by the phosphotriester method (47): ##STR3## As indicated, the amino acid sequence Met Ser Asn Glu Leu His Gln Val Pro encodes the initiation codon, ATG, and the eight amino-terminal amino acids of high molecular weight urokinase. 50 ng of each synthetic DNA fragment were phosphorylated and the fragments were mixed, heated to 65° C. for 1 minute and allowed to cool at room temperature for 5 minutes. 10 ng of the phosphorylated and mixed synthetic DNA fragments were combined with ˜200 ng of the partial EcoRI, BglII pHGH207-1 vector fragment and ˜50 ng of the 236 bp BglII TaqI DNA fragment, ligated overnight at 14° C. and transformed into E. coli 194. Individual plasmid DNAs from 24 ampicillin resistant colonies were digested with EcoRI and BglII and one plasmid (pInt1) demonstrating the proper construction was selected for DNA sequence analysis. This analysis verified the correct DNA sequence through the ATG initiation codon and the amino-terminal portion of high molecular weight urokinase.
4 μg of pNCV (Section M) was digested with BglII and BlaI and the large vector fragment was isolated and purified from a 5 percent polyacrylamide gel. 30 μg of pF1 was digested with PstI and BglII and electrophoresed through a 6 percent polyacrylamide gel. The 44 bp DNA fragment was electroeluted, phenol/CHCl 3 extracted and ethanol precipitated. 4 μg of pA3 DNA were digested with PstI and TaqI and the 192 bp DNA fragment was purified from a 6 percent polyacrylamide gel. ˜100 ng of the BglII ClaI vector DNA fragment, ˜50 ng of the 192 bp fragment and ˜50 ng of the 44 bp fragment were combined and ligated overnight at 14° C. then transformed into E. coli 294. BglII ClaI double digestion of plasmid DNA from several tetracycline resistant transformants demonstrated the correct construction of this new plasmid named pInt2.
5 μg of pUK33trp103Ap R Tc R grown in E. coli GM48 (ATCC No. 39099, Apr. 9, 1982) was digested with Bcl1 and Sal1 for isolation and purification of the 1366 bp DNA fragment. The 108 bp EcoR1-Bcl1 DNA fragment was isolated from the same plasmid. Approximately equal molar amounts of the EcoR1-Sal1 DNA fragment from pUK33trp103Ap R Tc R and the EcoR1-Bcl1 DNA fragment also from pUK33trp103Ap R Tc R were ligated overnight at 14° C. to yield pInt3.
5 μg of pInt3 DNA was digested with BglII and SalI, electrophoresed through 6 percent polyacrylamide and the 1701 bp fragment containing the carboxy terminal portion of full length urokinase and the amino terminal portion of the tetracycline resistance gene was purified. ˜5 μg of p intermediate 1 DNA was digested with BglII and SalI, electrophoresed through 6 percent polyacrylamide and the large vector fragment containing the carboxy-terminal portion of the tetracycline resistance gene, the origin of replication, the ampicillin resistance gene, the trp promoter, the initiation codon ATC, and the amino-terminal portion of full length urokinase was purified. ˜100 ng of the vector fragment and ˜100 ng of the 1701 bp fragment were combined, ligated overnight at 14° C. and transformed into E. coli 294. A plasmid from a tetracycline resistant and ampicillin resistant colony demonstrating the correct PvuII restriction endonuclease pattern was identified and confirmed the construction of full length urokinase downstream from the trp promoter. This is plasmid pUK54trp207-1. Full length urokinase is produced by expression of this plasmid in E. coli 294.
2. Direct Expression of Pre-UK 54K in E. coli (FIG. 10)
The following scheme was used to construct a plasmid for direct expression of preUK54. Two complementary DNA fragments were synthesized by the phosphotriester method (47) encoding the amino acid sequence initiation codon ATG followed by the first three N-terminal amino acids of the urokinase presequence Arg Ala Leu as shown below ##STR4## EcoR1 and Bgl1 restriction endonuclease cleavage sites flank this portion of the presequence. 50 ng of each synthetic DNA fragment was phosphorylated. The phosphorylated fragments were mixed, heated to 65° C. for 1 minute and allowed to cool to room temperature. 5 μg of pF1 DNA was digested with Bgl1 and Bgl2 and the 310 bp UK DNA fragment was isolated and purified. ˜50 ng of the 310 bp UK DNA fragment, ˜150 ng of the partial EcoR1, BglII vector DNA fragment from pHGH207-1 (see Section N) and 10 ng of the phosphorylated and mixed synthetic DNA fragments was ligated overnight at 14° C. and transformed into E. coli 294. Individual plasmid DNA's isolated from several ampicillin resistant transformants were analyzed to confirm the proper construction and nucleotide sequence of the presequence of high molecular weight urokinase.
One correct plasmid was named pInt4. 5 μg of pInt4 DNA was digested with BglII and EcoRv for isolation and purification of the vector DNA fragment containing the N-terminal nucleotides of pre-UK54, the trp promoter, ampicillin resistance genes, origin of replication and a portion of the tetracycline resistance encoding DNA. 5 μg of UK54trp207-1 DNA was digested with BglII and EcoRv. The BglIIEcoRv DNA fragment encoding the remainder of UK54 and the tetracycline resistance encoding DNA was isolated, purified and ligated with the BglII EcoRv vector DNA fragment to complete the construction of the plasmid p-preUK54trp207-1.
O. Direct Expression (Pre-)Urokinase in Tissue Culture
FIG. 11 depicts the introduction of the gene encoding preurokinase into the eukaryotic expression vector p342E (62) capable of replication and expression of preurokinase in permissive monkey cells. 10 μg of p342E DNA was digested with XBA1 and ˜100 base pairs were removed in each direction using Ba131 nuclease (fragment 1). 100 ng of HindIII linder 5' CTCAAGCTTGAG synthesized by the phosphotriester method (47) was phosphorylated, heated to 65° C. for 1 minute and allowed to cool to room temperature. The phosphorylated linker and fragment 1 were ligated overnight at 14° C. and transformed into E. coli 294. Restriction endonuclease analysis of one transformant named pEH3-Bal14 proved the introduction of a HindIII restriction endonuclease site and the loss of the XBA1 site. 5 μg of pEH3-BAL14 DNA was digested with HindIII and Hpa1. The cohesive ends were extended to blunt ends using Klenow PolI. The DNA was treated with BAP and the vector fragment containing the SV-40 early promoter, ampicillin resistance genes and origin of replication was isolated and purified (fragment 2). 5 μg of ppreUK54trp207-1 was digested with Cla1 and XBa1. The cohesive ends were extended with Klenow PolI and the DNA fragment encoding preUK54 was isolated and purified (fragment 3). ˜100 ng of fragment 2 and ˜100 ng of fragment 3 were ligated overnight at 14° C. and transformed in E. coli 294. Restriction endonuclease analysis of plasmid DNA named EH3-BAL14 preUK54 from one transformant verified the correct construction. pEH3-BAL14 pre UK54 DNA was then used to transfect permissive monkey cells (62) for the expression preUK54 and the secretion of full length high molecular weight urokinase.
P. Isolation and Characterization
Urokinase containing residue was isolated from E. coli. The residue was dissolved in 5M guanidine HCl, containing 50 mM Tris, pH 8.0. The solution was diluted to 1M guanidine HCl, 50 mM Tris HCl, pH 9, at a protein concentration of 1 ng/ml. The solution was then brought to 2 mM reduced glutathione (GSH), 0.2 mM oxidized glutathione (GSSG) and incubated overnight at room temperature. The resulting solution containing refolded protein was then dialyzed into aqueous medium. The resulting solution contained urokinase which showed 100PU/mg activity.
Upon purification following conventional techniques, the protein is characterized showing the expected N-terminal sequence for both chains of the low molecular weight, bioactive material. C-terminal analysis also shows the proper sequence for both chains. The protein migrates at a molecular weight of ˜30,000 daltons. It has a specific activity of ˜170,000 PU/mg 9225,000IU/mg), assuming 1 mg/ml has an OD 280 of 1.3.
Q. Assays for Detection of Expression of Urokinase
1. Chromogenic Substrate
a. Theory
The assay is based on the proteolytic cleavage of a tripeptide from a chromophoric group. The rate of cleavage can be directly related to the specificity and tot he concentration of the protease being tested. Urokinase cleaves the chromogenic substrate S2444 (purchased from Kabi Group Inc., Greenwich, Conn.). By monitoring the generation of the chromophore, one can determine the amount of functional urokinase present in a sample. Urokinase is synthesized as an inactive precurser form, with activation occurring via the cleavage between residue 26 (lysine) and 27 (isoleucine) (numbering based on the protease clone, FIG. 2A). Some preparations of urokinase were found to have been autoactivated and/or were activated by E. coli proteases. To insure activation of urokinase, allowing detection by this chromogenic technique, treatment of the sample with low amounts of trypsin is required. Trypsin is a protease which can cleave the lysine-isoleucine bond required for urokinase activation. However, trypsin can also cleave the chromogenic substrate, and therefore must be eliminated from the assay. Soybean trypsin inhibitor (STI) is a protein which will inactivate trypsin while having no effect on urokinase. Therefore, the assay consists of trypsin activation of urokinase, STI inhibition of the trypsin, and, finally, addition of the chromogenic substrate to measure the functional urokinase present.
b. Procedure
The assay is performed as follows: 0.2 mL of 0.1M Tris, pH 8.0, 50 μL of the sample to be assayed, and 5 μL of trypsin (0.1 mg/mL in b 0.1M Tris, pH 8.0 plus 0.25M CaCl 2 ) were added to a test tube and the sample incubated for 10 minutes at 37° C. The trypsin was inactivated by the addition of 2 μL of 10 mg/mL STI (in 0.1M Tris, pH 8.0). Urokinase activity was determined by adding 50 μL of a 1 mM solution of S2444 (in water) and incubating the reaction for 10 minutes at 37° C. Acetic acid (50 μL) was added to stop the reaction, the solution centrifuged to remove a precipitate, and the absorbance at 405 nm was determined. The actual amount of urokinase can be calculated by comparison of a sample with the reading obtained by performing the assay with dilutions of a standard solution of a known amount of urokinase (obtained from Calbiochem, San Diego, Calif.).
2. Direct Assay of Plasmin Formation
a. Theory
A much more sensitive assay for urokinase can be obtained by monitoring the urokinase catalyzed conversion of plasminogen to plasmin. Plasmin is an enzyme for which there are chromogenic substrate assays based on the same principles as described in 1 above. The basis of the assay is the determination of the amount of plasmin formed following incubation of the urokinase containing solution with a solution of plasminogen. The greater the amount of urokinase, the greater the amount of plasmin formed.
b. Procedure
An aliquot of the sample is mixed with 0.10 ml of 0.7 mgs/ml plasminogen (in 0.5M Tris·HCl, pH 7.4, containing 0.012M NaCl) and the volume adjusted to 0.15 ml. The mixture is incubated at 37° C. for various times (as indicated), 0.35 ml of S2251 (1.0 mM solution in above buffer) is added and the reaction continued for 5 minutes at 37° C. Acetic acid (25 μL) is added to terminate the reaction and absorbance at 405 nm is measured. Quantitation of the amount of activity is obtained by comparison with dilutions of a standard urokinase solution.
3. Indirect Assay of Plasmin Formation
a. Theory
A sensitive assay for urokinase activity has been developed (61). The assay is based on determination of plasmin formation by measuring the extent of plasmin digestion of fibrin in an agar plate containing fibrin and plasminogen. Plasmin produces a clear lysis zone in the fibrin plate. The area of this lysis zone can be correlated to the amount of urokinase in the sample.
b. Procedure
Following the procedure of Granelli-Piperno and Reich (61), the plates were incubated one to three hours at 37° C. and lysis zones measured. Quantitation was obtained by performing the assay with dilutions of a standard urokinase solution.
R. Detection of Urokinase Activity
1. Bacterial Growth and Urokinase Sample Preparation
A strain of E. coli (W3110) was transformed using a plasmid (pUK33trpLEs) containing a urokinase fusion protein. This expression vehicle (short trpLE fusion) was described above. The cells were grown on minimal media overnight, to an O.D. at 550 nm of 1.2. An additional 200 mL of media was added. Indole acrylic acid, a compound which appears to enhance expression of the tryptophan operon controlled genes, was added to a concentration of 10 μg/mL. The cells were incubated 2 hours and harvested. The cells obtained from 400 mL of media were suspended in water and guanidine was added to a concentration of 7M (final volume of 40 mL). The solution was incubated for 90 minutes at room temperature. Insoluble material was removed by centrifugation. The supernatant was dialyzed against 0.01M Tris·HCl, pH 7.5, containing 0.1M NaCl for 4 hours. Insoluble material was removed by centrifugation and the sample was dialyzed for 2.5 hours against 0.01M Tris·HCl, pH 7.5.
The sample was applied to a 3.9×9 cm DE-52 column, which had been equilibrated with 0.01M Tris·HCl, pH 7.5, and the column washed with the same buffer and eluted with 0.01M Tris·HCl, pH 7.5, containing 0.15M NaCl. The peak of activity was pooled and used for all further studies.
2. Activity Detection
FIG. 12 shows the results of the direct activation of plasminogen by fractionated E. Coli extracts when assayed under conditions similar to that described in Section Q.2. supra. An activity is generated which is dependent on the presence of plasminogen. Therefore, the activity being monitored is a plasminogen dependent activity. The activity being measured also increases with time, indicating a time dependent, catalytic generation of plasmin. These properties are consistent with those of urokinase, i.e., a catalytic activation of plasminogen. Similar extraction conditions performed on E. coli which do not contain the urokinase plasmid do not activate plasminogen under these conditions.
The extracts also were tested in the assays as described above in order to detect and quantitate urokinase activity. FIG. 13 shows the effect of various amounts of the bacterially derived fractions in the assay described in Section Q.2 with a 10 minute activation. The values obtained are compared to those obtained using a standard urokinase solution (Plough Unitage determination). The extent of plasminogen activation is directly proportional to the amount of added cloned urokinase. Antibodies raised against purified natural urokinase are known to decrease the activity of natural urokinase. The effect of these antibodies when added to this assay at time 0 are also shown in FIG. 13. A marked inhibition of the E. coli derived material is observed. This proves that the activity observed in the E. coli derived material has the same antigenic sites as natural urokinase and therefore that it is indeed urokinase being microbially synthesized.
Similar results for activity detection and antibody inhibition are observed using the fibrin plate assay (described in Section Q.3). These results are summarized in Table I.
TABLE I______________________________________FIBRIN PLATE ASSAY OF UROKINASE PROTEIN Activity Activity in presence (Plough of urokinase antibody PercentSAMPLE Units/mL).sup.1 (Plough Units/mL).sup.1 Inhibition______________________________________Urokinase 112 2.5 98standard 11 0.45 96 1.1 0 100Urokinase 480 1.12 99produced 224 0 100herein______________________________________ .sup.1 Standard curve obtained by addition of a known amount of urokinase standard to wells. Values obtained for E. coli fractions and antibody inhibition obtained by extrapolation from this standard curve.
The standard urokinase activity was inhibited 96 percent or greater by the addition of urokinase antibodies raised against this protein. Assay of the E. coli derived extracts had significant urokinase activity. This activity was almost completely inhibited when antibodies against natural urokinase were added to the assay.
The third assay (the chromogenic substrate assay) also detected a urokinase-like activity in the E. coli extracts. Since it is the least sensitive of the assays, antibody inhibition studies could not be performed due to the large quantities of antibody required to see an inhibition.
The above three assays were quantitated using the standard urokinase purchased from Calbiochem. The values obtained (Plough units per mL) were all of he same order of magnitude: 500 for fibrin plate; 100 for plasminogen activation; and 350 for the chromogenic substrate (S2444). Variations occurring are doubtless due to the relatively impure nature of the material at the time of testing.
PHARMACEUTICAL COMPOSITIONS
The compounds of the present invention can be formulated according to known methods to prepare pharmaceutically useful compositions, whereby the human urokinase product hereof is combined in admixture with a pharmaceutically acceptable carrier vehicle. Suitable vehicles and their formulation are described for example in Remington's Pharmaceutical Sciences by E. W. Martin, which is hereby incorporated by reference. Such compositions will contain an effective amount of the protein hereof together with a suitable amount of vehicle in order to prepare pharmaceutically acceptable compositions suitable for effective administration to the host.
A. Parenteral Administration
The human urokinase hereof may be parenterally administered to subjects suffering from thromboembolic diseases or conditions. Dosage and dose rate may parallel those currently in use in clinical applications of other cardiovascular, thrombolytic agents, e.g., about 4400IU/kg body weight as an intravenous priming dose followed by a continuous intravenous infusion at about 4400IU/kg/hr. for 12 hours, in patients suffering from pulmonary embolism.
As one example of an appropriate dosage form for essentially homogeneous human urokinase in parenteral form applicable herein, a vial containing 250000IU urokinase activity, 25 mg. mannitol and 45 mg. sodium chloride, may be reconstituted with 5 ml sterile water for injection and admixed with a suitable volume of 0.9 percent Sodium Chloride Injection or 5 percent Dextrose Injection for intravenous administration.
The human urokinase protein hereof has been defined by means of determined DNA gene and deductive amino acid sequencing. It will be understood that natural allelic variations exist and occur from individual to individual. These variations may be demonstrated by (an) amino acid difference(s) in the overall sequence or by deletions, substitutions, insertions, inversions or additions of (an) amino acid(s) in said sequence. In addition, the potential exists in the use of recombinant DNA technology for the preparation of various human urokinase derivatives, variously modified by resultant single or multiple amino acid substitutions, deletions, additions or replacements, for example, by means of site directed mutagenesis of the underlying DNA. All such modifications and allelic variations resulting in derivatives of human urokinase are included within the ambit of this invention so long as the essential, characteristic human urokinase activity remains unaffected in kind.
Notwithstanding that reference has been made to particular preferred embodiments, it will be further understood that the present invention is not to be construed as limited to such, rather to the lawful scope of the appended claims.
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Human urokinase is produced using recombinant DNA techniques. The invention disclosed thus enables the production of urokinase free of contaminants with which it is ordinarily associated in its native cellular environment. Methods, expression vehicles and various host cells useful in its production are also disclosed.
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BACKGROUND OF THE INVENTION
This invention is related to novel compounds and more particularly to compounds which are useful as dyes.
It is therefore the object of the invention to provide novel compounds.
It is another object of the invention to provide compounds which are useful as dyes.
It is a further object to provide compounds which include a ligand which is a radical of an iminodiacetic acid.
BRIEF SUMMARY OF THE INVENTION
These and other objects and advantages are accomplished in accordance with the invention by providing novel compounds which are chrome-complexed dyes and which include an ortho, ortho' dihydroxyazo dye moiety, an onium salt and a colorless ligand which is a radical of an iminodiacetic acid. Since the chromium complexes of ortho, ortho' dihydroxyazo dyes and iminodiacetic acids bear a single negative charge, a positive counterion is required in order to provide electrical neutrality. The novel compounds are represented by the structural formula: ##STR1## is the radical of an ortho, ortho' dihydroxy azo dye represented by the structural formula: wherein A is an aromatic radical, for example, a radical of benzene or naphthalene; B is an aromatic or a nitrogen-containing heterocyclic radical, for example, a radical of benzene, napathalene, pyrazolone or pyrimidine; X is a cation; R 1 and R 2 may be H or when taken together may represent the carbon atoms necessary to complete, with the nitrogen atom of the ligand, a five or six member heterocyclic moiety; and R 3 may be H or alkyl having from 1 to 6 carbon atoms.
The positive counterion, X, may be any of many suitable counterions. Typical suitable positive counterions include, for example, metals such as barium, lithium or sodium or H 3 O + ; or an onium salt such as an ammonium, phosphonium or sulfonium salt. A preferred class of onium salts which may be used is represented by the formula N + R 4 R 5 R 6 R 7 wherein R 4 , R 5 , R 6 and R 7 may be H or alkyl having from 1 to 8 carbon atoms. Other onium salts which may be used include the ammonium or quaternary salts of heterocyclic bases, e.g., pyridinium or alkyl picolinium or of aromatic amines, for example, aniline.
As noted, the ligand is a radical of an iminodiacetic acid which is represented by the structural formula: ##STR2## wherein R 1 and R 2 may be H or when taken together may represent the carbon atoms necessary to complete, with the nitrogen atom of the ligand, a five or six member heterocyclic moiety. A preferred ligand of the latter type is a radical of an iminodiacetic acid which is represented by the structural formula: ##STR3##
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Specific dyes which are within the scope of the present invention are represented by the following structural formulas: ##STR4##
The dye compounds of the invention are soluble in water and many organic solvents such as, for example, methyl cellosolve, dimethylformamide, ethanol, etc. The dyes may be applied to any object such as fabrics and the like by dissolving the dye in a suitable solvent and applying the solution to the material by any of many known techniques.
The invention will now be described in detail with respect to specific preferred embodiments by way of Examples it being understood that these are intended to be illustrative only, and the invention is not limited to the materials, process parameters, conditions, etc. which are recited therein.
EXAMPLE I
Preparation of Compound II
To 50 ml of acetic acid there were added 15 g (0.087 mole) of ##STR5## and 8.2 g (0.1 mole) of NaOCOCH 3 and the solution heated with stirring for 15 minutes at 60°-65° C. To the solution were added 11.8 g (0.09 mole) of ethyl acetoacetate and heating was continued for an hour. The mixture was filtered and the acetic acid removed by evaporation in a rotary evaporator. Ether was added to the residue giving 14.5 g of yellow solid, m.p. 186°-190° C. The solid was dissolved in chloroform and precipitated with hexane to give 10.75 g of solid, m.p. 186°-190° C.
C 12 H 14 N 2 O 2 requires 71.26% C, 6.98% H and 13.85% N. Elemental analysis found 71.05% C, 7.09% H and 13.64% N.
1.95 g (0.01 mole) of 4-cyanonaphthalene-1-diazo-2-oxide, 2.02 g (0.01 mole) of the previous product and 2.12 g (0.02 mole) of sodium carbonate were combined in 25 ml of water and acetone was added to form a solution. After stirring at room temperature for two hours, 10% hydrochloric acid was added to precipitate the dye product. The dye was heated in methyl cellosolve at 90° C. with stirring and methanol was added while the solution was hot. Upon cooling 2.8 g of the dye were obtained.
C 23 H 19 N 5 O 2 requires 69.33% C, 5.06% H and 17.58% N. Elemental analysis found 69.48% C, 5.03% H and 17.64% N.
Vis (meth. cell) γ max 510 nm (ε=30,800), 540 nm (ε=20,800)
2.0 g of the previous product were dissolved at room temperature in 20 ml of methyl cellosolve. To the mixture was added 2.66 g (0.01 mole) of chromium trichloride hexahydrate and the mixture heated overnight on a steam bath. The chrome complex product was obtained by precipitating on ice and water, filtering and washing with water.
Vis (meth. cell) γ max 537 nm (ε=19,000) 570 nm (ε=15,600 )
350 mg (0.7 m mole) of the chrome complex and 120 mg (0.885 m mole) of iminodiacetic acid were combined in 20 ml of methyl cellosolve and 5 ml of water. The mixture was heated on a steam bath and tri-n-butylamine was added to make the solution basic. The reaction mixture was heated for one hour and then precipitated into pH 4 buffer solution (potassium acid phthalate). The product was collected by filtration and washed with water.
C 39 H 50 N 7 O 6 Cr requires 59.83% C, 6.69% H, 12.52% N and 6.64% Cr. Elemental analysis found 59.92% C, 6.60% H, 12.54% N and 6.56% Cr.
Vis (meth. cell) γ max 532 nm (ε=25,600), 572 nm (ε=31,000)
EXAMPLE II
Preparation of Compound III
0.29 g (5×10 -4 mole) of a compound having the structure ##STR6## (prepared as described in Example 1 of U.S. Pat. No. 3,970,616) and 0.1 g (7.5×10 -4 mole) of iminodiacetic acid were combined with excess tri-n-butylamine in methyl cellosolve and heated for two hours on a steam bath. The solution was cooled and precipitated into pH 4 buffer solution and the solid collected by filtration.
Vis (meth. cell) γ max 566 nm (ε=24,400) 530 nm (ε=23,200)
EXAMPLE III
Preparation of Compound IV
0.25 g (5×10 -4 mole) of the chromium complex described in Example I was dissolved in methyl cellosolve and 0.1 g (6×10 -4 mole) of pyridine-2,6-dicarboxylic acid was added to the solution followed by an excess of tri-n-butylamine. The solution was warmed for a half-hour on a steam bath, cooled and then added to water. The product was collected by filtration, yielding 0.28 g on drying.
Vis (meth. cell) γ max 577 nm (ε=25,000) 540 nm (ε=23,600)
EXAMPLE IV
Preparation of Compound V
0.25 g (5×10 -4 mole) of the chromium complex described in Example I, 0.1 g (5.85×10 -4 mole) of piperidine-2,6-dicarboxylic acid and excess tri-n-butylamine were combined in methyl cellosolve and heated for a half-hour on a steam bath. The product was isolated by precipitation into water and filtration to yield 0.28 g on drying.
Vis (meth. cell) γ max 575 nm (ε=29,200) 535 nm (ε23,800)
EXAMPLE V
Preparation of Compound VI
Methyl hydrazine (4.6 g, 0.1 mole) was added dropwise to a 0° C. solution of ethyl benzoylacetate (19.2 g, 0.1 mole) in 100 ml of 2-propanol. The solution was warmed slowly to 50° C. for 12 hours. Then 400 ml of ether were added to the cooled solution and the solid was collected by filtration to yield, on drying, 13 g of product, m.p. 210.°-211° C.
The previous product (2 g, 1.1×10 -2 mole) was combined with 2.26 g (0.1×10 -2 mole) of 4-cyano-1-diazo-2 naphthol and 5.0 g of sodium carbonate in a mixture of 50 ml of acetone and 10 ml of water and stirred at ambient temperature for one hour. The solution was quenched in cold dilute hydrochloric acid and the solid was collected by filtration. Recrystallization from 2-propanol yielded 2.5 g of product.
Vis (meth. cell) γ max 492 nm (ε=21,600)
The previous product (2.5 g, 6.8×10 -3 mole) and chromium trichloride hexahydrate (5.4 g, 2×10 -2 mole) were combined in 2-methoxyethanol (30 ml) and heated to 90° C. for 12 hours. The solution was cooled, added to saturated salt solution and the solid collected by filtration. The solid was rinsed with water and air dried to yield 3.4 g of the chromium complex.
Hexylamine (10.1 g, 0.1 mole), chloroacetic acid (18.9 g, 0.2 mole) and barium hydroxide octahydrate 63.14 g, (0.2 mole) were stirred in 200 ml of water at 50° C. for 12 hours. The solid product was filtered, rinsed well with water and methanol and dried in vacuo to yield 30.4 g of the white powdery barium salt. The salt was then slurried in 500 ml of water at 90° C. and to the slurry there was added 5N sulfuric acid (32 ml) dropwise over a half-hour period. The slurry was filtered and the filtrate concentrated to a dense semi-solid. Treatment with acetone caused crystallization and the white solid was dried in vacuo to give 12.15 g of N-hexyliminodiacetic acid, m.p. 130°-131° C.
The chromium complex (1 g, 1.9×10 -3 mole) and the N-hexyliminodiacetic acid (1.4 g, 5×10 -3 mole) were combined with 20 ml of 2-methoxyethanol, 2 ml of water and triethylamine (1 g, 1×10 -2 mole) and warmed to 90° C. for a half-hour under an inert atmosphere. The solution was cooled, diluted with 100 ml of water and acidified with dilute hydrochloric acid. The solid dye was collected by filtration to yield 1.18 g.
Vis (meth. cell) γ max 580 nm (ε=23,400), 542 nm (68 =20,400)
Although the invention has been described in detail with respect to various preferred embodiments thereof, these are intended to be illustrative only and the invention is not limited thereto but rather those skilled in the art will recognize that modifications and variations may be made therein which are within the spirit of the invention and the scope of the appended claims.
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There are described novel compounds which are chrome-complexed dyes and which include an ortho, ortho' dihydroxyazo dye moiety, an onium salt and a ligand which is a radical of an iminodiacetic acid.
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[0001] A reinforced concrete structure comprising weight-lightening discs for making light reinforced concrete structures such as slabs, pre-slabs, floors, partitions and beams, comprising an upper and lower mesh suitable designed for this invention, and to the construction method of these structures. The method allows manufacturing the components that make it possible to construct buildings with light-weight reinforced concrete structures. The scope of the invention is construction in general, preferably the construction of houses, buildings and bridges.
[0002] The main technical problem this invention gives is a solution to lighten the structures of buildings in order to save material and simplify the construction process. Lifting heavy materials to heights requires physical effort and man hours and implies accident risks exposure for the workers, consumption of energy and other economic costs. By using the invention, the mass of slabs is reduced by 30 to 35%, that is to say, less concrete is needed, consequently saving up to 35% of such material. By pumping the concrete from the ground level, the material to be lifted in this process is much reduced.
[0003] At present, there are in the world methods to lighten structures by including spherical or polyhedral-shaped coffers.
[0004] Among the methods known that include weight-lightening elements, one is the prefabricated slabs produced in factories. The prefabricated slabs are made up of a layer of reinforced concrete; over this concrete layer there is an iron mesh stretching along two directions; over this iron mesh it is placed a plurality of blown plastic spheres, and over said spheres it is placed a second two directions iron mesh.
[0005] A prior art construction which includes the use of said light-weight elements distributed along the reinforced concrete components is given by US2005/0138877 A1, applied by Mr. Inoue and Inokuchi. This prior art teaches the use of a lower concrete strata, over which it is placed a plurality of parallel lower bars 2 a, 2 b, forming a hole 4 , through which passes said light-weight bodies 5 which may be hollow. Each one of said bodies 5 is retained in place by a corresponding plurality of saddles ( 6 , 13 , 15 ) extending downwards, being each one of said saddles welded to un upper plurality of reinforcing bars 3 a, 3 b. Said saddles can be regularly spaced, thus we have for a given plurality of saddles thus distributed a corresponding plurality of said bodies 5 , each one of them retained in place by one of said saddles. Therefore this above said constructions requires a precise and costly welding of these saddles, once the bodies 5 have been placed on said lower concrete strata.
[0006] Another prior art construction is given by US2009/0165420 A1, to Pfeffer. This teaches a linear displacement of bodies 5 , arranged adjacent the one to the other. Each body 5 is held in place by individual
[0000] lattice work made of bars 3 , 4 . Each body 5 has two opposed polar depressions 9 , eventually connected to its lateral surface by radial groves 11 . Also in this construction, an extensive prior preparation is needed in order to weld the individual lateral saddles retaining in each pair of said saddles one of said bodies 5 , which entails a heavy cost and man power.
[0007] Among the known methods including weight-lightening components, one is the prefabricated slabs produced in factories. Said prefabricated slabs are made up of a layer of reinforced concrete; over this layer is placed an iron mesh stretching along two directions. On said mesh it is placed a plurality of blown plastic hollow spheres, over which a second iron mesh in two directions is placed. Both meshes are welded to pyramidal three dimensional grid metal beams.
[0008] These prefabricated slabs are manufactured on a vibrating mould where in the site, a layer of concrete is poured where the compound comprising the metal beams and the spheres are then dipped by means of a crane. Thus, using specialized machinery, pressure and vibration are simultaneously exerted on the spheres, submerging them into the fresh concrete. Once the concrete hardens, the elements are stacked up until attaining the thickness required by the slab, and then subsequently transported to the construction site. This method generates relevant transport expenses and requires large warehouse space in the construction site. Once in the construction site, moreover, the weight of these pieces demands large capacity cranes in order to mount them in the construction. Once the pieces are positioned in their final location, the second concrete filling stage is carried out.
[0009] Another existing method consists of a three dimensional iron cage instead of the meshes containing the spheres, namely, a three dimensional trapezoidal beam which contains the aligned spheres in its interior. The slab is formed by placing these beams parallel to each other. The iron bars are placed in both directions on the beams, then to be filled with concrete.
[0010] In these two last described prior art it may be appreciated that the largest inconvenience is that of the relevant cost involved in transporting trapped air and heavy pre-cast structures, since the slabs and the pre-cast slabs are already given their final size before being mounted into their final place of destination. This demands large capacity means of transportation and cranes, as well as heavy investment in centralized factories, while in the first two named prior art patents the spheres must be placed into individual holes defined by two parallel lattice work or stirrups which must be individually welded to the supporting irons, thus rendering their construction process cumbersome and specifically with very high cost due to the extensive use of man power.
[0011] The present invention provides a solution to the problems of lightening the structures by providing a concrete structure comprising weight-lightening discs that includes a compound consisting of weight-lightening discs and electro-welded meshes, and hooks to hold together these meshes, which are specifically designed for each particular thickness of the slabs and their resistance to the applied forces, and a method of construction. Moreover, the set of discs allows lightening the weight of minimum thickness slabs. In fact, if spheres of a diameter equal to the height of the disc should be used, this would require the use of a large quantity of spheres and therefore double the work of assembly of the spheres and require the use of too dense a mesh. Furthermore, an excessive quantity of iron and of material of the spheres would be needed, in addition to the difficulty of pouring concrete in much reduced spaces. As regards traditional constructive methods, an excessive consumption of reinforced concrete and of steel frames may be observed, with the resulting increase of waste and man hours and, consequently, larger construction costs and time.
[0012] The object of the present invention is to provide a new concrete structure and a method for constructing very light reinforced concrete structures, in which the weight-lightening discs allows making slabs and prefabricated slabs of minimum thickness, optimizing materials and costs, which has not been accomplished by any of the prior art. Furthermore, this method has the advantage of being environment-friendly, crucial in a scenario of changing climate, where the construction sector is responsible for producing 40% of the CO 2 pollution in the planet. This method allows saving concrete and steel, building with progressively lighter structures and using recyclable plastic materials. Moreover, this method contributes to the reduction of 220 tns. of CO 2 for each 10000 m 2 built and 1000 m 3 of reinforced concrete.
[0013] Besides, it is possible to build on expansive clay soils and on flood-prone areas, which are alarmingly extending as a result of the climate changes and the rising of the water level. In effect, the seismic resistance of the accomplished structures increases by 30% approximately because of the reduction of the weight of the structures. In addition, this method allows building larger floor surfaces free from beams and with fewer columns, which provides a larger flexibility for the use of the buildings and allows changing their function over time.
[0014] The reduced energy costs resulting from the high thermal insulation of the slabs and the walls built with the weight-lightening discs may be combined with a system of sunscreens with large cantilevers to allow the passage of the sun in winter and prevent the passage of the sun rays inside the building in summer making this method a sustainable system.
[0015] The innovation of this patent is centered in the structures of reinforced concrete lightened by means of weight-reducing discs, which allows making thinner slabs, thus saving significant quantities of concrete and steel. In effect, these slabs are much lighter than the solid slabs and also more resistant. Another advantage of this innovation is the reduction of the load transmitted to the ground, the reduction if the cost of the foundations, columns and bearing walls in buildings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 : An overview of a construction of a weight-reducing disc used in this invention.
[0017] FIG. 2 : A side view of the weight-lightening disc according to FIG. 1 .
[0018] FIG. 3 : Top view of the embodiment of FIG. 1
[0019] FIG. 4 : Sectional view of the weight-lightening disc of FIG. 1
[0020] FIG. 5 : Overview of the specially designed mesh formed by specially designed mesh formed by welded or tied bars, having protruding bars in two of its adjoining sides.
[0021] FIG. 6 : View of the first stage of the construction process for construction of the slab: Placing of the traditional formwork ( 1 ).
[0022] FIG. 7 : View of the second stage of the construction process for construction of the slab: Placing of the lower steel mesh ( 2 ) separated from the bottom by means of spacers ( 6 ), such as plastic spacers.
[0023] FIG. 8 : View of the third stage of the construction process for construction of the slab: Placing of the weight-lightening discs ( 3 ).
[0024] FIG. 9 : View over the fourth stage of the construction process for construction of the slab: Placing of the upper steel mesh ( 4 ).
[0025] FIG. 10 : View over the fifth stage of the construction process for construction of a slab. Both meshes are attached be means of hooks ( 5 ), retaining in between the plurality of discs ( 3 ).
[0026] FIG. 11 : View over a sixth stage of the construction process for construction of a slab: Pouring of concrete ( 7 ).
[0027] FIG. 12 : View over the seventh stage of the construction process for construction of a slab: Removal of formwork.
[0028] FIG. 13 : Overview of the compound made up by the meshes, the weight-lightening discs and the tumbuckles.
[0029] FIG. 14 : A side view of the weight-lightening disc according to a second embodiment of this invention.
[0030] FIG. 15 : An overview of the weight-reducing disc according to the embodiment in FIG. 14 .
[0031] FIG. 16 : An overview of the weight-reducing disc according to a third embodiment of this invention.
[0032] FIG. 17 : A side view of the weight-lightening disc according to the third embodiment of this invention.
[0033] FIG. 18 : An overview of the weight-reducing disc according to a fourth embodiment of this invention.
[0034] FIG. 19 : A side view of the weight-lightening disc according to the fourth embodiment of this invention.
[0035] FIG. 20 : An overview of the weight-reducing disc according to a fifth embodiment of this invention.
[0036] FIG. 21 : A side view of the weight-lightening disc according to the fifth embodiment of this invention.
[0037] FIG. 22 : A side view of the weight-lightening disc according to a sixth embodiment of this invention.
[0038] FIG. 23 : An overview of the weight-reducing disc according to the sixth embodiment of this invention.
[0039] FIG. 24 : An overview of the weight-reducing disc according to a seventh embodiment of this invention.
[0040] FIG. 25 : A side view of the weight-lightening disc according to the seventh embodiment of this invention.
DETAILED DESCRIPTION OF THE INVENTION
[0041] FIG. 1 (overview in line), FIG. 2 (view), FIG. 3 (top view) and FIG. 4 (sectional view) show one embodiment of a weight-lightening disc according to this instant invention, this being a hollow revolution body volume, flattened along its Y axis, with flat upper and lower faces and curved sides.
[0042] The weight-lightening disc according to this invention is symmetrical with respect to its X axis, as shown in FIG. 2 , which X axis divides the disc horizontally.
[0043] The disc has added volume projecting from its upper and lower faces. These projections, in all the embodiments according to FIG. 1, 14 to 25 , are inscribed within a circle. Making specific reference to this first embodiment shown in FIG. 1 to 4 , these projections are shaped as a ring ( 8 ) ( FIG. 3 ).
[0044] The thus inscribed with in a circle projections fits snuggly into the mesh grid holes without the need of purposely arranging this part into any specifically defined position, thus expediting the work of construction. By being symmetrical, the disc can be placed in the mesh on any of its two sides, which also facilitates and expedites the works.
[0045] The ample bend radius of the disc sides allows optimal concreting, and the concrete can easily reach the bottom.
[0046] In the first embodiment of the disc according to this invention, ( FIG. 1 to 4 ) the projection ( 8 ) is an annulus with three radial slots ( 9 ) ( FIG. 3 ) of such size that the iron parts of the mesh may in no way pass into them, which prevents any type of mistake in the placing of the discs on the meshes. Also said annulus can made without slots ( 9 ).
[0047] The disc of this invention may have different proportions, dimensions of its Y or X axes or of its bend radius
[0048] As regards the manufacturing method of the disc, it may be made by blown-molding, roto-molding, as well as by injection or thermoforming (in two fitting parts thereof), while the material employed can be virgin or recycled material, preferably thermoplastic material.
[0049] The meshes, are specifically designed for this method, with the particular characteristic of having protruding bars ( 10 , 11 ) on two of their sides ( FIG. 5 ). This provides a solution to the technical problem of joining adjacent meshes and at the same time keeping the same thicknesses, and also helps save material that would otherwise be needed for the joints.
[0050] The upper and lower meshes are joined together exerting the one towards the other by any known means, such as tensioning elements or tumbuckles, specially designed for each thickness of the slab, so as to articulate and hold together the compound made up by the meshes and the discs placed in between, and to attach thereof to the framework, thus preventing the discs from floating when pouring the concrete.
[0051] A factor of paramount importance for this invention is the grid value or dimension of the hole ( 12 ) in the mesh. In a preferred embodiment, said holes ( 12 ) are equal sized squares and the holes ( 12 ) of the lower mesh ( 2 ) are equal to the holes ( 12 ) of the upper mesh. At the same time the circumference ( 13 ) of the projections has a diameter slightly lower that said squares ( 12 ) thus enabling said projections such as ( 8 ) to fit snugly into said openings ( 12 ). This allows placing the discs which will be retained in place by both meshes when same are joined together.
[0052] The invention also includes a method of construction which in turn, includes a method for slabs and a method for pre-fabricated slabs.
[0053] The slab-method consists of the following steps:
[0054] Placing the traditional formwork ( 1 ); ( FIG. 6 );
[0055] Placing the lower steel mesh ( 2 ), separated from the bottom by means of plastic spacers ( 6 ); ( FIG. 7 ).
[0056] Placing the weight lightening discs ( 3 ) fitting the lower projections ( 8 ) into the grid holes ( 12 ) of the lower mesh ( 2 ); ( FIG. 8 ).
[0057] Placing the upper steel mesh ( 4 ), fitting the upper projections ( 8 ) into said grid holes ( 12 ); ( FIG. 9 ).
[0058] Attaching the two meshes ( 2 , 4 ) by means of said hooks ( 5 ) or tumbuckles (not shown); ( FIG. 10 ).
[0059] Pouring the concrete ( 7 ); ( FIG. 11 ).
[0060] Removal of framework; ( FIG. 12 ).
[0061] The prefabricated slab method consists of the following steps:
[0062] Preparing the molding plate;
[0063] Placing the lower steel mesh ( 2 ), separated from the bottom by means of plastic spacers ( 6 );
[0064] Placing the weight lightening discs ( 3 ) fitting the lower projections ( 8 ) into the grid holes ( 12 ) of the lower mesh ( 2 );
[0065] Placing the upper steel mesh ( 4 ), fitting the upper projections ( 8 ) into said grid holes ( 12 );
[0066] Attaching the two meshes ( 2 , 4 ) by means of said hooks ( 5 ) or tumbuckles;
[0067] Pouring a first layer of concrete until reaching a height equivalent to the mid-section of said discs;
[0068] Assembly of the prefabricated slab in its final location;
[0069] Final concreting as per FIG. 11 ;
[0070] Removal of formwork.
[0071] The following elements make up the system that is the object of this instant patent:
[0072] The compound formed by the slab and the weight-lightening discs includes two metal meshes ( 2 , 4 ) that enclose the plurality of discs ( 3 ), which discs have a flattened upper and lower faces with protruding projections which volume is inscribed within a circumference ( 13 ) that fits into de square spaces or holes ( 12 ) of said mesh ( 2 , 4 ).
[0073] The meshes are held together by means of tensioning elements or tumbuckles that either have an upper and a lower fold with the shape of a hook ( 5 ) as shown in FIG. 10 or an upper and a lower shackle (not shown) which attach the compound of elements to formwork where the lightened slabs will be filled. The hooks ( 5 ) prevent the discs from floating.
[0074] The meshes are specifically designed for this method and have protruding bars ( 10 , 11 ) on two of their sides as shown in FIG. 5 . This is, on the one hand, in order to provide a solution to the technical problem of the joints along the meshes while keeping the desired thickness, and on the other hand, as a means of saving material that would be otherwise needed for these joints.
[0075] The meshes may be manufactured into ready-made modules formed by welded bars ( FIG. 5 ) delivered straight to the construction site, or may be assembled by bars in the construction site by tying them with wire, or else, already rolled mesh can be used.
[0076] If the slabs thus lightened by weight-reducing disc is used as foundations there are two variants. The first variant is that of using the slab as a foundation slab directly affixed to the ground. The second variant is that of a slab supported by reinforced concrete piles drilled into the ground. In this last case, to counter the effect of expansive clay, which could fracture a floor built in this manner, honeycomb is used, either made of paper or of recycled plastic bags, wrapped up in polythene to prevent the softening effect of humidity in the first days. The mesh with the discs is placed above this cardboard platform and the foundation slab is concreted together with the plies.
[0077] If the soil where to slab is grounded is expansive clay, after some days the cardboard platform will soften by effect of the moisture of the soil and the clay will be able to expand freely, without pushing the foundation slab.
[0078] As regards cover or roof slabs lightened by the discs, these slabs have a drainage slope and are kept covered by water during seven days being made fully water-proof by the inclusion in this mass of a chemical product that seals the concrete where the water penetrates through the smallest hair crack. In effect a process similar to that of nanotechnology occurs by virtue of an expansion of the salts contained in the chemical product, which immediately seals any hair-cracks thus preventing the passage of water.
[0079] The weight-lightening discs ( 3 ) are placed on the holes ( 12 ) or grid of the lower mesh ( 2 ) inserting the projections ( 8 ) with said holes, which fits into the grid of the mesh without the need of arranging said discs into any particular position. This speeds up the construction work and prevents possible mistakes. Since said discs are symmetrical in their Y axis ( FIG. 2 ), the discs can be places into said mesh on any of its two sides ( 14 , 15 ) ( FIG. 2 ), additionally facilitating the task. The ample bend radium of the sides ( 16 ) allows optimal concreting easily reaching he lower sections.
[0080] After this, the upper mesh ( 4 ) is placed on the upper surface ( 14 ) of the discs, fitting the projections ( 8 ) into the grid of said upper mesh, performing the laying of this upper mesh with minimum waste and maximum assembly speed.
[0081] Then, the lower mesh ( 2 ) and the upper mesh ( 4 ) are fixed together by means of hooks ( 5 ) or the like. These hooks can be zigzag stirrups or butcher hooks which articulate and holds together the upper and lower meshes.
[0082] When this is accomplished, with the eventual fixing of said compound to the lower formwork ( 1 ), ( FIG. 6 and FIG. 7 ), the concreting proceeds. Thanks to the ample bend radium of the disc sides ( 16 ), an optimal concreting may be accomplished by the concrete easily filling the lower sections. In the embodiment of FIG. 1 to 4 , the ring-shaped upper and lower volumes ( 8 ) of the disc has three interruptions ( 9 ), allowing the entrance of the concrete and the filling of the central section ( 17 ) of the disc.
[0083] FIG. 14 depicts a side view of weight-lightening disc of this invention according to a second embodiment thereof, wherein the projection instead of the annulus ( 8 ) is a eight arms cross inscribed within a circle ( 13 ), and FIG. 15 shows a overview of this second embodiment.
[0084] FIG. 16 is an overview of a third embodiment of the disc of this invention wherein the projecting volume is an hexagon ( 19 ) inscribed within a circle ( 13 ), and FIG. 17 is its side view.
[0085] FIG. 18 is an overview of a fourth embodiment of the disc of this invention wherein the salient volume is a plurality of small cylindrical projections ( 20 ) distributed crown-wise around a circle ( 13 ), and FIG. 19 is its side view.
[0086] FIG. 20 is an overview of a fifth embodiment of the disc of this invention wherein the salient volume is a lobular projection ( 21 ) inscribed within a circle ( 13 ) and FIG. 21 is its side view.
[0087] FIG. 22 is a side view of a sixth embodiment of the disc of this invention wherein the salient volume is a five point star projection ( 22 ) inscribed within a circle ( 13 ) and FIG. 23 is its overview.
[0088] FIG. 24 is an overview of a seventh embodiment of the disc of this invention wherein the salient volume is a six-point star ( 23 ) inscribed within a circle ( 13 ) and FIG. 25 is its side view.
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This invention refers to a weight-lightening disc for making light reinforced concrete structures such as slabs, prefabricated slabs, foundation slabs, partition walls and beams; to a mesh, specifically designed for this invention and to the construction method to make such structures. The method allows manufacturing the components that make it possible to construct buildings with light reinforced concrete structures. The field of application of the invention is construction in general, such as houses, buildings and bridges.
The invention provides a solution to the problem of lightening of the structures, including a construction method that comprises a set of weight-lightening discs in combination with electro-welded meshes (specially designed for the each specific thickness of the slab) and the hooks that hold together the meshes.
The compound of elements and the method allow lightening minimum-thickness slabs.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the cross benefit of U.S. Provisional Patent Application No. 61/115,154, which is incorporated by reference herein.
FIELD OF THE INVENTION
The field of the invention is a tool for endoscopic procedures. These include colonoscopy, upper endoscopy, endoscopic ultrasound etc.
BACKGROUND
Endoscopy procedures are used by physicians worldwide to assist in surgeries and various medical procedures including colonoscopy, upper endoscopy (esophagogastroduodenoscopy), bronchoscopy, thoracoscopy, laparoscopy, heart catherization, nasopharyngoscopy etc. As the endoscope is advanced from the proximal end by the operator, the distal end (tip) usually advances. However, at times especially around tight turns a loop forms which prevents the distal end from advancing with advancement of the proximal end. Any of the following are endoscopes: colonoscope, gastroscope, enteroscope, bronchoscope, endoscopic ultrasound endoscope, laparoscope, thoracoscope). During these procedures sometimes the scope bends unpredictably from friction and forms a loop. This loop may prevent advancement of the scope by the operator and result in bowel distention from the loop which can cause patient discomfort.
SUMMARY OF THE INVENTION
There is a need to minimize formation of these loops. Current technology requires the operator (physician) to remove the loop by twisting and or withdrawing the scope until the loop disappears. In addition, the patient position may be changed such as rolling the patient onto their back or belly or by applying abdominal pressure as in the case of colonoscopy. These maneuvers change the friction applied to the scope by the body and effect of gravity on the scope and these maneuvers take time to perform. Sometimes the maneuvers are sufficient to finish the procedure. Other times additional sedation must be administered due to patient discomfort from the loop(s) and the patient will have a longer recovery time from the extra sedation. Current techniques can be time consuming and not always successful. In colonoscopy, additional pressure is applied to the belly and the patient is rolled from side to side to attempt to remove these loops. Sometimes the procedure is aborted due to patient discomfort from looping and or inability of the physician to be able to complete the procedure due to the loops. There is a need for a de-looping tool to allow removal of the loops without re-orienting the patient, removing a portion of the scope, applying abdominal pressure, giving additional sedation due to increased patient discomfort from the formation of loops during the procedure, or even starting over.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1A Alpha Loop
FIG. 1B N shaped loop
FIG. 2 Endoscope with tool inserted in biopsy channel
FIG. 3A Handle in unlocked (unactuated) position
FIG. 3B Handle in locked (actuated) position
FIG. 4A Tool in biopsy channel unactuated and able to be repositioned or removed.
FIG. 4B Tool in biopsy channel actuated and locked in position
FIG. 5 Overall picture of tool
DETAILED DESCRIPTION
The figures below show an alpha loop ( FIG. 1A ) and an N-loop ( FIG. 1B ) which can occur during endoscopy. In either case, as the proximal end of the scope 6 is advanced, the distal (tip) end does not advance and the loop becomes larger. Sometimes the only way to get the tip of the scope to advance is to remove the loop entirely which may require removing all of the endoscope and starting over. Other times the loop expands but the operator is able to complete the procedure anyway, although additional sedation may be required due to ensuing patient discomfort. The de-looping tool 1 attaches to the distal end of the scope 6 internally through the scope's biopsy channel 4 . As force is applied to the tool by inserting a wire 3 into the biopsy channel 4 the tip of the scope is advanced since the attachment point is at the tip. Thus the tool 1 works by applying pressure near the tip of the tool as opposed to the proximal end of the endoscope 6 where the operator usually applies pressure. There are various ways of reversibly attaching the de-looping tool 1 to the endoscope 6 . In all cases an internal tool 1 is used to affix to the endoscope 6 . In case the tool slips, the tool remains inside of the endoscope and is not long enough to exit the endoscope biopsy channel and thus tool slippage will not harm the patient. This is an important safety consideration. One mechanism for attaching the tool to end of the scope is an umbrella apparatus which deploys when actuated in the channel. A second design has an expandable jack similar to a car jack used for changing a tire. A third design which is likely the simplest and most cost effective is a compressible foam or substantially compressible alternate material such as synthetic or natural rubber which expands radially to engage the biopsy channel when compressed in a linear direction. The material must substantially return to its original shape when the compression force is released to allow the tool to be removed.
Preferred Embodiment
In the preferred embodiment, a wire based tool 1 made of a metal, alloy metal, plastic, and/or a polymer may be either tightly coiled such as in many colonoscopy biopsy tools or a linear flexible yet strong metal wire is used. An outside flexible sleeve 2 of tightly coiled wire surrounds an inner linear wire 3 . The wire 3 may also be coiled and tightly wound for added flexibility or may be linear in shape. The sleeve 2 nearly fills the entire biopsy channel 4 for maximum strength. A handle 5 shaped to allow easy advancement of the wire 3 and sleeve 2 against resistance is used. The handle 5 may have various shapes such as loops, holes for fingers, a flat surface or a curved surface. Most likely the handle 5 would be made out of a strong plastic which is cost effective and durable. The wire 3 and sleeve 2 portion outside of the endoscope 6 attached to the handle 5 is reinforced to minimize kinking or bending of the wire when force is applied to the handle 5 . Near the distal end of the endoscope 6 , but before the highly articulate distal end of the endoscope 6 , the attachment apparatus will reversibly engage the biopsy channel 4 . Typically the de-looping tool 1 reversibly and non destructively engages the biopsy channel 4 about 10-15 cm from the distal end (scope tip) of the endoscope body. The sleeve 2 and wire 3 both have an annular lip 7 which can be a plastic, alloy, or metal washer affixed. The sleeve lip 7 is proximal and the wire lip 7 is distal. In between the lips 7 threaded over the wire 3 is a closed cell foam or rubber cylindrically shaped compressible piece 8 attached to lips 7 at its proximal and distal portions. Other shapes of the compressible piece may include any shaped polygon. Typically, this portion of compressible foam 8 may be 2-3 cm long but my be of any length desired.
In operation, the tool 1 ( FIG. 5 ) is inserted into an endoscope 6 ( FIG. 2 ) such as a colonoscope that has a loop. The tool handle 5 is initially undeployed (unactuated FIG. 3A ) such that the lips 7 of the sleeve 2 and wire 3 are far apart stretching the compressible piece (foam) 8 to allow easy insertion of the tool 1 . The tool 1 is inserted until the handle 5 is perhaps a half inch from resting on the biopsy insertion channel opening. At that time the handle 5 is placed in the actuated position ( FIG. 3B ) and locked into place by flexible tabs 9 engaging slots 11 . In the actuated position, the wire 3 is drawn towards the sleeve 2 and the two lips 7 compress the compressible piece 8 . The excess material from the compressible piece 8 expands radially outward and engages biopsy channel 4 . The lock 9 on handle 5 allows the operator to avoid manually applying force to continue engaging tool 1 against biopsy channel 4 . The tool handle 5 is held by a physician or technician and pressure to advance handle 5 is applied in the locked (actuated) position ( FIG. 4B ). However, handle 5 does not advance since compressible foam 8 is attached to the biopsy channel 4 . The resulting force is transmitted to the tip of scope 6 at the point of the engagement with biopsy channel 4 and the loop is removed by the tip of scope 6 moving forward. To remove the tool 1 , the tool 1 is unlocked (unactuated) by pressing in tabs 9 into slots 11 , the tension pulling the distal lip 7 against the proximal lip 7 is removed and compressible material 8 no longer expands in a radial direction ( FIG. 4A ). The biopsy channel 4 is no longer engaged and tool 1 is simply removed.
The portion of wire 3 inserted through the deformable material (foam) 8 may be of reduced diameter to allow additional deformable material to be applied. The de-looping tool 1 may be engaged at any distance into scope 6 desired by the operator by engaging the sleeve at that particular location. The insertion wire 3 may have paint marks or etchings at specific distances to allow the operator to easily estimate engagement depth. An external sleeve 10 outside of the endoscope 6 may be used to help minimize kinking of the de-looping tool 1 . This is important when advancement pressure is applied to handle 5 once tool 1 is actuated (engaged) with biopsy channel 4 . The tool 1 is designed to have a non destructive and reversible engagement to minimize wear or damage risk to the endoscope 6 . The de-looping tool 1 can be used on any conventional endoscope 6 listed above as well as scopes being designed for NOTES (natural orifice transluminal endoscopic surgery) procedures. Torque may be applied to the de-looping tool 1 to remove an alpha loop which is a twisted loop ( FIG. 1A ). The method can also be used to minimize formation of an N-loop ( FIG. 1B ) by applying light pressure to the distally engaged de-looping tool 1 while advancing the proximal end of scope 6 . This maneuver may be particularly useful when navigating around tight turns etc. which may normally tend to form loops.
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A method and apparatus for removing loops formed during endoscopic procedures including colonoscopy and small bowel enteroscopy. The device inserted through the biopsy channel of an endoscope reversibly engages the distal portion of the biopsy channel of the endoscope. When pressure is applied to the device handle external to the endoscope, the force is transmitted to the distal end of the endoscope advances and straightens out the loop. When the device is torqued, the distal end of the engaged endoscope torques which can remove a twist in the endoscope as well. Neither procedure requires removal of a portion of the scope or loss of position which occurs with conventional methods.
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FIELD OF THE INVENTION
This invention relates to color document scanners and more particularly to such scanners employing fiber optic bundles.
BACKGROUND OF THE INVENTION
My copending application Ser. No. 581,085 filed Feb. 17, 1984 and assigned to the assignee of the present application describes a document scanner employing a fiber optic bundle. (The above-identified patent application is incorporated herein by reference.) The bundle has a linear entrance face and a rectangular exit face. The positions of the fibers in the two faces not only are unknown but they bear no predetermined relationships to one another. In other words, the fiber bundle is non-coherent. The fibers at the entrance face, however, are constrained into a linear geometry and the fibers of the exit face are merely gathered randomly into the proper geometry to mate with the desired sensor array or arrays.
The fibers at the exit face are energy coupled in fixed positions with respect to a sensor array which is conveniently an optical random access memory (RAM) or a random access charge injection device (CID). The bundle is made coherent electronically.
Electronic coherence is achieved during an initialization process by moving a beam of light, small compared to the fiber size, in increments along a path at the entrance face which intersects all the fibers in sequence. A software program is operative to store all the addresses of the sensors illuminated for each position of the beam. The software also is operative to determine when maxima occur in the number of illuminated sensors as the beam is moved. The address of a single sensor is selected out of the group of illuminated sensors for each maximum. The sequence of addresses thus identified is reduced to one sensor address per maximum and their address is taken as corresponding to the exit position of a fiber.
In normal operation, a permanent memory is adapted to interrogate only the single sensor at the stored address for each fiber, in the sequence in which it was stored, each time a line of the document is scanned. Thus, only a small subset of the sensor array is addressed leading to high speed operation. It is clear that a non-coherent fiber optic bundle with a sensor array and a permanent memory with the initialized information as described is capable of faithfully reconstructing entrance pixel positions.
BRIEF DESCRIPTION OF AN ILLUSTRATIVE EMBODIMENT OF THE INVENTION
Such a device as described in the above-mentioned copending patent application is adapted for color herein by employing a plurality of such fiber optic arrays in close proximity astride a document to be copied. One fiber bundle is used for each desired color. For the customary color organization, red, green and blue filters are positioned at the exit ends of first, second, and third bundles respectively. The exit ends can be associated with individual sensor arrays. Alternatively, all the exit ends may be energy coupled to a common sensor array defined by a single optical RAM or CID chip.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic diagram of a color document scanner in accordance with this invention.
FIGS. 2 and 6 are enlarged front views of the entrance face of alternative fiber optic subsystem portions of the scanner of FIG. 1,
FIG. 3 is a schematic diagram of a portion of the fiber optic subsystem of the scanner of FIG. 1, and
FIGS. 4 and 5 are schematic block diagrams of portions of the electronic circuit organization of the scanner of FIG. 1.
DETAILED DESCRIPTION
FIG. 1 shows schematically an arrangement for scanning a document in accordance with this invention. The arrangement includes a RAM chip 61 divided into two sections 62 and 63 as is available commercially. Sections 62 and 63 are mated with first, second, and third randomly-bundled fiber arrays. FIG. 2 shows the linear ends of the three fiber arrays designated R1--RN, G1--GN, and B1--BN for red, green and blue respectively. The bundled ends of the respective arrays are abutted against different areas of chip 61 as shown in FIG. 1.
The fiber optic bundle for each color may be made with the exit end of the bundle abutted against or imaged upon a dedicated sensor array. Alternatively, the three arrays may have their respective exit faces abutted against a corresponding dedicated area of a single sensor array. For this latter embodiment, and particularly for color applications, a random access CID of adequate size would be preferred.
Initialization of the fiber entrance face as shown in FIG. 2 is carried out in a manner described in the above-identified patent application. Specifically, a slit is employed to pass white light into a narrow area small compared to a fiber size. The slit extends across three fibers one from each of the red, green and blue sets of fibers. The dedicated areas of chip 61 are interrogated separately to determine if a maximum group of illuminated sensors has occurred each time the position of the slit is incremented. A selected address out of each (maximum) group of illuminated sensors is stored for each of the areas corresponding to a color.
The sequence of addresses for each of the chip (color) areas is stored separately in a permanent memory in order to later interrogate only the stored sequence for each such area each time a scan period occurs. The sequences for the respective colors are, for example, concatenated during each scan period so that the sequence corresponding to red (as an example) is interrogated first followed by the sequence corresponding to green. Thereafter, the sequence corresponding to blue is applied. In each instance operation is entirely analogous to that described in the above-identified patent application.
FIG. 3 shows a single fiber optic bundle, say for the color red. The non-linear end of the bundle includes a red color filter 100 of a dichroic material evaporated onto the exit face of the bundle. Of course, the second and third bundles of FIGS. 1 and 2 would, similarly, include like-positioned green and blue filters (not shown).
FIG. 4 shows the linear (entrance) ends of the fibers of the bundles as lines of squares 200 designated b1R . . . b3025R for bits 1 through 3025 red. The FIG. also shows the exit face 195, 196 and 197 organized into respective areas of a square area corresponding to sensor arrays defined on a single chip such as a CID. Thus, all the bits (fibers) in the "red" fiber optic array are shown to the upper left portion 195 of a chip. The linear ends of the fibers corresponding to blue and green arrays could also be represented by this manner. They are not shown in the figure to avoid confusion. The exit ends of the fibers in the green and blue arrays are positioned to correspond to the upper right portion 196 and lower right portion 197 of the second array, respectively. The lower left portion 198 of the array is unused. The organization corresponds to that shown in FIG. 1.
The sensor array is designated 201 in FIG. 4. The fiber size is chosen conveniently to correspond to a plurality of sensors of the sensor array as is fully disclosed in the above-mentioned copending patent application. Specifically for a 256K (256,000) bit chip, the fiber size is chosen of a size to correspond to say sixteen sensors. Thus, 3025 fibers cover an area of the sensor array corresponding to 48400 sensors and three such chips cover an area corresponding to fewer than 150,000 sensors of the 256,000 sensors. Consequently, three separate areas of a single sensor chip can be used. Of course, three separate smaller chips can be used also as is clear.
The electronics for the operation of the scanner is analogous to that disclosed in the above-mentioned patent application incorporated herein by reference. Specifically, FIG. 4 shows a block 204 representing a mechanical apparatus for moving a document such as 70 of FIG. 1. The mechanical apparatus is operated under the control of a control circuit 205. Circuit 205 is clocked by clock 206 and is adapted to increment the document a distance equal to the width of the three color lines (i.e., the width of 3 fiber rows as shown in FIG. 2), a distance of about 6 mils in one embodiment.
Clock 206 also enables the generation of a string of sensor addresses corresponding to the sequence b1R . . . b3025R b1G . . . b3025G . . . b1B . . . b3025B of the linear (entrance) ends of the fibers. To this end, the scanner of FIG. 4 includes an address generator 207, the output of which is connected to a read only memory (ROM) 208. ROM 208 responds, in a well understood manner, to generate the address string corresponding to the sequences of fibers at the entrance face as stored during initialization. The address string is applied to sensor array 201 by means of eight (8) bit decoder 210, as shown in FIG. 5.
The decoder is operative to select a particular word in the sensor array. Each time a clock pulse occurs, the linear end of the fiber array scans a next segment of the document and ROM 208 applies an address string to decoder 210. Each address of the address string selects a word or block of bit addresses in arra 201 and applies the 256 bits of the selected word or block of bit addresses to multiplexer (MUX) 211. (In FIG. 4, particular blocks in the sensor array are designated by the notation bL followed by an identifying number and letter found to indicate the color.) MUX 211 is a 256 to 1 MUX and is operative to apply a binary 1 or 0 to linear memory 214 of FIG. 4 depending upon whether the selected block of bit addresses is illuminated or not in the instant scan period. Linear memory 214 also receives clock pulses from clock 20 for incrementing to a next set of positions. The reason why blocks are addressed rather than individual locations is the sensor array is explained in the above-identified patent application incorporated herein by reference.
In a second illustrative embodiment, the fibers at the linear end (entrance face) can be alternated RGB as shown in FIG. 6 at the exit faces, the "red", "green", and "blue" bundles are gathered, polished and coated with the corresponding filter material. The entrance faces are energy coupled (epoxy'd or imaged) onto corresponding sensor arrays or portions of a sensor array. In these embodiments, operation is exactly as disclosed in the above-mentioned copending patent application.
A color scanner thus is achieved by placing color filters adjacent the exit (or entrance) faces of three fiber optic bundles which are energy coupled to sensor arrays. The sensor arrays are initialized to relate the fiber ends in the entrance and exit faces of each of the bundles so that non-coherent bundles can be used as well as coherent bundles of fibers.
The color scanner has been described in terms of red, green, and blue filters. It is to be understood that other colors such as yellow, magenta and cyan can be used as well.
Further, it is advantageous to employ sensor arrays such as CID's because such arrays are inherently capable of providing grey scale which enhances color reproduction. An optical RAM is inherently binary but can be made to exhibit pseudo grey scale properties which are quite useful. Such grey scale operation of an optical RAM is disclosed in my copending application Ser. No. 752,501 now U.S. Pat. No. 4,702,552, filed July 3, 1985 and also assigned to the assignee of the present application.
The illumination of the document for scanning is disclosed in the above-mentioned copending application. Illumination can be accomplished via a separate fiber bundle (not shown) or by the appropriate use and positioning of a lamp or lamps. Transmission or reflection modes are both possible and can be useful for different tasks.
The scanner of FIG. 1 can be operated to produce three color images of a document simultaneously. Moreover, the document need not be incremented in distances equal to the three abutting arrays. The documents need be moved only a distance dictated by the desired resolution and each of the three images may be captured separately exactly as described in my copending application Ser. No. 581,085 now U.S. Pat. No. 4,674,834. It should be clear, for example, that a single fiber optic array with a red filter would produce a "red" image of the document scanned. Arrays with green and blue filters would similarly produce green and blue images. The operation need not be different just because the three arrays produce images during a single document scan operation. The three images can be superimposed electronically to produce a single color document.
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A color document scanner is achieved using three optical fiber bundles. Each bundle is linear at the entrance face and merely gathered at the exit face. The linear ends are abutted against one another and aligned across a document to be scanned. The (three) exit faces are abutted against one or more associated sensor arrays with, for example, red, green, and blue filters interposed between the fiber bundles and the sensor array(s). The sensor arrays are operative not only to relate the positions of fibers in the entrance and exit faces of the respective bundles, but also to organize the associated color information with the appropriate scanned line segment.
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This is a continuation of application Ser. No. 06/817,185 filed Jan. 8, 1986 now abandoned.
FIELD OF THE INVENTION
The present invention relates to a process for the preparation of amides using microorganisms. More particularly, it is concerned with a process for hydrating nitriles by the action of microorganisms, to thereby prepare the corresponding amides.
BACKGROUND OF THE INVENTION
In recent years, extensive investigations have been increasingly made on utilization of microorganisms and enzymes as catalysts for various productions of chemical substances.
An enzyme capable of hydrating nitriles to form the corresponding amides is known as nitrilase or nitrilehydratase. It has been described that bacteria belonging to the genus Bacillus, the genus Bacteridium in the sense of Prevot, the genus Micrococcus and the genus Brevibacterium (Japanese patent application (OPI) No. 86186/76 (corresponding to U.S. Pat. No. 4,001,081) (the term "OPI" as used herein refers to a "published unexamined Japanese patent application")), bacteria belonging to the genus Corynebacterium and the genus Norcardia (Japanese Patent Publication No. 17918/81, corresponding to U.S. Pat. No. 4,248,968), and bacteria belonging to the genus Pseudomonas (Japanese Patent Publication No. 37951/84) have nitrilase activity and hydrate nitriles to form the corresponding amides, particularly acrylonitrile, to form acrylamide.
SUMMARY OF THE INVENTION
The present invention is directed to a process for preparing an amide compound using microorganisms, which comprises subjecting a nitrile having from 2 to 6 carbon atoms to the action of bacteria belonging to the genus Rhodococcus, the genus Arthrobacter, or the genus Microbacterium having an activity to hydrate the nitriles to form the corresponding amides in an aqueous medium.
DETAILED DESCRIPTION OF THE INVENTION
The process of the present invention is particularly effective in the preparation of acrylamide from acrylonitrile.
The microorganisms used according to the present invention are bacteria having nitrilase activity belonging to the genus Rhodococcus, the genus Arthrobacter, and the genus Microbacterium. Typical examples are Rhodococcus sp. S-6 FERM BP-687, Rhodococcus erythropolis IFM 155, Rhodococcus rhodochrous IFM 153, Arthrobacter oxydans IFO 12138, Arthrobacter aurescens IAM 12340, and Microbacterium flavum IAM 1642.
Bacteria designated by the symbols IFM, IFO, and IAM are known microorganisms and are readily available through The Japanese Federation of Culture Collections of Microorganisms (JFCC) of The Research Institute for Chemobiodynamics, Chiba University (IFM); The Institute for Fermentation, Osaka (IFO); and Institute of Applied Microbiology, University of Tokyo (IAM), respectively. Rhodococcus sp. S-6 is a strain isolated by the present inventors, having particularly high nitrilase activity, and has been deposited in the Fermentation Research Institute, Agency of Industrial Science & Technology, Ministry of International Trade and Industry, Japan, as FERM-BP No. 687. Bacteriological characteristics of the strain are shown below. Rhodococcus sp. S-6
(a) Morphology
(1) Small rod-shaped, 0.5-0.8 μm diameter×1-5 μm length
(2) At an initial stage of cultivation, the cell is in a long rod-shaped form and irregular branches are observed. Later it breaks and splits into a spherical or short rod-shaped form (pleomorphism).
(3) Motility: none
(4) Formation of spore: none
(5) Gram staining: positive (+)
(6) Acid fastness: negative (-)
(b) Growth state in various culture media (30° C.)
(1) Bouillon agar plate culture: colonies are circular, irregular, smooth in surface, and colored slightly pink.
(2) Bouillon agar slant culture: good growth, trapezoidal in cross section, no luster, and slightly pink.
(3) Bouillon liquid culture: vigorous growth while forming a pellicle, and the liquid is transparent and precipitates with growth.
(c) Physiological characteristics
(1) Reduction of nitrate: positive (+)
(2) Decomposition of urea: positive (+)
(3) Indole production: negative (-)
(4) Hydrolysis of starch: negative (-)
(5) Decomposition of gelatin: negative (-)
(6) Decomposition of cellulose: negative (-)
(7) Oxidase: negative (-)
(8) Catalase: positive (+)
(9) Requirement of a free oxygen: positive (+)
(10) Growth in anaerobic condition: negative (-)
(11) O/F test: 0
(12) Growth at 37° C.: positive (+)
(13) Requirement of vitamins: negative (-)
(14) Production of gas from glucose: negative (-)
(15) Production of acid from glucose: positive (+)
(d) Chemical composition of cells
(1) Contains meso-diaminopimelic acid, arabinose and galactose (B. Becker et al., Applied Microbiology, Vol. 12, p. 421 (1964), and H. A. Lechevalier et al., The Actinomycetales, p. 311 (1970)).
(2) Contains fatty acids of C 16 (n, F 1 ), C 18 (F 1 ) and C 19 (10-CH 3 ) as main fatty acids (K. Komagata et al., International Journals of Systematic Bacteriology, Vol. 33 (2), p. 188 (1983)).
(3) Contains C 32 -C 46 mycolic acids as the mycolic acid type (M. Goodfellow, Microbiological Classification and Identification, (1980)).
Referring to Bergey's Manual of Determinative Bacteriology, H. Ans-G. Schlegel, The Prokaryotes, Vol. II (1981), and the literature described in (d) concerning chemical classification of microorganisms, the strain S-6 is determined such that it is a bacillus which is gram-positive, negative in formation of spore, aerobic, has polymorpholis, and is negative in acid fastness. This strain contains therein meso-diaminopimelic acid, arabinose and galactose, C 16 (n, F 1 ), C 18 (F 1 ) and C 19 (10-CH 3 ) as fatty acid types of acids, and C 32 -C 46 mycolic acids as the mycolic acid type.
Based on the above bacteriological characteristics, the present strain is identified as a bacterium belonging to the genus Rhodococcus.
In cultivation of microorganisms as used herein, an ordinary culture medium containing a carbon source (e.g., glucose, glycerol, and maltose), a nitrogen source (e.g., ammonium sulfate and ammonium chloride), an organic nutrient source (e.g., yeast extract, peptone, meat extract, soybean protein hydrolyzate, and corn steep liquor (CSL)), an inorganic nutrient source (e.g., phosphate, magnesium, potassium, zinc, iron, and manganese), and so forth is used. This cultivation is aerobically carried out with stirring at a pH value of from 6 to 8 and at a temperature of from 20° to 35° C., and preferably 25° to 30° C., for from 1 to 3 days.
In the practice of the process of the present invention, one strain selected from the above microorganisms is cultured for 2 to 3 days according to the above-described method, and the resulting cultures or cells separated from the cultures, or treated cells (crude enzymes, immobilized cells, etc.) are suspended in water, a buffer or physiological saline water and then a nitrile compound is added thereto.
The nitrile compound is acted on by cells by reacting an aqueous medium generally containing from about 0.01 to 10 wt % of the cells and from about 0.1 to 10 wt % of the nitrile compound at a temperature of from the freezing point thereof to 30° C., and preferably the freezing point to 15° C., at a pH of from 6 to 10, and preferably from 7 to 9, for a period of from 0.5 to 10 hours.
Nitrile compounds used as a substrate are biologically very toxic, and exert serious adverse influences on the present enzymatic reaction. For this reason, the nitrile compound is gradually added in a controlled manner such that the concentration of nitriles in the system is preferably not more than 5 wt %, and more preferably not more than 2 wt %.
If the pH value is outside the above-defined range, the amide formed and accumulated is further hydrolyzed, and the stability of the cells is reduced. Thus, it is preferred to control the pH value within the range of from 7 to 9 by gradually adding caustic alkali (e.g., NaOH and KOH), or by previously adding a buffer to the system.
If reaction conditions are appropriately controlled, the desired amide can be formed and accumulated from the nitrile compound at a conversion value of nearly 100%, and with substantially no formation of by-products.
The amide thus formed can be recovered from the reaction mixture by commonly known techniques. For example, cells are separated from the reaction mixture by techniques such as centrifugal separation, treated with activated carbon, an ion exchange resin or the like, to remove colored substances, impurities and the like, and then concentrated under reduced pressure to yield the desired amide, for example, acrylamide.
The present invention is described in greater detail with reference to the following examples. All parts and percents are by weight.
The various nitriles and their corresponding amides were quantitatively analyzed by gas chromatography, and their corresponding organic acids by high performance liquid chromatography.
EXAMPLE 1
A strain, Rhodococcus sp. S-6, was aerobically cultured on a medium (pH: 7.2) containing 1% of glucose, 0.5% of peptone, 0.3% of yeast extract, and 0.3% of meat extract at 30° C. for 48 hours. The cells thus formed were removed by centrifugal separation and washed with a 0.05M phosphate buffer (pH: 7.7). This procedure was repeated to prepare washed cells of the S-6 strain (water content: 80%).
A mixture of 0.5 part of the washed cells and 84.5 parts of a 0.05M phosphate buffer (pH: 8.5) was prepared, and then 15 parts of acrylonitrile was intermittently added with stirring at from 0° to 3° C. while controlling conditions such that the concentration of acrylonitrile in the reaction system did not exceed 2%, to thereby subject the acrylonitrile to a hydration reaction. Addition of acrylonitrile was completed in about 3 hours. To ensure the completion of the reaction, stirring was further continued for several hours. Then, cells were removed by centrifugal separation to yield a clear solution. This solution contained 20% of acrylamide, and the yield of acrylamide was more than 99.9%. Unreacted acrylonitrile was not detected at all, and the proportion of by-produced acrylic acid was not more than 0.1% (based on the weight of the acrylamide).
Water was distilled off from the clear solution at a temperature of not more than 50° C.; the clear solution was concentrated to precipitate crystals. These crystals were recrystallized from methanol to yield colorless plate-shaped crystals. This compound was identified as acrylamide based on melting point, elementary analysis, and IR.
EXAMPLE 2
Washed cells of the S-6 strain were obtained in the same manner as in Example 1 and measured for their reactivity to various nitriles under the following conditions.
______________________________________(a) Reaction Conditions Nitrile Compound 2.5% Potassium Phosphate Buffer pH 7.7/0.05M Cells (as dry cells) 5 mg Temperature 10° C. Reaction Time 10 min Amount of the Reaction Solution 10 ml(b) Reaction Results Type of Nitrile Amide-Forming Activity* Acetonitrile 30 Propionitrile 102 Acrylonitrile 100 Methacrylonitrile 123 Butyronitrile 51 Valeronitrile 11 Nicotinonitrile 16______________________________________ *Relative value indicated with the activity to acrylonitrile as 100.
EXAMPLE 3
100 ml of a culture medium comprising 1% of glycerol, 0.1% of KH 2 PO 4 , 0.05% of MgSO 4 .7H 2 O, 0.001% of FeSO 4 .7H 2 O, 0.5% of soybean protein hydrolyzate, and 0.1% of yeast extract (pH: 7.5) which had been sterilized and to which 0.5% of sterile isobutyronitrile had been added was prepared in 500 ml of an Erlenmeyer flask. Then, 1 ml of a culture of a type of culture strain as shown below which had been cultured for 48 hours in the same culture medium as in Example 1 was added, and cultured with vibration at 25° C. for 48 hours. After the cultivation was completed, cells were recovered by centrifugal separation and then washed with a 0.05M phosphate buffer (pH: 7.7). This procedure was repeated to yield washed cells. These cells were measured for activity of formation of acrylamide from acrylonitrile in the same manner as in Example 2.
The results are shown in Table 1.
TABLE 1______________________________________ Acrylamide- Forming ActivityType of Strain (μM/mg · hr)______________________________________Rhodococcus erythropolis IFM 155 3.5Rhodococcus rhodochrous IFM 153 2.5Arthrobacter oxydans IFO 12138 5.0Arthrobacter aurescens IAM 12340 2.0Microbacterium flavum IAM 1642 2.0______________________________________
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
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A process for the production of amides utilizing microorganisms is described, which comprises subjecting nitriles having from 2 to 6 carbon atoms to the action of a microorganism belonging to the genus Rhodococcus, and genus Arthrobacter or the genus Microbacterium having an ability to hydrate the nitriles to form the corresponding amides in an aqueous medium.
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This is a division, of application Ser. No. 08/982,858, filed Dec. 2, 1997, such prior application being incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
The present invention relates generally to systems in which it would be desirable to detect events or sequences of events and, in an embodiment described herein, more particularly provides a boiler system ignition sequence detector.
In many electromechanical systems, or simply electrical or mechanical systems, an event or sequence of events should occur in the normal course of operation. However, if the event or sequence of events do not occur as desired, remedial or emergency operations may need to be performed to restore the system to normal operation. Thus, a detector which is able to indicate when an event or sequence of events does not occur as desired would be very useful in these circumstances.
In the case of a boiler system, a desired sequence of events may be as follows: fuel is supplied to the boiler system, electrical power is supplied to the boiler system, a pilot valve is opened, a flame is ignited at a pilot burner, a thermostat indicates a need for heat, a main valve is opened, a flame is ignited at a main burner, the thermostat indicates that additional heat is not needed, the main valve is closed, etc. Several of these events are typically controlled by an ignition control module of the boiler system. For example, the ignition control module may control when the pilot valve opens, ignition of the pilot flame, opening of the main valve, etc.
Hazardous conditions may result if an improper sequence of events occurs in a boiler system. For example, if the main valve is opened before the pilot valve is opened, fuel may accumulate within the boiler system and lead to uncontrolled burning or explosion. As another example, if the main valve is opened before the thermostat indicates a need for heat, the boiler may become overheated.
In the past, simple relays have been used to ensure that a proper sequence of events has occurred in a boiler system. In this manner, for example, power could not be supplied to a main solenoid valve unless power had been previously supplied to a pilot solenoid valve and the thermostat had previously indicated a need for additional heat. Unfortunately, such types of relay networks are easily fooled and may fail to react if a sequence of events, although improper, does not occur exactly as prescribed. Additionally, such event detectors usually were constructed with relatively large and expensive mechanical latching relays. Due to the high radio frequency transmissions produced by ignition of the pilot flame, construction of a generally solid state event detector was thought to be unfeasible.
From the foregoing, it can be seen that it would be quite desirable to provide an event detector for electrical, mechanical, electromechanical or electronic systems which is capable of accurately detecting the occurrence of an event or sequence of events in the system, and which is suitable for use in high RFI level environments. When used in a boiler system, it would be desirable for the event detector to further be able to shut down the boiler system if an improper event or sequence of events occurs, and for the event detector to maintain the boiler system in this state until it is manually reset. It is accordingly an object of the present invention to provide such an event detector and associated methods of protecting systems.
SUMMARY OF THE INVENTION
In carrying out the principles of the present invention, in accordance with an embodiment thereof, a latching event detector is provided which uses solid state technology, utilization of which does not require a network of mechanical relays, but which is usable in high RFI environments. Methods of protecting systems are also provided.
In broad terms, a latching event detector is provided which includes at least one event detector, each of which is interconnected to a corresponding element of a system, so that each detector is capable of indicating when an event has occurred for its corresponding element. The output of each event detector is interconnected to a microprocessor. The microprocessor is programmed and interconnected to the system, such that the system is disabled when an improper event or sequence of events occurs. The system can be subsequently enabled by manually resetting the latching event detector while primary power is applied thereto.
In the disclosed and described embodiment, the event detectors are interconnected to a pilot valve, a main valve and a thermostat of a boiler system. When an improper sequence of events occurs, an ignition control module of the boiler system is disabled by removing primary power therefrom, thereby removing power from the pilot and main valves. Primary power may be restored to the ignition control module by depressing a reset switch of the latching event detector while power is supplied thereto.
A method of protecting boiler systems is also provided, which method includes the steps of reading the recorded state of a relay and determining whether a fault has occurred by reading the outputs of one or more event detectors. If a fault is detected, the relay is unlatched and the unlatched state is recorded in an EEPROM. Upon subsequent power-up, if an unlatched state is recorded in the EEPROM, the relay may be latched only if a reset switch is closed.
These and other features, advantages, benefits and objects of the present invention will become apparent to one of ordinary skill in the art upon careful consideration of the detailed description of a representative embodiment of the invention hereinbelow and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a boiler system embodying principles of the present invention;
FIG. 2 is a circuit diagram of a latching event detector embodying principles of the present invention, the latching event detector being incorporated as an ignition sequence detector in the boiler system of FIG. 1; and
FIG. 3 is a flow chart of a method of protecting boiler systems, the method embodying principles of the present invention.
DETAILED DESCRIPTION
Representatively and schematically illustrated in FIG. 1 is a boiler system 10 which embodies principles of the present invention. The boiler system 10 is of the gas-fired type which is well known to those ordinarily skill in the art, in that it includes a boiler 12 , a burner system 14 in close proximity to the boiler for providing heat to the boiler, and a thermostat 16 for regulating the temperature of the boiler. However, the burner system 14 described herein includes features not heretofore found in conventional burner assemblies.
The burner system 14 includes a conventional pilot valve 18 for regulating the supply of gas to a boiler pilot (not shown). The burner system 14 also includes a conventional main valve 20 for regulating the supply of gas to a main burner (not shown). In operation, the pilot valve 18 is typically open, thereby supplying gas to the boiler pilot continuously.
The main valve 20 is typically opened only when the thermostat 16 indicates that heat needs to be provided to the boiler 12 . When the main valve 20 is opened, a relatively large quantity of fuel (as compared to that supplied to the boiler pilot) is supplied to the main burner, and this fuel is ignited by a flame of the boiler pilot. Thus, it will be readily appreciated that it would be very hazardous for the main valve 20 to be opened while the pilot valve 18 is closed, or while the pilot valve is open and a flame has not been ignited at the boiler pilot. For example, either of these situations could lead to accumulation of a large quantity of fuel within the burner system 14 , which fuel might be inadvertently ignited and produce an uncontrolled explosion or other combustion of the fuel.
In the burner system 14 , opening and closing of the pilot and main valves 18 , 20 , and ignition of a flame at the boiler pilot is controlled using a conventional ignition module 22 . The ignition module 22 is interconnected to the pilot valve 18 , main valve 20 , and to the thermostat 16 . Power is supplied to the ignition module 22 via a power line 24 supplying, for example, 24 VAC.
In conventional operation, when power is initially supplied to the ignition module 22 by the power line 24 , such as when the boiler system 10 is turned on, the ignition module opens the pilot valve 18 and supplies a spark at the boiler pilot to ignite a flame at the boiler pilot. Thereafter, when the thermostat 16 indicates that heat needs to be supplied to the boiler 12 , the ignition module 22 opens the main valve 20 .
In an important aspect of the present invention, the burner system 14 further includes an ignition sequence detector 26 , in order to protect the boiler system 10 from an improper ignition sequence. The ignition sequence detector 26 is interconnected to the power line 24 , the thermostat 16 , and to the pilot valve 18 at their interconnections to the ignition module 22 . In this manner, the ignition sequence detector 26 is capable of monitoring whether a proper sequence has occurred, or whether a hazardous situation may be presented.
If a fault in the ignition sequence is detected by the ignition sequence detector 26 , the ignition sequence detector will prevent power from being supplied to the ignition module 22 by the power line 24 . In addition, the ignition sequence detector 26 will remain latched in this state, even if power is removed from the power line 24 and then restored. When latched to prevent power from being supplied to the ignition module 22 , the ignition sequence detector 26 will subsequently permit power to be supplied to the ignition module only if it is manually reset while power is present on the power line 24 , for example, by depressing a switch 28 connected to the ignition sequence detector.
Referring additionally now to FIG. 2, a circuit diagram of a latching event detector 30 embodying principles of the present invention is representatively illustrated. The latching event detector 30 is described herein as it may be used for the ignition sequence detector 26 of the boiler system 10 described above. However, it is to be clearly understood that the latching event detector 30 may be used in other systems, and other types of systems, without departing from the principles of the present invention.
The latching event detector 30 includes a power supply circuit 32 , a programmable microprocessor U 1 , three event detector circuits 34 , 36 , 38 , a relay K 1 , interconnected relay driver circuits 40 , 42 , a reset switch SW 1 , a single shot circuit 46 , a clock circuit 48 , and a watchdog circuit 50 . The power supply circuit 32 receives primary power from the power line 24 at terminals 1 and 3 of a connector P 1 . The clock circuit 48 provides the basic system clock at pins 15 , 16 of the microprocessor U 1 .
The event detector circuit 34 is connected to terminal 3 of a connector P 3 , which is connected to a line 52 connected between the ignition module 22 and the pilot valve 18 . Voltage present on terminal 3 of connector P 3 provides an indication that the pilot valve 18 is open, and the output of the event detector circuit 34 (at pin 6 of U 3 ) will be low. When voltage is not present on terminal 3 of connector P 3 , the pilot valve 18 is closed, and the output of the event detector circuit 34 will be high. The output of the event detector circuit 34 is connected to pin 8 of the microprocessor U 1 , and to the base of transistor Q 2 of the relay driver 40 .
The event detector circuit 36 is connected to terminal 6 of the connector P 3 , which is connected to a line 56 for supplying power to the ignition module 22 . Voltage present on terminal 6 of the connector P 3 provides an indication that primary power is available for supply to the ignition module 22 , and the output of the event detector circuit 36 (at pin 2 of U 3 ) will be low. When voltage is not present on terminal 6 of connector P 3 , primary power has been lost, and the output of the event detector circuit 36 will be high. The output of the event detector circuit 36 is connected to pin 6 of the microprocessor U 1 , and to the base of transistor Q 2 of the relay driver 40 .
The event detector circuit 38 is connected to terminal 7 of the connector P 3 , which is connected to a line 54 connected between the thermostat 16 and the ignition module 22 . Voltage present on terminal 7 of the connector P 3 provides an indication that a switch of the thermostat is closed, and the output of the event detector circuit 38 (at pin 4 of U 3 ) will be low. When voltage is not present on terminal 7 of connector P 3 , the thermostat switch is open, and the output of the event detector circuit 38 will be high. The output of the event detector circuit 38 is connected to pin 7 of the microprocessor U 1 , and to the base of transistor Q 2 of the relay driver 40 .
Note that an output of each of the event detectors 34 , 36 , 38 is connected to the relay driver 40 . If any one of the event detectors 34 , 36 , 38 indicates a fault, transistor Q 2 will conduct, thereby disconnecting ground from the power supplied (between VCC and ground) to the relay K 1 . When the relay K 1 is no longer powered (i.e., “unlatched”), the 24 VAC power source on terminal 6 of a connector P 4 (connected to K 1 pin 9 ) is no longer electrically connected to terminal 6 of the connector P 3 (connected to K 1 pin 13 ), which is connected to the line 56 for supplying power to the ignition module 22 . Thus, when any one of the event detectors 34 , 36 , 38 indicates a fault, the burner assembly 14 is disabled by unlatching the relay K 1 , and the pilot and main valves 18 , 20 will be closed, thereby preventing a potentially hazardous accumulation of fuel. Pins 4 & 6 of K 1 are connected to terminals 1 & 2 of a connector P 5 , which may optionally be used as an external indicator of the state of K 1 , such as by connecting the terminals to the contacts of an external relay (not shown).
As used herein, the term “latched” is used to indicate that power is supplied to the relay K 1 by the latching event detector 30 circuits, transistor Q 3 is conducting, and thereby connecting K 1 pins 9 and 13 (as well as pins 4 and 8 ) and supplying power to the ignition module 22 . The term “unlatched” is used to indicate that power is not supplied to the relay K 1 by the latching event detector 30 circuits, transistor Q 3 is not conducting, and power is not supplied to the ignition module 22 .
The outputs of the event detectors 34 , 36 , 38 are also connected to terminals 6 , 7 and 8 of the microprocessor U 1 . The microprocessor U 1 is programmed, using conventional methods well known to those of ordinary skill in the art, to detect when certain sequences of events occur, and to produce certain outputs when corresponding detected sequences do occur. For example, if the ignition module 22 is powered (24 VAC is present at terminal 6 of connector P 3 ), and the thermostat 16 switch is closed (24 VAC is present at terminal 7 of connector P 3 ), but the pilot valve 18 goes from on to off (24 VAC is present, and then removed from terminal 3 of connector P 3 ), the microprocessor U 1 program will cause its pin 5 to go from high to low, thereby unlatching the relay K 1 and disabling the burner system 14 . This is due to the fact that the microprocessor U 1 pin 5 is connected to the base of transistor Q 3 of the relay driver 42 . Note that the microprocessor U 1 program can also cause its terminal 9 to go high, thereby causing transistor Q 4 to conduct, to thereby unlatch the relay K 1 .
Terminals 3 & 4 of the connector P 2 may be connected to an external LED (not shown) for providing an external indication that a fault has occurred. For this purpose, the microprocessor U 1 program causes its pin 3 to go high when a fault has been detected, thereby causing transistor Q 1 to conduct. An internal indication is provided by an LED D 2 . The external indication is optional, and the internal indication may still be provided, even if no external indication is desired, by directly connecting terminal 3 to terminal 4 of the connector P 2 .
The microprocessor U 1 is connected to a conventional EEPROM U 2 , which records when the relay K 1 has been latched and unlatched. The microprocessor U 1 is, thus, able to “remember” the state of the relay K 1 . In the event that power supplied to the latching event detector 30 is interrupted, the microprocessor U 1 will have the state of the relay K 1 in its memory when the power is restored.
In order to reset the relay K 1 from its unlatched to its latched state, the switch SW 1 is momentarily depressed while primary power is being supplied to the latching event detector 30 on line 24 . Closing of the switch SW 1 causes the single shot circuit 46 to output a pulse to the microprocessor U 1 at its pin 2 . The EEPROM U 2 is made to record a latched state of the relay K 1 when the pulse is received by the microprocessor U 1 . The microprocessor U 1 program makes pin 3 go high if the EEPROM U 2 has a latched state of the relay K 1 recorded on initial power-up, that is, when primary power is initially supplied on line 24 .
The watchdog circuit 50 outputs a low frequency signal to pin 1 of the microprocessor U 1 . Pin 1 is the reset pin of the microprocessor U 1 .
The microprocessor U 1 is programmed to produce a 1 KHz clock signal on its pin 9 , which pulses the base of a transistor Q 5 , causing it to discharge a capacitor C 13 and hold the output on pin 12 of U 3 high. This clock signal is coupled through a capacitor C 6 to a network 58 . The network 58 produces a negative voltage from the clock signal, which is connected to the base of a transistor Q 4 . The negative voltage holds the transistor Q 4 off, thereby allowing the signal on pin 5 of the microprocessor U 1 to drive the base of the transistor Q 3 of the relay driver 42 .
If the microprocessor U 1 fails, or its program otherwise fails to execute properly, the 1 KHz clock signal will no longer be present on its pin 9 . Lack of the clock signal on pin 9 will cause Q 4 to conduct (the junction of R 16 and C 7 no longer being held low), thereby preventing the transistor Q 3 from conducting, and unlatching the relay K 1 . Thus, the network 58 provides “fail safe” operation of the microprocessor U 1 , i.e., if the microprocessor fails, the relay K 1 is unlatched.
When power is first supplied on Line 24 , the relay K 1 is unlatched and no power is supplied to terminal 6 of the connector P 3 . Thus, no power is supplied to the ignition module 22 on line 56 . There are no signals input to the event detectors 34 , 36 , 38 , so their outputs are all high. The transistor Q 2 of the relay driver 40 is turned on, pulling the anode of diode D 11 low and disconnecting resistor R 14 from the base of transistor Q 3 of the relay driver 42 . At this point, only the signal on pin 5 of the microprocessor U 1 can turn the relay K 1 on, and pin 5 will go high only when the microprocessor's program causes it to go high based on the data recorded in the EEPROM U 2 . If the microprocessor U 1 fails to operate properly, for example, if it fails to execute its program, the outputs of the event detectors 34 , 36 , 38 will still hold transistor Q 3 off. Thus, on initial power-up, pin 5 is high if a latched state of the relay K 1 is recorded in the EEPROM U 2 , and pin 5 is low if an unlatched state of the relay K 1 is recorded in the EEPROM.
A circuit 60 , including diodes D 16 , D 17 , resistors R 20 , R 21 and capacitor C 11 produces a 60 Hz clock signal. This clock signal is input to the microprocessor U 1 at its pin 4 . Reading of the event detector circuit outputs at pins 6 , 7 , 8 is controlled by the clock signal, as is the switching of the signal on pin 5 . In this manner, the detector 30 is “debounced” and false triggering due to noise is prevented. Such noise may be produced by a large quantity of RFI generated by a high voltage arc at the boiler pilot as the ignition module 22 attempts to ignite a flame. The wiring interconnecting the ignition module 22 and the latching event detector 30 carries this RFI to the latching event detector. Without the 60 Hz clock signal produced by the circuit 60 , the relay K 1 would chatter due to the noise disturbing the proper functioning of the microprocessor U 1 .
Thus, in a normal operating state of the boiler system 10 , all three event detectors 34 , 36 , 38 produce low outputs, which are input at pins 8 , 6 , 7 , respectively of the microprocessor U 1 . Transistor Q 2 , therefore, is nonconducting and the relay K 1 may be latched on by current flow through resistor R 14 .
If any one of the inputs to the event detectors 34 , 36 , 38 is turned off, that is, if primary power is disconnected from the ignition module 22 , the pilot valve 18 is closed, or the thermostat 16 switch opens, the base of Q 2 is powered and the junction of R 14 and D 11 is pulled low. At this point, the microprocessor U 1 program produces appropriate output, based on which of the inputs on its pins 6 , 7 , 8 are high and which are low, and the order in which they changed. For example, if the thermostat 16 switch cycles from closed to open, while the ignition module 22 remains powered and the pilot valve 18 remains open, Q 2 will conduct, but the output on pin 5 of U 1 will remain high and the relay K 1 will remain latched.
If, however, the microprocessor U 1 program detects a “fault”, i.e., an improper event or sequence of events at its inputs 6 , 7 , 8 , the program will cause the output on pin 5 of U 1 to go low, thereby unlatching the relay K 1 . Additionally, the program will write an “unlatched” state of the relay K 1 to the EEPROM U 2 .
The following is an example of an improper sequence of events, which may be detected as a fault by the microprocessor U 1 program. With the boiler system 10 in its normal operating state, K 1 is latched and power is supplied to the ignition module 22 at terminal 6 of connector P 3 . With the thermostat 16 switch closed, power is supplied to terminal 7 of connector P 3 and to the thermostat input of the ignition module 22 on line 54 . The ignition module 22 supplies power to the pilot valve 18 on line 52 , which is also connected to terminal 3 of connector P 3 . If the ignition module 22 fails to sense a flame at the pilot burner, it turns off the power to the pilot valve 18 . When the microprocessor U 1 senses this sequence of events, the program causes the output on its pin 5 to go low, thereby unlatching the relay K 1 . The program also writes this unlatched state in the EEPROM U 2 .
When power is initially applied at terminals 1 & 3 of connector P 1 , transistor is nonconducting and, therefore, transistor Q 3 is nonconducting and relay K 1 is unlatched. No power is supplied to any of the event detector 34 , 36 , 38 inputs, so transistor Q 2 conducts and resistor R 14 is effectively disconnected from the base of transistor Q 3 . The microprocessor U 1 reads the EEPROM U 2 and determines whether pin 5 of U 1 should be high or low (based on whether the relay K 1 was latched or unlatched at power-down as recorded in the EEPROM; the actual state of relay K 1 is irrelevant). The microprocessor U 1 also produces the 1 KHz clock signal on its pin 9 , thereby making transistor Q 4 nonconducting. Thus, if U 1 pin 5 is high, relay K 1 turns on and power is supplied to connector P 3 terminal 6 , powering the ignition module 22 and making the output of event detector 36 low. When the ignition module 22 supplies power to the pilot valve 18 , the output of event detector 34 goes low. When the thermostat 16 switch closes, the output of event detector 38 goes low. With all three of the event detectors 34 , 36 , 38 having low outputs, Q 2 is nonconducting and resistor R 14 is effectively connected to the base of transistor Q 3 . As long as all three outputs of the event detectors 34 , 36 , 38 are low (as is the case in the normal operating state of the boiler system 10 ), Q 2 remains nonconducting and the base of transistor Q 3 remains powered, even though normal operation of the microprocessor U 1 may be momentarily interrupted, for example, by RFI generated when the ignition module 22 generates an ignition spark at the pilot burner.
Referring additionally now to FIG. 3, a method 61 of protecting the boiler system 10 is schematically illustrated. In step 62 , power is initially supplied to the latching event detector 30 and the microprocessor U 1 is initialized (i.e., a programmed reset or initialization program is executed). The latched or unlatched state of the relay K 1 is then read from the EEPROM U 2 . If a latched state of the relay K 1 is recorded, U 1 pin 5 is caused to go high in step 66 , and the method 61 proceeds to step 76 .
If an unlatched state of the relay K 1 is recorded in U 2 , U 1 pin 5 is made to go low, and the method 61 will proceed no further unless the reset switch SW 1 is closed. Thus, if the EEPROM U 2 records an unlatched state of the relay K 1 , merely turning the power off and then back on will not result in the relay K 1 being latched. In step 70 the reset switch SW 1 is closed, causing U 1 pin 5 to go high in step 72 , and causing the EEPROM U 2 to record a latched state of the relay K 1 in step 74 . The method 61 then proceeds to step 76 .
In step 76 the outputs of the event detectors 34 , 36 , 38 are read at U 1 pins 6 , 7 , 8 . If a fault is detected, U 1 pin 5 is made to go low in step 78 and an unlatched state of the relay K 1 is recorded in the EEPROM U 2 in step 80 . If no fault is detected in step 76 , U 1 pin 5 is maintained high in step 82 and the latched state of the relay K 1 is recorded or maintained in the EEPROM U 2 in step 84 . Periodically, the outputs of the event detectors 34 , 36 , 38 are again read, so that any subsequent fault will be detected and, in the event of a fault, the relay K 1 will be unlatched and the unlatched state recorded in the EEPROM U 2 .
In parallel with the fault detection routine, a clock signal is produced at U 1 pin 9 in step 86 . If the clock signal is not present on U 1 pin 9 , the fail-safe network 58 causes the relay K 1 to unlatch in step 88 . Subsequent power-downs and power-ups will not cause the relay K 1 to latch, as long as there remains no clock signal at U 1 pin 9 .
Of course, a person of ordinary skill in the art would find it obvious to make modifications, additions, deletions, substitutions, and other changes to the boiler system 10 , latching event detector 30 , and method 61 . Accordingly, the foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims.
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An event detector and associated methods of protecting systems provide convenient and economical safety features. In a described embodiment, an ignition sequence detector for a boiler system has a microprocessor which is programmed so that an ignition control module of the boiler system is deprived of primary power when an improper sequence of events occurs. The ignition sequence detector includes multiple event detectors interconnected to the microprocessor, and is configured so that it is usable in high RFI environments.
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RELATED APPLICATIONS
This application claims the benefit of Provisional Patent Application Serial No. 60/160,450 filed on Oct. 21, 1999.
This application is a continuation-in-part of U.S. patent application Ser. No. 09/659,429, filed Sep. 8, 2000, now abandoned, the disclosure of which is expressly incorporated herein by reference.
BACKGROUND OF INVENTION
1. Field of Invention
This invention related to skateboard racking and locking devices, specifically to an improved device for storing and locking skateboards, scooters and similar sporting equipment.
2. Description of Relevant Prior Art
The popularity of skateboards among youths and young adults continues to grow at a rapid pace. For many, in addition to traditional recreational uses, skateboards have become an effective means of transportation. With this increase in popularity and uses has come a growing need for a durable, solid device for storing and locking skateboards at public places such as schools, parks and malls. Shortcomings in existing products render them unsatisfactory and unsuitable. A need therefore exists for a permanently mounted device that secures and safeguards skateboards at these types of public places.
Existing devices for storing and securing skateboards lack the combination of features necessary to protect this equipment effectively. Although several products are geared towards storing and/or securing skateboards, each of these products contains disadvantages and drawbacks that must be addressed to provide an effective and workable security device. In general, the current relevant art provides for either a device for holding skateboards or a device for locking skateboards. None of these devices however, combines the advantages of providing a permanent, secure holder that functions also as an effective locking device.
A number of U.S. patents provide for basic skateboard holders or racks but do not include a locking mechanism. U.S. Pat. No. 4,337,883 to Pate (1982) describes a removable skateboard holder that is attached to the belt of a wearer for transporting a skateboard. However, this device is intended only as a means of transporting a skateboard and does not provide for a secure, mounted holder or a locking mechanism. U.S. Pat. No. 5,120,012 to Rosenau (1991), U.S. Pat. No. 5,301,818 to Dix (1994), and U.S. Pat. No. 5,305,897 to Smith (1994) each describes a device for mounting or holding a skateboard or other skating device, but does not provide for a locking mechanism.
Each of the U.S. patents that provide for a skateboard locking mechanism has shortcomings that the present invention overcomes. U.S. Pat. No. 4,773,239 to Lowe (1988) describes a combination skateboard lock and trick device. However, this lock device is not mounted permanently to a fixed structure and requires the existence of a bicycle rack or post on which to affix the lock device. Without such a bicycle rack or post, the lock device, is completely ineffective. Further the Lowe patent leaves the front wheel truck of the skateboard exposed and thus vulnerable to theft or vandalism.
SUMMARY OF INVENTION
The invention which comprises a wall mountable rack for supporting and securing a skateboard, scooter or inline skate having one or a pair of wheels in proximity to each end of a board, footpiece or shoe by at least one of its wheels while allowing the board, footpiece or shoe and the remaining wheel or pair of wheels to hang below the rack, comprising a rear plate, a front plate and a floor plate running between said front and rear plates, an opening in said front plate to permit said board, footpiece or shoe to be held outside said front plate while one of said wheels or pair of wheels is received and carried on said floor plate between said front and rear plates, an overlying closure plate running between said front and rear walls which is adapted to be opened to position said wheel or pair of wheels between said front and rear plates and then locked in place over the top of said wheel or pair of wheels to prevent the removal of said wheel or pair of wheels from that position thereby securing the skateboard, scooter or inline skate.
More particularly, the invention which comprises a wall mountable rack for supporting and securing a skateboard by one pair of its wheels while allowing the board and the remaining pair of wheels to hang below the rack, comprising a rear plate, a front plate and a floor running between said front and rear plates, an opening in said front plate to permit said board to be held outside said front plate while said one pair of wheels is received and carried on said floor plate between said front and rear plates, an overlying closure plate running between said front and rear walls which is adapted to be opened to position said one pair of wheels between said front and rear plates and then locked in place over the top of said one pair of wheels to prevent the removal of said one pair of wheels from that position thereby securing the skateboard.
In another aspect, the invention which comprises a wall mountable rack for supporting a skateboard by one pair of its wheels while allowing the board and the remaining pair of wheels to hang below the rack, comprising a rear plate, a front plate and a floor running between said front and rear plates, an opening in said front plate to permit said board to be held outside said front plate while said one pair of wheels is received and carried on said floor plate between said front and rear plates.
THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of the wall mountable rack of this invention.
FIG. 2 is a top plan view of the wall mountable rack of FIG. 1 with a skateboard locked in place.
FIG. 3 is a front plan view of the wall mounted rack of FIGS. 1 and 2 with a skateboard locked in place.
FIG. 4 is a sectional view taken along the lines 4 — 4 in FIG. 2 .
FIG. 5 is a top view of an alternate embodiment of this invention.
FIG. 6 is a perspective view of another embodiment of this invention.
FIG. 7 is a perspective view of an embodiment where the rack holds a skateboard for storage where security is not paramount.
DESCRIPTION OF PREFERRED EMBODIMENTS
In one preferred embodiment, the present invention comprises a steel rectangularly-shaped box with a T-shaped cutout of the center top plate and front plate, a solid bottom plate, hinges attached to the rear plate, a lock hasp attached to the lid, and a wooden base attached to the rear plate. The invention is permanently attached to a vertical structure, such as a wall, by lag screws, bolts, anchors or combinations of various affixing methods.
According to another embodiment of the invention, as shown in FIG. 5, multiples of the embodiment of FIGS. 1 to 4 are combined into one device to hold and lock a number of skateboards.
According to yet another embodiment, as shown in FIG. 6, a U-shaped cutout in the center of the bottom plate enables the device to hold and lock a scooter.
According to a further embodiment, as shown in FIG. 7, removal of the top plate, the hinges and the lock hasp enables the device to hold or store a skateboard, scooter or in-line skates in the homes.
Turning to the main embodiment of the present invention as illustrated in FIGS. 1 to 4 , a wall-mounted lockable skateboard rack is comprised of a rectangularly shaped box 10 , preferably made of 3-inch tubular steel and having a length of 16 inches. The box 10 has a rear plate 12 , front plate 14 and bottom plate 16 . The box 10 has a top plate or lid 18 in top 20 which is carried by pair of hinges 22 . The locking portion of the rack is a T-shaped cutout formed by the cutout 24 in front plate 14 and the top opening provided by the lifting of lid 18 , as shown in FIG. 1 . The hinges 22 are attached to the rear plate 12 . The lid 18 , preferably measuring 3 inches wide and 11 inches in length, is adapted to close over the skateboard trucks. The typical skateboard has a truck 26 in proximity to each end of the board 28 , each truck 26 comprising a pair of wheels 30 . A lock hasp cover 32 is attached to the lid 18 which when pulled over the lock hasp 34 and completed with a key or combination lock 36 provides a much needed and secure device for locking and securing a skateboard to the rack. A base 38 , commonly made of wood, is attached to the rear plate 12 to provide a method for securing the invention to a wall or similar structure.
The rack is preferably made of steel.
The manner for using the present invention is straightforward. Secure the skateboard rack to a sturdy structure, such as a wall or similar structure, at base 38 with lag screws or anchor bolts or other appropriate affixing methods known to those skilled in the art. Place the skateboard trucks 26 in the T-shape cutout with the pair of wheels positioned between rear plate 12 and front plate 14 , and resting on bottom plate 16 . Pull down lid 18 over the skateboard trucks 26 and complete by pulling lock hasp cover 32 into place over lock hasp 34 and securing with a key or combination lock 36 .
The embodiment of FIG. 5 provides multiple skateboard racks in one device by combining and interconnecting any number of the individual devices depicted in FIGS. 1 to 4 .
The additional embodiment shown in FIG. 6 provides an effective mounting device for securing and locking scooters in public places. A U-shaped cutout 40 in the bottom plate 16 provides a slot in which to mount a scooter having a footpiece provided with front and rear trucks, each having a pair of wheels. One of the pair of wheels is held in the rack in the manner generally as depicted in FIGS. 1 to 4 .
Inline skates; can similarly be secured in the device shown in FIG. 6 . The manner for using this additional embodiment is identical to that of the main embodiment described above. It is to be understood that the skates can be held in the rack with or without the shoe since inline skates are provided as an attachment to shoes or as an integral part of so-called shoe skates.
Yet another embodiment as shown in FIG. 7, provides an effective device for mounting skateboards, scooters or in-line skates at home. The lid 18 and lock hasp 34 are removed to provide a solid durable device for mounting this equipment in places where the risk of theft is not great such as in homes and garages. This additional embodiment promotes safety at home by providing a device for storing potentially dangerous skateboards, scooters or in-line skates when they are not in use.
Accordingly, the invention provides an improved and reliable device for storing and locking skateboards. The present invention provides several important advantages over the prior relevant art. Because the invention is permanently affixed to a vertical structure at places such as schools, parks and malls, it is durable and effective as a theft-deterrent device. Moreover, this attribute of the invention precludes the need for a bicycle rack or a pole on which to attach the locking device. It also preclude the need for the user to transport a locking device to these public places.
Furthermore, the invention has additional advantages in that it is economical, reliable and durable. It also will minimize the risks associated with leaving skateboards, scooters and similar equipment on the ground when not in use, and it will encourage skateboard and scooter users not to carry their equipment into school or the mall.
Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Other embodiments and ramifications of the invention are possible as well. For example, the invention may be used to secure sporting equipment other than skateboards, scooters, and skates.
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A wall mountable rack for supporting and securing a skateboard, scooter or inline skate having one or a pair of wheels in proximity to each end of a board, footpiece or shoe by at least one of its wheels while allowing the board, footpiece or shoe and the remaining wheels or pair of wheels to hang below the rack.
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SUMMARY OF THE INVENTION
[0001] The present invention relates to genotyping animals for the leptin Arg25Cys functional mutation and also application of a class of compounds known as β-adrenergic agonists (β-AA), specifically Zilpaterol Hydrochloride (ZH), and Ractopamine Hydrochloride (RH), in order to take advantage of newly observed interactions between the leptin genotype and β-AA's on phenotypes; namely hot carcass weight (HCW) gain, body fat gain, rate of fat gain, marbling score, quality and yield grade, size of eye area (REA), percent empty body fat (% EBF), and daily dry matter intake (DDMI). Through knowledge of leptin genotype we can more precisely apply β-AA's yielding optimized HCW response of specific genotypes, reduced or no reduction in marbling score or carcass quality grades, reductions in REA, improvements in DDMI consistency, and improvements in % EBF consistency in comparison to mass application of β-AA's. The present invention allows for precise and specific administration of specific β-AA's to leptin genotype subgroups of animals.
BACKGROUND OF THE INVENTION
General β-Adrenergic Agonists (β-AA) Summary
[0002] A class of compounds known as β-adrenergic agonists (β-AA) has been used in the livestock industry as repartitioning agents. These phenethanolamine compounds promote the deposition of lean muscle tissue at the expense of adipose tissue by shifting nutrient use toward carcass lean tissue deposition and away from adipose tissue (3). β-agonists are used to produce maximum lean tissue growth, improved efficiency of gain and maximum feed efficiency in livestock (6). Two β-AA's that are commercially available to beef producers are Zilpaterol Hydrochloride (ZH) and Ractopamine Hydrochloride (RH).
[0003] β-adrenergic agonists are a class of organic molecules, which bind to β-adrenergic receptors (β-AR). β-AR's are present on the surface of most mammalian cells. There are three subtypes of β-AR's: β-AR 1 , β-AR 2 and β-AR 3 . The physiological response of a cell to a β-AA is specific to the combination of the three subtypes present on that cell (2). The distribution of receptor subtypes and the proportion of each subtype vary between tissue types in a species as well as between species. β-AR's are stimulated by the neurotransmitter norepinephrine and the medullary hormone epinephrine. β-AA's are administered orally to cattle, pigs, poultry and sheep in order to increase muscle accretion and decrease adipose tissue accretion (2).
[0004] β-AA's bind to the G-coupled protein β-adrenergic receptors, which releases the G s protein into the cell (2). The G s protein's alpha subunit activates the enzyme adenylylcyclase, which converts ATP to cyclic-adenosine monophosphate (cAMP), a major intracellular signaling molecule. Increased intracellular concentration of the secondary messenger cAMP causes the activation of Protein Kinase A (PKA). PKA goes on to phosphorylate many intracellular proteins. Two of the targets of phosphorylation by PKA are hormone sensitive lipase which is responsible for the rate limiting step in adipocytetriacylglycerol degradation and acetyl-CoAcarboxylase which is the rate limiting enzyme in long chain fatty acid synthesis (2). Hormone sensitive lipase is activated by phosphorylation by PKA to stimulate breakdown of triacylglycerols in adipose tissue. Acetyl-CoAcarboxylase is inactivated by phosphorylation by PKA which inhibits fatty acid synthesis. As a result of treatment with β-AA we expect the inhibition of lipogenesis and the stimulation of lipolysis in adipose tissue. PKA also phosphorylates and activates the cAMP response element binding protein (CREB), a transcription factor that is both a positive and a negative regulator of gene transcription. CREB is located in the nucleus, bound to the cAMP response element which is located in the regulatory element of various genes. CREB's phosphorylation by PKA can either up or down regulate expression of various genes (2).
[0005] The first β-AA used in the cattle industry was Clenbuterol (7). Clenbuterol was shown to decrease fat mass and increase weight gain and gain-to-feed ratio in livestock. Much remains unknown about the exact mechanism of action of β-AA's. The mechanism is complicated as a result of both cellular and systemic effects. Furthermore, many effects from β-AA's seen in vivo are not always replicated in vitro revealing that the effects at the cellular level may be linked to other effects in the animal. Treatment of animals with β-AA's lead to increased muscle mass, which may be due to either an increase in muscle protein synthesis, a decrease in muscle protein degradation or a combination of the two. The increase in lean tissue is due to muscle hypertrophy as there is no increase in the amount of DNA present in the skeletal muscle tissue (3). β-AA treatment results in increased mRNA transcripts for several muscle proteins such as the myosin light chain and alpha-actin and also increased mRNA transcripts of the calpain protease inhibitor calpastatin (3). Both β-AA's RH and ZH are applied in the last 20 to 42 days on feed in cattle (6). Over a course of 3 to 5 weeks of treatment with β-AA skeletal muscle is unable sustain this increased level of fiber hypertrophy without additional DNA and responsiveness to the β-adrenergic agonists is dampened and the response decreases with time.
[0006] β-AA's also act on β-adrenergic receptors (β-AR's) located in adipose tissue. Through phosphorylation, which activates hormone sensitive lipase, β-AA's stimulate adipocytetriacylglycerol degradation. Through the phosphorylation, which inactivates acetyl-CoAcarboxylase, β-AA's inhibit fatty acid and triacylglycerol synthesis. The β-AA's RH and ZH stimulate the lipolytic system and increase the plasma concentration of nonesterified fatty acids in animals undergoing treatment with β-AA's (2). β-AA's have also been shown to reduce expression of lipogenic genes (4). The net result of treatment with phenethanolamine repartitioning agents such as RH and ZH are increased protein accretion and decreased rate of fat deposition.
[0007] β-AA also exerts effects outside of the direct binding to the β-AR on skeletal muscle and adipose tissue. Other mechanisms which, may contribute to increased skeletal muscle accretion include the binding of β-AA's to β-AR's on the smooth muscle surrounding arteries and blood vessels. Treatment with β-AA's causes vasodilation which increase circulation to skeletal muscle and adipose tissue. Increased blood flow to skeletal muscle may also enhance muscle hypertrophy by delivering increased amounts of substrates and energy sources for amino acid uptake and protein synthesis (2). Increased blood flow to adipose tissue due to vasodilation may carry away nonesterified fatty acids and increase lipolysis. Mechanisms of action of β-AA may also include involvement of secondary hormones whose release is controlled by β-AR present on skeletal muscle and adipose tissue. It has also been suggested that β-AA can cross the blood-brain barrier and act directly on the central nervous system to control feed intake (2).
[0008] The effects of β-agonist vary between species. This may be because some animals have less potential for increased growth because they are closer to the biological maximum growth rate (example: broiler chickens) (2).
Summary of Zilpaterol Hydrochloride (ZH)
[0009] Zilpaterol Hydrochloride is a β-agonist, which was shown to bind to both the β-AR 1 and β-AR 2 receptors (5). ZH is marketed in North America under the Zilmax® trade name and is manufactured by Intervet Schering-Plough Animal Health (Millsboro, Del.). ZH produces similar results in livestock as its sister phenethanolamine compound RH. Much is still unknown regarding the mechanism by which ZH improves lean tissue deposition and increases feed efficiency in cattle. Treatment with ZH decreases the cellular levels of tumor necrosis factor alpha (TNF-α) and increases the cellular levels of cAMP mainly through the β-AR 2 receptors (5). Similar to RH, treatment of ZH results in increased levels of cAMP and inhibition of proteolysis in muscle tissue, stimulation of lipolysis and reduction of lipogenesis.
[0010] Studies comparing RH and ZH have been conducted (6). Although the patents state that ZH binds to β 2 adrenergic receptors it also binds to β 1 . In addition, ZH has anti-inflammatory properties. In one study RH was feed at a 300 mg/steer/day and ZH was fed at 6 mg/steer/day (6). Animals fed ZH had larger LM (Longissimus Muscle) area, but RH had no effect. Comparisons to non-treated steers showed a HCW increase of 14 kgs (30.8 lbs) and 22 kgs (48.5 lbs) for RH and ZH, respectfully (6). Both RH and ZH increased sheer force and increased toughness of the muscle tissue (6).
[0011] ZH, or Zilmax®, administered to cattle has been shown to increase HCW, final body weight, dressing percentage; and reduce subcutaneous fat (12 th rib fat), marbling score and USDA quality grade (17,18, & 20). It is generally understood that administration of ZH does not reduce daily dry matter intake (DDMI) of feed (20).
Summary of Ractopamine Hydrochloride (RH)
[0012] Ractopamine Hydrochloride (RH) is one β-AA, which is shown to increase protein accretion and increase growth of livestock (6). RH is marketed in North America under the Optaflexx® trade mark and is manufactured by Elanco Animal Health (Greenfield, Ind.). RH binds with a higher affinity to β-AR 2 . RH exists as four stereoisomers. The ranked order of affinities for the β-AR agonists are RR>RS>SR>SS. RH acts as a β-AR agonist in adipose tissue which results in an increase in plasma concentration of free fatty acids through the previously mentioned mechanisms. Swine fed RH have a reduced percentage of carcass fat but the rate of fat accretion is not consistently reduced. This effect is short live in adipose tissue because B-AR's are down-regulated by nearly 50% within the first 7 days of treatment with RH (8). Receptor down regulation may be responsible for the limited effectiveness of RH on adipose tissue. RH binds to the β-AR and increases the levels of intracellular cAMP. There is a direct link between cAMP and the transcriptional regulation for myosin heavy chain and bovine calpastatin (4). β-AA's have also been shown to activate other signaling pathways (such as the MAP kinase pathway) in common with insulin. Insulin promotes protein synthesis and inhibits protein degradation.
[0013] The β-adrenoceptor coupled adenylatecyclase system response has shown two different ways of desensitization to β-agonists. The first response is called heterologous desensitization in which there is a decrease in the cellular response to the original agonist. The second pattern is homologous desensitization, which is considered to be a refractory phase to the original β-agonist or similar compounds.
[0014] There are many possible explanations to homologous desensitization showing a decrease in β-adrenergic receptors in the presence of β-agonists over long periods. β-adrenergic receptors down regulation is accomplished through sequestering, internalization or removal of receptors from the cell surface to be degraded. They suggest intermediate feeding of RH. Although in swine a decrease of β-adrenergic receptors in adipose tissue has been observed there is no decrease of β-adrenergic receptors in skeletal muscle with prolonged RH treatment. There is a decreased response of muscle accretion in muscle after 4 weeks but not receptor response. The increase of muscle hypertrophy is due to in muscle α-actin synthesis and decreased activity of calpastatin (19).
[0015] RH, or Optaflexx®, like ZH has been shown to improve ADG (average daily gain), G:F (gain to feed, feed conversion), and hot carcass weight (HCW) gain (6 & 21).
Leptin Hormone and Genotyping Summary
[0016] Leptin is a 16 kDa protein transcribed from the obese gene in mammals. Leptin is mainly produced by and secreted from white adipose tissue. Leptin acts on central as well as peripheral tissues to regulate feed intake, energy expenditure and whole body energy balance (9). Leptin is involved in a feedback regulatory loop. Leptin acts as a sensor, monitoring the level of energy stores which are indicated by the size of the adipose tissue mass. Circulating leptin communicates this information to the appetite center at the hypothalamus. Once leptin is released by the adipose tissues it circulates in the bloodstream to the brain where it binds to the hypothalamic center which receives and processes the intensity of the leptin signal through leptin receptors. The binding of leptin to its receptors in the hypothalamus effects numerous systems including the sympathetic nervous system to control the two main determinants of energy balance: feed intake and energy expenditure. When functioning under ideal conditions, this feedback regulatory loop serves to maintain a constant body weight. Leptin production is increased following weight gain in order to decrease feed intake and increase metabolism, whereas leptin plasma levels decrease following weight loss in order to increase appetite and decrease metabolism. Chronic administration of leptin to ob/ob mice, which lack leptin due to a mutation in the obese gene, causes the animals to lose weight and to maintain their weight loss. Levels of leptin are increased in ruminants with increased body fat and/or energy balance (14).
[0017] There is a single nucleotide polymorphism (SNP) in the bovine leptin sequence which has a phenotypic affect on the animal. A cytosine to thyamine substitution in exon 2 of the bovine leptin gene encodes an amino acid transition of Arginine to Cysteine (Arg25Cys) (12). In the mature leptin protein, this amino acid change is located at the fourth amino acid position from the N-terminus of the molecule. A signal peptide on the immature protein (1st to 21st amino acids) is cleaved off before leptin is excreted from adipose tissue (12). Additionally the T allele in the obese gene, which causes the Arg to Cys transition, causes a structural change due to an alteration in disulfide bonding which in turn affects carcass level of fatness, yield grade, and quality grade (11). There is a disulphide bond between cysteine 96 and cysteine 146 which appears to be important for structure folding and receptor binding because a mutation of either of the cysteines renders the protein biologically inactive (15). It has been hypothesized that in TT animals, the Arg25Cys SNP disrupts the disulfide bond between Cys 96 and Cys 146 disrupting leptin's secondary and tertiary structure and altering the ability of leptin to bind to its receptor.
[0018] The Arg to Cys transition in animals homozygous for the T allele (TT) are believed to possess impaired leptin function, binding and recognition of leptin by the leptin receptors at the hypothalmus. In turn these animals are thought to show increased fat deposition and have higher levels of leptin mRNA (10). It is thought because leptin is not recognized at the receptor level, the signal to decrease appetite and increase metabolism is not delivered. The Arg25Cys transition has been associated with higher levels of fat deposition in beef cattle (10). There is a positive correlation between serum leptin concentration with insulin, live and carcass weight, days on feed as well as a negative correlation with lean meat yield (10). A positive correlation exists between serum leptin levels and quality grade. TT animals have higher levels of circulating leptin and have increased fat deposition compared to CC animals (22).
[0019] Circulating leptin binds on two families of hypothalamic neurons to the leptin receptor. The result of leptin binding to the first population of hypothalamic neurons is reduced expression of neuropeptide Y (NPY) and agouti-related peptide (AGRP). NPY and AGRP are both orexigenic (feed inducing) molecules therefore their down-regulation reduces appetite. When Leptin binds to the second population of receptors it induces the expression of two anorexigenic (feed inhibiting) neuropeptides: α-melanocyte-stimulating hormone (α-MSH) which is derived from pro-opiomelanocortin (POMC) and cocaine and amphetamine-related transcript (CART). α-MSH is an agonist of the melanocortin-4 receptor (MC4R), which reduces food intake when activated. Leptin also stimulates the release of corticotropin releasing hormone (CRH) which also upregulates POMC. The expression of leptin therefore induces a reduction in food intake through the suppression of orexigenic neuropeptides and the induction of anorexigenic neuropeptides (13).
[0020] The LeptinArg25Cys SNP has been demonstrated to impact carcass backfat level, live animal backfat level, marbling score, Canada and USDA Yield Grade, Canada and USDA Quality Grade, and rate of backfat accretion over time (11; Cactus Trial—08-01). Specifically, TT animals (animals homozygous for the T allele) have more carcass backfat, live animal backfat, and marbling than CT or CC animals respectively. As well, TT animals have been shown to have an increased probability of being scored yield grade (YG) 3 (Canada) and 4 (USDA) as compared to CT and CC animals, respectively; and TT animals have been shown to have a decreased amount of YG1 (Canada and USDA) as compared to CT and CC animals, respectively when slaughtered on the same day and all environmental factors being the same. Since the base associations and effects of the genotypes have been established, producers can now manipulate the days on feed (DOF) of feedlot animals in order to optimize these characteristics, i.e. shorten DOF of TT's in order to increase the percent of YG 1's and maintain marbling level; and/or lengthen the DOF of CT and CC animals in order to increase the level of marbling in the animals without negatively impacting the YG.
[0000] Current application of β-AA's
[0021] Currently β-AA's (either ZH or RH) are mass applied to pens of animals contained in one feedlot. Optaflexx® (RH) is registered in Canada and the USA for feeding during the 28-42 days prior to slaughter, with no withdrawal time required; and Zilmax® (ZH) is registered for feeding during the 20-40 days prior to slaughter with a three day withdrawal. No categorical identification of animals has been identified or used in differential application of ZH or RH. Although conceivable, targeted β-AA administration in the same feedlot, in practice would be unusual. Further, currently it is not conceivable of any method of administering a β-AA other than mass application of one β-AA in one feedlot to a pen. Currently there is no evidence of an effective system of categorizing animals such that multiple or selective β-AA application is advantageous. Currently there is no effective system, which identifies an animals' genetic propensity to respond to β-AA application. Currently there is no effective system, which sorts pens of animals based on a categorical identifying system, such as leptin genotype, and selectively apply the β-AA's to each subgroup. Therefore, multiple β-AA feeding in the same feedyard based on leptin genotype would be a novel change to the current β-AA application strategy.
SUMMARY OF THE INVENTION
Objectives
[0022] An objective of this invention is to select which cattle receive a β-AA, or if a β-AA should be administered, based on leptin genotype and which β-AA, if any, is then administered.
[0023] An objective of this invention is to select which β-AA is to be administered (i.e. ZH or RH) to animals based upon leptin genotype.
[0024] An objective is to administer two or more β-AA's in the same feedlot based on leptin genotype.
[0025] An objective of this invention is to select which leptin genotype does not receive a β-AA.
[0026] An objective of this invention is to manage marbling and quality grade by differential β-AA application to specific leptin genotypes.
[0027] An objective of this invention is to manage HCW gain response by differential β-AA application to specific leptin genotypes.
[0028] An objective of this invention is to manage REA size gain response by differential β-AA application to specific leptin genotypes.
[0029] An objective of this invention is to manage DDMI by differential β-AA application to specific leptin genotypes.
[0030] An objective of this invention is to manage yield grade and backfat by differential β-AA application to specific leptin genotypes.
[0031] An objective of this invention is to manage % EBF response by differential β-AA application to specific leptin genotypes.
[0032] Yet a further object of the invention is to determine what the leptin genotype is in order to determine the genetic propensity for daily dry matter intake, and rates of back fat accretion.
ADVANTAGES
[0033] The process of genotyping for the LeptinArg25CysSNP allows feedlot operators to identify animals by their genotype and their individual genetic potential for optimal responses to specific β-AA administration. This will give producers more knowledge that will allow them to be more informed about the decision process related to β-AA administration. The nature of the genetic propensity of each of the different genotypes will help feedlots more accurately characterize the projected animal response, based at least in part by genotype. This allows producers or owners of animals to make more informed decisions and take appropriate actions with respect to each of the genotype groups, i.e. control and manage the application of each β-AA differentially to different genotype groups, or have no β-AA administered. These actions will yield more predictable outcomes for the producers, and will include outcomes such as improving the consistency and response of DDMI, HCW gain, REA size, marbling and quality grades, and backfat and yield grades. It will also spare financial resources that would be expended upon animals whose response to β-AA results in very little economic value.
Impacts of β-Adrenergic Agonist and Leptin Genotyping
[0034] Producers will benefit from the integration of leptin genotyping and administration of β-adrenergic agonists by the identification and application of the interaction knowledge. Knowledge of leptin genotype will allow sub-grouping of animals for specific application of specific β-adrenergic agonists to specific genotype sub groups, or no application of β-AA's to certain genotypes. These interaction benefits include:
1. When β-AA's are selectively administered specific leptin genotype sub groups (CC's and CT's) having increased hot carcass weight gain as compared to other specific genotype sub groups (TT's). 2. When β-AA's are selectively administered to specific leptin genotype subgroups (CC's) having no reduction in quality grade or marbling score as compared to other specific genotype subgroups (CT's and TT's). 3. When β-AA's are selectively administered to specific leptin genotype subgroups (TT's) having reduced size of rib eye area gain and smaller overall piece size as compared to other specific genotype subgroups (CT's and TT's). 4. When β-AA's are selectively administered to specific leptin genotype subgroups (CT's and TT's) having a reduction in DDMI during β-adrenergic agonist administration as compared to other genotype subgroups (CC's). 5. When β-AA's are selectively administered to specific leptin genotype subgroups (CT's and TT's) having specific β-adrenergic agonist applied in order to avoid a reduction in daily dry matter intake during β-adrenergic agonist administration period as compared to other specific genotype subgroups (CC's). 6. When β-AA's are selectively administered to specific leptin genotype subgroups having differential β-adrenergic agonists administered in order to optimize rate of back fat accretion and days on feed to optimal slaughter date as compared to other specific genotype subgroups. 7. When β-AA's are selectively administered to specific leptin genotype subgroups will not receive β-adrenergic agonist administration while other specific genotype subgroups will receive β-adrenergic agonist administration. 8. When β-AA's are selectively administered to specific leptin genotype subgroups (TT's) have a larger reduction in % EBF as compared to other specific genotype subgroups (CC's and CT's).
[0043] Further examples of systems which take advantage of the present invention are as follows:
[0044] A system comprising ZH administration to only CC animals in order to avoid the adverse effect of reduced marbling in the CT and TT animals, optimize hot carcass weight gain (the largest in CC animals), optimize rib eye area gain (the smallest in CC animals), and not suffer the adverse effects of reduced dry matter intake during ZH administration in the CT and TT animals. Another system comprises of CC animals receiving ZH administration along with a subgroup of the CT animals which would optimize hot carcass weight gain response along with marbling response in those animals which are most probable candidates for ZH treatment so as to avoid excessive HCW gain which would result in final HCW which is above 453.7 kg (1000 lbs), or any weight which results in a discount from slaughter houses for excessive weight. Another system comprises TT animals not receiving any ZH treatment and receiving either no β-adrenergic agonist treatment or alternatively RH treatment in order to optimize the marbling response of animals and avoid any adverse consequences of ZH treatment, and potentially receive the weight gain benefits from RH treatment. Another system comprises feeding all animals ZH except black hided TT's and/or black hided CT's in order to allow animals to express their maximum genetic potential for marbling, which will increase the probability of reaching the Certified Angus Beef Quality standards. This same system would have the black hided TT and/or CT animals receive either RH treatment or no β-adrenergic agonists treatment.
[0045] A system comprising β-adrenergic agonist administration to only CC animals in order to avoid the adverse effect of reduced marbling in the CT and TT animals. Another system comprises of CC animals receiving RH administration along with a subgroup of the CT animals which would optimize hot carcass weight gain response along with marbling response in those animals which are most probable candidates for RH treatment so as to avoid excessive HCW gain which would result in final HCW which is above 453.7 kg (1000 lbs), or any weight which results in a discount from slaughter houses for excessive weight. Another system comprises TT animals not receiving any RH treatment and receiving no β-adrenergic agonist treatment in order to optimize the marbling response of animals and avoid any adverse consequences of RH treatment. Another system comprises feeding all animals RH except black hided TT's and/or black hided CT's in order to allow animals to express their maximum genetic potential for marbling, which will increase the probability of reaching the Certified Angus Beef Quality standards. This same system would have the black hided TT and/or CT animals receive no β-adrenergic agonists treatment.
[0046] These benefits will optimize the financial outcomes of feeding cattle for slaughter. By applying either different β-adrenergic agonists to different genotype subgroups or no β-adrenergic agonists to specific genotypes, potential adverse effects of β-adrenergic agonist administration to whole populations will be avoided and positive effects will be accentuated by the more precise application of β-adrenergic agonists.
[0047] To this end, in one of its aspects, the invention provides a method for identifying livestock animal subgroups of the same species, from a group of livestock animals of the same species wherein the subgroup has similar genetic predispositions for response to Zilpaterol Hydrochloride (ZH) treatment with respect to marbling, HCW gain, REA size gain, DDMI, % EBF, and YG's comprising: (a) determining genetic potential of each animal to respond to ZH treatment by determining the LeptinArg25Cys genotype; and (b) segregating individual animals into subgroups based upon the LeptinArg25Cys genotype.
[0048] In yet another of its aspects, the invention provides a method of producing subgroups of animals based on their Leptin R25C genotype in order to optimize ZH treatment, whereby genotype subgroups either receive ZH treatment—or either no ZH treatment or RH treatment; to capitalize on the known LeptinArg25Cys genotype interactions with ZH treatment for the phenotypes of marbling score, stamped Quality Grades, REA size gain, HCW gain, DDMI (daily dry matter intake), and % EBF.
[0049] A further aspect of the invention includes a method of producing subgroups of animals based on their Leptin R25C genotype in order to optimize ZH treatment, whereby genotype subgroups either receive ZH treatment—or either no ZH treatment or RH treatment; to capitalize on the known LeptinArg25Cys genotype interactions with ZH treatment for the phenotypes of marbling score, stamped Quality Grades, REA size gain, HCW gain, DDMI (daily dry matter intake), and % EBF.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] FIG. 1 is a schematic depiction of the trial design.
[0051] FIG. 2 illustrates the main effect of leptin genotype on carcass backfat level.
[0052] FIG. 3 illustrates backfat deposition rates by genotype (no Zilpaterol).
[0053] FIG. 4 visually describes the interaction between leptin genotype and ZH administration on USDA stamped quality grades Choice & Prime (Choice+Prime % by Zilpaterol and Leptin Genotype).
[0054] FIG. 5 visually describes the interaction between leptin genotype and ZH administration on marbling score (Marbling Score by Zilpaterol and Leptin Genotype (Small 0=400)).
[0055] FIG. 6 visually describes the interaction between leptin genotype and ZH administration on HCW gain (HCW Gain (lb): Genotype×Zilpaterol Tendency).
[0056] FIG. 7 visually describes the interaction between leptin genotype and ZH administration on daily dry matter intake during the 24 days preceding slaughter (21 days ZH administration+three days withdrawal)(Zilmax Feeding Period DMI, lb (last 24 days on feed): Genotype×Zilpaterol).
[0057] FIG. 8 illustrates the effect leptin genotype has on daily dry matter intake (DDMI) in the absence of any β-AA's.
[0058] FIG. 9 visually describes the interaction between leptin genotype and ZH administration on REA size gain (Rib Eye Area (in 2 ): Genotype×Zilpaterol Tendency).
[0059] FIG. 10 visually describes the interaction between leptin genotype and ZH administration on % empty body fat (% EBF).
[0060] FIG. 11 illustrates leptin genotype and % EBF on and off ZH.
DETAILED DESCRIPTION
[0061] In a trial completed at a private research facility in Texas, USA (Cactus Research, Amarillo Tex.) leptin genotype was assessed for potential interaction with Zilpaterol Hydrochloride (ZH). The trial consisted of 4,279 animals and occurred from summer of 2008 and carried through to spring of 2009. The trial was conducted as a randomized complete block design with approximately 90 animals being placed into pens based on leptin genotype and randomly assigned to drug treatment with pen being the experimental unit. Treatment structure was a 3×2 factorial including three letting genotypes (CC, CT and TT) and two drug treatments (zero control and drug treatment). Pens were blocked by time, specifically arrival date of the animal to the feedlot. Each block was slaughtered on the same day, and the complete process replicated eight times resulting in eight blocks. Below is a schematic summary of the trial design.
[0062] Upon arrival into the feedlot animals were individually weighed and back fat was measured using ultrasound. These measured were also taken 65, days on feed, and then one week prior to ZH treatment and 2-3 days prior to slaughter. All cattle were slaughtered and USDA carcass data were measured. Growth data were fitted to a non-linear growth model.
[0063] FIG. 1 illustrates a schematic summary of the trial design.
[0000] Backfat was measure by ultrasound at:
1) Arrival 2) 65 days on feed 3) 1 week prior to zilpaterol initiation 4) 2-3 days prior to slaughter
8 total blocks, 6 treatment pens per block, and 4,179 head total (avg initial wt=875 lbs) Within blocks, all treatments were killed on the same day (avg days on feed=129
[0068] Results:
[0069] Leptin genotype did affect some response variables independent of ZH administration. For some response variables though, response to ZH administration was dependent upon leptin genotype and interactions were observed.
Main Effect of Leptin Genotype on Carcass Back Observed:
[0070]
[0000]
TABLE 1
Carcass Backfat Depth (Leptin Main Effect Overall P = 0.01)
CC = 11.9 mm (0.47″)
CT = 12.2 mm (0.48″)
TT = 12.7 mm (0.50″)
Main Effect Final Ultrasound Backfat Observed:
[0071]
[0000]
TABLE 2
Ultrasound Backfat Depth two days prior to slaughter
(Leptin Main Effect Overall P < 0.01)
CC = 11.2 mm (0.44″)
CT = 11.4 mm (0.45″)
TT = 11.7 mm (0.46″)
Main Effect of Leptin Genotype Backfat Gain Observed:
[0072]
[0000]
TABLE 3
Overall Ultrasound Backfat Gain
(Leptin Main Effect Overall P = 0.03)
CC = 7.63 mm (0.30″)
CT = 7.88 mm (0.31″)
TT = 8.11 mm (0.32″)
Main Effect of Leptin Genotype—Rate of Fat Deposition Observed:
[0073]
[0000]
TABLE 4
Overall Rate of Ultrasound Backfat Deposition
(Leptin Main Effect Overall P = 0.11)
CC = 0.0073 mm/d (0.0002874″/d)
CT = 0.0075 mm/d (0.0002952″/d)
TT = 0.0077 mm/d (0.0003031″/d)
[0074] FIG. 2 illustrates the rates of backfat accretion by genotype (control only).
Main Effect of Leptin Genotype on USDA YG 4
[0075]
[0000]
TABLE 5
YG 4 Frequency (Leptin Main Effect Overall P = 0.015)
CC = 2.7%
CT = 3.0%
TT = 5.3%
Main Effect of Leptin Genotype on USDA YG 1
[0076]
[0000]
TABLE 6
YG 1 Frequency (Leptin Main Effect Overall P < 0.01)
CC = 26.4%
CT = 18.7%
TT = 17.7%
Interactions
[0077] FIG. 4 illustrates the interaction between leptin genotype and ZH on USDA stamped quality grades Choice+Prime.
[0078] ZH administration significantly interacted with leptin genotype (P<0.01). As measured by USDA stamped quality grade categories, Choice+Prime, TT animals had the highest % Choice+Prime, CT animals were intermediate and CC animals had the lowest Choice+Prime without ZH administration. In animals administered ZH, CC were unaffected with respect to % Choice+Prime but TT and CT animals had significant reductions in % Choice+Prime. See FIG. 4 .
[0079] FIG. 5 illustrates the interaction between leptin genotype and ZH on marbling score.
[0080] ZH administration significantly interacted with leptin genotype (P<0.02) as measured by marbling score. CC's administered ZH had only a slight reduction in marbling score where as TT's and CT's administered ZH had a much greater reduction in marbling score. See FIG. 5 .
[0081] FIG. 6 . Interaction between leptin genotype and ZH on HCW gain.
[0082] ZH administration has a statistical tendency to interact with leptin genotype (P=0.14) with respect to hot carcass weight gain. Response to ZH administration varied by genotype with the TT's having the lowest response to ZH administration. CC's and CT's have the largest response to ZH administration. There is a 3.4 kg (7.4 lb) HCW response difference between CC and TT animals (P<0.10). See FIG. 6 .
[0083] FIG. 7 illustrates the interaction between leptin genotype and ZH on daily dry matter intake (DDMI).
[0084] ZH administration has a statistically significant interaction with leptin genotype (P=0.01) with respect to daily dry matter intake (DDMI). In the absence of ZH administration, TT's had the highest DDMI, CC's had the lowest DDMI and the CT's consumed the intermediate amount ( FIG. 8 ). When the TT's were administered ZH they had the lowest DDMI as compared to the CC's which had the highest DDMI. Again the CT's had an intermediate amount and had a DDMI lower than the CC animals. In summary, the CC animals had no change in DDMI during ZH treatment, but CT & TT animals had a significant reduction in DDMI during ZH treatment. See FIG. 7 .
[0085] FIG. 8 illustrates the effect of leptin genotype on feed intake (DDMI).
[0086] Leptin genotype significantly impacted daily dry matter intake ( FIG. 8 ). Specifically total DDMI was assessed for the complete feeding period, and the final 24 days of the feeding period. This assessment did not consider animals fed ZH or any interactions. Therefore, it only considered animals not fed β-AA's. TT animals have a significant increase in DDMI over the complete feeding period and the final 24 days on feed time period in comparison to CT and CC animals, respectively.
[0087] FIG. 9 illustrates the interaction between leptin genotype and ZH on size of rib eye area (REA) gain.
[0088] ZH administration has a statistical tendency to interact with leptin genotype (P=0.118) with respect to rib eye area (in 2 ). Response to ZH administration varied by genotype with the CC's having the lowest response to ZH administration. TT's and CT's have the largest response to ZH administration. TT and CT animals had a gain of 1.4 square inches compared to CC's having a gain of 0.35 square cm's (0.9 square inches). See FIG. 9 .
[0089] FIG. 10 illustrates the interaction between leptin genotype and ZH on % empty body fat (% EBF).
[0090] ZH administration tends to interact with leptin genotype (P=0.09) with respect to % EBF. Response to ZH administration varied by genotype with the CC's having the lowest response to ZH administration. TT's and CT's have the largest response to ZH administration. TT and CT animals respectively had the largest reductions in % EBF, with the TT animals having the largest reduction in % EBF. Since % EBF is a mathematical formula (23), which relies on the amount of marbling (quality grade), it is understood that the % EBF is in part a function of the marbling interaction between leptin genotype and ZH. As TT animals have the largest reduction in marbling when fed ZH it is no surprise that TT animals have the largest in % EBF when fed ZH. Concurrently, since CC animals experience no reduction in marbling when fed ZH it is very supportive that they too experience the smallest reduction in % EBF when fed ZH. See FIG. 11 .
[0091] What was observed and discovered out of the trial work described herein is that mass application of Zilmax® and Optaflexx® is not necessary and does not yield optimal results. This is due the several interactions observed between leptin genotype and the β-AA's. These interactions teach that selective application of these growth promoting agents based on leptin genotype can yield results not obtained when the β-AA's are mass applied to pens of cattle.
[0092] Specifically, application of Zilmax® to CC genotype animals yields the most optimal results for this genotype. This is due to the larger than “label” or expected response in HCW, and small or no reduction in marbling and quality grade (USDA Choice or better). Marbling is an important attribute in carcass composition, and is commonly factored into how an animals' value is determined. Therefore, reaching a threshold amount of marbling is important to producers, and any factor that reduces the amount of marbling is a negative factor for producers; such as mass application of Zilmax®. In addition, REA size is optimal when it is kept to a size such that an acceptable portion size can be obtained, which in practice means that as the REA continues to get larger it is detrimental. Therefore, as Zilmax® is known to increase REA size, feeding Zilmax® to CC's can limit the downside in this area. Also, the detrimental effect of Zilmax® on % EBF is limited when fed to CC animals. And, importantly, no reduction in DDMI is observed when Zilmax® is fed to CC animals, which is contributing to the increased HCW observed in CC animals.
[0093] Conversely, when observing the TT animals fed Zilmax® it is clear that there are specific detrimental effects on important phenotypes. DDMI is reduced in TT animals fed Zilmax® in comparison to CT & CC animals, respectively, which is a contributor to the reduction in marbling and quality grades (USDA Choice or better). The reduction in DDMI in TT animals is detrimental to the economics of the animal as it increases its overall proportional maintenance cost. That is, as a proportion of the total energy available for gain, TT animals fed ZH have a smaller proportion out of their total energy intake per day than CC & CT animals. The reduction in marbling is also backed up by the fact that there is also the largest reduction in % EBF when TT animals are fed Zilmax® in comparison to CT & CC animals fed Zilmax®. Also, TT animals fed Zilmax® have the largest increase in REA size, which is detrimental to portion size acceptance. Also, importantly these same TT animals with reduced DDMI, marbling, quality grades, and increased REA size gain have a smaller than expected or label HCW gain when compared to CC & CT animals. This clearly has a negative impact on the value of feeding Zilmax® as producers are paid on the amount of HCW sold.
[0094] The process of genotyping each animal and determining their leptin genotype so that more homologous animals with respect to their leptin genotype can be grouped for selective β-AA feeding will yield improved biological results (DDMI, marbling, quality grades, HCW gain, and REA size gain), improved consumer friendly results, and improved economic results.
REFERENCES
[0000]
1. Marchant Forde, J. N., Lay J. R., D. C., Pajor, E. A., Richert, B. T., and A. P. Schinckel. The effects of ractopamine on behavior and physiology of finishing pigs. 2003. J. Anim. Sci. 81:416-422.
2. Mersmann, H. J. 1998. Overview of the effects of beta-adrenergic receptor agonists on animal growth including mechanisms of action. J. Anim. Sci. 76:160-172.
3. Johnson, B. J. and C. Y. Chung. 2007 The veterinary clinics of North America. Food animal Practice [0749-0720]. Alterations in the physiology of growth of cattle with growth enhancing components. 2007 vol:23 iss:2 pg:321-32, viii.
4. Mils, S. E. The biological basis for the Ractopamine Response, Journal of Animal Science. 2002.20:E28-E32.
5. Verhoeckx K C, Doornbos R P, van derGreef J, Witkamp R F, Rodenburg R J. 2005. Inhibitory effects of the beta-adrenergic receptor agonist zilpaterol on the LPS-induced production of TNF-alpha in vitro and in vivo. J Vet Pharm. Ther. 28(6):531-7.
6. Avendano-Reyes, L., Torres-Rodriguez, V., Meraz-Murillo, F. J., Perez-Linares, C., Figuearoa-Saavedra, F. and P. H. Robinson. 2006. Effects of two β-adrenergic agonists on finishing performance, carcass characteristics, and meat quality of feedlot steers. J. Anim. Sci. 84(12):3259-65.
7. Dalrymple, R. H., Baker, P. K., Gingher, P. E., Ingle, D. L., Pensack, J. M., and C. A. Ricks. 1984. A repartitioning agent to improve performance and carcass composition of broilers. J. Poult Sci. 63(12):2376-83.
8. Spurlock, M. E., Cusumano, J. C., Ji, S. Q., Anderson, D. B., Smith, C. K. 2nd, Hancock, D. L., and S. E. Mills. 1994. The effect of ractopamine on beta-adrenoceptor density and affinity in porcine adipose and skeletal muscle tissue. J. Anim. Sci. 72(1):75-80.
9. Houseknecht, K. L., Baile, C. A., Matteri, R. L., and M. E. Spurlock. 1998. The biology of leptin: a review. J. Anim. Sci. 76(5):1405-20.
10. Buchanan, F. C., Van Kessel, A. G., Boisclair, Y. R., Block, H. C. and J. J. McKinnon. The leptin ARg25Cys affects performance, carcass traits and serum leptin concentrations in beef. Can. J. of Anim. Sci. 87:153-156.
11. Kononoff, P. J., Deobald, H. M., Stewart, E. L., Laycock, A. D. and F. L. S. Marquess. 2005. The effect of a leptin single nucleotide polymorphism on quality grade, yield grade, and carcass weight of beef cattle. J. Anim. Sci. 83:927-932.
12. BUCHANAN, F. C., FITZSIMMONS, C. J., VAN KESSEL, A. G., THUE, T. D., WINKELMAN-SIM, D. C., and S. M. SCHMUTZ. 2002. Association of a missense mutation in the bovine leptin gene with carcassfat content and leptin mRNA levels. Genet. Sel. Evol. 34:105-116.
13. OUTER, E. 2002. Leptin Signaling, Adiposity, and Energy Balance. Annals of the New York Academy of Sciences. 967(1):379-388.
14. Ehrhardt, R. A., Slepetis, R. M., Siegal-Willott, J., Van Amburgh, M. E., Bell, A. W., and Y. R. Bosclair. 2000. Development of a specific radioimmunoassay to measure physiological changes of circulating leptin in cattle and sheep. J. Endocrinol. 166(3):519-28.
15. Zhang, F., Basinski, M. B., Beals, J. M., Briggs, S. L., Churgay, L. M., Clawson, D. K., DiMarchi, R. D., Furman, T. C., Hale, J. E., Hsiung, H. M., Schoner, B. E., Smith, D. P., Zhang, X. Y., Wery, J. P., and R. W. Schevitz. 1997. Crystal structure of the obese protein leptin-E100. Nature. May 8; 387(6629):206-9.
16. Kim, K. S., Larsen, N., Short, T., Plastow, G., and Rothschild, M. F. 2000. A missense variant of the porcine melanocortin-4 receptor (MC4R) gene is associated with fatness, growth, and feed intake traits. Mamm. Gen. 11:131-135.
17. Vasconcelos, J. T., Rathmann, R. J., Reuter, R. R., Leibovich, J., McMeniman, J. P., Hales, K. E., Covey, T. L., Miller, M. F., Nichols W. T., and M. L. Galyean. 2009. Effects of duration of zilpaterol hydrochloride feeding and days on the finishing diet on feedlot cattle performance and carcass traits. J Anim. Sci 86(8): 2005-2015.
18. Montgomery, J. L., Krehbiel, C. R., Cranston, J. J., Yates, D. A., Hutcheson, J. P., Nichols, W. T., Streeter, M. N., Bechtol, D. T., Johnson, E., TerHune, T., and T. H. Montgomery. 2009. Dietary zilpaterol hydrochloride. I. Feedlot performance and carcass traits of steers and heifers. J. Anim. Sci. 87:1374-1383.
19. Smith, S. B., D. K. Garcia, S. K. Davis, and D. B. Anderson. 1989. Elevation of a specific mRNA in longissimus muscle of steers fed ractopamine. J. Anim. Sci. 67:3495-3502.
20. Latest zilpaterol studies reviewed. 2010. K. S. Eng, J. Beckett, and J. Simpson. Feedstuffs. April 19.v82-No16.p 12.
21. Gruber, S. L., J. D. Tatum, T. E., Engle, M. A., Mitchell, S. B., Laudert, A. L., Schroeder, and W. J. Platter. 2007. Effects of ractopamine supplementation on growth performance and carcass characteristics of feedlot steers differing in biological type. J. Anim. Sci. 85:1809-1815.
22. Geary, T. W., McFadin, E. L., MacNeil, M. D., Grings, E. E., Short, R. E., Funston, R. N., and D. H. Keisler. 2003. Leptin as a predictor of carcass composition in beef cattle. J. Anim. Sci. 81:1-8.
23. Guiroy, P. J., Tedeschi, L. O., Fox, D. G., and J. P. Hutcheson. 2002. The effects of implant strategy on finished body weight of beef cattle. J. Anim. Sci. 80:1791-1800.
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A method of identifying livestock animal subgroups of the same species, from a group of livestock animals of the same species wherein the subgroup has similar genetic predispositions for response to Zilpaterol Hydrochloride (ZH) treatment with respect to marbling, HCW gain, REA size gain, DDMI, % EBF, and YG's. The genetic potential of each animal to respond to ZH treatment is established by determining the LeptinArg25Cys genotype and segregating individual animals into subgroups based upon the LeptinArg25Cys genotype.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to railings and barriers used to separate environmental areas, and more particularly to a system and method for installing railing members in residential and commercial decks, staircases, and balconies.
BACKGROUND OF THE INVENTION
[0002] Residential and commercial decks, stairs and balconies have railings to separate these structures from adjacent areas and prevent persons from falling off. The railings have top rails supported on upright posts that are attached to the decks and stairs. A number of laterally spaced upright members also typically extend between the top rails and the decks and/or stairs.
[0003] Upright post attachment for railings has been accomplished by many means. To ensure a strong connection, a carpenter/builder will typically use ½″ diameter through bolts to attach 4×4 upright wood posts to the deck rim, and the posts then support a horizontal top rail. Sometimes the builder will notch the posts to custom fit to the decking, while others will not. Some will attach the posts to the inside edge of the deck, while others secure the posts to the outside edge of the deck. Also, some builders will use a top bolt anchor method, mounting a post on top of the deck and affixing the post via multiple bolts and/or screws into the structural members of the deck material, such as the rim beams and joists. When bolts or screws penetrate in this way, it becomes very easy (for example, due to over-tightening of the penetrating bolts) to crush the wood fibers of the structural members and diminish the strength of the connection. Over time, collection of water and erosion within the bolt holes can lead to premature structural failure, including splintering, mold growth and rotting.
[0004] In addition to the use of through bolts, there are a number of patented devices which use a system of mounting brackets, plates, hollow tubes and/or mounting sleeves for securing posts to mounting surfaces. Such systems can have drawbacks, such as difficulty in installation of multiple bolts, plates and brackets. All of these systems puncture a deck's structural components in one fashion or another. Also, these bracket systems can become loose and unstable over time.
[0005] Accordingly, there is a need for an upright rail post anchoring system and method for use on a diversity of mounting surfaces which can provide superior structural rigidity and strength and strong securing capacity without creating holes in the substance of the deck material or its supporting members, so that there is no rotting, splintering or other type of erosion over time, and which utilizes an uncomplicated design that is easy to manufacture and install in both new and retrofit applications.
SUMMARY OF THE INVENTION
[0006] The present invention provides a rail post attachment system and method that eliminates the need for penetrating the structural members of the deck material. The system typically includes a securing member which fastens an upright post or railing member against a deck or floor rim beam. Specifically, the securing member can be a large, square clench bolt, a clench strap (either formed or welded), or clench brackets, as described herein. The inventive system and method can be used to install railings for decks, staircases and/or balconies, and can be used on structures made of wood, fiber, steel, concrete or other synthetic composite materials.
[0007] A first aspect of the invention provides a system, in a railing for a deck, stairway or balcony, comprising: (a) an anchored horizontal rim beam; (b) a plurality of railing members; and (b) a plurality of securing members for fastening the plurality of railing members in an upright and perpendicular orientation against the horizontal rim beam, wherein each one of the securing members is fitted about the rim beam and fastened to one of the plurality of railing members, thereby securing the railing member against the rim beam. Typically each railing member is laterally spaced along the length of the rim beam a predetermined distance from the preceding railing member.
[0008] A second aspect of the invention provides a railing for a deck, stairway or balcony, comprising: (a) a plurality of laterally spaced railing members; (b) an anchored horizontal rim beam; and (c) a plurality of securing members for attaching the plurality of railing members against the rim beam in general vertical alignment with the rim beam.
[0009] A third aspect of the invention provides a method of constructing a railing system, comprising the steps of: (a) providing a plurality of securing members and a plurality of railing members for fastening to an anchored horizontal rim beam; (b) aligning a first railing member of the plurality of railing members in a vertical position with the horizontal rim beam; (c) fitting a first securing member about the rim beam; (d) connecting the first securing member against the first railing member; (e) securing the rim beam against the first railing member by tightening the connection between the first securing member and the first railing member; and (f) repeating steps (b) through (e) with subsequent securing members and railing members, each railing member being laterally spaced along the length of the rim beam a predetermined distance from the preceding railing member.
[0010] These and further objects, features, advantages and characteristics of the system and method of the present invention will be more fully appreciated upon viewing the following drawings, detailed description of the preferred embodiments, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the principles of the invention.
[0012] FIG. 1 is a perspective view as seen from the inside of a deck constructed with one embodiment of a railing system of the present invention.
[0013] FIG. 2 is a side view of one embodiment of a square clench bolt used as a securing member in the present invention.
[0014] FIG. 3 is a perspective view showing embodiments of the securing members of the invention, including a formed clench strap, clench brackets, a welded clench strap, and a square clench bolt.
[0015] FIG. 4A is a perspective view of one embodiment of a formed clench strap used as a securing member in the present invention.
[0016] FIG. 4B is a perspective view of one embodiment of clench brackets used as a securing member in the present invention.
[0017] FIG. 4C is a perspective view of one embodiment of a welded clench strap used as a securing member in the present invention.
[0018] FIG. 5 is a perspective view as seen from the outside of a deck showing various embodiments of a securing member of the invention, including the formed clench strap, clench brackets, welded clench strap, and square clench bolt.
DETAILED DESCRIPTION OF THE INVENTION
[0019] As defined herein, the term “railing member” is a vertically-oriented post, baluster, support, column, spindle, picket, rod, bar, pole, stake, shaft, pillar, beam or the like, which forms and supports a railing section of a deck, stairway, balcony, parapet or the like. In a preferred embodiment, the railing member is a supportive post for a top rail or railing cap of a railing section, and is typically located at the corners of a deck and at regular intervals in between. A railing member can be made of materials such as wood, stone, steel, concrete, iron, plaster, polyurethane, or other polymeric materials.
[0020] The terms “rim beam,” “perimeter joist” or “rim joist” mean a horizontally-oriented beam, truss or joist which railing members can be secured to. The rim beam is typically anchored to the joist ends of a deck, stairway, or balcony. As a non-limiting example, the floor joists of a deck provide support for the flat decking boards (usually 16 inches on center), and the “rim beam,” “perimeter joist” or “rim joist” as defined herein can be attached to the ends of the floor joists, typically on the sides of the deck situated away from the house or fixed structure.
[0021] The present invention is a railing system and method of constructing such, including a plurality of upright railing members or posts in combination with a plurality of securing members. FIG. 1 illustrates a perspective view of the main elements of a deck 10 constructed using the system and method of the present invention, as viewed from inside the deck. The main decking, including the framing joists 12 , the deck flooring 14 and the rim beam 16 (also known as a rim joist or perimeter joist) are typically installed first (or have been previously installed, e.g. in retrofit applications), prior to the railing system installment. Each railing member 18 is vertically mounted against the structure of the rim beam 16 by a plurality of securing members 20 , which fasten together the plurality of railing members 18 in an upright and perpendicular orientation against the horizontal rim beam 16 . As illustrated, each railing member 18 is typically laterally spaced along the length of the rim beam 16 a predetermined distance from the preceding railing member.
[0022] In the embodiment shown in FIG. 1 , the railing members 18 are steel angle posts, typically 2.5 inches×2.5 inches× 3/16 inches, with pre-drilled holes for fitting stainless steel wire rope 22 therethrough. A top railing cap 24 is attached by a bolt or screw 25 onto the top portion of each post 18 , with the wire rope 22 strewn horizontally through holes in the steel angle posts 18 between the cap 24 and the deck flooring 14 . The wires 22 are equally horizontally spaced to meet local codes (typically 10 rows), and the railing cap 24 is typically 2 inches×3 inches× 3/16 inch steel, bolted to each steel angle post 18 . The railing members 18 can vary in height, but should at least be tall enough to meet local codes, and are typically between 30 inches and 45 inches above the deck surface. Other building methods besides horizontally strewn wire rope can be used between the main vertical posts as well, in order to meet local building codes. These include any type of vertical railing member as defined herein, and can be made of materials such as wood, glass, Plexiglas, wire mesh, or other panel material.
[0023] In FIG. 2 the securing member is a square clench bolt 26 , which is a cylindrical threaded fastener with square shoulders that is affixed about the rim beam 16 and fastened to the railing member 18 . The clench bolt 26 , like all of the securing members disclosed herein, thus fastens the railing member 18 against the outside vertical face of the horizontal rim beam 16 without creating holes in the substance of the rim beam, deck material or its supporting members. As illustrated, the square clench bolt 26 includes two externally threaded legs 27 a , 27 b , for passing through the railing member 18 , a shoulder portion 27 c between each of the legs for fitting about the inside vertical face of the rim beam 16 , and two internally threaded nuts 28 a , 28 b , for screwing on to the threaded legs 27 a , 27 b . Once the shoulder portion 27 c of the clench bolt is placed about the inside vertical face of the horizontal rim beam 16 , the nuts 28 a , 28 b are screwed onto the legs. Tightening of the nuts 28 a , 28 b above and below (respectively) the rim beam 16 causes the railing member 18 to be fastened against the outside vertical face of the rim beam 16 , with no penetration of any bolts or creation of holes in the substance of the rim beam.
[0024] The size and type of securing member chosen can depend on the size and dimensions of the rim beam 16 . The inside dimensions of a clench bolt 26 , as shown in FIG. 2 , installed at the end of the deck flooring 14 , has a vertical height ‘H’ of between 5.0 inches and 14.0 inches between leg portions 27 a , 27 b , and leg portion lengths of between 3.0 inches and 13.0 inches. Also, the legs 27 a , 27 b and shoulder portion 27 c of the bolt 26 have a diameter between 0.5 inches and 1.0 inches. The legs 27 a , 27 b include a threaded portion for receiving and mating with a corresponding threaded nut 28 a , 28 b . Typically a perimeter joist or rim beam 16 around which the bolt 26 fits is between 0.5 inches and 8.0 inches wide/thick, more typically between 1.5 inches and 3.0 inches wide, and is typically made of wood or steel, but can also be any synthetic structural material on the market.
[0025] As a non-limiting example, the shoulder portion 27 c of the square clench bolt 26 as shown in FIG. 2 has a height ‘H’ of 7.25 inches, the legs 27 a , 27 b have a length/width ‘L’ of 6.0 inches, and the thickness is 0.5 inches in diameter. The clench bolt 26 is fitted around a (previously installed/anchored) 1.5 inch rim beam 16 , and the legs 27 a , 27 b pass through and are bolted to a 4×4 inch wooden post 18 . Fastening of the clench bolt 26 to the post 18 after fitting the shoulders of the bolt 26 about the rim beam 16 creates a sturdy and secure connection without creating any holes in or otherwise penetrating the rim beam itself.
[0026] In addition to the square clench bolt 26 of FIG. 2 , FIG. 3 illustrates various other embodiments of a securing member, namely a formed clench strap 30 , a pair of clench brackets 32 , or a welded clench strap 34 . The formed clench strap 30 is similar to the square clench bolt 26 , but the shoulder and leg portions are typically flat instead of cylindrical, and the legs include foot portions with a hole therethrough for passing a bolt. The flat shoulder portion of the clench strap 30 can thus fit snugly with the rim beam 16 . The clench brackets 32 are similar to the clench strap 30 , but is a two-piece apparatus having two separated shoulder/leg portions that can be spaced apart to accommodate any size rim beam (i.e. a horizontal rim beam of any vertical height).
[0027] The welded clench strap 34 of FIG. 3 is typically used in conjunction with a steel angle post 18 (or other steel type post) as the railing member 18 , and includes a single leg 35 that is welded to the post 18 , while opposite the single leg 35 (at the lower end of the railing member 18 ) a threaded bolt and nut combination is included for passing through holes at the lower end of the shoulder portion and the post 18 , thereby securing/fastening/clenching the post member 18 against the rim beam 16 . It can be appreciated that the single leg 35 of the clench strap 34 , which is welded to the post 18 , must be substantially the same length as the thickness of the rim beam 16 to ensure a snug fit. This is better visualized in FIG. 4C . Also, from viewing FIG. 3 (better shown in FIGS. 4A and 4B ) it can be appreciated that both the formed clench strap 30 and the clench brackets 32 include legs with foot portions having holes that receive bolts therethrough, and two nuts for screwing on to the bolts, thereby securing the railing member 18 against the rim beam 16 .
[0028] In practice, the rim beam 16 is seated within the shoulder portion(s) prior to passing the bolts through the holes of the legs, which is then followed by passing the bolts through the railing member 18 . Typically the railing member 18 (e.g. a steel type post) will have pre-manufactured holes that can line up with the hole(s) of the securing member. However, holes can also be drilled through the railing member, if not already present. The nuts 43 a , 43 b are then screwed on to their corresponding bolts 42 a , 42 b and tightened, thereby securing the railing member 18 against the rim beam 16 . This is illustrated in better detail in FIGS. 4A-4C .
[0029] FIGS. 4A-4C illustrate the formed clench strap, clench brackets, and welded clench strap embodiments of the securing member of the present invention. The formed clench strap 30 of FIG. 4A includes two leg portions 40 a , 40 b , each leg having a foot portion 44 a , 44 b with holes 41 a , 41 b therethrough for passing externally threaded bolts 42 a , 42 b through both the corresponding foot portion 44 a , 44 b and the railing member 18 . A shoulder portion 40 c is placed around the rim beam 16 . The strap 30 is placed around the rim beam 16 so that the rim beam is seated within the shoulder portion 40 c and between the leg portions 40 a , 40 b prior to passing the bolts 42 a , 42 b through the holes 41 a , 41 b of the foot portions and then through the railing member 18 . Two internally threaded nuts 43 a , 43 b are then screwed on to their corresponding bolts 42 a , 42 b and tightened, fastening the railing member 18 against the rim beam 16 . The shoulder portion 40 c of the formed clench strap 30 can have a height of between 5.0 inches and 14.0 inches between leg portions 40 a , 40 b , and leg portion lengths of between 0.5 inches and 8 inches. Bolts 42 a , 42 b are typically between 2 inches and 8 inches long, in order to pass through the railing member 18 .
[0030] The clench brackets 32 of FIG. 4B are a two-piece apparatus having two separate shoulder/leg portions 50 a , 50 b , each of which include a foot portion 54 a , 54 b having a hole, 51 a and 51 b respectively, for passing threaded bolts 52 a , 52 b through the corresponding foot portion and railing member 18 . Two internally threaded nuts 53 a , 53 b screw on to the externally threaded bolts 52 a , 52 b and tighten each of the shoulder/leg portions 50 a , 50 b to the railing member 18 . The brackets 32 are placed about the rim beam 16 so that the rim beam is seated between the shoulder/leg portions 50 a , 50 b , with the shoulders of each shoulder/leg portion fitting around the edge of the rim beam 16 , prior to passing the bolts through the holes 51 a , 51 b and railing member 18 and tightening the nuts 53 a , 53 b . As noted above, the separate shoulder/leg portions 50 a , 50 b can be spaced apart to accommodate the vertical height of any size rim beam. Leg lengths and bolt sizes can be the same as disclosed above for the formed clench strap 30 .
[0031] The welded clench strap 34 of FIG. 4C includes a single leg 35 that is welded to a steel railing member 18 , and a hole 61 through the lower end of the shoulder portion 60 opposite the single leg 35 . A threaded bolt 62 and nut 63 combination is used for tightening the shoulder portion 60 to the railing member 18 after being fitted about the rim beam 16 . This nut and bolt combination (with complimentary female and male threads) fastens the post 18 against the rim beam 16 . As noted above, it can be appreciated that the single leg 35 of the clench strap 34 , which is welded to the post 18 , must be substantially the same length as the width/thickness of the rim beam 16 , which as noted above is typically between 0.5 inches and 8 inches thick, and more typically 1.5 inches and 3.0 inches thick. Also, the welded clench strap 34 is typically used in conjunction with a steel type post as the railing member 18 , as it can be easily welded thereto prior to use.
[0032] FIG. 5 illustrates a perspective view of a deck 10 constructed using the system and method of the present invention, as viewed from outside the deck. This view shows how the connections created by the various embodiments of the securing member of the present invention will look from outside the deck. It can be appreciate that the square clench bolt 26 , the formed clench strap 30 , the clench brackets 32 , and the welded clench strap 34 are all through-bolted (via a threaded bolt and nut combination) just above and below the structural rim beam member 16 , without any penetration of the rim beam 16 . Also, the welded clench strap 34 is through-bolted just below the rim beam 16 , with the top portion being welded on the opposite side to a steel type post 18 (see also FIGS. 3 and 4C ). Thus, while the clench means of the present invention are primarily functional, for securing railing members against the rim beam of a deck without penetrating the structural members of the deck with bolts or nails, they also make the structure aesthetically pleasing to the viewer.
[0033] While the present invention has been illustrated by the description of embodiments and examples thereof, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will be readily apparent to those skilled in the art. Accordingly, departures may be made from such details without departing from the scope of the invention.
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A system and method of fastening a railing member against an anchored horizontal rim beam of a deck, stairway or balcony. The system typically includes a series of upright railing members in combination with a plurality of securing members. The securing member can be a clench bolt, a clench strap (formed or welded), or clench brackets. The securing member is able to secure and/or fasten the railing member and the rim beam together without creating holes in the substance of the rim beam or other deck material, so that rotting, splintering or other type of erosion of the deck material over time is minimized. The railing attachment system and method can be used on wood, fiber, synthetic, steel or concrete decks, for either newly constructed or repair of pre-existing decks, balconies or stairways.
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BACKGROUND OF THE INVENTION
The present invention relates generally to gas turbine engines, and more particularly to internally cooled airfoils used in such engines.
Gas turbine engines, such as aircraft jet engines, include many components (e.g., turbines, compressors, fans and the like) that utilize airfoils. Turbine airfoils, such as turbine blades and nozzle vanes, which are exposed to the highest operating temperatures, typically employ internal cooling to keep the airfoil temperatures within certain design limits. A turbine rotor blade, for example, has a shank portion that is attached to a rotating turbine rotor disk and an airfoil blade portion which is employed to extract useful work from the hot gases exiting the engine's combustor. The airfoil is attached to the shank and includes a blade tip that is the free end of the airfoil blade. Typically, the airfoil of the turbine rotor blade is cooled by air (normally bled from the engine's compressor) passing through an internal circuit, with the air entering the airfoil through the shank and exiting through airfoil tip holes, airfoil film cooling holes and blade trailing edge slots or holes. Known turbine blade cooling circuits include a plurality of radially-oriented passageways that are series-connected to produce a serpentine flow path, thereby increasing cooling effectiveness by extending the length of the coolant flow path. It is also known to provide additional, unconnected passageways adjacent to the serpentine cooling circuit.
Turbine rotor blades with internal cooling circuits are typically manufactured using an investment casting process commonly referred to as the lost wax process. This process comprises enveloping a ceramic core defining the internal cooling circuit in wax shaped to the desired configuration of the turbine blade. The wax assembly is then repeatedly dipped into a liquid ceramic solution such that a hard ceramic shell is formed thereon. Next, the wax is melted out of the shell so that the remaining mold consists of the internal ceramic core, the external ceramic shell and the space therebetween, previously filled with wax. The empty space is then filled with molten metal. After the metal cools and solidifies, the external shell is broken and removed, exposing the metal that has taken the shape of the void created by the removal of the wax. The internal ceramic core is dissolved via a leaching process. The metal component now has the desired shape of the turbine blade with the internal cooling circuit.
In casting turbine blades with serpentine cooling circuits, the internal ceramic core is formed as a serpentine element having a number of long, thin branches. This presents the challenge of making the core sturdy enough to survive the pouring of the metal while maintaining the stringent requirements for positioning the core. Furthermore, the thin branches of the serpentine core can experience relative movement if not stabilized in some manner. Thus, core ties (i.e., small ceramic connectors between various branches) are used to strengthen the core. This prevents relative movement of the core branches such that the airfoil external wall thicknesses are controlled better. After casting, when they have been removed along with the core, the core ties leave holes in the ribs or walls separating adjacent passageways. These core tie holes provide unwanted flow communication between adjacent passageways if a pressure differential exists between the two passageways. That is, cooling fluid in the higher pressure passageway will flow into the lower pressure passageway through the core tie hole. This will result in an undesirable cooling flow distribution compared to the original design intent.
Accordingly, there is a need for an airfoil component in which cooling fluid flow through core tie holes is minimized.
SUMMARY OF THE INVENTION
The above-mentioned needs are met by the present invention which provides an airfoil component comprising at least two internal cooling passageways separated by a rib having a core tie hole formed therein. A means for metering flow through the inlet passage of one of the passageways is provided so that the pressures in the two passageways are substantially equal. This reduces the flow of cooling fluid through the core tie hole.
Other objects and advantages of the present invention will become apparent upon reading the following detailed description and the appended claims with reference to the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding part of the specification. The invention, however, may be best understood by reference to the following description taken in conjunction with the accompanying drawing figures in which:
FIG. 1 is a longitudinal cross-sectional view of a prior art turbine blade.
FIG. 2 is a longitudinal cross-sectional view of a turbine blade in accordance with a first embodiment of the present invention.
FIG. 3 is a longitudinal cross-sectional view of a turbine blade in accordance with a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings wherein identical reference numerals denote the same elements throughout the various views, FIG. 1 shows a prior art gas turbine engine rotor blade 10 having a hollow airfoil 12 and an integral shank 14 for mounting the airfoil 12 to a rotor disk (not shown) in a conventionally known manner. The airfoil 12 extends longitudinally or radially upwardly from a blade platform 16 disposed at the top of the shank 14 to a blade tip 18 . The airfoil 12 includes an internal serpentine cooling circuit having five series-connected, generally radially extending cooling passageways 20 - 24 .
The first passageway 20 receives a cooling fluid (usually a portion of relatively cool compressed air bled from the compressor (not shown) of the gas turbine engine) through a first inlet passage 46 in the shank 14 . The cooling fluid travels radially outwardly through the first passageway 20 , passes into the second passageway 21 and then flows radially inwardly through the second passageway 21 . From there, the cooling fluid similarly passes in series through the other passageways 22 - 24 , thereby cooling the airfoil 12 from the heating effect of the combustion gases flowing over the outer surfaces thereof. As is known, the cooling fluid exits the airfoil 12 through film cooling holes (not shown) and an opening 26 in the blade tip 18 .
The airfoil 12 includes a leading edge cooling passageway 28 in addition to the serpentine cooling circuit. The leading edge passageway 28 extends radially between the airfoil leading edge 30 and the first passageway 20 and is not connected to the serpentine cooling circuit. A separate flow of cooling fluid is introduced through a second inlet passage 48 in the shank 14 . The cooling fluid flows radially through the leading edge passageway 28 and is discharged from the airfoil 12 through conventional film cooling holes and/or a tip hole (not shown) formed through the exterior wall of the airfoil 12 . Similarly, a radially extending trailing edge cooling passageway 32 is disposed between the airfoil trailing edge 34 and the fifth passageway 24 of the serpentine cooling circuit. The trailing edge passageway 32 is also not connected to the serpentine cooling circuit and receives another separate flow of cooling fluid through a third inlet passage 50 in the shank 14 . This cooling fluid flows radially through the trailing edge passageway 32 and is discharged from the airfoil 12 through a conventional row of trailing edge film holes or slots and/or a tip hole (not shown). The arrows in FIG. 1 indicate the various paths of cooling fluid flow.
As seen in FIG. 1, each one of the passageways 20 - 24 , 28 , 32 is separated from adjacent passageways by six radially extending ribs 36 - 41 . That is, the leading edge passageway 28 and the first passageway 20 of the serpentine cooling circuit are separated by a first rib 36 , the first passageway 20 and the second passageway 21 are separated by a second rib 37 , and so on. At least some of the ribs 36 - 41 have a core tie hole 42 formed therein due to the use of core ties in the casting process. Specifically, the prior art blade 10 of FIG. 1 has core tie holes 42 formed in the first rib 36 , the third rib 38 , the fifth rib 40 and the sixth rib 41 , although other configurations are possible depending on how the core ties are deployed during the casting process. Core tie holes, which are often elliptical in cross-section, typically have an equivalent diameter of about 0.03-0.1 inches.
The cooling fluid, which is typically air bled from the compressor, is supplied to each of the three inlet passages 46 , 48 , 50 at the same pressure. However, the cooling fluid pressure in the passageways 20 - 24 tends to decrease along the serpentine flow path due to friction and turning losses in the five pass serpentine circuit. The first passageway 20 , the leading edge passageway 28 and the trailing edge passageway 32 , which are all directly connected to a corresponding one of the inlet passages 46 , 48 , 50 , all have substantially the same pressure, but the pressure in the fifth passageway 24 , the last pass of the serpentine circuit, will be substantially less. Accordingly, there is a pressure differential between the fifth passageway 24 and the adjacent trailing edge passageway 32 , which is a single pass circuit not subject to the same pressure loss as the five pass serpentine circuit. Because of this pressure differential, cooling fluid will pass from the trailing edge passageway 32 to the fifth passageway 24 through the core tie hole 42 in the sixth rib 41 , starving the tip region of the trailing edge passageway 32 of cooling fluid.
Referring now to FIG. 2, a turbine blade 110 is shown in which cooling fluid flow through core tie holes is minimized. For purposes of illustration only, the blade 110 has the same cooling circuit configuration as the blade 10 of FIG. 1 . However, it should be noted that the present invention is applicable to turbine blades having other cooling circuit configurations. Furthermore, the present invention is not limited to turbine blades and could be used with other types of airfoil components such as turbine nozzles. As will become apparent from the following description, the present invention is applicable to any airfoil component having individually fed cooling passageways that are short-circuited by core tie holes.
The blade 110 has a hollow airfoil 112 and an integral shank 114 . The airfoil 112 includes a serpentine cooling circuit having five series-connected, generally radially extending cooling passageways 120 - 124 , a leading edge cooling passageway 128 extending radially between airfoil leading edge 130 and the first passageway 120 , and a radially extending trailing edge cooling passageway 132 disposed between airfoil trailing edge 134 and the fifth passageway 124 . The first passageway 120 is supplied with cooling fluid through a first inlet passage 146 in the shank 114 , the leading edge passageway 128 is supplied with cooling fluid through a second inlet passage 148 in the shank 114 , and the trailing edge passageway 132 is supplied with cooling fluid through a third inlet passage 150 . Each one of the passageways 120 - 124 , 128 , 132 is separated from adjacent passageways by six radially extending ribs 136 - 141 . A core tie hole 142 is formed in the first rib 136 , the third rib 138 , the fifth rib 140 and the sixth rib 141 , although other configurations are possible depending on how the core ties are deployed during the casting process.
The blade 110 includes a root metering plate 152 disposed on the radially inner surface of the shank 114 so as to completely cover the third inlet passage 150 . The metering plate 152 is a thin plate of any suitable material attached to the shank 114 by an appropriate means such as brazing. A metering hole 154 is formed in the metering plate 152 to allow a metered flow of cooling fluid to pass into the third inlet passage 150 . The cross-sectional area of the metering hole 154 is smaller than the cross-sectional area of the third inlet passage 150 . Thus, the metering hole 154 presents a restriction at the entrance of the third inlet passage 150 that causes a pressure drop such that the pressure in the trailing edge passageway 132 is less than what it would be without the metering plate 152 .
The size of the metering hole 154 is selected to meter the cooling fluid flow through the third inlet passage 150 such that the pressure in the trailing edge passageway 132 is substantially equal to the pressure in the fifth passageway 124 , thereby minimizing the pressure differential across the core tie hole 142 in the sixth rib 141 . The specific size of the metering hole l 54 to achieve this result will be dependent on the overall cooling fluid flow level and the pressure differential that would exist between the trailing edge passageway 132 and the fifth passageway 124 without the metering plate 152 . By minimizing the pressure differential across the core tie hole 142 in the sixth rib 141 , the present invention lessens the adverse impact of the core tie hole 142 on the effectiveness of the airfoil cooling scheme.
Turning to FIG. 3, an alternative embodiment of the present invention is shown in the form of a turbine blade 210 . For purposes of illustration only, the blade 210 is similar to the blade 110 of FIG. 2, although, as before, it should be noted that this alternative embodiment of the present invention is applicable to turbine blades having other cooling circuit configurations as well as other types of airfoil components.
The blade 210 is similar to the blade 110 of FIG. 2 in that it has a hollow airfoil 212 and an integral shank 214 . The airfoil 212 includes a serpentine cooling circuit having five series-connected, generally radially extending cooling passageways 220 - 224 , a leading edge cooling passageway 228 extending radially between airfoil leading edge 230 and the first passageway 220 , and a radially extending trailing edge cooling passageway 232 disposed between airfoil trailing edge 234 and the fifth passageway 224 . The first passageway 220 is supplied with cooling fluid through a first inlet passage 246 in the shank 214 , the leading edge passageway 228 is supplied with cooling fluid through a second inlet passage 248 in the shank 214 , and the trailing edge passageway 232 is supplied with cooling fluid through a third inlet passage 250 . Each one of the passageways 220 - 224 , 228 , 232 is separated from adjacent passageways by six radially extending ribs 236 - 241 . A core tie hole 242 is formed in the first rib 236 , the third rib 238 , the fifth rib 240 and the sixth rib 241 , although other configurations are possible depending on how the core ties are deployed during the casting process.
The blade 210 differs from the blade 110 of FIG. 2 in that it has no metering plate. Instead, a restriction 256 is formed in the third inlet passage 250 . Preferably, the restriction 256 is cast as an integral part of the blade 210 . The restriction 256 presents a reduced cross-sectional area so as to cause a pressure drop such that the pressure in the trailing edge passageway 232 is less than what it would be if the restriction 256 was omitted.
Like the metering hole 154 of FIG. 2, the size of the restriction 256 is selected to meter the cooling fluid flow through the third inlet passage 250 such that the pressure in the trailing edge passageway 232 is substantially equal to the pressure in the fifth passageway 224 , thereby minimizing the pressure differential across the core tie hole 242 in the sixth rib 241 . The specific size of the restriction 256 to achieve this result will be dependent on the overall cooling fluid flow level and the pressure differential that would exist between the trailing edge passageway 232 and the fifth passageway 224 without the restriction 256 . By minimizing the pressure differential across the core tie hole 242 in the sixth rib 241 , the present invention lessens the adverse impact of the core tie hole 242 on the effectiveness of the airfoil cooling scheme.
The foregoing has described a turbine airfoil component in which cooling fluid flow through a core tie hole is minimized. While specific embodiments of the present invention have been described, it will be apparent to those skilled in the art that various modifications thereto can be made without departing from the spirit and scope of the invention as defined in the appended claims.
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The flow of cooling fluid through a core tie hole formed between a pair of internal cooling passageways of an airfoil component is reduced by providing a restriction that meters coolant flow through the inlet passage of one of the passageways so that the pressures in the two passageways are equalized, thereby minimizing the flow of cooling fluid through the hole. The restriction can be a metering plate disposed at the entrance of the inlet passage or a restriction integrally formed in the inlet passage.
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BACKGROUND
1. Field of the Invention
The present invention generally relates to optical read/write devices and, more particularly, to a mechanism for driving an optical pickup head of an optical read/write device.
2. Description of Related Art
In general, an optical pickup head records or reproduces information while moving across a recording data storage medium such as a disk. The optical pickup head includes a light source for emitting laser light and an objective lens for focusing the laser light to form an optical spot on the disk. As such, the optical pickup head is able to write or read information to or from the optical disk. The optical pickup head is driven by a driving mechanism to move along a path corresponding to a radial direction of the optical disk.
A conventional driving mechanism includes a motor, a worm gear connected to a rotor of the motor, and a gear portion attached to the optical pickup head. The gear portion engages the worm gear. The motor drives the worm gear to rotate and the gear portion is moved linearly by the worm gear. Thus the optical pickup head is moved linearly in the radial direction of the optical disk correspondingly.
However, the optical pickup head cannot be moved precisely because stress between the worm gear and the gear portion may cause the gear portion to disengage with the worm gear.
Therefore, a need exists for an optical read/write device resolving the above problem in the industry.
SUMMARY
According to one aspect, an optical read/write device for reading and/or writing an optical disk includes a rack disposed between the worm gear and the optical pickup head for transferring motion from the worm gear to the optical pickup head. The rack includes a fastening portion for fixing the rack to the optical pickup head, an engaging portion, a spring placed between the fastening portion and the engaging portion for pressing the engaging portion to engage with the worm gear, and a connecting portion. The connecting portion is configured for connecting the fastening portion and the engaging portion and preventing the engaging portion from disengaging from the worm gear.
Other systems, methods, features, and advantages of the present optical read/write device will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages included within this description, be within the scope of the present device, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Many aspects of the present optical read/write device can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, emphasis instead being placed upon clearly illustrating the principles of the present device. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
FIG. 1 is an isometric view of an optical read/write device in accordance with an exemplary embodiment.
FIG. 2 is an exploded, isometric view of the optical read/write device of FIG. 1 .
FIG. 3 is an enlarged, inverted isometric view of a rack in FIG. 1 .
FIG. 4 is an enlarged, inverted isometric view of the rack in accordance with a second embodiment.
FIG. 5 is an enlarged, inverted isometric view of the rack in accordance with a third embodiment.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Reference will now be made to the drawings to describe preferred embodiments of a present optical read/write device, in detail.
Referring to FIGS. 1 and 2 , an optical read/write device 10 in accordance with an exemplary embodiment is illustrated. The optical read/write device 10 includes a base 20 , an optical pickup head 30 slidably assembled on the base 20 , a driving mechanism 40 , and a spindle motor 60 mounted on the base 20 .
The base 20 includes a chassis 22 , a first guide member 24 a , and a second guide member 24 b . A center of the chassis 22 defines a substantially rectangular opening 26 . The spindle motor 60 is mounted adjacent to a shorter side of the chassis 22 and configured for rotating an optical disk (not shown). The guide members 24 a , 24 b are correspondingly disposed on opposite longer sides of the chassis 22 .
The optical pickup head 30 includes a main body 32 for housing optical lenses (not shown) etc. The optical pickup head 30 further includes a first projection portion 34 and a second projection portion 36 correspondingly formed at two lateral sides of the main body 32 . The first projection portion 34 defines a guide hole 342 for slidably receiving the first guide member 24 a . The second projection portion 36 defines a guide notch 362 for slidably receiving the second guide member 24 b . The guide hole 342 , the first guide member 24 a , the guide notch 362 , and the second guide member 24 b are configured for allowing the optical pickup head 30 to be slidably assembled on the base 20 .
The driving mechanism 40 includes a feed motor 44 , a worm gear 46 , a gear seat 48 , and a rack 50 .
The feed motor 44 is mounted on the chassis 22 at a same side of the first guide member 24 a . The worm gear 46 is parallel to the first guide member 24 a . An end of the worm gear 46 is connected to a rotor (not shown) of the feed motor 44 , and another end of the worm gear 46 is supported by the gear seat 48 . The surface of the worm gear 46 defines a thread 460 .
The rack 50 is connected to the optical pickup head 30 and engaged with the worm gear 46 for driving the optical pickup head 30 to move when the feed motor 44 rotates accordingly. Referring also to FIG. 3 , the rack 50 includes a fastening portion 52 on one side of the rack 50 , an engaging portion 54 on another side of the rack 50 opposite to the fastening portion 52 , a connecting portion 57 , a restricting portion 55 , and a spring 58 .
The fastening portion 52 includes a mounting plate 520 , a base plate 522 , and a block member 524 . The mounting plate 520 is configured for fastening the rack 50 to the optical pickup head 30 . The base plate 522 and the block member 524 perpendicularly extend from the mounting plate 520 . A first cylindrical protrusion 526 is formed on the base plate 522 and protrudes toward the engaging portion 54 . The block member 524 protrudes from the mounting plate 520 along a cylindrical axis of the worm gear 46 . When the optical pickup head 30 is reading/writing information near a center portion of the optical disk, the block member 524 abuts an inner edge 220 adjacent to the spindle motor 60 of the chassis 22 . Thus, the block member 524 prevents the main body 32 of the optical pickup head 30 from colliding with the spindle motor 60 .
The engaging portion 54 includes an assembling plate 540 , a pair of engaging teeth 542 , and a second cylindrical protrusion (not shown). The engaging teeth 542 and the second cylindrical protrusion correspondingly protrude from two opposite sides of the assembling plate 540 . The engaging teeth 542 are configured for meshing with the thread 460 of the worm gear 46 , thus rotational motion of the worm gear 46 is converted to linear motion so as to drive the optical pickup head 30 . The second cylindrical protrusion extends toward the first cylindrical protrusion 526 . The second cylindrical protrusion and the first cylindrical protrusion 526 collectively define a gap therebetween. Ends of the spring 58 are sleeved on the first cylindrical protrusion 526 and the second cylindrical protrusion correspondingly. In order words, the spring is compressibly aligned between the assembling plate 540 and the base plate 522 via the first cylindrical protrusion 526 and the second cylindrical protrusion correspondingly.
The restricting portion 55 extends from the assembling plate 540 and is configured for preventing the engaging portion 54 from detaching out of the worm gear 46 . The restricting portion 55 includes a junction member 552 and a grasping member 554 . The junction member 552 perpendicularly connects the assembling plate 540 and the grasping member 554 . Thus the assembling plate 540 is parallel to the grasping member 554 . The assembling plate 540 and the grasping member 554 defines a gap therebetween for housing the worm gear 46 . In this embodiment, the grasping member 554 includes two posts. In other embodiments, the grasping member 554 can be a flat plate parallel to the assembling plate 540 .
The connecting portion 57 connects the fastening portion 52 and the engaging portion 54 and includes a shock absorber part 571 and a connecting arm 573 for connecting the fastening portion 52 and the junction member 552 .
The shock absorber part 571 includes a first restricting arm 5711 , a second restricting arm 5712 , and an resilient member 5713 . The first restricting arm 5711 perpendicularly extends from the base plate 522 toward the assembling plate 540 . The second restricting arm 5712 perpendicularly extends from the assembling plate 540 opposite to the first restricting arm 5711 . In this embodiment, the resilient member 5713 is a U-shaped arm with two ends of the U-shaped arm connecting free ends of the first restricting arm 5711 and the second restricting arm 5712 respectively. In other alternative embodiments, the resilient member 5713 can be a spring, an M-shaped, V-shaped, or W-shaped arm.
Referring to FIGS. 1 and 2 , a detailed assembly procedure of the optical read/write device 10 will now be described. First, the spindle motor 60 is secured to the chassis 22 . The guide members 24 a , 24 b respectively pass through the guide hole 342 and the guide notch 362 of the optical pickup head 30 . Then the guide members 24 a , 24 b are respectively mounted on the two longer sides of the chassis 22 . Thus, the optical pickup head 30 is slidably assembled on the base 20 . The feed motor 44 and the gear seat 48 are mounted on the chassis 22 with the worm gear 46 being parallel and adjacent to the first guide member 24 a.
The rack 50 is then connected to the optical pickup head 30 . That is, the mounting plate 520 is fixed to the main body 32 of the optical pickup head 30 . Thus, the rack 50 engages with the worm gear 46 in a manner that the worm gear 46 is received in the gap between the grasping member 554 and the assembling plate 540 . Thus the engaging teeth 542 are meshed with the thread 460 of the worm gear 46 because the spring 58 pushes the assembling plate 540 .
When the optical read/write device 10 reads data from or writes data onto the optical disk, the feed motor 44 drives the worm gear 46 to rotate. The rack 50 moves linearly because the engaging teeth 542 of the rack 50 mesh with the thread 460 of the worm gear 46 . Accordingly, the optical pickup head 30 moves linearly because the rack 50 is fixed to the optical pickup head 30 .
Referring to FIG. 3 , when the pressure between the worm gear 46 and the engaging teeth 542 becomes too high that the engaging teeth 542 is about to detach from the thread 460 , the engaging portion 54 is pushed toward the base plate 522 . The resilient member 5713 is compressed accordingly. A maximum compressed length of the resilient member 5713 is determined by the depth of the thread 460 . That is, the maximum length is configured to be less than or equal to the depth of the thread 460 . Thus, a distance the engaging portion 54 is pushed toward the base is limited by the resilient member 5713 , thus preventing the engaging teeth 542 from detaching out of the thread 460 when the pressure is too high.
Referring to FIG. 4 , a second embodiment of a rack 50 a is illustrated. Comparing to the rack 50 in FIG. 3 , the first restricting arm 5711 a and the second restricting arm 5712 a of the shock absorber part 571 a are spaced apart by a deviation gap 572 . When the engaging portion 54 is pushed toward the base plate 522 and deviates to a predetermined distance, the second restricting arm 5712 a will collide with the first restricting arm 5711 a . Thus, the shock absorber part 571 a will prevent the engaging teeth 542 from separating from the thread 460 .
Referring to FIG. 5 , a third embodiment of a rack 50 b is illustrated. Comparing to the rack 50 a in FIG. 4 , the first restricting arm 5711 b and the second restricting arm 5712 b of the shock absorber part 571 b partially offset each other. The height of the first restricting arm 5711 b with respect to the junction member 552 is less than that of the second restricting arm 5712 b . When the engaging portion 54 is pushed toward the base plate 522 and deviates to a predetermined distance, the second restricting arm 5712 b will collide with the first restricting arm 5711 b . Thus, the shock absorber part 571 b will prevent the engaging teeth 542 from separating from the thread 460 .
The foregoing description of the exemplary embodiments of the invention has been presented only for the purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to explain the principles of the invention and their practical application so as to enable others skilled in the art to utilize the invention and various embodiments and with various modifications as are suited to the particular use contemplated. Alternative embodiments will become apparent to those skilled in the art to which the present invention pertains without departing from its spirit and scope. Accordingly, the scope of the present invention is defined by the appended claims rather than the foregoing description and the exemplary embodiments described therein.
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According to one aspect, an optical read/write device for reading and/or writing an optical disk includes a rack disposed between the worm gear and the optical pickup head for transferring motion from the worm gear to the optical pickup head. The rack includes a fastening portion for fixing the rack to the optical pickup head, an engaging portion, a spring placed between the fastening portion and the engaging portion for pressing the engaging portion to engage with the worm gear, and a connecting portion. The connecting portion is configured for connecting the fastening portion and the engaging portion and preventing the engaging portion from disengaging from the worm gear.
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FIELD OF THE INVENTION
[0001] The present invention relates to incorporation of a carboxylation system into the bleach plant of a wood pulp mill to provide carboxylated cellulosic fibers.
BACKGROUND OF THE INVENTION
[0002] Cellulose is a carbohydrate consisting of a long chain of glucose units, all β-linked through the 1′-4 positions. Native plant cellulose molecules may have upwards of 2200 anhydroglucose units. The number of units is normally referred to as degree of polymerization (D.P.). Some loss of D.P. inevitably occurs during purification. A D.P. approaching 2000 is usually found only in purified cotton linters. Wood derived celluloses rarely exceed a D.P. of about 1700. The structure of cellulose can be represented as follows:
[0003] Chemical derivatives of cellulose have been commercially important for almost a century and a half. Nitrocellulose plasticized with camphor was the first synthetic plastic and has been in use since 1868. A number of cellulose ether and ester derivatives are presently commercially available and find wide use in many fields of commerce. Virtually all cellulose derivatives take advantage of the reactivity of the three available hydroxyl groups (i.e., C2, C3, and C6). Substitution at these groups can vary from very low, about 0.01, to a maximum of 3. Among important cellulose derivatives are cellulose acetate, used in fibers and transparent films; nitrocellulose, widely used in lacquers and gunpowder; ethyl cellulose, widely used in impact resistant tool handles; methyl cellulose, hydroxyethyl, hydroxypropyl, and sodium carboxymethyl cellulose, water soluble ethers widely used in detergents, as thickeners in foodstuffs, and in papermaking. Cellulose itself has been modified for various purposes. Cellulose fibers are naturally anionic in nature, as are many papermaking additives. A cationic cellulose is described in U.S. Pat. No. 4,505,775, issued to Harding et al. This cellulose has greater affinity for anionic papermaking additives such as fillers and pigments and is particularly receptive to acid and anionic dyes. U.S. Pat. No. 5,667,637, issued to Jewell et al., describes a low degree of substitution (D.S.) carboxyethyl cellulose which, along with a cationic resin, improves the wet to dry tensile and burst ratios when used as a papermaking additive. U.S. Pat. No. 5,755,828, issued to Westland, describes a method for increasing the strength of articles made from crosslinked cellulose fibers having free carboxylic acid groups obtained by covalently coupling a polycarboxylic acid to the fibers.
[0004] For some purposes, cellulose has been oxidized to make it more anionic to improve compatibility with cationic papermaking additives and dyes. Various oxidation treatments have been used. Among these are nitrogen dioxide and periodate oxidation coupled with resin treatment of cotton fabrics for improvement in crease recovery as suggested by Shet, R. T. and A. M. Nabani, Textile Research Journal, November 1981: 740-744. Earlier work by Datye, K. V. and G. M. Nabar, Textile Research Journal, July 1963: 500-510, describes oxidation by metaperiodates and dichromic acid followed by treatment with chlorous acid for 72 hours or 0.05 M sodium borohydride for 24 hours. Copper number was greatly reduced by borohydride treatment and less so by chlorous acid. Carboxyl content was slightly reduced by borohydride and significantly increased by chlorous acid. The products were subsequently reacted with formaldehyde. Southern pine kraft springwood and summer wood fibers were oxidized with potassium dichromate in oxalic acid. Luner, P., et al., Tappi 50(3):117-120 (1967). Handsheets made with the fibers showed improved wet strength believed to be due to aldehyde groups. Pulps have also been oxidized with chlorite or reduced with sodium borohydride. Luner, P., et al., Tappi 50(5):227-230, 1967. Handsheets made from pulps treated with the reducing agent showed improved sheet properties over those not so treated. Young, R. A., Wood and Fiber 10(2):112-119, 1978 describes oxidation primarily by dichromate in oxalic acid to introduce aldehyde groups in sulfite pulps for wet strength improvement in papers. Shenai, V. A. and A. S. Narkhede, Textile Dyer and Primer, May 20, 1987: 17-22 describes the accelerated reaction of hypochlorite oxidation of cotton yarns in the presence of physically deposited cobalt sulfide. The authors note that partial oxidation has been studied for the past hundred years in conjunction with efforts to prevent degradation during bleaching. They also discuss in some detail the use of 0.1 M sodium borohydride as a reducing agent following oxidation. The treatment was described as a useful method of characterizing the types of reducing groups as well as acidic groups formed during oxidation. The borohydride treatment noticeably reduced copper number of the oxidized cellulose. Copper number gives an estimate of the reducing groups such as aldehydes present on the cellulose. Borohydride treatment also reduced alkali solubility of the oxidized product, but this may have been related to an approximate 40% reduction in carboxyl content of the samples. Andersson, R., et al. in Carbohydrate Research 206: 340-346 (1990) describes oxidation of cellulose with sodium nitrite in orthophosphoric acid and describe nuclear magnetic resonance elucidation of the reaction products.
[0005] Davis, N. J., and S. L. Flitsch, Tetrahedron Letters 34(7): 1181-1184 (1993) describe the use and reaction mechanism of 2,2,6,6-tetramethylpiperidinyloxy free radical (TEMPO) with sodium hypochlorite to achieve selective oxidation of primary hydroxyl groups of monosaccharides. Following the Davis et al. paper this route to carboxylation then began to be more widely explored. de Nooy, A. E. J., et al., Receuil des Travaux Chimiques des Pays-Bas 113: 165-166 (1994) reports similar results using TEMPO and hypobromite for oxidation of primary alcohol groups in potato starch and inulin. The following year, these same authors in Carbohydrate Research 269:89-98 (1995) report highly selective oxidation of primary alcohol groups in water soluble glucans using TEMPO and a hypochlorite/bromide oxidant.
[0006] WO 95/07303 (Besemer et al.) describes a method of oxidizing water soluble carbohydrates having a primary alcohol group, using TEMPO with sodium hypochlorite and sodium bromide. Cellulose is mentioned in passing in the background although the examples are principally limited to starches. The method is said to selectively oxidize the primary alcohol at C-6 to carboxylic acid group. None of the products studied were fibrous in nature.
[0007] WO 99/23117 (Viikari et al.) describes oxidation using TEMPO in combination with the enzyme laccase or other enzymes along with air or oxygen as the effective oxidizing agents of cellulose fibers, including kraft pine pulps.
[0008] A year following the above noted Besemer publication, the same authors, in Cellulose Derivatives, Heinze, T. J. and W. G. Glasser, eds., Ch. 5, pp. 73-82 (1996), describe methods for selective oxidation of cellulose to 2,3-dicarboxy cellulose and 6-carboxy cellulose using various oxidants. Among the oxidants used were a periodate/chlorite/hydrogen peroxide system, oxidation in phosphoric acid with sodium nitrate/nitrite, and with TEMPO and a hypochlorite/bromide primary oxidant. Results with the TEMPO system were poorly reproduced and equivocal. In the case of TEMPO oxidation of cellulose, little or none would have been expected to go into solution. The homogeneous solution of cellulose in phosphoric acid used for the sodium nitrate/sodium nitrite oxidation was later treated with sodium borohydride to remove any carbonyl function present.
[0009] Chang, P. S. and J. F. Robyt, Journal of Carbohydrate Chemistry 15(7):819-830 (1996), describe oxidation of ten polysaccharides including α-cellulose at 0 and 25° C. using TEMPO with sodium hypochlorite and sodium bromide. Ethanol addition was used to quench the oxidation reaction. The resulting oxidized α-cellulose had a water solubility of 9.4%. The authors did not further describe the nature of the α-cellulose. It is presumed to have been a so-called dissolving pulp or cotton linter cellulose. Barzyk, D., et al., in Transactions of the 11 th Fundamental Research Symposium, Vol. 2, 893-907 (1997), note that carboxyl groups on cellulose fibers increase swelling and impact flexibility, bonded area and strength. They designed experiments to increase surface carboxylation of fibers. However, they ruled out oxidation to avoid fiber degradation and chose to form carboxymethyl cellulose in an isopropanol/methanol system.
[0010] Isogai, A. and Y. Kato, in Cellulose 5:153-164, 1998 describe treatment of several native, mercerized, and regenerated celluloses with TEMPO to obtain water soluble and insoluble polyglucuronic acids. They note that the water soluble products had almost 100% carboxyl substitution at the C-6 site. They further note that oxidation proceeds heterogeneously at the more accessible regions on solid cellulose.
[0011] Kitaoka, T., A. Isogai, and F. Onabe, in Nordic Pulp and Paper Research Journal 14(4):279-284, 1999, describe the treatment of bleached hardwood kraft pulp using TEMPO oxidation. Increasing amounts of carboxyl content gave some improvement in dry tensile index, Young's modulus, and brightness, with decreases in elongation at breaking point and opacity. Other strength properties were unaffected. Retention of PAE-type wet strength resins was somewhat increased. The products described did not have any stabilization treatment after the TEMPO oxidation.
[0012] U.S. Pat. No. 6,379,494 describes a method for making stable carboxylated cellulose fibers using a nitroxide-catalyzed process. In the method, cellulose is first oxidized by nitroxide catalyst to provide carboxylated as well as aldehyde and ketone substituted cellulose. The oxidized cellulose is then stabilized by reduction of the aldehyde and ketone substituents to provide the carboxylated fiber product. Nitroxide-catalyzed cellulose oxidation occurs predominately at the primary hydroxyl group on C-6 of the anhydroglucose moiety. In contrast to some of the other routes to oxidized cellulose, only very minor oxidation occurs at the secondary hydroxyl groups at C-2 and C-3.
[0013] In nitroxide oxidation of cellulose, primary alcohol oxidation at C-6 proceeds through an intermediate aldehyde stage. In the process, the nitroxide is not irreversibly consumed in the reaction, but is continuously regenerated by a secondary oxidant (e.g., hypohalite) into the nitrosonium (or oxyammonium or oxammonium) ion, which is the actual oxidant. In the oxidation, the nitrosonium ion is reduced to the hydroxylamine, which can be re-oxidized to the nitroxide. Thus, in the method, it is the secondary oxidant (e.g., hypohalite) that is consumed. The nitroxide may be reclaimed or recycled from the aqueous system.
[0014] The resulting oxidized cellulose product is an equilibrium mixture including carboxyl and aldehyde substitution. Aldehyde substituents on cellulose are known to cause degeneration over time and under certain environmental conditions. In addition, minor quantities of ketone may be formed at C-2 and C-3 of the anhydroglucose units and these will also lead to degradation. Marked degree of polymerization loss, fiber strength loss, crosslinking, and yellowing are among the consequent problems. Thus, to prepare a stabilized carboxylated product, aldehyde and ketone substituents formed in the oxidation step are reduced to hydroxyl groups, or aldehyde substituents are oxidized to a carboxyl group in a stabilization step.
[0015] In addition to TEMPO, other nitroxide derivatives for making carboxylated cellulose fibers have been described. See, for example, U.S. Pat. No. 6,379,494 and WO 01/29309, Methods for Making Carboxylated Cellulose Fibers and Products of the Method.
[0016] A method of preparation of carboxylic acids or their salts by oxidation of primary alcohols using hindered N-chloro hindered cyclic amines and hypochlorite, in aqueous solutions or in mixed solvent systems containing ethyleneglycol dimethyl ether, diethyleneglycol dimethyl ether, triethyleneglycol dimethyl ether, toluene, acetonitrile, ethylacetate, t-butanol and other solvents is described in JP10130195, “Manufacturing Method of Carboxylic Acid and Its Salts”. Other oxidants described include chlorine, hypobromite, bromite, trichloro isocyanuric acid, tribromo isocyanuric acid, or combinations.
[0017] Despite the advances made in the development of methods for making carboxylated cellulose pulps including catalytic oxidation systems, there remains a need for improved methods and catalysts for making carboxylated cellulose pulp. The present invention seeks to fulfill these needs and provides further related advantages.
SUMMARY OF THE INVENTION
[0018] A carboxylation system and process for wood pulp which may be placed in an existing pulp mill bleach plant, or incorporated into a new bleach plant with little additional equipment. A carboxylation system and process for wood pulp which will allow the mill to transition from regular pulp to carboxylated pulp and back with ease.
[0019] What is needed is a process and equipment that allows pulp to be carboxylated in an existing pulp mill without large capital costs.
[0020] Long reaction times require large tanks, land on which to put the tanks and a great deal of capital. One of the aspects of the present carboxylation reaction is the ability to place the needed equipment into the confines of an existing pulp mill bleach plant. This required reducing the time of reaction so that it could take place within the confines of the equipment in the plant.
[0021] A wood pulp carboxylation system has a first stage in which the pulp is oxidized to provide a pulp containing both carboxyl and aldehyde functional groups and second stage in which the aldehyde groups are converted to carboxyl groups. The first stage is a carboxylation stage and the second stage is a stabilization stage.
[0022] It was initially thought that the first stage of carboxylation would require at least 15 minutes so that carboxylating wood pulp would require two additional units after the bleach plant. The first unit would be a tank for the carboxylation process and the second unit would be another tank for the stabilization reaction. These would be expensive to install.
[0023] After much work the time for the first stage was reduced to 2 minutes. This still required a separate tank for the first stage carboxylation.
[0024] Additional work reduced the time for the first stage to 1 minute. The carboxylation unit could be placed between the extraction stage and the chlorine dioxide stage of the bleach plant, but additional piping was required to provide the necessary reaction time. The chlorine dioxide tower could be used for the stabilization reaction. Again the carboxylation unit would be expensive to install, though not as expensive as with longer reaction times.
[0025] Additional work reduced the first stage reaction time to 30 seconds or less. Now it was possible to use the existing pulp mill equipment with only the addition of mixers and supply lines and supply storage.
[0026] By using advantageous chemical loadings and chemicals it was found that the time for the first stage of carboxylation could be shortened into a range of less than a minute. Times of 1 second to 60 seconds are preferred and times of 5 to 30 seconds most preferred.
[0027] The first stage of the carboxylation unit can now be a short length of pipe between the extraction stage washer and the chlorine dioxide tower. The length and diameter of pipe will depend on the time required for the first stage of carboxylation process. The chlorine dioxide tower can be the stabilization unit. In mills which have two chlorine dioxide towers with a washer between them, the unit for the first stage of carboxylation can be placed between the first chlorine dioxide washer and the second chlorine dioxide tower.
[0028] Another aspect was to use chemicals normally found at the pulp mill and keep new chemicals to a minimum.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is diagram of an extraction stage and a chlorine dioxide stage of a standard pulp mill.
[0030] FIGS. 2 and 3 are diagrams of an extraction stage and a chlorine dioxide stage showing the changes to provide a carboxylation reaction.
DETAILED DESCRIPTION OF THE INVENTION
[0031] In Applicant's copending U.S. patent application Ser. No. 09/875,177 filed Jun. 6, 2001, which is incorporated herein by reference in its entirety, the use of chlorine dioxide is disclosed as a secondary oxidant for use with a hindered cyclic oxammonium salt as the primary oxidant.
[0032] This application discusses the nitroxide, oxammonium salt, amine or hydroxylamine of a corresponding hindered heterocyclic amine compound. The oxammonium salt is the catalytically active form but this is an intermediate compound that is formed from a nitroxide, continuously used to become a hydroxylamine, and then regenerated, presumably back to the nitroxide. The secondary oxidant will convert the amine form to the free radical nitroxide compound. The term “nitroxide” is normally used for the compound in the literature. The secondary oxidant will also regenerate the oxammonium salt from the hydroxylamine.
[0033] The method described in the application is suitable for carboxylation of chemical fibrous cellulose pulp. This may be bleached sulfite, kraft, or pre-hydrolyzed kraft hardwood or softwood pulps or mixtures of hardwood or softwood pulps.
[0034] The cellulose fiber in an aqueous slurry or suspension is first oxidized by addition of a primary oxidizer comprising a cyclic oxammonium salt. This may conveniently be formed in situ from a corresponding amine, hydroxylamine or nitroxyl compound which lacks any α-hydrogen substitution on either of the carbon atoms adjacent the nitroxyl nitrogen atom. Substitution on these carbon atoms is preferably a one or two carbon alkyl group. For sake of convenience in description it will be assumed, unless otherwise noted, that a nitroxide is used as the primary oxidant and that term should be understood to include all of the precursors of the corresponding nitroxide or its oxammonium salt.
[0035] Nitroxides having both five and six membered rings have been found to be satisfactory. Both five and six membered rings may have either a methylene group or a heterocyclic atom selected from nitrogen, sulfur or oxygen at the four position in the ring, and both rings may have one or two substituent groups at this location.
[0036] A large group of nitroxide compounds have been found to be suitable. 2,2,6,6-tetramethylpiperidinyl-1-oxy free radical (TEMPO) is among the exemplary nitroxides found useful. Another suitable product linked in a mirror image relationship to TEMPO is 2,2,2′,2′,6,6,6′,6′-octamethyl-4,4′-bipiperidinyl-1,1′-dioxy di-free radical (BITEMPO). Similarly, 2,2,6,6-tetramethyl-4-hydroxypipereidinyl-1-oxy free radical; 2,2,6,6-tetramethyl-4-methoxypiperidinyl-1-oxy free radical; and 2,2,6,6-tetramethyl-4-benzyloxypiperidinyl-1-oxy free radical; 2,2,6,6-tetramethyl-4-aminopiperidinyl-1-oxy free radical; 2,2,6,6-tetramethyl-4-acetylaminopiperidinyl-1-oxy free radical; 2,2,6,6-tetramethyl-4-piperidone-1-oxy free radical and ketals of this compound are examples of compounds with substitution at the 4 position of TEMPO that have been found to be very satisfactory oxidants. Among the nitroxides with a second hetero atom in the ring at the four position (relative to the nitrogen atom), 3,3,5,5-tetramethylmorpholine-1-oxy free radical (TEMMO) is useful.
[0037] The nitroxides are not limited to those with saturated rings. One compound anticipated to be a very effective oxidant is 3,4-dehydro-2,2,6,6-tetramethyl-piperidinyl-1-oxy free radical.
[0038] Six membered ring compounds with double substitution at the four position have been especially useful because of their relative ease of synthesis and lower cost. Exemplary among these are the 1,2-ethanediol, 1,2-propanediol, 2,2-dimethyl-1-3-propanediol (1,3-neopentyldiol) and glyceryl cyclic ketals of 2,2,6,6-tetramethyl-4-piperidone-1-oxy free radical.
[0039] Among the five membered ring products, 2,2,5,5-tetramethyl-pyrrolidinyl-1-oxy free radical is anticipated to be very effective.
[0040] The following groups of nitroxyl compounds and their corresponding amines or hydroxylamines are known to be effective primary oxidants:
in which R 1 -R 4 are one to four carbon alkyl groups but R 1 with R 2 and R 3 with R 4 may together be included in a five or six carbon alicyclic ring structure; X is sulfur or oxygen; and R 5 is hydrogen, C 1 -C 12 alkyl, benzyl, 2-dioxanyl, a dialkyl ether, an alkyl polyether, or a hydroxyalkyl, and X with R 5 being absent may be hydrogen or a mirror image moiety to form a bipiperidinyl nitroxide. Specific compounds in this group known to be very effective are 2,2,6,6-tetramethylpiperidinyl-1-oxy free radical (TEMPO); 2,2,2′,2′,6,6,6′,6′-octamethyl-4,4′-bipiperidinyl-1,1′-dioxy di-free radical (BI-TEMPO); 2,2,6,6-tetramethyl-4-hydroxypiperidinyl-1-oxy free radical (4-hydroxy TEMPO); 2,2,6,6-tetramethyl-4-methoxypiperidinyl-1-oxy free radical (4-methoxy-TEMPO); and 2,2,6,6-tetramethyl-4-benzyloxypiperidinyl-1-oxy free radical (4-benzyloxy-TEMPO).
in which R 1 -R 4 are one to four carbon alkyl groups but R 1 with R 2 and R 3 with R 4 may together be included in a five or six carbon alicyclic ring structure; R 6 is hydrogen, C 1 -C 5 alkyl, R 7 is hydrogen, C 1 -C 8 alkyl, phenyl, carbamoyl, alkyl carbamoyl, phenyl carbamoyl, or C 1 -C 8 acyl. Exemplary of this group is 2,2,6,6-tetramethyl-4-aminopiperidinyl-1-oxy free radical (4-amino TEMPO); and 2,2,6,6-tetramethyl-4-acetylaminopipdereidinyl-1-oxy free radical (4-acetylamino-TEMPO).
in which R 1 -R 4 are one to four carbon alkyl groups but R 1 with R 2 and R 3 with R 4 may together be included in a five or six carbon alicyclic ring structure; and X is oxygen, sulfur, NH, N-alkyl, NOH, or NO R 8 where R 8 is lower alkyl. An example might be 2,2,6,6-tetramethyl-4-oxopiperidinyl-1-oxy free radical (2,2,6,6-tetramethyl-4-piperidone-1-oxy free radical).
wherein R 1 -R 4 are one to four carbon alkyl groups but R 1 with R 2 and R 3 with R 4 may be linked into a five or six carbon alicyclic ring structure; and X is oxygen, sulfur, -alkyl amino, or acyl amino. An example is 3,3,5,5-tetramethylmorpholine-4-oxy free radical. In this case the oxygen atom takes precedence for numbering but the dimethyl substituted carbons remain adjacent the nitroxide moiety.
wherein R 1 -R 4 are one to four carbon alkyl groups but R 1 with R 2 and R 3 with R 4 may be linked into a five or six carbon alicyclic ring structure. An example of a suitable compound is 3,4-dehydro-2,2,6,6-tetramethylpiperidinyl-1-oxy free radical.
wherein R 1 -R 4 are one to four carbon alkyl groups but R 1 with R 2 and R 3 with R 4 may together be included in a five or six carbon alicyclic ring structure; X is methylene, oxygen, sulfur, or alkylamino; and R 9 and R 10 are one to five carbon alkyl groups and may together be included in a five or six member ring structure, which in turn may have one to four lower alkyl or hydroxy alkyl substitutients. Examples include the 1,2-ethanediol; 1,3-propanediol,2,2-dimethyl-1,3-propanediol, and glyceryl cyclic ketals of 2,2,6,6-tetramethyl-4-piperidone-1-oxy free radical. These compounds are especially preferred primary oxidants because of their effectiveness, lower cost, ease of synthesis, and suitable water solubility.
in which R 1 -R 4 are one to four carbon alkyl groups but R 1 with R 2 and R 3 with R 4 may together be included in a five or six carbon alicyclic ring structure; X may be methylene, sulfur, oxygen, —NH, or NR 11 , in which R 11 is a lower alkyl. An example of these five member ring compounds is 2,2,5,5-tetramethylpyrrolidinyl-1-oxy free radical.
[0048] Where the term “lower alkyl” is used it should be understood to mean an aliphatic straight or branched chain alky moiety having from one to four carbon atoms.
[0049] The above named compounds should only be considered as exemplary among the many representatives of the nitroxides suitable for use with the invention and those named are not intended to be limited in any way.
[0050] During the oxidation reaction the nitroxide is consumed and converted to an oxammonium salt then to a hydroxylamine. Evidence indicates that the nitroxide is continuously regenerated by the presence of a secondary oxidant. Chlorine dioxide, or a latent source, is a preferred secondary oxidant. Since the nitroxide is not irreversibly consumed in the oxidation reaction only a catalytic amount of it is required. During the course of the reaction it is the secondary oxidant which will be depleted.
[0051] The amount of nitroxide required is in the range of about 0.0005% to 1.0% by weight based on carbohydrate present, preferably about 0.005-0.25%. The nitroxide is known to preferentially oxidize the primary hydroxyl which is located on C-6 of the anhydroglucose moiety in the case of cellulose or starches. It can be assumed that a similar oxidation will occur at primary alcohol groups on hemicellulose or other carbohydrates having primary alcohol groups.
[0052] The chlorine dioxide secondary oxidant is present in an amount of 0.2-35% by weight of the carbohydrate being oxidized, preferably about 0.5-10% by weight.
[0053] Abundant laboratory data indicates that a nitroxide catalyzed cellulose oxidation predominantly occurs at the primary hydroxyl group on C-6 of the anhydroglucose moiety. In contrast to some of the other routes to oxidized cellulose, only very minor reaction has been observed to occur at the secondary hydroxyl groups at the C-2 and C-3 locations. Using TEMPO as an example, the mechanism to formation of a carboxyl group at the C-6 location proceeds through an intermediate aldehyde stage.
[0054] The TEMPO is not irreversibly consumed in the reaction but is continuously regenerated. It is converted by the secondary oxidant into the oxammonium (or nitrosonium) ion which is the actual oxidant. During oxidation the oxammonium ion is reduced to the hydroxylamine from which TEMPO is again formed. Thus, it is the secondary oxidant which is actually consumed. TEMPO may be reclaimed or recycled from the aqueous system. The reaction is postulated to be as follows: nitrosonium) ion which is the actual oxidant. During oxidation the oxammonium ion is reduced to the hydroxylamine from which TEMPO is again formed. Thus, it is the secondary oxidant which is actually consumed. TEMPO may be reclaimed or recycled from the aqueous system. The reaction is postulated to be as follows:
[0055] The resulting oxidized cellulose product will have a mixture of carboxyl and aldehyde substitution. Aldehyde substituents on cellulose are known to cause degeneration over time and under certain environmental conditions. In addition, minor quantities of ketone carbonyls may be formed at the C-2 and C-3 positions of the anhydroglucose units and these will also lead to degradation. Marked D.P., fiber strength loss, crosslinking, and yellowing are among the problems encountered. For these reasons it is desirable to oxidize aldehyde substituents to carboxyl groups, or to reduce aldehyde and ketone groups to hydroxyl groups, to ensure stability of the product.
[0056] To achieve maximum stability and D.P. retention the oxidized product may be treated with a stabilizing agent to convert any substituent groups, such as aldehydes or ketones, to hydroxyl or carboxyl groups. The stabilizing agent may either be another oxidizing agent or a reducing agent. Unstabilized oxidized cellulose pulps have objectionable color reversion and may self crosslink upon drying, thereby reducing their ability to redisperse and form strong bonds when used in sheeted products. It has been found that acidifying the initial reaction mixture to the pH range given for chlorites without without draining or washing the product is often sufficient to convert the aldehyde moieties to carboxyl functions. Peroxide and acid is also a desirable stabilizing mixture under the conditions shown for chlorite. Otherwise one of the following oxidation treatments may be used. Alkali methyl chlorites are one class of oxidizing agents used as stabilizers, sodium chlorite being preferred because of the cost factor. Other compounds that may serve equally well as oxidizers are permanganates, chromic acid, bromine, silver oxide, and peracids. A combination of chlorine dioxide and hydrogen peroxide is also a suitable oxidizer when used at the pH range designated for sodium chlorite. Oxidation using sodium chlorite may be carried out at a pH in the range of about 0-5, preferably 2-4, at temperatures between about 10°-110° C., preferably about 20°-95° C., for times from about 0.5 minutes to 50 hours, preferably about 10 minutes to 2 hours. One factor that favors oxidants as opposed to reducing agents is that aldehyde groups on the oxidized carbohydrate are converted to additional carboxyl groups, thus resulting in a more highly carboxylated product. These oxidants are referred to as “tertiary oxidizers” to distinguish them from the nitroxide/chlorine dioxide primary/secondary oxidizers. The tertiary oxidizer is used in a molar ratio of about 1.0-15 times the presumed aldehyde content of the oxidized carbohydrate, preferably about 5-10 times. In a more convenient way of measuring the needed tertiary oxidizer, the preferred sodium chlorite usage should fall within about 0.01-20% based on carbohydrate, preferably about 1-9% by weight based on carbohydrate, the chlorite being calculated on a 100% active material basis.
[0057] When stabilizing with a chlorine dioxide and hydrogen peroxide mixture, the concentration of chlorine dioxide present should be in a range of about 0.01-20% by weight of carbohydrate, preferably about 0.3-1.0%, and concentration of hydrogen peroxide should fall within the range of about 0.01-10% by weight of carbohydrate, preferably 0.05-1.0%. Time will generally fall within the range of 0.5 minutes to 50 hours, preferably about 10 minutes to 2 hours and temperature within the range of about 10°-110° C., preferably about 30°-95° C. The pH of the system is preferably about 3 but may be in the range of 0-5.
[0058] In Applicant's copending U.S. patent application (attorney's docket 25065) filed contemporaneously herewith, which also is incorporated herein by reference in its entirety, the use of chlorine dioxide is a secondary oxidant for use with N-halo hindered cyclic amine compounds as the primary oxidant. The N-halo hindered cyclic amine compounds are as effective as TEMPO and other related nitroxides in methods for making carboxylated cellulose fibers.
[0059] The N-halo hindered cyclic amine compounds are fully alkylated at the carbon atoms adjacent to the amino nitrogen atom (i.e., the N—Cl or N—Br) and have from 4 to 8 atoms in the ring. In one embodiment, the N-halo hindered cyclic amine compounds are six-membered ring compounds. In another embodiment, the N-halo hindered cyclic amine compounds are five-membered ring compounds.
[0060] Representative N-halo hindered cyclic amine compounds useful in the method of the invention for making carboxylated cellulose pulp fibers include Structures (I)-(VII).
Structure (I):
[0062] For Structure (I), R 1 -R 4 can be C1-C6 straight-chain or branched alkyl groups, for example, methyl, ethyl, propyl, butyl, pentyl, or hexyl groups. Alternatively, R 1 and R 2 taken together can form a five- or six-carbon cycloalkyl group, and R 3 and R 4 taken together can form a five- or six-carbon cycloalkyl group. The cycloalkyl group can be further substituted with, for example, one or more C1-C6 alkyl groups or other substituents. X can be sulfur or oxygen. R 5 can be hydrogen, C1-C12 straight-chain or branched alkyl or alkoxy, aryl, aryloxy, benzyl, 2-dioxanyl, dialkyl ether, alkyl polyether, or hydroxyalkyl group. Alternatively, R 5 can be absent and X can be hydrogen or a mirror image moiety to form a bipiperidinyl compound. A is a halogen, for example, chloro or bromo. Representative compounds of Structure (I) include N-halo-2,2,6,6-tetramethylpiperidine; N,N′-dihalo-2,2,2′,2′,6,6,6′,6-octamethyl-4,4′-bipiperidine; N-halo-2,2,6,6-tetramethyl-4-hydroxypiperidine; N-halo-2,2,6,6-tetramethyl-4-methoxypiperidine; and N-halo-2,2,6,6-tetramethyl-4-benzyloxypiperidine.
Structure (II):
[0064] For Structure (II), R 1 -R 4 can be C1-C6 straight-chain or branched alkyl groups, for example, methyl, ethyl, propyl, butyl, pentyl, or hexyl groups. Alternatively, R 1 and R 2 taken together can form a five- or six-carbon cycloalkyl group, and R 3 and R 4 taken together can form a five- or six-carbon cycloalkyl group. The cycloalkyl group can be further substituted with, for example, one or more C1-C6 alkyl groups or other substituents. X can be oxygen or sulfur. R 6 can be hydrogen, C1-C6 straight-chain or branched alkyl groups. R 7 can be hydrogen, C1-C8 straight-chain or branched alkyl groups, phenyl, carbamoyl, alkyl carbamoyl, phenyl carbamoyl, or C1-C8 acyl. A is a halogen, for example, chloro or bromo. Representative compounds of Structure (II) include N-halo-2,2,6,6-tetramethyl-4-aminopiperidine and N-halo-2,2,6,6-tetramethyl-4-acetylaminopiperidine.
Structure (III):
[0066] For Structure (III), R 1 -R 4 can be C1-C6 straight-chain or branched alkyl groups, for example, methyl, ethyl, propyl, butyl, pentyl, or hexyl groups. Alternatively, R 1 and R 2 taken together can form a five- or six-carbon cycloalkyl group, and R 3 and R 4 taken together can form a five- or six-carbon cycloalkyl group. The cycloalkyl group can be further substituted with, for example, one or more C1-C6 alkyl groups or other substituents. X can be oxygen, sulfur, NH, alkylamino (i.e., NH-alkyl), dialkylamino, NOH, or NOR 10 , where R 10 is a C1-C6 straight-chain or branched alkyl group. A is a halogen, for example, chloro or bromo. A representative compound of Structure (III) is N-halo-2,2,6,6-tetramethylpiperidin-4-one.
Structure (IV):
[0068] For Structure (IV), R 1 -R 4 can be C1-C6 straight-chain or branched alkyl groups, for example, methyl, ethyl, propyl, butyl, pentyl, or hexyl groups. Alternatively, R 1 and R 2 taken together can form a five- or six-carbon cycloalkyl group, and R 3 and R 4 taken together can form a five- or six-carbon cycloalkyl group. The cycloalkyl group can be further substituted with, for example, one or more C1-C6 alkyl groups or other substituents. X can be oxygen, sulfur, alkylamino (i.e., N—R 10 ), or acylamino (i.e., N—C(═O)-R 10 ), where R 10 is a C1-C6 straight-chain or branched alkyl group. A is a halogen, for example, chloro or bromo. A representative compound of Structure (IV) is N-halo-3,3,5,5-tetramethylmorpholine.
Structure (V):
[0070] For Structure (V), R 1 -R 4 can be C1-C6 straight-chain or branched alkyl groups, for example, methyl, ethyl, propyl, butyl, pentyl, or hexyl groups. Alternatively, R 1 and R 2 taken together can form a five- or six-carbon cycloalkyl group, and R 3 and R 4 taken together can form a five- or six-carbon cycloalkyl group. The cycloalkyl group can be further substituted with, for example, one or more C1-C6 alkyl groups or other substituents. A is a halogen, for example, chloro or bromo. A representative compound of Structure (V) is N-halo-3,4-dehydro-2,2,6,6,-tetramethylpiperidine.
Structure (VI):
[0072] For Structure (VI), R 1 -R 4 can be C1-C6 straight-chain or branched alkyl groups, for example, methyl, ethyl, propyl, butyl, pentyl, or hexyl groups. Alternatively, R 1 and R 2 taken together can form a five- or six-carbon cycloalkyl group, and R 3 and R 4 taken together can form a five- or six-carbon cycloalkyl group. The cycloalkyl group can be further substituted with, for example, one or more C1-C6 alkyl groups or other substituents. X can be methylene (i.e., CH 2 ), oxygen, sulfur, or alkylamino. R 8 and R 9 can be independently selected from C1-C6 straight-chain or branched alkyl groups, for example, methyl, ethyl, propyl, butyl, pentyl, or hexyl groups. Alternatively, R 8 and R 9 taken together can form a five- or six-membered ring, which can be further substituted with, for example, one or more C1-C6 alkyl groups or other substituents. A is a halogen, for example, chloro or bromo. Representative compounds of Structure (VI) include N-halo-4-piperidone ketals, such as ethylene, propylene, glyceryl, and neopentyl ketals. Representative compounds of Structure (VI) include N-halo-2,2,6,6-tetramethyl-4-piperidone ethylene ketal, N-halo-2,2,6,6-tetramethyl-4-piperidone propylene ketal, N-halo-2,2,6,6-tetramethyl-4-piperidone glyceryl ketal, and N-halo-2,2,6,6-tetramethyl-4-piperidone neopentyl ketal.
Structure (VII):
[0074] For Structure (VII), R 1 -R 4 can be C1-C6 straight-chain or branched alkyl groups, for example, methyl, ethyl, propyl, butyl, pentyl, or hexyl groups. Alternatively, R 1 and R 2 taken together can form a five- or six-carbon cycloalkyl group, and R 3 and R 4 taken together can form a five- or six-carbon cycloalkyl group. The cycloalkyl group can be further substituted with, for example, one or more C1-C6 alkyl groups or other substituents. X can be methylene, oxygen, sulfur, NH, (i.e., N—R 10 ), or acylamino (i.e., N—C(═O)—R 10 ), where R 10 is a C1-C6 straight-chain or branched alkyl group. A is a halogen, for example, chloro or bromo. A representative compound of Structure (VII) is N-halo-2,2,5,5-tetramethylpyrrolidine.
[0075] In general, the N-halo hindered cyclic amine compounds noted above can be prepared by chlorination or bromination of the corresponding amine compounds.
[0076] Carboxylated cellulose pulp fibers can be made using hindered cyclic amine compounds or N-halo hindered cyclic amine compound in aqueous media under heterogeneous conditions. In the method, the hindered cyclic amine compound or the N-halo hindered cyclic amine compound reacts with a secondary oxidizing agent (e.g., chlorine dioxide, peracids, hypochlorites, chlorites, ozone, hydrogen peroxide, potassium superoxide) to provide a primary oxidizing agent that reacts with cellulose pulp fibers to provide cellulose pulp fibers containing both carboxyl and aldehyde functional groups. In one embodiment, the cellulosic fibers containing carboxyl and aldehyde functional groups are further treated to provide stable carboxylated cellulosic fibers. In the method, under basic pH conditions and in the presence of a secondary oxidizing agent, the primary oxidizing agent is generated from the hindered cyclic amine compound or the N-halo hindered cyclic amine compound. In one embodiment, the cellulosic fibers containing both carboxyl and aldehyde functional groups obtained at the end of the first stage of the carboxylation process are further treated to provide stable carboxylated cellulosic fibers.
[0077] As noted above, in one embodiment, the method for making carboxylated cellulose pulp fibers includes two steps: (1) a first stage of carboxylation; and (2) a stabilization step in which any remaining aldehyde groups are converted to carboxyl groups providing a stable pulp.
[0078] In the first stage of carboxylation, cellulose pulp fibers are oxidized (i.e.,oxidized to aldehyde and carboxyl functional groups) under basic pH conditions and in the presence of a secondary oxidizing agent, such as chlorine dioxide, hypochlorite, peracids, or certain metal ions, with a catalytically active species (e.g., an oxammonium ion) generated from a N-halo hindered cyclic amine compound described above.
[0079] The first stage of the carboxylation process generally takes place at a temperature from about 20° C. to about 90° C. The hindered cyclic amine compound or the N-halo hindered cyclic amine compound is present in an amount from about 0.002% to about 0.25% by weight based on the total weight of the pulp. The secondary oxidizing agent is present in an amount from about 0.1 to about 10% by weight based on the total weight of the pulp. Reaction times for the first stage of carboxylating the pulp range from about 5 seconds to about 10 hours, depending upon reaction temperature and the amount of hindered cyclic amine compound or N-halo hindered cyclic amine compound and secondary oxidizing agent.
[0080] Chlorine dioxide is a suitable secondary oxidizing agent. The pH during oxidation should generally be maintained within the range of about 6.0 to 11, preferably about 6.0 to10, and most preferably about 6.25 to 9.0. The oxidation reaction will proceed at higher and lower pH values, but at lower efficiencies.
[0081] A study was conducted to determine effects of time and chemical loadings on the carboxyl content and viscosity of the pulp. The study was conducted at 50° C. and 70° C.
[0082] In each set of studies, water sufficient to achieve a final pulp consistency of 7.5% was placed in a Quantum mixer. The water was heated to the desired temperature (50° C. or 70° C.). Sodium hydroxide was added to the water in the amounts shown in Tables 2 and 3. 32.1% never-dried partially bleached softwood pulp from the Weyerhaeuser Prince Albert SK mill was added to the water. The pulp was taken from the E2 bleach stage. It weighed 150 g. on an oven-dry basis. The sample was quickly mixed at 100% power.
[0083] 2.25 grams of 2% EGK-TAA (ethylene glycol ketal of triacetonamine) was added to a chlorine dioxide solution. The amount of EGK-TAA was 0.03 weight % of the dry oven dry weight of the pulp. The amount of chlorine dioxide was varied as shown in the Tables 2 through 5.
[0084] The EGK-TAA/chlorine dioxide mixture was injected into the mixer while it was being stirred. Time 0 is the time that the injection of the mixture started.
[0085] At the end of the reaction time the stabilizing mixture was pressure injected into the pulp to quench the stage 1 oxidation and start the stage 2 stabilization. The pulp was stabilized with 0.5% HOOH and 3.9% sulfuric acid (pH<4) for 1 hours. The pH was not measured, but based on earlier experience the pH would have been below 4 and was probably between 2 and 3. There was a yellow color indicating the regeneration of chlorine dioxide by the reaction of chlorite with aldehyde groups which also indicated that the pH was below 4. Each sample was stabilized for about 1 hour. The stabilization temperature was targeted to be either 50° C. or 70° C. All samples were washed with DI water, treated with NaOH to convert the carboxylic acid groups on the pulp to the sodium salt form and washed. The samples were analyzed for carboxyl, viscosity, brightness and brightness reversion.
[0086] The control was the uncarboxylated pulp. The carboxyl content, viscosity, brightness and brightness reversion are shown in table 1.
TABLE 1 Carboxyl Visc Brightness Brightness Example meq/100 g mPa * s ISO Reversion 1 4.61 33.0 85.37 84.17
[0087] The results of the 70° C. tests are shown in Table 2 and the results of the 50° C. tests are shown in Table 3. The results of the 70° C. and 50° C. tests are listed by carboxyl content in Tables 4 and 5, respectively.
TABLE 2 Time ClO 2 NaOH Ratio Carboxyl Visc Brightness Brightness Ex. sec wt. % wt % ClO 2 :NaOH meq/100 g mPa * s ISO Reversion 2 5 1.0 0.70 0.70 7.14 28.0 91.07 89.61 3 5 1.0 1.00 1.00 7.56 24.5 91.74 90.37 4 15 1.0 0.85 0.85 7.85 25.4 91.90 90.45 5 25 1.0 0.70 0.70 8.02 25.8 91.23 89.32 6 25 1.0 1.00 1.00 6.88 19.4 91.39 89.80 7 5 1.2 1.02 0.85 8.35 24.1 91.48 89.99 8 15 1.2 0.84 0.70 8.53 24.8 91.56 90.26 9 15 1.2 1.02 0.85 7.74 20.3 91.55 90.20 10 15 1.2 1.02 0.85 8.11 20.0 92.14 90.56 11 15 1.2 1.02 0.85 8.21 20.2 91.93 90.61 12 15 1.2 1.20 1.00 7.59 19.4 91.64 90.19 13 25 1.2 1.02 0.85 7.32 18.9 91.19 89.73 14 5 1.4 1.40 1.00 7.81 21.6 91.73 90.38 15 5 1.4 0.98 0.70 8.71 24.1 92.00 90.79 16 15 1.4 1.19 0.85 8.77 19.4 92.07 90.65 17 25 1.4 0.98 0.70 9.23 24.8 91.61 90.06 18 25 1.4 1.40 1.00 8.23 17.5 92.22 90.69
[0088]
TABLE 3
Time
ClO 2
NaOH
Ratio
Carboxyl
Visc
Brightness
Brightness
Ex.
sec
wt. %
wt %
ClO 2 :NaOH
meq/100 g
mPa * s
ISO
Reversion
20
5
1.0
0.70
0.70
7.58
29.0
91.66
90.18
19
5
1.0
1.00
1.00
7.12
26.0
91.81
90.34
21
15
1.0
0.85
0.85
6.82
24.8
92.08
90.49
23
25
1.0
0.70
0.70
7.71
27.3
90.87
89.00
22
25
1.0
1.00
1.00
6.74
21.7
92.14
90.71
24
5
1.2
1.02
0.85
7.90
26.0
92.18
90.45
28
15
1.2
0.84
0.70
8.60
27.9
90.91
89.50
26
15
1.2
1.02
0.85
7.58
22.8
91.88
90.35
27
15
1.2
1.02
0.85
8.14
24.9
91.81
90.32
29
15
1.2
1.02
0.85
8.54
25.1
92.13
90.76
30
25
1.2
1.02
0.85
8.21
24.4
92.16
90.69
25
15
1.2
1.20
1.00
6.96
24.2
92.52
91.00
32
5
1.4
0.98
0.70
8.83
26.0
92.19
90.63
31
5
1.4
1.40
1.00
7.85
23.4
92.90
91.42
33
15
1.4
1.19
0.85
8.63
23.6
91.87
90.13
34
25
1.4
0.98
0.70
9.34
27.9
91.77
90.29
35
25
1.4
1.40
1.00
8.03
19.8
92.41
90.79
[0089]
TABLE 4
Time
ClO 2
NaOH
Ratio
Carboxyl
Visc
Brightness
Brightness
Ex.
sec
wt. %
wt %
ClO 2 :NaOH
meq/100 g
mPa * s
ISO
Reversion
6
25
1.0
1.00
1.00
6.88
19.4
91.39
89.80
2
5
1.0
0.70
0.70
7.14
28.0
91.07
89.61
13
25
1.2
1.02
0.85
7.32
18.9
91.19
89.73
3
5
1.0
1.00
1.00
7.56
24.5
91.74
90.37
12
15
1.2
1.20
1.00
7.59
19.4
91.64
90.19
9
15
1.2
1.02
0.85
7.74
20.3
91.55
90.20
14
5
1.4
1.40
1.00
7.81
21.6
91.73
90.38
4
15
1.0
0.85
0.85
7.85
25.4
91.90
90.45
5
25
1.0
0.70
0.70
8.02
25.8
91.23
89.32
7
5
1.2
1.02
0.85
8.35
24.1
91.48
89.99
10
15
1.2
1.02
0.85
8.11
20.0
92.14
90.56
11
15
1.2
1.02
0.85
8.21
20.2
91.93
90.61
18
25
1.4
1.40
1.00
8.23
17.5
92.22
90.69
8
15
1.2
0.84
0.70
8.53
24.8
91.56
90.26
15
5
1.4
0.98
0.70
8.71
24.1
92.00
90.79
16
15
1.4
1.19
0.85
8.77
19.4
92.07
90.65
17
25
1.4
0.98
0.70
9.23
24.8
91.61
90.06
[0090]
TABLE 5
Time
ClO 2
NaOH
Ratio
Carboxyl
Visc
Brightness
Brightness
Ex.
sec
wt. %
wt %
ClO 2 :NaOH
meq/100 g
mPa * s
ISO
Reversion
22
25
1.0
1.00
1.00
6.74
21.7
92.14
90.71
21
15
1.0
0.85
0.85
6.82
24.8
92.08
90.49
25
15
1.2
1.20
1.00
6.96
24.2
92.52
91.00
19
5
1.0
1.00
1.00
7.12
26.0
91.81
90.34
20
5
1.0
0.70
0.70
7.58
29.0
91.66
90.18
26
15
1.2
1.02
0.85
7.58
22.8
91.88
90.35
23
25
1.0
0.70
0.70
7.71
27.3
90.87
89.00
31
5
1.4
1.40
1.00
7.85
23.4
92.90
91.42
24
5
1.2
1.02
0.85
7.90
26.0
92.18
90.45
35
25
1.4
1.40
1.00
8.03
19.8
92.41
90.79
27
15
1.2
1.02
0.85
8.14
24.9
91.81
90.32
30
25
1.2
1.02
0.85
8.21
24.4
92.16
90.69
29
15
1.2
1.02
0.85
8.54
25.1
92.13
90.76
28
15
1.2
0.84
0.70
8.60
27.9
90.91
89.50
33
15
1.4
1.19
0.85
8.63
23.6
91.87
90.13
32
5
1.4
0.98
0.70
8.83
26.0
92.19
90.63
34
25
1.4
0.98
0.70
9.34
27.9
91.77
90.29
[0091] Another set of studies was conducted to determine carboxylation at times of 15 seconds, 30 seconds, 60 seconds, 120 seconds, 180 seconds and 240 seconds.
Example 35
[0092] Never-dried partially bleached softwood pulp collected after the E2 bleach stage of the Weyerhaeuser Prince Albert SK mill pulp having an oven dry weight of 60 g, and 9.2 g sodium carbonate was added to 310 g of DI water and the mixture was heated to 70° C. 98 mL of chlorine dioxide, 6.7 g/L, and 1.2 g of ethylene glycol ketal of triacetoneamine (EGK-TAA) were mixed and added to the pulp. The pulp was mixed rapidly by hand. Samples were taken at 15, 30, 60, 120, 180 and 240 seconds after the ClO 2 /EGK-TAA solution first contacted the pulp. Each of the samples were placed in a solution of 0.5 g NaBH 4 in 100 mL of water and left overnight at room temperature with periodic stirring. The pulps were then tested for carboxyl content. The carboxyl content in meq/100 g were as follows: 15 seconds—6.7, 30 seconds—6.8, 60 seconds—7.2, 120 seconds—7.5, 180 seconds—7.55, 240 seconds—7.6.
Example 36
[0093] Northern softwood partially bleached kraft pulp collected after the E2 stage of the Weyerhaeuser Prince Albert, SK pulp mill was dewatered to 25-30% solids with a screw press.
[0094] All percentages are weight percentages based on the oven dry weight of the pulp.
[0095] The pulp was slurried in water and fed to a twin roll press which delivered pulp at a predetermined constant rate of 3.0 kg/minute pulp solids at 8-9% consistency (weight of pulp/weight of water) to a pilot process. Just after the twin roll press, sodium hydroxide was sprayed on the pulp stream at a rate of 0.65%. The pulp slurry was then mixed and heated in a steam mixer and fed to a Seepex progressive cavity pump which provided pulp slurry flow through two high intensity mixers and an upflow tower. The upflow tower fed a downflow tower by gravity. Pulp product was mined from the bottom of the downflow tower, adjusted to pH 7-9 with sodium hydroxide and dewatered on a belt washer.
[0096] EGK-TAA was dissolved in water and metered into a chlorine dioxide line. The mixture was 0.03% EGK-TAA and 0.88% chlorine dioxide. This line was connected to the pulp slurry process pipe just before it entered the first high intensity mixer. The Chlorine dioxide/EGK-TAA mixture was injected into the flowing pulp slurry and immediately mixed in the first high intensity mixer. Just before the second high intensity mixer, a mixture of sulfuric acid (0.17%) and hydrogen peroxide (0.5%) was injected into the pulp slurry. The distance between the 1 st high intensity mixers and the injection of the sulfuric acid/hydrogen peroxide, and the speed of the pulp slurry will determine the reaction time for the first stage of the carboxylation of the pulp. This setup allowed times as short as 6 seconds, but was preferred to be 15-30 seconds. In this example the time was 6 seconds. The pulp immediately enters the 2 nd high intensity mixer and mixed again. The pulp slurry flowed into the upflow tower and spent approximately 30 minutes there before entering the downflow tower where it spent approximately an hour. It was then mined from the bottom of the downflow tower.
[0097] The temperature at the bottom of the upflow tower was maintained at 50° C. by adjustments to the steam flow to the steam mixer. The pH was monitored near the end of the retention pipe prior to the sulfuric acid/hydrogen peroxide injection and was maintained at 6.25-6.75 by minor adjustments to the sodium hydroxide addition level to the pulp after the twin wire press. The pH was monitored at the bottom of the upflow tower and was maintained at 3.5-4.0 by minor adjustments to the sulfuric acid flow.
[0098] The dewatered pulp product had a carboxyl level of 8.5 meq/100 g, an ISO brightness of 90.38% and a viscosity of 25.6 mPa-s.
[0099] It can be seen that short reaction times are possible and that it is possible to use existing equipment with little modification to carboxylate wood pulp.
[0100] FIG. 1 shows a standard extract stage and a chlorine dioxide stage of a pulp mill. Pulp, in slurry form, which has been bleached with a bleaching chemical such as chlorine, chlorine dioxide or hydrogen peroxide is treated with sodium hydroxide is extraction tower 10 . Sodium hydroxide solubilizes the chemicals in the pulp that have reacted with the bleaching chemical. The pulp is carried to washer 12 in which the solubilized material is washed from the pulp.
[0101] The pulp slurry is moved from the washer 12 to the next stage by pump 18 (shown in FIGS. 2 and 3 ) and then mixed with chlorine dioxide in mixer 24 (shown in FIGS. 2 and 3 ) and flows into the upflow section 13 of chlorine dioxide tower 14 . The pulp slurry then passes through the downflow section 15 of the tower 14 where it continues to react with the chlorine dioxide. The slurry then leaves the tower 14 and is washed in a washer 16 (shown in FIGS. 2 and 3 ).
[0102] The short reaction time of the first stage of the carboxylation process allows a simple modification to the standard extraction and chlorine dioxide stage to allow carboxylation and stabilization in these units.
[0103] This is shown in FIGS. 2 and 3 . These are different representations of the process.
[0104] There is an additional mixer and a reaction chamber between the washer 12 and the chlorine dioxide tower 14 .
[0105] The pump 18 mixes a base chemical with the pulp slurry. The base chemical is any chemical which will provide an appropriate pH for the slurry. Sodium hydroxide or sodium carbonate are preferred. Sodium hydroxide is the most preferred because it is the chemical used in the extraction reaction and no new chemical is required. The base chemical is supplied from unit 17 through line 19 . The base chemical may be supplied to the slurry either before or at the pump 18 . The base chemical should be mixed thoroughly with the slurry before the addition of the carboxylation chemicals.
[0106] The mixer 20 mixes the carboxylation chemicals with the pulp slurry. The carboxylation chemicals are supplied from units 21 or 21 ′ through lines 22 and 22 ′. The carboxylation chemicals may be supplied to the slurry either before or at mixer 20 . The carboxylation chemicals may be any of those mentioned. The preferred secondary oxidant is chlorine dioxide. The preferred primary oxidant is triacetoneamine ethylene glycol ketal (TAA-EGK).
[0107] The pulp slurry then enters the reaction chamber 23 in which the first stage of the carboxylation process occurs. The size of the reaction chamber 23 will depend on the length of time of the catalytic oxidation reaction. The reaction chamber will be a tank if the reaction is over 1 minute. It will be a good-sized tank if the reaction is over 2 minutes and a large tank if the reaction is over 15 minutes. The reaction chamber 23 can be a pipe if the reaction is under a minute. It will be a large and probably curved pipe, as shown, if the reaction is over 30 seconds. It can be a straight pipe, and possibly the existing pipe, if the reaction is 30 seconds or less. The reaction can be around 15 seconds and can, in certain instances, be as short as 1 second. The diameter and length will be of a size that will accommodate the flow of pulp slurry for the time required for the oxidation reaction.
[0108] Mixer 24 mixes the stabilization chemicals with the pulp slurry. The stabilization chemicals are supplied from units 25 and 25 ′ through lines 26 and 26 ′. The chemicals may be supplied to the slurry either before or at mixer 24 . The stabilization chemicals can be any of those mentioned. Alkali metal chlorites, hydrogen peroxide, acid, chlorine dioxide and peracids are among the chemicals that may be used. It is preferred that an acid, such as sulfuric acid, and a peroxide, such as hydrogen peroxide, be used. It is most preferred that an acid be used.
[0109] The pulp slurry then enters the upflow section 13 of the chlorine dioxide tower 14 and then transfers to the downflow section 15 of tower 14 . The stabilization reaction occurs in tower sections 13 and 15 .
[0110] While the system has been described in terms of an extraction stage 10 , it can also be used in systems in which there are two chlorine dioxide towers separated by a washing stage. The system would be identical to that described herein except that extraction tower 10 would be a chlorine dioxide tower. It may be necessary to use more chlorine dioxide in this system.
[0111] It can be seen that the system can be changed from a regular pulp bleach stage to a carboxylation stage may simply adding or removing chemicals from the system. The addition of the base chemicals, the catalyst, the acid and the peroxide turns it into a carboxylation unit, the absence of these chemicals returns it to a standard pulp bleach stage.
[0112] Those skilled in the art will recognize that the present invention is capable of many modifications and variations without departing from the scope thereof. Accordingly, the detailed description set forth above is meant to be illustrative only and is not intended to limit, in any manner, the scope of the invention as set forth in the appended claims. It will be noted that other catalytic oxidation and stabilization chemicals may be used, but the chemicals noted are the preferred chemicals.
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An apparatus for carboxylating wood pulp which utilizes the wood pulp bleach plant and the method of carboxylating the pulp which takes place in the bleach plant.
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