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REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and is a nonprovisional of U.S. Provisional Patent Application No. 62/060,056, filed on Oct. 6, 2014, with title INTEGRATED VEHICLE MONITORING AND CONTROL SYSTEM BY SMARTPHONE.
FIELD
[0002] The present disclosure relates to circuits and systems for monitoring and control of vehicle systems and sensors using or as a function of the presence of a personal communication device and/or app.
BACKGROUND
[0003] The dangers of drivers sending text messages or otherwise manually operating mobile telephones, smartphones, or other personal communication devices (generically, Personal Communication Devices (“PCDs”) herein) while driving are well understood, yet the behavior continues. According to the US Department of Transportation, in 2014, distracted driving caused 1,566,000 collisions, 500,000 injuries, and 6,000 deaths in the United States. Improved techniques for discouraging attention-impaired driving and/or reducing the risk associated therewith are needed. Likewise, parental management of distracted vehicle use by young drivers and fleet company management of distracted vehicle use by employees is awkward and uninformative at best, and sometimes impossible. Improved techniques for managing distracted vehicle use are also needed.
SUMMARY
[0004] Some embodiments of the disclosed system integrate a PCD and a vehicle, thereby allowing monitoring of driver activity and providing audible and visible warnings to passengers and external observers that a distracted driver might be operating the vehicle. In some embodiments, the system does not restrict the operation or use of PCDs by vehicle passengers accompanying the driver, provided that a passenger is seated in the front passenger compartment. In some embodiments, the system also provides for one or more specific PCDs to act as “parallel” and/or “serial” vehicle keys. Some embodiments use a physical key device as a “valet key” that allows limited operation of the vehicle. Various other embodiments of the disclosed, integrated system are intended to reduce the incidence of distracted motor vehicle operation and thereby reduce accidents and injury caused by distracted driving.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a top cutaway schematic view of a vehicle with a PCD use alert system according to one embodiment of the present disclosure.
[0006] FIG. 2 is a flowchart illustrating the sequence of operation of the embodiment of FIG. 1 .
[0007] FIG. 3 is a schematic diagram of a computing device for use in various roles in the disclosed systems.
[0008] FIG. 4 is a flowchart illustrating a sequence of operation of a PCD-vehicle interlock according to the present disclosure.
[0009] FIG. 5 is a flowchart illustrating an optional sequence of operation for valet key in connection with the sequence of operation in FIG. 4 .
[0010] FIG. 6 is a flowchart illustrating the sequence of operation for a “parallel key” interlock according to the present disclosure.
DESCRIPTION
[0011] For the purpose of promoting an understanding of the principles of the present invention, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It will, nevertheless, be understood that no limitation of the scope of the invention is thereby intended; any alterations and further modifications of the described or illustrated embodiments, and any further applications of the principles of the invention as illustrated therein, are contemplated as would normally occur to one skilled in the art.
[0012] Generally, one form of the present system is an integrated PCD-vehicle monitoring and control system that uses vehicle systems to discourage use of the PCDs features while driving and/or to enforce certain limits on operation of the vehicle. An interlock (e.g., a control connection between the PCD and the vehicle's ignition system) connects with operational systems of the vehicle and modifies their operation as a function of the operational state of the vehicle, a key, the PCD, and/or inputs thereto.
[0013] With reference to FIG. 1 , example system 100 includes vehicle 105 and PCD 110 . As is well understood in the art, vehicle 105 includes driver's seat 115 , passenger's seat 120 , and rear seats 125 , headlights 130 , taillights 135 , “Cyclops” taillight 140 , and corner/warning lights 145 . Additional standard or optional devices and sensors, such as those associated with seat belt buckles 150 and 155 , passenger seat occupant sensor 160 , Bluetooth antenna 175 , engine control microprocessor (ECM) 180 , memory 182 , alarm sound generator 185 , chime generator 187 , dashboard indicator 189 , and display 190 are included as would occur to those skilled in the art.
[0014] Operation of the illustrated system will now be described with reference to FIG. 2 and continuing reference to FIG. 1 . At the beginning of example process 200 , ECM 180 detects the presence of PCD 110 in or near vehicle 105 , identifies PCD 110 , and creates ( 210 ) a data connection therewith, such as via Bluetooth antenna 175 . In other embodiments, alternative data connection techniques are used, such as wired or wireless USB, near-field communications (NFC), or other techniques as will occur to those skilled in the art.
[0015] The system 100 then monitors the transmission of vehicle 105 , such as whether the transmission is in “Park” (or, in some embodiments, either in “Park” or “Neutral”) ( 220 ). If so (a positive result at conditional block 220 ), the system continues this monitoring. When vehicle 105 is shifted out of Park (a negative result at conditional block 220 ), system 100 begins to monitor ( 230 ) PCD 110 for trigger activity.
[0016] The system 100 then monitors operation of the PCD 110 and, if certain conditions (a “trigger activity”) are met, generates an alert. In some embodiments, this monitoring is performed by an app, service, or other software running on PCD 110 that monitors its activity and communicates relevant aspects of it using available communications channels to ECM 180 . In some embodiments, monitoring alternatively or additionally occurs at ECM 180 by monitoring traditional bus/interface communications. In still others, activity is monitored indirectly by detecting levels, location, direction, timing, and/or changes in the level of electromagnetic radiation emanating from sources within the passenger compartment of vehicle 105 .
[0017] This monitoring continues as long as the system 100 waits for a trigger activity ( 230 ). When such an event is observed (positive result at conditional block 230 ), system 100 checks ( 240 ) whether the driver is the only adult riding in the front seat(s). This check uses, for example, a logical combination of outputs from one or more of passenger seat occupant sensor 160 , a sensor in passenger seatbelt buckle 155 , and other available sensors. If there is an adult passenger in the passenger seat (negative result at conditional block 240 ), system 100 suggests ( 250 )—using one or more of the display of PCD 110 , audio prompts played through the audio output of PCD 110 or the cabin of vehicle 105 , or another available visual or audio interface, such as display 190 built into vehicle 105 —that the other adult complete the activity. (In some implementations, when a person is present in the front passenger-side seat, the monitoring alert aspects of the system are disabled. In some others, trigger actions yield an audio and/or visual announcement to avoid driver distraction. In still others, the presence or absence of a person in the front passenger-side seat has no effect on system 100 .) The system waits ( 260 ) for the trigger activity to end, then goes back to monitoring for trigger activity. In some embodiments, the announcements, prompts, and/or alerts continue throughout the duration of the trigger activity, while in others, they stop after a period of time.
[0018] If the driver is the only adult in the front seat (a positive result at conditional block 240 ), the system 100 initiates an alarm ( 270 ). In various embodiments, the alarm action includes one or more of:
[0019] engaging the vehicle's flashing “hazard” lights ( 145 );
[0020] engaging the audible chime 187 in the passenger compartment, such as one that is also used to indicate an unfastened seatbelt;
[0021] turn on the interior “cabin light,” “dome light,” dashboard light and/or other indicator 189 , or other interior lighting;
[0022] intermittently sound the vehicle's horn or external alarm sound generator 185 ;
[0023] store the date, time, and trigger information for collection and reporting;
[0024] send a notification of the trigger to law enforcement authorities, insurance companies, parents, fleet managers, or other interested parties; and
[0025] send notification of the presence of a distracted driver to other users of the same or similar systems who are in the geographical vicinity of vehicle 105 .
[0026] System 100 then waits ( 280 ) for the conditions to occur when it should cease the alarm action(s). In various embodiments, this may be the passage of a particular amount of time (for example, 10 minutes) from triggering of the alarm, the passage of a certain amount of time after the last trigger behavior, the vehicle 105 coming to a complete stop with the transmission in “Park” (or, in some embodiments, either in “Park” or “Neutral”) and/or the ignition off (perhaps also requiring passage of a particular amount of time, such as 1-5 minutes), or some combination of two or more conditions combined using Boolean or other programmatic logic, as will occur to those skilled in the art. When the conditions for ending the alarm occur (a “yes” result at conditional block 280 ), the alarm is turned off ( 290 ), and the system returns to monitoring ( 230 ) for a trigger event.
[0027] The monitoring of PCD 110 is implemented in this embodiment using a software application running on the processor of the PCD, which in the present embodiment comprises a computing device (see below). In this embodiment, the software application registers listeners with the device's operating system to get (internal, automatic, electronic) notices when the user receives, composes, and/or sends a text message, places a phone call, operates email or a chat application, actuates a physical or virtual button, interacts with an activated touchscreen, or otherwise uses the device in any other way. In other embodiments, more, fewer, or different activities are monitored. When the application receives notice of such activity from the operating system, it communicates data describing the activity to ECM 180 , which initiates an alarm.
[0028] The illustrated embodiment also detects whether the vehicle operator is the sole adult in the front of the vehicle and in possession of the PCD 110 . It uses passenger seat occupant sensor 160 to determine whether a second adult is present in the front, passenger-side seat(s). If so, in some embodiments, the alarm functionality is disabled. In others, when a passenger is detected by the passenger seat occupant sensor 160 , ECM 180 plays an audio prompt, engages a chime (as when a seat belt is unfastened though a passenger is detected), and/or displays a message on the PCD 110 or display 190 suggesting that the driver ask a passenger to complete the activity. If no second adult is present, and if the driver proceeds to use the PCD 110 in spite of the warning, the alarm proceeds.
[0029] While the present description is being given in terms of certain components of the system taking certain actions, sending signals, and initiating notices, those skilled in the art will appreciate that variations of signal initiation and flow can implement various embodiments without undue experimentation. For example, the system may be implemented using an aftermarket processor to implement all of the steps, using a standard external interface (e.g., Controller Area Network (CAN), OBD II, etc.) to the original equipment manufacturer's system to collect relevant sensor data and take responsive actions through other vehicle systems. In some embodiments, part of the processing is done by one or more processors built into the vehicle's original systems, with other portions of the processing occurring in an external processor. And in some embodiments, all of the vehicle-side processing occurs in original equipment.
[0030] In some embodiments, information about trigger events is recorded in a memory associated with ECM 180 , including, as an example, the type of communication detected, GPS location of the vehicle at that time, sensor readings, date, and time. This data is then made available to the owner of the vehicle (such as a parent), corporate owner, fleet operator, governmental agency or entity, insurance company, law enforcement agency, or operator of a toll road or throughway on which the vehicle was operating at the time of infraction, such as through the EZ-Pass system. In some of these systems, payment of a fine for the infraction is automatically paid through the associated payment relationship between the driver/vehicle owner and the insurance company, fleet operator, or toll road operator or authority.
[0031] In some embodiments, the app on the PCD 110 functions as a key for access to and operation of vehicle 105 . In these embodiments, if the app is not operating to correctly report the status of PCD 110 , vehicle 105 refuses to operate or, in a variation, refuses to perform certain functions. On the other hand, when PCD 110 is running the app in the proximity of vehicle 105 , the app can be used to start its ignition, lock doors, adjust climate control options, control the audio system, and take other actions as will occur to those skilled in the art. In a variation of this embodiment, a wireless data connection between vehicle 105 and a data center connects a web portal to the integrated control system on vehicle 105 , enabling authenticated users to control various systems of vehicle 105 via a website or remote app. In a particularly useful variation, the website or remote app is able to dynamically de-authorize PCD 110 and authorize a new device to serve as PCD 110 in the event that the existing PCD 110 is lost or stolen.
[0032] In some embodiments of the systems described herein, the computing resources/devices that are applied generally take the form of a mobile, laptop, desktop, or server-type computer, as mentioned above and as will occur to those skilled in the art. With reference to FIG. 3 , the “computer” 300 (as this example will generically be referred to) includes a processor 320 in communication with a memory 330 , input interface(s) 340 , output interface(s) 350 , and network interface 360 . Memory 330 stores a variety of data, but is also encoded with programming instructions executable to perform the functions described herein. Power, ground, clock, and other signals and circuitry (not shown) are used as appropriate as will be understood and easily implemented by those skilled in the art.
[0033] The network interface 360 connects the computer 300 to a data network 370 for communication of data between the computer 300 and other devices attached to the network 370 . Input interface(s) 340 manage communication between the processor 320 and one or more touch screens, sensors, pushbuttons, UARTs, IR and/or RF receivers or transceivers, decoders, or other devices, as well as traditional keyboard and mouse devices. Output interface(s) 350 provide signals to one or more output devices (not shown) such as LEDs, LCDs, or audio output devices, local multimedia devices, local notification devices, or a combination of these and other output devices and techniques as will occur to those skilled in the art.
[0034] The processor 320 in some embodiments is a microcontroller or general purpose microprocessor that reads its program from the memory 330 . The processor 320 may be comprised of one or more components configured as a single unit. Alternatively, when of a multi-component form, the processor may have one or more components located remotely relative to the others. One or more components of the processor may be of the electronic variety including digital circuitry, analog circuitry, or both. In some embodiments, the processor is of a conventional, integrated circuit microprocessor arrangement, such as one or more CORE i3, i5, or i7 processors from INTEL Corporation of 2200 Mission College Boulevard, Santa Clara, Calif. 95052, USA, or OPTERON or PHENOM processors from Advanced Micro Devices, One AMD Place, Sunnyvale, Calif. 94088, USA, while in others nontraditional or innovative data processing technology is used. In alternative embodiments, one or more reduced instruction set computer (RISC) processors, graphics processing units (GPU), application-specific integrated circuits (ASICs), general-purpose microprocessors, programmable logic arrays, or other devices may be used alone or in combinations as will occur to those skilled in the art.
[0035] Likewise, the memory 330 in various embodiments includes one or more types such as solid-state electronic memory, magnetic memory, or optical memory, just to name a few. By way of non-limiting example, the memory 330 can include solid-state electronic Random Access Memory (RAM), Sequentially Accessible Memory (SAM) (such as the First-In, First-Out (FIFO) variety or the Last-In First-Out (LIFO) variety), Programmable Read-Only Memory (PROM), Electrically Programmable Read-Only Memory (EPROM), or Electrically Erasable Programmable Read-Only Memory (EEPROM); an optical disc memory (such as a recordable, rewritable, or read-only DVD or CD-ROM); a magnetically encoded hard drive, floppy disk, tape, or cartridge medium; a solid-state or hybrid drive; or a plurality and/or combination of these memory types. Also, the memory in various embodiments is volatile, nonvolatile, or a hybrid combination of volatile and nonvolatile varieties.
[0036] Computer programs implementing the methods described herein will commonly be stored and/or distributed either on a physical distribution medium such as CD-ROM or pluggable memory module (for example, a flash memory device with a USB interface), or via a network distribution medium such as an internet protocol and/or cellular data network, using other media, or through some combination of such distribution media. From there, they will in some embodiments be copied to a hard disk, non-volatile memory, or a similar intermediate storage medium. When the programs are to be run, they are loaded either from their distribution medium or their intermediate storage medium into the execution memory of the computer, configuring the computer to act in accordance with the methods described herein. All of these operations are well known to those skilled in the art of computer systems.
[0037] The term “computer-readable medium” herein encompasses non-transitory distribution media, intermediate storage media, execution memory of a computer, and any other medium or device capable of storing a computer program implementing a method for later reading by a computer.
[0038] In some embodiments, which will be discussed with reference to FIGS. 4 and 5 and with continuing reference to FIG. 1 , PCD 110 operates as a “serial key” to traditional key 195 that is made available to certain drivers. (That is, both traditional key 195 and PCD 110 are required for operation of vehicle 105 .) Following process 400 , the engine of vehicle 105 will only start in response to presentation of key 195 if the vehicle is in communication with (or can promptly establish communication with) one or more particular PCD's 110 . Exemplary process 400 begins with the transmission of vehicle 105 locked ( 402 ) in a “Park” (or, in some embodiments, either “Park” or “Neutral”) state. In various alternative embodiments, the vehicle's engine is also off, while in others, other features and functionality of vehicle 105 are disabled.
[0039] ECM 180 receives ( 404 ) an indication of the presence of key 195 . In various embodiments, this indication includes physical insertion of key 195 into a traditional three-position ignition switch, proximity detection of a fob with a Bluetooth transceiver via Bluetooth or Bluetooth LE, NFC data exchange, RF communications, or other techniques as will occur to those skilled in the art, and key (or “physical key device”) 195 has a corresponding form.
[0040] Upon receiving that indication of the presence of key 195 , ECM 180 attempts ( 406 ) to establish a data connection with a nearby PCD 110 . In some embodiments, this connection attempt occurs by way of Bluetooth protocols, wired or wireless USB, Wi-Fi, or other connection protocol as will occur to those skilled in the art. If the connection attempt is successful (“yes” at decision block 408 ), ECM 180 uses the data connection to attempt to identify ( 410 ) PCD; that is, ECM 180 reads/receives an identifier, engages in a challenge-response or other cryptographic authentication process, or otherwise determines the identity of PCD 110 using techniques that will occur to those skilled in the art. In some embodiments, this identification of PCD 110 will occur as part of the process of establishing a data connection, while in others it will be done separately.
[0041] In some such embodiments, a unique identifier for the presented PCD (which might be a MAC address, Bluetooth device ID, IMEI number, encrypted authentication data, or other identifier as will occur to those skilled in the art) is communicated to ECM 180 to confirm that the particular phone is present. In some of these embodiments, the identifier is compared ( 412 ) with a list of identifiers previously stored in memory 182 . Some embodiments store this list when the system 100 is installed (such as at the factory or dealership or by an aftermarket installer), while the vehicle owner has the ability to maintain the list by way of a website, application, or through the vehicle display 190 .
[0042] If the identifier for PCD 110 is on the list of acceptable devices (positive result at decision block 412 ), ECM 180 unlocks ( 414 ) the transmission (or enables the vehicle 105 to start, or otherwise enables functionality or operation that was initially limited at ( 402 )). On the other hand, if the identifier for PCD 110 is not on the list (negative result at decision block 412 ), or if the attempted connection to a PCD 110 failed (negative result at decision block 408 ), process 400 returns to waiting for a key (and does not enable [full] operation of the vehicle 105 ).
[0043] In a variation on these embodiments, process 400 operates in a special “valet key” mode and/or allows override using a passcode in the absence of an approved PCD 110 . In these embodiments, upon a negative result's decision block 408 or decision block 412 , process 400 turns to subprocess 420 , shown in FIG. 5 , (at connection point A) before returning to waiting for a key (via connection point B). Subprocess 420 in this embodiment begins by prompting ( 422 ) the driver using display 190 to proceed in “valet key” mode or for entry of a vehicle access passcode. If the user chooses to operate as a “valet key” (positive result at decision block 424 ), then system 100 imposes ( 426 ) limits on the vehicle's travel, including speed and distance limitations and other limitations as will occur to those skilled in the art. Violations of these limitations are logged and reported. Entertainment and built-in communication systems are turned off ( 428 ), and these limitations are preferably displayed ( 430 ) to the user on display device 190 . In embodiments where vehicle 105 has an available data connection, the state, location, and operation of vehicle 105 while in “valet key” mode is communicated ( 442 ) to an owner's device (perhaps using the same app as identifies an authorized PCD 110 ) so the owner can monitor that operation substantially in real time. Process 400 then continues (via connection point C) by unlocking ( 414 ) the transmission and allowing (limited) vehicle operation.
[0044] If the user elects not to enter “valet key” mode (negative result at decision block 424 ) and decides to enter a passcode (positive result at decision block 432 ), system 100 accepts entry of a passcode ( 434 ) and compares ( 436 ) the entered passcode with one or more stored, authorized passcodes. If a match is found (positive result from decision block 438 ), use of the passcode is logged ( 440 ), and the user is guided ( 450 ) through the process of pairing PCD 110 with system 100 and adding PCD 110 to the list of acceptable devices (see above discussion regarding decision block 412 ) or otherwise managing that list. Process 400 continues (via connection point C) by unlocking the transmission ( 414 ). On the other hand, if the user elects not to enter a passcode (negative result at decision block 432 ) or the entered passcode is not on the list of authorized passcodes (negative result at decision block 438 ), process 400 returns (via connection point B) to waiting for presentation of the key at block 404 .
[0045] In variations on these embodiments, entry of an acceptable passcode (positive result at decision block 438 ) gives the user the option of adding a new PCD 110 to the list of authorized devices. If that new PCD 110 is present and activated, the transmission may be unlocked (or other functionality enabled), and vehicle 105 continues as described above. If the user entered a correct passcode and does not want to add a new PCD 110 , but needs to operate vehicle 105 , system 100 prompts the user via display 190 to certify that no PCD 110 is in vehicle 105 . In some implementations, in contrast with process 420 illustrated in FIG. 5 , multiple passcode entry attempts are allowed before the vehicle turns off and removal of operational limitations is aborted. Passcode entry and valet mode operation are logged and reported.
[0046] Similarly, as will now be discussed with reference to FIG. 6 and continuing reference to FIG. 1 , software on PCD 110 operates in some embodiments as a “parallel key” to traditional key 195 . (That is, vehicle 105 is configured to operate using either PCD 110 or key 195 for operation.) In this process 450 , vehicle 105 begins in the state of waiting to detect the presence of key 195 or PCD 110 . (While this and other waiting and monitoring states described herein may be implemented using polling, interrupt, or other techniques as will occur to those skilled in the art, FIG. 6 illustrates the state as a tight conditional loop.) If ECM 180 does not connect to and identify a PCD 110 (negative result at decision block 452 ), ECM 180 determines whether a key 195 is present (as discussed above, though here illustrated only as decision block 454 ). If there is also no key 195 (negative result at decision block 454 ), process 450 continues its waiting.
[0047] If a PCD 110 is connected (positive result at decision block 452 ) or key 195 is detected, authenticated, and running appropriate software (positive result at decision block 454 ), the vehicle 105 is unlocked ( 456 ), and its ignition switch is enabled ( 458 ). Activity monitoring software is enabled ( 460 ) on PCD 110 , and the transmission is unlocked ( 462 ).
[0048] In some alternative embodiments, upon detection of a key 195 at decision block 454 , system 100 operates in “valet key” mode as described herein together with a positive result at decision block 424 and blocks 426 , 428 , and 430 in FIG. 5 .
[0049] Some embodiments are advantageously used to manage the vehicle use by minors, employees, fleet drivers, and the like. In these restricted-use embodiments, the driver's key 195 cannot operate vehicle 105 without an authenticated PCD 110 that is running associated software. Various parameters of operation of vehicle 105 are monitored, such as speed, location, radio volume, time of operation, location, seatbelt usage, and other parameters as will occur to those skilled in the art. In some implementations, all such data is logged and reported, while in others, data beyond certain limits is logged and reported. In some embodiments, one or more of these parameters are limited so that limits are imposed on settings (such as radio volume) or operation (such as starting the car after certain time) by leveraging the connection between the PCD 110 and ECM 180 .
[0050] In some embodiments, PCD 110 periodically communicates information to ECM 180 , confirming that the monitoring software (mentioned herein) is still operating and detecting no trigger events. If the software detects a trigger event, or if ECM 180 loses communication with PCD 110 , or if the periodic signal is not received within a particular window of time, ECM 180 responds as to a trigger event (e.g., as described above). In some variations of these embodiments, ECM 180 only allows the vehicle's engine to be started if authenticated communication can be established with any of one or more previously approved PCD's 110 . The list of approved PCD's 110 can be maintained by an interaction with display 190 that includes authentication using a particular pass code, an “owner” device, or other techniques as will occur to those skilled in the art.
[0051] In some variations of this embodiment, the app on PCD 110 is further operable to control systems of vehicle 105 , such as starting the engine, locking or unlocking the doors, opening the trunk, triggering alarms, flashing or turning on lights, adjusting climate control, managing or controlling the entertainment or navigation systems, adjusting environmental controls, logging maintenance activities/schedules/diagnoses, enabling an engine block or fuel supply heater based on temperature sensors in the vehicle, and the like. In some implementations, the app on PCD 110 enables a navigation app also on PCD 110 to connect to and override a navigation system built into vehicle 105 so that the display 190 and other interface components of vehicle 105 operate as user interface devices for the navigation app. Some or all of the data collected by the app or by ECM 180 in communication (and communication attempts) with PCD 110 may be communicated to the vehicle owner (or fleet owner, insurance company, law enforcement agency, toll road operator, etc.) for accountability or other purposes. These communications (commands and data) proceed in some embodiments via a local data connection such as Bluetooth, Wi-Fi, USB, or other wired or wireless protocol as will occur to those skilled in the art), while in others they pass through a wireless wide-area network (such as the cellular data network and/or the Internet).
[0052] Similarly, settings for system 100 are managed in some embodiments by means of a website or other interface as will occur to those skilled in the art. Any relevant parameter of system 100 , from the identities of authorized PCD's 110 to the speed and distance allowed under “valet key” operation and the like can be customized. For vehicles 105 that have persistent, long-range data connections (such as via cellular data networks), settings are communicated to ECM 180 either immediately, the next time the vehicle is powered on and connected to the network, or at some polling interval. Vehicles 105 that do not have such data connections leverage the data connections of PCD's 110 that connect to ECM 180 to download settings updates.
[0053] Throughout this description, various data elements are described as being collected, logged, and/or reported. In each case, various embodiments store those data elements in a memory ( 182 , 330 , etc.) that is part of one or more systems on vehicle 105 , part of PCD 110 , or elsewhere. The data may be periodically summarized as will occur to those skilled in the art. In various embodiments, the data or summary is transferred in real time, at regular intervals, and/or at opportune times when data connections (or inexpensive data connections, such as Wi-Fi or Bluetooth) are available. In various implementations, these transfers go to one or more drivers of vehicle 105 , parents, fleet owners/operators, cloud computing servers, Internet sites, vehicle manufacturers, government agencies, insurance companies, banks, contractors, accountability partners, and other interested persons.
[0054] In variations of the embodiments described herein, ECM 180 (see FIG. 1 ) comprises a plurality of processors 320 (see FIG. 3 ), and the various actions by, connections with, and communications involving ECM 180 in those descriptions involve separate processing components that might or might not have anything to do with traditional “engine control” or traditional “ECM's.”
[0055] The term “computer-readable medium” herein encompasses non-transitory distribution media, intermediate storage media, execution memory of a computer, and any other medium or device capable of storing a computer program implementing a method for later reading by a computer.
[0056] When an act is described herein as occurring “as a function of” something, the system is configured so that the act is performed in different ways depending on one or more characteristics of that thing.
[0057] In this description, and “identifier” means something that uniquely identifies a thing, and “identifying” means uniquely determining which among multiple possibilities a thing is.
[0058] In this description, a “personal communication device” (PCD) might be a smartphone, smart watch, tablet computer, Google Glass, or other individually usable device that has built-in data communication capabilities.
[0059] All publications, prior applications, and other documents cited herein are hereby incorporated by reference in their entirety as if each had been individually incorporated by reference and fully set forth. While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.
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The disclosed system discourages drivers from manual use of mobile personal communications devices while operating a vehicle. Software installed on the mobile device uses the mobile device itself to determine whether the device is being used during operation of the vehicle. The system uses vehicle equipment for alerts that notify passengers as well as others outside the vehicle (such as owners, parents, other drivers, pedestrians, law enforcement agencies) that the driver is operating the vehicle while distracted by a communications device, and as such, may be operating the vehicle in an unsafe manner. The system can use a mobile device running a security app as a required or alternative entry and ignition key. A web portal enables remote control of the vehicle's systems and limitations on its operation in the presence of a particular device, even disassociating the vehicle from a particular mobile device, and provisioning of a replacement device.
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Pursuant to 35 U.S.C. §120, this application is a continuation of and claims priority from U.S. patent application Ser. No. 09/560,784, filed Apr. 28, 2000, now abandoned which in turn claims priority from Provisional U.S. Patent Application Ser. No. 60/133,492, filed May 10, 1999. The contents of the prior applications are incorporated herein by reference in their entirety.
TECHNICAL FIELD
This invention relates to authentication.
BACKGROUND OF THE INVENTION
Consider a situation, such as described in FIG. 1 , where a computer network ( 100 ) is formed from one or more remote clients [e.g., computers ( 101 - 103 )] interacting over communication links ( 500 - 506 ) [e.g., telephone lines, hard wire, satellite links, IR, etc.] The Network wants authorized clients (e.g., 104 ) to gain access easily and unauthorized clients (e.g., 400 ) to be totally prevented from gaining access. [Note that this diagram is intended only to represent known elements of a computer network and its security system. In particular, it is intended to show the basic topology of these parts. Also, it is not intended to be an exhaustive example of current computer networks or their security systems. Consequently, items such as routers, firewalls, gateways and the like have not been explicitly displayed.]
The Authentication Process is the means by which the system stops unauthorized access to the Network. The Authentication Process constitutes the security measures protecting the Network. Typically, in the Prior Art, the Authentication Process is a multistep sequence based on User Credentials and the Network Authentication Server ( 200 ).
“User Credentials” are information, such as access codes and user ID's, that are assigned by the Network to all authorized users (i.e., people who have authorized access to the Network.) The Authentication Server is the part of the Network that reviews the credentials of a user when access is requested. Here the term “Authentication Server” is meant to represent whatever network hardware and software is used for this purpose.
The following is a typical Authentication Process sequence executed when a user wishes to gain access to the network, (See FIG. 2 ):
1) The user uses his client computer, and its specialized network software, to request access to the network. 2) The software prompts the user to enter his credentials into a certain location on a “Network LogOn” screen. This could include, for example, his user ID and access code (123, XYZ) 3) The client's Network software translates the credentials into digital information, i.e., a digital version of the user's credentials. 4) The client then creates an electronic message that includes the digitized credentials and transmits it to the Authentication Server. [Diagram 1 is meant to represent this electronic message.]
Diagram 1
| | 1 | 2 | 3 | X | Y | Z | | | |
5) The Authentication Server converts the electronic message into digital information, i.e., a digital version of the user's credentials.
6) The Authentication Server has in its database a list of digitized credentials for all authorized users. When the electronic message from the client arrives, the Authentication Server takes the user's digitized credentials and compares these to the credentials it has stored in its database for this particular user. If they match, access to the network is granted to the user. If they don't match [e.g., (123, XZZ)] then access is denied.
Unauthorized users can gain access to the Network by defeating the security measures, i.e., the Authentication Process. The source of this problem is that current Authentication Processes are based on analyzing digital information sent from the client to the Authentication Server. It is only the electronic signal itself that is analyzed. Security is based on analysis of this signal. Neither the physical client, nor its human operator, is analyzed directly. This same problem exists for all credentials data as long as the Authentication Process remains the same.
Computer hackers break through this type of security just by mimicking valid digital credentials in the electronic message (See Diagram 1) sent to the Authentication Server by the client. This only requires a computer (client), a communication link, and a valid set of credentials. The first two are readily available and the last can be obtained by a variety of means such as: guess work, simple theft, etc. That is, the hurdles (technological, financial, etc.) to unauthorized entry are fairly low.
The electronic message containing the credentials does not come with any indelible indicators of the actual person or client who has sent it because it is just a series of computer generated electronic impulses and is therefore susceptible to hackers.
To illustrate this point, consider the following analogy:
Imagine a situation where physical access to a building is protected by an “Authentication Process” based on analysis of a person's handwriting. And the actual process only requires that a person wishing to access the building give the guard a piece of paper with handwriting on it. The handwriting is compared to that on file for the name that was given. If they match, the person is emitted. But a sample of the handwriting could be stolen or forged, thus allowing an unauthorized person admission to the building. Here, as in the computer network case, it was information supposedly about the person that was analyzed. It was not the person themselves, or even information known to have come from the person, that is analyzed.
The above network Authentication Process is based on traditional User Credentials. It could be argued that more modem credentials exist. These would include client CPU Chips with ID's (such as the Pentium III with Processor Serial Number from Intel) and User Biometrics (such as thumb prints, facial scans, etc. which are used, for example, by the BioNetrix Systems Corporation of Vienna, Va., USA) But these modem credentials, although useful, are still employed in the same type of authentication process. And therefore, the network is susceptible to the same type of unauthorized user, i.e., the hacker.
To see this, consider the employment of the user's thumbprint as a means of authenticating a network user. In this case, the user's client has a special scanner connected to it. The Authentication Process would be a sequence similar to the following (See FIG. 3 ):
1) The user uses his client computer, and its Network software, to request access to the Network. 2a) The client software prompts the user to enter his credentials into a certain location on a “Network LogOn” screen. This could include, for example, his user ID and access code: (123, XYZ) 2b) Thumb Print Scan
The client's software also prompts the user to place his thumb on the scanner. The client then scans the thumb. Scanning “digitizes” an image of the thumbprint. That is, it turns the physical thumb print into a set of pixels containing digital information that characterize the thumbprint.
3) The client's software translates the credentials into digital information. 4) The client then creates an electronic message that includes the digitized credentials and the digital thumb print. The client then transmits these to the Authentication Server. [Diagram 2 is meant to represent this electronic message.]
Diagram 2
5) The Authentication Server receives the electronic message and translates it back to digital information.
6) The Authentication Server has in its database a list of digitized credentials and digitized thumbprints for all authorized users. When the electronic message from the client arrives, the Authentication Server takes the user's digitized credentials and thumb print and compares these to the credentials and thumb prints it has stored in its database for this particular user. If they match, access to the network is granted to the user. If they don't match then access is denied.
Note that not only is the actual thumb not being analyzed, but neither is a physical thumbprint (such as on a law enforcement finger print card) being analyzed. Rather it is only the digitized version of the thumbprint created by the client that is analyzed. And this gives a hacker a way of breaking into the system. For example, if he were to obtain a copy of a user's thumbprint, he could digitize it and then use that digital version to send to the Authentication Server when the request came for the thumbprint.
Therefore, the three types of authentication data:
User Credentials User Biometrics Client Branding
all suffer from the same problem. They are all turned into digital messages by the client. This “client formed digital message” is then analyzed in the Authentication Process. And it is the nature of a “client formed digital message” that it can be hacked with readily available, and inexpensive, technology. In addition, the skills needed to overcome this type of security system are within the expertise of the traditional hacker.
Finally, it should be pointed out that one of the additional weaknesses of this type of authentication process is that when a Network decides to make its authentication process more difficult for the hacker to break through, it also becomes more of an irritant for the legitimate user to access the Network. The Process is non-transparent to the legitimate user.
In summation, current authentication processes are based on having the user's client take user credentials, form them into a digital message and then transmit this message to the Network Authentication Server where it is this digital message that is analyzed. This approach has several weaknesses and deficiencies that include the following:
1. it relies on data digitized and transmitted by the user's client. 2. it analyzes digital representations of information about the client/user and not the client/user themselves. [For example, it analyzes a digital representation of a thumbprint and not a thumb print itself, let alone a thumb.] 3. it presents a low hurdle, both in expense and technical skills necessary, to an unauthorized user. 4. it is an irritant to the legitimate user (i.e., it is non-transparent) 5. it can be overcome by traditional hacking, i.e., software and readily available computer and telecommunications technology.
Finally, the enormity of the computer network security problem cannot be over estimated. Computers are pervasive in our society. The national defense itself is tied inseparably to them. Unauthorized access to critical mission computers (e.g. those controlling the Ballistic Missile System) could jeopardize our national existence.
There is a need for an authentication process which will uniquely identify the originator of a network access request and which includes the following:
1. it doesn't just rely on messages created by the requesting client 2. it analyzes information empirically obtained about the client, not just information sent from the client. 3. it raises the hurdles, in both expense and technical skills needed, to gain unauthorized access to the system 4. it is transparent to the legitimate user 5. it cannot be overcome by hacking
SUMMARY OF THE INVENTION
In general, in one aspect, the invention features, in connection with authenticating a client of a network, acquiring information that characterizes the client in a manner that enables a determination about authenticating the client of the network, the information being acquired other than in the form of a digital message that is passed on behalf of the client to the network, and making an authentication decision based on the information.
In general, in another aspect, the invention features encrypting information in a manner that is based on a physical property of an intended recipient of the information, and delivering the encrypted information to the recipient.
In general, in another aspect, the invention features physically associating a source of a beacon with a person, measuring times of receipt of the beacon at multiple stations, and determining the location of the person based on the times of receipt.
In general, in another aspect, the invention features establishing a set of stations that are configured to acquire information that characterizes each of multiple clients in a manner that enables a determination about authenticating each of the clients with respect to a corresponding network, the information being acquired other than in the form of digital messages that are passed on behalf of the clients to the corresponding networks, and providing the information to operators of the networks to enable them to make authentication decisions based on the information.
In general, in another aspect, the invention features encrypting and decrypting a message by expressing the message as a message signal comprised of a sum based on eigenfunctions. The message is decomposed into partial sums such that each of the partial sums conveys no meaning relative to the message. Electromagnetic signals are formed based on the respective partial sums. The electromagnetic signals are sent from respective sources at times selected to assure the simultaneous arrival of the signals at an intended location, such that the electromagnetic signals superpose themselves to form the message signal.
The invention relates to a system and method that uses:
1. data empirically gathered about the user/client, by the network itself, as the basis for the authentication process instead of the traditional client generated digital message, and 2. message encryption with decryption based on an inherent physical property of the user/client as one aspect of the security system.
In another aspect, the invention relates to a system and method that changes how a computer system interacts with a client from one where the client sends certain data to the system to one where the system obtains certain data empirically. This second invention is independent of:
computer network security systems the quantity that is being empirically measured the technique used to measure it the “message encryption based on an inherent physical property” technique.
In general, in another aspect, the invention features a system and method for sending coded information from one entity to another such that the method of encoding the information is specifically chosen so that it is decoded by an inherent physical property of the recipient. This third invention is independent of all of the following: computer network security systems, the particular inherent physical property of the recipient that is being used, the particular method of encoding the information, and of the empirically gathered data concept.
The last two aspects of the invention are independent of computer security systems and can be applied in a large variety of areas.
In implementations of the invention, computer hardware, software, telecommunications hardware and software, empirical data gathering devices, and a method of operating these create a computer network authentication process (i.e., a computer network security system) which is based on analysis of empirical data obtained directly by the network itself about the user/client requesting access and which is not based solely on analysis of digital messages created by the requesting client.
Implementations of the invention empirically obtain user/client information and then include this information as part of a computer network authentication process.
It is important to note that it isn't just different “credentials data” that the invention's Authentication Process is based on. Rather, the invention's Authentication Process itself is different. In particular, it includes a different method of obtaining data about the client from that used in the Prior Art's authentication process. An example of this method would be to employ Remote Sensing techniques to gather the required data.
Implementations of the invention also empirically obtain information about a subordinate. This inventive concept is independent of computer network security and can be applied in a wide variety of areas (e.g., the location of a particular individual or object by some authority not related to access to a computer system.)
In examples of the invention, precise physical location of the clients is used as a means of identifying authorized users of a closed computer network. [There are many other physical observables that could be used.] The location is determined by means that are not “hackable.” Specifically, the client doesn't tell the Authentication Server where it is (i.e., it does not transmit a digital message saying “I am at location X Longitude Y Latitude.”) Rather, the invention acts to make direct measurements of the client's position. Many methods of Remote Sensing can be employed for this purpose. One particular method of doing this is by measuring time of reception of a radio beacon signal from the client.
Other aspects of the invention provide:
i) a novel System and method for encrypting and decrypting messages ii) use of this encryption/decryption method as part of the authentication process for a computer network security system.
i) In this approach to encryption/decryption there are basically three levels.
a. The concept of encoding a message based on some inherent physical property of the recipient. b. The particular physical quantity used c. The particular method used with the chosen property to encode the information.
Information can be encrypted in a special way, such that, a specific, and unique, physical property of the recipient automatically decrypts the information. There are many physical properties this could be based on, for example:
a. physical location b. unique sensitivity to light or sound c. DNA (unique to each individual)
For each unique physical property, there will be many ways to encrypt the information such that when it arrives it is automatically decoded by the physical property itself of the authentic recipient.
ii) Messages to the user/client are encrypted in such a way that certain inherent physical properties of the user/client itself (in particular those mentioned above that are empirically measured as part of the authentication process) are used as “keys” that automatically decrypt the messages. In other words, if the user/client is who he says he is, then the message will arrive in-the-clear.
For example, the client's stated physical location is used as a means to decrypt messages from the Authentication Server. This message is then used as part of the Authentication Process.
This works in the following way: An encryption method is created whereby a message, in the form of an electromagnetic signal, is decomposed into several parts. These parts are individually unintelligible. Then the different parts are transmitted at different retarded times and from different locations (e.g. satellites, microwave towers, etc.) such that they recombine (superpose) at some specified time and are intelligible in-the-clear at only one physical location. That is, they are understandable without analysis only at the authorized client's position. Finally, the response of the client to the message is noted and used as part of the Authentication Process.
Client Response Time may be Used for Authentication. A message is sent from the authentication server to the requesting client which orders the client to take a particular action. The response time of the client is measured and used as part of the authentication process.
The invention ties each authorized user to a particular authorized client.
The novel aspects of the invention's Authentication Process are totally transparent to the authorized user. That is, its novel aspects require no additional work for the legitimate user.
The invention creates an interactive method of computer network security
The invention includes spoofing counter-measures. That is, it is flexible enough to allow for changes in the Authentication Process.
The invention changes the dynamics between the network and the unauthorized user. The invention gives network administrators an entirely new dimension in which to pursue security. Clever network administrators will find additional ways to employ the basic concepts of the invention to thwart unauthorized users.
The invention raises the hurdle to gain unauthorized access to a network. It does this by redefining the dynamics of the hacker/authentication server battle. That is, it forces the unauthorized user to do things (e.g., finding satellite positions, radio transmissions, electromagnetic pulse generation, signal analysis, telephone fraud measure, etc.) that are not just clever uses of software. These are things that require large financial resources and access to many technologies: things that the traditional hackers do not have.
Among the benefits achieved by the invention may be one or more of the following:
1. Make computer networks more secure. 2. Create a network security system that doesn't just rely solely on the analysis of digital messages sent from the client to the authentication server for the authentication process. 3. Create a network security system whereby the computer network itself empirically gathers information about the client/user and then incorporates this information into the authentication process. 4. Raise the hurdles to unauthorized access so as to essentially eliminate the traditional hackers from the ranks of potential unauthorized users. That is, only extremely well funded and technologically sophisticated organizations have any possibility of overcoming the hurdles and gaining unauthorized access to a Network. (See Appendix A) 5. Make the novel security measures of its Authentication Process transparent to the authorized users. 6. Change the dynamics between the Network and the unauthorized user.
The invention creates an authentication process that gives the network administrator an entire new class of authentication methods and data to use, using an authentication process that can't be fooled by traditional hacking techniques.
The invention gives network administrators an entirely new dimension in which to pursue security. In doing so it changes the dynamics between the network and the unauthorized user. This alone adds to the level of security for the Network. Clever network administrators will find additional ways to employ the basic concepts of the invention to thwart unauthorized users.
7. Use the concept of “empirically gathered data about a subordinate” in areas outside computer network security. These could be in areas such as: a system that can physically locate a teenager who is away from home or location of patients who could become incapacitated. 8. Use the concept of “encryption with decryption based on a physical property of the recipient” in areas other than computer network security.
In some implementations of the invention these and other benefits are provided by a combination including: A computer network with an authentication server, one or more remote clients, several software packages, routers, firewalls, and communication links. The clients have monitors, keyboards, CPUs, memory, antennas, radio transmitters, and a means to convert a digital signal from the CPU into a command to a radio transmitter. Also included in the invention is an empirical data-gathering device such as a satellite. This device is equipped with an antenna for transmission and reception of radio or other Electromagnetic (EM) radiation. It also has software that includes, but is not limited to, packages that receive and send messages to clients and that receive and send messages to the Authentication Server.
BRIEF DESCRIPTION OF THE DRAWINGS
Implementations of the Invention are described with reference to the drawings in which like elements are denoted by like or similar numbers and in which:
FIG. 1 is a high-level block diagram that is useful in understanding the topology of a computer network and its security system in the Prior Art.
FIG. 2 is a combination high-level block diagram and flow diagram that is useful in understanding the operation and attendant problems of the Prior Art for network security.
FIG. 3 is a combination high-level block diagram and flow diagram that is useful in understanding the operation and attendant problems of the Prior Art for network security when biometric data is included in the authentication process.
FIG. 4 is a combination high-level block diagram and flow diagram that is useful in understanding the operation and system of the computer network security Authentication Process according to a preferred embodiment of the present invention.
FIG. 5 is a high-level block diagram showing how different satellites intercept a client beacon at different times.
FIG. 6 is a block diagram showing the distances D Ai from each satellite to the requesting client C A.
FIG. 7 is a high level block diagram illustrating the differences between the spherical EM beacon pulse ( 700 ) emitted by an authorized client C A , at position P A , and the three time-staggered narrow beamed EM pulses emitted by a spoof C S , at position P S , trying to fool the network security system into thinking it is at position P A.
FIG. 8 is a high-level block diagram showing the relative distances to a particular satellite from C A and from C S.
FIG. 8A is a high level block diagram and flow chart showing the relative differences between the operation of a preferred embodiment of the current invention and the operation of the Global Positioning System.
FIG. 8 b is a high level block diagram and flow chart showing the sequence first of the spoof C S emitting three staggered narrow beamed pulses which try to fool the current invention's security system into thinking that its location is at P A and second the response of the Authentication Server of the present invention to order the satellites to transmit a narrow beamed message to P A as a means of exposing the spoof
FIG. 9 is a high level block diagram and flow chart showing the three partial sums f 1 , f 2 , and f 3 that superpose at the point P A to form the command f (t, P A ) which is only intelligible in-the-clear at P A . These partial sums can be omnidirectional beams or narrow beamed EM pulses.
FIG. 10 is a diagram showing the shape and time dependence of a signal to be transmitted to the client.
FIG. 10A is a high level diagram showing how a signal f (t, P A ) might be modified by using only a finite number of eigenfunctions and still be acceptable for our purposes.
FIG. 11 is a graphic representation of the partial decompositions f 1 , f 2 , and f 3 showing that they are individually unintelligible but that their superposition forms the intelligible signal f (t, P A ).
FIG. 11A is a graphic representation showing how the shape of an EM pulse remains the same at Pi and P A but that it has been shifted on the time axis.
FIG. 12 shows the time dependent graphs of the functions f 1 , f 2 , and f 3 as they appear at the position P S and that they are displaced in time relative to one another and that therefore they do not superpose to form an intelligible command.
FIG. 13 is a high level block diagram and flow chart showing the sequence of the Authentication Server ordering the satellites to transmit partial representations f 1 , f 2 , and f 3 to the position P A and then the partial representations actually being transmitted.
FIG. 14 shows the time dependent graphs of the three partial representations that have now been disguised to thwart mathematical analysis by a spoof
FIG. 15 is a graph showing how the command signal could be broken into three time-sequenced parts that superpose at the desired location P A to form an intelligible message.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides an improved system and method for authenticating clients and/or users as they request access to computer network systems. Generally described, the invention's authentication process is based on analysis of empirical data obtained directly by the network about the client and/or user and is not solely based on analysis of digital messages created by the client.
The invention uses data that the network itself empirically obtains about the client/user as the basis of the authentication process. There are many physical quantities that could be used to authenticate a client/user (e.g., physical location, emission spectra in various electromagnetic wavelength regions, internal clock phasing with respect to a network master clock, biometrics of the user, etc.) And, for each of these, there are many methods by which to obtain empirical data about that physical quantity (e.g., satellites equipped with Remote Sensing devices, ground based equipment, etc.) A variety of physical quantities and methods of empirically measuring them by the Network may be used to implement the invention.
An example of the invention will be described that is based on physical location of the client as the quantity to be empirically measured and which uses satellites to measure this quantity.
The example will now be described with reference to FIG. 4 . In particular, as shown in FIG. 4 , the overall system according to the present invention includes: A computer network including an Authentication Server ( 200 ), one or more remote clients ( 104 ), and a communication link ( 505 ). The clients have monitors, keyboards CPUs, memory (RAM and hard disk drive), a means to convert a digital signal from the CPU into a command to a radio transmitter/receiver ( 105 ), and a radio antenna ( 106 ). Also included are empirical data gathering devices such as satellites ( 601 - 603 ) [or, for example, microwave antennas, cellular phone infrastructure, etc.] These are equipped with antennas for reception of radio or other electromagnetic radiation, computer hardware and software to receive and send messages to clients, and to receive and send messages to the Authentication Server. [Note that it is also assumed that any other standard computer network hardware and software (such as routers, firewalls, gateways, etc.) is included.]
In FIG. 4 :
AS—Authentication Server C A —An authentic client trying to access the system CPU A —Central Processing Unit of Client A R A —Radio Transmitter/Receiver T A —Antenna Ei—Satellite (i=1, 2, 3)
Beacon Signal Method
Assume that this is a “closed” computer network and that the network has “control” over the remote client computers.
In this specific embodiment the word “closed” means that the network limits access to specific client machines. [In other embodiments, this limitation could be removed.] These clients have hardware/software configurations that the network itself can determine. So, for example, a user cannot just take the Network access software and install it on any PC to gain access. The Network, therefore, is different from the traditional ISP such as America On Line.
The word “control” means that the network can dictate certain issues. For example:
It can configure the hardware and software that is on the client. Such as, it could require:
i) the use of a Branded CPU such as the Pentium III with Processor Serial Number from Intel ii) the installation of PC Anywhere or similar software that will allow the network manager to take control of the client. iii) the placement of client specific information into hidden Nonvolatile Read Only Memory (ROM) of the client. (This could be done in a similar fashion to how BIOS/Flash information is handled. This information could include for example: a variety of different commands, a random list of signature pulse signals, etc.) iv) the installation of a highly accurate clock which is synchronized with a central network clock. [Similar to those used by the Global Positioning System (GPS).] v) a radio transmitter and antenna to be connected to the client.
It can demand that each user be restricted to a specific client. (This coordinates User Credentials with physical location of the client.) It can demand that clients not be physically moved without authorization from the network. It can demand that a client go through an initialization process.
When a new user is brought onto the network, an official from the network administration could go to the physical location of the authentic user and install the client. He could then do any number of things, such as:
execute trial runs to see what the client's response time is to an order from either the Authentication Server or the satellites to transmit a specific message, having the client/Authentication Server linked through PC Anywhere such that the commands to the client are being given directly by the Authentication Server using a Global Positioning System (GPS) device to get the precise location of the client.
Electronically connected to each client's CPU is a radio signal transmitter/receiver. Within the network, each client is assigned a specific electromagnetic pulse form [or a random sequence of such forms hidden in Nonvolatile Read Only Memory (ROM)] that is only used by that particular client. There are also at least three satellites that are within the control of the Network. The primary function of these satellites is to gather empirical data about the clients and to transmit this data to the Authentication Server. In addition, these satellites could also be used to send and receive information from the Authentication Server and to send and receive information from the clients.
While not required in all implementations, these features and hardware allow the Network in this example to institute a novel security system for network access. This security system will now be described in terms of the steps of an Authentication Process.
1) The user uses his client computer, C A ( 104 ), and its software to request access to the Network ( 200 ). This client, which is configured by the Network, has specific hardware and software pre-loaded on it related to the Authentication Process. 2) When the client's Network software is opened, it prompts the user to enter his User Credentials into a certain location on a “Network LogOn” screen. This could include, for example, his user ID and access code: (123, XYZ). It could also contain, for example, biometric information, Processor Serial Number, encryption keys (public/private), etc. 3) The client's software translates the credentials into digital information. 4) Data is transmitted to the Authentication Server; Empirical Data is obtained
a) The client's software then creates an electronic message that includes the digitized credentials (as shown in Diagram 3 ).
Diagram 3
| | 1 | 2 | 3 | X | Y | Z | | | |
When the “Connect” button on the Graphic User Interface (GUI) screen is clicked the software forces two events to occur:
i) the above electronic message is transmitted to the Authentication Server via the normal communications link ( 505 ) ii) the software orders the radio transmitter R A ( 105 ) to emit the beacon signal ( 700 ) from the antenna T A ( 106 ) with the pulse signature that has been assigned to this particular client.
b) Empirical Data on Client's Physical Location is Obtained
The act of transmitting the credentials to the Network triggers a radio beacon signal to be emitted from the client. (The user doesn't have to do anything additional to have this beacon emitted.) This beacon signal is typically a spherical (i.e., omnidirectional) EM wave with a unique pulse shape.
The radio signal is detected by the satellites Ei ( 600 ). The satellites note the client's signature pulse and the time of reception, t A1 , t A2 , and t A3 of the pulse. The arrival times will, in general, be different for the three different satellites. (See FIG. 5 ) The results of these measurements are transmitted to the Authentication Server. [Note that in other embodiments there will be other quantities measured, such as: direction of the EM beam, polarization, etc.]
It is important to note that the present invention differs from the Prior Art at this point in two fundamental ways:
i. the authentication data is different from the prior art. ii. the method for obtaining that data is active (empirical) rather then passive.
5) Checking for Authenticity: A Two Step Process
a) The Authentication Server has in its database a list of digitized credentials for all authorized users. When the electronic message from the client arrives via the normal communications link ( 505 ), the Authentication Server takes the user's digitized credentials and compares these to the credentials it has stored in its database for this particular user. b) Using Empirical Position Data To Determine Authenticity
i) The Authentication Server also has in its database the physical location of each authorized client. (This can be obtained, for example, in an unequivocal manner by having a Network Official use a Global Positioning System (GPS) device during the initialization process. Once this physical position is established, movement of the user's client is restricted to a certain physical region established by the Network.) ii) The Authentication Server receives information from the satellites on their direct measurement of the clients beacon signal, i.e., t A1 , t A2 , and t A3 . iii) The Authentication Server uses beacon signal information to calculate the location of the client. (See Below) iv) It then compares the actual position against the registered one.
c) Both the User Credentials in (a) and the physical location in (b) must match the information stored in the Authentication Server's database for access to be given. If either, or both, of these quantities do not match those in the database, then access is denied.
Note that the radio signal is a beacon not a message. That is, it does not tell the satellites the location of the client (e.g., it is not a message that says “the client is at 77° 03′ 56″ West Longitude and 38° 55′ 14″ North Latitude”.) Rather, the client's CPU orders the radio transmitter to emit a spherical wave with the client's signature pulse. This is detected by the satellites and certain empirical data about the signal is recorded. The empirical data could include, but is not limited to: time of arrival, pulse shape, polarization of the wave, etc. This empirical data is then sent to the Authentication Server. By analyzing this data the Authentication Server calculates the position of the radio emitter.
Calculation of Position
(See FIG. 6 )
The Network Administration knows the position of all authorized clients and their radio antennas.
It also knows the positions of the three satellites. It therefore can calculate the distances D A1 , D A2 , and D A3 from the client C A to each of the satellites at any given time.
Consider the situation where the client seeking access has emitted a single beacon signal at time t Ae and this has been detected by the three satellites at times t A1 , t A2 , and t A3 . (In this embodiment, it is these times that are the empirically measured quantities.)
The goal of the system is to confirm the physical location of the client. If the distances D A1 , D A2 , and D A3 were known this would give us the position. That is, knowing these distances would given us three simultaneous quadratic equations with three unknowns. (These are spheres composed of the points that the signal could have come from.) These equations can be solved to give the position of the client's antenna. In essence, the solution is the point where the three spheres intersect.
The issue then is to calculate the distances D A1 , D A2 , and D A3 from the empirical data t A1 , t A2 , and t A3 . There are several ways to do that. A specific example will now be given.
Consider the situation where the Network has electronically configured a very sensitive clock that is synchronized with a central Network clock on all authorized clients. [Sensitive clocks of this type are already being used by the Global Positioning System (GPS).] This clock ticks off “time segments” of some specified length (e.g. five seconds). These “time segments” are further broken down into smaller elements (e.g., milliseconds.) Each authorized client is assigned a beacon signature pulse form and a specific element within each “time segment” during which to transmit its beacon pulse. For example, client C A could be allowed to emit (transmit) its beacon at the 50 millisecond mark from the beginning of a “time segment.” This time is labeled as t Ae .
The Network has a highly accurate clock that all the client clocks are synchronized with. Therefore, the Authentication Server knows precisely when every “time segment” starts and what the assigned t Ae is for each client. So that when it receives the empirically measured times t A1 , t A2 , and t A3 it knows the transition times, (t Ai −t Ae ), of the pulses from the client to each of the three satellites. This then allows it to calculate the distances from
D Ai= c ( t Ai −t Ae ) [Equation 1]
c=speed of light i=1, 2, 3 t Ae =time signal is emitted by C A t Ai =time signal is received by E i
[Note that the “time segment” has been chosen to be large enough so that the signal from every client can reach the satellites before the next “time segment” begins.]
We know that there is only one spot on the earth that has the same set of distances D A1 , D A2 , and D A3 . Once we calculate these, we can compare them to the known physical distances that have been stored in the database of the Authentication Server for the authorized client C A .
Almost any degree of accuracy in position determination is possible. The primary limitation is cost. But whatever method and accuracy is chosen, there will always be a “cell” within which the client must stay in order to satisfy the criterion of the Authentication Process. As we will see, the smaller this cell is the harder it will be for an unauthorized user to gain access to the network.
The invention achieves several benefits compared to the prior art, namely:
1. The invention uses information empirically gathered on the client by the Network itself as a key basis of its authentication process. 2. The invention analyzes empirical data on the users and/or clients themselves (e.g. electromagnetic radiation.) 3. The invention raises the hurdles by requiring an unauthorized user who is trying to gain access to the Network to not only possess hacking skills, but also to overcome the empirical data gathering system. (In some implementations this is the “location determining system.”) This is expensive and requires skills that are not in the traditional hacker's repertoire. It also means that he must have particular information not only about the user but also about the user's assigned client (e.g., he must know the signature pulse of the user's client.) 4. The user carries out the invention's Authentication Process without any additional steps. In fact, the authentic user will not even be aware that additional steps are being executed. Therefore, the network has become more secure without additional annoyances to the legitimate user. Key steps of the invention's Authentication Process are totally transparent to the legitimate user. 5. The invention cannot be overcome with hacking, i.e., mimicking of electronic messages sent to the Authentication Server. Instead it requires a host of non-hacking skills and methods to penetrate its security measures. 6. The invention gives network administrators an entirely new dimension in which to pursue security. In doing so it changes the dynamics between the network and the unauthorized user. This alone adds to the level of security for the Network. Clever network administrators will find additional ways to employ the invention to thwart unauthorized users.
As we have seen, the invention is not susceptible to the traditional hacker's trick of just sending an electronic message to the Authentication Server that mimics the message an authentic client would send in the authentication process.
But, as with all security systems, it can be fooled. Some of the methods by which the system's defenses could be compromised are listed under the next section titled “Spoofing.”
As will be seen, the Spoofing problem quickly devolves into one reminiscent of the Radar Field. That is, for each measure taken by the network to stop unauthorized access, the spoof attempts to break it down with a counter-measure. To which there is, in turn, a counter-counter measure. And so on. This is very similar to the situation that has existed in radar since World War II.
The following section will go through several generations of measure/counter-measure, the only limit to this being the ingenuity of those playing the measure/counter-measure game.
But a key element of the invention will not change, namely basing network security on direct (or quasi-direct) empirical measurements of physical quantities of the client/user and then including these measurements as part of the authentication process for access to the network.
The fact that the Authentication Process is not foolproof in no way detracts from its benefits.
Spoofing
The invention includes a system and method for empirically obtaining user/client information and then including this information as part of a computer network authentication process.
An example of the invention has been described that uses physical location as the quantity that is empirically measured. Other physical quantities could be used. In addition, the preferred example uses a particular method to obtain the empirical measurements of the physical location. Other methods are possible.
Spoofing is the act of an unauthorized user, C S , trying to represent himself as an authorized user, C A . He does this by fooling the system into thinking that he not only has the proper User Credentials, but that he also has the same empirically measurable physical quantities as the authorized client/user. In the example described above, this would be fooling the system into thinking that the spoof (i.e., unauthorized user) is at the proper physical location.
The response then of the Network to this is to employ a new (or an additional) method to obtain further empirical data on the user/client, i.e., the invention's authorization process is modified. Unauthorized users will then try new methods to fool it. This then spurs yet additional measures on the part of the Network.
Three additional things should be noted:
i) The invention has raised the hurdle to unauthorized access. For example, whereas in the prior art the hacker could just try to guess access codes and ID's, the potential unauthorized user must now come up with additional information such as:
pulse signature for a specific client position of satellites information specific to a particular client, e.g., pulse signature, processor ID, clock synchronization (such as that used by the Global Positioning System), possible hidden information that is built into non-volatile ROM (similar to how BIOS/FLASH information is installed), time coding of hidden information, etc. distance from C A to C S . This may require going to the exact physical location of the client that is the target of the spoof knowledge of which client a given user is assigned to. (In a building with several authorized users, this adds considerable difficulty to the spoofing problem.)
ii) In the example, authentication works by requiring each user to use a particular client. It also includes both empirically gathered client data and user credentials as part of the authentication process. Because of this, the authentication system of the example has the additional benefit of exposing users who are potential security risks. That is, for a spoof to break into the system, he must have intimate knowledge about both the user and the user's client. If a spoof tries to break into the system, and only partially succeeds on the first try, he will expose which client and user he is trying to mimic. The Network Administrator would definitely want to discuss this with the authentic user. The invention has taken away from the hacker the trial-and-error approach to breaking into the system. iii) Employee Spying The authentication system could also be employed to stop random employees from logging onto the system using their fellow workers computers. For example, if employee X decides to use employee Ys computer he could do so under the prior art by just using his own access code. But in the example authentication system, he would be denied because his access code is only authentic for his computer i.e. his computer's location.
Several generations in the Measure/Counter Measure battle will now be discussed.
Spoof: Time-Staggered Narrow Beamed Pulses
(See FIG. 7 )
C S —Spoof trying to appear as C A .
P Ei —Position of the satellite E i (i=1, 2, 3)
D Ai —Distance from C A to a satellite E i ( FIG. 6 )
D Si —Distance from C S to a satellite E i ( FIG. 7 )
D AS —Distance between C A and C S
P A —Position of the authorized client
P S —Position of the Spoof
t Ae —Emission time from C A of a signal the spoof wants to imitate
t Sie —Emission time of a spoof signal directed at satellite E i (i=1, 2, 3)
t Ai —Time that a spoof signal is to be received at the satellite E i (i=1, 2, 3)
As we have seen, in one example of the invention, the Authentication Process works by having an authorized client, C A , emit a beacon ( 700 ). This beacon is, for example, a spherical radio wave of a given frequency and/or pulse shape. (Note: This could be any frequency of electromagnetic radiation, or even non-electromagnetic radiation.) The emission is just a beacon. It is not a message stating the location of the client.
In the example, there are satellites (possibly three or more) that intercept this beacon signal. The satellites record the time (t A1 , t A2 , t A3 ) that each of them intercepts the beacon pulse. This information is then transmitted to the Authentication Server computer. From this empirical data the location of the client is determined.
Even if the Spoof, through some method, has obtained the characteristic signature pulse of the client C A , the assigned emission time t Ae , and the credentials of C A 's user, he still must overcome the invention's “location determining system.” He could try to do this by emitting radio signals from his position P S which are received by the satellites and misinterpreted as being from the position P A .
As an example, the Spoof, C S , could try to defeat the Authentication System in the following way:
i) He must determine the position, P A , of the authorized user. One way to do this is to use a GPS (Global Positioning System) measurement to get the precise coordinates of P A . [Obtaining this information is a non-trivial exercise and therefore raises the hurdle to unauthorized access.] ii) He needs to know the distances D Si and D Ai (i=1, 2, 3). One way to do this is to get the exact positions of each of the satellites P Ei as a function of time. Once these are obtained he can calculate distances D Si and D Ai from his location, P S , to the satellites and from the authorized client's location, P A , to the satellites. [There are many ways to get the positions P Ei . One of these is to use Radar.] iii) Calculation of Beacon Intercept Times For C A By knowing the D Ai the spoof can calculate what the relative intercept times (t A1 , t A2 t A3 ) would be of a hypothetical spherical wave beacon emitted at t Ae from the authentic client C A to the three satellites. (Remember that it is these times that the satellites record as empirically gathered data on the client. And it is these times that the Authentication Server uses to calculate the position of the client. Therefore, it is these intercept times that the spoof will have to artificially create with a spoof EM signal in order to fool the invention's security system.) iv) Calculation of Radio Emission Times For The Spoof Signal From C S The spoof wants to emit signals from his location so that they are intercepted by the three satellites in the same sequence as they would be if a single spherical wave were emitted from C A . One way to do that is to emit three separate narrow beamed signals, one to each satellite. [Narrow beamed signals are required because if the spoof used three broad beamed signals each would be detected by more then one of the satellites, thus revealing him as a spoof.] But he must determine the proper sequencing. He does that in the following way:
Assume that the Spoof wants to imitate a hypothetical beacon signal emitted from C A at a particular time. Label the assigned time of emission as t Ae . The spherical pulse wave would be received by the three satellites at times t A1 , t A2 , t A3 . The Spoof calculates these times from:
t
Ai
-
t
Ae
=
D
Ai
c
[
Equation
2
]
Here (t Ai −t Ae )=transition time
c=speed of light
He now must calculate the time of emission, t Sie (i=1, 2, 3), of each of his three narrow beamed signals such that they are intercepted at their respective satellites at the time t Ai . Since he knows the distance, D Si , that each beam must cover and the time, t Ai , at which he wants it to arrive, he can write:
t
Ai
-
t
Sie
=
D
Si
c
[
Equation
3
]
Where (t Ai −t Sie )=transition time
Solving Equation (3) for t Sie gives:
t
Sie
-
t
Ai
=
D
Si
c
[
Equation
4
]
Substituting for t Ai from Equation (2) gives:
t
Sie
=
[
D
Ai
-
D
Si
]
c
+
t
Ae
[
Equation
5
]
The Spoof then knows that if he emits three narrow beamed signals at the staggered times t S1e , t S2e , and t S3e , respectively, to the three satellites E 1 , E 2 , E 3 , they will be received at times t A1 , t A2 , and t A3 .
iv) Spoof Authentication Process
The spoof then starts the Network Authentication Process as has been previously described. But at step 4 (b) he replaces the single spherical wave beacon that the authentic client C A would emit, with three spoof beams. The spoof beams are three narrow beamed radio signals with staggered emission times t S1e , t S2e , and t S3e . The satellites E i intercept these narrow beamed signals and record the intercept times t A1 , t A2 , and t A3 .
The satellites would send this empirical time of reception data to the Authentication Server. The Network would then use the above described position calculation method and erroneously conclude that the signal had come from the authentic client C A . And would thus allow access to the spoof C S .
Network Counter—Measures to Spoof
The Network must now try to implement methods that would expose this type of Spoof We note that the spoof, C S , differs from the authentic client, C A , in at least four fundamental ways:
i) He is in a different physical location ii) He is emitting a different signal form (i.e., C A emits one spherical wave whereas C S emits three narrow beamed signal.) iii) He does not have an authorized client. The authorized clients have hardware, clock synchronization, hidden BIOS-type nonvolatile ROM with Network information stored in them, and other client specific data registered with the Network. iv) He is not being used by an authorized user.
The invention's approach is to employ an additional empirical process to measure one or more of the above fundamental differences and then to include these in the Authentication Process. This will expose the spoof and deny him access to the network. Some of these will now be listed.
Any one of the following steps may be added to the invention's Authentication Process.
a) Interactive Approach
After the first five steps of the Authentication Process that have already been described, additional ones can be added. For example, over normal communications links, the Authentication Server orders the requesting client to emit a particular radio signal “now.” The Network then knows the time the signal was emitted and the time it was received by the three satellites. It can then calculate the distances from each satellite to the emitter and compare these to the D Ai it has in its database for the authentic client. (In this method, the Authentication Server doesn't assume that the signal was emitted at t Ae )
[Remember the example system is a “closed” system. When a new user is brought on, an official from the Network could go to the physical location of the authentic user and install the client. He then does several things, such as: synchronizing the clock, doing checks to see how long the response time is to a signal to transmit “now”, having the client/Authentication Server linked through PC Anywhere such that the commands to the client are being given directly by the Authentication Server, etc. These all become part of the Authentication Server's database. And can be used at later times to check the authenticity of an access request.]
Spoof counter-counter measures (See FIG. 8 ):
The Spoof targets a client such that
D Si <D Aj for all i and j
If D Si to all three satellites is less than D Ai to all three satellites, then the spoof could build software that would take the Authentication Server command to emit a signal and delay the emission to make it appear that the D Si are longer then they are.
But note that this further raises the hurdle. First it requires the spoof to find an appropriate target client. And the fact is that there may not be one. Second, he is then required to get the user credentials of the person with that particular client.
Continuing, there are a variety of ways to employ the Interactive Approach. For example, there are many things that can be one to the client to make it unique. The Network could encode into Nonvolatile ROM hidden information that is specific to that client. One example would be to include a prearranged, but random, sequence of signature waveforms that would be used for the beacon. This sequence is known to the Network but not the user. In fact, even if the client were stolen, the information could not be obtained without the Management Entity. And therefore, the unauthorized user would be in a position of having to first obtain very secure data in order to break into the Network. And even if it succeeded in getting this data, it isn't clear that it would do the spoof any good. See Counter-Measures.
The counter measure to the spoof would be as follows: After the first five steps of the Authentication Process, the Authentication Server adds additional ones by asking that the client to emit a beacon at a particular time. In the hidden memory of the authorized client there is information as to the pulse shape the client is to use for this. The Authentication server (and satellites) wait to receive the correct pulse shape at the correct time. If they don't, access is denied.
The approach of the invention is not to be confused with the Global Positioning System (GPS). GPS works in a very different way. (See FIG. 8A ) GPS is used by a client to determine its own position and to stop others from interfering with that determination;
whereas, in the invention, the Network is trying to empirically determine the position of a remote client and to prevent an unidentified client from misrepresenting its position.
Comparison of GPS to the Authentication System: [See FIG. 8A ]
Authentication System—a single time coded specific, but random, beacon pulse is transmitted by a requesting client. This is detected by multiple satellites. The Authentication Server uses this information to calculate the position of the requesting client. GPS—multiple satellites send out time coded specific, but random, signals. These are detected by a GPS receiver and from the relative time sequences of the reception of the different signals the receiver can calculate its position.
b) Spherical (Omni-directional) Wave Detection
In this counter-measure the Authentication System uses any available technique to detect omni-directional radio waves. If it doesn't detect omni-directional waves, it denies access. That is, it uses some method to distinguish the nature of the waveform itself. For example, there could be additional satellites that are not publicly known to be part of the system. These will intercept the spherical waves but not the narrow beams from a spoof.
c) Angle Detection
The data stored in the Authentication Server database includes not just the position of all authorized clients but also the direction from them to each of the satellites. The satellites could carry antennas equipped to detect the direction from which the emitted signal is coming from. (These could be Phased Array antennas for example.) This additional empirical information could then be checked against the Authentication Server's database. The directions measured will be different for C A and C S .
d) Satellites Emit Narrow Beamed Command to the Client
The spoof has started an authentication process by transmitting to the Authentication Server its User Credentials and by transmitting radio signals to the satellites that are deliberately designed to be misinterpreted as the beacon from the authorized user C A . In other words, an unidentified client wishing to gain access to the system is, in fact, stating that it is at the location, P A , of the authorized client C A . (See FIG. 8 b —Top Portion)
This counter-measure verifies that statement by adding the following steps to the Authentication Process: The Authentication Server orders one or more of the satellites to transmit a narrow beam command (See FIG. 8 b —Lower Portion) to the physical position that the client is supposed to be at (again, this can be done with Phased Array antennas for example.) This message directs the client to do something that can be verified, e.g., send a particular message to the Authentication Server. If it doesn't respond, access is denied.
This then forces the spoof to have a receiver within a specific vicinity of the authentic client CA. Therefore, again, the hurdle to unauthorized access has been raised.
e) System and Method for Encrypting Messages to a User/Client with Decryption Based on Inherent Physical Properties of the User/Client
The general concept can be stated as follows: Information to a recipient is encrypted in such a way that certain inherent physical properties of the recipient itself are used as “keys” that automatically decrypt the messages. This is an inventive concept independent of computer network security invention. The remainder of this section, though, will be devoted to disclosing how this concept could be employed in the area of computer network security. Appendix E gives a more detailed description of the basic concept and two additional examples of how it could be used. [See also parts (e) and (j) of the section titled “Alternate Embodiments”]
In the case of computer network security, messages to the requesting user/client are encrypted in such a way that certain inherent physical properties of the user/client itself are used as “keys” that automatically decrypt the messages. In other words, if the client is who he says he is, then the message will arrive in-the-clear.
The encryption method is designed specifically for the physical property of the user/client that the Network intends to use to decrypt the message. If a different physical property is used, it will demand a different encryption method. But the general concept will not change: Build the encryption method so that an inherent physical property of the authorized user/client itself decrypts the message automatically.
Consider the situation where an unidentified client requesting network access has, as prescribed under Authentication Process steps 1 through 5, sent an access message to the Authentication Server and has emitted a radio signal that has been interpreted by the Authentication Server as a beacon signal from the authorized location. In essence, the requesting client is stating that it is at a particular authorized position P A . (See FIG. 7 )
The approach of this counter-measure to spoofing is for the Authentication Server to send a command to the client such that:
1. The message can only be read by the authorized client, that is, by a client with the physical quantities that this client is known, by the Network, to possess. This translates into “The message can only be read at the stated physical position P A .”(See FIG. 9 and compare to FIG. 7 ) 2. The message is, for example, a command that orders the client to take a particular action. The Authentication Server then verifies that the action has been taken and notes the response time. [The specific response time of the authentic client C A has been calibrated as part of the initial setup for the user with that client. This can be done by having the network send a representative to P A with the client C A . The Authentication Server then executes the sequence of steps listed below making note of the elapsed time, i.e., the amount of time for the client C A to respond. This is then stored in the database of the Authentication Server as empirical data and used as part of the Authentication Process.] 3. If there is no response within a certain specified time period, access is denied.
This method will defeat the spoofing measure described above.
The details of the method will, of course, depend on the particular physical quantity of the authorized client that is used. In one example, the quantity is its physical location. The steps listed below are tailored for this. But the method that this illustrates is more general in that it applies to other possible physical quantities also.
Note that even though we will restrict the following description to an encryption method based on physical-location decryption, there are still several ways that the message could be encoded. Two of these are discussed in the section title “Alternate Embodiments” parts (e) and (j).
A detailed description of one type of spatial decryption method and counter-measure will now be given.
Eigenfunction Decomposition Encryption with Decryption Based on Physical-Location-Dependent Superposition Used as Part of the Authentication Process [See FIGS. 7 and 9 ]
The first goal of this counter-measure is to send a message to the client such that it can be understood at, and only at, the physical location, P A (i.e., the physical position the client requesting access has implied it is at.)
We will send the message as an electromagnetic signal from the satellites to the position P A . In particular, we will have the three satellites transmit three different parts of an electromagnetic signal containing the message. When these superpose at the location P A they will form a message that is intelligible, in-the-clear, by the client. In addition, at any other physical position, the superposition of the three signals are unintelligible in-the-clear. [By the term “in-the-clear”, we mean that the message needs no further decryption to be understood.] Stated another way: Encryption is based on a particular decomposition of the electromagnetic signal that is specifically designed with the foreknowledge of letting superposition and spatial position do the decrypting.
To execute this approach, the Network employs the principles of Eigenfunction Representation and Linear Superposition of Electromagnetic Waves. In doing so, it creates a novel method for encryption and decryption of messages.
The calculations given below follow the traditional method of using a complete set of orthogonal eigenfunctions to span a space. However, there are many other methods that could be used. For example, a spanning set of non-orthogonal over complete eigenfunctions could be used.
Information on this technique can be found under the Wavelet and Reproducing Kernel literature.
The actual technique employed is irrelevant to the concept of encoding and decoding a message based on the physical position of the user/client.
Consider then that the message we want the client to receive is in an electromagnetic signal, f (t, P A ), such as that in FIG. 10 . Here we have represented the signal as being digital in nature, but other forms are possible. The message starts at time t*. Physically, f (t, P A ) could be the electromagnetic field itself or it could be a modulation of it.
Using a complete set of eigenfunctions, G K (t, P A ), the digital signal f (t, P A ) can be expressed as:
f
(
t
,
P
A
)
=
∑
K
=
0
∞
g
K
G
K
(
t
,
P
A
)
[
Equation
6
]
where
g
K
=
∫
f
(
t
,
P
A
)
G
K
(
t
,
P
A
)
ⅆ
t
[
Equation
7
]
See George Arfken, “Mathematical Methods for Physicists” and Harry F. Davis, “Fourier Series and Orthogonal Functions”. Note that if the G K (t, P A ) are sines and cosines, then the above is a Fourier representation of the function f (t, P A ). In this case we can associate electromagnetic plane waves with the basis set GK. (See Appendix C)
Many possible basis sets can be used to represent the function f (t, P A ) as long as the selected set gives an accurate representation of f (t, P A ).
The summation can be truncated to a finite number of terms M and still represent the signal adequately for our purposes (i.e., the message is intelligible.) See FIG. 10A for an example.
f ( t , P A ) = ∑ K = 0 M g K G K ( t , P A ) [ Equation 8 ]
where M is some finite integer
Here we have picked K=0, 1, 2, . . . , M, but other assortments are possible.
The representation can now be separated into three partial summations
f ( t , P A ) = ∑ K 1 g K1 G K1 ( t , P A ) + ∑ K 2 g K2 G K2 ( t , P A ) + ∑ K 3 g K3 G K3 ( t , P A ) [ Equation 9 ] f ( t , P A ) = f 1 ( t , P A ) + f 2 ( t , P A ) + f 3 ( t , P A ) [ Equation 10 ]
where each partial sum, f i , is itself an electromagnetic signal and we have defined
f
i
(
t
,
P
A
)
=
∑
Ki
g
Ki
G
Ki
(
t
,
P
A
)
(
i
=
1
,
2
,
3
)
[
Equation
10
A
]
The partial sums are over different values of the index K, such that together they add to the set (0, 1, . . . , M). For example:
K 1 ranges over the set (1, 7, 8, 9, . . . M−1) K 2 ranges over the set (0, 2, 3, 10, 11, . . . M−2) K 3 ranges over the set (4, 5, 6, 12, . . . M)
such that the three sets together contain all the integers from 0 to M. [Note that other arrangements of the integers from 1 to M among the three sets K 1 , K 2 , and K 3 are possible.
The issue is to divide the information between the three partial sums in such a way as to make it the hardest for a Spoof to analyze. One way to do this is to employ the methods of Maximum Entropy. (See the publications of J. P. Burg and Edwin T. Jaynes.)]
There is one condition on this separation. It must be done in such a way that each of the partial summations, f i , alone conveys no meaning relative to the full message f, i.e., each partial sum is unintelligible. (See Appendix D) One way to help ensure this is to pick M small enough such that the full representation of f (t, P A ) in Equation (8) is just barely adequate, i.e., it just barely intelligible to the authentic client C A . Then any one of the partial sums f i , by itself, will be unintelligible to the client as the intended message. (See FIG. 11 .) Other than this requirement, the separation may be done in a variety of ways.
In essence, the above decomposition has given us three electromagnetic signals which, when superimposed at P A , will add to become the message f (t, P A ). We now want to associate each of these partial sums, f i , with a particular satellite Ei.
We start by noting that the shape of the partial representation f i , at satellite E i , will be the same as when it arrives at the desired location P A . What is different is that the pulse has been shifted on the time axis. (See FIG. 11A ) Therefore, all we need do is calculate the retarded time t Ei that satellite E i would have to emit f i at such that it will propagate to P A and arrive at time t*.
[Note that the concept of “Spatial Encryption” is partly based on retarded time of emission t Ei . That is, we know that there is only one location on the surface of the earth where, if we emit at times t E1 , t E2 , and t E3 , the three signals will arrive simultaneously. This is basically the reverse problem from that used to calculate the location of the client from its beacon signal. Therefore, at any other location the three signals will not arrive simultaneously. And will not superpose in the designed way.]
Calculation of the emission time t Ei of the partial wave f i :
The distance from the authorized client C A to satellite E i is D Ai . If we want each of the three signals to reach the client at time t*, then they have to be emitted at staggered times t Ei where
t
*
-
t
Ei
=
D
Ai
c
[
Equation
11
]
Here (t*−t Ei ) the time interval between emission and reception of the signal (i=1, 2, 3)
Solving Equation (11) for t Ei :
t
Ei
=
t
*
-
D
Ai
c
[
Equation
12
]
This gives the relative times (t E1 , t E2 , and t E3 ) at which each satellite must emit its signal such that the three partial representations f 1 , f 2 , and f 3 arrive at P A at the same time t* That is, they arrive at the proper time and location to superpose to form the full signal f (t, P A ).
The technique will work whether the three transmitters are coherent or incoherent. However, there are advantages to making them coherent.
Coherence between the three transmitters can be maintained by knowing their phase relationship and the distances between them.
Distances can be found using Laser Ranging techniques. Coherence can be established in several ways. One example would be to use three synchronized atomic clocks. Each transmitter is electronically linked to one of the atomic clocks. Then the electromagnetic signals f 1 , f 2 , and f 3 can be emitted coherently. [Other examples can be found in the literature on Beam Forming techniques used for acoustic arrays and Hot Spot Tracking from Synthetic Aperture Radar.]
To summarize, if each satellite, E i , transmits the electromagnetic signal f i at the time t Ei , the signals will propagate such that they will all reach P A at the time t* and superpose to form f (t, P A ). Here f (t, P A ) is the command the Authentication Server wants to give to the client who is supposedly at P A .
Note though that at any other physical location (e.g., P S which is outside a cell around the point P A ) the electromagnetic signals f i will have no meaning, either singly or superposed. They will be unintelligible singly because we specifically constructed them to have no meaning singly.
They will be unintelligible even when superimposed because these other locations will have different transition time intervals between emission and reception. Thus the signals will arrive displaced from each other in time. (See FIG. 12 and compare it to FIG. 11 ) And this will destroy the sensitive phase relationship that must be maintained between the different signals f 1 f 2 , and f 3 in order for them to superimpose to give f (t, P A ).
Therefore, the signal
f ( t, P )= f 1 ( t, P )+ f 2 ( t,P )+ f 3 ( t,P )
only has meaning, in-the-clear, within a cell around the physical location P=P A That is, it can be read, and only read, by the client at P A .
Once the above analysis has been completed the Network executes the following steps as a means of authenticating the physical location of the requesting client:
The authentication process (steps 1 through 5) is modified by adding the following steps:
6. The Authentication Server orders the satellites to transmit f 1 , f 2 , and f 3 at times t E1 , t E2 , and t E3 respectively. 7. Satellites receive the order and comply. (See FIG. 13 ) 8. At the location P A , the three signals arrive at time t* and superimpose to form the complete command signal f (t, P A ). The Authentication Server knows the time t*. The command f (t, P A ) is in-the-clear. No analysis needs to be done to decipher it. 9. If the requesting client's antenna is at P A it reads this command. 10. The command orders the client to perform a task that is verifiable by the network. For example, it orders the client to transmit a particular message via the already existing communications channel ( 505 ) to the Authentication Server. 11. The Authentication Server waits to verify the response from the client. It also notes the nature of the response and the time at which the response comes in. 12. In its database the Network has the response time of the client C A . This was empirically determined at the time of the initial setup of the client and the user. 13. If the correct response does not come within the specified time, access is denied.
These additional steps will expose a spoof using the measures described above.
Spoofing Counter-Counter Measure to: Superposition Encryption with Decryption Based on Physical Location
1. Spoof picks a physical location that is within the cell that the network can resolve. Or it just places an antenna in this cell.
This spoof counter-counter measure will work, that is, it will defeat the eigenfunction decomposition counter-measure if the spoof can also comply with the command. Even so, it forces the spoof to place a physical antenna in the authentic client's cell. Therefore, the eigenfunction decomposition counter-measure has succeeded in raising the hurdle to accessing the network. Note that the smaller the cell the harder the spoofs problem is.
2. Mathematical Analysis of the partial waves.
At any location except Phd A the partial sums f i individually and as a sum are unintelligible in-the-clear. But it might be possible to use mathematical techniques to decipher the message. For example, if the spoof could intercept the three messages independently and then mathematically slide them back and forth along a time axis he might be able to artificially get the proper superposition to decipher the message. But this will take time. And it is this empirical variable that the Network is keeping track of. So that if the response time is too long, which is an indication that the signal is being analyzed, access is denied. To make things more difficult for the spoof trying to analyze the signal, the network could employ many techniques. (See FIG. 14 .) Some of these are:
i. Adding noise. ii. Deliberately adding nonsensical waves before and after the message part of the signal. iii. Staggering starting time and length of the emissions from the satellites. iv. Assuming that there are many clients, there will be many commands going out from the satellites. It wouldn't be clear to the spoof which of these he should be analyzing unless he has specific information about individual clients. Again, this raises the hurdle to unauthorized access. v. Change the basis set G K (t, P A ).
Note that the authentic client never needs to do any analysis. There is no decryption necessary at the physical site P A . Therefore, the Authentication Server can represent the command f (t, P A ) any way it wants to. And it can make changes without ever notifying the authentic client.
vi. False signals can be sent out by the Network. vii. The command signal f (t, P A ) might only be a statement to execute a particular command that is hidden in a set of commands that is stored in Nonvolatile Read Only Memory. Therefore, decoding it will not do any good unless the spoof also has the set of hidden commands.
Alternate Embodiments
Other embodiments are within the scope of the claims.
Any or all of the variations described here can be used at the same time with the methods already described and they could be combined into more complex authentication processes.
a) Cellular Phone System Replaces Satellites for Empirical Data Gathering.
The cellular phone system infrastructure has built into it a mechanism whereby it can calculate the physical location of the “user”. It is the only way the system knows when to hand off a moving user and to what station the user needs to be handed off to. In fact, recently the FCC has looked into the possibilities that Cellular Phone companies be required to give the location of a 911 call to within 125 feet.
The Authentication System could employ this technology in the following way: Clients have a cellular phone electronically connected to them. Logging on commands the cell phone to emit a signal. The Cellular Phone System receives the signal and determines where it has physically come from. The Cellular Phone System then transmits this information to the Authentication Server.
b) Employing the Global Positioning System (GPS)
The GPS satellites emit prearranged but random signals that are known to the GPS management.
These random signals could, if known in advance, be employed by the invention. There are many ways that these signals could be used. For example, they could be incorporated into signals from the Authentication Server, or that are stored in nonvolatile ROM, to form a complete command to the client. Also, this could be done in such a way that the message depends on the position of the client.
c) Caller ID
If traditional phone lines are used by the client to access the network, then the network could use caller ID to help identify the client. That is, during initialization the authorized client's phone is identified by the network. A spoof trying to mimic the authorized client would have to mimic the phone line itself This, of course, would fall under traditional telephone service fraud. The phone companies have extensive divisions to deal with this.
Assume the spoof has somehow managed to fake the Caller ID system into thinking that it is calling from one line, whereas, it is really calling from another. To expose this the Authentication Server institutes the following sequence. Once it gets the initial call from the client and reads the
Caller ID phone number and access codes, it disconnects. It then calls the stated phone number itself. The only way for the spoof to break this is to physically intercept the message as it is transmitted over the line to the proper number.
Another way is for the Authentication Server to use another telephone line and to call the one supposedly being used by the client. If it doesn't get a busy signal it knows that the client on the line is not at the correct number, regardless of what the Caller ID says.
d) Employ Public/Private Keys in Conjunction with Other Aspects of the Invention.
e) Time Sequencing Approach
Note that we have described one way to encrypt a message such that it is decrypted in-the-clear based on physical location. There are many others. For example, the digital signal in FIG. 10 could just be broken into three sequential parts without doing an eigenfunction decomposition. These would then be transmitted by the three satellites at staggered times such that only at the authorized client's site, PA, do they arrive in the correct arrangement to form the message. (See FIG. 15 )
f) Leave All Clients on All the Time, but not Connected to the Network.
This could then be employed in the following way. When the spoof requests access to the network, a message is sent from the satellites to the authentic client's position. If the authentic client receives such a message when, in fact, the client didn't ask to go on-line, it could be programmed to transmit a signal back to the satellites telling them so, i.e., pointing out that the request for access was from a spoof Or, another method would be for the authentic users to be chirping (emitting random, but known, EM signals) all the time when not connected to the Network. These would be monitored from the satellites. If the authorized client keeps chirping after a request for access is received, the request is known to be from a spoof
g) Use Lasers Instead of Radio Signals as a Means of Sending Messages to the Client.
This has the advantage of being easy to direct i.e. narrow beams. But it has the disadvantage of requiring the client's receiver to be in clear sight of the satellites.
h) Use Different Raw Data at Different Times to Determine Access.
Spoof doesn't know what to mimic. And if he tries to mimic them all the Authentication System could detect the bogus and unasked for signals, and deny access.
i) Ground Based Equivalent
Earth Bound Towers (such as microwave antenna towers) could be erected that serve the same purpose as the satellites. These would contain equivalent empirical data gathering devices as the satellites. But they would have the flexibility of having ground connections to the Authentication Server if desired.
j) Vector Decomposition Encryption Approach
This is another method to encrypt a message such that it is decrypted in-the-clear based on physical location. This method uses the vector nature of the EM field as a means of accomplishing the position dependent decryption. That is, when two or more electromagnetic fields reach a particular point they add together vectorally.
Consider the situation where the message we want to send to the client is a wave polarized along the x-axis. This wave could be of a certain duration in time. We can then design waves to be emitted from the three satellites that, when added together at P A , give the desired result. These waves are individually not polarized along the x-axis. Let E represent the total electric field at P A . Then, for example, we could have:
E 1 =4 {circumflex over (x)}−ŷ^ here {circumflex over (x)} and {circumflex over ( y )} are unit vectors along their
E 2 =−3 {circumflex over (x)} +3 ŷ respective axes.
E 3 ={circumflex over (x)} −2 ŷ
This gives E=E 1 +E 2 +E 3 =2{circumflex over (x)} for the total electric field.
Since the actual signal could be embedded in noise, and since at the location P S the three signals will not arrive at a time that facilitates the above superposition, this is a viable method of encryption.
[Spatial encryption is partly based on retarded time emission of specific nature t Ei . That is, we know that there is only one location on the surface of the earth where, if we emit at time t Ei then the three signals will arrive simultaneously.]
k) Applying the Inventive Concepts on Computer Network Security to the Wireless Computing Environment: Removing the Limitation of Fixed Position
As has been described in the examples, the network security system is based on empirically gathering information about the physical location of a client/user and incorporating this into the authentication process. One particular embodiment employs mobile (cellular) phone technology in a computer that isn't mobile. [See (a) above.]
However, wireless (i.e., mobile) computing has recently been growing in popularity. In this situation, the computer is using the cellular phone system as the primary method of communicating with a network. There is no conventional wire connection to the network and there is no fixed location for the client.
The inventive concepts can easily be extended to a network security system that would encompass the use of wireless computers. Two methods will now be described.
[Note that there are several concepts (e.g., branded CPU, hidden information in ROM, clock synchronization, etc.) that obviously translate into the wireless environment.]
Continuous Monitoring
Just as in the earlier examples, this embodiment also requires that the client be initialized by a network representative. This could include any of the previously described things such as determining precise physical location of the client, clock synchronization, etc.
Then, in this embodiment, the authorized client is left on all the time and “chirping.” That is, it is emitting a beacon signal at specific intervals even when not connected to the network. This allows the Network to continuously monitor the client's location. [In addition, the Network could keep a record of all these locations.]
Therefore, since the location is known at any given time, to within a certain range, all the security measures of the earlier examples can be employed to address authentication. This range is a region around the last known location. The size of this region is determined by the “chirp” rate and what velocity is physically possible for the client. If a signal is received that is outside this region, the client is denied access.
A variation of this would be that the client is kept within a relatively small cell size and there is no chirping. However, if the user decides that he wants to move outside the cell he informs the Network, through his software, that he is now in the “mobile” mode and the chirping begins.
Cell Size Is Increased
Even though wireless computers are mobile, they tend to be used within a limited geographical region. Therefore, starting at the initialization point the user can, through the software loaded on the client, inform the network that it intends to be in a certain region. An example would be a city. The authentication process works as it did in the earlier examples, except that now the cell encompasses the city not just a small region around a desk. The system is effective because it still can be used to address all those spoofs who are outside the cell. [In this embodiment, the client does not have to be chirping all the time.]
Other variations of these methods could be employed. For example:
Equipping the wireless computer with a means to connect to a standard telephone line. If the client/user has moved outside the allowed cell in an unauthorized fashion, he can be required to go to a location where he can be uniquely identified by the Network.
Appendix A
Raising the Hurdle to Unauthorized Access
One of the goals is to raise the security hurdle to unauthorized access. This is done because the hacker/spoof looks at a given network and weighs “cost of overcoming security hurdle” against “possible reward.”
The authentication system raises the hurdle by using empirically gathered client information and doesn't rely solely on client generated digital information for authentication. This then changes the dynamics of the Hacker/Authentication Server battle and raises the hurdle in three ways:
1. The technology needed to spoof the system is not readily available 2. The skills needed to use the technology aren't within the normal knowledge domain of the traditional hacker. 3. The technology needed is very expensive.
That is, the Authentication System forces the hacker to do things (e.g., satellite positioning, radio transmissions, etc.) that are not just based on clever uses of software. These are things that the vast majority of hackers have no experience with. Therefore, the system, although not perfect, is effective in dealing with the normal, or even the clever, hacker. And, consequently, the authentication system could be used to protect standard business computer networks.
As we have seen, it is possible to spoof the authentication system. But with each counter measure comes ever increasing technological sophistication and expense on the part of the spoof.
In essence, the authentication system makes breaking into a network very expensive and technologically challenging.
Therefore, one example of how it could be fruitfully employed is that a company could be set up to provide authentication services to many private business with computer networks to protect. Even if no single one of them could afford to set up the authentication system, as a group they would constitute the customer base that would make the system a viable business. Similarly, no traditional hacker could afford to overcome the hurdles set up by the system. And if a Counter-Authentication group were established to break through the barriers, the only way it could be done would be by the expenditure of a great amount of money and effort. It would be hard to keep this secret. Especially if Counter-Authenticaion group went about trying to get customers.
Therefore the system, although not perfect, is effective in dealing with the normal, or even the clever, hacker. And it is hackers who are the major problem for the standard business network. Consequently, the invention could be used to protect standard business computer networks. The hackers of these systems do not have the resources to overcome the hurdles the invention puts up.
Therefore a commercially viable business based on the invention could be set up where the business runs security for many companies at once.
Appendix B
An Example of The Invention's Authentication Process That Includes One Counter-Measure to Spoofing
1) The user uses his client computer C A ( 104 ), and its software, to request access to the Network ( 200 ). This client, which is configured by the Network, has very specific hardware and software pre-loaded on it related to the Authentication Process.
2) When the client's Network software is opened, it prompts the user to enter his User Credentials into a certain location on a “Network LogOn” screen. This could include, for example, his user ID and access code: (123, XYZ). It could also contain, for example, biometric information, Processor Serial Number, encryption keys (public/private), etc.
3) The client's software translates the credentials into digital information.
4) Data is Transmitted to the Authentication Server; Empirical Data is Obtained
a) The client's software then creates an electronic message that includes the digitized credentials.
Diagram 3
| | 1 | 2 | 3 | X | Y | Z | | | |
When the “Connect” button on the Graphic User Interface (GUI) screen is clicked, the software forces two events to occur:
i) the above electronic message is transmitted to the Authentication Server via the normal communications link ( 505 ) ii) the software orders the radio transmitter R A ( 105 ) to emit a beacon signal ( 700 ) from the antenna T A ( 106 ) with the pulse signature that has been assigned to this particular client.
b) Empirical Data on Client's Physical Location is Obtained
The act of transmitting the credentials to the network triggers a radio beacon signal to be emitted from the client. (The user doesn't have to do anything additional to have this beacon emitted.) This beacon signal is typically a spherical (i.e., omnidirectional) EM wave with a unique pulse shape.
The radio signal is detected by the satellites E i ( 600 ). The satellites note the client's signature pulse and the time of reception, t A1 , t A2 , and t A3 of the pulse. The arrival times will, in general be different for the three different satellites. (See FIG. 5 ) The results of these measurements are transmitted to the Authentication Server. [Note that in other embodiments there will be other quantities measured, such as: direction of the EM beam, polarization, etc.]
Note the following features of the sequence:
i. the authentication data is different from the prior art. ii. the method for obtaining that data is active (empirical) rather then passive.
5) Checking for Authenticity: A Two Step Process
a) The Authentication Server has in its database a list of digitized credentials for all authorized users. When the electronic message from the client arrives via the normal communications link ( 505 ), the Authentication Server takes the user's digitized credentials and compares these to the credentials it has stored in its database for this particular user. b) Using Empirical Position Data To Determine Authenticity
i) The Authentication Server also has in its database the physical location of each authorized client. (This can be obtained, for example, in an unequivocal manner by having a Network Official use a Global Positioning System (GPS) device during the initialization process. Once this physical position is established, movement of the user's client is restricted to a certain physical region established by the Network.) ii) The Authentication Server receives information from the satellites on their direct measurement of the clients beacon signal. iii) The Authentication Server uses beacon signal information to calculate the location of the client. iv) It then compares the actual position against the registered one.
c) Both the User Credentials in (a) and the physical location in (b) must match the information stored in the Authentication Server's database for access to be given. If either, or both, of these quantities do not match those in the database, then access is denied.
6. The Authentication Server orders the satellites to transmit f 1 , f 2 , and f 3 at times t E1 , t E2 , and t E3 respectively.
7. Satellites receive the order and comply. (See FIG. 13 )
8. At the location P A , the three signals arrive at time t* and superimpose to form the complete command signal f (t, P A ). The Authentication Server knows this time t*. The command f (t, P A ) is in-the-clear. That is, no analysis needs to be done to decipher it.
9. If the requesting client's antenna is at P A it reads this command.
10. The command orders the client to perform a task that is verifiable by the network. For example, it orders the client to transmit a particular message via the already existing communications channel ( 505 ) to the Authentication Server.
11. The Authentication Server waits to verify the response from the client. It also notes the nature of the response and the time at which the response comes in.
12. In its database the Network has the response time of the client C A . This was empirically determined at the time of the initial setup of the client and the user.
13. If there is no response within the specified time, access is denied.
Appendix C
A Statement about Eigenfunctions
A particular example of a complete set of eigenfunction would be that of plane waves. (See John David Jackson, “Classical Electrodynamics”, Second Edition, page 270.) These waves are, for example, functions of the argument
Kx−ωt
Here I have used the notation of Jackson with:
K=the wave vector x=position in three dimensional space (a vector quantity) ω=frequency t=time
This set of functions is only given as an example. There are many others. Which set is chosen is determined by, among other factors, the nature of the message that is being sent, i.e., f (t, P A ).
Appendix D
A Comment about Signal Analysis
We have used phrases such as “each of the partial summations, f i , alone conveys no meaning relative to the full message f” and “any one of the partial sums f i , by itself, will be unintelligible.” These and other similar terms can be quantified using Signal Processing techniques such as autocorrelation, cross correlation, etc. [See A. Papoulis, “Signal Analysis”] These techniques give a quantitative way of measuring the relationship of one signal to another.
For example, the cross correlation function is a measure of how much one signal is like another. That is, how much information contained in one signal can be said to also be in another signal. Saying that a “partial summation, f i , alone conveys no meaning relative to the full message f” is basically saying that the cross correlation between the two is very low.
The idea is to set up the partial sums such that the cross correlation is sufficiently low that it would not be easy for a spoof to discern what the full signal was.
Finally, it must be remembered that the spoof is dealing with the three signals after they have propagated from the transmitters to his antenna. That is, he receives signals that are distorted by noise.
Appendix E
Decryption Based on Physical Property of the Recipient
(Note that this concept can be used for many other things besides computer network security.)
In this approach to encryption/decryption there are basically three levels.
1. The concept of encoding a message based on some inherent physical property of the recipient. 2. The particular physical quantity used 3. The particular method used with the chosen property to encode the information.
Information can be encrypted in a special way, such that, a specific, and unique, physical property of the recipient automatically decrypts the information. There are many physical properties this could be based on.
a. physical location b. unique sensitivity to light or sound c. DNA (unique to each individual)
For each unique physical property, there will be many ways to encrypt the information such that when it arrives it is automatically decoded by the physical property itself of the authentic recipient.
The main body of the disclosure has gone into details on using physical location to decrypt a message. The following are two additional examples to illustrate the general principles of encoding a message based on some inherent physical property of the recipient such that when it is received it is automatically decoded by the physical property itself of the intended recipient.
Note that the technique can be applied in a variety of areas, computer network security is but one of them.
DNA Decoding
DNA is a chemical. Each person's DNA is different. Therefore, this chemical is different for each person.
Imagine a situation where a message is sent to a recipient in the form of a card. The material used to print the message on the card is made of two chemicals. One of these chemicals is tailored to react to the recipient's DNA and the other does not react with it. To the naked eye the card appears to be blank. The message, as originally sent, is encrypted using the two chemicals and cannot be decrypted by normal cryptography. (For example, the message could appear as just a black area across the card made up of the two chemicals.) But when the legitimate recipient's DNA is smeared across the black area, a chemical reaction takes place that automatically deciphers the message. This could be accomplished using, for example, the recipient's blood or saliva.
This gives but one example of how the differences between each person's DNA could be used to decode messages. There are others. For example, light passing through a suspension of the DNA would be affected differently by different DNA.
Physical Senses Decoding of Messages
The sensitivity of our physical senses (sight, hearing, smell, touch, taste) varies from person to person. This sensitivity could be used to decipher messages.
PC's have the ability to produce over 1 million different colors. At any given color, there are many colors near it in wavelength that cannot be discerned by the average person. But there are some people who have such sensitive sight that they can distinguish two particular colors that only a very few others could. This sensitivity could be used to encrypt messages to that person.
Consider a situation where it is know that the legitimate recipient can discern two colors with wavelengths λ 1 and λ 2 . In addition, these wavelengths are not discernible to the average person. A message can be encrypted by using the colors of the PC to first create a background in the color λ 1 and then writing the text of the message in color λ 2 on a computer monitor. The person with average sensitivity would not be able to discern the message. While the person with the heighten sensitivity would see the message, i.e., the message would come in the clear.
There are many other ways that the variations in sense sensitivity could be exploited both in:
what sense is used how it is used for what purpose it is use.
Appendix F
Non-Computer Security Uses for the Invention
Teenager Positioning System TPS
Consider a situation where teenagers are required to wear an Authentication System “Beacon Beeper.” The Beeper automatically sends out a radio beacon signal at preset intervals. The Authentication System signal detection system (satellites, microwave antennas, or some other method) detects these signals. The raw data is sent to a central processor (the equivalent of the authentication server) where it is analyzed to calculate the actual position. This information is then stored. Parents could then get this stored information in a variety of ways such as:
1. by access to a secured web page 2. by having the information emailed to them
Thus, parents could unobtrusively know where their kids are.
In addition, the system could be programmed to do the following:
a) Take a reading every five minutes and then, on request of the parent, print out a map of where the teenager had been over a specified time period. (This is a solution to the old response of “No where.” which is commonly given by kids when asked where they were the night before.) b) Restrict the teenager from going to certain geographic places. (Beeper gives a shock) c) System detects if the kid is moving faster than walking, e.g., in a car. It can then change its sampling frequency to accurately determine the speed the kid is going at and record this. d) Location is coordinated with roads and their speed limits e) If the speed is in excess of the limit for that road, a note is made of it, the parent is alerted either through a phone call, email, or on a computer screen to a secured web page, and the police are alerted. f) Parents can map out certain physical locations that
the kid must stay in, and/or the kid can't go to (e.g. a person's house)
The parent is alerted if these are violated. g) Two set of parents can coordinate their efforts. Both their kids can be equipped with Beepers. The system could then be programmed to coordinate their movements: either to alert if they get together or if they get apart. This could be used for keeping girls and boys apart for example. h) Shock is delivered This happens if the kid is doing something that the system has been programmed not to allow the kid to do. These could include such things as driving to fast, position where the kid isn't supposed to go, etc.
A system similar to this could be used to track toddlers. Parents could know at any moment where they were in the house.
Of course, there is the obvious use for criminal location.
This system could also be used to locate people with health related problems. For example, there are those who could become incapacitated. The location system could be tied to other measures that would transmit a signal to authorities under certain conditions (e.g., when pulse rate falls below a certain level, no motion is detected, etc.)
Note also that the Beeper could be more elaborate. It could be an electronic beacon electronically connected to a GPS hand held device. In this case the beacon is really sending out a message stating the teenager's position. (Note that in this case we are really not that worried about spoofing with anything sophisticated.) And the full authentication system would not be needed.
Appendix G
TPS Teenager Positioning System:
Simplified Method Based On A Modification to current Cellular Systems
A cellular phone system has data on the position of an active user. (This position is to within a certain resolution that may vary from one system to another.) That is, the system itself has this information currently. It is how the system knows when to “hand off” a user as he drives from one cell to another.
The cellular phone system could be modified by adding special software to transmit the position location of a user to an authorized person or web site.
The invention would work in the following way. A parent gives a cell phone to his kid who is going out for the evening. Whenever the parent wants, he calls the cell phone. The kid answers and the cellular phone system automatically locates the kid. Using its modified software, the system then transmits this information to the parent. There are many ways to do this: 1. through a secured web page. 2. directly on one of the new phone computer devices such as those that are allowing users to get email such as a Palm Pilot III, 3. email, etc.
In addition, variations of the standard cell phone could be developed. For example, something similar to the Authentication System Beeper, but instead of sending out a continuous radio beacon to satellites, it could be programmed to dial a particular telephone number automatically every five minutes. The location data would be recorded in a fashion similar to that described in Appendix F.
Appendix H
Location within A Geographically Limited Area
There are a host of situations (Homes, prisons, shopping malls, etc.) where an authority would like to know the physical location of a person (or an object) at any given moment. For example, a mother with several small children has to spend an inordinate amount of time making sure she knows where each one is. Also, parents going to shopping malls with the kids who are old enough to be on their own find themselves in the position of wondering where their kids went and how to make contact. Variations on the Authentication System could be employed to solve these problems.
There are several ways to accomplish this.
1. Beeper with Authentication System 2. Beeper with detection infrastructure specific to the geographical location 3. GPS Receiver connected to a local computer
1. Beeper with Authentication System:
As an example, the system could work in the following way: A mother puts a beeper on the wrist of each child. Then at strategic locations around the house she has a PC monitor on and connected to a secure web page. The page displays a map of her home. On the map is the location of the child. This could be updated as often as desired by the parent. The basic technology is the same as that discussed in Appendix F.
2. Beeper with Detection Infrastructure Specific to the Geographical Location
In this case, instead of using satellites or cellular phone technology to empirically measure the position of a child within a home, the system has its own detection infrastructure within the home and surrounding area. This could be based on extremely low level microwave, radio or other emissions from a beeper. This system is connected directly to a home PC. The PC calculates the location of each child and displays in on a map. Also the PC could be programmed to alert the parent if one of the children is going into restricted areas.
3. GPS Receiver Connected to a Local Computer
In this situation, the beeper isn't just a beacon. Instead it is connected to a GPS device. Upon entering a Shopping Mall, a mother goes to an area that has Location Beepers for lease. She is given one for each child and an ID number. The device is programmed to respond to a command from the central authority. For example, a mother wants to know where in a Shopping Mall her kids are. She goes to a computer (several of which are conveniently located around the Mall) and punches in her ID number. The computer sends out a wireless signal to the GPS devices to determine their location and to send that information back to the computer. The computer then displays the information for the parent.
Another variation on this would be for a parent who is dropping his kid off at the Mall. When the parent returns he could be given a map of where the kid has been.
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In connection with authenticating a client of a network, information is acquired that characterizes the client in a manner that enables a determination about authenticating the client of the network, the information being acquired other than in the form of a digital message that is passed on behalf of the client to the network; an authentication decision is made based on the information.
Information is encrypted in a manner that is based on a physical property of an intended recipient of the information, and delivering the encrypted information to the recipient.
A source of a beacon is physically associated with a person, times of receipt of the beacon at multiple stations are measured, and the location of the person is determined based on the times of receipt.
A set of stations is established that are configured to acquire information that characterizes each of multiple clients in a manner that enables a determination about authenticating each of the clients with respect to a corresponding network, the information being acquired other than in the form of digital messages that are passed on behalf of the clients to the corresponding networks. The information is provided to operators of the networks to enable them to make authentication decisions based on the information.
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This is a division, of application Ser. No. 680,776, filed Apr. 27, 1976, and now U.S. Pat. No. 4,077,239.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present disclosure pertains to a pumping agitator for circulating wash liquids between the tub and basket of a clothes washing machine.
2. Description of the Prior Art
The prior art discloses a number of different types of washing machine agitation and liquid flow systems including the following.
U.S. Pat. Nos. 2,554,229; 2,621,505; and 2,274,402 each disclose a somewhat different liquid circulation system for a washing machine wherein a clothes basket or receptacle contains an agitator for washing clothes in wash liquid within the receptacle while some wash liquid is continuously overflowing the receptacle and a separate pump is utilized to pump this overflow liquid back into the receptacle by way of a filter.
U.S. Pat. Nos. Re. 18,280 and Re. 20,424 each disclose a different form of agitator for circulating wash liquid through the agitator itself in order to create liquid currents within the machine's washing basket for aiding the roll-over pattern of the basket's contents.
U.S. Pat. Nos. 3,022,655; 3,068,680; 3,330,135; and 3,381,505 each disclose a different form of agitator utilizing pumping vanes for circulating wash liquid through the agitator for wash liquid filtering.
Additionally, U.S. Pat. Nos. 2,744,402; 2,916,900; and 3,543,541 disclose different forms of washing machine agitators each including vanes below or within the skirt portion of the agitator for pumping wash liquid through the agitator for filtering purposes.
U.S. Pat. No. 3,352,130 discloses an agitator including radial downwardly-facing pumping vanes on the bottom of the agitator skirt for inducing a flow of wash liquid from the tub to the basket of an automatic washer through filter openings in the basket; and U.S. Pat. No. 3,626,728 (assigned to the assignee of this invention) discloses an integral basket and agitator wherein the bottom of the basket carries downwardly-facing vanes for inducing wash liquid flow from the washing machine's tub into the basket through holes in the bottom of the basket.
Finally, U.S. Pat. No. 2,722,118 discloses an agitator for an automatic washer having a double skirt portion which defines radial flow passageways therethrough; and U.S. Pat. No. 3,330,135 discloses an agitator including hollow upstanding vanes on a skirt portion of the agitator for defining radial flow passageways through the agitator.
SUMMARY OF THE INVENTION
An agitator of a vertical axis washing machine according to the present invention includes spaced upper and lower skirt portions and a plurality of peripherally spaced, radially-extending flow channels or passageways between the skirt portions. Each flow channel has a first end at the periphery of the skirt in communication with the interior of the basket and a second end in communication with a center post portion of the tub through a distribution chamber and openings in the center post portion of the basket wall. Holes in the bottom of the basket spaced radially outwardly of the agitator skirt provide for a limited flow of liquid from the basket to the tub. As the agitator oscillates it acts as a centrifugal pump drawing wash liquid from the area of the tub center post portion through the openings in the basket center post wall and radially outwardly through the passageways of the agitator into the basket. Peripheral scallops formed between the flow channel outlets augment centrifugal forces to provide a strong pumping action.
If the flow of liquid from the basket back to the tub is sufficiently limited a saving of water in each washing cycle will occur since the pumping action of the agitator will maintain the volume of liquid in the tub at a minimum, while maximizing the amount of water in the effective part of the treatment zone. In any event, a desirable toroidal action or roll-over of basket contents will be effected by the pumping action of the agitator according to the present invention, and a simple, positive fluid circulation system for filtering and/or otherwise treating the wash liquid will be provided. The device of the present invention accomplishes these advantages with virtually no additional drive power required for the agitator system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general perspective view of an automatic washing machine partially cut away to show the placement therein of the pumping agitator of the present invention.
FIG. 2 is a cross-sectional view through the tub and basket of the automatic washer, with the agitator shown partially in elevation view and partially cut away to show a portion of the pumping means in cross-section.
FIG. 3 is a perspective view of the agitator assembly including the pumping means of the present invention.
FIG. 4 is a view along line IV--IV of FIG. 2, through the center post of the oscillatible agitator, showing the vanes and skirt of the agitator assembly.
FIG. 5 is a cross-sectional view from above through the flow channels of the pumping means of the present invention, also showing lower wall portions of the basket and tub taken along line V--V of FIG. 2.
FIG. 6 is a partial view similar to FIG. 2 but showing a basket including a perforated sidewall portion.
FIG. 7 is a detailed view in cross-section of the lower center post area of the tub showing the relationship of the tub, the basket, and the agitator according to the present invention.
FIG. 8 is a view similar to FIG. 6 but showing an alternative embodiment of the pumping agitator according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A washing machine, more specifically, a clothes washing machine of the vertical axis type, is shown in FIG. 1. The washer, indicated at 10, includes a cabinet 11 having a top access door 12. Directly beneath the access door a tub 13 and a clothes basket 14 are mounted within the cabinet, the basket and tub being coaxial and the basket contained in the tub as shown in FIGS. 1 and 2.
Within the basket and coaxial therewith is mounted agitation means shown in FIGS. 1 and 2 as an agitator assembly 15 comprising an auger portion 16 and an agitator portion 17. The auger portion 16 includes helical vanes 16a, and the agitator portion 17 includes an upstanding barrel portion 19 and a skirt portion 20. A plurality of scrubbing vanes are mounted directly above and adjacent the skirt portion 20, and in the illustrated embodiment shown in FIG. 3 the agitator includes rigid vanes 18b fixed to an upper surface of the skirt portion 20 and flexible vanes 18a attached to surfaces of the barrel portion 19.
Drive means 22 are provided for oscillating the agitator portion 17 in a conventional manner as is well-known in the art. The drive means also drives the auger portion 16 of the agitator assembly so that the auger rotates unidirectionally as the agitator portion 17 oscillates. Thus the auger portion 16 rotates relative to the oscillating agitator portion 17 to auger the clothes or other fabrics adjacent the auger portion downwardly towards the lower portion of the receptacle or treatment zone where agitation is taking place. The construction and operation of a dual action agitator including an auger portion similar to the one just described is disclosed in the co-pending U.S. patent application of Clark Platt, Ser. No. 595,792, assigned to the assignee of the present invention.
The basket 14 and the tub 13, upon the start of a washing cycle, will be filled with water to a level 50 (see FIG. 2), which will be common in both the basket and tub if a certain form of input stream splitter is used or if water can flow through apertures in the bottom portion of the basket 14 quickly enough with regard to the input rate to raise the level in the tub at the same rate as it is raised in the basket. As soon as water fill is complete, through operation of conventional controls in a known manner, the drive means 22 will begin to operate the agitator assembly 15. Thus during a washing cycle the tub 13 contains washing liquid and the basket 14 contains washing liquid and items to be washed such as, for example, clothing or other fabrics. The agitation means subject the basket contents to a washing action as the agitator portion 17 creates a turbulence adjacent the items being washed, with the rotating auger portion 16 moving the items to be washed downwardly in proximity to the scrubbing vanes and the oscillating scrubbing vanes contacting the items and subjecting them to a scrubbing action.
In a washing machine having a pumping agitator according to the present invention, laundry detergent and other appropriate additives may be introduced into the wash liquid by dumping them directly either into the basket or into the space between the tub and the basket, and the pumping action of the agitator will thoroughly mix them with the liquid already in the tub.
The drive means also spins the basket during a centrifuging operation at the conclusion of the washing cycle. During the centrifuging operation liquid in the basket is drained or forced out into the tub through holes in the basket sidewall or through spin outlet openings 42 in the upper sidewall of the basket subjacent a spin overflow lip 43. The liquid is then pumped from the tub to drain.
While the agitator means according to the present invention is shown as including an auger means which rotates unidirectionally relative to the oscillating agitator portion, it should be understood that the principles of the present invention may be applied equally well to an agitation means without the auger portion.
The details of the improved agitator 17 according to the present invention are shown in FIGS. 2, 3, 4 and 5. It will be observed that the agitator according to the invention is a pumping agitator including water pumping means 21 integral with the skirt portion 20. The skirt portion includes spaced lower and upper wall portions 25 and 25a respectively, and circumferentially-spaced radially-extending pumping channels are defined by lateral walls 29 and the lower and upper wall portions 25 and 25a. Eight such pumping channels or walled flow passages 26 are shown in FIG. 5, and each one includes a radially inner end portion 27 and a radially outer end portion 28. The outer end portion of each flow passage is joined to the outer end portions of adjacent flow passages by radially inwardly-scalloped peripheral wall segments 55, and the inner end portions 27 of adjacent flow channels are joined by peripheral wall segments 34. The lower and upper wall portions 25 and 25a respectively may be attached to one another adhesively or by any other convenient means such as screws 38.
As shown in FIG. 7, the lower wall portion 25 extends radially inwardly of the end portions 27 and includes an annular flange portion or water lip seal 31 which terminates adjacent a center post portion 32 of the basket 14. A distribution chamber 33 is therefore defined by surfaces of the agitator 17, the basket center post portion 32, the lower wall portion 25, and the peripheral walls 34 (see FIG. 5); and the distribution chamber 33 communicates with each of the flow passages 26.
Openings 36 are provided in the center post area 32 of the basket wall so that fluid communication will exist between the interior 100 of the basket and the volume 45 of the interior of the tub defined outside the basket as shown in FIG. 6. Therefore, as the agitator 17 oscillates the skirt portion 20 of the agitator acts as a centrifugal pump and pumping means 21 tends to pump liquid from the volume 45 between the basket and the tub, specifically from the space 45 beneath the basket, and into the basket. This liquid is pumped through the basket openings 36, into the distribution chamber 33, and outwardly through the flow channels 26 as indicated by the arrows 26a in FIG. 2, 5, 6 and 7. The liquid directed outwardly through the flow passages passes outwardly into the basket and tends to create favorable liquid currents in the basket which aid roll-over of the basket contents.
Roll-over, or toroidal movement of the contents within the basket is defined, for purposes of this application, as a movement pattern of the contents including fabrics being washed downwardly along the center post of the agitator assembly, outwardly along the bottom region of the basket, upwardly along the outer perimeter regions of the basket, and inwardly towards the upper portion of the agitator assembly. During the wash cycle this roll-over or toroidal movement pattern is repeated continuously and contributes significantly to good washing results.
The pumping agitator according to the present invention improves roll-over of the basket contents during the wash cycle by the centrifugal pumping action it generates. Thus in the embodiment shown in FIG. 2, the auger portion 16 of the agitator assembly will move fabrics including articles of clothing downwardly along the agitator assembly center post, and the scrubbing vanes adjacent the skirt portion 20 will tend to move fabrics outwardly along the lower regions of the basket. In addition, the liquid being pumped outwardly through the skirt portion 20 will cause outwardly directed currents along the bottom region of the basket which liquid currents will be directed upwardly along the outer perimeter of the basket by contact with the basket sidewall. The oscillatory to-and-fro motions of the agitator skirt follow one another so rapidly that there will be little or no flow of liquid radially inwardly through the flow channels 26 in opposition to the momentum of the outwardly moving fluid.
Openings in the lower portion of the basket wall such as those indicated at 40 in FIGS. 2 and 5 will allow liquid to flow from the basket back to the tub. The volume of liquid flowing from the basket to the tub may be increased by increasing the size and number of holes through the basket walls. For example, in FIG. 6 the basket is shown as having an apertured sidewall so as to allow practically unrestricted flow of liquid through openings 14a from the basket to the tub. Of course, the total flow even in the embodiment shown in FIG. 6 will be limited by the pumping capacity of the pumping agitator, but generally the greater the flow volume the greater will be the pumping agitator's contribution to the roll-over pattern of the basket contents during a wash cycle.
The liquid barrier or water lip seal means comprising the annular flange 31 encompassing the basket center post below the openings 36 serves to insure that the pumping agitator will draw liquid from the tub through the first set of openings 36 and substantially prevent radially-inward liquid flow in the basket under the lower portion of the agitator, that is in the region 100a between the lower portion of the agitator skirt portion and the lower wall portion of the basket. Such radially-inward flow would substantially impair the pumping efficiency of the pumping agitator and would also have an undesirable tendency to pull clothes under the agitator skirt. Providing the water lip seal or barrier means ensures a positive net flow into the basket through the first set of openings 36 and back into the tub through the second set of basket openings 40 or 14a. Appreciable liquid flow in the basket under the lower portion of the agitator is prevented inasmuch as virtually all liquid passing through the first set of openings 36 must pass through the pumping agitator. Thus any counter flow of liquid from the basket to the tub through holes 36 must also first pass through the flow channels 26.
A somewhat modified form of liquid barrier means is shown in FIG. 8. In this form of the invention an annular water lip seal or flange 31a extends downwardly from the lower wall portion 25 of the skirt 20 to contact the bottom surface of the basket. This modified form of flange also prevents appreciable liquid flow between the agitator and the bottom of the basket and ensures efficient pumping of liquid through the openings 36.
With the first set of openings 36 and the second set of openings 40 defined through a bottom wall portion 41 of the basket a substantially continuous flow of liquid will be maintained from the tub to the basket through holes 36 and from the basket to the tub through holes 40. In addition, heavy particles such as sand or the like will pass from the basket to the tub through the holes 40 and settle on the bottom of the tub in a sump portion 45 thereof until the washing cycle is completed, at which time these heavy sediment particles are discharged to a drain along with the used wash liquid.
Referring again to FIG. 2, the basket there shown includes a first set of openings 36 and a second set of openings 40 but the outer sidewall 14b of the basket is substantially imperforate (although there are spin outlet openings 42 in the upper sidewall of the basket as mentioned above). With this arrangement and with an appropriate number of properly sized holes 40 the pumping agitator, when oscillated during the washing cycle, will initially pump liquid from the tub into the basket faster than the liquid can run from the basket back into the tub through the holes 40. In this way, when the pumping rate has stabilized, the liquid level in the basket will be maintained during the washing cycle at a level substantially above the level of the wash liquid in the tub outside the basket. Thus, as seen in FIG. 2, wash fluid is pumped from the center post portion 35 of the tub 13 into the basket 14, and washing fluid in the sump portion 45 of the tub is consequently drawn radially inwardly beneath the bottom portion 41 of the basket. The apertures 40 in the lower wall portion 41 of the basket are appropriately sized so that only a very limited quantity of fluid from the basket may flow out of the basket to replenish the fluid drawn from the tub sump 45 through the openings 36 and the distribution chamber 33 and into the main portion of the basket. The net removal of water from the space between the basket and the tub by the pumping agitator will raise the water level 50 inside the basket to an operating level 52 while the liquid level in the space between the tub and basket is reduced to a level 51. The foregoing assumes that only the apertures 36, 40, and 42 are provided in the walls of the basket 14.
This difference in water levels between liquid in the basket and liquid in the tub outside the basket is held relatively stable during the washing cycle through the above-described basket construction and pumping action of the agitator and is advantageous because all the washing occurs within the basket and the volume of wash liquid in the tub region outside the basket generally contributes nothing to the washing operation. The pumping agitator in combination with a substantially imperforate basket or in combination with a basket having an appropriate number of appropriately sized holes such as, for example, the embodiment shown in FIG. 2 will thus provide a highly desirable water saver feature. Less liquid is added to the tub at the beginning of the cycle, and consequently less detergent and less additives are needed and less energy is required to heat the reduced volume of water. When the washing cycle begins the pumping agitator will quickly bring the liquid level in the basket up to the level required for the washing operation, and will maintain this higher level in the basket so long as the agitator continues to oscillate.
Although substantial pumping action is provided by the pumping agitator merely from centrifugal forces operating on fluid within the flow channels, it has been shown that addition of the radially inwardly-scalloped wall portions 55 joining the lateral walls 29 of the flow channels 26 between their outer end portions 28 will substantially augment the net flow from the pumping means 21. As shown in FIG. 5, a counter-clockwise oscillation of the agitator portion 17, which comprises the pumping means 21, relative to the basket 14 will induce a generally clockwise peripheral motion of fluid adjacent and above the axis of the pumping means 21, as indicated by the arrows 56. An opposite motion will be produced upon a clockwise oscillation of the agitator 17. The flow indicated by the arrows 56 produces a venturi-like effect on fluid within the flow channels 26, which will increase the efficiency of the pumping means and significantly multiply the flow rate through the flow channels 26.
It has been found that the combination of a tub having a 23 gallon capacity, a basket having four 1/2" holes 36 equally spaced around the center post and sixteen 3/8" holes 40 circumferentially spaced along the bottom of the basket, and a pumping agitator according to the present invention, provided an initial flow rate of 5 gallons per minute and an equilibrium flow rate during the wash cycle of about 3 gallons per minute. A four inch liquid level differential was maintained at equilibrium between the basket and the tub outside the basket, and this amounted to a liquid savings of approximately 4 gallons. To achieve this indicated water savings the skirt portion of the agitator including the pumping vanes had a diameter of 12-3/4" and oscillated with a 196° stroke at a rate of 68 strokes per minute in a basket having an outside diameter of approximately 21-1/2" and a center post diameter of approximately 3-3/16". It was found that the 4" liquid level differential was maintained regardless of the quantity of liquid in the tub so long as the liquid level in the tub was no less than 7 inches.
Although various modifications might be suggested by those versed in the art, it should be understood that we wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art.
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In a clothes washer an agitator that is also a water pump draws water from the zone between the basket and the tub of the clothes washer and pumps it to the inside of the basket thereby raising the water level in the area where washing occurs during agitation and also promoting good clothes roll-over action in the treatment zone. A method of laundering articles includes the step of pumping laundering liquid into a treatment zone and radially outwardly along a lower portion of the zone during agitation to obtain a desired level of laundering liquid in the part of the zone where laundering occurs.
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BACKGROUND OF THE INVENTION
The present invention relates to magnetic head materials used for magnetic disc devices, VTR and the like and particularly, to a ferromagnetic film having a high saturation magnetic flux density, high permeability, high thermal stability, high corrosion resistance, and reaction resistance and a magnetic head which uses the ferromagnetic film.
Recently, magnetic recording techniques have been remarkably developed and improvement of recording density has been hastened. In order to enhance recording density, it is necessary to use recording mediums of high coercivity and in order to magnetize the recording mediums of high coercivity, magnetic pole materials having a high saturation magnetic flux density are required. Therefore, Ni-Fe alloy (Permalloy) or Co based amorphous alloy thin films have began to be used in place of conventional ferrites as magnetic pole materials. Furthermore, magnetic pole materials are required to have a high permeability in addition to a high saturation magnetic flux density for improvement of read/write efficiency. Moreover, magnetic pole materials are also required to have a thermal stability enough to stand the heating step for filling with glass in the process for the formation of a magnetic head to maintain the high permeability.
As such magnetic pole materials, materials made by the simultaneous addition of Nb, Zr, Ti, Ta, Hf, Cr, W, or Mo and nitrogen to a metal selected from Fe, Co, Ni, and Mn are reported in U.S. Pat. No. 4,836,865. A method for making this material comprises sputtering a metal target having a given composition using a mixed gas of argon and nitrogen as sputtering gas. According to this report, a film having a saturation magnetic flux density of 1.5T and a coercivity of 1 Oe or less has been obtained by alternately laminating a nitrided layer and un-nitrided layer by modulating the nitrogen concentration in the sputtering gas. The coercivity of this film can be kept at a low level until 600° C. and the thermal stability is 600° C.
Furthermore, it is disclosed in MR89-12 (1989. 7) published from The Institute of Electronics, Information and Communication Engineers that a Fe based amorphous film is formed by the simultaneous addition of Ti, Zr, or Hf and C to Fe and then this film is heat treated, thereby to obtain microcrystalline soft magnetic materials having a high thermal stability.
SUMMARY OF THE INVENTION
The inventors conducted additional tests on the content of the above-mentioned report by sputtering Fe-Nb, Fe-Ta, and Fe-Hf materials in a mixed gas of argon and nitrogen. As a result, it has been found that the film has a low coercivity of lower than 1 Oe even when heated to 400°-600° C. as reported. It has also been found that a ferromagnetic film having a coercivity of less than 1 Oe is obtained by sputtering an Fe-Hf-C material in argon and then heat treating the material at 500°-600° C.
However, when the inventors produced on an experimental basis a metal-in-gap type head by forming such a conventional material on an Mn-Zn ferrite single crystal substrate and subjecting it to the heat treatment at 600° C. for filling with glass, it has become clear that the Mn-Zn ferrite single crystal substrate reacts with a magnetic film to form an oxide layer at the interface. When the read/write characteristics of a magnetic head were examined, a large contour signal based on a nonmagnetic layer at the interface between a crystal substrate and a magnetic film was observed as expected. When such a contour signal is observed, normal reading/writing cannot be performed. Furthermore, in this case, the reaction between the magnetic film and the filler glass was observed, and it was seen that the magnetic film became thinner. That is, it has been found that the conventional magnetic film shows excellent soft magnetic properties as a single magnetic film, but when a magnetic head is produced through the glass bonding process, reaction with the substrate or filler glass must be inhibited.
On the other hand, when a film formed on a glass substrate as a dummy sample was subjected to salt spray testing and testing at a constant temperature and constant humidity to evaluate the corrosion resistance of the film, it was found that the sample was very easily corroded as compared with a conventionally used Sendust film or Co-Nb-Zr type film and thus, use of it as a magnetic film was questionable.
Therefore, the object of the present invention is to provide a novel magnetic head material free from the defects in the conventional techniques.
The inventors have conducted intensive research in an attempt to solve the above problems and, as a result, a magnetic head material which not only maintains the saturation magnetic flux density and soft magnetic properties even at high temperatures, but also is high in resistance to the reaction with oxides such as ferrites or glass and is also high in corrosion resistance, has been developed by incorporating an oxide into a ferromagnetic metal. The oxide here includes substances comprising oxygen and an element of Groups IVa, Va and VIa, which have a bond such as Hf-O, Nb-O, Ta-O, Ti-O, Zr-O, V-O, W-O, Mo-O, or the like. Besides, additives for improving magnetic properties (decreasing coercivity and increasing specific permeability) may be added. Especially, for improvement of the soft magnetic properties, addition of B, C, N, or P is effective. Furthermore, for improvement of corrosion resistance, addition of Ni, Rh, Ru, Pd, Zr, Nb, Ta, Ag, Os, Ir, Pt, Au, Cr, Mo, W, or Ti is effective.
The ferromagnetic film of the present invention comprises a metallic phase in which an oxide phase is incorporated. There is no limitation in a method of the incorporation of the oxide phase, and even if any oxide is not present at the time of the formation of the ferromagnetic film, the oxide may be produced by the heat treatment and the like. It is also possible to previously incorporate it in the oxide form into the film at the time of the formation of the ferromagnetic film. For example, there may be employed any of methods of the lamination of a metal layer and an oxide layer, the lamination of a metal layer and a layer of an element which composes oxides with the metal and the simultaneous deposition of a metal and an element which composes oxides.
Magnetic recording devices excellent in write/read effeciency can be obtained by using the ferromagnetic film of the present invention as magnetic core of magnetic head. Especially, further advantageous effect can be obtained when the ferromagnetic film of the present invention is applied to a magnetic head made by a method which includes a glass bonding step, such as a metal-in-gap type head.
As explained above, the saturation magnetic flux density and soft magnetic properties are maintained even at high temperatures, but the mechanism therefor is not necessarily fully elucidated. However, as a result of studying by the inventors, it has been found that the heating of the ferromagnetic film containing an oxide to 600° C. results in substantially no enlargement of crystallite size, and the oxide inhibits the diffusion of elements constituting the ferromagnetic film and prevents the growth of crystallites due to heating. The film heated to 600° C. was analyzed by high resolving power EPMA (Electron Probe Micro Analysis method). As a result, the oxide phase was observed around crystallites which constitute ferromagnetic film and it has been found that the crystallite growth (enlargement) constituting the ferromagnetic film is inhibited by the presence of this phase. It has been known that except for materials which have a magnetocrystalline anisotropy constant of nearly zero, the soft magnetic properties of ferromagnetic materials have a relation with the size of the crystallites which constitute the ferromagnetic materials, and with increase in the size of the crystallites the soft magnetic properties deteriorate. Accordingly, it is considered that similarly, since the crystallites of the ferromagnetic film of the present invention are maintained at a small size, any deterioration of the soft magnetic properties do not occur. However, when the same film was examined by an X-ray diffraction method, no oxide was detected and thus the substance was either present in a slight amount or in an amorphous state.
Furthermore, the saturated magnetic flux density of the ferromagnetic film of the present invention has showed a tendency to decrease with increase in the amount of the oxide added, which is considered to be due to simple dilution of the magnetic material by addition of the non-magnetic material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of the ferromagnetic metal film of the present invention.
FIG. 2 is a graph which shows influence of an oxygen concentration in the film on the coercivity and corrosion resistance of the ferromagnetic film of the present invention.
FIG. 3A is an oblique view of the magnetic head of the present invention, and FIG. 3B is a plan view of the vicinity of the gap portion of the magnetic head of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will be illustrated by the following examples referring to the drawings.
EXAMPLE 1
Ferromagnetic films mainly composed of Fe and/or Co were formed on crystallized glass substrates using an ion beam sputtering apparatus. The ion beam sputtering apparatus used in this example was provided with two ion guns, one of which carries out sputtering of a target and can deposit sputtered particles on a substrate and the other of which can clean the substrate. The target holder of this apparatus is of a revolving type and four kinds of targets at maximum can be mounted thereon. Optional one of them can be selected to perform the sputtering. Therefore, an optional laminate film can be formed from these target materials. Such an apparatus is known (see Journal of APPLIED PHYSICS, Vol. 61, No. 12, June 15, 1987). Targets of ferromagnetic metals mainly composed of Fe and/or Co and a target of oxide were alternately sputtered by this apparatus to form a laminate film. The sputtering was conducted under the following conditions.
______________________________________Sputtering gas: ArAr gas pressure in the 2.5 × 10.sup.-2 Paapparatus:Acceleration voltage of the ion gun for deposi- 800 Vtion:Ion current of the ion gun for deposition: 120 mADistance between the target and the substrates: 130 mmSubstrate temperature: 50-100° C.______________________________________
The cross-sectional view of the laminate film made under the above conditions is shown in FIG. 1. In this example, the laminate film was comprised of a ferromagnetic metal layer 2 of 9 nm thick and an oxide layer 3 of 1 nm thick, which was produced using a crystallized glass substrate as substrate 1. Since the total thickness of the laminate film was 1 μm in this example, this laminate film totally consisted of 100 ferromagnetic metal layers 2 and 99 oxide layers 3.
The resulting laminate films were heat treated at 100°-700° C. for 1 hour in Ar gas and evaluation of the soft magnetic properties of the respective films and crystallographical evaluation of the films by X-ray diffraction were conducted and confirmation of presence of the oxide layer by analysis was conducted.
The results are shown in Table 1. In Table 1, with reference to the ferromagnetic metal film and oxide, the compositions of the target at the formation of film are shown. In the case of an ideal film-forming process, the composition of the target may be considered to be nearly the same as that of the film formed. However, under some conditions, light elements may be expelled at the surface of the substrate and the composition of the film may be less than that of the target. The values of coercivity and corrosion test were those which were obtained by measurement after heat treatment at 500° C. for 1 hour. The coercivity was measured using a B-H curve tracer. Thermal stability was shown by a temperature at which the coercivity of the heat treated sample reached 1.5 Oe or more. The corrosion test was conducted by intermittently spraying a 0.5% aqueous NaCl solution onto the sample which was kept at 35° C., and the result was shown by a time required before corrosion progressed by 5%. Here, the progress of the corrosion was measured by the reduction of a magnetization of the sample.
As a result, a ferromagnetic film having excellent soft magnetic properties of 1.5 Oe or less even at a high temperature of 600° C. was able to be obtained by laminating ferromagnetic metal films mainly composed of Fe and/or Co through the intermediary of an oxide of element of Groups IVa, Va and VIa of the Periodic Table. The results of the corrosion test show that all the samples had a corrosion resistance of at least 50 days. A multi-layer film including a ferromagnetic metal film mainly composed of Fe and/or Co to which an element such as B, C, N or the like was added, was similarly produced and was evaluated to obtain a similar corrosion resistance except a coercivity decreased by 5-15%. The inventors have reported in U.S. Pat. No. 4,858,049 that effect of reduction in coercivity was obtained by adding 5-20 at% of B, N, C, or P, and it is supposed that similar effects have been obtained. Moreover, further improvement of the corrosion resistance can be expected by further adding to such a ferromagnetic metal at least one element selected from Ni, Rh, Ru, Pd, Zr, Nb, Ta, Ag, Os, Ir, Pt, Au, Cr, Mo, W, Ti, Bi, V, Co, and Cu. Effect of addition of these elements is disclosed in U.S. Pat. No. 4,935,314 by the inventors.
For comparison, multi-layer films were prepared using a boride, carbide and nitride of elements of Groups IVa, Va and VI in place of oxide. However, these films were found to be very low in corrosion resistance. That is, it is guessed that when the boride, carbide or nitride is incorporated, the films are oxidized and corroded if they are exposed to a salt in the air for a long time, because these compounds easily change to oxides with a lower energy. Furthermore, when a film of 1 μm was prepared from only Fe and Co and heat treated, the enlargement of crystallite size occurred at 400° C. and the coercivity increased to higher than 5 Oe. Thus, it is clear that the thermal stability and corrosion resistance are improved by incorporating oxide materials of Ti, Zr, Hf, V, Nb, Ta, Cr or the like into ferromagnetic metal films.
As a result of observation of the cross-sectional structure of the laminate film heat treated at 600° C. by an electron microscope, it was found that the laminate structure was maintained even after the heat treatment at 600° C. and the high melting point oxides inhibited the growth of crystallites of the ferromagnetic metal films. Separately, the inventors carried out the lamination of these ferromagnetic metal films through the intermediary of a metal film such as of Ni or Cr in place of the oxide and heat treated the films at 600° C. and observed the cross-sectional structure to find that the ferromagnetic metal film and the intermediary metal film completely diffused into each other, and no laminate structure was recognized and, besides, the enlargement of crystallite size occurred and some of the crystallites formed a single crystal from the surface of the film to the interface with the substrate.
There is no special limitation in thickness of the intermediary film in the present invention, but when the proportion of the intermediary film of non-magnetic material increases in the laminate film, the saturation magnetic flux density decreases owing to the effect of simple dilution. This is not preferred. From this viewpoint, the intermediary film should preferably be as thin as possible. However, as disclosed in Japanese Patent Kokai (Laid-Open) No. Sho 59-9905, when a crystalline ferromagnetic metal film and an intermediary layer different therefrom are laminated, the crystalline structure of the ferromagnetic metal film can be made finer and suitable magnetic properties can be obtained. In order to expect the effect of such intermediary layer, it is necessary that the thickness of the intermediary layer is 1 nm or more. It is considered that when the intermediary layer of 1 nm or more in thickness and the ferromagnetic metal layer are laminated by sputtering, the crystal structure of the ferromagnetic metal layer becomes finer and even when this is heated, the oxide of the intermediary layer penetrates into the grain boundry of the ferromagnetic metal layer to inhibit enlargement of crystallites.
As a result of examination of the magnetic film of the present invention by an X-ray diffraction method, it was found that the crystal structure of the film heat treated at 600° C. was in a body-centered cubic form when the film was mainly composed of Fe, and was in a hexagonal closed packing form when it was mainly composed of Co. In this case, these Fe and Co constituted a single phase having no other crystal structure. Therefore, Fe and Co do not form non-ferromagnetic substances having other crystal structures (for example, Y-Fe, Fe 3 C, Fe 2 O 3 ) and a high saturation magnetic flux density of 1.7 T or higher was obtained even after the heat treatment at 600° C. or higher.
EXAMPLE 2
Laminate films were prepared in the same manner as in Example 1 using a target comprising a ferromagnetic metal to which oxygen was added and a target comprising a metal of Groups IVa, Va and VIa. The target comprising the ferromagnetic metal to which oxygen was added was prepared by mixing Fe with Fe 2 O 3 or Co with CoO. Results obtained are shown in Table 2. In Table 2, the compositions of the ferromagnetic film and the metal are shown by those of the targets at the time of formation of the film. The values of the coercivity and crystallite size were those measured after heat treatment at 600° C. for 1 hour. Corrosion resistance was measured by salt spray testing in the same manner as in Example 1.
As a result, the ferromagnetic films having excellent soft magnetic properties of 1.1 Oe or less in coercivity even at a high temperature of 600° C. were obtained by laminating the ferromagnetic metal films mainly composed of Fe and/or Co to which oxygen was added between which a metal of Groups IVa, Va and VIa was incorporated.
It was found that the crystallite size at this time was maintained at 200 Å or less. The crystallite size before the heat treatment was 150 Å or less and, thus, it was clear that the crystallite size did not almost change by the heat treatment. However, examination of the change of the coercivity caused by the heat treatment showed that the coercivity once increased at temperatures in the range of 300°-450° C. and when the temperature was further elevated, the coercivity again decreased. These results were different from those which were obtained when the ferromagnetic metal films were laminated through the intermediary of oxide.
Change of the saturated magnetic flux density due to the heat treatment was similar to that in Example 1 and no great change was recognized. Especially, the saturated magnetic flux density did not decrease at a temperature of higher than 600° C.
The cross-sectional structure of the laminate film heat treated at 700° C. was observed by an electron microscope, and it was seen that the laminate structure was maintained even after the heat treatment at 700° C. and the laminate structure inhibited the growth of the crystallites of the ferromagnetic metal film. Furthermore, as a result of analysis of these ferromagnetic metal laminate films by a high resolution power electron probe micro analysis method, it can be considered that the oxygen added to the ferromagnetic films also gather at the part of the metal layer inserted as an intermediary layer and an oxide is formed. Moreover, it was found that a part of the inserted metal diffused and existed so that it covered the crystallites which constituted the ferromagnetic films. It is considered that the added carbon and boron also exist there and a carbide or boride are also simultaneously present.
A film as formed by sputtering and this film heat treated at 600° C. were analyzed by XPS (X-ray photo-electron spectroscopy). As a result, a peak which shows the metal element constituting the intermediary layer before the heat treatment became smaller after the heat treatment and instead, a peak which shows the presence of an oxide of the element constituting the intermediary layer was observed. That is, it was found that the oxygen and the metal of the intermediary layer were in a bonded state (namely, oxide) in the ferromagnetic film after the heat treatment. Therefore, it is clear that the thermal stability can be improved by allowing the oxide to be present around the crystallites which constitute the ferromagnetic metal film.
The resulting magnetic films were tested on corrosion resistance in the same manner as in Example 1 and, as a result, all the samples had a corrosion resistance of at least 50 days and it has become clear that the presence of the oxide in the magnetic film inhibits corrosion.
In Example 2, other elements can also be added for the reduction of coercivity and improvement of corrosion resistance as in Example 1. Furthermore, the relation between the intermediary layer and the ferromagnetic metal layer can also be considered as in Example 1.
EXAMPLE 3
Ferromagnetic films were prepared using ferromagnetic metals shown in Table 3 as target and a mixed gas of argon and oxygen as a sputtering gas.
The results are shown in Table 3. In Table 3, the compositions of the ferromagnetic films are shown by that of the target at formation of the films. The oxygen concentration is shown by an oxygen concentration in the sputtering gas. Coercivity and corrosion resistance are shown with values measured after the heat treatment at 600° C. for 1 hour. The corrosion resistance was measured as in Example 1. As a result, the ferromagnetic films having excellent soft magnetic properties of 1 Oe or less in coercivity even at a high temperature of 600° C. were obtained by sputtering in oxygen atmosphere, the ferromagnetic metal films mainly composed of Fe and/or Co to which elements of Groups IVa, Va and VIa were added. It was found that the crystallite size was maintained at 200 Å or less. The crystallite size before the heat treatment was 150 Å or less and thus, it became clear that there occurred substantially no change in crystallite size by the heat treatment.
The corrosion resistances of the films heat treated at 600° C. were all at least 50 days. Thus, the corrosion resistance was clearly improved as compared with a corrosion resistance of 10-30 days of the magnetic films containing no oxygen.
When the amount of oxygen contained in the magnetic film after the heat treated was measured by an EPMA method, it was found that 5.2-8.4 at% of oxygen was present in the film. For studying the influence of oxygen content in more detail, Fe 86 Nb 10 B 4 film was subjected to sputtering with changing the oxygen concentration of the sputtering gas and, as a result, the relations between the oxygen content and the coercivity and corrosion resistance were as shown in FIG. 2. That is, it was found that in order to keep the coercivity at low values, the oxygen concentration in the film was preferably 15 at% or less, more preferably 10 at% or less and the corrosion resistance was improved with increase in the amount of oxygen. Furthermore, in order to obtain desired conditions of 2 Oe or less in coercivity and 50 days or more in corrosion resistance, the oxygen concentration in the film was 0.1-15 at%.
As a result of observation of the cross-sectional structure of the magnetic film heat treated at 600° C. by an electron microscope, the crystallite size was maintained at 200 Å or less even after the heat treatment at 600° C. and it was seen that the oxide formation inhibited the growth of crystallites of the ferromagnetic metal film. Furthermore, the inventors analyzed the ferromagnetic metal film by a high resolution power EPMA method to confirm that the oxide of an element of Groups IVa, Va and VIa was present at the grain boundary of the magnetic film. Thus, it is clear that when materials of a high melting point such as oxides are present around crystallites which constitute the ferromagnetic metal film, the thermal stability and corrosion resistance can be improved as in Example 2.
Elements to be added can be selected also in Example 3 as in Examples 1 and 2.
EXAMPLE 4
Magnetic poles of metal-in-gap type heads were produced using the ferromagnetic films obtained in Examples 1-3 as shown in FIG. 3 and were evaluated for the head of a high density magnetic recording apparatus. FIG. 3A is a whole oblique view of the head, and FIG. 3B shows the enlarged portion in the vicinity of the gap. A magnetic core coated with a ferromagnetic film 5 of 5 μm thick was butted against a Mn-Zn ferrite substrate 4 to form a gap 8. The length of the gap was 0.3 μm. The magnetic core was provided with a coil 7. A glass bonding temperature at the time of formation of the head was 520° C. A medium used was of 1500 Oe in coercivity. As a result, the recording characteristics of the head in which the Fe based ferromagnetic film of the present invention was used for a magnetic pole were improved by 4.6 dB and read/write output was higher by about 3 dB as compared with a conventional Sendust head. Besides, a recording density of at least 100 kBPI was obtained. This is because the saturation magnetic flux density of the ferromagnetic film of the present invention is higher than that of other materials.
Furthermore, the contour signal output due to the contour gap effect of the head was measured and, as a result, it was found that when a conventional magnetic film comprising Fe or Co to which Nb, Zr, Ti, Ta, Hf, Cr, W, or Mo and nitrogen or carbon were simultaneously added was used as a magnetic pole of head, a contour signal output of 3 to 5 dB was detected when the magnetic film of the present invention was used, the contour signal output decreased to 2 dB or less. The glass bonded portion of the head was peeled off and depth analysis from the magnetic film side towards a ferrite by an Auger electron spectroscopy was conducted. As a result, it was formed that in the case of the conventional head, an oxide layer of 50-180 Å was present at the interface between the magnetic film and the ferrite. On the other hand, in the case of the head of the present invention, the oxide layer at the interface between the magnetic film and the ferrite was at most 20 Å thick and thus, it has become clear that when the oxide phase is present in the magnetic film, the thickness of the oxide layer at the interface becomes thin, and the contour signal output decreases.
Furthermore, when the conventional magnetic film was used for a magnetic pole, the reaction between the magnetic film and the filler glass took place at glass bonding and a part of the magnetic film was converted to a film inferior in soft magnetic properties to deteriorate read/write properties of the head. In the worst case, the film of a high coercivity was formed and signal recorded in the medium is spontaneously erased. However, according to the present invention, observation of the interface between the magnetic film and the filler glass by an optical microscope did not reveal formation of the reaction product layer and high read/write properties were obtained.
In the above Examples, the magnetic film was formed by an ion beam sputtering method, but the inventors made the similar investigation using a RF sputtering method and have found that the magnetic films having nearly the same magnetic properties and thermal stability as above can be obtained only by elevating a substrate temperature to about 150° C. Therefore, the present invention is effective irrespective of a method of film formation.
As explained above in detail, the film having a high thermal stability and high saturation magnetic flux density of the present invention is superior in soft magnetic properties up to a temperature of at least 600° C. and the saturation magnetic flux density also does not decrease. Moreover, this soft magnetic film is not only markedly excellent in corrosion resistance, but also a reaction product layer such as the oxide is formed with difficulty at the interface between the magnetic film and the ferrite and so, when this film is used for the magnetic head of a magnetic recording apparatus, especially magnetic head of a metal-in-gap type, glass bonding can be performed at a high temperature of 500° C. or higher and a glass layer having a sufficient strength can be formed. Besides, the contour signal output caused by contour gap effect is low, namely 2 dB or lower.
TABLE 1______________________________________Ferro- Corro-magnetic Coercivity Thermal sionNo. metal film Oxide (Oe) stability (°C.) test (day)______________________________________ 1 Fe TiO.sub.2 0.8 600 70 2 Fe Ti.sub.2 O.sub.3 0.9 600 74 3 Fe ZrO.sub.2 0.9 600 58 4 Fe HfO.sub.2 0.8 600 82 5 Fe V.sub.2 O.sub.3 0.8 600 67 6 Fe Nb.sub.2 O.sub.5 0.9 600 86 7 Fe Ta.sub.2 O.sub.5 0.8 600 73 8 Fe Cr.sub.2 O.sub.3 0.8 600 67 9 Co Ti.sub.2 O.sub.3 0.8 600 9310 Co ZrO.sub.2 0.9 600 8811 Co HfO.sub.2 0.9 600 9512 Co V.sub.2 O.sub.3 0.8 600 8713 Co Nb.sub.2 O.sub.5 0.9 600 9814 Co Ta.sub.2 O.sub.5 0.8 600 9415 Co Cr.sub.2 O.sub.3 0.8 600 8116 Fe.sub.70 Co.sub.30 Ti.sub.2 O.sub.3 0.9 600 8417 Fe.sub.70 Co.sub.30 HfO.sub.2 0.9 600 7618 Fe.sub.70 Co.sub.30 Nb.sub. 2 O.sub.5 0.9 600 7919 Fe.sub.70 Co.sub.30 Ta.sub.2 O.sub.5 0.8 600 8220 Fe.sub.70 Co.sub.30 Cr.sub.2 O.sub.3 0.9 600 77______________________________________
TABLE 2______________________________________Ferro- Crystal-magnetic Coercivity lite size ThermalNo. film Metal (Oe) (Å) stability (°C.)______________________________________ 1 Fe.sub.95 O.sub.5 Hf 0.7 160 650 2 Fe.sub.95 O.sub.5 Nb 0.8 180 650 3 Fe.sub.95 O.sub.5 Ta 0.7 190 650 4 Fe.sub.95 O.sub.5 Ti 0.8 190 650 5 Fe.sub.95 O.sub.5 Zr 0.9 190 650 6 Fe.sub.95 O.sub.5 V 0.9 200 650 7 Fe.sub.95 O.sub.5 W 0.9 180 650 8 Fe.sub.95 O.sub.5 Mo 0.8 190 650 9 Fe.sub.90 B.sub.4 O.sub.6 Nb 0.6 160 65010 Fe.sub.90 B.sub.4 O.sub.6 Ta 0.6 170 65011 Fe.sub.90 C.sub.4 O.sub.6 Nb 0.7 170 65012 Fe.sub.90 C.sub.4 O.sub.6 Ta 0.6 160 65013 Fe.sub.88 N.sub.6 O.sub.6 Nb 0.8 180 65014 Fe.sub.88 N.sub.6 O.sub.6 Ta 0.8 180 65015 Co.sub.94 O.sub.6 Ta 0.8 170 65016 Co.sub.95 O.sub.5 Nb 0.7 170 65017 Co.sub.95 O.sub.5 Zr 0.9 190 65018 Co.sub.95 O.sub.5 Ti 1.1 200 65019 Co.sub.95 O.sub.5 Hf 0.8 170 65020 Fe.sub.70 Co.sub.25 O.sub.5 Ta 0.9 180 650______________________________________
TABLE 3______________________________________Ferro- Oxygen Coer- Thermal Corrosionmagnetic concen- civity stability resistanceNo. film tration (%) (Oe) (°C.) (day)______________________________________ 1 Fe.sub.95 Hf.sub.5 18 0.6 600 82 2 Fe.sub.90 Nb.sub.10 18 0.7 600 78 3 Fe.sub.95 Ta.sub.5 18 0.7 600 85 4 Fe.sub.95 Ti.sub.5 18 0.7 600 76 5 Fe.sub.85 Zr.sub.15 18 0.8 600 93 6 Fe.sub.95 V.sub.5 18 0.9 600 83 7 Fe.sub.95 W.sub.5 18 0.8 600 77 8 Fe.sub.95 Mo.sub.5 18 0.7 600 89 9 Fe.sub.92 Nb.sub.5 B.sub.3 15 0.7 600 9110 Fe.sub.88 Nb.sub.6 C.sub.6 15 0.8 600 9611 Fe.sub.90 Nb.sub.6 N.sub.4 15 0.8 600 7512 Fe.sub.88 Ta.sub.8 B.sub.4 15 1.0 600 7813 Fe.sub.88 Ta.sub.8 C.sub.4 15 0.9 600 8014 Fe.sub.88 Ta.sub.8 N.sub.4 15 0.7 600 9215 Co.sub.90 Ta.sub.10 25 0.8 600 9016 Co.sub.95 Nb.sub.5 25 0.7 600 8817 Co.sub.95 Zr.sub.5 25 0.7 600 7618 Co.sub.95 Ti.sub.5 25 1.0 600 7919 Co.sub.95 Hf.sub.5 25 0.8 600 6920 Fe.sub.70 Co.sub.25 V.sub.5 15 0.9 600 73______________________________________
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A ferromagnetic film which comprises ferromagnetic metal in which an oxide phase is present, a method for producing it, and a magnetic head in which said ferromagnetic film is used are disclosed. The ferromagnetic metal includes iron and cobalt and the oxide phase contains preferably at least one element selected from IVa, Va and VIa group elements.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Divisional Application of U.S. application Ser. No. 11/136,398, filed May 25, 2005, the entire contents therein is incorporated by reference.
FIELD OF THE INVENTION
[0002] The invention generally relates to a system and method for delivering and deploying a medical device within a vessel, more particularly, it relates to a system and method for delivering and deploying an endoluminal therapeutic device within the vasculature of a patient to embolize and occlude aneurysms, particularly cerebral aneurysms.
BACKGROUND ART OF THE INVENTION
[0003] Walls of the vasculature, particularly arterial walls, may develop areas of pathological dilatation called aneurysms. As is well known, aneurysms have thin, weak walls that are prone to rupturing. Aneurysms can be the result of the vessel wall being weakened by disease, injury or a congenital abnormality. Aneurysms could be found in different parts of the body with the most common being abdominal aortic aneurysms and brain or cerebral aneurysms in the neurovasculature. When the weakened wall of an aneurysm ruptures, it can result in death, especially if it is a cerebral aneurysm that ruptures.
[0004] Aneurysms are generally treated by excluding the weakened part of the vessel from the arterial circulation. For treating a cerebral aneurysm, such reinforcement is done in many ways including: (i) surgical clipping, where a metal clip is secured around the base of the aneurysm; (ii) packing the aneurysm with small, flexible wire coils (micro-coils); (iii) using embolic materials to “fill” an aneurysm; (iv) using detachable balloons or coils to occlude the parent vessel that supplies the aneurysm; and (v) intravascular stenting.
[0005] Intravascular stents are well known in the medical arts for the treatment of vascular stenoses or aneurysms. Stents are prostheses that expand radially or otherwise within a vessel or lumen to provide support against the collapse of the vessel. Methods for delivering these intravascular stents are also well known.
[0006] In conventional methods of introducing a compressed stent into a vessel and positioning it within in an area of stenosis or an aneurysm, a guiding catheter having a distal tip is percutaneously introduced into the vascular system of a patient. The guiding catheter is advanced within the vessel until its distal tip is proximate the stenosis or aneurysm. A guidewire positioned within an inner lumen of a second, inner catheter and the inner catheter are advanced through the distal end of the guiding catheter. The guidewire is then advanced out of the distal end of the guiding catheter into the vessel until the distal portion of the guidewire carrying the compressed stent is positioned at the point of the lesion within the vessel. Once the compressed stent is located at the lesion, the stent may be released and expanded so that it supports the vessel.
SUMMARY OF THE INVENTION
[0007] Aspects of the present invention include a system and method of deploying an occluding device within a vessel. The occluding device can be used to remodel an aneurysm within the vessel by, for example, neck reconstruction or balloon remodeling. The occluding device can be used to form a barrier that retains occlusion material such as a well known coil or viscous fluids, such as “ONYX” by Microtherapeutics, within the aneurysm so that introduced material will not escape from within the aneurysm. Also, during deployment, the length of the occluding device can be adjusted in response to friction created between the occluding device and an inner surface of a catheter. When this occurs, the deployed length and circumferential size of the occluding device can be changed as desired by the physician performing the procedure.
[0008] An aspect of the present invention includes a system for supporting and deploying an occluding device. The system comprises an introducer sheath and an assembly for carrying the occluding device. The assembly includes an elongated flexible member having an occluding device retaining member for receiving a first end of the occluding device, a proximally positioned retaining member for engaging a second end of the occluding device and a support surrounding a portion of the elongated flexible member over which the occluding device can be positioned.
[0009] Another aspect of the present invention includes a system for supporting and deploying an occluding device. The system comprises an assembly for carrying the occluding device. The assembly comprises an elongated member including a flexible distal tip portion, a retaining member for receiving a first end of the occluding device, and a support surrounding a portion of the elongated flexible member for supporting the occluding device.
[0010] A further aspect of the present invention comprises a method of introducing and deploying an occluding device within a vessel. The method includes the steps of introducing an elongated sheath including an introducer sheath carrying a guidewire assembly into a catheter and advancing the guidewire assembly out of the sheath and into the catheter. The method also includes the steps of positioning an end of the catheter proximate an aneurysm, advancing a portion of the guidewire assembly out of the catheter and rotating a portion of the guidewire assembly while deploying the occluding device in the area of the aneurysm.
BRIEF DESCRIPTION OF THE FIGURES
[0011] FIG. 1 is a cross section of an occluding device delivery assembly and occluding device according to an aspect of the invention;
[0012] FIG. 2 illustrates a catheter and introducer sheath shown in FIG. 1 ;
[0013] FIG. 3 is a partial cut away view of the introducer sheath of FIG. 2 carrying a guidewire assembly loaded with an occluding device;
[0014] FIG. 4 is a cross section of the guidewire assembly illustrated in FIG. 3 ;
[0015] FIG. 5 is a schematic view of the guidewire assembly of FIG. 4 ;
[0016] FIG. 6 is a second schematic view of the guidewire assembly of FIG. 4 ;
[0017] FIG. 7 illustrates the occluding device and a portion of the guidewire assembly positioned outside the catheter, and how a proximal end of the occluding device begins to deploy within a vessel;
[0018] FIG. 8 illustrates a step in the method of deploying the occluding device;
[0019] FIG. 9 illustrates the deployment of the occluding device according to an aspect of the present invention;
[0020] FIG. 10 is a schematic view of a guidewire assembly according to another embodiment of the present invention; and
[0021] FIG. 11 is a schematic view of the deployed occluding device after having been deployed by the guidewire assembly of FIG. 10 .
DETAILED DESCRIPTION OF THE INVENTION
[0022] An occluding device delivery assembly having portions with small cross section(s) and which is highly flexible is described herein. FIG. 1 illustrates an introducer sheath 10 according to an aspect of the present invention that receives, contains and delivers an occluding device 100 to a flexible micro-catheter 1 for positioning within the vasculature of an individual. The occluding device 100 can include those embodiments disclosed in copending U.S. patent application titled “Flexible Vascular Occluding Device”, (Atty. Docket No. 006258.00010), filed on May 25, 2005, which is expressly hereby incorporated by reference in its entirety.
[0023] A distal end 12 of the introducer sheath 10 is sized and configured to be received within a hub 2 of the micro-catheter 1 , as shown in FIGS. 1 and 2 . The hub 2 can be positioned at the proximal end of the micro-catheter 1 or at another location spaced along the length of the micro-catheter 1 . The micro-catheter 1 can be any known micro-catheter that can be introduced and advanced through the vasculature of a patient. In an embodiment, the micro-catheter has an inner diameter of 0.047 inch or less. In another embodiment, the micro-catheter has an inner diameter of about 0.027 inch to about 0.021 inch. In an alternative embodiment, the micro-catheter could have an inner diameter of about 0.025 inch. However, it is contemplated that the catheter 1 can have an inner diameter that is greater than 0.047 inch or less than 0.021 inch. After the introducer sheath 10 is positioned within the catheter hub 2 , the occluding device 100 can be advanced from the introducer sheath 10 into the micro-catheter 1 in preparation for deploying the occluding device 100 within the vasculature of the patient.
[0024] The micro-catheter 1 may have at least one fluid introduction port 6 located adjacent the hub 2 or at another position along its length. The port 6 is preferably in fluid communication with the distal end of the micro-catheter 1 so that a fluid, e.g., saline, may be passed through the micro-catheter 1 prior to insertion into the vasculature for flushing out air or debris trapped within the micro-catheter 1 and any instruments, such as guidewires, positioned within the micro-catheter 1 . The port 6 may also be used to deliver drugs or fluids within the vasculature as desired.
[0025] FIG. 3 illustrates the introducer sheath 10 , an elongated flexible delivery guidewire assembly 20 that is movable within the introducer sheath 10 and the occluding device 100 . As shown, the guidewire assembly 20 and the occluding device 100 , carried by the guidewire assembly 20 , have not been introduced into the micro-catheter 1 . Instead, as illustrated, they are positioned within the introducer sheath 10 . The introducer sheath 10 may be made from various thermoplastics, e.g., PTFE, FEP, HDPE, PEEK, etc., which may optionally be lined on the inner surface of the sheath or an adjacent surface with a hydrophilic material such as PVP or some other plastic coating. Additionally, either surface may be coated with various combinations of different materials, depending upon the desired results.
[0026] The introducer sheath 10 may include drainage ports or purge holes (not shown) formed into the wall near the area covering the occluding device 100 . There may be a single hole or multiple holes, e.g., three holes, formed into introducer sheath 10 . These purge holes allow for fluids, e.g., saline, to readily escape from in between the introducer sheath 10 and the guidewire assembly 20 when purging the sheath prior to positioning the introducer sheath 10 in contact with the catheter hub 2 , e.g., to remove trapped air or debris.
[0027] As shown in FIG. 4 , the guidewire assembly 20 includes an elongated flexible guidewire 21 . The flexibility of the guidewire 21 allows the guidewire assembly 20 to bend and conform to the curvature of the vasculature as needed for positional movement of the occluding device 100 within the vasculature. The guidewire 21 may be made of a conventional guidewire material and have a solid cross section. Alternatively, the guidewire 21 can be formed from a hypotube. In either embodiment, the guidewire 21 has a diameter D 5 ranging from about 0.010 inch to about 0.020 inch. In an embodiment, the largest diameter of the guidewire 21 is about 0.016 inch. The material used for the guidewire 21 can be any of the known guidewire materials including superelastic metals, e.g., Nitinol. Alternatively, the guidewire 21 can be formed of metals such as stainless steel. Length L 4 of the guidewire can be from about 125 to about 190 cm. In an embodiment, the length L 4 is about 175 cm.
[0028] The guidewire assembly 20 can have the same degree of flexion along its entire length. In an alternative embodiment, the guidewire assembly 20 can have longitudinal sections, each with differing degrees of flexion/stiffness. The different degrees of flexions for the guidewire assembly 20 can be created using different materials and/or thicknesses within different longitudinal sections of the guidewire 21 . In another embodiment, the flexion of the guidewire 21 can be controlled by spaced cuts (not shown) formed within the delivery guidewire 21 . These cuts can be longitudinally and/or circumferentially spaced from each other. The cuts can be formed with precision within the delivery guidewire 21 . Different sections of the delivery guidewire 21 can include cuts formed with different spacing and different depths to provide these distinct sections with different amounts of flexion and stiffness. In any of the above embodiments, the guidewire assembly 20 and the guidewire 21 are responsive to torque applied to the guidewire assembly 20 by the operator. As discussed below, the torque applied to the guidewire assembly 20 via the guidewire 21 can be used to release the occluding device 100 from the guidewire assembly 20 .
[0029] The size and shape of the cuts formed within the delivery guidewire 21 may be controlled so as to provide greater or lesser amounts of flexibility. Because the cuts can be varied in width without changing the depth or overall shape of the cut, the flexibility of the delivery guidewire 21 may be selectively altered without affecting the torsional strength of the delivery guidewire 21 . Thus, the flexibility and torsional strength of the delivery guidewire 21 may be selectively and independently altered.
[0030] Advantageously, longitudinally adjacent pairs of cuts may be rotated about 90 degrees around the circumference of the delivery guidewire 21 from one another to provide flexure laterally and vertically. However, the cuts may be located at predetermined locations to provide preferential flexure in one or more desired directions. Of course, the cuts could be randomly formed to allow bending (flexion) equally, non-preferentially in all directions or planes. In one embodiment, this could be achieved by circumferentially spacing the cuts.
[0031] The flexible delivery guidewire 21 can include any number of sections having the same or differing degrees of flexion. For example, the flexible delivery guidewire 21 could include two or more sections. In the embodiment illustrated in FIG. 4 , the flexible delivery guidewire 21 includes three sections, each having a different diameter. Each section can have a diameter of about 0.005 inch to about 0.025 inch. In an embodiment, the diameter of one or more sections can be about 0.010 inch to about 0.020 inch. A first section 22 includes a proximal end 23 that is located opposite the position of the occluding device 100 . The first section 22 can have a constant thickness along its length. Alternatively, the first section 22 can have a thickness (diameter) that tapers along its entire length or only a portion of its length. In the tapered embodiment, the thickness (diameter) of the first section 22 decreases in the direction of a second, transition section 24 . For those embodiments in which the guidewire 21 has a circular cross section, the thickness is the diameter of the section.
[0032] The second, transition section 24 extends between the first section 22 and a third, distal section 26 . The second section 24 tapers in thickness from the large diameter of the first section 22 to the smaller diameter of the third section 26 . As with the first section 22 , the second section 24 can taper along its entire length or only a portion of its length.
[0033] The third section 26 has a smaller thickness compared to the other sections 22 , 24 of the delivery guidewire 21 . The third section 26 extends away from the tapered second section 24 that carries the occluding device 100 . The third section 26 can taper along its entire length from the second section 24 to the distal end 27 of the delivery guidewire 21 . Alternatively, the third section 26 can have a constant diameter or taper along only a portion of its length. In such an embodiment, the tapering portion of the third section 26 can extend from the second section 24 or a point spaced from the second section 24 to a point spaced from distal end 27 of the delivery guidewire 21 . Although three sections of the delivery guidewire 21 are discussed and illustrated, the delivery guidewire 21 can include more than three sections. Additionally, each of these sections can taper in their thickness (diameter) along all or only a portion of their length. In any of the disclosed embodiments, the delivery guidewire 21 can be formed of a shape memory alloy such as Nitinol.
[0034] A tip 28 and flexible tip coil 29 are secured to the distal end 27 of the delivery guidewire 21 as shown in FIGS. 4 and 5 . The tip 28 can include a continuous end cap or cover as shown in the figures, which securely receives a distal end of the tip coil 29 . Flexion control is provided to the distal end portion of the delivery guidewire 21 by the tip coil 29 . However, in an embodiment, the tip 28 can be free of the coil 29 . The tip 28 has a non-percutaneous, atraumatic end face. In the illustrated embodiment, the tip 28 has a rounded face. In alternative embodiments, the tip 28 can have other non-percutaneous shapes that will not injure the vessel in which it is introduced. As illustrated in FIG. 4 , the tip 28 includes a housing 45 that securely receives the distal end of the guidewire 21 within an opening 46 in the interior surface of the housing 45 . The guidewire 21 can be secured within the opening by any known means.
[0035] As shown in FIG. 4 , the tip coil 29 surrounds a portion of the guidewire 21 . The tip coil 29 is flexible so that it will conform to and follow the path of a vessel within the patient as the tip 28 is advanced along the vessel and the guidewire 21 bends to follow the tortuous path of the vasculature. The tip coil 29 extends rearward from the tip 28 in the direction of the proximal end 23 , as shown.
[0036] The tip 28 and coil 29 have an outer diameter D 1 of about 0.010 inch to about 0.018 inch. In an embodiment, their outer diameter D 1 is about 0.014 inch. The tip 28 and coil 29 also have a length L 1 of about 0.1 cm to about 3.0 cm. In an embodiment, they have a total length L 1 of about 1.5 cm.
[0037] A proximal end 30 of the tip coil 29 is received within a housing 32 at a distal end 24 of a protective coil 35 , as shown in FIGS. 1 and 4 . The housing 32 and protective coil 35 have an outer diameter D 2 of about 0.018 inch to about 0.038 inch. In an embodiment, their outer diameter D 2 is about 0.024 inch. The housing 32 and protective coil 35 have a length L 2 of about 0.05 cm to about 0.2 cm. In an embodiment, their total length L 2 is about 0.15 cm.
[0038] The housing 32 has a non-percutaneous, atraumatic shape. For example, as shown in FIG. 5 , the housing 32 has a substantially blunt profile. Also, the housing 32 can be sized to open/support the vessel as it passes through it. Additionally, the housing 32 can include angled sidewalls sized to just be spaced just off the inner surface of the introducer sheath 10 .
[0039] The housing 32 and protective coil 35 form a distal retaining member that maintains the position of the occluding device 100 on the flexible guidewire assembly 20 and helps to hold the occluding device 100 in a compressed state prior to its delivery and deployment within a vessel of the vasculature. The protective coil 35 extends from the housing 32 in the direction of the proximal end 23 of the delivery guidewire 21 , as shown in FIG. 4 . The protective coil 35 is secured to the housing 32 in any known manner. In a first embodiment, the protective coil 35 can be secured to the outer surface of the housing 32 . In an alternative embodiment, the protective coil 35 can be secured within an opening of the housing 32 so that the housing 32 surrounds and internally receives the distal end 51 of the protective coil 35 ( FIG. 4 ). As shown in FIGS. 3 and 4 , the distal end 102 of the occluding device 100 is retained within the proximal end 52 so that the occluding device 100 cannot deploy while positioned in the sheath 10 or the micro-catheter 1 .
[0040] At the proximal end of the occluding device 100 , a bumper coil 60 and cap 62 prevent lateral movement of the occluding device 100 along the length of the guidewire 21 in the direction of the proximal end 23 , see FIG. 3 . The bumper coil 60 and cap 62 have an outer diameter D 4 of about 0.018 inch to about 0.038 inch. In an embodiment, their outer diameter D 4 is about 0.024 inch. The cap 62 contacts the proximal end 107 of the occluding device 100 and prevents it from moving along the length of the guidewire 21 away from the protective coil 35 . The bumper coil 60 can be in the form of a spring that contacts and pressures the cap 62 in the direction of the protective coil 35 , thereby creating a biasing force against the occluding device 100 . This biasing force (pressure) aids in maintaining the secured, covered relationship between the distal end 102 of the occluding device 100 and the protective coil 35 . As with any of the coils positioned along the delivery guidewire 21 , the bumper coil 60 can be secured to the delivery guidewire 21 by soldering, welding, RF welding, glue, and/or other known adhesives.
[0041] In an alternative embodiment illustrated in FIG. 10 , the bumper coil 60 is not utilized. Instead, a proximal end 107 of the occluding device 100 is held in position by a set of spring loaded arms (jaws) 140 while positioned within the introducer sheath 10 or the micro-catheter 1 . The inner surfaces of the micro-catheter 1 and the introducer sheath 10 limit the radial expansion of the arms 140 . When the proximal end of the occluding device passes out of the micro-catheter 1 , the arms 140 would spring open and release the occluding device as shown in FIG. 11 .
[0042] In an alternative embodiment, the bumper coil 60 and cap 62 can be eliminated and the proximal end of the occluding device 100 can be held in position relative to the protective coil 35 by a tapered section of the guidewire 21 . In such an embodiment, the enlarged cross section of this tapered section can be used to retain the occluding device 100 in position along the length of the delivery guidewire 21 and prevent movement of the occluding device 100 in the direction of the proximal end 23 .
[0043] As shown in FIG. 4 , the guidewire assembly 20 includes a support 70 for the occluding device 100 . In a first embodiment, the support 70 can include an outer surface of the delivery guidewire 21 that is sized to contact the inner surface of the occluding device 100 when the occluding device 100 is loaded on the guidewire assembly 20 . In this embodiment, the outer surface of the delivery guidewire 21 supports the occluding device 100 and maintains it in a ready to deploy state. In another embodiment, illustrated in the Figures, the support 70 comprises a mid-coil 70 that extends from a location proximate the protective coil 35 rearward toward the bumper coil 60 . The mid-coil 70 extends under the occluding device 100 and over the delivery guidewire 21 , as shown in FIG. 1 . The mid-coil 70 can be coextensive with one or more sections of the delivery guidewire 21 . For example, the mid-coil 70 could be coextensive with only the second section 24 of the delivery guidewire 21 or it could extend along portions of both the third section 26 and the second section 24 of the delivery guidewire 21 .
[0044] The mid-coil 70 provides the guidewire assembly 20 with an outwardly extending surface that is sized to contact the inner surface of the occluding device 100 in order to assist in supporting the occluding device and maintaining the occluding device 100 in a ready to deploy state. Like the other coils discussed herein and illustrated in the figures, the coiled form of the mid-coil 70 permits the mid-coil 70 to flex with the delivery guidewire 21 as the delivery guidewire 21 is advanced through the vasculature of the patient. The mid-coil 70 provides a constant diameter along a length of the delivery guidewire 21 that is covered by the occluding device 100 regardless of the taper of the delivery guidewire 21 beneath the occluding device 100 . The mid-coil 70 permits the delivery guidewire 21 to be tapered so it can achieve the needed flexibility to follow the path of the vasculature without compromising the support provided to the occluding device 100 . The mid-coil 70 provides the occluding device 100 with constant support regardless of the taper of the delivery guidewire 21 prior to the occluding device 100 being deployed. The smallest diameter of the occluding device 100 when in its compressed state is also controlled by the size of the mid-coil 70 . Additionally, the diameter of the mid-coil 70 can be chosen so that the proper spacing, including no spacing, is established between the occluding device 100 and the inner wall of the micro-catheter 1 prior to deployment of the occluding device 100 . The mid-coil 70 can also be used to bias the occluding device 100 away from the delivery guidewire 21 during its deployment.
[0045] In either embodiment, the support 70 can have an outer diameter D 3 of about 0.010 inch to about 0.018 inch. In an embodiment, the outer diameter D 3 is about 0.014 inch. The support 70 can also have a length L 3 of about 2.0 cm to about 30 cm. In an embodiment, the length L 3 of the support 70 is about 7 cm.
[0046] The occluding device 100 may also be placed on the mid-coil 70 between an optional pair of radio-opaque marker bands located along the length of the guidewire assembly 20 . Alternatively, the protective coil 35 , bumper coil 60 and or mid-coil 70 can include radio-opaque markers. In an alternative embodiment, the guidewire assembly 20 may include only a single radio-opaque marker. The use of radio-opaque markers allows for the visualization of the guidewire assembly 20 and the occluding device 100 during placement within the vasculature. Such visualization techniques may include conventional methods such as fluoroscopy, radiography, ultra-sonography, magnetic resonance imaging, etc.
[0047] The occluding device 100 can be delivered and deployed at the site of an aneurysm A according to the following method and variations thereof. The delivery of the occluding device 100 includes introducing the micro-catheter 1 into the vasculature until it reaches a site that requires treatment. The micro-catheter 1 is introduced into the vasculature using a conventional technique such as being advanced over or simultaneously with a conventional vascular guidewire (not shown). The positioning of the micro-catheter 1 can occur before it receives the guidewire assembly 20 or while it contains the guidewire assembly 20 . The position of the micro-catheter 1 within the vasculature can be determined by identifying radio-opaque markers positioned on or in the micro-catheter 1 .
[0048] After the micro-catheter 1 is positioned at the desired location, the guidewire is removed and the distal end of the introducer sheath 10 is inserted into the proximal end of the micro-catheter 1 , as shown in FIG. 1 . In an embodiment, the distal end of the introducer sheath 10 is introduced through the hub 2 at the proximal end of the micro-catheter 1 . The introducer sheath 10 is advanced within the micro-catheter 1 until a distal tip of the introducer sheath 10 is wedged within the micro-catheter 1 . At this position, the introducer sheath 10 cannot be advanced further within the micro-catheter 1 . The introducer sheath 10 is then securely held while the delivery guidewire assembly 20 carrying the occluding device 100 is advanced through the introducer sheath 10 until the occluding device 100 is advanced out of the introducer sheath 10 and into the micro-catheter 1 .
[0049] The guidewire assembly 20 and the occluding device 100 are advanced through the micro-catheter 1 until the tip coil 29 is proximate the distal end of the micro-catheter 1 . At this point, the position of the micro-catheter 1 and guidewire assembly 20 can be confirmed. The guidewire assembly 20 is then advanced out of the micro-catheter 1 and into the vasculature of the patient so that the proximal end 107 of the occluding device 100 is positioned outside the distal end of the micro-catheter 1 and adjacent the area to be treated. At any point during these steps, the position of the occluding device 100 can be checked to determine that it will be deployed correctly and at the desired location. This can be accomplished by using the radio-opaque markers discussed above.
[0050] When the distal end 102 of the occluding device 100 is positioned outside the micro-catheter 1 , the proximal end 107 will begin to expand, in the direction of the arrows shown in FIG. 7 , within the vasculature while the distal end 102 remains covered by the protective coil 35 . When the occluding device 100 is in the proper position, the delivery guidewire 21 is rotated (See FIG. 8 ) until the distal end 102 of the occluding device 100 moves away from the protective coil 35 and expands within the vasculature at the desired location. The delivery guidewire 21 can be rotated either clockwise or counter clockwise as needed to deploy the occluding device 100 . In an embodiment, the delivery guidewire 21 may be rotated, for example, between two and ten turns in either or both directions. In another example, the occluding device may be deployed by rotating the delivery guidewire 21 clockwise for less than five turns, for example, three to five turns. After the occluding device 100 has been deployed, the delivery guidewire 21 can be retracted into the micro-catheter 100 and removed form the body.
[0051] In an alternative or additional deployment step shown in FIG. 9 , friction between the occluding device 100 and inner surface of the micro-catheter 1 cause the distal end of the occluding device 100 to separate from the protective coil 35 . The friction can be created by the opening of the occluding device 100 and/or the mid-coil 70 biasing the occluding device 100 toward the inner surface of the micro-catheter 1 . The friction between the micro-catheter 1 and the occluding device 100 will assist in the deployment of the occluding device 100 . In those instances when the occluding device 100 does not open and separate from the protective coil 35 during deployment, the friction between occluding device 100 and the inner surface of the micro-catheter 1 will cause the occluding device 100 to move away from the protective coil 35 as the delivery guidewire 21 and the micro-catheter 1 move relative to each other. The delivery guidewire 21 can then be rotated and the occluding device 100 deployed within the vessel.
[0052] After the occluding device 100 radially self-expands into gentle, but secure, contact with the walls of the vessel so as to occlude the neck of the aneurysm A, the micro-catheter 1 may be removed entirely from the body of the patient. Alternatively, the micro-catheter 1 may be left in position within vasculature to allow for the insertion of additional tools or the application of drugs near the treatment site.
[0053] Known materials can be used in the present invention. One common material that can be used with the occluding device 100 and the guidewire 21 is Nitinol, a nickel-titanium shape memory alloy, which can be formed and annealed, deformed at a low temperature, and recalled to its original shape with heating, such as when deployed at body temperature in the body. The radio-opaque markers can be formed of radio-opaque materials including metals, such as platinum, or doped plastics including bismuth or tungsten to aid in visualization.
[0054] The apparatus and methods discussed herein are not limited to the deployment and use within the vascular system but may include any number of further treatment applications. Other treatment sites may include areas or regions of the body such as organ bodies. Modification of each of the above-described apparatus and methods for carrying out the invention, and variations of aspects of the invention that are obvious to those of skill in the art are intended to be within the scope of the claims. Furthermore, no element, component or method step is intended to be dedicated to the public regardless of whether the element, component or method step is explicitly recited in the claims.
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A system and method for deploying an occluding device that can be used to remodel an aneurysm within the vessel by, for example, neck reconstruction or balloon remodeling. The system comprises an introducer sheath and an assembly for carrying the occluding device. The assembly includes an elongated flexible member having an occluding device retaining member for receiving a first end of the occluding device, a proximally positioned retaining member for engaging a second end of the occluding device and a support surrounding a portion of the elongated flexible member over which the occluding device can be positioned.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. utility application entitled, “SUBSCRIBER LINE DRIVER AND TERMINATION,” having Ser. No. 09/439,933, filed Nov. 12, 1999 now U.S. Pat. No. 6,782,096, which is entirely incorporated herein by reference.
This document claims priority to and the benefit of the filing date of co-pending commonly assigned Provisional Application entitled, “SUBSCRIBER LINE DRIVER AND TERMINATION,” having Ser. No. 60/108,044, filed Nov. 12, 1998. The foregoing provisional application is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates generally to the art of data communications. The preferred embodiment generally relates to the art of telephony, and more particularly, to a communication signal driver system (and associated methodology) for connection between a telephony switching unit, which may be located at a central office (CO), at a private branch exchange (PBX) or the like, and customer premises equipment via an existing telephony connection (e.g., copper wire twisted-pair, digital subscriber loop or the like).
BACKGROUND OF THE INVENTION
With the increasing bandwidth demands from the advent of the Internet, service providers have looked for ways to increase data performance over the copper wire twisted-pair local loop transmission lines that connect the telephone central offices (COs) to the customer premises (CPs). The customer premises equipment (CPE) is connected to the CO switches over transmission lines known as “local loops,” “subscriber loops,” “loops,” or the “last mile” of the telephone network. Historically, the public switched telephone network (PSTN) evolved with subscriber loops connected to a telephone network with circuit-switched capabilities that were designed to carry analog voice communications. Digital service provision to the customer premises is a more recent development, with the evolution of the telephone network from a system just designed to carry analog voice communications into a system which could simultaneously carry voice and digital data.
Because of the prohibitive costs of replacing or supplementing existing subscriber loops, technologies have been implemented that utilize existing subscriber loops to provide easy and low cost customer migration to digital technologies. Subscriber loops capable of carrying digital channels are known as digital subscriber lines (DSLs). Logical channels within a subscriber line which carry digital signals are known as DSL channels, while logical channels within a subscriber line which carry plain old telephone service (POTS) analog signals are known as POTS channels. Furthermore, to provide customers with additional flexibility and enhanced services, frequency-division multiplexing and/or time-division multiplexing techniques have been designed to fill a subscriber loop with multiple logical channels. These newer DSL technologies provide digital service to the customer premises without significantly interfering with the existing POTS equipment and wiring. The newer DSL technologies accomplish this functionality by frequency-division multiplexing (FDM) their digital signal above (at higher frequencies than) the 0 KHz to 4 KHz baseband of standard, analog POTS signals. Multiplexing techniques and terminology are common to those skilled in the art, and are not described herein.
Several variants of new DSL technology exist (e.g., ADSL, SDSL, RADSL, VADSL, MVL™, Tripleplay™, etc.), with this group generally referred to as xDSL. Communications systems carrying xDSL usually multiplex xDSL signals and a POTS signal onto a single physical local loop.
Historically, the POTS subscriber loop was designed with the functions needed to communicate both analog, voice-conversation signals and subscriber loop signaling. The CO switch uses subscriber loop signaling to notify the customer premises about events in the telephone network, while customer premises equipment (CPE) use subscriber loop signaling to inform the CO to perform actions for the customer. Some examples of subscriber loop signaling include: the CO switch signaling to the CPE that an incoming call has arrived by ringing the phone, the CPE (e.g., a telephone) signaling to the CO switch that the CPE is initiating a call by an on-hook to off-hook transition of the telephone handset, and the CPE signaling to the CO switch that a call should be connected to a location by sending the phone number of the location.
Although the transmission of both digital and analog POTS signals over a subscriber loop offers many potential advantages for customers, several practical problems must be solved in implementing DSL solutions. One significant problem resulting from the POTS subscriber loop signaling functions is the generation of high-frequency interference, known in the art as noise, into DSL channels. For instance, the on-hook/off-hook signal and the pulse-dialing signal are square waveforms which have high-frequency components and harmonics, and theoretically require infinite frequency bandwidth. This high-frequency noise may degrade the signal to noise (S/N) ratio of the DSL channel. The S/N ratio is commonly known to those skilled in the art, but can be simply described as the ratio of the transmit signal amplitude to the noise amplitude, expressed in decibels (dB). Thus, a heretofore unaddressed need exists in the industry for a way to prevent or substantially minimize the adverse affects on the DSL channel S/N ratio caused by noise introduced by the POTS subscriber loop functions.
Another practical problem facing the industry effort to implement DSL technology on the existing PSTN system is the large voltage magnitude change occurring on the subscriber loop during transitions between on-hook and off-hook conditions, as is well known in the art. Some embodiments of prior art DSL technology require a change in the input impedance of the DSL device upon sensing of a transition between on-hook and off-hook conditions. Thus, a heretofore unaddressed need exists in the industry for a way to prevent or substantially minimize the adverse affects of the on-hook/off-hook transition.
Another practical problem facing the industry effort to implement DSL technology on the existing PSTN system is the unpredictable nature of the subscriber loop transmission system impedance. Signal attenuation (decrease in signal strength) and signal distortion (changes in the signal shape) are caused by real and reactive impedance losses incurred on the subscriber loop as the signal is transmitted between the CO and the CPE. Each subscriber loop, consisting of a copper wire twisted-pair circuit connecting the CO to the CPE, is unique. That is, each subscriber loop differs in length, and often these subscriber loops are constructed with varying copper wire gauge sizes. Therefore, the actual circuit impedance of any given subscriber loop is unique and different from other subscriber loops. DSL technology utilizes FDM to shift the frequency of the communication signal into the 25 KHz to 1 MHz frequency range. As is well known in the art, subscriber loop circuit impedance is not a constant, but rather a variable over the frequency spectrum because the subscriber loop impedance is complex (having reactive impedance components as well as resistive impedance components). Therefore, signal attenuation also varies with the frequency of a transmission signal. That is, some frequencies will be attenuated more or less than other frequencies.
The presence of bridged taps connected to the subscriber loop introduces another unpredictable impedance component. Bridged taps are unused copper wire twisted-pair lengths connected at various points of the subscriber loop. Bridged taps constitute parallel circuits which alter the impedance of the subscriber loop circuit, and effectively reduce the transmit signal strength.
Finally, the wiring of the customer premise and the various types of customer equipment and devices, including multipoint communication, connected to the subscriber loop is unique. These differences at the customer premise also impact the overall impedance of the subscriber loop transmission system.
For the purpose of establishing the transmitter frequency domain specifications and limits, current practice typically models the subscriber loop impedance as a resister, R L , that is representative of the characteristic impedance of the subscriber loop transmission line. At the remote end of the transmission line, the receiver equipment is typically modeled as a terminating resister, R R , usually of the same value as R L . Transmission of signals onto subscriber loops has been provided by a voltage signal source, V s , and a series resister, R T . Current practice is to transmit at the subscriber loop transmission line input a transmit signal spectral shape of V S that is designed to be the same as a voltage power spectral distribution (PSD) standard. The PSD standard specifies maximum signal strength (amplitude) and frequency bandwidth boundaries for a DSL channel.
Design of the transmit signal spectral shape of V S necessarily requires certain assumptions about the subscriber loop transmission system. Traditional transmission line theory teaches that for optimum communication, the subscriber loop transmission system should have R T =R L =R R . As an example, it is customary in some DSL technologies to select R L =135 ohms for transmission signals in the band from approximately DC to 192 kHz. This 135 ohm value is a reasonable best choice for a simplistic resistive compromise model. Because the prior art model is resistive, the design transmit signal is the same as the design PSD of V S .
However, the prior art assumptions may be wholly inadequate in representing the wide range of subscriber loop transmission lines found in practice. R T is not ideal (R T ≠R L ≠R R ) since each individual subscriber loop is unique. Also, R L is not ideal because customer premises wiring are often different and because of bridged taps on the subscriber loop. In practice, the actual subscriber loop transmission system impedance can vary in magnitude from well over 200 ohms to less than 50 ohms, and the actual impedance is complex. The result in practice is that the actual transmit signal on any given transmission line can vary dramatically, and this variance is usually such that the transmit signal amplitude is lower than permitted in part of or all of the transmission band as defined by the PSD standard. It can be shown, for example, that the actual transmit signal amplitude can be 12 dB lower than the PSD standard in part of the band, and even average power can be 6 dB lower than allowed. This means that 6 dB or more of potential transmit signal power is being sacrificed, and that the receive signal S/N ratio is thus 6 dB lower than the S/N that could be realized with an optimized transmit signal.
Another problem involves instances where the actual transmit signal voltage exceeds the PSD standard. If the actual transmit signal voltage exceeds the PSD standard, undesirable interference or noise is induced onto other subscriber loops sharing the same underground cable or overhead wire.
Thus, a heretofore unaddressed need exists in the industry for a way to provide for a transmit signal which conforms to a defined PSD standard regardless of the actual impedance characteristics of the transmission system.
SUMMARY OF THE INVENTION
The present invention provides a subscriber line driver (SLD) for transforming the characteristics of a communication system signal. The signal is transformed by the SLD which increases (amplifies) portions of the signal to a predefined specification, decreases (attenuates) portions of the signal to a predefined specification, and/or frequency modulates or filters the transmit signal frequencies to fit within the communication channel frequency bandwidth as defined by the frequency band of the predefined specification. After modification by the SLD, the transformed communication signal is injected (transmitted) into a communication transmission line. The SLD may operate in a continuous and automatic mode. An SLD may be applicable to a variety of communication systems, for example but not limited to, a public telephony system, a private branch exchange (PBXs), a coaxial cable system, a fiber optic system, a microwave system or a radio communication system. In the preferred embodiment, the SLD operates on a telephony system subscriber loop which is operated as a digital subscriber loop (DSL) having a plain old telephone system (POTS) channel and at least one DSL channel.
The method of the preferred embodiment of the SLD comprises the following steps. The direction of travel of a communication signal is sensed when in the transmit signal direction, where the transmit direction is defined as traveling in a direction out to the communication system, here a subscriber loop. The SLD transforms the communication signal traveling in the transmit direction such that the transformed communication signal conforms to a predefined specification.
The preferred embodiment of the SLD comprises at least two functional components, a transmit signal equalizer and a current driver connected to the output of the transmit signal equalizer. In the preferred embodiment, the current driver injects (transmits) the transformed communication signal into the subscriber loop. Another embodiment of the SLD utilizes a voltage driver (rather than the current driver). A voltage feedback loop can be added to the SLD circuitry which further optimizes the transformed communication signal.
The SLD has an infinite input impedance at all frequencies. Addition of a parallel resister connected to a tip wire and a ring wire of the telephony system can enable the design engineer to set the transmission system terminating impedance to any desired value.
Another embodiment of the SLD modifies the transmit signal to conform to a first predefined specification, and also modifies the receive signal to conform to a second predefined specification. This embodiment of the SLD may have any of the methods, features and options of the SLD embodiments previously described.
This invention also provides for a telephony system central office (CO), comprising at least one telephony switching unit, at least one digital equipment unit and at least one subscriber line driver (SLD). The telephony switching unit is ultimately connected to a telephony transmission system on one side and to at least one telephony subscriber loop or DSL on the other side. At least one subscriber line driver (SLD) would be connected between one terminal of the digital equipment unit and one subscriber loop or DSL. The SLD would receive a communication signal from the digital equipment unit, and would transform the communication signal into a transformed communication signal so that the transformed communication signal conforms to a predefined specification.
This invention also provides for a private branch exchange (PBX), comprising at least one telephony switching unit, at least one digital equipment unit and at least one subscriber line driver (SLD). The telephony switching unit is ultimately connected to a telephony transmission system on one side and to at least one of telephony subscriber loop or DSL on the other side. At least one SLD would be connected between one terminal of the digital equipment unit and one subscriber loop or DSL. The SLD would receive a communication signal from the digital equipment unit, and would transform the communication signal into a transformed communication signal so that the transformed communication signal conforms to a predefined specification.
Other features and advantages of the present invention will become apparent to one skilled in the art upon examination of the following drawings and detailed description. It is intended that all such additional features and advantages be included herein within the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be better understood with reference to the following drawings. The elements of the drawings are not necessarily to scale relative to each other, emphasis instead being placed upon clearly illustrating the principles of the present invention. Furthermore, like reference numerals designate corresponding parts throughout the several views.
FIG. 1 is a block diagram of an existing telephony system of the prior art.
FIG. 2 is a block diagram of an SLD of an embodiment of the present invention located on the premises of a transmitting company, organization, and/or individual.
FIG. 3A is a graph illustrating ideal transmit signal amplitude spectra for a POTS channel and two DSL channels.
FIG. 3B is a graph illustrating non-ideal transmit signal amplitude spectra for a POTS channel and two DSL channels.
FIG. 3C is a graph illustrating the modification of a non-ideal transmit signal by the preferred embodiment of the SLD of FIG. 2 .
FIG. 3D is a graph illustrating the modification of a non-ideal transmit signal by another embodiment of the SLD of FIG. 2 .
FIG. 3E is a graph illustrating the modification of a non-ideal transmit signal by the another embodiment of the SLD of FIG. 2 .
FIG. 4 is a block diagram illustrating an SLD located at the telephone company central office and an SLD located at the customer premises.
FIG. 5A is a block diagram illustrating two components of a first embodiment of the SLD of FIG. 4 , a transmit signal equalizer and a current driver.
FIG. 5B is a block diagram illustrating two components of a second embodiment of the SLD of FIG. 4 , a transmit signal equalizer and a voltage driver.
FIG. 6 is a block diagram illustrating electrical components of the SLD of FIG. 4 ; a transmit signal equalizer, a current driver, an amplifier and a parallel resister (R o ).
FIG. 7A is a block diagram illustrating a central office with a SLD located at the premises of the central office.
FIG. 7B is a block diagram illustrating a private branch exchange (PBX) with a SLD located at the premises of the PBX.
FIG. 8 is a diagram illustrating a transmitter with a SLD.
DETAILED DESCRIPTION
FIG. 1 is a block diagram illustrating an existing telephony system 20 which includes a telephone company central office (CO) 22 connected to a customer premises (CP) 24 via a subscriber loop 26 . The subscriber loop 26 may be any suitable connection for passing electrical signals, but is typically a copper wire twisted-pair, as is well known in the art, that was originally designed to carry a 0-4 KHz analog voice channel. Located within the CO 22 is the CO telephony switching unit 28 which transmits communication signals received from the outside world to the CP 24 via the subscriber loop 26 , or which receives communication signals from the customer premises equipment (CPE) 29 via the subscriber loop 26 for transmission to designated locations in the outside world. In the context of this disclosure describing the existing telephony system, “outside world” means any telephone or communications device connected to or having access to the global telephone network, the public switched telephone network (PSTN) and/or a private telephony system, and where designated locations in the outside world are identified by telephone numbers or some other identification manner commonly employed by the art. CO digital equipment 21 and CP digital equipment 52 may be added at the central office and the customer premises to facilitate transmission of digital data. When the copper wire twisted-pair is used for digital transmission, the twisted-pair is often referred to as a digital subscriber loop (DSL). “Central office” or “CO” means any site where a subscriber loop 26 connects into a telephony switching unit, such as a public switched telephone network (PSTN), a private branch exchange (PBX) telephony system, or any other location functionally connecting subscriber loops to a telephony network.
FIG. 2 is a block diagram illustrating the relative location of the preferred embodiment of the subscriber line driver (SLD) at the transmit signal site. The preferred embodiment of the SLD continuously and automatically modifies a non-ideal communication signal amplitude spectra 238 , which will be further described in detail hereinafter in FIG. 3A through FIG. 3E , received from the transmit signal equipment 128 , to fit within the frequency bandwidth and within the maximum amplitude of the PSD standard 40 ( FIG. 3A ) prior to injecting (transmitting) the transformed communication signal into the communication connection 126 . The communication signal is then delivered to the receive signal equipment 129 .
The method of the preferred embodiment of the SLD comprises the following steps. The direction of travel of a communication signal is sensed when in the transmit signal direction, where the transmit direction is defined as traveling in a direction out to the subscriber loop. The SLD transforms the communication signal traveling in the transmit direction such that the transformed communication signal conforms to a predefined specification or a predefined difference threshold. This method is described in detail hereinafter.
FIG. 3A illustrates examples of an ideal communication signal amplitude spectra 32 consisting of three communication signals multiplexed into three separate channels. The three signals would be transmitted into, or injected into, a communications system, for example but not limited to, a DSL subscriber loop. The vertical axis of the spectra is the signal strength or amplitude measured in dB, where dB is commonly known in the art as decibels (dB). The horizontal axis of the spectra is signal frequency measured in Hertz (Hz). The same axis definitions will apply to FIG. 3B through FIG. 3E .
In FIG. 3A , the analog voice communication signal occupies the plain old telephone system (POTS) channel 34 . As is well known in the art, the POTS channel typically occupies a bandwidth from about 0 to 4 KHz. Two additional channels may be used in the DSL industry to transmit digital data. In this embodiment of the DSL system, channel A 36 occupies a bandwidth of 30 KHz to F 1 KHz, and channel B 38 occupies a bandwidth of F 2 KHz to F 3 KHz. Channel A 36 and channel B 38 each contain an ideal communication signal of a two channel DSL system. The communication signals may be comprised of either analog or digital data. F 1 , F 2 and F 3 are communication bandwidth frequency boundaries of a PSD standard 40 selected by the system design engineer. The 30 KHz lower frequency of the channel A 36 bandwidth is a typical value encountered in the art, but which may be adjusted to a different value by the system design engineer.
Shown in FIG. 3A with a dashed line is the power spectral distribution (PSD) standard 40 for a channel A and channel B. A PSD standard 40 defines the allowable PSD frequency range (bandwidth) and the maximum signal strength (amplitude) for a communication channel at the sending (transmitting) location. If the transmitted communication signal amplitude exceeds the PSD standard 40 , then undesirable interference or noise could be induced onto other subscriber loops sharing the same underground cable or overhead wire. If a transmitted communication signal amplitude is less that the PSD standard 40 , the transmitted communication signal is under-powered resulting in a less than optimal S/N ratio. If the bandwidth of a transmitted communication signal lies outside of the frequency boundaries of the PSD standard 40 , then the transmitted communication signal may overlap onto and interfere with other communication channels. The transmitted communication signals of channel A 36 and channel B 38 as shown in FIG. 3A are nearly ideal. That is, the two transmitted communication signals occupy the greatest region of the PSD 40 standard without exceeding the amplitude and bandwidth limits as defined by the PSD standard 40 .
Often, on a prior art two channel DSL system, a communication signal in one channel is traveling in the opposite direction of a communication signal in the other channel. Direction of signal travel depends upon the application of the DSL system user. As an illustrative example, the communication signal of channel A 36 could be transmitted at the CO digital equipment 21 ( FIG. 1 ) into the subscriber loop 26 for transmission to the CP digital equipment 52 . Similarly, the communication signal of channel B 38 could be transmitted at the CP digital equipment 52 into the subscriber loop 26 for transmission to the CO digital equipment 21 . (For the remainder of the disclosure of the preferred embodiment, for illustrative purposes only, the communication signal transmission location of channel A 36 will be designated as the CO 22 and the communication signal transmission location of channel B 38 will be designated as the CP 24 .) In actual practice of the prior art, signals may be transmitted from or received by both the CO digital equipment 21 and the CP digital equipment 52 .
Often, signal transmission direction in a channel changes direction regularly, as in the POTS channel. For example, during a telephone voice conversation between two people over the PSTN, the speaker determines the transmission location of the communication signal and the listener determines the location of the received signal. As a conversation proceeds between the two people, the direction of travel of the communication signal regularly changes depending upon which party is doing the talking. Direction of travel of the communication signals of a DSL system can also be regularly changing.
FIG. 3B is illustrative of non-ideal communication signal amplitude spectra 132 which may be encountered with the prior art DSL technologies. The transmitted communication signal 136 of channel A is illustrated in FIG. 3B as degraded below the maximum signal strength allowed by the PSD standard 40 due to effects of the actual impedance of the subscriber loop, the presence of bridged taps, wiring of the customer premises, and/or the various types of customer equipment as previously described in the Background section of this disclosure. For further illustrative purposes, a part of the communication signal channel B 138 has been degraded below the maximum signal strength allowed by the PSD standard 40 , while part of the communication signal channel B 138 exceeds the maximum signal amplitude allowed by the PSD standard 40 . Also, the higher frequencies of communication signal channel B 138 are greater than the high frequency (F 3 ) bandwidth limit of the PSD standard 40 due to the reactive components of the transmission system.
FIG. 3C is an enlarged view illustrating the non-ideal communication signal amplitude spectra 238 of channel B ( FIG. 3B ) before processing by the SLD. Transmitting this non-ideal communication signal amplitude spectra 238 into a subscriber loop will cause a variety of problems, as previously discussed in the Background section. The preferred embodiment of the SLD 30 senses the direction of travel of a communication signal and selects the signal if traveling in the transmitting direction, defined as traveling in a direction out to the subscriber loop. Once a communication signal has been selected, the SLD 30 would continuously and automatically amplify a digital signal to transform the communication signal into a transformed communication signal such that the transformed communication signal conforms to a predefined specification. This specification would not be greater than the maximum amplitude allowed by the PSD standard 40 . Here, in this illustrative example, the lower frequency portion 238 a of the non-ideal communication signal amplitude spectra 238 exceeds the maximum amplitude of the PSD standard 40 . If the communication signal portion 238 a is injected (transmitted) into the subscriber loop, undesirable interference could be induced in adjacent subscriber loops, as previously described in the Background section. That portion of the communication signal 238 a would be reduced (attenuated) by the preferred embodiment of the SLD 30 to an amplitude value in close proximity to the maximum amplitude of the PSD standard 40 , as shown by the transformed communication signal 338 . Here, close proximity can be defined as the amplitude of the transformed communication signal 338 being below, at, or above the PSD standard 40 , or another predefined standard, such that the error (difference) between the PSD standard 40 and the transformed communication signal 338 is within some predefined difference threshold.
Here, in the illustrative example of FIG. 3C , the mid-range portion 238 b of the non-ideal communication signal amplitude spectra 238 is less than the maximum amplitude of the PSD standard 40 . If the communication signal portion 238 b is transmitted into the subscriber loop, the S/N ratio will not be maximized, as previously discussed in the Background section. The mid-range portion 238 b of the non-ideal communication signal amplitude spectra 238 , which is below the maximum amplitude of the PSD standard 40 , would be increased (amplified) by the preferred embodiment of the SLD 30 to a value in close proximity to the maximum amplitude of the PSD standard 40 , as shown by the transformed communication signal 338 .
Another embodiment of the SLD 30 may have the additional feature of providing for frequency modulation, frequency shifting, or filtering a non-ideal communication signal to conform the transformed communication signal to a predefined frequency band specification that is within the frequency bandwidth limits specified by the PSD standard 40 . As shown in the illustrative example of FIG. 3C , the highest frequency portion 238 c of the non-ideal communication signal amplitude spectra 238 exceeds the high frequency limit F 3 of the PSD standard 40 . If the communication signal portion 238 c is transmitted into the subscriber loop, undesirable interference could be induced in adjacent DSL channels, as previously described in the Background section. This embodiment of SLD 30 would frequency shift or filter the non-ideal communication signal amplitude spectra 238 to fit within the frequency boundaries of the PSD standard 40 , as shown by the transformed communication signal 338 .
FIG. 3D depicts an illustrative non-ideal communication signal amplitude spectra 438 before processing of a DSL channel. Another embodiment of the SLD 30 acts upon the non-ideal communication signal amplitude spectra 438 to conform the non-ideal communication signal amplitude spectra 438 to a predefined specification which is equal to a percentage of the PSD standard 40 , as shown by the transformed communication signal 538 . For illustrative purposes, FIG. 3D shows the transformed communication signal 538 to be approximately 85 percent of the PSD standard 40 . The SLD 30 continuously and automatically determines the amount of amplification at any specific frequency of the non-ideal communication signal amplitude spectra 438 and selects the degree of amplification necessary to conform the non-ideal communication signal amplitude spectra 438 to the predefined specification of the PSD standard 40 . For example, the degree of amplification of the lower frequencies of the non-ideal communication signal 438 is seen to be about ten to fifty percent. The degree of amplification of the higher frequencies of the non-ideal communication signal 438 is seen to be as great as five hundred percent.
FIG. 3E depicts an illustrative non-ideal communication signal amplitude spectra 438 before processing by the SLD 30 . Another embodiment of the SLD 30 modifies a non-ideal communication signal amplitude spectra 438 by simply amplifying the non-ideal communication signal amplitude spectra 438 by some fixed amount as determined by the predefined specification, as shown by the transformed communication signal 638 . For illustrative purposes, FIG. 3E shows the fixed amount of amplification applied to the non-ideal communication signal amplitude spectra 438 to be approximately thirty percent of the non-ideal communication signal.
FIG. 1 shows an existing telephone central office 22 and the customer premises 24 without the SLD 30 ( FIG. 2 ). Digital signal transmission and signal receiving equipment is depicted as the CO digital equipment 21 and the CP digital equipment 52 . FIG. 4 shows a more detailed telephone system with installation of a telephony system embodiment of the SLD 30 . One skilled in the art will realize that the telephone system illustrated in FIG. 4 can be replaced with other types of communication systems where transmit signal processing by the SLD would be beneficial. Other types of communication systems could include, but are not limited to, private telephony systems, coaxial cable systems, fiber optic systems, microwave systems or radio communication systems.
FIG. 4 is now described in greater detail. Three communication equipment components of the telephony system CO 22 are shown, the telephony switching unit 28 , digital equipment 21 and the SLD 30 a . (More communication equipment components, unrelated to the operation of the SLD 30 a , would likely be located at the telephone company CO 22 , but are not shown in FIG. 4 .) Three communication equipment components of the customer premises 24 are shown, a telephone 54 , the SLD 30 b , and the CP digital equipment 52 . Examples of the CP digital equipment 52 could be, but are not limited to, a computer, or a television set-top-box. For illustrative purposes for the preferred embodiment of this SLD, and as previously noted during the discussion of FIG. 3A , the communication signal transmission location of channel A 36 of the DSL system will be designated as the CO 22 and the communication signal transmission location of channel B 38 will be designated as the CP 24 . One skilled in the art will realize that the transmission location of the communication signals could be at either, or both, the CO 22 or the CP 24 . Also, one skilled in the art will realize that any data channel could be applicable to the illustrative example of FIG. 4 and to the application of the SLD.
When a communication signal is transmitted from the CO 22 to the CP 24 over channel A, the transmitted communication signal may not be ideal (channel A 136 of FIG. 3B ). The preferred embodiment of the SLD 30 a , located at the CO 22 , will continuously and automatically transform (amplify, attenuate and/or frequency modulate) a communication signal from the CO digital equipment 21 to conform to a predefined specification which does not exceed the signal strength or the frequency bandwidth of the PSD standard 40 (channel A 36 of FIG. 3A ). The SLD then transmits the transformed communication signal of channel A onto the DSL 226 for transmission to the CP 24 . When the communication signal is received at the CP 24 , then becoming the receive signal, the receive signal is delivered to the CP digital equipment 52 . One skilled in the art will realize that the receive signal will pass through the SLD 30 b unaffected, or entirely bypass the SLD 30 b , depending upon the actual circuitry configuration of the digital signal processing equipment. That is, the preferred embodiment of the SLD will sense the direction of travel of the communication signal and selectively operate only in the communication signal transmission direction.
Similarly, when a communication signal is transmitted from the CP 24 to the CO 22 over the channel B, the communication signal may not be ideal (channel B 138 of FIG. 3B ). The preferred embodiment of the SLD 30 b , located at the CP 24 , will transform (amplify, attenuate and/or frequency modulate) a communication signal from the CP digital equipment 52 to conform to a predefined specification which does not exceed the signal strength or the frequency bandwidth of the PSD standard 40 (channel B 38 of FIG. 3A , or channel B 338 of FIG. 3C ). The SLD 30 b then transmits the transformed communication signal of channel B onto the DSL 226 for transmission to the CO 22 . When the communication signal is received at the CO, then becoming a receive signal, the receive signal is delivered to the CO digital equipment 21 . One skilled in the art will realize that the receive signal will pass through the SLD 30 a unaffected, or entirely bypass the SLD 30 a , depending upon the actual circuitry configuration of the digital signal processing equipment.
As shown in FIG. 4 , and which is well known by those skilled in the art, the analog telephony signal transmitted on the POTS channel 34 ( FIGS. 3A and 3B ) between the CO telephony switching unit 28 and the telephone 54 over the DSL 226 is transmitted without interacting with the DSL, 30 a or 30 b , which is transmitting over channels A and B.
FIG. 5A is a block diagram showing two of the components of the preferred embodiment of the SLD 30 , a transmit signal equalizer 60 and a current driver 62 . The transmit signal equalizer 60 detects the incoming communication signal (not shown), and transforms (amplify, attenuate and/or frequency shift) the communication signal to conform to a predefined specification. The current driver 62 then transmits the transformed communication signal into the communication connection 126 . One skilled in the art will recognize that the degree of communication signal distortion and the amount of amplification and frequency modulation required to transform the communication signal will dictate the complexity of the transmit signal equalizer 60 . FIG. 5B is a variation of the SLD 30 wherein a voltage driver 64 is used to inject the transformed communication signal into the communication connection 126 .
FIG. 6 shows two enhancements of the SLD 30 of FIG. 5A . The first enhancement is a voltage feedback loop wherein an amplifier 66 provides signal feedback to the transmit signal equalizer 60 . The feedback loop detects a communication signal that may not be ideal (Channel B 138 of FIG. 3B ) and provides for the continuous and automatic adjustment of the communication signal after the current driver 62 injects the transformed communication signal into the subscriber loop. The SLD 30 has the capability to provide a transformed communication signal PSD that is ideal regardless of the transmission channel impedance. Also, the SLD 30 has the capability to provide a transformed communication signal PSD that is ideal regardless of other multipoint transceivers. Once the SLD 30 transmit signal equalizer 60 has been calibrated for a particular DSL circuit, there is no need for continuing recalibration under practical applications. Here in FIG. 6 , the subscriber loop is shown as a twisted pair copper wire local loop 326 of a telephony system or a DSL system consisting of a Tip 70 line and a Ring 72 line. The twisted pair copper wire local loop 326 is referenced in FIG. 1 as the telephony system subscriber loop 26 and in FIG. 4 as the DSL 226 . As is well known by those skilled in the art, all of the above expressions describing telephony and DSL communication systems may be equivalent.
The second enhancement of the SLD 30 shown in FIG. 6 is the addition of a parallel resistor 68 of some finite impedance. The SLD 30 enjoys an infinite input impedance, often defined in the prior art as RR. Note especially that with the SLD 30 , an infinite input impedance RR is true for all frequencies. An infinite input impedance of the SLD 30 in the POTS band is desirable, as there would be no loading of the POTS band. And, although tradition of the prior art implies that for practical applications the terminating impedance of a transmission line should be assumed to be the “characteristic impedance” of the transmission line, one skilled in the art will realize that this is an incorrect conclusion based on “maximizing power transfer.” In actuality, the ideal signal transmission optimization technique is to maximize the receive signal level as long as loss vs. frequency is within the tolerances of the receive signal equipment (can be read with acceptable bit error tolerances) and potential signal reflection on the transmission line is suitable. Although tradition of the existing prior art indicates the frequency band above 25 kHz should be terminated from 100 ohms to 135 ohms, empirical tests show that that termination at 1000 ohms or higher, or even at an infinite impedance, would provide for superior voltage signal transmission. One skilled in the art will recognize that the simple addition of a parallel resister 68 shown in FIG. 6 can enable the design engineer to set the transmission system terminating impedance to any desired value without compromising the other attributes of the subscriber loop or the SLD 30 .
Another benefit is provided by the infinite input impedance of the SLD 30 . “Splitter-less” DSL technologies, well known in the art, require a subscriber loop transmission system with a relatively low RT and RR in the DSL frequency bands while having a relatively high RR in the POTS frequency band. For example, a desirable DSL transmission system RT and RR would be 100 ohms at 26 kHz and above, and for the POTS perhaps 1200 ohms at 4 kHz and below. This desirable DSL transmission system is very difficult, and perhaps impossible, to achieve with the prior art. The SLD 30 provides a way to implement specified impedances on a DSL system which provides for desirable impedances on both a POTS channel and splitter-less DSL channels. Also, the infinite input impedance of the SLD 30 minimizes the adverse affects of the POTS on-hook/off-hook transition on the DSL channel.
Yet another practical benefit from the SLD 30 is optimizing a DSL transmission system when two or more transceivers are placed at one or both ends of the subscriber loop, as in multipoint communication. The transmitted communication signal amplitude would, in the absence of the SLD 30 , be significantly reduced due to the lowered net load impedance seen by that transmitter. For two transceivers, the transmitted communication signal could be reduced by as much as 4 dB. Similarly, the effective RR now becomes the parallel combination of the RR of the two transceivers, and the receive signal is reduced. Thus, the SLD provides for a transmitted communication signal which is not affected by the presence of multipoint operation, thereby optimizing the receive signal.
The inclusion of an SLD 30 into a larger system may be considered as an improvement to the larger system. When an SLD is incorporated into a CO 22 , as shown in FIG. 7A , the CO 22 is improved in that the CO 22 may now transmit transformed communication signals from CO 22 digital equipment 21 which have been modified to conform to a predefined specification. Similarly, an SLD can be incorporated into a PBX 23 as an improvement, as shown in FIG. 7B . In both the CO 22 and the PBX 23 , at least one SLD may be installed at the CO 22 or PBX 23 , with one SLD 30 being ultimately located at some point between the digital equipment 21 or 121 and communication system transmission line, such as, but not limited to, a DSL 226 .
The SLD 30 may be considered as an improvement to a transmitter 130 system. The SLD 30 , when incorporated into the transmitter 130 , would transform communication signals to conform to a predefined specification. A transmitter 130 with an SLD 30 is shown in FIG. 8 . The SLD 30 is ultimately connected to a communication system transmission line, such as, but not limited to, a DSL 226 .
It should be emphasized that the above-described embodiments of the present invention, particularly, and “preferred” embodiments or configurations, are merely possible examples of implementation, merely set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiment(s) of the invention without departing substantially form the spirit and principles of the invention. All such modifications and variations are intended to be included herein within the scope of the present invention.
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Various embodiments are configured to transform characteristics of a communication signal. One embodiment is a method comprising decreasing amplitude of a first detected portion of the communication signal so that the decreased amplitude is in close proximity to a predefined specification; and increasing amplitude of a second portion of the communication signal so that the increased amplitude is in close proximity to the predefined specification, thereby resulting in a transformed communication signal.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a power supply to which a DC voltage is input from a DC power supply, such as a battery, and from which a controlled DC voltage is output, more particularly, to a soft-start technology in the power supply.
[0002] Power conversion systems, such as a series regulator system comprising a voltage control device connected in series with a load and a switching regulator system comprising switching devices, are used for power supplies. In order that a power supply supplies a stable output DC voltage to a load, both the systems are common in that its output DC voltage is detected and fed back. In a power supply, its supply power increases when its output DC voltage is lower than a target value and decreases when the output DC voltage is higher than the target value. For this reason, at the start-up of the power supply, during which the output DC voltage is going to reach the target value, the supply power is increased to the limit of the capacity. As a result, there is a problem that inrush current is generated from the input DC power supply of the power supply. Furthermore, since the power supply is configured such that the supply power is decreased after the output DC voltage exceeds the target value, there is a problem of generating overshoot that supplies excessive power exceeding the target value to the load.
[0003] The soft-start technology for limiting the supply power at the start-up is used to suppress inrush current generated at the start-up. FIG. 11 is a circuit diagram showing the configuration of a conventional power supply having a soft-start function and disclosed in Japanese Patent Application Laid-Open Publication No. 2005-269838.
[0004] Referring to FIG. 11 , an input DC power supply 201 , such as a battery, generates and outputs an input DC voltage Vi. A voltage conversion section, referred to as a step-down converter, comprises a switching transistor 202 , a diode 203 , an inductor 204 and an output capacitor 205 . This voltage conversion section converts the input DC voltage Vi into an output DC voltage Vo and supplies the output DC voltage Vo from the output capacitor 205 to a load 206 . A reference voltage supply 207 generates a reference voltage serving as the target of the output DC voltage Vo. An error amplifier 208 amplifies the difference voltage between the output DC voltage Vo and the reference voltage and outputs an error signal Ve. A comparator circuit 209 compares the output DC voltage Vo with a predetermined value. This predetermined value is set at 95% of the reference voltage, for example.
[0005] A PWM circuit 210 generates and outputs a drive pulse signal having a pulse width based on the error signal Ve input thereto. The switching transistor 202 repeats ON/OFF operation according to the drive pulse signal output from the PWM circuit 210 . Since the switching transistor 202 repeats ON/OFF operation, the input DC voltage Vi is chopped and rectified using the diode 203 , and smoothed using the inductor 204 and the output capacitor 205 , whereby the output DC voltage Vo is supplied to the load 206 . The output DC voltage Vo becomes high when the ratio (hereinafter referred to as the “duty ratio”) of the ON time in the switching cycle of the switching transistor 202 is large. The output of the comparator circuit 209 is input to a clamp circuit 211 . During a period in which the output DC voltage Vo does not reach the predetermined value, the clamp circuit 211 suppresses the error signal Ve from rising, thereby limiting the error signal Ve to a predetermined value.
[0006] In addition, referring to FIG. 11 , the voltage of the error signal Ve generated by the error amplifier 208 rises when the output DC voltage Vo is lower than the reference voltage, and lowers when the output DC voltage Vo is higher than the reference voltage. During the normal operation time, the clamp circuit 211 does not operate, and the error signal Ve generated by the error amplifier 208 is directly input to the PWM circuit 210 . The pulse width of the drive pulse signal output from the PWM circuit 210 is larger as the voltage of the error signal Ve is higher. In other words, when the output DC voltage Vo is lower than the reference voltage, the voltage of the error signal Ve rises, the duty ratio of the switching transistor 202 becomes larger, and the output DC voltage Vo becomes higher. Conversely, when the output DC voltage Vo is higher than the reference voltage, the voltage of the error signal Ve lowers, the duty ratio of the switching transistor 202 becomes smaller, and the output DC voltage Vo becomes lower. By virtue of this feedback operation, the output DC voltage Vo is controlled so as to become equal to the reference voltage.
[0007] On the other hand, at the start-up, since the output DC voltage Vo does not reach the predetermined value (95% of the reference voltage), the clamp circuit 211 operates to limit the voltage of the error signal Ve input to the PWM circuit 210 to a clamp voltage. In reality, since the clamp voltage being lower than the voltage of the error signal Ve having a high potential is input to the PWM circuit 210 , the duty ratio of the switching transistor 202 becomes small, and the supply power is limited. As a result, the generation of inrush current is prevented in the conventional power supply. When the output DC voltage Vo reaches the predetermined value (95% of the reference voltage) in the power supply, the limitation of the supply power is released, and the operation shifts to the normal operation in which the output DC voltage Vo is adjusted to the reference voltage.
[0008] However, although inrush current can be limited in the power supply having the conventional soft-start function and configured as described above, when the limitation of the supply power is released after the output DC voltage Vo reaches the preset voltage, overshoot is generated in the output DC voltage Vo in the case that the load 206 is light. To solve this problem, there is a method in which the limitation of the supply power to limit inrush current is continued after the start-up. However, in the case that the limitation level of the supply power for suppressing overshoot is lower than the limitation level of the supply power for limiting inrush current, this method has a problem of being unable to sufficiently suppress overshoot.
[0009] An object of the present invention is to provide a power supply capable of securely carrying out soft-start operation, more particularly, to provide a power supply having a soft-start function capable of raising the output DC voltage without generating overshoot even when the load is set light at the start-up.
SUMMARY OF THE INVENTION
[0010] To attain the above-mentioned object, a power supply according to a first aspect of the present invention, for converting an input DC voltage into an output DC voltage and supplying power to a load, comprises:
[0011] an error amplifier for outputting an error signal corresponding to the error between the output DC voltage and the target value thereof,
[0012] a control section for adjusting power to be supplied to the load on the basis of the error signal, and
[0013] a limiting circuit for limiting the voltage of the error signal to a predetermined level for a predetermined time after the output DC voltage at the start-up exceeds a predetermined value being set less than the target value.
[0014] With the power supply configured as described above, when the load condition is set light at the start-up, the output DC voltage can rise without generating overshoot.
[0015] The power supply according to a second aspect of the present invention may be configured such that the limiting circuit according to the first aspect limits the voltage of the error signal to a first predetermined level until the output DC voltage at the start-up reaches the predetermined value being set less than the target value, and limits the voltage of the error signal to a second predetermined level for a predetermined time after the output DC voltage at the start-up exceeds the predetermined value being set less than the target value.
[0016] The power supply according to a third aspect of the present invention may be configured such that the limiting circuit according to the second aspect comprises a comparator circuit for comparing the output DC voltage with the predetermined value being set less than the target value; a first clamp circuit for limiting the voltage of the error signal to a first predetermined level on the basis of the output of the comparator circuit until the output DC voltage at the start-up reaches the predetermined value being set less than the target value; and a second clamp circuit for limiting the voltage of the error signal to a second predetermined level for a predetermined time on the basis of the output of the comparator circuit after the output DC voltage at the start-up exceeds the predetermined value being set less than the target value.
[0017] The power supply according to a fourth aspect of the present invention may be configured such that the second clamp circuit according to the third aspect limits the voltage of the error signal to a second predetermined level on the basis of the output of the comparator circuit for a predetermined time after the output DC voltage at the start-up exceeds the predetermined value being set less than the target value, and releases the limitation to the second predetermined level when the error between the output DC voltage at the start-up and the target value becomes a reference voltage or less.
[0018] The power supply according to a fifth aspect of the present invention may be configured such that the limiting circuit according to the second aspect comprises a first comparator circuit for comparing the output DC voltage with a first value being set less than the target value; a second comparator circuit for comparing the output DC voltage with a second value that is set less than the target value and higher than the first value; a first clamp circuit for limiting the voltage of the error signal to a first predetermined level on the basis of the output of the first comparator circuit until the output DC voltage at the start-up reaches the first value being set less than the target value; and a second clamp circuit for limiting the voltage of the error signal to a second predetermined level for a predetermined time on the basis of the output of the first comparator circuit after the output DC voltage at the start-up exceeds the first value being set less than the target value, the limitation to the second predetermined level being released on the basis of the output of the second comparator circuit.
[0019] The power supply according to a sixth aspect of the present invention may be configured such that the predetermined time according to the first and second aspects is set at a period elapsed after the output DC voltage exceeds the predetermined value being set less than the target value and until the output DC voltage reaches the target value.
[0020] The power supply according to a seventh aspect of the present invention may be configured such that the control section according to the first to fifth aspects comprises a voltage conversion section having a switch, a rectifier and an inductor, and a PWM circuit for ON/OFF controlling the switch according to the error signal.
[0021] The power supply according to an eighth aspect of the present invention may be configured such that the PWM circuit according to the seventh aspect comprises a current detector for detecting the current flowing through the voltage conversion section, and a timing setting circuit for setting the ON/OFF timing of the switch on the basis of the output of the current detector and the error signal.
[0022] Since the present invention is configured so as to limit supply power immediately before the output DC voltage reaches the target value, it is possible to provide a power supply capable of securely suppressing output overshoot even at the start-up under light load.
[0023] While the novel features of the invention are set forth particularly in the appended claims, the invention, both as to organization and content, will be better understood and appreciated, along with other objects and features thereof, from the following detailed description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a circuit diagram showing the configuration of a power supply according to a first embodiment of the present invention;
[0025] FIGS. 2A to 2F are waveform diagrams showing the operation of the power supply according to the first embodiment at the start-up;
[0026] FIG. 3 is a circuit diagram showing the configuration of a power supply according to a second embodiment of the present invention;
[0027] FIGS. 4A to 4F are waveform diagrams showing the operation of the power supply according to the second embodiment at the start-up;
[0028] FIG. 5 is a circuit diagram showing the configuration of a power supply according to a third embodiment of the present invention;
[0029] FIGS. 6A to 6G are waveform diagrams showing the operation of the power supply according to the third embodiment at the start-up;
[0030] FIG. 7 is a circuit diagram showing the configuration of a power supply according to a fourth embodiment of the present invention;
[0031] FIG. 8 is a circuit diagram showing the configuration of a current detection circuit in the power supply according to the fourth embodiment;
[0032] FIG. 9 is a circuit diagram showing the configuration of a timer circuit in the power supply according to the fourth embodiment;
[0033] FIGS. 10A to 10G are waveform diagrams showing the operation of the power supply according to the fourth embodiment at the start-up; and
[0034] FIG. 11 is the circuit diagram showing the configuration of the conventional power supply.
[0035] It will be recognized that some or all of the Figures are schematic representations for purposes of illustration and do not necessarily depict the actual relative sizes or locations of the elements shown.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] Preferred embodiments of a power supply according to the present invention will be described below referring to the accompanying drawings.
First Embodiment
[0037] A power supply according to a first embodiment of the present invention will be described below referring to FIGS. 1 and 2 . FIG. 1 is a circuit diagram showing the configuration of the power supply according to the first embodiment of the present invention. FIGS. 2A to 2F are waveform diagrams showing the operations of various sections of the power supply shown in FIG. 1 at the start-up thereof.
[0038] Referring to FIG. 1 , an input DC power supply 1 , such as a battery, generates and outputs an input DC voltage Vi. A voltage conversion section, referred to as a step-down converter, comprises a switching transistor 2 , a diode 3 , an inductor 4 and an output capacitor 5 . This voltage conversion section converts the input DC voltage Vi into an output DC voltage Vo and supplies the output DC voltage Vo from the output capacitor 5 to a load 6 . A reference voltage supply 7 generates a reference voltage serving as the target of the output DC voltage Vo. An error amplifier 8 amplifies the difference voltage between the output DC voltage Vo and the reference voltage and outputs an error signal Ve. A comparator circuit 9 comprises a comparator 90 and two resistors 91 and 92 , and the comparator 90 compares the output DC voltage Vo with a predetermined value. The predetermined value that is compared using the comparator 90 is obtained by dividing the reference voltage using the resistors 91 and 92 . The predetermined value is set at 95 % of the reference voltage, for example. The error signal Ve is input to the PWM circuit 10 , and the PWM circuit 10 outputs a drive pulse signal Vg having a pulse width based on the error signal Ve input thereto. The switching transistor 2 repeats ON/OFF operation according to the drive pulse signal Vg output from the PWM circuit 10 . Since the switching transistor 2 repeats ON/OFF operation, the input DC voltage Vi is chopped and rectified using the diode 3 , and smoothed using the inductor 4 and the output capacitor 5 , whereby the output DC voltage Vo is supplied to the load 6 . The output DC voltage Vo becomes high when the ratio (hereinafter referred to as the “duty ratio”) of the ON time in the switching cycle of the switching transistor 2 is large. In the power supply according to the first embodiment, the step-down converter comprising the switching transistor 2 , the diode 3 , the inductor 4 and the output capacitor 5 , and the PWM circuit 10 constitute a control section.
[0039] A first clamp circuit 11 serving as a limiting circuit comprises a transistor 110 that is driven using the output signal of the comparator circuit 9 , a resistor 111 , a constant current supply 112 for supplying a constant current to this resistor 111 and a transistor 113 that is driven using the voltage generated at the connection point of the resistor 111 and the constant current supply 112 . When the transistor 110 is ON, the addition voltage (Vt+Vr) of the source-gate voltage Vt of the transistor 110 and the constant voltage Vr generated across the resistor 111 is applied to the gate of the transistor 113 , and the transistor 113 is turned ON. On the other hand, when the transistor 110 is OFF, the input voltage Vi is applied to the gate of the transistor 113 , and the transistor 113 is turned OFF.
[0040] A second clamp circuit 12 serving as a limiting circuit comprises an integrating circuit comprising a resistor 120 and a capacitor 121 for integrating the output signal of the comparator circuit 9 , an inverter 122 for inverting the output of the capacitor 121 , a NAND circuit 123 for outputting the NAND of the output signal of the inverter 122 and the output signal of the comparator circuit 9 , and a transistor 124 that is driven using the output of the NAND circuit 123 .
[0041] Next, the operation of the power supply according to the first embodiment configured as described above will be described below. First, the operation of the power supply according to the first embodiment during the normal operation time will be described below.
[0042] Referring to FIG. 1 , the voltage of the error signal Ve generated by the error amplifier 8 rises when the output DC voltage Vo is lower than the reference voltage, and lowers when the output DC voltage Vo is higher than the reference voltage. During the normal operation time, the first clamp circuit 11 and the second clamp circuit 12 do not operate, and the error signal Ve generated by the error amplifier 8 is directly input to the PWM circuit 10 , as described later. The pulse width of the drive pulse signal Vg output from the PWM circuit 10 is larger as the voltage of the error signal Ve is higher. In other words, when the output DC voltage Vo is lower than the reference voltage, the voltage of the error signal Ve rises, the duty ratio of the switching transistor 2 becomes larger, and the output DC voltage Vo becomes higher.
[0043] Conversely, when the output DC voltage Vo is higher than the reference voltage, the voltage of the error signal Ve lowers, the duty ratio of the switching transistor 2 becomes smaller, and the output DC voltage Vo becomes lower. By virtue of this feedback operation, the output DC voltage Vo is controlled so as to become equal to the reference voltage. In the first clamp circuit 11 , the transistor 110 is turned OFF using the H-level (high-level) output signal of the comparator circuit 9 that is input thereto, whereby the transistor 13 is also turned OFF. Furthermore, in the second clamp circuit 12 , the capacitor 121 is charged using the H-level output signal of the comparator circuit 9 that is input thereto, and the inverter 122 outputs an L-level (low-level) signal. As a result, the NAND circuit 123 outputs an H-level signal, and the transistor 124 is turned OFF.
[0044] Next, the operation of the power supply at the start-up will be described below referring to FIGS. 2A to 2F . FIGS. 2A to 2F are waveform diagrams showing the operations of various sections of the power supply shown in FIG. 1 at the start-up thereof.
[0045] FIG. 2A shows the waveform of the output DC voltage Vo, FIG. 2B shows the waveform of the output signal V 9 of the comparator circuit 9 , FIG. 2C shows the waveform of the voltage of the capacitor 121 of the second clamp circuit 12 , that is, the input signal V 121 of the inverter 122 . In addition, FIG. 2D shows the waveform of the output signal V 122 of the inverter 122 of the second clamp circuit 12 , FIG. 2E shows the waveform of the error signal Ve, and FIG. 2F shows the waveform of the drive pulse signal Vg, that is, the output of the PWM circuit 10 for driving the switching transistor 2 .
[0046] First, at the start-up in which the output DC voltage Vo does not reach the predetermined value (95% of the reference voltage) that is less than the target value, the output signal V 9 of the comparator circuit 9 is L level, the voltage of the error signal Ve input to the PWM circuit 10 is limited to the addition voltage (2Vt+Vr) of the source-gate voltage Vt of the transistor 110 , the voltage Vr across the resistor 111 and the source-gate voltage Vt of the transistor 113 of the first clamp circuit 11 . In reality, since the voltage of the error signal Ve rising to a high potential is limited to the first clamp voltage (2Vt+Vr) and input to the PWM circuit 10 , the duty ratio of the switching transistor 2 becomes small, and the supply power is limited. As a result, the generation of inrush current can be prevented in the power supply according to the first embodiment. During this period, in the second clamp circuit 12 , the NAND circuit 123 outputs an H-level signal by virtue of the L-level output signal of the comparator circuit 9 that is input thereto, and the transistor 124 is turned OFF. Since the capacitor 121 is discharged to L level, the output signal V 122 of the inverter 122 is H level.
[0047] When the output DC voltage Vo reaches the predetermined value (95% of the reference voltage) at time t 1 in FIGS. 2A to 2F , the output signal V 9 of the comparator circuit 9 becomes H level, and the clamp limitation using the first clamp circuit 11 is released. At the same time, in the second clamp circuit 12 , since the output signal V 122 of the inverter 122 is H level and the output signal of the comparator circuit 9 becomes H level, the output of the NAND circuit 123 becomes L level. As a result, the transistor 124 is turned ON, and the voltage of the error signal Ve is limited to the source-gate voltage Vt of the transistor 124 . Since the error signal Ve, the voltage of which is limited to the second clamp voltage (Vt) instead of the first clamp voltage (2Vt+Vr) as described above, is input to the PWM circuit 10 , the duty ratio of the switching transistor 2 becomes further smaller, the rising speed of the output DC voltage Vo is further suppressed, and the generation of overshoot is prevented. This limitation continues until the charging of the capacitor 121 proceeds via the resistor 120 and the output of the inverter 122 is inverted to L level. At time t 2 in FIGS. 2A to 2F , the input signal V 121 of the inverter 122 rises above the threshold value at which the output signal V 122 is switched from H level to L level, and the output signal V 122 of the inverter 122 becomes L level. Hence, the output of the NAND circuit 123 becomes H level, and the transistor 124 is turned OFF. When the transistor 124 is turned OFF, the limitation using the error signal Ve, the voltage of which is limited to the second clamp voltage (Vt), is released, and the operation shifts to the normal operation in which the output DC voltage Vo is controlled to the reference voltage.
[0048] As described above, in the power supply according to the first embodiment, at the light-load start-up in which the output DC voltage Vo does not reach the predetermined value that is less than the target value, the voltage of the error signal Ve is limited to the first clamp voltage (2Vt+Vr), and the supply power is limited, whereby inrush current is prevented. Furthermore, for a predetermined period after the output DC voltage Vo has reached the predetermined value, the voltage of the error signal Ve is limited to the second clamp voltage (Vt), and the rising speed of the output DC voltage Vo is further suppressed. As a result, the generation of overshoot is prevented securely.
Second Embodiment
[0049] A power supply according to a second embodiment of the present invention will be described below referring to the accompanying FIGS. 3 and 4 . FIG. 3 is a circuit diagram showing the configuration of the power supply according to the second embodiment of the present invention. FIGS. 4A to 4F are waveform diagrams showing the operations of various sections of the power supply shown in FIG. 3 at the start-up thereof. In the power supply according to the second embodiment shown in FIGS. 2A to 2F , the components having the same functions and configurations as those of the above-mentioned power supply according to the first embodiment are designated by the same numerals, and their descriptions are omitted. The power supply according to the second embodiment differs from the power supply according to the first embodiment in that a resistor 80 is connected to the output terminal of the error amplifier 8 and the output (Ve) of the error amplifier 8 is input as an input (Ve 2 ) to the PWM circuit 10 via the resistor 80 , and that the configuration of a second clamp circuit 12 a serving as a limiting circuit differs from that of the second clamp circuit 12 . The second clamp circuit 12 a of the power supply according to the second embodiment is designated by numeral 12 a so as to be distinguished from the second clamp circuit 12 according to the first embodiment shown in FIG. 1 .
[0050] As shown in FIG. 3 , the second clamp circuit 12 a comprises a NAND circuit 123 , a transistor 124 , a voltage supply 125 and a comparator 126 . The configurations of the NAND circuit 123 and the transistor 124 are similar to those of the NAND circuit 123 and the transistor 124 of the second clamp circuit 12 shown in FIG. 1 . The comparator 126 compares the voltage of the first error signal Ve output from the error amplifier 8 with the voltage V 125 of the voltage supply 125 . The voltage V 125 of the voltage supply 125 is set at a level slightly higher than the source-gate voltage Vt of the transistor 124 .
[0051] Since the operation of the power supply according to the second embodiment configured as described above during the normal operation time is similar to that of the power supply according to the above-mentioned first embodiment, the description thereof is omitted herein.
[0052] Next, the operation of the power supply according to the second embodiment at the start-up will be described below referring to FIGS. 4A to 4F . FIGS. 4A to 4F are waveform diagrams showing the operations of various sections of the power supply according to the second embodiment shown in FIGS. 4A to 4F at the start-up.
[0053] FIG. 4A shows the waveform of the output DC voltage Vo, FIG. 4B shows the waveform of the output signal V 9 of the comparator circuit 9 , FIG. 4C shows the waveform of the first error signal Ve, FIG. 4D shows the waveform of the output signal V 126 of the comparator 126 , FIG. 4E shows the waveform of a second error signal Ve 2 input to the PWM circuit 10 , and FIG. 4F shows the waveform of the drive pulse signal Vg, that is, the output of the PWM circuit 10 for driving the switching transistor 2 .
[0054] First, at the start-up in which the output DC voltage Vo does not reach the predetermined value (95% of the reference voltage), the first error signal Ve generated by the error amplifier 8 has a high potential. However, the output signal V 9 of the comparator circuit 9 is L level, and the voltage of the second error signal Ve 2 that is input to the PWM circuit 10 is limited to the addition voltage (2Vt+Vr) of the source-gate voltage Vt of the transistor 110 , the voltage Vr across the resistor 111 and the source-gate voltage Vt of the transistor 113 of the first clamp circuit 11 . Hence, the duty ratio of the switching transistor 2 becomes small, and the supply power is limited. As a result, the generation of inrush current can be prevented in the power supply according to the second embodiment. During this period, in the second clamp circuit 12 a, since the voltage of the first error signal Ve is higher than the voltage V 125 of the voltage supply 125 , the output signal V 126 of the comparator 126 is H level. Furthermore, since the output signal V 9 of the comparator circuit 9 is L level, the NAND circuit 123 outputs an H-level signal and the transistor 124 is turned OFF.
[0055] When the output DC voltage Vo reaches the predetermined value (95% of the reference voltage) at time t 1 in FIGS. 4A to 4F , the output signal V 9 of the comparator circuit 9 becomes H level, and the clamp limitation using the first clamp circuit 11 is released. At the same time, in the second clamp circuit 12 a, since the comparator 126 outputs an H-level signal and the output signal V 9 of the comparator circuit 9 becomes H level, the output of the NAND circuit 123 becomes L level. As a result, the transistor 124 is turned ON, and the voltage of the second error signal Ve 2 is limited to the source-gate voltage Vt of the transistor 124 . Since the second error signal Ve 2 , the voltage of which is limited to the second clamp voltage (Vt) instead of the first clamp voltage (2Vt+Vr) as described above, is input to the PWM circuit 10 , the duty ratio of the switching transistor 2 becomes further smaller. As a result, the rising speed of the output DC voltage Vo of the power supply according to the second embodiment is suppressed, and the generation of overshoot is prevented. The output DC voltage Vo soon reaches the reference voltage of the reference voltage supply 7 , that is, the target value, and the voltage of the first error signal Ve lowers. Since it is premised that the load 6 at the start-up is light, the voltage of the first error signal Ve lowers to a level lower than the voltage V 125 of the voltage supply 125 . When the voltage of the first error signal Ve lowers to a level lower than the voltage V 125 of the voltage supply 125 at time t 2 in FIGS. 4A to 4F , the output signal V 126 of the comparator 126 is inverted to L level. As a result, the output of the NAND circuit 123 becomes H level, and the transistor 124 is turned OFF, whereby the limitation state in which the voltage of the second error signal Ve 2 is limited to the second clamp voltage (Vt) is released. Then, in the power supply according to the second embodiment, the operation shifts to the normal operation in which the output DC voltage Vo is controlled to the reference voltage.
[0056] As described above, in the power supply according to the second embodiment, the resistor 80 is provided so that the output level (Ve) from the error amplifier 8 is separated from the input level (Ve 2 ) to the PWM circuit 10 . Furthermore, a judgment as to whether the output DC voltage Vo has reached the target value is made depending on the output level from the error amplifier 8 , whereby it becomes possible to set the limitation period using the second clamp voltage. Since the first clamp circuit 11 and the second clamp circuit 12 do not carry out clamp operation during the normal operation time, the output level from the error amplifier 8 is equal to the input level to the PWM circuit 10 .
[0057] As described above, in the power supply according to the second embodiment, at the light-load start-up in which the output DC voltage Vo does not reach the predetermined value that is less than the target value, the voltage of the second error signal Ve 2 is limited to the first clamp voltage (2Vt+Vr), and the supply power is limited, whereby the generation of inrush current is prevented. Furthermore, for a predetermined period after the output DC voltage Vo has reached the predetermined value, the voltage of the second error signal Ve 2 is limited to the second clamp voltage (Vt), and the rising speed of the output DC voltage Vo is further suppressed. As a result, the generation of overshoot is prevented securely.
Third Embodiment
[0058] A power supply according to a third embodiment of the present invention will be described below referring to the accompanying FIGS. 5 and 6 . FIG. 5 is a circuit diagram showing the configuration of the power supply according to the third embodiment of the present invention. FIGS. 6A to 6G are waveform diagrams showing the operations of various sections of the power supply shown in FIG. 5 at the start-up thereof. In the power supply according to the third embodiment, the components having the same functions and configurations as those of the above-mentioned power supplies according to the first and second embodiments are designated by the same numerals, and their descriptions are omitted. The power supply according to the third embodiment differs from the power supply according to the first embodiment in that a second comparator circuit 9 a is provided additionally. In the power supply according to the third embodiment, the output of the second comparator circuit 9 a is input to the non-inverting input terminal of the comparator 126 of the second clamp circuit 12 a.
[0059] The power supply according to the third embodiment is provided with a first comparator circuit 9 , the output signal of which is input to the first clamp circuit 11 and the second clamp circuit 12 a , and the second comparator circuit 9 a , the output signal of which is input to the second clamp circuit 12 a. The configuration of the first comparator circuit 9 according to the third embodiment is substantially the same as that of the comparator circuit 9 according to the first embodiment. The first comparator circuit 9 is provided with a comparator 90 and two resistors 91 and 92 , and the comparator 90 compares the output DC voltage Vo with a first predetermined value. The first predetermined value that is compared by the comparator 90 is formed by dividing the reference voltage using the resistors 91 and 92 . The first predetermined value is formed so as to be 95% of the reference voltage, for example. The second comparator circuit 9 a in the power supply according to the third embodiment is provided with a comparator 90 a and two resistors 91 a and 92 a , and the comparator 90 a compares the output DC voltage Vo with a second predetermined value. The second predetermined value that is compared by the comparator 90 a is formed by dividing the reference voltage using the resistors 91 a and 92 a. The second predetermined value is formed so as to be 99% of the reference voltage, for example.
[0060] Since the operation of the power supply according to the third embodiment configured as described above during the normal operation time is similar to that of the power supply according to the above-mentioned first embodiment, the description thereof is omitted herein.
[0061] Next, the operation of the power supply according to the third embodiment at the start-up will be described below referring to FIGS. 6A to 6G . FIGS. 6A to 6G are waveform diagrams showing the operations of various sections of the power supply according to the third embodiment shown in FIGS. 4A to 4F at the start-up.
[0062] FIG. 6A shows the waveform of the output DC voltage Vo, FIG. 6B shows the waveform of the output signal V 9 of the first comparator circuit 9 , FIG. 6C shows the waveform of the output signal V 9 a of the second comparator circuit 9 a , FIG. 6D shows the waveform of the first error signal Ve output from the error amplifier 8 , FIG. 6E shows the waveform of the output signal V 126 of the comparator 126 , FIG. 6F shows the waveform of the second error signal Ve 2 input to the PWM circuit 10 , and FIG. 6G shows the waveform of the drive pulse signal Vg, that is, the output of the PWM circuit 10 for driving the switching transistor 2 .
[0063] First, at the start-up in which the output DC voltage Vo does not reach the first predetermined value (95% of the reference voltage), the first error signal Ve generated by the error amplifier 8 has a high potential, and the output signal V 9 of the first comparator circuit 9 is L level. Hence, the voltage of the second error signal Ve 2 that is input to the PWM circuit 10 is limited to the addition voltage (2Vt+Vr) of the source-gate voltage Vt of the transistor 110 , the voltage Vr across the resistor 111 and the source-gate voltage Vt of the transistor 113 of the first clamp circuit 11 . Hence, the duty ratio of the switching transistor 2 becomes small, and the supply power is limited. As a result, the generation of inrush current can be prevented in the power supply according to the third embodiment. During this period, in the second clamp circuit 12 a , since the output DC voltage Vo is lower than the second predetermined value (99% of the reference voltage), the output signal V 9 a of the second comparator circuit 9 a is H level, the output signal V 126 of the comparator 126 is H level, and the output signal V 9 of the first comparator circuit 9 is L level, the NAND circuit 123 outputs an H-level signal. Hence, the transistor 124 is turned OFF.
[0064] When the output DC voltage Vo reaches the first predetermined value (95% of the reference voltage) that is less than the target value at time t 1 in FIGS. 6A to 6G , the output signal V 9 of the first comparator circuit 9 becomes H level, and the clamp limitation using the first clamp circuit 11 is released. At the same time, in the second clamp circuit 12 a , since the comparator 126 outputs an H-level signal and the output signal V 9 of the first comparator circuit 9 becomes H level, the output of the NAND circuit 123 becomes L level. As a result, the transistor 124 is turned ON, and the voltage of the second error signal Ve 2 is limited to the source-gate voltage Vt of the transistor 124 . The second error signal Ve 2 , the voltage of which is limited to the second clamp voltage (Vt) instead of the first clamp voltage (2Vt+Vr) as described above, is input to the PWM circuit 10 . For this reason, the duty ratio of the switching transistor 2 becomes further smaller, and the rising speed of the output DC voltage Vo is further suppressed. As a result, the generation of overshoot is prevented. The output DC voltage Vo rises further to the second predetermined value (99% of the reference voltage). When the output DC voltage Vo rises above the second predetermined value (99% of the reference voltage) at time t 2 in FIGS. 6A to 6G , the output signal V 126 of the comparator 126 is inverted to L level. Hence, the output of the NAND circuit 123 becomes H level, and the transistor 124 is turned OFF. As a result, the limitation state in which the voltage of the second error signal Ve 2 is limited to the second clamp voltage (Vt) is released, and the operation shifts to the normal operation in which the output DC voltage Vo is controlled to the reference voltage.
[0065] As described above, in the power supply according to the third embodiment, the second comparator circuit 9 a is provided, and a judgment as to whether the output DC voltage Vo has reached the target value is made, whereby it becomes possible to set the limitation period using the second clamp voltage. Since the first clamp circuit 11 and the second clamp circuit 12 do not carry out clamp operation during the normal operation time, the output level (Ve) from the error amplifier 8 is equal to the input level (Ve 2 ) to the PWM circuit 10 .
Fourth Embodiment
[0066] A power supply according to a fourth embodiment of the present invention will be described below referring to the accompanying FIGS. 7 to 10 . FIG. 7 is a circuit diagram showing the configuration of the power supply according to the fourth embodiment of the present invention. FIGS. 8 and 9 are circuit diagrams showing an example of a current detection circuit and an example of a timer circuit in the power supply according to the fourth embodiment. FIGS. 10A to 10G are waveform diagrams showing the operations of various sections of the power supply shown in FIG. 7 at the start-up thereof. In the power supply according to the fourth embodiment, the components having the same functions and configurations as those of the above-mentioned power supplies according to the first to third embodiments are designated by the same numerals, and their descriptions are omitted. The power supply according to the fourth embodiment differs from the power supply according to the first embodiment in that a current detection circuit 13 , a comparator 14 , a pulse-forming circuit 15 , an RS latch circuit 16 and a timer circuit 17 are provided and configured so as to set the operation timing of the switching transistor 2 and to drive the transistor according to the operation timing. In the power supply according to the fourth embodiment, a timing setting circuit comprising the comparator 14 , the pulse-forming circuit 15 , the RS latch circuit 16 and the timer circuit 17 is configured so as to set the operation timing of the switching transistor 2 .
[0067] The power supplies according to the first to third embodiments according to the present invention employ voltage mode control in which the duty ratio of the switching transistor 2 is changed using the error signal Ve obtained by comparing the output DC voltage Vo with the reference voltage so that the output DC voltage Vo is controlled so as to become equal to the reference voltage. On the other hand, the power supply according to the fourth embodiment employs current mode control in which the error signal Ve obtained by comparing the output DC voltage Vo with the reference voltage is compared with a voltage V 13 being proportional to the current flowing through the inductor 4 , and the current flowing through the inductor 4 is adjusted so that the output DC voltage Vo is controlled so as to become equal to the reference voltage. In the fourth embodiment, the current flowing through the diode 3 is used instead of the current flowing through the inductor 4 .
[0068] In the power supply according to the fourth embodiment, the voltage of the first error signal Ve generated by the error amplifier 8 rises when the output DC voltage Vo is lower than the reference voltage, and lowers when the output DC voltage Vo is higher than the reference voltage. During the normal operation time, the first clamp circuit 11 and the second clamp circuit 12 do not operate, and the first error signal Ve generated by the error amplifier 8 is input to the comparator 14 via the resistor 80 .
[0069] As shown in FIG. 8 , for example, the current detection circuit 13 comprises resistors 131 , 132 and 138 , a transistor 133 , transistors 134 and 137 constituting a current mirror circuit, a constant current supply 136 , and a diode 135 , the forward voltage of which is equal to the base-emitter voltage of the transistor 133 . Using the resistor 131 connected between the anode of the diode 3 and the ground, the current detection circuit 13 detects the current flowing through the diode 3 , that is, the current flowing through the inductor 4 at the time when the switching transistor 2 is OFF, and then converts the current into a voltage and outputs the voltage. The output of the current detection circuit 13 and the output (the second error signal Ve 2 ) derived from the error amplifier 8 via the resistor 80 are input to the comparator 14 . When the output level of the current detection circuit 13 becomes lower than the output level (Ve 2 ) derived from the error amplifier 8 , the comparator 14 outputs an H-level signal. The pulse-forming circuit 15 comprises an integrating circuit comprising a resistor 150 and a capacitor 151 for integrating the output signal of the comparator 14 , an inverter 152 and an AND circuit 153 , and forms the H-level signal of the comparator 14 into a pulse signal and outputs the pulse signal.
[0070] As shown in FIG. 9 , for example, the timer circuit 17 comprises an inverter 172 , transistors 171 and 173 , a constant current supply 174 , a capacitor 175 , a voltage supply 176 and a comparator 177 . In the timer circuit 17 , when an H-level signal is input to the inverter 172 , the transistor 171 is turned ON, the capacitor 175 is begun to be charged at a constant current, and the voltage of the capacitor 175 rises. When the voltage of the capacitor 175 becomes higher than the voltage of the voltage supply 176 , the comparator 177 outputs an H-level signal.
[0071] When the H-level signal is input from the pulse-forming circuit 15 to the set (S) terminal of the RS latch circuit 16 , the RS latch circuit 16 outputs an H-level signal. When this H-level signal is input to the timer circuit 17 , the timer circuit 17 outputs an H-level signal after the elapse of a predetermined time that is determined by the capacity of the capacitor 175 , the constant current from the constant current supply 174 and the voltage of the voltage supply 176 .
[0072] When the H-level signal of the timer circuit 17 is input to the reset (R) terminal of the RS latch circuit 16 , the RS latch circuit 16 outputs an L-level signal. In other words, the ON period of the switching transistor 2 is set at a predetermined time using the pulse-forming circuit 15 , the RS latch circuit 16 and the timer circuit 17 .
[0073] Next, the operation of the power supply according to the fourth embodiment configured as described above will be described below.
[0074] First, the operation of the power supply according to the fourth embodiment during the normal operation time will be described below.
[0075] In the power supply according to the fourth embodiment, the voltage of the first error signal Ve generated by the error amplifier 8 rises when the output DC voltage Vo is lower than the reference voltage, and lowers when the output DC voltage Vo is higher than the reference voltage. Furthermore, the output of the current detection circuit 13 rises and lowers in proportion to the current flowing through the inductor 4 . Hence, when the second error signal Ve 2 derived from the first error signal Ve via the resistor 80 has a high potential, the comparator 14 outputs an H-level signal while a large amount of current flows through the inductor 4 . On the other hand, when the second error signal Ve 2 has a low potential, the comparator 14 outputs an H-level signal while a small amount of current flows through the inductor 4 . When the comparator 14 outputs the H-level signal, the switching transistor 2 is turned ON, thereby increasing the current flowing through the inductor 4 . As a result, the amount of the current flowing through the inductor 4 is proportional to the potential of the first error signal Ve. In other words, when the output DC voltage Vo is lower than the reference voltage, the voltage of the first error signal Ve rises, the current flowing through the inductor 4 becomes larger, and the output DC voltage Vo becomes higher. Conversely, when the output DC voltage Vo is higher than the reference voltage, the voltage of the first error signal Ve lowers, the current flowing through the inductor 4 becomes smaller, and the output DC voltage Vo becomes lower. This feedback operation controls the output DC voltage Vo so as to become equal to the reference voltage.
[0076] During the normal operation time, in the first clamp circuit 11 , the transistor 110 of the first clamp circuit 11 is turned OFF using the H-level signal of the comparator circuit 9 that is input thereto. In addition, in the second clamp circuit 12 a , since the voltage of the first error signal Ve is lower than the voltage V 125 of the voltage supply 125 , the output signal of the comparator 126 is L level. Furthermore, since the output of the comparator circuit 9 is H level, the NAND circuit 123 outputs an H-level signal, and the transistor 124 is turned OFF.
[0077] Next, the operation of the power supply at the start-up will be described below referring to FIGS. 10A to 10G . FIGS. 10A to 10G are waveform diagrams showing the operations of various sections of the power supply shown in FIG. 7 at the start-up.
[0078] FIG. 10A shows the waveform of the output DC voltage Vo, FIG. 10B shows the waveform of the output signal V 9 of the comparator circuit 9 , FIG. 10C shows the waveform of the first error signal Ve, FIG. 10D shows the waveform of the output signal 126 of the comparator 126 , FIG. 10E shows the waveform of the second error signal Ve 2 input to the comparator 14 , FIG. 10F shows the waveform of the output signal V 13 of the current detection circuit 13 , and FIG. 10G shows the waveform of the drive pulse signal Vg output from the RS latch circuit 16 for driving the switching transistor 2 .
[0079] At the start-up in which the output DC voltage Vo does not reach the predetermined value (95% of the reference voltage), the first error signal Ve generated by the error amplifier 8 has a high potential, and the output signal V 9 of the comparator circuit 9 is L level. Hence, the voltage of the second error signal Ve 2 that is input to the comparator 14 is limited to the addition voltage (2Vt+Vr) of the source-gate voltage Vt of the transistor 110 , the voltage Vr across the resistor 111 and the source-gate voltage Vt of the transistor 113 of the first clamp circuit 11 . Hence, the current of the inductor 4 is limited. As a result, the generation of inrush current can be prevented in the power supply according to the fourth embodiment. During this period, in the second clamp circuit 12 a , since the voltage of the second error signal Ve is higher than the voltage V 125 of the voltage supply 125 , the output signal V 126 of the comparator 126 is H level, and the output signal V 9 of the comparator circuit 9 is L level. Hence, the NAND circuit 123 outputs an H-level signal, and the transistor 124 is turned OFF.
[0080] When the output DC voltage Vo reaches the predetermined value (95% of the reference voltage) at time t 1 in FIGS. 10A to 10G , the output signal V 9 of the comparator circuit 9 becomes H level, and the clamp limitation using the first clamp circuit 11 is released. At the same time, in the second clamp circuit 12 a , since the comparator 126 outputs an H-level signal and the output signal V 9 of the comparator circuit 9 becomes H level, the output of the NAND circuit 123 becomes L level. As a result, the transistor 124 is turned ON, and the voltage of the second error signal Ve 2 is limited to the source-gate voltage Vt of the transistor 124 . Since the second error signal Ve 2 , the voltage of which limited to the second clamp voltage (Vt) instead of the first clamp voltage (2Vt+Vr), is input to the comparator 14 , the current flowing through the inductor 4 is limited so as to become further smaller, the rising speed of the output DC voltage Vo is further suppressed, and the generation of overshoot is prevented. The output DC voltage Vo soon reaches the reference voltage of the reference voltage supply 7 , that is, the target value, and the voltage of the first error signal Ve lowers. On the premise that the load 6 at the start-up is light, the voltage of the first error signal Ve lowers to a level lower than the voltage V 125 of the voltage supply 125 . When the voltage of the first error signal Ve lowers to a level lower than the voltage V 125 of the voltage supply 125 at time t 2 in FIGS. 10A to 10G , the output signal V 126 of the comparator 126 is inverted to L level. As a result, the output of the NAND circuit 123 becomes H level, and the transistor 124 is turned OFF. When the transistor 124 is turned OFF, the limitation of the voltage of the first error signal Ve to the second clamp voltage (Vt) is released, and the operation shifts to the normal operation in which the output DC voltage Vo is controlled to the reference voltage.
[0081] As described above, even in the power supply according to the fourth embodiment employing the current mode control, the supply power is limited immediately before the output DC voltage reaches the target value, whereby the output overshoot under light load at the start-up can be suppressed. In the case of the current mode control, since the error signal to be limited directly corresponds to the current flowing through the inductor 4 , that is, the current supplied to the output, the power supply has excellent characteristics capable of setting the suppression level of inrush current and capable of speedily responding to transient phenomena, such as output overshoot.
[0082] Although the present invention has been described in terms of the presently preferred embodiments, it is to be understood that such disclosure is not to be interpreted as limiting. Various alterations and modifications will no doubt become apparent to those skilled in the art to which the present invention pertains, after having read the above disclosure. Accordingly, it is intended that the appended claims be interpreted as covering all alterations and modifications as fall within the true spirit and scope of the invention.
[0083] The present invention is thus useful for a power supply to which a DC voltage is input from a DC power supply, such as a battery, and from which a controlled DC voltage is output.
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A power supply has a soft-start function capable of raising its output DC voltage without generating overshoot even when its load condition is set light at the start-up. The power supply comprises an error amplifier for outputting an error signal corresponding to the error between the output DC voltage and the target value thereof, a control section for adjusting power to be supplied to the load on the basis of this error signal, and a limiting circuit for limiting the voltage of the error signal to a predetermined level for a predetermined time after the output DC voltage at the start-up exceeds a predetermined value being set less than the target value.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/101,773 filed on Oct. 1, 2008 and European Patent Application No. 09157013.5 filed on Mar. 31, 2009, the disclosures of which are incorporated herein.
BACKGROUND
[0002] a. Field of the Invention
[0003] One aspect of the invention relates to supplying power to a module for an Industrial Process Control System and for providing a power supply with over voltage protection in particular for an Industrial Process Control System suitable for:
Emergency Shutdown systems Critical process control systems Fire and Gas detection and protection systems Rotating machinery control systems Burner management systems Boiler and furnace control systems Distributed monitory and control systems
[0011] Such control systems are applicable to many industries including oil and gas production and refining, chemical production and processing, power generation, paper and textile mills and sewage treatment plants.
[0012] b. Related Art
[0013] In industrial process control systems, fault tolerance is of utmost importance. Fault tolerance is the ability to continue functioning safely in the event of one or more failures within the system.
[0014] Fault tolerance may be achieved by a number of different techniques, each with its specific advantages and disadvantages.
[0015] An example of a system which provides redundancy is a Triple Modular Redundancy (TMR) system. Using TMR, critical circuits are triplicated and perform identical functions simultaneously and independently. The data output from each of the three circuits is voted in a majority-voting circuit, before affecting the system's outputs. If one of the triplicated circuits fails, its data output is ignored. However, the system continues to output to the process the value (voltage, current level, or discrete output state) that agrees with the majority of the functional circuits. TMR provides continuous, predictable operation.
[0016] However, TMR systems are expensive to implement if full TMR is not actually a requirement, and it is desirable to utilize an architecture which provides flexibility so that differing levels of fault tolerance can be provided depending upon specified system requirements.
[0017] Another approach to fault tolerance is the use of hot-standby modules. This approach provides a level of fault tolerance whereby the standby module maintains system operation in the event of module failure. With this approach there may be some disruption to system operation during the changeover period if the modules are not themselves fault-tolerant.
[0018] Fault tolerant systems ideally create a Fault Containment Region (FCR) to ensure that a fault within the FCR boundary does not propagate to the remainder of the system. This enables multiple faults to co-exist on different parts of a system without affecting operation.
[0019] Fault tolerant systems generally employ dedicated hardware and software test and diagnostic regimes that provide very fast fault recognition and response times to provide a safer system.
[0020] Safety control systems are generally designed to be ‘fail-operational/fail-safe’. Fail operational means that when a failure occurs, the system continues to operate: it is in a fail-operational state. The system should continue to operate in this state until the failed module is replaced and the system is returned to a fully operational state.
[0021] An example of fail safe operation occurs, for example if, in a TMR system, a failed module is not replaced before a second failure in a parallel circuit occurs, the second failure should cause the TMR system to shut down to a fail-safe state. It is worth noting that a TMR system can still be considered safe, even if the second failure is not failsafe, as long as the first fault is detected and annunciated, and is itself failsafe.
[0022] This invention relates to improved power supplies within a controller controlling an industrial process control system.
[0023] It is advantageous if input or output modules for an industrial process control system are powered with their own independently isolated power supplies. It is desired that the method for generating the isolated power supply for each channel require a minimum number of isolation components. This has benefits in the areas of cost and flexibility. If individual channel isolation supplies of an input module are excited independently then each channel power supply converter may be driven at a unique frequency or phase, providing a reduction in peak radiated and conducted EMI/RFI emissions.
[0024] Ideally, critical systems will be protected from over-voltage faults in the components of their power supplies. Preferably a method of overvoltage protection will provide for the detection of the over-voltage faults, while permitting the system to continue to operate. Ideally any power supply over-voltage fault circuitry is testable in order to detect any faults.
[0025] Preferably common mode noise spikes are suppressed within a power supply.
SUMMARY OF THE INVENTION
[0026] According to one aspect of the invention, there is provided a power supply that includes a primary voltage converter having a first voltage input and a second voltage output, and overvoltage protection components preventing said second voltage rising above a predetermined maximum. A first low dropout regulator is connected to receive said second voltage and to generate a third voltage. A second low dropout regulator is connected to receive said second voltage and to generate a fourth voltage and a third low dropout regulator is connected to receive the fourth voltage and to generate a fifth voltage.
[0027] In one embodiment said first voltage is greater than said second voltage; said second voltage is greater than said third voltage; said third voltage is greater than said fourth voltage; and said fourth voltage is greater than said fifth voltage.
[0028] The overvoltage protection components may comprise a series fuse and a parallel avalanche diode.
[0029] The power supply accordingly may further comprise a microprocessor connected to each of said low dropout regulators and to said primary voltage converter. The microprocessor is arranged in operation to send a test signal and an enable signal to each low dropout regulator and to receive a monitored voltage from each low dropout regulator and further arranged in operation to apply the test signal to cause a small perturbation in a voltage received by one of said low dropout regulators and said primary voltage converter. The microprocessor monitors the resulting generated voltages and shuts down any one of said low dropout regulators by use of said enable signal.
[0030] The primary voltage converter may utilize a capacitor network comprising two parallel sets of two series capacitors to suppress the propagation of parasitic noise spikes at their source.
[0031] According to another aspect of the invention combinable with one or more of the above aspects, there is also provided a power supply for a channel of an input/output module comprising: a field programmable gate array for generating a pair of complementary square waves on two output pins and a transformer comprising two inputs connected to receive each of said pair of complementary square waves.
[0032] In this aspect, a pair of clamping diodes may be connected to each output pin.
[0033] The power supply may also comprise a damping resistor in series with each transformer input.
[0034] According to another aspect of the invention combinable or useable with one or more of the above aspects, there is provided a power supply system comprising a plurality of power supplies for a plurality of channels of an input/output module and in which each power supply is arranged in operation to generate a pair of complementary square waves at a different frequency to the frequency at which each other pair of complementary square waves is generated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0036] FIG. 1 is an illustration showing the architecture of a distributed industrial process control system which uses the apparatus and method of the present invention;
[0037] FIG. 2 illustrates schematically a controller of the industrial process control system illustrated in FIG. 1 ;
[0038] FIG. 3 illustrates a possible configuration of a controller;
[0039] FIG. 4 shows various options for an input assembly and output assembly of associated with the controller shown in FIG. 3 ;
[0040] FIG. 5 shows one possible configuration implementing a two out of three voting strategy;
[0041] FIG. 6 illustrates a second possible configuration for a two out of three voting strategy;
[0042] FIG. 7 is a schematic illustration showing an input module;
[0043] FIG. 8 is a block diagram of a channel of an input module;
[0044] FIG. 9 is a circuit diagram of a power isolator;
[0045] FIG. 10 illustrates an exemplary power supply in accordance with the present invention; and
[0046] FIG. 11 illustrates a noise filtered power supply.
DETAILED DESCRIPTION
[0047] In the Industrial Process Control System shown in FIG. 1 , a distributed architecture is designed to be used in different SIL environments, so that if a high SIL is required it can be provided, but if a low SIL is all that is needed, the system can be reduced in complexity in order to reduce unnecessary costs.
[0048] An exemplary Industrial Process Control System 10 , comprises a workstation 12 one or more controllers 14 and a gateway 16 . The workstation 12 communicates with the controllers 14 and the gateway 16 via Ethernet connections 18 to one or more control networks 13 . Multiple Ethernet connections 18 provide redundancy to improve fault tolerance. The workstation 12 may be connected via a conventional Ethernet connection 11 to another external network 15 .
[0049] A controller 14 will now be described in more detail with reference to FIGS. 2 and 3 .
[0050] FIG. 2 illustrates a schematic diagram of the controller 14 comprising an input assembly 22 , a processor assembly 24 and an output assembly 26 . In this schematic illustration the input assembly 24 and output assembly 26 are on different backplanes but they may equally well share a single backplane.
[0051] Assemblies 22 , 24 , 26 are created from one or more communications backplane portions which have three slots to accommodate up to three modules together with termination assemblies which have one, two, or three slots, and which interface to field sensors and transducers. A termination assembly may straddle two contiguous backplane portions. A module comprises a plug in card with multiple connectors for plugging onto a communications backplane and a termination assembly.
[0052] It will be appreciated that having three slots in a communications backplane portion is one design option and other design options with greater (or fewer) slots are possible without departing from the scope of the invention as defined in the appended claims.
[0053] FIG. 3 illustrates a possible physical configuration of the controller 14 . In this embodiment of the invention, the input assembly 22 , output assembly 26 and processor assembly 24 are physically separated from one another by grouping the modules of different types onto separate communications backplanes.
[0054] In the example shown, the input assembly 22 comprises two communications backplane portions, 22 ′, 22 ″. The first backplane portion 22 ′ has a triplex input termination assembly and three input modules 22 a , 22 b , 22 c , the second backplane portion 22 ″ has a duplex input termination assembly 22 ″ and two input modules 22 d , 22 e . The processor assembly 24 comprises a single processor backplane portion 24 ′ having three processor modules 24 a , 24 b and 24 c . The output assembly 26 comprises two backplane portions 26 ′, 26 ″. The first backplane portion 26 ′ has a duplex output termination assembly with two output modules 26 a , 26 b and the second backplane portion 26 ″ has a simplex output termination assembly with a single output module 26 c.
[0055] The flexibility of the input assembly 22 , will now be described, in more detail with reference to FIG. 4 .
[0056] An input assembly 22 comprises one or more backplane portions and termination assemblies 22 ′ 22 ″ 22 ′″ etc. For example, a triplex portion 22 ′ having three modules 22 a , 22 b , 22 c might be used for high availability requirement, a duplex portion 22 ″ having two modules 22 d , 22 e might be provided for fault tolerant applications and a simplex portion 22 ′″ with a single module 22 f might be provided for failsafe applications. The termination assemblies may be provided with different types of field conditioning circuits. For example assembly 22 ′ may be provided with a 24V DC field conditioning circuit 41 , assembly 22 ″ may be provided with a 120V DC field conditioning circuit 42 , and assembly 22 ′″ may be provided with a 4-20 mA field conditioning circuit 43 . Similarly possible configurations are shown for an output assembly 26 . It will be appreciated that numerous configurations of backplane portions and termination assemblies with various different numbers of modules and various different types of field conditioning circuits are possible and the invention is not limited to those shown in these examples.
[0057] Where an assembly provides more than one module for redundancy purposes it is possible to replace a failed module with a replacement module whilst the industrial process control system is operational which is also referred to herein as online replacement (i.e. replacement is possible without having to perform a system shutdown). Online replacement is not possible for a simplex assembly without interruption to the process. In this case various “hold last state” strategies may be acceptable or a sensor signal may also be routed to a different module somewhere else in the system.
[0058] The processor assembly configures a replacement processor module using data from a parallel module before the replacement module becomes active.
[0059] The field conditioning circuits 41 , 42 , 43 transform a signal received from a sensor monitoring industrial process control equipment to a desired voltage range, and distribute the signal to the input modules as required. Each field conditioning circuit 41 , 42 , 43 is also connected to field power and field return (or ground) which may be independently isolated on a channel by channel basis from all other grounds, depending on the configuration of the input termination assembly. Independent channel isolation is the preferred configuration because it is the most flexible. The field conditioning circuits 41 , 42 , 43 comprise simple non active parts and are not online replaceable.
[0060] FIG. 5 and FIG. 6 illustrate the flexibility of the architecture described herein showing different configurations for a triplex system for generating a signal with a high availability requirement. Referring to FIG. 5 , a three module input assembly 51 receives a signal from a sensor 50 via a field conditioning circuit in termination assembly 54 . The field conditioning circuit 54 transforms the signal to a desired voltage range and distributes the signal to three replicated input modules 53 a , 53 b , 53 c . Each input module processes the signal and the results are sent to a two out of three voter 52 to generate a result signal in dependence thereon.
[0061] Referring to FIG. 6 , replicated sensors 60 a , 60 b , 60 c each send a signal to a respective simplex assemblies 61 a , 61 b , 61 c via respective field conditioning circuits in termination assemblies 64 a , 64 b , 64 c . Each input module 63 a , 63 b , 63 c processes the signal and sends an output to a two out of three voter 62 to generate a signal in dependence thereon. It will be appreciated that many variations and configurations are possible in addition to those illustrated here.
[0062] FIG. 7 illustrates schematically an input module 70 in accordance with the present invention:
[0063] An input module 70 comprises eight isolated channels 71 . Each channel 71 receives signals 72 , 73 a , 73 b from field conditioning circuits in a termination assembly 74 . Each channel communicates with a field programmable gate array (FPGA) 75 which interfaces to an backplane (not shown) via a non-isolated backplane interface 76 . Light emitting diodes (LEDs) 77 are used to indicate status of the module via red and green indicators.
[0064] It will be appreciated that having eight channels is one design option and other design options with greater (or fewer) channels are possible without departing from the scope of the invention as defined in the appended claims.
[0065] Programmable I/O pins of the FPGA 75 are used to directly drive low power isolated supplies, supplying the channels 71 without the need for additional power amplifiers.
[0066] Referring now to FIG. 8 the channel 71 is shown in more detail.
[0067] The input channel 71 comprises a blown fuse circuit 111 receiving blown fuse signal 72 , a primary input circuit 113 receiving primary sense signal 73 a and a secondary input circuit 112 receiving secondary sense signal 73 b . The input channel also comprises microcomputers 114 and 115 for processing signals 72 , 73 a and 73 b.
[0068] The input channel 71 further comprises a power isolator circuit 118 receiving power inputs 78 from the FPGA 75 which will be described in more detail below. The signal isolator 20 receives a command signal 80 and returns a response signal 79 which are routed to and from the microprocessor 114 . The signal isolator 120 is not discussed further here.
[0069] Isolated power for each input channel 71 is created with direct drive from pins of the FPGA 75 by complementary square wave signals 78 . Multiple pins of the FPGA may be paralleled to provide greater drive current capability.
[0070] FIG. 9 shows the power isolator 118 in more detail. The signals 78 are input into a transformer 103 (which in the preferred embodiment is an ultra miniature 1:1 or 1:1.5 isolation transformer). Clamping diodes 101 are used to ensure that the output pins of the FPGA 75 are protected from switching transient spikes from the leakage inductance of the transformer 103 .
[0071] Low value damping resistors 102 may be used to absorb ringing from any switching transients.
[0072] The advantages of this approach are the small size, low cost, and small number of components that are required to generate the isolated supply. In a preferred embodiment of the invention, multiple isolated channels 71 are driven with square wave signals having slightly different excitation frequencies or phases to distribute the EMI/RFI peak amplitudes, which provides improved radiated and conducted emissions performance.
[0073] All of the input and output modules require a power supply which is protected from overvoltage faults.
[0074] FIG. 10 is an illustration of a power supply for providing two voltages to an input or output module. The supply is protected from over-voltage faults in such a manner that over-voltage faults can be detected and tolerated as will now be described.
[0075] A primary DC/DC converter 121 provides a 3.4V±1% output from a 24V input.
[0076] This output is not directly protected from an over-voltage fault. However, low dropout linear regulators 122 and 125 discussed below protect downstream circuitry from an over-voltage fault on the DC/DC converter 121 .
[0077] A low dropout linear regulator 122 receives this output where it is regulated down to 3.2V±1%. If the low dropout regulator 122 develops an input-to-output short-circuit fault, the worst case fault, then the output supplied cannot rise above 3.4V, which is still within the acceptable recommended operating range for 3.3V±5% integrated circuitry.
[0078] Extreme over-voltage fault protection components, consisting of a series fuse 123 and transient over-voltage protection avalanche diode 124 , are provided for the case where the DC/DC converter 121 develops an output fault condition where the output would otherwise rise above the tolerance level of the low dropout regulators 122 and 125 .
[0079] A further over-voltage protected output voltage is provided by the combination of a further low dropout regulator 125 providing 1.3V±1% from the 3.4V source and an ultra-low dropout regulator 126 . In this example the ultra low dropout regulator 126 provides 1.2V±1% from the 1.3V source voltage provided by the further low dropout regulator 125 , at an amount of current that is adequate to supply an FPGA core, so that there is no possible short circuit fault that will result in more than 1.3V being applied to an FPGA core and resulting in un-predictable operation.
[0080] A supervisor micro-computer 127 is responsible for enabling the regulators 122 , 125 , 126 in sequence after the output from the DC/DC converter 121 has stabilized. This provides a confidence level in the functionality of the linear supplies.
[0081] The supervisor micro-computer 127 may generate a test signal 128 to the converter 121 and/or regulators 122 , 125 , 126 to coerce the generated voltages by ±0.5%, allowing the linear operation of the linear regulators to be verified by monitoring the generated voltages via monitor signals 129 a , 129 b , 129 c , 129 d.
[0082] This test can be performed either just at power-up, or periodically during normal system operation if desired. The supervisor micro-computer 127 is also responsible for monitoring the over/under-voltage operation of the linear regulators, and shutting the system down using enable signals in the event of an out-of-tolerance fault using enable signals 130 a , 130 b , 130 c.
[0083] An alternative to protecting power supplies from over-voltage faults is to sense the over-voltage condition with a comparator and then “crowbar” the output to deliberately create a short circuit fault which must blow the fuse, but saves the system from the consequences of an over-voltage event. Obviously this alternative would be difficult to test and maintain.
[0084] The advantage of the arrangement of the present is that un-testable crowbar circuits are not required, with their large and un-testable components.
[0085] With an isolated DC/DC power supply such as 121 shown in FIG. 10 it is desirable to provide noise filtering.
[0086] FIG. 11 illustrates a power supply protection circuit in accordance with the present invention. A capacitor network 119 provides a low impedance path for any high frequency noise spikes due to the interaction of a primary winding being driven by a switching power supply controller, and the primary-secondary coupling parasitic capacitances of a flyback transformer.
[0087] Filter capacitors in the network 119 are sized so that the individual capacitors can withstand the necessary isolation voltage, and the series combination of two of them (half that of a single one) provides enough filtration. The resulting system can withstand a short circuit or open circuit fault of either of the capacitors.
[0088] It will be appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately, or in any suitable combination.
[0089] It is to be recognized that various alterations, modifications, and/or additions may be introduced into the constructions and arrangements of parts described above without departing from the scope of the present invention as defined in the appended claims.
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A power supply that is capable of supplying power to an input/output channel for an Industrial Process Control System. The power supply includes a primary voltage converter having a first voltage input and a second voltage output, and overvoltage protection components that prevent the second voltage from rising above a predetermined maximum. The power supply includes a first low dropout regulator that is connected to receive the second voltage and to generate a third voltage, a second low dropout regulator that is connected to receive the second voltage and to generate a fourth voltage, and a third low dropout regulator that is connected to receive the fourth voltage and to generate a fifth voltage. The power supply provides an over-voltage fault tolerant self-testable architecture, allows for compact low cost individual channel isolation and fault tolerant EMI/RFI filtration.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Application No. 60/313,289 filed Aug. 17, 2001, entitled VAPOR COMPRESSION CYCLE FAULT DETECTION AND DIAGNOSTICS in the name of Todd Rossi, Dale Rossi and Jon Douglas.
[0002] U.S. Provisional Application No. 60/313,289, filed Aug. 17, 2001, is hereby incorporated by reference as if fully set forth herein.
FIELD OF THE INVENTION
[0003] The present invention relates generally to an apparatus and a method for servicing an air-conditioning system. More particularly, the present invention relates to an apparatus and a method for servicing an air-conditioning system, which utilizes a data acquisition system for communicating with the air-conditioning system and a hand-held computer, which analyzes the information, received from the data acquisition system.
BACKGROUND OF THE INVENTION
[0004] Air conditioners, refrigerators and heat pumps are all classified as HVAC&R systems. The most common technology used in all these systems is the vapor compression cycle (often referred to as the refrigeration cycle), which consists of four major components (compressor, expansion device, evaporator, and condenser) connected together via a conduit (preferably copper tubing) to form a closed loop system. The term refrigeration cycle used in this document refers to the vapor compression cycle used in all HVAC&R systems, not just refrigeration applications.
[0005] Light commercial buildings (e.g. strip malls) typically have numerous refrigeration systems located on their rooftops. Since servicing refrigeration systems requires highly skilled technician to maintain their operation, and there are few tools available to quantify performance and provide feedback, many of refrigeration cycles are poorly maintained. For example, two common degradation problems found in such commercial systems are fouling of the evaporator and/or condenser by dirt and dust, and improper refrigerant charge.
[0006] In general, maintenance, diagnosis and repair of refrigeration systems are manual operations. The quality of the service depends almost exclusively upon the skill, motivation and experience of a technician trained in HVAC&R. Under the best circumstances, such service is time-consuming and hit-or-miss opportunities to repair the under-performing refrigeration system. Accordingly, sometimes professional refrigeration technicians are only called upon after a major failure of the refrigeration system occurs, and not to perform routine maintenance on such systems.
[0007] The tools that the technician typically uses to help in the diagnosis are pressure gauges, service units which suggest possible fixes, common electronic instruments like multi-meters and component data books which supplement the various service units that are available. Even though these tools have improved over the years in terms of accuracy, ease of use and reliability, the technician still has to rely on his own personal skill and knowledge in interpreting the results of these instruments. The problems associated with depending upon the skill and knowledge of the service technician is expected to compound in the future due in part to the introduction of many new refrigerants. Thus, the large experience that the technicians have gained on current day refrigerants will not be adequate for the air-conditioning systems for the future. This leads to a high cost for training and a higher incident of misdiagnosing which needs to be addressed. During the process of this diagnosis by the technician, he typically relies on his knowledge and his past experience. Thus, accurate diagnosis and repair require that the technician possess substantial experience. The large number of different air-conditioning systems in the marketplace complicates the problem of accurate diagnosis. While each air-conditioning system includes a basic air-conditioning cycle, the various systems can include components and options that complicate the diagnosis for the system as a whole. Accordingly, with these prior art service units, misdiagnosis can occur, resulting in improperly repaired systems and in excessive time to complete repairs.
[0008] Although service manuals are available to assist the technician in diagnosing and repairing the air-conditioning systems, their use is time-consuming and inefficient. In addition, the large number of manuals requires valuable space and each manual must be kept up to date. Attempts to automate the diagnostic process of HVAC&R systems have been made. However, because of the complexity of the HVAC&R equipment, high equipment cost, or the inability of the refrigeration technician to comprehend and/or properly handle the equipment, such diagnostic systems have not gained wide use.
SUMMARY OF THE INVENTION
[0009] The present invention includes an apparatus and a method for fault detection and diagnostics of a refrigeration, air conditioning or heat pump system operating under field conditions. It does so by measuring, for each vapor compression cycle, at least five—and up to nine—system parameters and calculating system performance variables based on the previously measured parameters. Once the performance variables of the system are determined, the present invention provides fault detection to assist a service technician in locating specific problems. It also provides verification of the effectiveness of any procedures performed by the service technician, which ultimately will lead to a prompt repair and may increase the efficiency of the refrigeration cycle.
[0010] The subject data acquisition system coupled with a hand held computer using sophisticated software provides a reasonable cost diagnostic tool for a service technician. In the very cost sensitive systems like residential air-conditioning system, this diagnostic tool eliminates the need for having each system equipped with independent sensors and electronics, yet they will still have the capability to assist the technician to efficiently service the air-conditioning system when there is a problem.
[0011] The diagnostic tool may also include a wireless Internet link with a master computer which contains the service information on all of the various systems in use. In this way, the hand held computer can be constantly updated with new information as well as not being required to maintain files on every system. If the technician encounters a system not on file in his hand held computer, a wireless Internet link to the master computer can identify the missing information.
[0012] The present invention is intended to be used with any manufacturer's HVAC&R equipment, is relatively inexpensive to implement in hardware, and provides both highly accurate fault detection and dependable diagnostic solutions which does not depend on the skill or abilities of a particular service technician.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention and, together with the following description, serve to explain the principles of the invention. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred, it being understood, however, that the invention is not limited to the specific instrumentality or the precise arrangement of elements or process steps disclosed.
[0014] In the drawings:
[0015] [0015]FIG. 1 is a block diagram of a conventional refrigeration cycle;
[0016] [0016]FIG. 2 schematically illustrates an air-conditioning service system in accordance with the present invention; and
[0017] [0017]FIG. 3 schematically illustrates the air-conditioning service system shown in FIG. 2 coupled with the air-conditioning system shown in FIG. 1.
[0018] [0018]FIG. 4 is a schematic representation of the apparatus in accordance with the present invention;
[0019] [0019]FIG. 5 is a schematic representation of the pipe mounting of the temperature sensors in accordance with the present invention; and
[0020] [0020]FIG. 6 is a schematic representation of the data collection unit;
[0021] [0021]FIG. 7 is a schematic representation of the computer in accordance with the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0022] In describing preferred embodiments of the invention, specific terminology will be selected for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.
[0023] The terms “refrigeration system” and “HVAC&R system” are used throughout this document to refer in a broad sense to an apparatus or system utilizing a vapor compression cycle to work on a refrigerant in a closed-loop operation to transport heat. Accordingly, the terms “refrigeration system” and “HVAC&R system” include refrigerators, freezers, air conditioners, and heat pumps.
[0024] Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings in which a device used to carry out the method in accordance with the present invention is generally indicated by reference numeral 200 . The term “refrigeration cycle” referred to in this document usually refers to systems designed to transfer heat to and from air. These are called direct expansion (evaporator side) air cooled (condenser side) units. It will be understood by those in the art, after reading this description, that another fluid (e.g., water) can be substituted for air with the appropriate modifications to the terminology and heat exchanger descriptions.
[0025] The vapor compression cycle is the principle upon which conventional air conditioning systems, heat pumps, and refrigeration systems are able to cool (or heat for heat pumps) and dehumidify air in a defined volume (e.g., a living space, an interior of a vehicle, a freezer, etc.). The vapor-compression cycle is made possible because the refrigerant is a fluid that exhibits specific properties when it is placed under varying pressures and temperatures.
[0026] A typical refrigeration system 100 is illustrated in FIG. 1. The refrigeration system 100 is a closed loop system and includes a compressor 10 , a condenser 12 , an expansion device 14 and an evaporator 16 . The various components are connected together via a conduit (usually copper tubing). A refrigerant continuously circulates through the four components via the conduit and will change state, as defined by its properties such as temperature and pressure, while flowing through each of the four components.
[0027] The refrigerant is a two-phase vapor-liquid mixture at the required condensing and evaporating temperatures. Some common types of refrigerant include R-12, R-22, R-134A, and R-410A. The main operations of a refrigeration system are compression of the refrigerant by the compressor 10 , heat rejection by the refrigerant in the condenser 12 , throttling of the refrigerant in the expansion device 14 , and heat absorption by the refrigerant in the evaporator 16 . This process is usually referred to as a vapor compression or refrigeration cycle.
[0028] In the vapor compression cycle, the refrigerant nominally enters the compressor 10 as a slightly superheated vapor (its temperature is greater than the saturated temperature at the local pressure) and is compressed to a higher pressure. The compressor 10 includes a motor (usually an electric motor) and provides the energy to create a pressure difference between the suction line and the discharge line and to force a refrigerant to flow from the lower to the higher pressure. The pressure and temperature of the refrigerant increases during the compression step. The pressure of the refrigerant as it enters the compressor is referred to as the suction pressure and the pressure of the refrigerant as it leaves the compressor is referred to as the head or discharge pressure. The refrigerant leaves the compressor as highly superheated vapor and enters the condenser 12 .
[0029] A typical air-cooled condenser 12 comprises a single or parallel conduits formed into a serpentine-like shape so that a plurality of rows of conduit is formed parallel to each other. Metal fins or other aids are usually attached to the outer surface of the serpentine-shaped conduit in order to increase the transfer of heat between the refrigerant passing through the condenser and the ambient air. Heat is rejected from the refrigerant as it passes through the condenser and the refrigerant nominally exits the condenser as slightly subcooled liquid (its temperature is lower than the saturated temperature at the local pressure). As refrigerant enters a “typical” condenser, the superheated vapor first becomes saturated vapor in the approximately first quarter section of the condenser, and the saturated vapor undergoes a phase change in the remainder of the condenser at approximately constant pressure.
[0030] The expansion device 14 , or metering device, reduces the pressure of the liquid refrigerant thereby turning it into a saturated liquid-vapor mixture at a lower temperature, to enter the evaporator. This expansion is a throttling process. In order to reduce manufacturing costs, the expansion device is typically a capillary tube or fixed orifice in small or low-cost air conditioning systems and a thermostatic expansion valve (TXV) or electronic expansion valve (EXV) in larger units. The TXV has a temperature-sensing bulb on the suction line. It uses that temperature information along with the pressure of the refrigerant in the evaporator to modulate (open and close) the valve to try to maintain proper compressor inlet conditions. The temperature of the refrigerant drops below the temperature of the indoor ambient air as it passes through the expansion device. The refrigerant enters the evaporator 16 as a low quality saturated mixture (approximately 20%). (“Quality” is defined as the mass fraction of vapor in the liquid-vapor mixture.)
[0031] A direct expansion evaporator 16 physically resembles the serpentine-shaped conduit of the condenser 12 . Ideally, the refrigerant completely evaporates by absorbing energy from the defined volume to be cooled (e.g., the interior of a refrigerator). In order to absorb heat from this ambient volume, the temperature of the refrigerant must be lower than that of the volume to be cooled. Nominally, the refrigerant leaves the evaporator as slightly superheated gas at the suction pressure of the compressor and reenters the compressor thereby completing the vapor compression cycle. (It should be noted that the condenser 12 and the evaporator 16 are types of heat exchangers and are sometimes referred to as such in the following text.) Although not shown in FIG. 1, a fan driven by an electric motor is usually positioned next to the evaporator; a separate fan/motor combination is usually positioned next to the condenser. The fan/motor combinations increase the airflow over their respective evaporator or condenser coils, thereby increasing the transfer of heat. For the evaporator in cooling mode, the heat transfer is from the indoor ambient volume to the refrigerant circulating through the evaporator; for the condenser in cooling mode, the heat transfer is from the refrigerant circulating through the condenser to the outside air. A reversing valve is used by heat pumps operating in heating mode to properly reverse the flow of refrigerant, such that the outside heat exchanger (the condenser in cooling mode) becomes an evaporator and the indoor heat exchanger (the evaporator in cooling mode) becomes a condenser.
[0032] Finally, although not shown, is a control system that allows users to operate and adjust the desired temperature within the ambient volume. The most basic control system comprises a low voltage thermostat that is mounted on a wall inside the ambient volume, and relays that control the electric current delivered to the compressor and fan motors. When the temperature in the ambient volume rises above a predetermined value on the thermostat, a switch closes in the thermostat, forcing the relays to make and allowing current to flow to the compressor and the motors of the fan/motors combinations. When the refrigeration system has cooled the air in the ambient volume below the predetermined value set on the thermostat, the switch opens thereby causing the relays to open and turning off the current to the compressor and the motors of the fan/motor combination.
[0033] U.S. Pat. No. 6,324,854, titled AIR-CONDITIONING SERVICING SYSTEM AND METHOD issued Dec. 4, 2001, to Nagara, Jayanth, is hereby incorporated by reference as if fully set forth herein.
[0034] Referring now to FIGS. 2 and 3, an air-conditioning service system or apparatus 30 is illustrated. Apparatus 30 comprises a data acquisition system 32 , a hand held computer 34 , a pair of pressure hoses 36 and 38 , and a plurality of sensors 40 . Data acquisition system 32 includes a micro-controller 42 , a pair of pressure sensors 44 and 46 and an Analog to Digital converter 48 . Pressure hose 36 is adapted to be attached to port 22 to monitor the pressure at or near the suction port of compressor 12 . Pressure hose 38 is adapted to be attached to port 24 to monitor the pressure at or near the discharge port of compressor 12 . Each hose 36 and 38 is in communication with sensors 44 and 46 , respectively, and each sensor 44 and 46 provides an analog signal to A/D converter 48 which is indicative of the pressure being monitored. A/D converter 48 receives the analog signal from sensors 44 and 46 , converts this analog signal to a digital signal which is indicative of the pressure being monitored and provides this digital system to micro-controller 42 .
[0035] Sensors 40 are adapted to monitor various operating characteristics of compressor 12 . Several sensors 40 monitor specific temperatures in the system, on sensor monitors compressor supply voltage, one sensor monitors compressor supply amperage and one sensor monitors the rotational speed (RPM) for compressor 12 . Typical temperatures that can be monitored include evaporator refrigerant temperature, condenser refrigerant temperature, ambient temperature and conditioned space temperature. The analysis of parameters like compressor voltage, compressor current, compressor RPM and discharge temperature can provide valuable information regarding the cause of the problem. Each sensor 40 is connected to A/D converter 48 and sends an analog signal indicative of its sensed parameter to A/D converter 48 . A/D converter 48 receives the analog signals from sensors 40 and converts them to a digital signal indicative of the sensed parameter and provides this digital signal to micro-controller 42 .
[0036] Micro-controller 42 is in communication with computer 34 and provides to computer 34 the information provided by micro-controller 42 . Once computer 34 is provided with the air-conditioning system configuration and the sensed parameters from sensors 40 , 44 and 46 , a diagnostic program can be performed. The air-conditioning system configuration can be provided to computer 34 manually be the technician or it can be provided to computer 34 by a bar code reader 50 if the air-conditioning system is provided with a bar code label which sufficiently identifies the air-conditioning system.
[0037] In order for the diagnostic program to run, computer 34 must know what the normal parameters for the monitored air-conditioning system should be. This information can be kept in the memory of computer 34 , it can be kept in the larger memory of a master computer 52 or it can be kept in both places. Master computer 52 can be continuously updated with new models and revised information as it becomes available. When accessing the normal parameters in its own memory, computer 34 can immediately use the saved normal parameters or computer 34 can request the technician to connect to master computer 52 to confirm and/or update the normal parameters. The connection to the master computer 52 is preferably accomplished through a wireless Internet connection 54 in order to simplify the procedure for the technician. Also, if the particular air conditioning system being monitored is not in the memory of computer 34 , computer 34 can prompt the technician to connect to master computer 52 using wireless Internet connection 54 to access the larger data base which is available in the memory of master computer 52 . In this way, computer 34 can include only the most popular systems in its memory but still have access to the entire population or air-conditioning systems through connection 54 . While the present invention is being illustrated utilizing wireless Internet connection 54 , it is within the scope of the present invention to communicate between computers 34 and 52 using a direct wireless or a wire connection if desired.
[0038] The technician using apparatus 30 would first hook up pressure hose 36 to port 22 and pressure hose 38 to port 24 . The technician would then hook up the various temperature sensors 40 , the compressor supply voltage and current sensors 40 and the compressor RPM sensor 40 . The technician would then initialize computer 34 and launch the diagnostics application software. The software on start-up prompts the technician to set up the test session. The technician then picks various options such as refrigerant type of the system and the system configuration, like compressors and system model number, expansion device type or other information for the configuration system. Optionally this information can be input into computer 34 using a barcode label and barcode reader 50 if this option is available. The software then checks to see if the operating information for the system or the compressor model exists within its memory. If this information is not within its memory, computer 34 will establish a wireless connection to master computer 52 through wireless Internet connection 54 and access this information from master computer 52 . Also, optionally, computer 34 can prompt the technician to update the existing information in its memory with the information contained in the memory of master computer 52 or computer 34 can prompt the technician to add the missing information to its memory from the memory of master computer 52 .
[0039] Once the test session is set up, the software commands micro-controller 42 to acquire the sensed values from sensors 40 , 44 , and 46 . Micro-controller 42 has its own custom software that verifies the integrity of the values reported by sensors 40 , 44 and 46 . An example would be that micro-controller 42 has the ability to detect a failed sensor. The sensors values acquired by micro-controller 42 through A/D converter 48 are reported back to computer 34 . This cycle of sensor data is acquired continuously throughout the test session. The reported sensed data is then used to calculate a variety of system operating parameters. For example, superheat, supercooling, condensing temperature, evaporating temperature, and other operating parameters can be determined. The software within computer 34 then compares these values individually or in combination with the diagnostics rules programmed and then based upon these comparisons, the software derives a set of possible causes to the differences between the measured values and the standard operating values. The diagnostic rules can range from simple limits to fuzzy logic to trend analysis. The diagnostic rules can also range from individual values to a combination of values.
[0040] For example, the current drawn by compressor 12 is related to the suction and discharge pressures and is unique to each compressor model. Also, the superheat settings are unique to each air-conditioning system. Further, the diagnostic rules are different for different system configurations like refrigerant type, expansion device type, compressor type, unloading scheme, condenser cooling scheme and the like. In some situations, the application of the diagnostic rules may lead to the requirement of one or more additional parameters. For example, the diagnostic system may require the indoor temperature which may not be currently sensed. In this case, the technician will be prompted to acquire this valve by other means and to input its value into the program. When the criteria for a diagnostic rule have been satisfied, then a cause or causes of the problem is displayed to the technician together with solutions to eliminate the problem. For example, a high superheat condition in combination with several other conditions suggests a low refrigerant charge and the solution would be to add refrigerant to the system. The technician can then carry out the suggested repairs and then rerun the test. When the system is again functioning normally, the test results and the sensed values can be saved for future reference.
[0041] While sensors 40 are disclosed as being hard wired to A/D converter 48 , it is within the scope of the preset invention to utilize wireless devices to reduce the number of wiring hookups that need to be made.
[0042] Also, while apparatus 30 is being disclosed as a diagnostic tool, it is within the scope of the present invention to include an automatic refrigerant charging capability through hoses 36 and 38 if desired. This would involve the addition of a control loop to meter refrigerant into the system from a charging cylinder. Accurate charging would be accomplished by continuously monitoring the system parameters during the charging process.
[0043] There are common degradation faults in systems that utilize a vapor compression cycle. For example, heat exchanger fouling and improper refrigerant charge both can result in performance degradations including reductions in efficiency and capacity. Low charge can also lead to high superheat at the suction line of the compressor, a lower evaporating temperature at the evaporator, and a high temperature at the compressor discharge. High charge, on the other/hand, increases the condensing and evaporating temperature. Degradation faults naturally build up slowly and repairing them is often a balance between the cost of servicing the equipment (e.g., cleaning heat exchangers) and the energy cost savings associated with returning them to optimum (or at least an increase in) efficiency.
[0044] The present invention is an effective apparatus and corresponding process for using measurements easily and commonly made in the field to:
[0045] Detect faults of a unit running in the field;
[0046] 1. Provide diagnostics that can lead to proper service in the field;
[0047] 2. Verify the performance improvement after servicing the unit; and
[0048] 3. Educate the technician on unit performance and diagnostics.
[0049] The present invention is useful for:
[0050] 1. Balancing the costs of service and energy, thereby permitting the owner/operator to make better informed decisions about when the degradation faults significantly impact operating costs such that they require attention or servicing.
[0051] 2. Verifying the effectiveness of the service carried out by the field technicians to ensure that all services were performed properly.
[0052] The present invention is an apparatus and a corresponding method that detects faults and provides diagnostics in refrigeration systems operating in the field. The present invention is preferably carried out by a microprocessor-based system; however, various apparatus, hardware and/or software embodiments may be utilized to carry out the disclosed process. In effect, the apparatus of the present invention integrates two standard technician hand tools, a mechanical manifold gauge set and a multi-channel digital thermometer, into a single unit, while providing sophisticated user interface implemented in one embodiment by a computer. The computer comprises a microprocessor for performing calculations, a storage unit for storing the necessary programs and data, means for inputting data and means for conveying information to a user/operator. In other embodiments, the computer includes one or more connectors for assisting in the direct transfer of data to another computer that is usually remotely located.
[0053] Although any type of computer can be used, a hand-held computer allows portability and aids in the carrying of the diagnostic apparatus to the field where the refrigeration system is located. Therefore, the most common embodiments of a hand-held computer include the Palm Pilot manufactured by 3COM, a Windows CE based unit (for example, one manufactured by Compaq Computers of Houston, Tex.), or a custom computer that comprises the aforementioned elements that can carry out the requisite software instructions. If the computer is a Palm Pilot, the means for inputting data is a serial port that is connected to a data collection unit and the touchpad/keyboard that is standard equipment on a Palm. The means for conveying information to a user/operator is the screen or LCD, which provides written instructions to the user/operator.
[0054] Preferably, the apparatus consists of three temperature sensors and two pressure sensors. The two pressure sensors are connected to the unit under test through the suction line and liquid line ports, which are made available by the manufacturer in most units, to measure the suction line pressure SP and the liquid line pressure LP. The connection is made through the standard red and blue hoses, as currently performed by technicians using a standard mechanical manifold. The temperature sensors are thermistors. Two of them measure the suction line temperature ST and the liquid line temperature LT, by attaching them to the outside of the copper pipe at each of these locations, as near as possible to the pressure ports.
[0055] A feature of the present invention is that the wires connecting the temperature sensors ST and LT to the data collection unit are attached to the blue and red hoses, respectively, of the manifold. Thus, there is no wire tangling and the correct sensor is easily identified with each hose. The remaining temperature sensor is used to measure the ambient air temperature AMB. These five sensors are easily installed and removed from the unit and do not have to be permanently installed in the preferred embodiment of the invention. This feature allows for the portability of the apparatus, which can be used in multiple units in a given job.
[0056] Although these five measurements are sufficient to provide fault detection and diagnostics in the preferred embodiment, four additional temperatures can optionally be used to obtain more detailed performance analysis of the system under consideration. These four additional temperatures are: supply air SA, return air RA, discharge line DT, and air off condenser AOC. All the sensor positions, including the optional, are shown in FIG. 1.
[0057] Referring again to FIG. 1, the pressure drop in the tubes connecting the various devices of a vapor compression cycle is commonly regarded as negligible; therefore, the important states of a vapor compression cycle may be described as follows:
[0058] State 1: Refrigerant leaving the evaporator and entering the compressor. (The tubing connecting the evaporator and the compressor is called the suction line 18 .)
[0059] State 2: Refrigerant leaving the compressor and entering the condenser (The tubing connecting the compressor to the condenser is called the discharge or hot gas line 20 ).
[0060] State 3: Refrigerant leaving the condenser and entering the expansion device. (The tubing connecting the condenser and the expansion device is called the liquid line 22 ).
[0061] State 4: Refrigerant leaving the expansion device and entering the evaporator (connected by tubing 24 ).
[0062] A schematic representation of the apparatus is shown in FIG. 4. The data collection unit 20 is connected to a computer 22 . The two pressure transducers (the left one for suction line pressure SP and the right one for liquid line pressure LP) 24 are housed with the data collection unit 20 in the preferred embodiment. The temperature sensors are connected to the data collection unit through a communication port shown on the left of the data collection unit. The three required temperatures are ambient temperature (AMB) 48 , suction line temperature (ST) 38 , and liquid line temperature (LT) 44 . The optional sensors measure the return air temperature (RA) 56 , supply air temperature (SA) 58 , discharge temperature (DT) 60 , and air off condenser temperature (AOC) 62 .
[0063] In one embodiment, the computer is a handheld computer, such as a Palm™ OS device and the temperature sensors are thermistors. For a light commercial refrigeration system, the pressure transducers should have an operating range of 0 to =700 psig and −15 to 385 psig for the liquid and suction line pressures, respectively. The apparatus can then be used with the newer high-pressure refrigerant R-410a as well as with traditional refrigerants such as R-22.
[0064] The low-pressure sensor is sensitive to vacuum to allow for use when evacuating the system. Both pressure transducers are connected to a mechanical manifold 26 , such as the regular manifolds used by service technicians, to permit adding and removing charge from the system while the apparatus is connected to the unit. Two standard refrigerant flow control valves are available at the manifold for that purpose.
[0065] At the bottom of the manifold 26 , three access ports are available. As illustrated in FIG. 4, the one on the left is to connect to the suction line typically using a blue hose 30 ; the one in the middle 28 is connected to a refrigerant bottle for adding charge or to a recovery system for removing charge typically using a yellow hose; and the one on the right is connected to the liquid line through a red hose 32 . The three hoses are rated to operate with high pressures, as it is the case when newer refrigerants, such as R-410a, are used. The lengths of the hoses are not shown to scale in FIG. 4. At the end of the pressure hoses, there are pressure ports to connect to the unit pipes 40 and 46 , respectively. The wires, 50 and 52 respectively, leading to the suction and liquid line temperature sensors are attached to the respective pressure hoses using wire ties 34 to avoid misplacing the sensors. The suction and liquid line pipes, 40 and 46 , respectively, are shown to provide better understanding of the tool's application and are not part of the apparatus. The suction and liquid line temperature sensors, 38 and 44 respectively, are attached to the suction and liquid line pipes using an elastic mounting 42 .
[0066] The details of the mounting of the temperature sensor on the pipe are shown in FIG. 5. It is assumed that the temperature of the refrigerant flowing through the pipe 102 is equal to the outside temperature of the pipe. Measuring the actual temperature of the refrigerant requires intrusive means, which are not feasible in the field. To measure the outside temperature of the pipe, a temperature sensor (a thermistor) needs to be in good contact with the pipe. The pipes used in HVAC&R applications vary in diameter. As an alternative, in another embodiment of the present invention, the temperature sensor 110 is securely placed in contact with the pipe using an elastic mounting. An elastic cord 104 is wrapped around the pipe 102 , making a loop on the metallic pipe clip 106 . A knot or similar device 112 is tied on one end of the elastic cord, secured with a wire tie. On the other end of the elastic cord, a spring loaded cord lock 108 is used to adjust and secure the temperature sensor in place for any given pipe diameter. Alternatively, temperature sensors can be secured in place using pipe clips as it is usually done in the field.
[0067] Referring now to FIG. 6, the data collection unit 20 comprises a microprocessor 210 and a communication means. The microprocessor 210 controls the actions of the data collection unit, which is powered by the batteries 206 . The batteries also serve to provide power to all the parts of the data collection unit and to excite the temperature and pressure sensors. The software is stored in a non-volatile memory (not shown) that is part of the microprocessor 210 . A separate non-volatile memory chip 214 is also present. The data collection unit communicates with the handheld computer through a bi-directional communication port 202 . In one embodiment, the communication port is a communication cable (e.g., RS232), through the serial communication connector. The temperature sensors are connected to the data collection unit through a port 216 , and connectors for pressure transducers 218 are also present. In the preferred embodiment of the invention, the pressure transducers are housed with the data collection unit. Additional circuits are present in the preferred embodiment. Power trigger circuitry 204 responds to the computer to control the process of turning on the power from the batteries. Power switch circuitry 208 controls the power from the batteries to the input conditioning circuitry 212 , the non-volatile memory 214 and the microprocessor 210 . Input conditioning circuitry 212 protects the microprocessor from damaging voltage and current from the sensors.
[0068] A schematic diagram of the computer is shown in FIG. 7. The computer, preferably a handheld device, has a microprocessor 302 that controls all the actions. The software, the data, and all the resulting information and diagnostics are stored in the memory 304 . The technician provides information about the unit through an input device (e.g. keyboard or touchpad) 306 , and accesses the measurements, calculated parameters, and diagnostics through an output device (e.g. LCD display screen) 308 . The computer is powered by a set of batteries 314 . A non-volatile removable memory 310 is present to save important data, including the software, in order to restore the important settings in case of power failure.
[0069] The invention can be used in units using several refrigerants (R-22, R-12, R-500, R-134a, and R-410a). The computer prompts (through LCD display 308 ) the technician for the type of refrigerant used by the refrigeration system to be serviced. The technician selects the refrigerant used in the unit to be tested prior to collecting data from the unit. The implementation of a new refrigerant requires only programming the property table in the software. The computer also prompts (again through LCD display 308 ) the technician for the type of expansion device used by the refrigeration system. The two primary types of expansion devices are fixed orifice or TXV. After the technician has answered both prompts, the fault detection and diagnostic procedure can start.
[0070] The process will now be described in detail with respect to a conventional refrigeration cycle. FIGS. 8 A- 8 F is a combined flowchart/schematic block diagram of the main steps of the present invention utilizing five field measurements. As described above, various gauges and sensors are known to those skilled in the art that are able to take the five measurements. Also, after reading this description, those skilled in the art will understand that more than five measurements may be taken in order to determine the efficiency and the best course of action for improving the efficiency of the refrigeration system.
[0071] The method consists of the following steps:
[0072] A. Measure high and low side refrigerant pressures (LP and SP, respectively); measure the suction and liquid line temperatures (ST and LT, respectively); and measure the outdoor atmospheric temperature (AMB) used to cool the condenser. These five measurements are all common field measurements that any refrigeration technician can make using currently available equipment (e.g., manifold pressure gauges, thermometers, etc.). If sensors are available, also measure the discharge temperature (DT), the return air temperature (RA), the supply air temperature (SA), and the air off condenser temperature (AOC). These measurements are optional, but they provide additional insight into the performance of the vapor compression cycle. (As stated previously, these are the primary nine measurements—five required, four optional—that are used to determine the performance of the HVAC unit and that will eventually be used to diagnose a problem, if one exists.) Use measurements of LP and LT to accurately calculate liquid line subcooling, as it will be shown in step B. Use the discharge line access port to measure the discharge pressure DP when the liquid line access port is not available. Even though the pressure drop across the condenser results in an underestimate of subcooling, assume LP is equal to DP or use data provided by the manufacturer to estimate the pressure drop and determine the actual value of LP.
[0073] B. Calculate the performance parameters (pressure difference, condensing temperature over ambient, evaporating temperature, suction line superheat, and liquid line subcooling) that are necessary for the fault detection and diagnostic algorithm.
[0074] B.1 Use the liquid pressure (LP) and the suction pressure (SP) to calculate the pressure difference (PD), also known as the expansion device pressure drop
PD=LP−SP.
[0075] B.2 Use the liquid line temperature (LT), liquid pressure (LP), outdoor air ambient temperature (AMB), and air of condenser temperature (AOC) to determine the following condenser parameters:
[0076] i) the condensing temperature (CT)
CT=T sat ( LP ),
[0077] ii) the liquid line subcooling (SC)
SC=CT−LT,
[0078] iii) the condensing temperature over ambient (CTOA)
CTOA=CT−AMB,
[0079] iv) the condenser temperature difference (CTD), if AOC is measured
CTD=AOC−AMB.
[0080] B.3 Use the suction line temperature (ST), suction pressure (SP), return air temperature (RA), and supply air temperature (SA) to determine:
[0081] i) the evaporating temperature (ET):
ET=T sat ( SP ),
[0082] ii) the suction line 59 d superheat (SH):
SH=ST−ET
[0083] iii) the evaporator temperature difference (ETD), if RA and SA are measured:
ETD=RA−SA.
[0084] C. Define the operating ranges for the performance parameters. The operating range for each performance parameter is defined by up to 3 values; minimum, goal, and maximum. Table 1 shows an example of operating limits for some of the performance parameters. The operating ranges for the superheat (SH) are calculated by different means depending upon the type of expansion device. For a fixed orifice unit, use the manufacturer's charging chart and the measurements to determine the manufacturer's suggested superheat. For units equipped with a thermostatic expansion valve (TXV) the superheat is fixed: for air conditioning applications use 20° F.
TABLE 1 Example of Operating Ranges for Performing Indices Symbol Description Minimum Goal Maximum CTOA (° F.) Condensing over Ambient — 20 30 Temperature Difference ET (° F.) Evaporating Temperature 30 40 47 PD (psi) Pressure Difference 100 — — SC (° F.) Liquid Line Subcooling 6 12 20 SH (° F.) Suction Line Superheat 12 20 30 CTD (° F.) Condenser Temperature — — 30 Difference ETD (° F.) Evaporator Temperature 17 20 26 Difference
[0085] For the evaporating temperature (ET), there is also a VERY HI limit, which, for example, can be equal to 55° F. Note that the values presented illustrate the concept and may vary depending on the actual system investigated. For example, the suction line superheat expectation for units equipped with fixed orifice expansion devices varies with the load.
[0086] D. A level is assigned to each performance parameter. Levels are calculated based upon the relationship between performance parameters and the operating range values. The diagnostic routine utilizes the following 4 levels: Low (LO), Below Goal, Above Goal, and High (HI). A performance parameter is High if its value is greater than the maximum operating limit. The evaporating temperature has also a MMaximum level, so if ET is higher than Mmaximum, its level is Very Hi. It is Above Goal if it the value is less than the maximum limit and greater than the goal. The performance parameter is Below Goal if the value is less than the goal but greater than the low limit. Finally, the parameter is Low if the value is less than the minimum. The following are generally accepted rules, which determine the operating regions for air conditioners, but similar rules can be written for refrigerators and heat pumps:
[0087] D.1 The limits for evaporating temperature (ET) define two boundaries: a low value leads to coil freezing and a high value leads to reduced latent cooling capacity.
[0088] D.2 The maximum value of the condensing temperature over ambient difference (CTOA) defines another boundary: high values lead to low efficiency. Note that a high value is also supported by high condenser temperature difference (CTD).
[0089] D.3 The minimum value of the pressure drop (PD) defines another boundary. A lower value may prevent the TXV from operating properly.
[0090] D.4 Within the previously defined boundaries, suction superheat (SH) and liquid subcooling (SC) provides a sense for the amount of refrigerant on the low and high sides, respectively. A high value of suction superheat leads to insufficient cooling of hermetically sealed compressors and a low value allows liquid refrigerant to wash oil away from moving parts inside the compressor. A high or low liquid subcooling by itself is not an operational safety problem, but it is important for diagnostics and providing good operating efficiency. Low SC is often associated with low charge.
[0091] E. The fault detection aspect of the present invention determines whether or not service is required, but does not specify a particular action. Faults are detected based upon a logic tree using the levels assigned to each performance parameter. If the following conditions are satisfied, the cycle does not need service:
[0092] E.1 Condenser temperature (CT) is within the limits as determined by:
[0093] i) The cycle pressure difference (PD) is not low.
[0094] ii) The condensing temperature over ambient (CTOA) is not high.
[0095] iii) The condenser temperature difference (CTD) is not high
[0096] E.2 Evaporator temperature (ET) is neither low nor high.
[0097] E.3 Compressor is protected. This means the suction line superheat (SH) is within neither low nor high.
[0098] If any of these performance criteria is not satisfied, there must be a well define course of action to fix the problem
[0099] F. Similar to the fault detection procedure, diagnoses are made upon a logic tree using the levels assigned to each performance parameter. Table 1 shows the conditions and the diagnostics for each case when a fault is present.
TABLE 1 Diagnostics Conditions Condition Diagnostics CTOA > HI, SC > HI Overcharged unit CTOA > HI, SC < HI High side heat transfer problem ET > VERY HI Inefficient compressor ET > HI, SH < Goal Too fast evaporator fan ET > HI, SH < GOAL, SC > GOAL Too fast evaporator fan and overcharged unit ET > HI, SH < GOAL, SC < GOAL Difficult diagnostics ET < LO, SH > HI, SC > GOAL Check for flow restriction ET < LO, SH > HI, SC < GOAL Undercharged unit ET < LO, SH < LO Low side heat transfer problem ET < LO, LO < SH < HI Low side heat transfer problem and undercharged unit CTOA < HI, LO < ET < HI, SH > HI, Check for flow restriction SC > HI CTOA < HI, LO < ET < HI, SH > HI, Undercharged unit SC < LO CTOA < HI, LO < ET < GOAL, Undercharged unit LO < SC < HI CTOA < HI, GOAL < ET < HI, Fast evaporator fan LO < SC < HI CTOA < HI, LO < ET < HI, SH < LO, Overcharged unit SC > HI CTOA < HI, LO < ET < HI, SH < LO, Difficult diagnostics SC < LO CTOA < HI, LO < ET < HI, SH < LO, Low side heat transfer problem LO < SC < HI CTOA < HI, LO < ET < HI, Low side heat transfer problem LO < SH < HI, SC < LO and undercharged unit
[0100] Although the preferred embodiment of the present invention requires measuring three temperatures and two pressures, one skilled in the art will recognize that the two pressure measurements may be substituted by measuring the evaporating temperature (ET) and the condensing temperature (CT). The suction line pressure (SP) and the liquid line pressure (LP) can be calculated as the saturation pressures at the evaporating temperature (ET) and at the condensing temperature (CT), respectively.
[0101] 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 that 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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An apparatus and method for detecting faults and providing diagnostic information in a refrigeration system comprising a microprocessor, a means for inputting information to the microprocessor, a means for outputting information from the microprocessor, and five sensors. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that this abstract will not be used to interpret or limit the scope or meaning of the claims.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a tablet having an optical security feature formed as a diffractive micro-structure, a compression die for producing such tablets and a method for producing such tablets.
[0003] 2. Discussion of Related Art
[0004] Counterfeit and gray market products and illegal re-imports are a major problem for pharmaceutical drugs. Drugs and medicines are counterfeited to an ever increasing extent, which is a problem not only in developing countries, where counterfeit products in the supply chain often amount to more than 50%, but this problem also exists in industrial countries where the prices of pharmaceutical drugs are often much higher. The prices for AIDS drugs or cancer drugs are often reduced significantly in developing countries, for example, for social reasons, but this increases the risk of abusive re-importing of these drugs into industrial nations.
[0005] To prevent abuse, packages of pharmaceutical drugs are provided with counterfeit-proof features. Holograms, optically variable inks, fluorescent dyes, special printing techniques such as microprinting and other security features are attached to the package with adhesive labels, are laminated onto the box or are applied directly to the package. One main disadvantage of such labeling is that it can be removed from the product or package and then reused or analyzed. Some companies apply security features to the sealing film of blister packs, but these have the same disadvantages.
[0006] Methods of applying counterfeit-proof signatures, such as DNA of a known sequence, U.S. Pat. No. 5,451,505, for example, molecules with a characteristic isotope composition or microparticles with a characteristic color layer sequence, U.S. Pat. No. 6,455,157, for example, are extremely critical because these signatures are taken together with the drug. For this reason, approval authorities such as the U.S. Food and Drug Administration (FDA) have not yet given approval for such methods.
[0007] Some attempts to apply a hologram to edible products have been published. PCT International Publication WO 01/10464 A1 discloses the coating of edible products with a thermally moldable and embossable layer. However, the application of this layer alters the composition and the production process of pharmaceutical pills, so it requires a new official approval. In addition, heating during the thermal shaping steps is problematical for many active ingredients.
[0008] U.S. Pat. No. 4,668,523 describes another approach in which a polymer solution is brought in contact with a mold having a diffractive relief. Then the polymer is hardened by drying. This step can be accelerated by heating. At the end, the hardened, edible polymer product carries the diffractive relief. This method is limited to polymer solutions and is very slow. In addition, the heating of the active ingredients used for the production of pharmaceutical tablets is again problematical. These disadvantages have prevented the market introduction of these techniques.
SUMMARY OF THE INVENTION
[0009] One object of this invention is to provide a tablet having an integrated security feature, the tablet having essentially the same composition as a traditional tablet which can be produced without elevated temperatures during the manufacturing process and which does not require an extension of the production process in comparison with the traditional methods. Another object of this invention is to provide a compression die with which such tablets can be produced as well as methods for producing such molds.
[0010] The term “tablet” in this context is understood to refer not only to tablets and pills intended for swallowing, sucking, chewing or dissolving in the mouth, but also other medicinal dosage forms such as suppositories or products that are dissolved in liquids before being taken. Besides pharmaceutical tablets, this is also understood to include non-pharmaceutical products such as bonbons or sweetener tablets.
[0011] These and other objects are achieved by a tablet, a compression die and by methods for manufacturing such compression dies according to the specification and the claims.
[0012] A tablet according to this invention has on its surface a diffractive microstructure, which creates perceptible diffraction effects in the optical spectral range and thus functions as a security feature. The microstructured surface may also be macroscopically structured to form, for example, logos, brand names, etc. The security feature cannot be removed from the tablet and also cannot be transferred subsequently to counterfeit products. To produce such tablets, an inventive compression die including one compression mold and two compression rams is used. The surface of the compression mold and/or one or both compression rams facing the powder mixture to be compressed each has a diffractive microstructure, which is formed during the compression operation, more precisely during the compression and compaction process, on the surface of the powder particles, thus forming a permanent diffractive microstructure on the surface of the finished tablet.
[0013] The traditional temperatures, pressures and process speeds of known tablet presses can be retained in producing the inventive tablets. In particular, a compression time of much less than 100 ms per tablet is sufficient. The inventive molds may be used in traditional tableting machines. Production of the inventive tablets is thus compatible with the existing and qualified tablet production methods and is thus inexpensive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] This invention is explained in greater detail below with reference to drawings, wherein:
[0015] FIG. 1 shows a simplified schematic diagram of the tablet pressing operation;
[0016] FIG. 2 shows a schematic cross section taken through diffractive microstructures on the surface of tablets produced with the method of this invention, with (a) rectangular, (b) sinusoidal and (c) triangular grating lines;
[0017] FIG. 3 shows a photograph of a pressed tablet with a diffractive microstructure produced by the method of this invention;
[0018] FIG. 3( a ) shows a schematic diagram of the inventive tablets with microstructures in recesses;
[0019] FIG. 3( b ) shows a schematic diagram of a reading device for authentication of inventive tablets;
[0020] FIG. 4( a ) shows a photograph of a microstructured compression die for use in the method of this invention and FIG. 4( b ) shows an SEM micrograph (SEM=scanning electron microscope) of a table produced by the method of this invention;
[0021] FIGS. 5( a )- 5 ( d ) show schematically the steps of the ion etching method for producing a compression die according to: (a) holographic lighting, (b) oblique chromium sputtering, (c) dry etching, and (d) finished microstructured compression die surface;
[0022] FIG. 6 shows a graph of an example of a stress-strain curve;
[0023] FIG. 7 shows a photograph of an aluminum plate microstructured by cold embossing; and
[0024] FIGS. 8( a )- 8 ( c ) each shows a schematic diagram of a hammering process to illustrate a diffractive microstructure on a compression die surface.
DETAILED DESCRIPTION OF THE INVENTION
Powder Mixtures for Pharmaceutical Tablets
[0025] Most tablets are produced by pressing a powder mixture in a compression mold. If active powders and fillers are merely mixed and then pressed directly to form tablets, it relates to direct tableting. This process is mainly a high-pressure molding process.
[0026] The mixture to be pressed comprises particles of different sizes, where the size distribution of the particles is critical for the tablet pressing process. Table 1 shows an example of a typical mixture including excipients for production of a pharmaceutical tablet. Table 2 shows the respective typical particle size distribution.
[0000]
TABLE 1
Amount wt %
Substance
72.75
lactose monohydrate
24.25
microcrystalline cellulose
1.00
Aerosil (colloidal silica,
dried)
1.00
magnesium stearate
1.00
sodium salicylate (example
of an active ingredient)
[0000]
TABLE 2
Diameter of
Amount in
particles in μm
wt %
<75
15-25
75-150
30-50
150-250
15-25
250-500
5-15
>500
<2
[0027] Lactose and cellulose are the most widely used binders and fillers in direct tableting processes. These substances are especially suitable when provided with a diffractive microstructure.
[0028] The powder is transported by gravity in the tablet press equipment. Thus, a good free-flowing property is obligatory. Aerosil improves powder flow.
[0029] Magnesium stearate is used as a lubricant. Lubricants function by being distributed over the surface of the powder. They reduce the frictional forces between the powder and the compression dies and thus prevent the tablet from adhering to the compression die.
[0030] Decomposition active ingredients may be added to the powder mixture to improve decomposition, such as dissolution in water. The decomposition time of pills is typically measured in water at 37° C.
[0031] Sometimes a dye is added, but only a few dyes are allowed for use in medication. Practically all pharmaceutical tablets are thus a dull white. Some are bright red or light blue. Thus, all the tablets produced by the direct tableting process have a luminous and/or light-scattering surface.
[0032] Particles larger than 500 μm and/or smaller than 75 μm are critical for the compressing operation. The former reduce the mechanical stability of the pressed tablet while the latter are problematical for particle flow during the filling of the cavity of the compression die. Thus, the amount of these particles must be kept as low as possible. On the whole, it can be concluded that practically all powder particles used in the tablet pressing process are much larger than the diffractive microstructures, which are typically structures smaller than 5 μm in size and are created in the surface.
[0033] To prevent an unwanted chemical change in the ingredients during the production of the tablets, the temperature should advantageously be 50° C., or even better 40° C. The temperature is preferably between 15° C. and 35° C., such as room temperature.
Parameters of the Diffractive Microstructures
[0034] It is difficult to reliably and permanently create typical diffractive microstructures with a period Λ of approx. 1-2 μm and a depth t on the order of 200-300 nm in the surface of a tablet, as illustrated in FIG. 2 , for example, and reliably maintain them during the direct tableting process. These powder mixtures are naturally not intended for microstructuring and the size of the microstructures is much smaller than the dimension of the particles. For this reason, the surface of the particles themselves must be microstructured. Finally, the tableting process is ultimately not so fast that the time for microstructuring is extremely short. To be able to achieve this, certain parameters of the diffractive microstructure must be optimized, in particular the diffractive microstructure on the die surface, which acts as an embossing pattern. The parameter ranges of the microstructures for the inventive tablets which have been found particularly suitable are summarized in Table 2a.
[0000]
TABLE 2a
Especially
Parameter
Suitable range
Preferred range
preferred range
Period Λ
300-5000 nm
800-2500 nm
1200-2500 nm
Depth t
80-1000 nm
100-500 nm
150-300 nm
Shape
rectangular,
sinusoidal or
sinusoidal or
sinusoidal, triangular
rounded shapes
rounded shapes
or rounded shapes
[0035] It is a challenge in the tableting process to prevent the diffractive microstructures that protrude out of the surface of the inventive tablet from being broken off. Microstructures including linear grating lines ( 1 d grating) are more suitable than spot gratings ( 2 d gratings) because the lines have a greater mechanical stability than the spots. Crossed gratings in the form of a hole grating are equally suitable in view of the stability of the connected grating lines.
[0036] The microstructuring increases the surface area of the compression die and thus increases the contact area between the compression die and the pressed tablet. This results in increased adhesion and thus may interfere with the separation of the finished tablet from the mold. To minimize this effect, the microstructure advantageously has a rounded or triagonal shape, such as a sinusoidal grating ( FIG. 2( b ), 2 ( c )). Microstructures having perpendicular walls, as illustrated in FIG. 2( a ), are less ideal. In addition, the depth t of the microstructures should be as low as possible. However, a minimum depth t of approx. 80 nm is required for a visible diffractive effect. The diffraction efficiency of a sinusoidal grating is at its maximum, for example, when the grating depth corresponds to 0.3-0.4 grating periods. In addition, the microstructure must be deeper than the lubricant layer between the surface and the compression die or the wall of the compression mold and the tablet mass. Most lubricants have a laminar structure with sliding planes running slightly parallel to the surface of the compression die or the compression mold. For this reason, microstructures introduced into only this lubricant layer are easily broken off.
Producing Tablets with Diffractive Microstructures
[0037] FIG. 1 shows schematically the process for producing a tablet. The powder 2 to be pressed is a mixture of powdered constituents placed in a compression mold 3 . Two axially aligned compression rams 1 a , 1 b exert mechanical forces axially, thus forming the tablet.
[0038] The diffractive microstructure to be created on the tablet is provided on the surface of the compression ram 1 a , 1 b and/or on the inside wall of the compression mold 3 . If the wall of the compression mold 3 has a linear diffractive grating as the microstructure, then to support the ejection of the finished tablet 4 , the grating lines are preferably arranged parallel to the axial direction of movement of the compression ram dies. It is simpler with regard to the mechanical stresses occurring in the compression process to apply the microstructure to the compression rams 1 a , 1 b.
[0039] The powder fills the cavity in the compression mold 3 , which is sealed by the lower compression ram 1 b (see FIG. 1( a )). The volume of the compression mold defines the quantity of powder that is compressed to form the tablet. This volume can be adjusted through the position of the lower compression ram 1 b during the filling of the cavity. The compression force is typically between 5 and 25 kN. Modern rotary presses achieve maximal compression forces of up to 160 kN. During the compression process, two interrelated phenomena take place simultaneously: compression and consolidation (K. Marshall, “Tablet press fundaments,” Tablets & Capsules 2005, pp. 6-11). The former leads to a reduction in the volume of the mass, while the latter causes an increase in the mechanical strength of the mass. Then when a force is applied to the powder, first its volume is reduced because the air between the particles is displaced (see FIG. 1( b )). This phase is known as the “repacking phase” and is limited by reaching the highest possible packing density and/or by friction at the contact points of the powder particles. Then most materials undergo elastic deformation up to the limit of plasticity (see FIG. 1( c )). This phase is known as the “squeezing phase.” The particles may also experience brittle fractures due to the reduction in volume. Following this phase, the components may undergo plastic and/or viscoelastic deformation.
[0040] The diffractive microstructure is introduced into the tablet surface mainly by this plastic and/or viscoelastic deformation. Many materials used for pressing tablets, such as some polymers that are used as binders, have viscoelastic properties. If the surface of the particles is coated with a plastic material, the plasticity of a powder can be further improved. Particles can be partially coated with a binder, such as polyvinyl pyrrolidone (PVP), such as in moist granulation, thereby improving the compressibility of the particles. Because of particle-particle interactions, the mechanical resistance force of the tableting mass becomes progressively greater, the greater the applied compression force. In particle-particle interactions, bonds are formed at the particle surfaces because the number of contact points increases. Depending on the chemical composition, the bonds are ionic or covalent bonds, dipole-dipole interactions and van der Waals forces. There is often a mixture of these bonds. In addition, liquid films may solidify. Solidification of liquid films may take place in two ways. First, when heat of friction at the points of contact results in softening or melting of an ingredient having a low melting point, the mechanical stress at this point is dissipated. The ingredient then hardens via a melt bond. Second, an ingredient at the contact points where there is a high stress may dissolve in the liquid film present at the surface of a particle. Here again, the mechanical stress is dissipated and the material recrystallizes to form a bond. If the hardening takes place close to the surface of the microstructured compression mold, then the softened, molten or dissolved ingredient supports the replication of the diffractive microstructure.
[0041] At the end of the tablet pressing process, the pressure is removed ( FIG. 1( d )) and the finished tablet 4 is ejected ( FIG. 1( e )). The subsequent elastic recoil is minimized to achieve a high mechanical stability of the tablet. The recipe is thus optimized.
[0042] For tablets with diffractive microstructures in their surfaces, a recipe that meets all the requirements of tablet production and still has a sufficiently high plastic deformability to be able to create the microstructure is required. As mentioned, the powder to be compressed is of a mixture of various substances having different functions. The amount of plastically deformable materials in the recipe is selected to be as high as possible, but the requirements of the end product as well as FDA standards are still met. The amount of microcrystalline cellulose or plastic binders such as PVP may be increased, for example, or these materials used instead of excipients that are equivalent except for having a lower plastic deformability.
[0043] Modern industrial tablet presses are high-performance machines capable of producing tablets at very high speeds. The production speed of ultramodern single rotary presses is approximately 30,000 to 300,000 tablets per hour. In addition, they must offer extreme reliability and precision because all tablets must meet strict specifications with regard to thickness, weight, hardness and shape. The machines as well as all their components must be compliant with GMP (good manufacturing practice) and FDA requirements.
[0044] Table 3 shows examples of speed-specific data for various tablet presses. Additional information can be found in N. A. Armstrong, “Considerations of Compression Speed in Tablet Manufacture,” Pharmaceutical Technology , September 1990, pp. 106-114. The short compression time is sufficient to compress the powdered raw material into a hard tablet.
[0000]
TABLE 3
Speed per
Lowering time
Holding
Type of press
compression mold
for the last 5 mm
time
Eccentric
85 tablets/min
68.6 ms
0 ms
Small rotary press
44 tablets/min
61.4 ms
10.84 ms
Large rotary press
100 tablets/min
26.7 ms
3.94 ms
Large rotary press
121 tablets/min
19.1 ms
3.16 ms
[0045] The lowering time and the holding time together are approximately equal to or somewhat longer than the time required in roll-to-roll processes (R2R) to hot-emboss diffractive microstructures in polymer films. Such R2R processes are used to produce holograms for bank note security and work with polymer feed rates of approx. 100 m/min. The polymer substrate, the process parameters and the temperature are optimized for good replication of the microstructure.
[0046] By analogy with that, the compression process in the method of this invention is adapted to the requirements of microstructuring. Most pharmaceutical pills have a round shape. This facilitates the production process because the compression die is rotationally symmetrical and can rotate freely during the compression process. For creating a diffractive microstructure, however, it is advantageous if rotation of the compression ram is prevented to reduce the resulting shearing forces, in particular during separation of the die from the tablet, because while the compression ram is moving away from the surface of the tablets, the tablet and the die surfaces may remain in contact for a short period of time due to elastic recoil.
Protecting the Microstructured Tablet Surface from Mechanical Damage
[0047] To protect the microstructure during the entire product life cycle from mechanical effects, in particular from abrasive forces, the contact between the microstructured surface and other surfaces can be minimized, for example, by arranging the diffractive microstructure 11 in a macroscopic recess 12 in the surface of the tablet 4 (see FIG. 3 a )).
[0048] Such macroscopic recesses 12 are customary with the conventional direct tableting process. They are mainly used for marketing purposes to show, for example, the logo of the company, and the like. If the recess 12 is deep enough and small enough so that the sharpest edge of another pill cannot touch the microstructured surface (see FIG. 3 a )), then the diffractive structure is well-protected from mechanical damage. No abrasion may occur in collecting containers, sorting machines or storage bottles. Recesses that are not as deep do not offer as much protection, but are occasionally unavoidable due to design requirements.
[0049] Alternatively or additionally, the microstructured tablets may be coated with an additional protective layer without destroying the diffractive effect, assuming the protective layer is transparent in the visible spectral range and has a refractive index that does not correspond to that of the material carrying the microstructure. Such a coating likewise protects the diffractive microstructure. If the refractive index of this coating is higher, the thickness is below 1 μm and the grating period of the microstructure is less than 500 nm, then diffractive color effects of the zero order may be achieved. These color effects are extremely counterfeit-proof and are easy to recognize.
Example of an Inventive Pharmaceutical Tablet with a Diffractive Microstructure
[0050] A powder mixture formulated according to Table 1 was compressed in a simple rotary press of the type 1200 i from the company Fette, Germany with 24 compression ram pairs to form tablets. The compression rams had a diameter of 11.8 mm and a hard chrome-plated surface. A diffractive microstructure with a period of 1.4 μm and a depth of approx. 500 nm was ionically etched into the hard chrome-plated surface (see FIG. 4( a )). Visible diffractive effects in tablets with a weight of 540 mg were achieved with a compression force of 25 kN and a production speed of 30,000 tablets per hour. FIG. 3 shows one of the tablets produced in this way. The diffractive microstructure produces a clearly visible inscription “CSEM.” The diffraction effects produced cannot be justifiably represented in the black-and-white photograph in FIG. 3 . The hardness of the tablet is 154 N, which is a satisfactory value with respect to the dissolvability of the tablet. FIG. 4 b shows an SEM micrograph of the microstructured surface of such a tablet. The diffractive microstructure is clearly visible.
Authentication of the Tablets of this Invention
[0051] If the tablets of this invention have a bright and/or luminous color, this strong background may make it difficult to recognize a rainbow effect in the diffractive microstructures. Because the usual powder components have a refractive index of approximately 1.5 in the visible spectral range, only a small percentage of the incident light on the tablet surface is reflected back in the first or higher diffraction orders. The angular distribution of the diffracted light is given by:
[0000] Λ(sin θ m −sin θ i )= mλ,
[0000] where θ m is the angle of reflection of the m-th diffraction order, θ i is the angle of incidence and λ is the wavelength of the light (see FIG. 2( a )).
[0052] Because diffraction effects of a higher order are weaker, detection of the typical diffraction pattern may not be entirely simple for a layperson. The deep reflected intensity is not a disadvantage, however, because strong diffractive color effects could irritate the end consumer. Many patients are afraid of strongly colored pills. On the other hand, the visibility of the diffraction effect can easily be increased by suitable lighting with an optimized angle of incidence. This makes the effect a so-called security feature of the second level. In the pharmaceutical industry, second- or third-level security features are widespread because the corporations do not necessarily want to reveal to their end consumers that counterfeiting is a problem. Under exposure from a white LED, for example, the rainbow effect of the diffractive microstructure lights up at a certain angle of observation. With some practice, a person can check for the presence of the diffractive microstructure in less than one second with the help of such a verification device.
[0053] Checking for the presence of a diffractive microstructure is a qualitative authentication. A rapid and simple method of quantitative checking of diffractive microstructures includes exposing the structures with the beam of a laser diode (for example λ=650 nm) at a fixed angle of incidence. The laser beam is diffracted in the various diffraction orders according to the formula given above. Because the laser wavelength λ and the angle of incidence θ i are known, the period Λ of the microstructure can be determined by measuring the diffraction angle of at least one order. This is done, for example, with the help of a portable reading device, which has a recess in which the pill is secured, ensuring a fixed angle of incidence of the laser beam (see FIG. 3( b )). The diffracted laser beams are collected by an array of photodiodes and the period of the microstructure is calculated on the basis of the positions of the diffracted rays. Such mobile reading devices may be used in pharmacies or by customs officials, for example.
Producing a Compression Die According to this Invention
[0054] To ensure a long lifetime, the material of the die carrying the microstructure must be very hard. At the same time, however, it must be possible to provide the microstructure in its surface. Suitable materials include, for example, hardened steel, hard chrome-plated steel, tungsten carbide or molybdenum carbide. All of these materials have been approved by the FDA and may be used for the compression rams or the compression molds. However, these materials are not compatible with the traditional holographic and lithographic techniques, but they can be microstructured by using other methods which are described below.
Ion Etching
[0055] Hardened steel, steel with a hard chrome coating, tungsten carbide or molybdenum carbide may be microstructured with a special ionic etching technique. This technique comprises the following steps, which are diagrammed schematically in FIGS. 5( a ) to 5 ( d ):
[0000] 1. A thin light-sensitive layer 20 , a so-called photo-resist, is applied to the microstructured surface of the compression die. In FIG. 5( a ), this is a compression ram 1 . The coating is performed in a special room without blue radiation or UV. Suitable photoresist materials include, for example, ma-N440 (MRT) Microposit S1800 (Röhm & Haas) and AZ1500 (Clariant). The optimal thickness of layer 20 is in the range of 300 nm to 2000 nm. If the die is secured appropriately, the coating may be applied by spin coating (Convac 1001s) or by spray coating (EFD MicroCoat MC780S). The latter must be optimized for good homogeneity in the desired thickness range. After coating, the layer is hardened for 1-60 minutes, depending on the thickness and the material of the layer at 100° C. to 120° C., a so-called soft bake.
2. As the next step, the photoresist layer 20 is exposed using two interfering laser beams 21 in a holographic exposure (see FIG. 5( a )). Crossed gratings are implemented by two orthogonal exposures. The integrated performance is controlled by a photodiode and depends on the photoresist material and the desired grating parameters. The laser is, for example, an HeCd laser with a wavelength of λ=441.6 nm. Depending on the angle of incidence Θ of the two beams as well as the optical components of the holographic setup used, grating periods Λ of 270 nm to 16,000 nm are possible, Λ=λ/(2n sin Θ), where n is the refractive index of the material through which the laser beams expose the photoresist surface. If the exposure takes place in air, then n=1. Shadow masks may be used to define the shape of the grating surface. This makes it possible, for example, to implement logos, trademarks, etc.
3. After the exposure, the photoresist layer is developed in a suitable developing solution. For example, the basic developer S303 (Microposit) or concentrate (Microposit) may be used for this purpose. The developing time depends on the grating parameters to be established. Immediately after developing, the die is placed in a stop bath with pure water. The temperatures of the two baths are 30° C. and are monitored at ±0.2° C. At the end of the developing step, the photoresist layer on the pill compression die has a grating with the desired period and depth (see FIG. 5( b )). The shape may be sinusoidal, as already shown, or may be more complex.
4. To be able to dry etch the grating in the die surface, a contrast of at least 2:1 must be achieved in the etching rate. This is achieved by applying a metal hood, preferably a chromium hood with a bulk thickness of 10 nm to 200 nm to the elevated sides of the grating to which the photoresist layer 20 is applied. The optimal thickness depends on the grating depth and period. The tablet compression die with the developed photoresist layer 20 is arranged in a vacuum chamber (Balzers BAK550) so that the vaporized atoms are unable to reach the recesses in the grating. This oblique sputtering is diagrammed schematically in FIG. 5( b ). The angle of incidence α of the metal atoms here is between 3° and 45°, depending on the grating depth and period. If necessary, oblique sputtering is performed from two or more sides to form symmetrical metal caps.
5. Then the photoresist layer 20 is opened, thus forming a mask 22 . As shown in FIG. 5( c ), the parts of the polymer resist layer are then etched with O 2 plasma (Oxford RIE) without chromium caps. The kinetic energy of the reactive oxygen ions is in the range of 500 eV. The etching rate also depends on the pressure in the vacuum chamber. The end of this opening step is defined by an end point detection system, which is based on laser interferometry.
6. The opened mask 22 is then used to transfer the grating structure 11 into the die surface by another dry etching step. This etching into the hard surface of the pill compression die is performed by bombarding it with argon ions (Veeco RF 350) with a kinetic energy on the order of magnitude of 500 eV. At 500 eV, the energy is low enough to prevent a great depth of penetration of the source ions into the sample but without reducing the etching rate. Table 4 shows typical etching rates r for such an argon bombardment at an ionic current density of 1 mA/cm 2 , a kinetic energy of the ions of 500 eV and with perpendicular bombardment for various elements and compounds.
[0000]
TABLE 4
Element
Argon etching
or compound
rate r (nm/min)
Al
73
C
4.4
Cr
58
Cu
110
Fe
53
Mo
54
Ni
66
Si
38
SiC
35
SiO 2
40
Ta
42
TaC
10
Ti
38
V
37
W
38
Zr
62
[0056] If the desired grating depth has been reached, the remaining chromium and photoresist material are removed, leaving behind the finished microstructured surface of the inventive compression die (see FIG. 5( d )).
[0057] For an inexpensive production of the diffractive microstructures on the inventive compression dies, several such dies are produced in parallel in the most time-consuming steps, namely oblique sputtering and dry etching.
[0058] With the previously mentioned ionic etching method, coated compression dies can also be microstructured, for example hard chrome electroplating. FIG. 4( a ) shows an illustration of an inventive compression ram 1 ( a ) with a hard chrome electroplated surface. According to the method described above, a diffractive microstructure 11 is created in the surface. FIG. 4( b ) shows an SEM micrograph of the microstructured surface of a tablet pressed using this compression die.
Embossing
[0059] Another method of creating a diffractive microstructure on an inventive compression ram includes hammering the desired microstructure into the surface of the inventive compression die by an embossing method using a main die. This main die can be microstructured with the ionic etching method described above.
[0060] It is known that macroscopic structures, such as chassis numbers or brand names can be hammered into metal. In the smallest case, such structures are typically a few millimeters in size. The required precision in structuring is low because the only requirement is that the numbers and letters must be legible. Hammering diffractive microstructures with periods on the order of 1 μm into inventive compression dies is of course much more complicated. The required precision is very high in order to obtain the interference effect in the microstructures. In addition, the microstructures are smaller than the internal structures of metals (grain size) and the dies are made of very hard metal alloys.
[0061] To facilitate an understanding of this method, a few characteristic mechanical properties of metals are summarized below. Metals tend to have a high melting point because of the strength of the metallic bond. The bond strength varies from one metal to the next and depends on, among other things, the number of electrons which each atom releases into the so-called free electron gas. In addition, it depends on the packing density. Each metal consists of a plurality of individual grains and/or crystallites, such as perfectly ordered microcrystalline regions. The average diameter of such grains is typically between 10 μm and 100 μm. The atoms at the grain boundaries, also known as dislocations, are also improperly aligned. Special treatments allow larger grain sizes and thus harder metals.
[0062] If a low mechanical stress acts on a metal, individual metal layers begin to slide over one another. As soon as the stress is removed, the atoms fall back into their original position, elastic deformation. If the stress is greater, the atoms slide into a new position and the metal is permanently deformed, plastic deformation. The movement of the dislocations causes a limited number of atomic bonds to be broken. The force required to break the bonds of all the atoms in a crystal plane simultaneously is very high. The movement of the dislocations, however, allows the atoms in crystal planes to slide by one another with much lower stresses. The energy required for such movement is the lowest along the densest crystal planes, so the dislocations within a metal grain have a preferred direction of movement. This leads to sliding dislocations along parallel planes within the grain. The diameter of such sliding lines is typically in the range of 10 nm to 1000 nm. The sliding lines are grouped and form sliding line stripes. The latter are visible even under an optical microscope. As described below, the sliding lines and sliding line stripes support the replication of microstructures. The displacement of atomic layers over one another is hindered by grain boundaries, which can be attributed to an unsuitable constellation of rows of atoms. Thus, the more grain boundaries there are in a piece of metal, for example, the smaller the individual crystal grains, the harder is the metal. The grain boundaries are regions where the atoms are not in good contact with one another, so metals tend to break at grain boundaries. The metal is thus not only harder due to the increase in the number of grain boundaries but also becomes more breakable.
[0063] The harder a metal, the more difficult it is to shape. Table 5 lists the Vickers hardness (HV), the material density ρ and the modulus of elasticity or Young's modulus E for various materials, not only metals and alloys.
[0000]
TABLE 5
Hardness
σ y
σ u
Material
ρ (g/cm 2 )
(HV)
E (GPa)
(MPa)
(MPa)
Diamond (C)
3.52
10,060
1000
—
—
Polycrystalline
2.8-4.1
3000-12,000
150-800
—
—
diamond/diamond-like carbon
DLC (C)
Cubic boron nitride (c-BN)
3.48
4500
680
—
50
Silicon carbide (SiC)
3.22
3300
480
—
140
Boron carbide (B 4 C)
2.5
3200
450
—
380
Titanium carbide (TiC)
4.93
3200
460
—
330
Vanadium carbide (VC)
5.4
2940
420
—
—
Aluminum nitride (AIN)
3.2
2500
350
—
500
Tungsten carbide (W 2 C)
15.6
2400
≈700
—
530
Titanium nitride (TiN)
5.22
2100
260
—
—
Corundum (Al 2 O 3 )
3.97
2060
≈400
—
320
Molybdenum carbide (Mo 2 C)
8.2
1950
550
—
—
Tantalum carbide (TaC)
13.9
1800
≈340
—
—
Silicon nitride (Si 3 N 4 )
3.2
1400-1700
≈340
—
580
Zirconium oxide (ZrO 2 )
5.6
1400-1600
240
—
1000
Chromium (Cr)
6.9-7.2
750-1050
289
360
690
Hardened nickel
7.9-8.1
600-950
214
—
—
Hardened steel
≈7.8
500-900
190-214
520
860
Nickel
8.91
550
214
940
1010
Unhardened steel
≈7.8
100-500
190-214
365
900
Aluminum
2.7
25
≈70
260
290
[0064] The modulus of elasticity does not depend on the degree of hardness. The hardness is a measure at which plastic deformation begins due to mechanical stress. Young's modulus E=dσ/dε is the slope of the linear portion of the stress-strain curve σ(ε). FIG. 6 shows an example of such a curve for a ductile material such as steel. The greater the resistance of a material to elastic deformation, larger is the value of Young's modulus. Plastic deformation takes place above the elastic limit ( 40 ). The yield point σ y measures the resistance to plastic deformation. Any increase in stress above the yield point ( 40 ) causes permanent deformation of the material. In this so-called flow zone, deformation is relatively great even with a slight increase in stress. This process, which is often characterized by a very low slope of the stress-strain curve, is often referred to as “perfect plasticity.” After flowing, this stress is increased up to the breaking strength or ultimate tensile stress σ u at which the material breaks ( 41 ). In the case of breakable materials, the flow zone practically does not exist at all. Breakable materials in comparison with ductile materials often have a relatively high Young's modulus and ultimate tensile stress. Table 5 lists the maximum values for σ y and σ u . All the values in Table 5 are merely reference values. The data from proper samples may deviate from this considerably. Values of coatings of such materials depend on the process parameters and the growth mechanism, among others.
[0065] To be able to hammer a diffractive microstructure with a main die into an inventive compression die, the following prerequisites are met:
[0066] 1. The hardness of the main die is greater than that of the compression die.
[0067] 2. Young's modulus is as high as possible for both in order to minimize the elastic deformation.
[0068] 3. The applied stress must be higher than the yield point but lower than the ultimate tensile stress of the compression die. Furthermore, it must be lower than the yield point, if any, and the ultimate tensile stress of the main die.
[0069] If necessary, the compression mold or its surface may be hardened after hammering in the microstructure by a subsequent heat treatment or ion implantation.
[0070] FIG. 8 shows schematically how the microstructures of the main die in the embossing step are replicated by filling the cavities through the sliding planes in the metal grains on the compression die.
[0071] To be able to microstructure a compression die with an electroplated hard chrome surface, a main die of tungsten carbide, for example, is necessary and an embossing force of approximately 400-500 MPa is required. As an alternative to that, the main die may also be made of hardened steel with a coating of tungsten carbide, Si 3 N 4 or ZrO 2 , for example, which carries the microstructure. The latter embodiment is less expensive because only the coating must be made of the very hard and fracture-resistant material.
[0072] FIG. 7 shows an example of a microstructure produced with such an embossing method on a metal surface. A block of aluminum 61 with a thickness of approximately 4 mm was microstructured using a round nickel shim 60 with a diameter of approximately 12 mm. The nickel shim 60 is resting on the metal block 61 in FIG. 7 . The shim 60 has a diffractive grating with a period of 1400 nm and a depth of approx. 300 nm which shows the four letters CSEM in mirror image. The shim 60 was pressed onto the aluminum block for approximately 0.5 sec under a pressure of 3 tons at room temperature. As FIG. 7 shows, the diffractive microstructure was reproduced well on the aluminum block.
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A tablet ( 4 ) for pharmaceutical use has on at least one part of its surface a diffractive microstructure ( 11 ) which generates diffraction effects which can be perceived in the visible spectral range and which serve as visual safety feature. The tablet ( 4 ) consists of a plurality of individual powder particles, where the diffractive microstructures ( 11 ) are impressed into the surface of the individual powder particles. A compression tool ( 1, 1 a, 1 b, 3 ) to produce such tablets ( 4 ) has on one pressing surface of the compression tool ( 1, 1 a, 1 b, 3 ) micro-structures ( 11 ), where said microstructures ( 11 ) have dimensions which are smaller than the dimensions of the individual crystallites ( 30 ) of the material of the pressing surface of the compression tool ( 1, 1 a, 1 b, 3 ). The micro-structures ( 11 ) of the compression tool can be produced for example by ion etching or by imprinting.
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This application is a continuation of application Ser. No. 08/203,207 filed Feb. 28, 1994, now U.S. Pat. No. 5,540,860.
FIELD OF THE INVENTION
The present invention relates generally to a process for preparing copper pyrithione and, more specifically, to a process for preparing a gel-free dispersion of copper pyrithione using surfactants.
BACKGROUND OF THE INVENTION
Pyrithione salts are well-known salts useful in a wide variety of applications. Heavy metal salts of pyrithione, including zinc, tin, cadmium and zirconium, as well as the magnesium and aluminum salts, in the form of flat platelets suitable for use in shampoo, are disclosed in U.S. Pat. Nos. 4,345,080 and 4,323,683. For example, paints containing a pyrithione salt (e.g. zinc or sodium pyrithione) plus a copper salt (e.g. cuprous oxide or cuprous thiocyanate) are known in the art, as disclosed, for example, in U.S. Pat. No. 5,057,153. U.S. Pat. No. 5,185,033 describes a process for making a paint or paint base containing copper pyrithione or pyrithione disulfide plus cuprous oxide, wherein the paint exhibits stability against gelation during storage. U.S. Pat. No. 5,246,489 discloses a process for providing in situ generation of copper pyrithione in a paint or paint base which comprises incorporating a metal salt of pyrithione, cuprous oxide and a controlled amount of water into the paint either during or after the formation of the paint.
Copper pyrithione itself is now being considered for use in supplementing or supplementing or supplanting zinc pyrithione in view of the fact that copper pyrithione is more favored from a low-toxicity standpoint and provides stability against gellation in products such as paint during storage prior to use. However, seemingly straight-forward processes for producing copper pyrithione, such as by contacting an aqueous solution of any water soluble copper salt with an aqueous solution of sodium pyrithione, have now been found to provide a gelled precipitate of copper pyrithione. The gelled precipitate exhibits poor flowability characteristics, causing processing problems such as flowability and filterability difficulties for the gelled copper pyrithione.
New processes for producing copper pyrithione while avoiding this gellation or thickening problem during production of the copper pyrithione solution or dispersion, would be highly desired by the biocides manufacturing community. The present invention provides are such solution.
SUMMARY OF THE INVENTION
In one aspect, the present invention relates to a process for producing a solution or dispersion of gel-free copper pyrithione which comprises reacting, in an ion-exchange reaction, a reaction mixture comprising a copper salt, a pyrithione salt, and said carrier, to produce said solution or dispersion, said reaction being carried out in the presence of a stabilizing effective amount of at least one surfactant (preferably at least two surfactants), the total amount of said surfactant being sufficient to prevent or inhibit the formation of gels or thick thixotropic precipitate in said carrier.
In another aspect, the present invention relates to a gel-free product produced by a process comprising reacting, in an ion-exchange reaction, a reaction mixture comprising a copper salt, a pyrithione salt, and said carrier, to produce said solution or dispersion, said reaction being carried out in the presence of a stabilizing effective amount of at least one surfactant (preferably at least two surfactants), the total amount of said surfactant being sufficient to prevent or inhibit the formation of gels in said carrier.
In yet another aspect, the present invention relates to a process for producing a gel-free dispersion or solution of copper pyrithione employing at least one surfactant. Also claimed is the dispersion or solution itself, as well as a solid particulate copper pyrithione composition comprising copper pyrithione particles having a particle shape selected from the group consisting of rods, spheres, needles, platelets and combinations thereof, and optionally containing at least a trace amount of a surfactant on the outer surface of at least a portion of said particles.
These and other aspects will become apparent upon reading the following detailed description of the invention.
DETAILED DESCRIPTION OF THE INVENTION
It has now been surprisingly found, in accordance with the present invention, that a solution is provided to a problem that occurs when carrying out an ion-exchange reaction of a copper salt with a pyrithione salt in water or an organic carrier in order to produce copper pyrithione, namely the problem of the formation of a gelatinous copper pyrithione product. The present inventors have solved this problem utilizing surfactant(s) to provide gel-free copper pyrithione in the carrier.
Without wishing to be bound by any particular theory, the efficacy of the surfactant(s) employed in the process of the present invention, in overcoming or avoiding the above-described gellation or thickening problem, is believed by the present inventors to be attributable to the chemical affinity between the copper pyrithione molecule (a polar molecule) and the molecules of surfactant. It is believed that this affinity reduces or eliminates the propensity of the copper pyrithione molecules to hydrogen-bond to each other, thereby reducing or eliminating agglomeration of the copper pyrithione molecules in the form of human eye-visible gelatinous bodies, or agglomerates in the carrier medium (therein after referred to as "gels").
In accordance with the process of the present invention, a reaction is carried out between a copper salt and a pyrithione salt, in an aqueous or organic carrier medium, in the presence of a surfactant. Suitable pyrithione salts are those which are soluble in the organic or aqueous carrier, such as, for example, the alkali metal or alkaline earth metals, such as sodium, calcium, potassium, and magnesium salts of pyrithione, pyrithione acid, or the non-metal salts such as the ethanolamine salt, chitosan salt, and the disulfide salt of pyrithione (which is commercially available as OMADINE MDS). The pyrithione salt is preferably employed in an amount of between about one and about 40 (more preferably between 5 and 25, most preferably between 15 and 25) weight percent, based upon the weight of the reaction mixture.
The copper salt is suitably any salt containing copper that is soluble in the carrier employed in the reaction. For example, if water is the carrier, useful copper salts include copper chloride dihydrate, copper sulfate, copper carbonate, copper nitrate, and copper acetate, as well as combinations thereof. The copper salt is preferably employed in an amount of between about one and about 50 (preferably between 5 and 30, more preferably between 15 and 20) weight percent, based upon the weight of the reaction mixture.
Useful carriers include water, organic solvents, and combinations thereof. Useful organic solvents include alcohols, such as methanol, ethanol, amines such as diethanolamine, ether, esters, and the like.
The surfactant(s) employed in the process of the present invention are suitably selected from the classes of surfactants known as nonionics, anionics, cationics, and amphoterics (the latter being also commonly referred to as "zwitterionics"). The surfactants are suitably employed singly, or in combinations of two, three, or even four surfactants selected from the above-mentioned four classes of surfactants. When use singly, nonionics are preferred, although the anionic surfactants were also found to provide good results. Although less preferred when employed as the sole surfactant, the cationics and amphoteric surfactants provided an improvement in reducing the extent of the gelation problem during production of the copper, as compared to copper pyrithione prepared without employing any surfactant.
Useful nonionic surfactants include linear alcohol alkoxylates, such as the linear alcohol ethoxylates, ethyoxylated/propoxylated block copolymers, ethyoxylated/propoxylated fatty alcohols, and polyoxyethylene cetyl ethers, and the like. Useful linear alcohol alkoxylates are commercially available, for example, under the registered trademark POLY-TERGENT SL-42, a product of Olin Corporation. If desired, the alcohol alkoxylate is suitably end-capped with a lower alkyl group, and such a product is commercially available as POLY-TERGENT SLF-18, a propylene oxide-capped linear alcohol alkoxylate that is also a product of Olin Corporation, and these end-capped linear alcohol alkoxylates are notably low foaming during use. Also advantageous for use in accordance with the present invention are surfactants within the group commercially available as POLY-TERGENT SLF-18B series surfactants, which are surfactants characterized by enhanced biodegradability (also products of Olin Corporation), being alkene oxide-capped linear alcohol alkoxylates, containing ethylene oxide moieties in the backbone, and suitably also containing at least one propylene oxide moiety in the backbone, as disclosed, for example, in U.S. Pat. Nos. 4,925,587 and 4,898,621.
Other useful nonionic surfactants include one commercially available as NEODOL 91-6, a trademarked surfactant product of Shell Chemical. This surfactant is a detergent range mixture of C9-C11 linear primary alcohol ethoxylates having an average of six moles of ethylene oxide per mole of alcohol. Other useful nonionic surfactants include those containing a linear C9-C11 carbon chain and five or six ethylene oxide or propylene oxide groups per molecule.
Useful anionic surfactants include alkyl diphenylether disulfonates, alkyl phenyl ethoxylated phosphate esters, carboxylated linear alcohol alkoxylates, linear alkyl benzene sulfonic acid, diisobutyl sulfosuccinate, and alkyl sulfonates. Particularly useful anionics are the alkylated diphenyl oxide sulfonates, and their methods of preparation are well-known, as illustrated by the disclosures of U.S. Pat. Nos. 3,264,242; 3,634,272; and 3,945,437, the disclosures of which are all incorporated herein by reference. Commercial methods of preparation of the alkylated diphenyl oxide sulfonates generally do not produce species which are monoalkylated, monosulfonated, dialkylated or disulfonated. The commercially available species typically are predominately (greater than 90 percent) disulfonated and are a mixture of mono- and di- alkylated with the percentage of dialkylation being about 15 to about 25 percent, and the percentage of monoalkylation being about 75 to 85 percent. Most typically, the commercially available species are about 80 percent monoalkylated and 20 percent dialkylated.
Two illustrative commercially available solutions containing alkylated diphenyl oxide sulfonate surfactants are DOWFAX 8390 and DOWFAX 8390A surfactants, trademarked products of The Dow Chemical Company. In each, the alkyl group is predominantly a hexadecyl C-16 group. These products are suitably employed in a solution fully or partially neutralized with ammonium hydroxide if desired.
An advantageous anionic surfactant is also provided by reacting the above-described alkylated diphenyl oxide sulfonates with a piperazine compound to produce a molar ratio of sulfonate compound to piperazine compound of between about 10:1 and about 1:10, preferably between about 2:1 and about 1:2. Although any piperazine compound can be used for such reaction, preferred compounds include those selected from the group consisting of 1,2-aminoethyl piperazine, 1,4-piperazinediethane sulfonic acid, anhydrous piperazine, hydrated piperazine, and combinations thereof.
Other useful anionics are polycarboxylated alcohol alkoxylates, preferably those selected from the group consisting of the acids or organic or inorganic salts of the following: polycarboxylated linear alcohol alkoxylates, polycarboxylated branched alcohol alkoxylates, polycarboxylated cyclic alcohol alkoxylates, and combinations thereof. These polycarboxylated alcohol alkoxylates typically contain at least two succinic acid radicals per molecule. Preferred polycarboxylated alcohol alkoxylates are those having a backbone containing both poly(propylene oxide) and poly(ethylene oxide) blocks, and such preferred polycarboxylated alcohol alkoxylates are readily commercially available, for example, as POLY-TERGENT CS-1, a trademarked surfactant of Olin Corporation. If desired, at least a portion of the acid groups on the polycarboxylated alcohol alkoxylate are neutralized with a base to provide the corresponding salt. Suitable bases include alkali metal hydroxides, alkaline earth metal hydroxides, and metal-free hydroxides, including potassium hydroxide, ammonium hydroxide, calcium hydroxide, magnesium hydroxide, ammonia, mono-, id- and tri-ethanol amines, and combinations thereof. Sodium hydroxide is preferred, and although potassium hydroxide can be employed, it is not preferred. The organic or inorganic base is preferably employed in at least an equimolar amount relative to the number of moles of polycarboxylated alcohol alkoxylated used. The polycarboxylated alcohol may also contain a polycarboxylic acid, for example, polyacrylic acid, along with the starting alcohol alkoxylate and esters of the alkoxylate of the polycarboxylic acid.
Although individually the cationic and the amphoteric surfactants are acceptable for use in the process of the present invention, it is preferred that they be used in combination with at least one surfactant from one of the other classes. Illustrative cationics include alkyl triammonium halide, non-linear alkyl dimethyl halide and alkyl dimethyl benzyl ammonium halide-containing surfactants. Illustrative amphoteric surfactants include polyglycol ether derivatives, ethoxylate oxazolin derivatives, lauramidopropyl betaine and lecithin.
Suitable blends can be employed in the process of the present invention based on various combinations of the above-described surfactants. Such a blend can be any combination of two or more surfactants, between or within the above-described four broad classes of surfactants. Combinations can include blends of: anionic with anionic, anionic with nonionic, anionic with cationic, artionic with amphoteric, cationic with cationic, cationic with amphoteric, nonionic with nonionic, nonionic with amphoteric, and amphoteric with amphoteric. Likewise, ternary and quaternary blends of surfactants by selecting three or four surfactants, respectively, from within or among the above-described classes.
Suitably, any single or combination of two, three or four surfactants from the following illustrative list are suitably employed: (a) nonionics, including alkoxylated linear alcohols (such as POLY-TERGENT SLF-18 surfactant, a product of Olin Corporation), linear alcohol ethoxylates (such as NEODOL 91-8 surfactant, a product of the Shell Corporation), ethoxylated linear alkyl benzene (such as TRITON X-100 surfactant, a product of Union Carbide Corporation), and EO/PO block copolymers (such as POLY-TERGENT E-17A surfactant, a product of Olin Corporation); (b) anionics, including alkyl diphenyl ether disulfonates (such as POLY-TERGENT 2A1 surfactant, a product of Olin Corporation), alkyl phenyl ethoxylated phosphate esters (such as Wayfos M-60 surfactant, a product of Olin Corporation), carboxylated linear alcohol alkoxylates (such as POLY-TERGENT CS-1 surfactant, a product of Olin Corporation), linear alkyl benzene sulfonic acid (such as BIOSOFT S-130 surfactant, a product of Stepan Company), alpha-olefin sulfonates (such as BIO TERG AS-40 surfactant, a product of Stepan Company), dialkylsulfosuccinates (such as AROWET SC-75 surfactant, a product of Arol Chemical Products), and alkyl sulfates (such as STEPANOL SLS surfactant, a product of Stepan Company); (c) cationics including alkyl triammonium halides (such as CTAB surfactant, a product of VWR Scientific Inc.), polyoxyethylene cocoamine (such as MAZEEN surfactant, a product of PPG Industries), primary alkyl amines (such as ARMEEN surfactant, a product of Akzo Chemical Co.), dicoco dimethyl ammonium halide (such as JET QUAT surfactant, a product of Jetco Chemical Inc.), di-isodecyl dimethyl ammonium halides (such as AMMONYX K9 surfactant, a product of Stepan Company), and diethyl aminoethyl stearate (such as CERASYNT 303 surfactant, a product of ISP Van Dyke); and, (d) amphoterics, including polyglycol ether derivatives (such as ALBEGAL A surfactant, a product of Ciba-Geigy), ethoxylated oxazolin derivatives (such as ALKATERG T-IV surfactant, a product of Angus Chemicals), lauramide propyl betain (such as LEXAINE C surfactant, a product of Inolex Chemicals), lecithin (such as CANASPERSE surfactant, a product of Can Amoral), disoaium cocoamphodiacetate (such as MONATERICS surfactant, a product of Mona Industries), complex fatty amine salt (such as MAFO 13 surfactant, a product of PPG Industries), and cocoamine oxide (such as MACKAMINE CO surfactant, a product of the Mcintyre Group Ltd.).
The surfactant(s) is preferably employed in a total amount of between about 0.05 and about 10%, more preferably between about 0.1 and about 5, most preferably between about 0.5 and about 1.5% by weight, based upon the weight of the aqueous or organic solution of pyrithione salt employed.
The use of the surfactants in accordance with the process of the present invention provides a variety of advantages over trying to process gelled copper pyrithione, including easy processing, including drying and filtering, of the copper pyrithione, as well as shorter cycle times due to a shorter drying time and faster dewatering of the copper pyrithione than is possible in the absence of surfactant(s). In addition, it has been found that the milling of the product copper pyrithione is facilitated by the fact that a softer copper pyrithione product is obtained in the presence of the surfactant(s).
The reaction in accordance with the process of the present invention is suitably employed to provide the desired gel-free copper pyrithione. Suitable reaction times range from about one hour or less, up to about six hours or more. The reaction temperature is suitably between about 0° and about 100° Centigrade, preferably between about 25° and about 90° Centigrade, most preferably between about 65° and about 70° Centigrade. Suitable pHs for the reaction are between 1 and 12, preferably between about 3 and about 8, most preferably between about 4 and about 5.
The following examples are intended to illustrate, but in no way limit the scope of, the present invention.
Example 1--Preparation of Copper Pyrithione
A preferred process for carrying out the present invention entails the steps of: (1) charging alkali 2-mercapto-N-oxide solution into a reactor, (2) add the surfactant or blend of surfactants to the reactor, and (3) heat the reactor to an desired elevated temperature, and then slowly add the copper salt solution to the pyrithione/surfactant mixture in the reactor.
As an illustrative example, two hundred and forty grams of aqueous sodium 2-mercaptopyridine N-oxide (having a dry solids assay of 17.3 percent- also referred to herein as "sodium pyrithione") solution is charged into a 500 ml 4-neck, round-bottom flask reactor. A three-surfactant blend was prepared by mixing 25 grams of POLY-TERGENT 2A-1L anionic surfactant, 50 grams of POLY-TERGENT SLF-18 nonionic surfactant, and 37.5 grams of nonionic TRITON X-100 nonionic surfactant (all three surfactants being commercially available surfactants utilized "as received"). Two grams of the surfactant mixture was added to the flask with ongoing agitation for 20 minutes to insure proper mixing of the surfactant blend with the sodium pyrithione solution in the reactor. The reactor was then heated up to 70 degrees Centigrade over a period of between 40 and 60 minutes. A thermometer and pH probe were then inserted into the reactor, and a copper chloride-containing feed hose was connected to the reactor. The copper chloride (a 20% aqueous solution comprising 24.4 grams of solid copper chloride dihydrate) was slowly added to the heated reactor at an addition rate of 2 ml/minute. The reaction mixture was continuously stirred, the pH of the mixture was monitored until the pH reached about 4, and the sodium pyrithione in the flask was assayed until it reached 0.0% indicating that the reaction was complete. A constant temperature of 70 degrees Centigrade was maintained throughout the reaction.
Once the reaction was complete, stirring was continued for 30 minutes, and the product mixture was allowed to cool to a temperature of about 50 degrees Centigrade by standing in the lab. The resulting copper pyrithione product had a viscosity of 150 to 250 centipoise, and was easily filtered. Filtration was completed in less than 30 seconds. The resulting copper pyrithione cake was washed with cold water until the filtrate is free of ions and measures less than 1000 in a conductivity measurement. The cake was weighed and dried in an oven at 70 degrees Centigrade. About 40 to 44 grams of copper pyrithione was produced which is equivalent to almost 100% of theoretical with a copper pyrithione purity of above 98%.
The shape of dried particles of pyrithione was examined under a microscope and found to be of a needle shape, and the mass of dried needles was found to have a relatively narrow particle size distribution. By varying the types of surfactants employed, it was found that non-needle "platelets" are produced having a more symmetrical crystalline shape. The platelets are expected to be an advantageous form for use in products such as paints and personal care products (e.g., soaps, shampoos and skin care medicaments) due to the increased surface area associated with platelets, affording enhanced biocidal protection relative to the needle configuration. The platelets are also an advantageous configuration for copper pyrithione since such particles tend to provide favorable bulk density, dispersibility and/or ease of milling for subsequent processing prior to use. Advantageously the platelets will have a mean sphericity of less than about 0.65 and a median equivalent spherical diameter based on volume of at least about 2 microns but less than 15 microns.
As a comparison, when an identical procedure was conducted in the absence of surfactant, a visually gelatinous copper pyrithione product was produced that was difficult to filter, difficult to dry and difficult to handle due to its high viscosity.
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The present invention relates to a process for producing a gel-free dispersion or solution of copper pyrithione employing at least one surfactant. Also claimed is the dispersion or solution itself, as well as a solid particulate copper pyrithione composition comprising copper pyrithione particles having a particle shape selected from the group consisting of rods, spheres, needles, platelets and combinations thereof, and optionally containing at least a trace amount of a surfactant on the outer surface of at least a portion of said particles.
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FIELD OF THE INVENTION
The present invention relates to a semiconductor memory device and a manufacturing method thereof. More particularly, it relates to the structure of a cell of a static random access memory (SRAM) device.
BACKGROUND OF THE INVENTION
The conventional circuit of a cell of a static random access memory (SRAM) device is well known. It has two access transistors, two driver transistors (also known as "pull-down" transistors), and two load elements.
Three types of load elements are typically used in the conventional SRAM cell. These are: i) a depletion-type NMOS transistor; ii) a high-resistance polysilicon; or iii) a PMOS transistor.
The SRAM devices constructed of a CMOS process typically have PMOS transistor load elements. The PMOS load element provides for a memory device with low standby current and power consumption. However, the use of a PMOS transistor as the load element significantly enlarges the two-dimensional area required by a single SRAM memory cell, because of the formation of six transistors in the cell.
A conventional CMOS SRAM cell with PMOS transistor load elements comprises two NMOS access transistors, two NMOS driver transistors, and two PMOS transistors formed together on a semiconductor substrate.
The conventional CMOS SRAM cell with high-resistance polysilicon load elements has only four transistors formed for each cell. The high-resistance polysilicon load element is conventionally formed above the two NMOS access and two NMOS driver transistors.
Conventional SRAM cells have also been formed with two PMOS thin film transistors (TFT) as load elements laid over the conventional structure of two NMOS access and two NMOS driver transistors. The conventional layout of the two access and two driver transistors is illustrated in FIG. 1. However, the conventional PMOS TFT structure does not reduce the required area of an SRAM cell beyond that which was required by the SRAM device which uses high-resistance polysilicon load elements.
A CMOS SRAM memory cell using PMOS TFT load elements is illustrated in an NEC paper by H. Ohkubo et al. in IEDM '91 entitled "16 Mbit SRAM Cell Technologies for 2.0 V Operation". In this paper, an insulating film is deposited to form the PMOS TFT load elements within the area occupied by the access and driver transistors, but the use of the PMOS TFT does not reduce the required area of the conventional SRAM memory cell. A reduction in the area of each cell is required to achieve a higher integration of memory in a single device.
FIG. 1 illustrates the layout of the access and driver transistors of a conventional SRAM cell, such as in the Ohkubo paper and a Fujitsu paper by Kazuo Itabashi et al., in IEDM '91, entitled "A Split Wordline Cell for 16 Mb SRAM Using Polysilicon Sidewall Contacts". The SRAM cell comprises two word lines forming the gates of the access transistors, and the gates of the driver transistors and word lines are formed from the same layer.
A more complicated structure of an SRAM cell was by A. O. Adan et al. at the 1990 Symposium on VLSI Technology, in a paper entitled "A Half-micron SRAM Cell Using a Double-gated Self-aligned Polysilicon PMOS Thin Film Transistor (TFT) Load". In Adan's paper, the gates of the two access transistors are formed with a single word line. However, this more complicated structure has disadvantageous features, such as a higher amount of bird's beak into the active regions, ultimately resulting in a less reliable device.
There are two word lines which interconnect the memory cells in a conventional SRAM device, both serially connected to adjacent memory cells. The gates of the driver transistors, the gates of the access transistors, and the word lines are all formed by patterning the same conductive layer. Because the gates of the driver transistors are located on the same layer but between the word lines, the minimum area of the memory cell is dictated by the minimum size of these common layer components.
Therefore, because the word line is formed from the same layer as the gate of the driver transistor, it is difficult to achieve further significant reductions in the size of the memory cell with the structure of the conventionally known SRAM device.
SUMMARY OF THE INVENTION
One object of the present invention is to provide an SRAM device wherein the gates of the access transistors are formed from a different conductive layer than that of the word lines.
Another object of the present invention is to provide an SRAM device in which the area occupied by the memory cell is minimized.
A further object of the present invention is to provide a manufacturing method suitable for carrying out the above objects.
The present invention achieves these objects by providing a structure of an SRAM device which, while utilizing PMOS TFT load elements, the gate of the access transistor is formed from a different layer than that of the word line. This allows for the resulting reduction in the size of the memory cell.
The word line of this invention is formed on an insulating layer which insulates it from the gates of the access transistors. The wordline is, however, electrically connected to the gates of the access transistors through contact holes formed in the insulating layer.
Each memory cell is arranged symmetrically with respect to an adjacent memory cell, and the components of each memory cell are symmetrical.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objects and other advantages of the present invention will become more apparent by describing in detail a preferred embodiment thereof with reference to the attached drawings in which:
FIG. 1 is a diagram of the layout of the conventional SRAM cell showing the gate of an access transistor and a word line formed from the same layer;
FIGS. 2 to 11 are diagrams showing the layout of a symmetrical pair of SRAM cells according to the present invention, wherein the gates of the access transistors and the word lines are formed from different layers;
FIGS. 12 to 21 are cross-sectional views taken along lines AA' of each of FIGS. 2 to 11, respectively, for illustrating the method for manufacturing the semiconductor memory device according to the present invention; and
FIGS. 22 to 31 are cross-sectional views taken along lines BB' of each of FIGS. 2 to 11, respectively, for illustrating the method for manufacturing the semiconductor memory device according to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will now be described in more detail, referring to the attached drawings.
Referring to FIGS. 2, 12 and 22, a pad oxide film (not shown) and a nitride film pattern (not shown) are sequentially formed on a semiconductor substrate 10. The substrate 10 is then oxidized by the nitride film pattern according to a conventional selective oxidation processes, using mask patterns 100 and 102, thus forming a field oxide film 12 defining a first active region and a second active region. The first active region is in the upper portion of the cell, and the second active region is in the lower portion of the cell. Thereafter, the nitride film pattern and the pad oxide film are removed.
The first and second active regions are symmetrical but offset to each other, and the active regions of adjacent memory cells are symmetrical. The components of the memory cells are also symmetrical to one another.
FIGS. 3, 13, and 23 illustrate the step of forming the first and second access transistors, and the first and second driver transistors.
A gate insulating film 13 is formed over the entire surface of the semiconductor substrate 10 where the field oxide film 12 is formed, for insulating the gates of the first and second access and first and second driver transistors. Then a conductive material, e.g., polysilicon or a lamination of polysilicon and silicide, is deposited over the gate insulating film 13 to form the first conductive layer (not shown). The first conductive layer is then patterned by a photo-etching process using mask patterns 110, 112, 114 and 116, forming the gate 14 of the first access transistor, the gate 16 of the first driver transistor, the gate 18 of the second driver transistor and the gate (not shown) of the second access transistors. The gate 14 of the first access transistor is disposed near the upper edge of each memory cell, extending across the first active region and connecting to the gate of the first access transistor of an adjacent memory cell. This pair of connected gates is separate from the gates of adjacent memory cells.
The gate 16 of the first driver transistor is disposed toward the center portion of each memory cell, extending across the first active region perpendicular to the gate 14 of the first access transistor.
The gate 18 of the second driver transistor is also disposed in the center portion of each memory cell, but parallel to the gate 16 of the first driver transistor. The gate 18 extends across the second active region.
The gate (not shown) of the second access transistor is disposed near the lower edge of each memory cell, extending across the second active region and connecting to the gate of a second access transistor in an oppositely adjacent memory cell. These connected gates are separate from the gates of the other adjacent memory cells.
An impurity, e.g., phosphorus or arsenic, is then ion-implanted on the surface of the resultant substrate where the gates of the transistors are disposed, to form i) the source 20 and drain 22 of the first access transistor, ii) the source (not shown) and drain 20 of the first driver transistor, iii) the source and drain (not shown) of the second driver transistor, and iv) the source (not shown) and drain 24 of the second access transistor. The sources and drains of the individual transistors may be reversed with respect to one another.
The source 20 and drain 22 of the first access transistor, and the source and drain 20 of the first driver transistor are arranged in the first active region. The source 20 of the first access transistor and the drain 20 of the first driver transistor are in a common region.
The source and drain of the second driver transistor, and the source and drain 24 of the second access transistor, are arranged in the second active region. The drain of the second driver transistor and the source of the second access transistor are in a common region.
The layout of the conventional SRAM cell, as illustrated in FIG. 1, is formed such that the gates of the access transistors are respectively near the edge of the upper and lower parts of each memory cell, to connect to adjacent memory cells throughout the memory cell array. In the layout of the present invention, as illustrated in FIG. 3, the gate 14 of the first access transistor is connected to the gate 14 of a first access transistor of one adjacent memory cell, while the gate of the second access transistor arranged in the lower part of a memory cell is connected to the gate of a second access transistor in an oppositely adjacent memory cell. Each gate couples directly to the respectively adjacent memory cell, and to no others.
The structure of the present invention, with the gates of the access transistors connected to adjacent memory cells, reduces the area of the memory cell but does not change the circuit of the conventional SRAM memory cell.
Referring to FIGS. 4, 14 and 24, a first insulating layer 28 is formed over the entire surface of the resultant substrate. The first insulating layer 28 insulates the gates of the transistors from the word line formed in a subsequent process step. It is formed from a monolayer of an oxide film, e.g., a high-temperature oxide (HTO) film. An insulating material, e.g., boro-phosphor-silicate glass (BPSG), can be laid over the surface of the first insulating layer 28 to planarize it.
The first insulating layer 28 is then selectively removed by a photo-etching process using mask patterns 120, 122, 124 and 126 to form, respectively, a first, second, third and fourth contact hole. The first contact hole 1 exposes the first access transistor gate 14, the second contact hole exposes the first driver transistor source, the third contact hole exposes the second driver transistor source, and the fourth contact hole exposes the second access transistor gate.
Referring to FIGS. 5, 15 and 25, a second conductive layer (not shown) is formed by depositing a conductive material, e.g., polysilicon or a lamination of polysilicon and silicide, over the surface of the resultant substrate where the contact holes were formed. The second conductive layer is then patterned by a photo-etching process, using mask patterns 130, 132 and 134, to form the first word line 30, the first power supply line 32, and the second word lines 34, respectively.
The first word line 30 is connected to the first access transistor gate 14 through the first contact hole 1, and the second word line 34 is connected to the second access transistor gate through the fourth contact hole. The first power supply line 32 is connected to the first and second driver transistor sources through the second and third contact holes, respectively. In the present embodiment, the first power supply line 32 is ground.
As can be seen in FIG.15, the gates of first and second access transistors and the gates of the first and second driver transistors are disposed on the gate insulating film 13, and the first and second word lines 30, 34 are disposed on the first insulating layer 28.
The circuit of the conventional SRAM cell is accomplished by the present invention because the first and second word lines 30, 34 are respectively connected to the gates of the first and second access transistors. The gates of the access transistors are formed from the first conductive layer, while the word lines are formed from the second conductive layer, linking each separated pair of gates of access transistors.
Referring to FIGS. 6, 16 and 26, a monolayer of oxide film, e.g., the HTO film, is deposited over the entire surface of the resultant structure to form a second insulating layer 36. The surface of the second insulating layer 36 may be planarized with the lamination of BPSG as an insulating material.
The second insulating layer 36 is then selectively removed using a photo-etching process with mask patterns 140, 142, 144 and 146. The photo-etching process forms the fifth (not shown), sixth 2, seventh and eighth contact holes which expose, respectively, i) the first access transistor drain 22, ii) the second driver transistor gate 18 and first driver transistor drain, iii) the first driver transistor gate 16 and second driver transistor drain, and iv) the second access transistor drain 24.
The fifth contact hole (not shown) is for connecting a first pad 40 with the first access transistor drain 22. The sixth contact hole 2 is for connecting the second PMOS TFT gate 42 with the second driver transistor gate 18 and first driver transistor drain 20. The seventh contact hole (not shown) is for connecting the first PMOS TFT gate 44 with the first driver transistor gate 16 and second driver transistor drain, and the eighth contact hole 3 is for connecting a second pad 46 with the second access transistor drain 24. The mask patterns 140, 142, 144 and 146 are used for forming the respective fifth through eighth contact holes.
Referring to FIGS. 7, 17 and 27, a conductive material, e.g., polysilicon, is deposited over the entire surface of the resultant structure. The polysilicon is then patterned by a photo-etching process using mask patterns 150, 152, 154 and 156, thus forming the first and second pad 40, 46, and gates, 44 and 42 respectively, for the first and second PMOS TFT.
The first pad 40, disposed parallel to the first word line 30, is connected to the first access transistor drain 22 through the fifth contact hole. The first pad 40 contacts a first bit line formed in a subsequent step.
The second PMOS TFT gate 42, disposed parallel to the first pad 40, is connected to the second driver transistor gate 18 and the first driver transistor drain 20 through the sixth contact hole 2.
The first PMOS TFT gate 44, also disposed parallel to the first pad 40, is connected to the first driver transistor gate 16 and to either the second driver transistor drain or the first access transistor source 20 through the seventh contact hole.
The second pad 46, disposed parallel to the first pad 40, is connected to the second access transistor drain 24 through the eighth contact hole 3. The second pad 46 contacts a second bit line formed a subsequent step.
The first PMOS TFT gate 44 is formed perpendicular to the second driver transistor gate 18. The second PMOS TFT gate 42 is formed perpendicular to the first driver transistor gate 16.
Referring to FIGS. 8, 18 and 28, an oxide film, e.g., HTO, is deposited thinly over the entire surface of the resultant structure to form a gate insulating film 48 for the first and second PMOS TFTs. The gate insulating film 48 is then selectively removed by a photo-etching process using mask patterns 160 and 162 to form respectively a ninth contact hole 4 for exposing the second PMOS TFT gate 42, and a tenth contact hole for exposing the first PMOS TFT gate 44.
The ninth contact hole 4 is for connecting the first PMOS TFT drain with the first access transistor source 20, the second PMOS TFT gate 42, and the second driver transistor gate 18. The tenth contact hole (not shown) is for connecting the second PMOS TFT drain with the second access transistor source, the first PMOS TFT gate 44, and the first driver transistor gate 16.
Referring to FIGS. 9, 19 and 29, an amorphous silicon is deposited over the entire surface of the resultant structure and then patterned with a conventional photo-etching process using mask patterns 170 and 172, thus respectively forming the active regions of the first and second PMOS TFTs, and the second and third power supply lines.
An impurity, e.g., boron, is then ion-implanted over the resulting structure, excluding the areas corresponding to the channels of the first and second PMOS TFT. The channels are at the upper portion of the first and second PMOS TFT gates. The active region of the first PMOS TFT will then be divided into a drain 50, a source 52 and a channel 54, and the active region of the second PMOS TFT will also be divided into a drain, a source, and a channel.
A second power supply line 52, disposed parallel to the second word line 34, is connected to the first PMOS TFT source 52. The active region of the first PMOS TFT, disposed perpendicular to the second word line 34, is connected to the second power supply line 52. The third power supply line 56, disposed parallel to the first word line 30, is connected to the second PMOS TFT source (not shown), and the active region of the second PMOS TFT, disposed perpendicular to the first word line 30, is connected to third power supply wiring 56.
Referring to FIGS. 10, 20 and 30, a monolayer of oxide film, e.g., HTO, is deposited over the entire surface of the resultant structure to form a third insulating layer 60. The surface of the third insulating layer 60 may be planarized by laminating a BPSG insulating material over it.
The third insulating layer 60 is then selectively removed by a conventional photo-etching process using mask patterns 180 and 182, exposing the eleventh 5 and twelfth contact holes, respectively. The eleventh contact hole 5 is for exposing the surface of the first pad 40, and the twelfth contact hole is for exposing the surface of the second pad 46. The first bit line is connected to the first pad 40 through the eleventh contact hole 5, and the second bit line is connected to the second pad 46 through the twelfth contact hole.
Referring to FIGS. 11, 21 and 31, a metal, e.g., aluminum, is deposited over the entire surface of the resultant structure. The metal is then patterned by a conventional photo-etching process using mask patterns 190, 192 to form the first and second bit lines 62, 64, respectively.
The first bit line 62 contacts the first pad 40 through the eleventh contact hole 5, thereby contacting the first access transistor drain 22. The second bit line 64 contacts the second pad 46 through the twelfth contact hole, thereby contacting the second access transistor drain 24. The first and second bit lines 62, 64 are formed perpendicular to the first and second word lines 30, 34, respectively.
The present embodiment was described as having PMOS TFT load elements of a bottom-gate structure. PMOS TFT's with either a top-gate or a double-gate structure can be easily substituted within the scope and spirit of the invention.
It is apparent that modifications can be made by persons skilled in the art without departing from the scope and spirit of the invention.
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An SRAM memory cell structure is provided which has the access transistor gates formed from a different layer than that of the word line. The first access transistor gate of a first memory cell is connected to the first access transistor gate of an adjacent second memory cell, and a second access transistor gate of the first memory cell is connected to a second access transistor gate of an third oppositely adjacent memory cell. Each pair of coupled gates are formed separate from the access transistor gates in adjacent memory cells. The word lines connect the separated access transistor gates. The word lines are formed on an insulating layer above the gates of the access transistors. The word lines are, however, electrically connected to the gates of the access transistors through contact holes formed in the insulating layer. Each memory cell is arranged symmetrically with respect to an adjacent memory cell, and the components of each memory cell are symmetrical. Therefore, a structure and a method for a reduction in the area of an SRAM cell of the conventional circuit design is provided, resulting in a larger layout margin and a more reliable and more highly integrated SRAM device.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 10/539,658, filed on Jul. 11, 2005, which was a national stage filing under 35 U.S.C. § 371 of PCT/CH02/00708, filed on Dec. 17, 2002, the contents of which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The invention relates to an intervertebral implant and to a process for the replacement of a defect, natural intervertebral disk by an intervertebral implant.
[0003] After removal of a damaged, natural intervertebral disk or a damaged nucleus pulpous of an intervertebral disk, implants or prostheses are inserted into the intervertebral space of two neighboring vertebral bodies. This suggests the idea of restoring the situation as much as possible to a natural state, i.e. specifically to restore the original height of the intervertebral disk and thus the original distance between the two neighboring vertebral bodies. Furthermore, the patient should be able to carry out movements of the neighboring vertebral bodies relative to each other in the natural way, thereby incurring as little obstruction as possible. This essential feature of this system is its ability to retain the freedom of movement in forward/reverse inclination, i.e. flexion and extension of the vertebral bodies, and in lateral bending of the vertebral bodies within the natural limits. The natural sinews and muscles along the spinal column are in general left intact so that they further stabilize the movements of a mechanical intervertebral disk prosthesis.
[0004] A characteristic intervertebral disk endoprosthesis is state of the art from DE-A 35 29 761 BuTTNER. This known intervertebral disk endoprosthesis basically consists of two symmetric closing plates with concave sliding surfaces facing each other, and each having an external surface for laying on the base plate, or the cover plate of the adjoining vertebral body, and a distance piece positioned between the closing plates with convex sliding surfaces arranged complementary to the concave sliding surfaces on the closing plates. The sliding surfaces are designed in one embodiment as section surfaces of a cylinder coat area, wherein the sliding surfaces arranged on the two closing plates are provided complementary to each of the adjoining sliding surfaces at the distance piece, and two complementary sliding surfaces form the articulation surfaces, which can be moved towards each other, of a joint element rotating around a swivel axle. The joint comprises an upper and a lower joint element, each of which has one swivel axle. The two swivel axles are set at 90 degree to each other. The disadvantages of this known intervertebral disk endoprosthesis is that
a) the arrangement of an intervertebral disk endoprosthesis with only one fulcrum does not take sufficient account of the overlaying swivel movements transferred by the natural intervertebral disk, specifically in the anterior-posterior direction and in lateral flexion, which in the natural intervertebral disk are independent of each other; b) disadvantageous friction forces are generated by two articulating surfaces sliding on each other. This also leads to wear on the surfaces, including also abrasion and resistance in movement of the joint elements. There is also the risk of the “stick slip” effect; and c) a mechanical intervertebral disk prosthesis can scarcely prevent the further degeneration of the affected movement segments. Restoration of the original freedom of movement significantly reduces pain, with the resulting improvement to the patient's quality of life. A review of treatment will, however, have to be undertaken if pain recommences. This will normally involve complete removal of an intervertebral disk prosthesis of the standard model and a stiffening of the movement segment. This operation represents extreme discomfort and strain on the patient.
[0008] The invention is intended to remedy this situation. The invention is based on the task of creating an intervertebral implant that comprises a joint, the axles of which are provided with bearings with minimum friction.
BRIEF SUMMARY OF THE INVENTION
[0009] The invention solves the task with an intervertebral implant that has the features of claim 1 and with a process for replacing a defect, natural intervertebral disk by an intervertebral implant, comprising the steps of claim 23 .
[0010] The advantages achieved by the invention can generally be seen in that with the intervertebral implant according to the invention: the swivel movements in the anterior-posterior and the lateral direction are independent of each other; the friction surface of the movements on the total of four linear contacts is reduced to a minimum; and the linear contact between the joint sections instead of sliding surfaces reduces the friction forces in the joint and as a result relative movement among the vertebral bodies, specifically lateral bending and flexion/extension movement of the spinal column is not impaired.
[0011] In a further embodiment of the intervertebral implant according to the invention, two surfaces opposite each other or both pairs of surfaces opposite each other are formed as sliding surfaces for the circular-cylindrical rod(s). These sliding surfaces can thereby be formed as flat, circular-cylindrical or conical surfaces.
[0012] The advantages of the different realizations of the sliding surfaces can be found in: the flat sliding surfaces allowing the circular-cylindrical rods an unrestricted freedom of movement with an inclination of the neighboring vertebral bodies relative to each other and with regard to a translation movement of the neighboring vertebral bodies relative to each other; concave or specifically circular-cylindrical surfaces mean that sufficient account will be taken of the physiological tilting behavior of the neighboring vertebral bodies according to the movement segment of the spinal column; and tilted sliding surfaces allow correction of the lordosis or kyphosis to take place at the same time as the operation.
[0013] In a further embodiment of the intervertebral implant according to the invention the surfaces on the three plate-shaped sections arranged as sliding surfaces are provided with a peripheral perimeter as security for the rods. This arrangement achieves the advantage of the circular-cylindrical rods being protected by the perimeter against falling out or being squeezed out from the intermediate spaces between the three plate-shaped sections.
[0014] In a further embodiment of the intervertebral implant according to the invention, a number of limits/stops are provided for restricting the rotation of the cylindrical rods around the central axle at least on one section of the sliding surfaces. This arrangement allows the following advantages to be achieved: the rotation of the two rods is limited to a certain direction but with an angular freedom of movement; this direction can be set to anterior-posterior for the one rod and medio-lateral for the other rod; and it is prevented that the two rods are aligned parallel to each other, so that the joint of the implant would have two parallel swivel axles at a distance from each other and then the two vertebral bodies in the proximity of the intervertebral implant would be able to carry out only flexion/extension movements and no lateral bending or vice versa.
[0015] In another embodiment, a pair of grooves is provided on one or both of the sliding-surface pairs formed by the four sliding surfaces as a bearing for the first and/or second rod. Each pair of grooves is preferably congruent to the circular-cylindrical rods it has to bear. The advantage of this embodiment is that the positioning of the grooves ensures that the gradient of the neighboring vertebral bodies can only be strictly set in the specified directions, such as lateral slant, as well as flexion and extension. Transverse forces that could have an effect on the vertebral joints, can be collected by the intervertebral implant since no translation movements of the plate-shaped sections bordering on the vertebral bodies is possible.
[0016] In another embodiment, at least one pair of grooves is designed incongruent to the circular-cylindrical rods they have to bear and is preferably provided with a width that allows a restricted rotation of the rods around the central axle in the grooves. The advantage of this embodiment lies in the restriction is gives to the freedom of movement of the neighboring vertebral bodies with gradient. Translation is at the same time possible in a strictly lateral or strictly anterior-posterior direction.
[0017] In a further embodiment, at least one part of the grooves is provided with a limit/stop to prevent against axial shifting of the rod carried by the groove, which stop is attached on the periphery. The grooves preferably do not lead into the side surfaces of the plate-shaped sections but are closed at their ends. This will ensure that the circular-cylindrical rods cannot slip out of the grooves parallel to their longitudinal axes.
[0018] The one pair of grooves for the first rod runs preferably from the ventral to the dorsal side surfaces of the corresponding plate-shaped sections whereas the second pair of grooves for the second rod runs between the lateral side surfaces of the corresponding plate-shaped sections.
[0019] The anterior-posterior orientation of the longitudinal axis of the first rod and the lateral orientation of the longitudinal axis of the second rod results in a joint with crossed swivel axles. The grooves are preferably arranged in such a way that in one case the rod with the longitudinal axis oriented in an anterior-posterior direction is at the top and the rod with the longitudinal axis oriented in a lateral-lateral direction is below. The reverse is, however, also possible, which can take account of the circumstances that the individual movement segments of the spinal column are provided with naturally different axle positions.
[0020] Instead of by grooves, this orientation of the rods can also be carried out by arrangement of the limiters/stops.
[0021] In a further embodiment this comprises elastically malleable means that hold together the upper and the lower section with the intermediate central section and the two rods to each other. The elastically malleable means can be springs or elastomer connection elements.
[0022] In a further embodiment the four sliding surfaces and the two rods are made of metal.
[0023] In a further embodiment of the intervertebral implant according to the invention the four sliding surfaces are made of metal and the two rods are ceramic.
[0024] The following dimensions are suitable for the plate-shaped sections and the cylindrical rods: length of the circular-cylindrical rods: larger than half the expansion of the sliding surface coming in contact with the rod; radius of the circular-cylindrical rods: between 0.3 mm and 5.0 mm; cylinder radius of the sliding surfaces: between 12 mm and 140 mm; width of the grooves: between 3 mm and 12 mm; depth of the grooves: between 0.2 mm and 4.8 mm; and angle range of the admissible rotation of the circular-cylindrical rods around the central axle of the intervertebral implant: between 1 degree and 32 degree.
[0025] In a further embodiment of the intervertebral implant according to the invention, a means can be attached to the three plate-shaped sections from the ventral side areas which fixes the three plate-shaped sections ventral at a specific distance relative to each other. This measure provides the advantage that the three plate-shaped sections for insertion into the intervertebral space can be brought to a position with fixed implant height and can be moved around the joint after insertion into the intervertebral space and can be placed on the base or cover plate of the adjoining vertebral body.
[0026] In a further embodiment of the intervertebral implant according to the invention, the means allows temporary blocking of the mobility of the three plate-shaped sections around the joints. This measure provides the advantage that the joints integrated in the intervertebral space can be blocked by a minimum invasive operation. This is particularly advantageous in cases where the patient suffers from post-operative pain, i.e. where degeneration of the affected spinal column segment continues and the surgeon is considering a fusion of the affected vertebra. The means can preferably be attached to the ventral side areas of the three plate-shaped sections. With this subsequent, secondary blocking of the mobility of the three plate-shaped sections around the joints, the intervertebral implant is stiffened and transferred to an arthrodesis implant (fusion cage).
[0027] In a further embodiment of the intervertebral implant according to the invention, the means comprises an insert, which can be placed into each depression on the surfaces of the upper and lower plate-shaped section opposite each other. These depressions are preferably provided as dovetail guides that are open on the ventral side areas of the two external plate-shaped sections, so that the ends of the insert arranged complementary to the dovetail guides can be inserted from ventral into the dovetail guides. This provides the advantage that the mobility of the two plate-shaped sections around the joint is blocked due to the positioning of the insert. The rigidity of the blocking can be increased when the dovetail guides are designed so that they are reduced is size towards the central axis of the intervertebral implant, which creates additional wedging of the insert in the dovetail guides.
[0028] In a further embodiment of the intervertebral implant according to the invention, the two plate-shaped sections are provided with drill holes for receiving the bone fixation means, specifically bone screws, wherein the drill holes are provided with longitudinal axes that stand perpendicular to the central axis. Preferably two drill holes will pass through one of the two plate-shaped sections from the ventral side area to the apposition surface. The longitudinal axes, if only an axial fixing of the intervertebral implant is provided, will then be able to stand only perpendicular to the central axis from a lateral perspective, or, if fixing of the intervertebral implant with stable angle is provided, will also from a lateral perspective diverge from the inner surfaces of the two plate-shaped sections against the apposition surfaces.
[0029] In a further embodiment of the intervertebral implant according to the invention, the drill holes for receiving the bone fixation means are provided with internal threads, which allows additional, rigid fixing of the bone fixation means in the two plate-shaped sections. The drill holes preferably have a conical shape so that a stronger fixing of the bone fixation means to each of the two plate-shaped sections can be achieved by the resulting conical thread connections between the internal threads and the external threads on the heads of the bone fixation means.
[0030] The apposition surfaces are preferably of convex shape and provided with a three-dimensional structure, preferably in the form of pyramid elevations. This arrangement of the apposition surfaces takes account of the anatomy of the vertebral body end plates.
[0031] The process according to the invention is intended primarily for replacing a defect, natural intervertebral disk by an intervertebral implant and comprises the following steps:
A) blocking of the joint(s) of an intervertebral implant by means of a special device placed in a certain position of the joint; B) insertion of the intervertebral implant into the intervertebral space to be treated; C) release and removal of the device inserted into the intervertebral implant for blocking the joint. Blocking the joint provides the advantage that the moveable plate-shaped sections with the external apposition surfaces can be inserted more easily into the intervertebral space to be treated.
[0035] In a further application of the process according to the invention, this comprises the subsequent blocking of the joint on the implanted intervertebral implant by means of the device intended for blocking the joint. This provides the advantage that if the patient should suffer from post-operative pains or in case of a further degeneration of the movement segment, the joint on the intervertebral implant are blocked post-operative by the insertion of the means intended for this purpose. This subsequent blocking can be achieved with an minimally invasive, preferably a laparoscopic operation. The intervertebral implant then assumes the function of a cage, so that the affected movement segment of the spinal column can be stiffened.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] The invention and refinements of the invention are described in more detail below on the basis of a partially schematic illustration of several embodiments.
[0037] FIG. 1 shows an explosion diagram of one embodiment of the intervertebral implant according to the invention;
[0038] FIG. 2 a - 2 c shows three perspective illustrations of different embodiments of the sliding surfaces by the example of the lower plate-shaped section;
[0039] FIG. 3 a shows a view of an embodiment of the intervertebral implant according to the invention;
[0040] FIG. 3 b shows a section parallel to the second swivel axle of the embodiment of the intervertebral implant according to the invention illustrated in FIG. 3 a;
[0041] FIG. 4 shows an explosion drawing of a further embodiment of the intervertebral implant according to the invention;
[0042] FIG. 5 shows a section parallel to the second swivel axle of the embodiment of the intervertebral implant according to the invention illustrated in FIG. 4 ;
[0043] FIG. 6 shows an explosion drawing of a further embodiment of the intervertebral implant according to the invention;
[0044] FIG. 7 shows an explosion drawing of a further embodiment of the intervertebral implant according to the invention;
[0045] FIG. 8 a shows a view of the embodiment of the intervertebral implant according to the invention illustrated in FIG. 7 ;
[0046] FIG. 8 b shows a section parallel to the second swivel axle of the embodiment of the intervertebral implant according to the invention illustrated in FIG. 7 and FIG. 8 a;
[0047] FIG. 9 shows an explosion drawing of a further embodiment of the intervertebral implant according to the invention;
[0048] FIG. 10 a shows a view of the embodiment of the intervertebral implant according to the invention illustrated in FIG. 9 ;
[0049] FIG. 10 b shows a section parallel to the second swivel axle of the embodiment of the intervertebral implant according to the invention illustrated in FIG. 9 and FIG. 10 a;
[0050] FIG. 11 shows a perspective view of a further embodiment of the intervertebral implant according to the invention; and
[0051] FIG. 12 shows a perspective view of an embodiment of the intervertebral implant according to the invention in the implanted state.
DETAILED DESCRIPTION OF THE INVENTION
[0052] An embodiment of the intervertebral implant according to the invention 1 is illustrated in FIG. 1 that comprises with regard to the central axle 2 , arranged on top of each other, an upper section 10 , with a ventral, a dorsal and two lateral side surfaces 11 ; 12 ; 13 ; 14 as well as an upper apposition surface 15 and a lower surface 16 arranged perpendicular to the central axle 2 , a lower section 30 , with a ventral, a dorsal and two lateral side surfaces 31 ; 32 ; 33 ; 34 , and a lower apposition surface 35 and an upper surface 36 arranged perpendicular to the central axle 2 , and a central section 20 positioned between the upper and the lower section 10 ; 30 , with a ventral, a dorsal and two lateral side surfaces 21 ; 22 ; 23 ; 24 and towards the lower section 30 with a lower surface 25 and towards the upper section 10 an upper surface 26 . The three plate-shaped sections 10 ; 20 ; 30 are provided with an oval, elliptical, circular or polygonal cross-section surface orthogonal to the central axle 2 . The surfaces 16 ; 26 ; 25 ; 35 of the three plate-shaped sections 10 ; 20 ; 30 arranged facing each other in pairs are designed here as flat surfaces. A first circular-cylindrical rod 40 is inserted between the upper surface 26 of the central section 20 and the lower surface 16 of the upper section 10 . In addition, a second circular-cylindrical rod 50 is inserted between the lower surface 25 of the central section 2 and the upper surface 36 of the lower section 30 . The two circular-cylindrical rods 40 ; 50 are arranged between the surfaces 16 ; 26 ; 25 ; 36 so that their longitudinal axes 41 ; 51 are standing vertically to the central axle 2 . The circular-cylindrical rods 40 ; 50 arranged between the surfaces 16 ; 26 ; 25 ; 36 lead to the upper section 10 being able to rotate relative to the lower section 30 around the longitudinal axes 41 ; 51 of the circular-cylindrical rods 40 ; 50 .
[0053] Various embodiments of the surface 36 functioning as a sliding surface are illustrated in FIGS. 2 a to 2 c by the example of the lower plate-shaped section 30 , in which the surface 36 in FIG. 2 a is arranged vertically and at a plane to the central axle 2 and in FIG. 2 c concave and circular cylindrical. The lower plate-shaped section 30 according to FIG. 2 b has a conical design, wherein the surface 36 is arranged at a plane and is not vertical to the central axle 2 . The surfaces 16 ; 26 ; 25 of the upper and of the central plate-shaped section 10 ; 20 functioning as sliding surfaces can be arranged in the same way.
[0054] The embodiment of the intervertebral implant according to the invention 1 illustrated in FIG. 3 a and FIG. 3 b differs from the embodiment illustrated in FIG. 1 only in that the surfaces 16 ; 25 ; 26 ; 36 of the three plate-shaped sections 10 ; 20 ; 30 , as illustrated in FIG. 2 c , functioning as sliding surfaces are provided with concave and circular-cylindrical arrangement. The surfaces 16 ; 25 ; 26 ; 36 are furthermore arched so that the longitudinal axis 41 of the first circular-cylindrical rod 40 runs anterior-posterior and intersects the central axle 2 of the intervertebral implant 1 , whereas the longitudinal axis 51 of the second circular-cylindrical rod 50 runs medio-lateral and at a distance from the longitudinal axis 2 of the intervertebral implant 1 . The surfaces 16 ; 25 ; 26 ; 36 are furthermore provided with a partial perimeter 70 , which is arranged vertically to the longitudinal axes 41 ; 51 of the two circular-cylindrical rods 40 ; 50 , and prevent the shifting of the rods 40 ; 50 parallel to their longitudinal axes 41 ; 51 .
[0055] An embodiment of the intervertebral implant according to the invention is illustrated in FIG. 4 and FIG. 5 that differs from the embodiment illustrated in FIG. 1 only in that the surfaces 16 ; 25 ; 26 ; 36 arranged as sliding surfaces on the three plate-shaped sections 10 ; 20 ; 30 are provided with a peripheral perimeter 70 .
[0056] The embodiment of the intervertebral implant according to the invention 1 illustrated in FIG. 6 differs from the embodiment illustrated in FIG. 4 and FIG. 5 only in that four limits/stops 80 are arranged on the upper surface 26 of the central plate-shaped section 20 in order to restrict the movement of the first circular-cylindrical rod 40 between the upper and the central section 10 ; 20 and again four limits/stops 80 are arranged on the upper surface 36 of the lower plate-shaped section 30 in order to restrict the movement of the second circular-cylindrical rod 50 . The limits/stops 80 restricts the swivel angle of the longitudinal axes 41 ; 51 of the two rods 40 ; 50 around the central axle 2 .
[0057] An embodiment of the intervertebral implant according to the invention 1 is illustrated in FIG. 7 and FIG. 8 , in which the surfaces 16 ; 26 ; 25 ; 36 of the three plate-shaped sections 10 ; 20 ; 30 assigned to each other in pairs are provided with grooves 17 ; 27 ; 28 ; 37 running perpendicular to the central axle 2 . The grooves 17 ; 27 ; 28 ; 37 are used for partial bearing of the circular-cylindrical rods 40 ; 50 and are provided with cross-section surfaces orthogonal to the longitudinal axes 41 ; 51 of the circular-cylindrical rods 40 ; 50 , which cross-section surfaces are part areas of an oval. The grooves 17 ; 27 functioning as bearing for the first circular-cylindrical rod 40 are thereby arranged so that the longitudinal axis 41 of the first circular-cylindrical rod 40 runs in an anterior-posterior direction. The grooves 28 ; 37 bearing the second circular-cylindrical rod 50 are arranged so that the longitudinal axis 51 of the second circular-cylindrical rod 50 runs in a medio-lateral direction. The grooves 17 ; 27 ; 28 ; 37 are furthermore closed against the side surfaces 11 ; 12 ; 21 ; 22 ; 23 ; 24 ; 33 ; 34 of the three plate-shaped sections 10 ; 20 ; 30 by means of limits/stops 75 , so that the circular-cylindrical rods 40 ; 50 cannot be raised from the grooves 17 ; 27 ; 28 ; 37 parallel to their longitudinal axes 41 ; 51 . The two circular-cylindrical rods 40 ; 50 are received in part by the grooves 17 ; 27 ; 28 ; 37 so that they are conducted in an axial direction. The grooves 17 ; 27 ; 28 ; 37 are arranged in such a way that the longitudinal axis 41 of the first circular-cylindrical rod 40 running in an anterior-posterior direction is arranged diametrically and intersects the central axle 2 , whereas the longitudinal axis 51 of the second circular-cylindrical rod 50 running in a medio-lateral direction is set at a distance from the central axle 2 .
[0058] An embodiment of the intervertebral implant according to the invention 1 is illustrated in FIG. 9 and FIG. 10 that differs from the embodiment illustrated in FIG. 7 and FIG. 8 only in that the grooves 17 ; 27 ; 28 ; 37 are provided with a cross-section surface orthogonal to the longitudinal axes 41 ; 51 of the circular-cylindrical rods 40 ; 50 , with a circular-segment type of cross-section surface. The two circular-cylindrical rods 40 ; 50 are received in part by the grooves 17 ; 27 ; 28 ; 37 , so that they are conducted through the two grooves 17 ; 27 ; 28 ; 37 both axially and perpendicularly to its longitudinal axis 41 and can carry out only a rotation movement around their longitudinal axes 41 ; 51 . The grooves 17 ; 27 ; 28 ; 37 are arranged in such a way that the longitudinal axis 41 of the first circular-cylindrical rod 40 running in an anterior-posterior direction is arranged diametrically and intersects the central axle 2 , whereas the longitudinal axis 51 of the second circular-cylindrical rod 50 running in a medio-lateral direction is set at a distance from the central axle 2 .
[0059] An embodiment of the intervertebral implant is illustrated in FIG. 11 that differs from the embodiments illustrated in FIGS. 1 to 10 in that the intervertebral implant 1 also comprises means 90 , wherein the mobility of the three plate-shaped sections 10 ; 20 ; 30 relative to each other is blocked in a way that can be released. The means 90 in the embodiment illustrated here comprise an insert 91 that can be slid in from the ventral side perpendicular to the central axle 2 and parallel to the lateral side surfaces 13 ; 14 ; 23 ; 24 ; 33 ; 34 of the three plate-shaped sections 10 ; 20 ; 30 . The insert 91 is slid in this way in two depressions 92 ; 93 , which are arranged as dovetail guides. The insert 91 is inserted from the ventral side surfaces of the two external plate-shaped sections 10 ; 30 into the depressions 92 ; 93 , realized as dovetail guides and secured to two plate-shaped sections 10 ; 30 by means of a screw 94 in each case. The insert 91 is moreover arranged terminally complementary to the depressions 92 ; 93 , so that the two external plate-shaped sections 10 ; 30 are fixed parallel to the central axle 2 relative to each other when the insert 91 is in position. The intervertebral implant 1 arranged as springs 61 furthermore comprises elastically malleable means 60 , by means of which the three plate-shaped sections 10 ; 20 ; 30 are held together parallel to the central axle 2 . The axial elastic malleability of the elastically malleable means 60 ensures there is no restriction on the mobility of the three plate-shaped sections 10 ; 20 ; 30 around the longitudinal axes 41 ; 51 of the two circular-cylindrical rods 40 ; 50 functioning as swivel axles. The springs 61 are arranged as tension springs and secured to catches 62 that are attached to the side surfaces 11 ; 12 ; 13 ; 14 ; 31 ; 32 ; 33 ; 34 of the two external plate-shaped sections 10 ; 30 .
[0060] FIG. 12 shows an embodiment of the intervertebral implant 1 implanted between two vertebral bodies bordering on each other. The orientation of the three plate-shaped sections 10 ; 20 ; 30 is such that the longitudinal axis 41 of the first circular-cylindrical rod 40 runs anterior-posterior and the longitudinal axis 51 of the second circular-cylindrical rod 50 runs lateral-lateral.
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An intervertebral implant, specifically an artificial intervertebral disk, with a central axis, and an upper plate-shaped section, suitable for laying onto the base plate of a vertebral body lying on top, a lower plate-shaped section, suitable for laying onto the cover plate of a vertebral body lying below, wherein a central, plate-shaped section is arranged between the upper and the lower sections, a first circular-cylindrical rod with a longitudinal axle is arranged between the upper section and the central section, and a second circular-cylindrical rod with a longitudinal axle is arranged between the lower section and the central section.
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FIELD OF THE INVENTION
This invention is in the field of pipeline construction safety devices and in particular the field of pipeline alignment instrumentation platforms for underground pipeline construction.
BACKGROUND OF THE INVENTION
The construction of underground pipelines, and in particular the construction of pipelines for the non-pressurized, gravity flow of wastewater with suspended solids, such as sanitary sewers and storm sewers, requires tight alignment and slope control. Such pipelines are typically constructed with a uniform pipe diameter, uniform slope and uniform alignment between manholes, with slope changes and alignment changes occurring at manholes only. The manholes are used for access for inspection, maintenance and cleaning of the pipeline. The uniform slope and alignment between manholes provides for the free flow of the waste water with the solids remaining in suspension and not settling out in the pipeline.
Modern construction techniques for such pipelines utilize a construction laser which emits a pinpoint laser beam on a selected alignment and slope for alignment and slope control as the pipeline is laid. The laser is simply mounted in the bottom of the manhole from which the next segment of pipeline is to be constructed. The laser must be adjusted to emit the laser beam on the alignment and with the slope desired for the construction of the next segment of pipeline which connects to the manhole. The horizontal alignment of the laser beam must be set based on reference to survey markers in place on the surface of the ground. While the construction lasers are self-leveling and therefore provide for simply dialing in the desired slope, the alignment of the laser must be surveyed in by reference to survey markers on the surface. The most commonly used method for aligning the laser is to position a surveying instrument known as a transit directly over the laser with the transit being above the surface of the ground with the survey markers in view. The transit can then be set on the proper alignment for the pipeline. With the pipeline trench dug away from the manhole a few feet thereby allowing the laser beam to be directed roughly in the direction of the desired pipeline alignment, the transit is rotated vertically from the desired alignment and the laser beam alignment is adjusted to match the alignment established by the transit. Thereafter, depending upon the soil conditions, the alignment can be checked as the pipe sections are laid and minor adjustments can be made to the laser alignment as the pipeline construction proceeds further away from the manhole. This can continue only so long as the pipe trench is not back filled as trench back filling will obstruct the view of the laser beam through the transit.
The manholes for sanitary sewer and storm sewer lines are generally constructed from pre-formed circular manhole sections which have an inside diameter of 4 feet, 5 feet or more. These manhole sections, which are usually several feet in height are stacked one upon the other on top of a manhole base. The number of manhole sections is dependent upon the depth of the pipeline at the manhole location. On top of the circular manhole sections, a manhole cone narrows the diameter of the manhole down to 2 ½ or 3 feet typically. On top of the cone, manhole rings are used to bring the manhole to the desired finish elevation, where the manhole cover is installed.
During the pipeline construction, typically the manhole sections are placed for a manhole up to the level where the cone would be installed. At this point, the transit that is used to align the laser for the next section of pipe is perched on tope of the manhole sections. This is accomplished by spreading the legs of the transit tripod placing them on top of the top manhole section, or placing a board or some other standing surface on top of the top manhole section, leaving an opening for the proper positioning of the transit over the laser. The transit operator is standing on some board on top of the manhole section at great safety risk to himself and others including particularly the workmen inside the manhole to adjust the laser.
An apparatus is needed that will improve efficiency and safety of the construction laser alignment procedure. Despite the inefficiency and obvious safety deficiencies of commonly used procedures, Applicant has found no prior art devices that are designed to address this need. U.S. Pat. No. 5,787,955 and U.S. Pat. No. 5,265,974 to Dargie disclose a safety net for a ground level hatch frame opening. U.S. Pat. No. 4,960,150 discloses a safety cover movable deck on tracks and rollers.
The objective of the present invention is to provide a movable platform which is mountable on the top of a manhole pipe section, providing a safer working surface for workmen for accessing the manhole to set up a pipeline construction laser and for setting up and operating surveying instruments for aligning the construction laser with the desired pipeline alignment.
SUMMARY OF THE INVENTION
The present invention is a safety platform for which a preferred embodiment comprises a platform deck, one set of four internal anchor pedestals for anchoring to the inside wall of a small diameter manhole section, another set of four external anchor pedestals for anchoring to the outside wall of a larger diameter manhole section, two opposing pairs of folding handrails with handrail anchor brackets securing the handrail sections to the platform deck, and four sets of safety barrier chains. For preferred embodiments, the platform deck is constructed of grating trimmed with structural angle. However, the platform deck can be constructed of plate material. Grating or plate material can be metallic, such as steel or aluminum, or non-metallic, such as fiberglass. The platform deck has an access opening which is likewise trimmed with structural angle to provide smooth edges for persons using the access opening. The access opening is positioned in the platform deck such that when the platform is positioned on the manhole the access opening outside edge is over the manhole inside wall and the manhole rungs, if there are any. This promotes easy access to the manhole from the platform deck and easy exit from the manhole to the platform deck. A pair of access cover rails is attached to the platform deck bottom, the access cover rail length typically being approximately twice the width of the access opening to allow for the access opening cover to be slid completely under the platform deck to an access position which provides for the access opening to be completely opened. Rail stop plates on each ends of the access cover rails confines the access cover to the access cover rails. Alternatively, tabs or other mechanisms can be used to confine the access cover to the rails. The distance between the access cover rails will generally be approximately equal to the length of the access opening since the length and width of the access cover will generally be approximately equal to the length and width of the access opening. This provides for a complete closure of the access opening when the access cover is in the closed position. A lock pin inserted through an upper lock pin opening in an upper lock pin collar, through the access cover and through a lower lock and opening in the lower lock pin collar secures the access cover in the fully closed or partially closed position. The upper lock panel collar and lower lock pin collar are welded to the top and bottom respectively of the access opening frame. A first handrail section and a second handrail section are anchored on opposing sides of the platform deck. The first handrail section is anchored to the platform deck by a pair of first handrail anchor brackets and the second handrail section is anchored to the platform deck by a pair of second handrail anchor brackets. The first handrail section and the second handrail section respectfully are secured in the upright position by a handrail lock pin inserted in anchor bracket lock pin holes in opposing anchor bracket side walls and handrail lock pin holes in opposing sides of each handrail post, the anchor bracket lock pin holes and the handrail lock pin holes have been aligned when the handrail is in the upright position a kick tab on the inside face of each anchor bracket prevents each bottom of each handrail post from rotating inward and hence the top of the handrail from rotating outward, hence providing stability to the handrail in the upright position with the locking pins in place.
The third handrail section and a fourth handrail section are likewise anchored on opposing sides respectively of the platform deck. The third handrail section and fourth handrail section are perpendicular to the first handrail section and the second handrail section. Handrail sections three and four lay flat on top of handrail sections one and two when the handrail sections are retracted to the transport position.
With the handrail sections all in the upright position the perimeter safety chains are connected between the respective handrail sections thereby creating a safety barrier completely around the perimeter of the platform deck. The perimeter safety chains are connected at each end to the outside edge of the handrail section by a chain bracket. Generally for enhanced safety, an upper perimeter safety chain and a lower perimeter safety chain are used between adjacent handrail sections.
The platform may also be equipped with optional features such as the lifting chain storage box built into the platform deck and typically equipped with a hinged cover. A section of the hinged lifting chain storage box cover may also be equipped with a battery anchor bracket which allows a battery to be secured to the platform deck for use in powering the pipeline construction laser as well as lighting or ventilation for use in the manhole or on the platform.
The present invention shown has two sets of anchor pedestals, a set of four interior anchor pedestals and a set of four exterior anchor pedestals. The two sets of anchor pedestals provide for the utilization of the platform on two different sizes of manholes. Screw anchors extend from the anchor pedestals to secure the platform to the manhole.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective top view of a preferred embodiment of the safety platform of the present invention with handrail sections in the upright position.
FIG. 2 is a perspective top view of a preferred embodiment of the safety platform of the present invention with handrail sections in the transport position.
FIG. 3 is a perspective top view of the access opening with access cover in the partially open, laser alinement position.
FIG. 4 is a perspective top view of the access opening with access cover in the open, access position and secured with lock pin in lock pin bracket.
FIG. 5 is a perspective top view of the access opening with access cover in the closed, safety position and secured with lock pin in lock pin bracket.
FIG. 6 is a top view of a preferred embodiment of the platform deck of the present invention, with anchor pedestal layout.
FIG. 7 is a perspective detail of first handrail anchor bracket.
FIG. 8 is a perspective detail of a third handrail anchor bracket with handrail in the upright position.
FIG. 9 is a perspective detail of a third handrail anchor bracket with handrail in the transport position.
FIG. 10 is a perspective top view of an embodiment of the chain storage box and storage box cover with battery bracket.
FIG. 11 is an elevation detail of inside anchor pedestals of the present invention.
FIG. 12 is an elevation detail of outside anchor pedestals of the present invention.
FIG. 13 is perspective top view of a chain storage box extended above the platform deck with battery bracket mounted in the chain storage box.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring first to FIG. 1, this preferred embodiment of the safety platform 1 of the present invention shown comprises a platform deck 2 , two opposing pairs of folding handrails 5 affixed to the platform deck by handrail anchor brackets 6 , four sets of safety barrier chains 7 , and, referring now also to FIG. 6, one set of four internal anchor pedestals 3 , for anchoring to the inside wall 77 of a smaller diameter manhole section 78 , another set of four external anchor pedestals 4 for anchoring to the outside wall 79 of a larger diameter manhole section 80 . For the embodiment shown in FIG. 1 the platform deck is constructed of grating 8 trimmed with structural angle 9 . However, for other embodiments, the platform deck may be constructed of plate material. For those embodiments, the plate will likewise preferably be trimmed with structural angle to improve structural stability. The grating or plate may be made of steel, aluminum, fiberglass or other common structural materials.
The platform deck has an access opening 10 which for this preferred embodiment is likewise trimmed with structural angle 81 to provide smooth edges for those using the access opening. Referring again to FIG. 6, for this embodiment the access opening is positioned in the platform deck so that when the platform is placed on the manhole section, the access opening outside edge 11 is over the manhole inside wall 12 and the manhole rungs 13 , if there are any. This promotes easy access to the manhole from the platform deck and easy exit from the manhole to the platform deck. The access opening width 14 and access opening length 15 are selected to allow ease of access to and from the manhole. A pair of access cover rails 16 is attached to the platform deck bottom 17 . For this embodiment the access cover rails are constructed of structural angle. Referring also to FIG. 4, the access cover rail length is typically approximately twice the width of the access opening to allow for the access opening cover 18 to be slid mostly or completely under the platform deck to the access position 19 which provides for the access opening to be open. Rail stop plates 20 on each end 21 of the access cover rails confines the access cover to the access cover rails. Alternatively, tabs or other mechanisms can be used to confine the access cover to the rails. The distance 22 between the access cover rails will generally be approximately equal to the length of the access opening since the length 23 and width 24 of the access cover will generally be approximately equal to the length and width of the access opening. This provides for a complete closure of the access opening when the access cover is in the closed position 25 .
Referring to FIG. 4 and FIG. 5, a lock pin 26 inserted through a first lock pin opening 27 in first lock pin collar 28 and into the access cover grating secures the access cover in the closed position 25 . A lock pin inserted through a second lock pin opening 29 in a second lock pin collar 30 and into the access cover grating secures the access cover in the access position 19 . A lock pin inserted through the second lock pin opening in the second lock pin collar and into the access cover grating with the access cover in a partially open, laser alignment position 31 as shown in FIG. 3 . The first lock pin collar and the second lock pin collar, are welded to the the access opening frame 33 . A lock pin tether 34 , as shown in FIG. 4 and FIG. 5, may be used to keep the lock pin handy for use at all times.
Referring again to FIG. 1, a first handrail section 35 and a second handrail section 36 are anchored on opposing sides of the platform deck. The first handrail section is anchored to the platform deck by a pair of first handrail anchor brackets 37 and the second handrail section is anchored to the platform deck by a pair of second handrail anchor brackets 38 . Referring now to FIG. 7 and FIG. 8, the first handrail section and the second handrail section respectfully are secured in the upright position 39 by a handrail lock pin 40 inserted in anchor bracket lock pin holes 41 in opposing anchor bracket side walls 42 and handrail lock pin holes 43 in opposing sides of each handrail post 44 , the anchor bracket lock pin holes and the handrail lock pin holes being aligned for the insertion of the handrail lock pin as shown in FIG. 8 . When the handrail is in the upright position the bottom 45 of each handrail post extends downward into the anchor bracket recess 46 , which prevents the bottom of the handrail post from rotating inward 47 and hence the top 48 of the handrail from rotating outward 49 , thereby providing stability to the handrail in the upright position with the handrail lock pins in place.
A third handrail section 51 and a fourth handrail section 52 likewise are anchored on opposing sides respectively of the platform deck. The third handrail section and fourth handrail section are perpendicular to the first handrail section and the second handrail section for the embodiment shown in FIG. 1. A pair of third handrail anchor brackets 53 secures the third handrail section and a pair of fourth handrail anchor brackets 54 secures the fourth handrail section to the platform deck. For the embodiment shown in FIG. 1, the third handrail anchor brackets and the fourth handrail anchor brackets, which are shown in FIG. 9, are identical and the only difference between these handrail anchor brackets and the first or second handrail anchor brackets is that the third and fourth anchor brackets have bracket tabs 50 in the front face 55 of the brackets. For the embodiment shown in FIG. 1, when the handrail locking pins are removed and the handrail is lowered to the handrail transport position 56 as shown in FIG. 2 and in FIG. 7 and FIG. 9, the bracket tabs on the third and fourth handrail anchor brackets provide that, the handrail sections three and four will lay flat on top of handrail sections one and two, the height of the bracket tab being equal to the thickness 57 of the handrail.
Referring again to FIG. 1, with the handrail sections one, two, three and four in the upright position, the safety barrier chains 7 are connected between the respective handrail sections thereby creating a safety barrier 58 completely around the perimeter 59 of the platform deck. The safety barrier chains are connected at each end 60 to the outside edge 61 of a handrail section by a chain bracket 62 . Generally for enhanced safety, an upper safety chain 63 and a lower safety chain 64 are used between adjacent handrail sections. Other types of removable barrier elements may also be used between the handrail sections which will be known by persons skilled in the art.
The safety platform of the present invention may also be equipped with optional features such as a lifting chain storage box 65 shown in FIG. 1 and FIG. 2, which may inset into the platform deck, and lift rings 71 which are attached to the platform deck at the perimeter. The storage box may be equipped with a hinged chain storage box cover 66 as shown in FIG. 10. A section of the chain storage box cover may also be equipped with a battery anchor bracket 67 which allows a battery 68 to be secured to the platform deck for use in powering the pipeline construction laser as well as lighting or ventilation in the manhole or lighting for the platform. Alternatively, the top 82 of the chain storage box may extend above the top 83 of the platform deck as shown in FIG. 13, the depth of the chain storage box providing for the battery to be mounted and stored in the chain storage box with the battery anchor bracket 67 secured to the bottom 84 of the chain storage box. The lift rings are preferably equally spaced around the perimeter of the platform deck. The embodiment shown in FIG. 1 and FIG. 2 has four lift rings. At least three lift rings are ordinarily used in order to provide for stability in handling the safety platform.
Referring again to FIG. 6, the embodiment of the present invention shown has two sets of anchor pedestals, a set of four interior anchor pedestals 3 and a set of four exterior anchor pedestals 4 . The two sets of anchor pedestals provide for the utilization of the platform on two different sizes of manholes. For instance, the common inside diameter for sanitary sewer manholes is four feet. A less common but occasionally used inside diameter for sanitary sewers is six feet. The configuration of anchor pedestals shown in FIG. 6 works well for four foot and six foot diameter manhole combination. The interior set of four anchor pedestals fit inside of and provide for the centering of the platform on a four foot diameter manhole. Screw anchors 69 are extended from two of the interior pedestals to the inside wall 77 of the smaller diameter manhole 78 to secure the platform to the manhole. For the larger diameter manhole 80 , screw anchors are extended from two of the exterior pedestals to the outside wall 79 of the manhole.
For this embodiment the set of four exterior anchor pedestals 4 , which are illustrated in FIG. 12, are longer than the four interior anchor pedestals 3 , which are illustrated in FIG. 11, because the exterior anchor pedestals must fit on the outside 81 of the manhole section. Since the manhole sections typically have the side with the exterior joint groove oriented up, the anchor pedestals must extend below the exterior groove 70 as shown in FIG. 12 . The screw anchors extend inwardly from two of the exterior anchor pedestals to the exterior surface of the manhole section below the joint groove in the top of the manhole section. While the embodiment shown utilizes four pedestals to position and secure the safety platform to a manhole, a three pedestal set could be used effectively, with only one of the pedestals having a screw anchor.
Other embodiments of the invention and other variations and modifications of the embodiments described above will be obvious to a person skilled in the art. Therefore, the foregoing is intended to be merely illustrative of the invention and the invention is limited only by the following claims.
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A buried pipeline construction laser alignment survey platform mountable on manhole sections. The platform has a platform deck and two opposing sets of foldable handrail mounted on the perimeter of the platform deck which are inter-connected by safety chains to complete a safety perimeter. A manhole access in the platform deck has a slideable access cover providing for a closed set-up position, an open access position, and a partially open laser alignment position. One or more sets of anchor pedestals on the bottom of the platform deck provide for securing the platform to manhole sections of one or more diameters.
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FIELD OF THE INVENTION
[0001] This invention relates to retainers for rolling doors and in particular to rolling doors for aircraft hangars in which relatively wide openings are closed by multiple doors arranged at opposite sides of the door opening to be stacked in a door open position at one side of the opening and to slightly overlap each other in a door closed position.
BACKGROUND OF THE INVENTION
[0002] Sliding or rolling doors and windows are commonly used in household and commercial buildings usually with a pair of doors closing an enclosure. Such doors typically have their own upper and lower guide tracks and are removable by vertical movement upwardly a small amount into the upper guide track to dislodge the lower portion of the door and permit its removal. Various devices have been developed to prevent such movement but their installation and use require the sides of guiding tracks or doors to be exposed. Also, such devices often prevent all movement of the doors which prevents their normal use. With aircraft hangar doors the door opening is very wide and multiple doors are used at each side of the door opening which obstruct the access to the upper track and upper door portions that are required to make the prior art installation.
[0003] Aircraft doors of the rolling type typically are of light structure with a perimeter formed of channel members on the skin of light metal on one or both sides. The lower perimeter of the door typically supports track-engaging rollers which support the weight of the door during rolling and sliding movement between open and closed positions. The upper perimeter member of the door also supports rollers on vertical axis which engage the inside surfaces of flange members of a channel shaped guide member and hold the door in vertical position. Such doors are moveable vertically upwardly into the upper guide channel to permit placement of the lower track engaging rollers on the guide track. It is this characteristic of sliding doors to which the invention is directed.
SUMMARY OF THE INVENTION
[0004] Hurricanes and high winds are known to cause such doors to be lifted off of the tracks and to fall against expensive aircraft causing much damage. Violent earth motion during earthquakes can cause the same phenomenon.
[0005] Examination of aircraft hangars damaged following hurricanes that impacted Florida in 2004 found that a principal damage to aircraft in hangars was caused by the doors of the hangars which high winds caused to be displaced from their intended position and crash against the airplane housed in the hangar.
[0006] It would be very desirable to provide a means for preventing door displacement from their guiding tracks unless needed for door replacement and repair. Therefore, it is an object of the invention to provide a door retainer which prevents vertical displacement of the door and its rollers from its supporting track and at the same time permits the doors to be used without interference.
[0007] It is another object of the invention to provide such a door retainer which is easily installed on existing doors when they are in position on their tracks.
[0008] It is an object of the invention to provide a door retainer which prevents vertical displacement of the door and its rollers from the supporting track.
[0009] These and other objects of the invention are attained by a door retainer for aircraft hangar doors in which vertical movement of the door rollers to raise them off of their supporting tracks is prevented by a vertical retainer bolt adjustable to project above the upper top edge of the doors to engage the top guiding channel of the doors to limit upward door movement that might otherwise occur in strong or high wind conditions or during earthquakes. Such adjustment does not hinder normal opening and closing of the doors. The door retaining bolts are adjustable to a retracted position to permit door removal or replacement when required.
DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is an elevation of an airplane hangar with multiple doors of the type to which the present invention is directed shown with the doors in their closed position;
[0011] FIG. 2 is an elevation similar to FIG. 1 in which the doors are in an open position;
[0012] FIG. 3 is a diagrammatic sectional view generally on line 3 - 3 in FIG. 1 showing the doors in their closed position;
[0013] FIG. 4 is an elevation of one door separated from the upper guiding tracks;
[0014] FIG. 5 is a cross-sectional view of three doors in their stacked condition as shown along line 5 - 5 in FIG. 2 ;
[0015] FIG. 6 is a cross sectional view of one of the door rollers taken on line 6 - 6 in FIG. 5 ;
[0016] FIG. 7 is a view of an alternative form of roller used with doors of the type related to this invention;
[0017] FIG. 8 is a cross sectional view of the upper end of one of the doors on line 8 - 8 in FIG. 5 ; and
[0018] FIG. 9 is an enlarged view of the retainer of the invention shown in cross section
DETAILED DESCRIPTION
[0019] The rolling doors to which the retainer of the present invention are related are shown in FIGS. 1 through 3 . There are a wide variety of rolling and sliding doors and windows in use but those used for aircraft hangars such as designated at 10 must cover wide openings 12 to accommodate large wing spans of airplanes 14 . Consequently, they are used in larger numbers of four, six, eight or more to cover the hangar wide door opening. The present description will make reference to three doors at each side of an opening for a total of six doors.
[0020] Such doors are designated generally at 16 and typically are fabricated of light metal channel members defining the perimeter of the door with at least one side of the doorframe being covered with a light metal panel 18 often of a corrugated configuration. Each door typically has an upper channel member 20 , a lower horizontal frame member 22 and opposed vertically disposed door edge members 24 as seen diagrammatically in FIG. 4 .
[0021] With a six door arrangement having three doors disposed at each side of the door opening 12 a pair of central doors 16 a are disposed to roll on a track 26 a . A pair of intermediate doors 16 b are disposed adjacent each of the central doors 16 a and are disposed to roll on tracks 26 b . Similarly a pair of end doors 16 c are disposed to roll on tracks 26 c and are adjacent to the intermediate door 16 b.
[0022] The tracks 26 a , 26 b and 26 c are parallel to each other and each support a pair of doors 16 a , 16 b and 16 c , respectively, for movement at opposite sides of the door opening 12 . Such tracks extend beyond the sides of the door opening 12 to provide storage space for the doors in their open position as indicated at FIG. 2 .
[0023] In FIGS. 1 and 2 the doors 16 are disposed on the outside of the hangar 10 with storage of the stacked open doors extending beyond the sides of the building. Alternatively, however, where space permits, such doors are often mounted on the inside of the building so the stacked open doors 16 are within the interior of the hangar.
[0024] The bottom frame member 22 of each of the doors 16 a , 16 b and 16 c are provided with rollers or wheels 34 which roll on tracks 26 a , 26 b and 26 c . The rollers 34 seen in FIG. 5 are formed with a V groove 36 which are complementary to the tracks 26 a , 26 b and 26 c . Such tracks typically are fabricated of ninety-degree angle iron which is readily available. The rollers 34 as seen in FIG. 5 have a central track engaging portion 38 and opposed cheeks 40 . The cheeks 40 are larger radius than the central portion 38 to maintain the doors on their track. Because of the shape of the tracks, the V shaped wheels have a tendency to be cammed off the tracks when lateral pressure such as that due to high winds or earthquakes is applied to the doors. As an alternative to the V shaped rollers those of the type seen in FIGS. 6 and 7 are used. Such rollers 42 are intended to engage conventional rail type tracks 44 . The rollers 42 have a central track engaging portion 46 and a larger diameter opposed cheeks 48 to maintain the rollers on the track 44 .
[0025] Whether the rollers 34 or 42 or employed both are supported on axles 50 which are held in position on the doors 16 a , 16 b and 16 c by a U shaped bracket member 52 which can be bolted or otherwise fastened to the bottom channel member 22 of each of the doors. Preferably, a roller is attached adjacent to each of the opposite edges of each of the doors.
[0026] The doors 16 a , 16 b and 16 c are maintained in a vertical position by means of guide rollers 58 arranged at the upper edge of each of the doors for engagement with a guide track 60 . The guide track 60 is an inverted channel member having a central web 62 with opposed depending flanges 64 . A separate guide track 60 is used for each of the pairs of doors and each of the tracks 26 a , 26 b and 26 c . The upper tracks 60 extend continuously across the opening 12 in the hangar 10 and often extend beyond the opposite edges of the building as seen in FIGS. 1 and 2 .
[0027] The guide rollers 58 are adapted to roll about vertical axis for engagement with the inner walls of opposed flanges 64 . For that purpose a pair of rollers 58 is disposed adjacent the opposite edges of the door so that one of the pair engages one of the flanges and the other of the pair engages the other flange 64 of the guide tracks 16 .
[0028] The guide rollers 58 are spaced from the central web 62 of the guide tracks 16 a sufficient amount so that the doors 16 a , 16 b and 16 c can be placed on their respective tracks 36 or 42 by moving a door upwardly in the space between the flanges 64 until they engage the rollers 58 with the central web 62 . This allows sufficient space of the rollers 34 or 42 to clear their respective tracks 36 or 44 by moving the bottom of the door laterally to align the rollers with the tracks. It is this vertical movement which causes aircraft hangar doors to be displaced by high winds during hurricanes and tornadoes or earthquakes. It is to this characteristic of rolling doors for aircraft hangars to which the invention is addressed.
[0029] The door retainer to which the invention is directed is designated generally at 70 . The retainer 70 is disposed vertically in the upper door channel 20 of each of the doors and is in the form of a threaded bolt 72 passing through an opening 74 in a horizontal web portion 76 of the top door channel 20 of each of the doors, 16 a , 16 b and 16 c . Because hangar doors typically are made of light materials, the web 76 is often best reinforced with washers 78 disposed at the underside and topside of the web 76 . Similarly nuts 80 are threaded on the bolt 72 and tightened against each other to clamp the washers 78 and web 76 together and to firmly hold the bolt 72 in a vertical position. Adjustment of the retainer bolt 72 vertically to place its upper end 82 in closely spaced relation to the web 62 of the guide marks 60 . Proper adjustment requires that the space designated at 86 in FIG. 9 be less than the depth of the guide rollers 34 or 42 at the bottom of the doors. The depth is the difference between the radius of the central portion 38 and checks 40 in the case of the roller 34 in FIG. 5 and the central portion 46 and checks or flanges 48 of the rollers 42 in FIG. 7 .
[0030] The difference in the radius of the central track engaging portions 38 or 46 and the associated checks 40 or 48 represents the amount of vertical movement of the associated door required to remove the door from its track and also the amount of required movement of the upper guide rollers 58 in the channel shaped guide track 60 . By adjusting the bolt 72 in close relation to web 62 thus vertical movement is limited to prevent removal manually or due to high winds or earthquakes. To remove the doors under normal conditions the retainer bolt 72 must be retracted a sufficient amount.
[0031] Installation of the retainer 70 preferably is at least two to each door closely adjacent to the opposite side edges of each door. If a single retainer is installed on each door, it should be disposed centrally between the side edges of the door.
[0032] Such installation of retainers 70 can be made easily with the doors in their usual vertical position on the tracks 16 a , 16 b and 16 c by drilling a hole 74 to receive bolt 72 with the backing washers 78 and nuts 80 at opposite sides of the web as seen in FIG. 5 . Tightening of the nuts toward each other grips the threaded bolt 72 and holds it firmly in position.
[0033] The installation of the retainer 70 and adjustment to their position to prevent displacement of the rollers from the associated tracks does not interfere with normal opening and closing of the doors 16 a , 16 b and 16 c.
[0034] It should be noted that with stackable rolling doors such as those used with aircraft hangars, various prior art retainers cannot be used because they require the sides of the doors or the guide tracks to be accessible for installation.
[0035] A retainer for aircraft hangar rolling doors has been provided in which multiple doors at either side of a door opening are each provided with retainers that are adjustable between positions permitting movement of door rollers from being displaced laterally of their supporting tracks 26 a , 26 b and 26 c a position preventing such movement to maintain the doors on their tracks. In the latter position the doors can operate manually between open and closed positions. The retainers are easily installed in new construction or on existing doors.
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A retainer for aircraft hangar doors in which vertical movement of doors is adjustably limited to allow sufficient movement to permit door removal from their supporting tracks or to prevent such undesirable displacement during high wind conditions as experienced during hurricanes and tornadoes or violent earth motions during earthquakes. The retainer in its retaining position does not obstruct normal opening and closing of the doors and is economical to manufacture and install.
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BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to exhaust manifolds for internal combustion engines, and more particularly to those installed in internal combustion engines in association with a means for cleaning the exhaust gases, in particular a start catalyst, which for example is mounted on the manifold.
SUMMARY OF THE INVENTION
One object of the invention is to provide such a manifold whose heat loss is as small as possible in order to shorten the time for starting the cleaning means.
Another object of the invention is to ensure that the gas velocity field over the inlet face of the cleaning means is as uniform as possible.
Yet another object of the invention is to permit easy assembly of the manifold in the factory.
The invention therefore provides an exhaust manifold for internal combustion engines. According to one general characteristic of the invention, this manifold comprises a flange for fixation on the engine cylinder head, a wide exhaust-gas collecting cavity joined to the flange to receive the exhaust gases delivered by the cylinder head exhaust pipes, this wide collecting cavity having a reentrant wall element subdividing the said cavity into two mutually communicating sub-cavities. The manifold also comprises an end portion joined to the collecting cavity outlet and having an outlet orifice for the exhaust gases.
The combination of the “plenum” form of the manifold (wide exhaust-gas collecting cavity) subdivided into two “lungs” ensures that the heat loss will be minimal and contributes to achieving a uniform velocity field and uniform distribution of the exhaust gases at the inlet of a gas cleaning means.
According to one embodiment of the invention, the reentrant wall element provides, on the outside surface of the collecting cavity, a central indentation extending substantially perpendicular to the flange fixation plane, the two sub-cavities being symmetric with respect to the central plane of this central indentation.
This embodiment thus not only makes it possible easily to construct the wide cavity formed by these two lungs but also permits, by virtue of the central indentation, easy introduction of a wrench for establishing a point for fixation of the manifold on the cylinder head.
The wide collecting cavity has an appropriate internal volume. More particularly, it has been found that it is advantageous for the volume of the collecting cavity to be greater than about 0.8 times the cubic capacity of the engine in order to achieve a noteworthy reduction of heat loss as well as good uniformity of the velocity field at the inlet of the cleaning means. In addition, and especially for reasons of overall size, it is preferable that the volume of the collecting cavity be smaller than about 1.5 times the cubic capacity of the engine.
According to a preferred embodiment of the invention, the volume of the collecting cavity is chosen substantially equal to the cubic capacity of the engine, thus permitting an optimal compromise between the criteria of heat loss and uniformity of the velocity field and distribution, and overall manifold size.
It is also particularly advantageous for the end portion to have substantially the form of a bowl, thus permitting the uniformity of the velocity field to be further improved.
In addition, the end portion is preferably provided with an elliptical throttle plate, the major axis of the ellipse being parallel to the plane of fixation of the fixation flange. This also contributes to obtaining better uniformity of the velocity field.
The fixation flange is advantageously provided with four inlet ports to receive the exhaust gases and with five points of fixation on the cylinder head, those points being disposed in crisscross arrangement around the four inlet ports. Furthermore, the line segment connecting the respective centers of two consecutive fixation zones passes substantially through the center of the port situated between these two fixation zones.
Such an embodiment makes it possible to minimize the number of bolts for fixation of the manifold on the cylinder head and thus to minimize the assembly stresses associated with the introduction of wrenches. In addition, the criss-cross disposition of the fixation bolts relative to the centers of two consecutive fixation zones aligned with the center of the inlet port situated between these two fixation zones contributes to ensuring excellent leaktightness of fixation of the manifold on the cylinder head.
According to another embodiment of the invention, the manifold also comprises an intermediate connecting portion which connects the fixation flange to the collecting cavity and is provided with exhaust conduits joined respectively to the inlet ports of the fixation flange. Advantageously, the exhaust conduits disposed at the ends of the intermediate connecting portion are convergent. Consequently, all the exhaust conduits make it possible to force the exhaust-gas streams toward the manifold center, thus additionally contributing to achievement of a uniform velocity field over the inlet face of the cleaning means. In addition, this intermediate connecting portion contributes to increasing the rigidity of the manifold.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages and characteristics of the invention will become evident upon examination of the detailed description of one embodiment, which in no way is limitative, and of the attached drawings, wherein:
FIG. 1 schematically shows a manifold according to the invention,
FIG. 2 is a section through line II—II of FIG. 1,
FIG. 3 is a section through line III—III of FIG. 2,
FIG. 4 shows the section of the throttle plate of the manifold through line IV—IV of FIG. 2,
FIG. 5 shows a section through line V—V of FIG. 2,
FIG. 6 is a view in the direction of arrow F of FIG. 2 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In these FIGS., reference 1 denotes in general an exhaust manifold according to the invention. This manifold is provided with a fixation flange 2 having five fixation holes 20 to 24 , by means of which the manifold can be fixed by bolts onto the engine cylinder head.
The manifold is also provided with a wide exhaust-gas collecting cavity 3 , which is connected to the fixation flange by an intermediate connecting portion 5 .
This wide collecting cavity 3 is prolonged by an end connecting portion 4 provided with a portion 41 having substantially the form of a bowl followed by a fixation flange 42 provided with an exhaust-gas outlet orifice 49 , a start catalyst CT being fixed, by welding in the present case, on the said fixation flange.
The outlet orifice 40 of bowl 41 is a throttle plate having elliptical section (FIG. 4 ), the major axis of the ellipse being parallel to the plane of fixation of the manifold on the cylinder head.
As illustrated more particularly in FIG. 3, the wide exhaust-gas collection cavity 3 , which is cast in one piece, supports a reentrant wall element 32 , which forms on the outside surface of cavity 3 a central indentation 34 , thus creating two symmetric lateral portions 30 and 31 . In this way collection cavity 3 is divided into two sub-cavities 300 and 310 , which are in mutual communication at the level of constricted section 320 of cavity 3 , situated in the plane of symmetry thereof.
Central fixation zone 20 of fixation flange 2 is situated in the extension of central indentation 34 , thus permitting introduction of central wrench VS. In addition, lateral portions 30 , 31 are provided with reentrant wall elements 39 , 38 respectively, which form on the outside surface of these lateral portions two auxiliary indentations 37 , 36 respectively.
It will be noted here that fixation zones 22 and 23 are situated respectively in the extension of auxiliary indentations 37 and 36 , thus permitting easy introduction of automatic wrenches.
As illustrated more particularly in FIG. 5, it is evident that fixation flange 2 is provided with four ports O 1 to O 4 corresponding to the four exhaust pipes made in the cylinder head and joined to the four cylinders of the engine. Fixation holes 20 to 24 are situated in criss-cross pattern around these ports O 1 to O 4 . The center of each inlet port of the fixation flange is substantially aligned with the centers of the two fixation orifices disposed on both sides of this inlet port. Such an arrangement permits the number of manifold fixation bolts to be minimized while at the same time ensuring excellent leaktightness of fixation on the cylinder head.
Intermediate connecting portion 5 is provided with four exhaust conduits 51 to 54 prolonging the exhaust pipes of the cylinder head. As illustrated more particularly in FIG. 6, axes A 51 and A 54 of the two exhaust conduits situated at the end of intermediate connecting portion 5 converge. Thus the entire group of exhaust conduits 51 to 54 , and in particular the two end conduits, ensure that the exhaust-gas streams are forced toward the manifold center.
Finally, at the top of collecting cavity 3 , and in the extension of wall element 32 and consequently of central indentation 34 , there is disposed a port 35 for housing any desired transducer or sensor, especially a sensor for measuring the oxygen concentration, commonly referred to as “lambda sensor” by those skilled in the art, which sensor is used traditionally in air/fuel ratio control circuits.
The location of this port 35 permits lambda sensor SL to be positioned centrally, which is particularly advantageous.
The invention makes it possible to obtain an exhaust manifold with mounted-on start catalyst, which manifold is particularly efficient as regards heat loss and also as regards uniformity of the velocity field of the gases delivered to the start catalyst. In fact, except for exhaust conduits 51 to 54 , which prolong the exhaust pipes for a distance of about 30 mm and incidentally contribute to ensuring good manifold rigidity because of this fact, the pulsations arriving from the four cylinders are collected in a large volume and circulate toward outlet orifice 40 of the bowl as illustrated by arrows CG in FIG. 3 . In addition, bowl 41 permits even better homogenization of the gases, especially by causing vortexing action MC (FIG. 3) of the gases, this bowl followed by elliptical throttle plate 40 contributing to the creation of a uniform velocity field at the inlet of the start catalyst.
It will be understood that the invention as described hereinabove is not limited to an exhaust manifold equipped with a mounted-on start catalyst, but that it is also suitable for any gas cleaning means, such as a three-way catalyst, a particulate filter, an NO x trap, an SO x trap, etc., whether it is mounted on the manifold or effectively connected thereto by, for example, a tube portion.
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An exhaust manifold which includes a flange to be fixed on an engine cylinder head. A wide exhaust gas collecting cavity is connected to the flange to receive exhaust gases discharged by exhaust pipes of the cylinder head. The wide collecting cavity has a recessed wall element subdividing the cavity into two mutually communicating sub-cavities. An end portion is connected to the collecting cavity outlet and has a discharge outlet for the exhaust gases.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Priority is claimed to European Patent Application No. EP 11 172 830.9, filed Jul. 6, 2011, the disclosure of which is incorporated herein by reference, in its entirety.
AREA OF THE INVENTION
[0002] The present invention concerns a device and a method for surveying jet grouting piles in the ground, which is suitable for a drilling and grouting linkage assembly for creating a hole, and a jet grouting pile in the region of the hole.
PRIOR ART
[0003] The method for producing jet grouting piles is a method of special excavation in which an energy-rich, high pressure jet of water and/or binder emerges from a rotating drilling and grouting linkage assembly and thus destroys the stratification of the surrounding soil and turns it into mortar by the addition of binder. In this context it is desirable to monitor the quality of the jet grouting pile and hence the work result. For this there is a possibility of providing a measuring device during processing, for example on the drilling and grouting linkage assembly.
[0004] A known drilling and grouting linkage assembly with a measurement device is disclosed in European Patent Application EP 1 974 122 A1 (published as WO2007/101500 and US2009178849 A1). The known device comprises a drilling and grouting linkage assembly to create a hole and a jet grouting pile in the region of the drilling hole, and a measurement device for surveying the jet grouting pile, wherein this measurement device is at least partly integrated in the drilling and grouting linkage assembly. With such a device it is possible to monitor the quality of the jet grouting piles in a flexible and reliable manner during operation of the drilling and grouting linkage assembly.
SUMMARY OF THE INVENTION
[0005] An object of the present invention is to provide a measuring device for assessing a jet grouting pile which is easier to handle than the prior art and in particular takes up less space.
[0006] The above and other objects are achieved by a measurement device adapted for integration in a drilling and grouting linkage assembly used to create a hole and a jet grouting pile in a region of the hole, wherein the measurement device is used for surveying the jet grouting pile. The measurement device includes: a hollow body; a retraction and extension housing mounted on the hollow body; and a scanning element movable from a retracted position into an extended position and being deflectable inside the measurement device through the retraction and extension housing, wherein the scanning element at least in segments comprises a shape-memory alloy.
[0007] In an embodiment, the scanning element is fitted with a sensor with the properties preferred for the required use and the scanning element is advantageously integrated and guided in the drilling and grouting linkage assembly.
[0008] In one embodiment, a measurement device is provided for a drilling and grouting linkage assembly. The drilling and grouting linkage assembly is intended to create a hole and a jet grouting pile in the region of the hole. This means that with the drilling and grouting linkage assembly, first a hole is made in the subsoil/soil, and the soil is softened at a suitable depth (jet grouting pile).
[0009] The measuring device according to the invention is also intended for surveying a jet grouting pile, in particular for measuring the diameter of the jet grouting pile, and the measuring device is integrated in the drilling and grouting linkage assembly. Furthermore the measurement device has a scanning element which may be fitted with a sensor, can move from a retracted position to an extended position, and is deflected within an extension and retraction housing fitted on the measurement device. According to an embodiment, the scanning element comprises at least in segments a shape-memory alloy. Preferably this is a metal alloy of nickel titanium. A variant of this metal alloy is known under the name Nitinol. Such materials surprisingly have advantageous properties for use in excavation/special excavation work. The scanning element is flexible for deflection but outside the measurement device, i.e. within the jet grouting pile, resists the external conditions and can thus guide the sensor into the jet grouting pile for measurement.
[0010] In a further embodiment the scanning element can be deflected by an angle of substantially 90°. This has the advantage that the scanning element is guided within the drilling and grouting linkage assembly and can be moved laterally out of the drilling and grouting linkage assembly.
[0011] If this scanning element is fitted with the sensor, this sensor can be a pressure and/or tilt sensor. Furthermore with such a sensor the diameter of the jet grouting pile can be determined, wherein the tilt sensor can ensure a valid measurement. The sensor may comprise several combined individual sensors. However in an alternative embodiment it is possible that measurement is performed with the scanning element and a further device in order to assess the jet grouting pile. In particular on extension of the scanning element, by monitoring the motor power it can be established when the scanning element has reached the wall of the jet grouting pile: if the current consumption of the motor increases and at the same time no increase is established in the extended length of the scanning element, then the scanning element has reached the wall of the jet grouting pile.
[0012] The measures described for detection and evaluation of the jet grouting pile can also be used in combination with each other.
[0013] If the scanning element is fitted with the sensor, the scanning element is retracted and extended in operation of the device according to the invention through the opening of the retraction and extension housing mounted on the measurement device. In one embodiment the sensor is designed, amongst others dimensioned, such that it seals the opening of the retraction and extension housing in the retracted state.
[0014] In a further embodiment of the measurement device, rollers are provided inside the measurement device which deflect the scanning element. The rollers provide a safe deflection with little susceptibility to error, wherein on transport over the rollers, the scanning element is not substantially changed externally (i.e. for example not deformed).
[0015] In a further embodiment the scanning element is sealed in relation to the drilling and grouting linkage assembly. However the scanning element is protected inside the drilling and grouting linkage assembly against dirt and contamination which can cause friction on movement.
[0016] In particular a flushing channel can be provided in the retraction and extension housing through which the scanning element can be flushed with water or a suspension on retraction and extension. This facilitates the sealing process and ensures that no contaminants can enter the drilling and grouting linkage assembly.
[0017] In a further variant of the measurement device, a drive device is provided in this with which the scanning element can be driven. The force may be applied in the region of the deflection of the scanning element. This guarantees safe retraction and extension of the scanning element into and out of the measurement device.
[0018] In another embodiment, the scanning element may be curved before its deflection. This pre-curvature can, for example, be provided with the first roller in the region of the deflection. Thus the scanning element is not deflected directly in the direction which leads to the outlet point of the scanning element from the measurement device, but against this direction. This facilitates the movement of the scanning element and under certain circumstances a greater deflection radius can be achieved within the measurement device when the scanning element is pre-curved further towards the wall of the measurement device. This pre-curvature also achieves the stabilisation of the scanning element.
[0019] The scanning element may comprise a nickel titanium alloy, for example an alloy known under the name of Nitinol. This is particularly suitable for the required properties for the scanning element.
[0020] Furthermore the present invention comprises a drilling and grouting linkage assembly to create a hole, wherein the drilling and grouting linkage assembly has a nozzle device and attached thereto a measurement device according to one of the variants described above. Furthermore a drill bit can be attached to the measurement device, in particular via an adapter mounted in between. A hole is created with the drill bit and the nozzle device may be used to form a jet grouting pile.
[0021] As well as the measurement device according to the invention and the drilling and grouting linkage assembly comprising this measurement device, the present invention also comprises a method for measuring a jet grouting pile. This method can be carried out in one embodiment with a measurement device according to the invention or with the drilling and grouting linkage assembly according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The present invention is described below with reference to a preferred embodiment. This embodiment is explained in detail in the context of the attached drawings.
[0023] FIG. 1 shows an overall view of a drilling and grouting linkage assembly with a measurement device according to the invention mounted on a drill.
[0024] FIG. 2 is a functional view of the drilling and grouting linkage assembly with a drill bit, the nozzle device, adapter and measurement device.
[0025] FIG. 3 shows an enlarged view of the region of the drilling and grouting linkage assembly of FIG. 1 in which the measurement device and the jet grouting nozzle are shown enlarged.
DETAILED DESCRIPTION
[0026] FIG. 1 shows diagrammatically an overall view of a drilling and grouting linkage assembly 1 . The drilling and grouting linkage assembly 1 here is mounted on a mobile machine 2 and in the depiction in FIG. 1 already introduced into the ground. At a particular depth, using a nozzle device described later, a jet grouting pile D is introduced into the soil. Here the original stratification of the soil is changed by the energy-rich, high pressure jet and at the same time or with a time delay it is filled with a suspension so that underground reinforcement bodies are produced which can be used as sealing elements or as supporting elements or as sealing and supporting elements.
[0027] FIG. 2 shows a functional view of a drilling and grouting linkage assembly 1 . This comprises various segments, namely a connecting segment 11 , an intermediate segment 12 , a nozzle device 13 , a measuring device 14 , an adapter 15 and a drill bit 16 . These elements are arranged in the corresponding order and connected by threaded connectors.
[0028] FIG. 3 shows in detail the threads 7 , 8 , 9 and 10 between the segment 12 , the nozzle device 13 , the measurement device 14 , the adapter 15 and the drill bit 16 . A high pressure suspension line 3 for the high pressure suspension, a line 4 for air and a line 5 for the drill flusher are routed to the drilling and grouting linkage assembly 1 .
[0029] At the connection of the line 3 for the high pressure suspension is provided a bearing/seal 100 . On an attachment 101 to line 4 is also provided a bearing/seal 102 and a further bearing/seal 103 . The line 5 for the drill flusher is mounted on an attachment 104 with a 2″ hose connection 105 . Furthermore a bearing/seal 106 is provided between attachment 104 and the drilling and grouting linkage assembly 1 , in particular segment 11 .
[0030] FIG. 3 shows part of the nozzle device 13 mounted on segment 12 and measuring device 14 in detail. The nozzle device 13 and the measuring device 14 are coupled detachably together in this embodiment by a screw connection 8 .
[0031] The nozzle device 13 is intended for application under high pressure of a high pressure suspension supplied via a high pressure line 3 . The working fluid for supporting the high pressure suspension is preferably air, which is supplied through a further line 4 .
[0032] In the present embodiment screw connections 7 to 10 are provided. Sealing rings ensure that no contaminants enter the measuring device 14 for example during operation. As an alternative to the screw connections 7 to 10 , individual radially acting bolts can be provided with which for example the measurement device 14 is bolted to the nozzle device 13 . Other plug connections are also conceivable.
[0033] Guided in the measurement device 14 is a rod or cable-like scanning element 40 with a sensor 40 a , the sleeve of which in the present embodiment comprises a nickel titanium alloy. This nickel titanium alloy belongs to the group of shape-memory alloys and is known under the name Nitinol. Usually such materials are used in the field of medical technology. However in the present development work it was found that Nitinol is surprisingly suitable also for devices which are used in the field of excavation or special excavation work.
[0034] The scanning element 40 is guided parallel to the high pressure suspension line 3 and accommodated in the measurement device 14 . For this in a region of the measurement device 14 pointing towards the nozzle device 13 , a motor 41 is provided with which the scanning element 40 can be driven. The drive force is transmitted via a drive roller 41 a to the scanning element 40 .
[0035] Furthermore the scanning element 40 in the region of the measurement device is deflected from a vertical direction into horizontal direction. “Vertical” in the sense of the present application means a direction along the drilling and grouting linkage assembly 1 whereas a “horizontal” direction is oriented perpendicular to this.
[0036] Several rollers 42 are provided inside the measurement device 14 such that the scanning element 40 is guided substantially at an angle of 90° in relation to the guide parallel to the high pressure suspension channel 3 . In this context FIG. 2 shows that before deflection of the scanning element 40 , a pre-curvature is produced, namely before the first roller 42 in the feed direction. In this way the deflection of the scanning element 40 by an angle of 90° which takes place later in the advance direction can be set better in the measurement device.
[0037] After the scanning element 40 inside the measurement device 14 has been brought from the vertical direction (path within the nozzle device 13 ) into a substantially horizontal direction, the scanning element 40 extends through a retraction and extension housing 43 . The retraction and extension housing 43 has a sealing element 45 which seals the inside of the measurement device 14 against the outside.
[0038] Furthermore the sensor element 40 a mounted at one end of the scanning element 40 is formed such that it can lie against the opening of the retraction and extension housing and thus alternatively or additionally to the sealing element 45 provide a seal against the inside of the measurement device 14 .
[0039] The movement of the scanning element 40 in the present embodiment is initiated by means of motor 41 in the region of the deflection of the scanning element 40 . Where applicable, alternatively or additionally, individual rollers can also be driven. Furthermore in the region of the drilling and grouting linkage assembly, further integrated motors can be provided. The drives are excited for example via the battery operation of the measurement system.
[0040] For measurement the scanning element 40 is moved away from the sealing device 45 and enters the horizontal direction, and is introduced into the jet grouting pile not yet hardened. For example the scanning element 40 can be extended up to 2 m out of the sealing device. The inherent rigidity of the scanning element 40 and the support from the sealed rod allows it to maintain a substantially horizontal direction even outside the measurement device 14 .
[0041] Initialisation of the measurement process using the scanning element takes place by means of body-borne sound pulses which are initiated in the drilling and grouting linkage assembly 1 or by radio transmission. The steps for surveying a jet grouting pile in the ground can then take place as follows. In a first step a suitable drill contact point is established. In a further working step the drilling and grouting linkage assembly 1 is brought to the new drill contact point and then the drilling and grouting linkage assembly 1 is lowered to a desired depth by means of drilling, wherein accompanying the drilling, the hole course can be measured by the integral tilt sensors.
[0042] After reaching the desired drilling depth, a jet grouting pile is created in the region of the hole and the diameter of the jet grouting pile produced is measured at different heights. The scanning element 40 is moved in the jet grouting pile which has not yet hardened. The scanning element 40 is advantageously designed so that because of the drive, its inherent rigidity, its own weight and the lift, it can be held substantially horizontally. The data detected and stored by the scanning element 40 can be read in parallel to measurement or with a time delay on raising of the drilling and grouting linkage assembly from the hole. From this data, concrete information can be obtained on the composition of the soil and the resulting composition of the jet grouting pile produced. These results can be used for further calculations.
[0043] When measurement has been carried out, the scanning element 40 on retraction into the measurement device 14 is flushed with water pressure via the flushing channel 44 provided on the retraction and extension housing 43 , and during retraction sealed against the liquid medium in the hole and the pile. The water flushing before the retraction and extension housing 43 thus facilitates the sealing process and ensures that no contamination can penetrate inside the measurement device 14 .
[0044] The drill bit 12 can for example be connected directly to the measurement device 14 . Alternatively as shown in the present embodiment, an adapter 15 can be provided between the measurement device 14 and the drill bit 12 . Instead of an adapter 15 , several elements can also be provided between the measurement device 14 and the drill bit 12 .
[0045] The drill bit 16 has openings 61 for a drill flusher. From these openings 61 a fluid emerges from the drill bit and thus allows penetration of the drilling and grouting linkage assembly 1 into the ground/soil.
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A device and a method for surveying jet grouting piles in a subsoil, which is suitable for a drilling and grouting linkage assembly for creating a hole and a jet grouting pile in a region of the hole. A measurement device is integrated in the drilling and grouting linkage assembly and comprises a scanning element that is movable from a retracted position to an extended position. The scanning element is deflected inside the measurement device through a retraction and extension housing mounted on the measurement device. The scanning element comprises at least in segments a shape-memory alloy.
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FIELD OF INVENTION
The present invention relates to a window lift system, especially a window lift system for a side window of an automotive vehicle, comprising a catch for a window pane which can be moved up and down by a pulling device, in accordance with the preamble of the main claim. The present invention relates furthermore to a door or side panel module which contains such a window lift system, as well as to a method for fitting a window pane in such a window lift system.
BACKGROUND INFORMATION
In a window lift system of this type, the catch has a first fastening point for an upwardly pulling end of the pulling device and a second fastening point for a downwardly pulling end of the pulling device, this second point being horizontally offset to the first fastening point in the window pane plane once the window pane is fitted. Such a window lift system is known from the publication DE 690 27 127 T2.
Window lift systems of this type are of particular interest when fastening of the upwardly pulling end and the downwardly pulling end of the pulling device at two fastening points on the catch which are horizontally offset in the above-mentioned manner ensures that a drive force for movement is so applied to the window pane that, independently of the direction of movement, the window pane is always pressed against merely a single guiding edge or rail which remains the same for each direction of movement. Tilting of the window pane in a corresponding guiding device can thus be effectively prevented.
A window lift system designed in this way is proposed in the German patent application DE 102 55 461.7 which had not been published on the application day of the present application. The invention described below is suitable especially for window lift systems of the type proposed in that patent application, the content of which is hereby entirely incorporated by reference into the present application.
Window lift systems of the type thus described bring with them a problem which forms the starting point for the present invention. In such window lift systems, torque is exerted on the window pane independently of the direction of pulling and movement. This torque is typically also desired in order to press the window pane constantly against the same guiding edge or rail. The same torque transferred via the catch to the window pane once the window pane is fitted, however, results in the catch being pulled, before the fitting of the window pane, into an oblique position which makes fitting the window pane extraordinarily difficult, especially connecting the window pane to the catch. Fitting the window pane is also made more difficult in that the catch which previously was typically only held by the two ends has at least one degree of rotational freedom, and can thus rotate freely at least about one axis. This can furthermore lead to undesired rattling when the corresponding door or side panel module which contains a corresponding window lift system is transported.
SUMMARY OF INVENTION
The present invention relates to a window lift system which continue to be suitable for transferring torque in the depicted manner to the corresponding window pane. Furthermore, the present invention relates to a practical method for fitting a window pane in a window lift system of this type.
Because a window life system according to the invention has means for positioning and fixing the catch at least in respect of three degrees of freedom, so that the catch can be held in a position defined in respect of these degrees of freedom even when the window pane is not fitted, the fitting of the corresponding window pane is decisively simplified. A corresponding advantageous fitting method for the window pane in such a window lift system provides for the catch to be initially positioned and fixed in respect of the mentioned degrees of freedom using the means provided for this purpose, and for the window pane to be then introduced into the window lift system until the window pane and the catch assume positions which correspond to each other (in a suitable window lift system according to the invention this can happen virtually automatically by introducing the window pane sufficiently far), and provision is also made for the window pane then to be connected to the catch as a form-fit and/or in a force-locking manner.
In embodiments of the invention, the catch has an upwardly open slit for receiving a lower edge of the window pane. As the window pane is being fitted and after the positioning and fixing of the catch from above (direction indications and relative location indications should always relate to the installation or operating state of the window lift system), the window pane can then be introduced so far into the window lift system that the lower edge of the window pane has travelled from above into the slit in the catch. Introducing the window pane (from above in typical window lift systems and corresponding fitting methods) can take place before or after the installation of the window lift system in a door or a vehicle side panel.
Simple and reliable connection of the window pane to the catch can be effected in that the catch has a single locking element or a plurality of locking elements for snapping into at least one corresponding recess in the window pane. A form-fit connection then comes about virtually automatically due to the introduction of the window pane.
Alternatively or additionally, an opening or two facing openings can be provided in the catch and a recess or recesses in alignment with this opening or these openings once the window pane is fitted can be provided in the window pane, through which opening(s) a pin or bolt can be pushed to connect the window pane to the catch. This pin or bolt should fit as exactly as possible in the corresponding openings or recesses. Such a pin joint or screw-bolt connection can ensure a particularly reliable force transmission from the ends of the pulling device to the window pane. Good force transmission is here particularly desirable for the downwardly pulling end of the pulling device, since a downwardly directed tractive force could tend to pull the catch away from the window pane. If a single pin joint or screw-bolt connection of the described type is provided, it is therefore expedient so to arrange this connection that it can in particular absorb forces emanating from the downwardly pulling end of the pulling device. In advantageous embodiments of the invention, however, two such pin joints or screw-bolt connections can be provided which are arranged horizontally offset and guarantee a torque-proof connection of the catch to the window pane. The connection of the window pane to the catch in such a device can then come about in that each pin or bolt is pushed through the corresponding openings or recesses when the window pane and the catch have assumed positions corresponding to each other after the introduction of the window pane into the window lift system.
Particularly expedient embodiments of the invention provide for the described window lift system to be a constituent part of a door or side panel module or to be arranged on such a door or side panel module before the window pane is fitted and before the corresponding door or side panel module is fitted. Such a module can have a panel part which, for stability reasons, is preferably formed from a fibre-reinforced plastics material, which can in turn be moulded or injection-moulded. With a view to economical manufacturing and simple fitting, those embodiments in which at least some of the mentioned means for positioning and fixing the catch and/or other components of the window lift system are integrally moulded onto this panel part as one piece are particularly advantageous. In particular with a combination of window lift systems according to the invention with such door or side panel modules, in addition to the advantage of simplified fitting, a further advantage applies in that using the means for positioning and fixing the catch can prevent undesired clattering of the catch during transportation of the window lift system or of the door or side panel module. Thus ultimately also damage can be avoided which otherwise could be caused by a catch knocking around freely in the event of jolts during transportation.
The advantages of a window lift system of the described type come to bear above all with so-called rail-less window lift systems or with window lift systems which have window panes guided only on one side (for example on a single rail or guiding edge). With such or similar window lift systems it is namely crucial that, through an arrangement of two offset fastening points for the two ends of the pulling device, a uniformly directed torque can be transmitted to the window pane independently of the direction of movement.
From what has been said so far it follows that in advantageous embodiments of the invention the catch should be able to be positioned sufficiently exactly, even when the window pane is not yet fitted, to make possible a reliable bringing-together of the catch and the window pane which can as far as possible also come about automatically as the window pane is introduced. To this end it is not absolutely necessary for the catch to be fixed in respect of all conceivable (six) degrees of freedom. Depending on the dimensions and relative arrangement of the various components of the window lift system, it can be sufficient if the catch is able to be positioned and fixed in this sense in respect of three degrees of freedom. Various advantageous embodiments of the invention can also be so designed that the catch can be positioned and fixed in respect of four, five or even all six degrees of freedom by the above-mentioned means.
In a window pane fitting method according to the invention, the catch can, especially in those embodiments which permit positioning and fixing of the catch in respect of all six degrees of freedom, advantageously be fixed, before the introduction of the window pane, in a position which corresponds to a possible position of the catch once the window pane is fitted. This can be a lowermost position of the catch which corresponds to a completely open window, but this is not necessarily the case.
In other embodiments of methods according to the invention, provision can be made for the catch to be, in respect of at least one degree of freedom, not yet fixed in a position which corresponds to a position of the catch once the window pane is fitted, and for the catch only to be pressed into the above-mentioned position by the introduction of the window pane, in which position then the connection of window pane and catch can take place. When the catch is so shaped that it has an upwardly opening slit for receiving the lower edge of the window pane, independently of the exact embodiment of the fitting method and of the number of degrees of freedom in respect of which the catch is positioned and fixed before the introduction of the window pane, it is in every case helpful if, for introducing the window pane, the catch is held in a position in which the above-mentioned slit lies in a plane or area defined by the window pane. Then bringing together the window pane and catch for the purpose of connecting the two is unproblematic.
In typical embodiments of the invention, the pulling device will have a cable pull or a chain, so that the upwardly pulling end and the downwardly pulling end of the pulling device each form one end of this cable pull or chain. A wire or plastic cable suggests itself for example as the cable pull, with a view to as high tensile stability as possible, low linear extensibility and good flexibility. Possible, too, are those embodiments in which two independent pulling devices, for example cable pulls or chains, are provided each for one end fastened to the catch. The pulling device of a window lift system of the described art typically has furthermore deflections formed for example by rollers and/or sliding blocks, as well as a drive system provided e.g. by a crank drive or an electric motor.
The means for positioning and fixing the catch can be designed in various ways. In particularly simple embodiments, these means can for example be provided by a lower stop for the catch or have such a lower stop or even two such stops. Positioning and fixing the catch before introducing the window pane can then come about in a simple manner in that the catch is pulled by the downwardly pulling end of the pulling device against this stop or these stops and held there by the same end. It is conceivable here that the catch already abutting against the stop at one end initially remains in an inclined position and is only pressed by the window pane into a position in which it is correctly orientated. In other embodiments, provision can be made for the catch to be pulled out of a possible inclined position even before the introduction of the window pane by the downwardly pulling end of the pulling device, for which purpose the downwardly pulling end of the pulling device, cooperating with the stop, exerts torque on the catch. As a supplement to a lower stop or even a plurality of lower stops for the catch, as further constituent parts of the means for positioning and fixing the catch, guiding means can also be provided for the lateral guidance of the catch at least in a lower movement section in the vicinity of the lower stop or stops. The term “lateral guidance” is here intended to refer in particular to guidance of the catch which limits the freedom of movement of the catch in a direction perpendicular to the plane defined by the window pane. Such guiding means can, however, also serve to position the catch in a longitudinal direction. The guiding means can here be designed for example, in a manner which is simple to realise, by walls guiding the catch laterally and preferably converging downwards in the manner of a funnel. In addition or alternatively, a cone can also be provided on which the catch sits in a lowermost position. Even more precise and reliable positioning can be achieved if two such cones are provided; instead of cones naturally also elements of other upwardly tapering geometries can be considered which are so positioned that the downwardly moving catch sits on same via a depression, bore or recess.
Instead of a lower stop, an upper stop and possibly guiding means for the lateral guidance of the catch could be provided in an upper movement section in the vicinity of the upper stop as means for positioning and fixing the catch, functioning in a similar way to the fitting of the window pane in an upper position which corresponds to a completely closed window.
When the window lift system is integrated in a door or side panel module or is arranged on such a module, the positioning and fixing means can also be provided by an opening or a plurality of openings in a panel part of this module and in each case by a corresponding opening in the catch, as well as by a pin each which can be pushed through the mutually corresponding openings to fix the catch in a defined fitting position. It is also possible for the means for positioning and fixing the catch to include these features in addition to other features such as guiding means for example. The above-mentioned fitting position should correspond here to a possible position of the catch once the window pane is fitted; this position can, but does not have to, correspond to the lowermost position of the catch.
Positioning which is advantageous because it can be defined in respect of all the degrees of freedom is produced if two pins are provided which can each be pushed through an opening in the catch and a corresponding opening in the panel part. The pins can be simple bolts or also screws, preferably headless screws. Then at least one of two corresponding openings should be provided with a thread matching the screw. Such a screw can be screwed through the door or side panel module into the catch or also through the catch into the door or side panel module. In the first case it is sufficient if the corresponding opening in the catch is designed merely as a depression; correspondingly in the second case it is sufficient if the opening in the door or side panel module is not designed as a complete recess but only as a depression (the same is true if a simple bolt is used as the pin instead of a screw).
A door or side panel module of the described art usually serves as a partition between a wet side and a dry side of an automotive vehicle door or side panel. When therefore such a module is provided with an opening in the described manner, advantageously care should be taken to ensure that this opening remains or is sealed after the window pane has been fitted. For this purpose such an opening can be sealed with a plug after the corresponding pin has been removed; however it is also possible for a screw, which has previously been used as means for fixing the catch, to be screwed back after the fitting of the window pane only so far that the catch is released, but the opening remains sealed by the screw.
In similar embodiments of door or side panel modules according to the invention or of methods according to the invention for fitting a window pane, openings can also be provided in the corresponding panel part of the module, through which openings a tool can be guided instead of pins, said tool being capable of gripping the catch and positioning and fixing same during fitting relative to the panel part and thus to the door or side panel module.
Particularly advantageous applications of the present invention arise especially through a combination of the essential features of the invention with those window lift systems which are claimed and described in the already-mentioned patent application DE 102 55 461.7. Through such a combination, particularly advantageous embodiments of window lift systems and door or side panel modules according to the invention are produced. Correspondingly, the method described here is particularly suitable for fitting a window pane in a window lift system of this type. The content of the application DE 102 55 461.7, which is referred to in this connection, is hereby incorporated into the present application.
BRIEF DESCRIPTION OF DRAWINGS
Embodiments of the present invention are explained in greater detail below with the aid of FIGS. 1 to 3 . The figures show:
FIG. 1 shows a stylised front elevation of a door module for a front left-hand side door of an automotive vehicle with a window lift system according to an exemplary embodiment of the present invention,
FIG. 2 shows a door module according another exemplary embodiment of the present invention, and
FIG. 3 shows a further modification of a window lift system according to the present invention on a door module.
DETAILED DESCRIPTION
Thus in FIG. 1 a door module is illustrated which is intended to be installed in the left-hand front side door of an automotive vehicle. This door module has a panel part 1 formed from an injection-moulded fibre-reinforced plastic on which a window lift system is arranged and which at the same time serves as a partition between a wet region and a dry region, covered by the panel part in the figure, of the corresponding side door. The window lift system has a catch 2 , which can be moved up and down by a pulling device, for a window pane 3 indicated with a broken line in the figure. Recognisable in the figure as constituent parts of the pulling device are a drum, which may be driven by a crank drive, not shown, or an electric motor, a traction cable 5 wound over this drum 4 and therefore mobile, as well as two deflection elements for the traction cable 5 in the form of rollers. In other embodiments of the invention, the deflection elements 6 can also be in the form of sliding blocks.
The traction cable 5 is in the form of a plastic cable; corresponding embodiments with a wire cable or even a chain instead of the traction cable 5 would also be possible. The traction cable 5 is fastened to the catch 2 , said catch 2 having a first fastening point 7 for an upwardly pulling end 8 and a second fastening point 9 for a downwardly pulling end 10 of the cable 5 . As can be seen in FIG. 1 , when the window pane 3 is fitted, the second fastening point 9 is arranged horizontally offset from the first fastening point 7 . In the depicted window lift system and also other window lift systems of this type, this ensures that the window pane 3 is pressed by torque exerted by the traction cable 5 via the catch 2 on the window pane 3 independently of the direction of movement, i.e. independently of whether the window pane 3 is pulled upwards or downwards, always against the same guiding edge or rail 11 which is only indicated in FIG. 1 .
In addition, the illustrated window lift system has means for positioning and fixing the catch 2 , with the aid of which the catch can be held in a defined position even when the window pane has not yet been fitted. In the illustrated embodiment of the invention, these means for positioning and fixing the catch 2 are provided by two supports 12 which are integrally moulded onto the panel part 1 as one piece and serve as lower stops for the catch 2 . On each of these supports 12 is moulded in turn a cone 13 , these cones 13 being so arranged that the catch 2 rests on these cones 13 with two openings, which are arranged at the bottom of the catch 2 but not recognisable in FIG. 1 , when the catch assumes a lowermost position. In this lowermost position of the catch 2 , which is indicated by a dotted contour in FIG. 1 , the catch 2 rests on the supports 12 . During a downward movement of the catch 2 , the cones 13 serve as guiding means for the catch 2 during a last movement section shortly before the lowermost position is reached.
Before a window pane 3 is fitted, the catch 2 is initially held only by the upwardly pulling end 8 and the downwardly pulling end 10 of the traction cable 5 . Due to an offset arrangement of the first fastening point 7 and the second fastening point 9 , the catch is here normally pulled into an oblique position and can also rotate freely within certain limits about an axis then defined by the upwardly pulling end 8 and the downwardly pulling end 10 . If further measures are dispensed with, that would not only lead to the catch 2 knocking about freely in an undesired manner during transportation of the door module and possibly causing damage but in addition the fitting of the window pane 3 and especially connecting the window pane 3 to the catch 2 would only be possible with extraordinary difficulty. Due to the design of the window lift system with the supports 12 and the cones 13 as means for positioning and fixing the catch or as guiding means, however, the catch 2 can now be pulled, for transportation of the door module or for fitting the window pane 3 , into the lowermost position, resting then initially, pulled downwards by the downwardly pulling end 9 , on the support 12 lying on the right in FIG. 1 , and then being pulled out of an inclined position by the downwardly pulling end 10 until it also comes to rest on the support 12 lying on the left in FIG. 1 . In this process it is guided laterally by the cones 13 in such a way that the catch 2 then also assumes a position which is already defined in respect of all six degrees of freedom even if the window pane 3 is not yet fitted. Knocking about of the catch 2 caused by jolts during transportation is thus avoided and the fitting of the window pane 3 is considerably facilitated.
The catch 2 , an injection-moulded plastics part, has an upwardly open slit 14 for receiving a lower edge 15 of the window pane 3 . In order to make possible the connection of the window pane 3 and the catch 2 as a form-fit, the catch has in addition two locking elements 16 for snapping into two recesses in the window pane 3 which are not recognisable in the figure. In addition, an opening 17 is provided in the catch 2 which, for connecting the catch 2 to the window pane 3 , can receive as an exact fit a pin which at the same time engages through a recess in the window pane 3 which is in alignment with this opening 17 when the window pane 3 is fitted. A form-fit connection of the catch 2 and the window pane 3 is then produced both by the locking elements 16 and by the above-mentioned pin.
The window pane 3 can now be fitted in an advantageous manner in the illustrated window lift system by the catch 2 being first positioned in the described manner and fixed in respect of all the degrees of freedom by being pulled by the downwardly pulling end 10 of the traction cable 5 into its lowermost position and thus onto the supports 12 with the cones 13 . Thereafter the window pane 3 can be introduced into the window lift system until the window pane 3 and the catch 2 assume positions which correspond to each other, i.e. in the depicted example until the window pane 3 also assumes a lowermost position. In this process, a form-fit connection of the catch 2 and the window pane 3 is produced virtually automatically in that the locking elements 16 snap into the corresponding recesses in the window pane 3 . An even better connection can by produced by the already-mentioned pin (or bolt) being pushed through the opening 17 and the recess in the window pane 3 which corresponds to this opening 17 . Because the catch is positioned and fixed in a defined position before the window pane 3 is introduced, the lower edge 15 of the window pane 3 travels virtually automatically into the slit 14 in the catch 2 as the window pane 3 is introduced, without the catch 2 having to be held manually in an expensive manner for this purpose.
Another embodiment of the invention is shown in FIG. 2 . There, too, a door module for an automotive vehicle is illustrated in a corresponding view. Recurring features are here and in the following figure provided with the same reference numerals and are not specifically explained any more. Differing from the previously described embodiment, the means for positioning and fixing the catch 2 are here provided by a single lower stop 18 and two walls 19 and 19 ′ communicating with this lower stop 18 , serving as guiding means and laterally guiding the catch 2 on a lower section of a downward movement. The two walls 19 and 19 ′ converge downwards in a funnel-like manner.
The window lift system illustrated in FIG. 2 is here so designed that, for fitting the window pane 3 , the catch 2 is only positioned and fixed in respect of five of six degrees of movement. For this purpose it is again pulled downwards by the downwardly pulling end 10 until one of its ends rests on the stop 18 , where it is admittedly also held in a defined position in respect of a direction perpendicular to the window pane 3 as a result of lateral guidance by the walls 19 and 19 ′ (wall 19 ′ being part of the panel portion 1 of the door module), but first remains in an inclined position which is indicated in FIG. 2 by a dotted line. Even if the catch 2 has not yet been positioned and fixed in respect of all the degrees of freedom, the slit 14 thus comes to rest in an area defined by the window pane 3 , for which reason fitting the window pane 3 by introducing it into the window lift system is also possible here without any problem. The catch 2 is then, as the window pane 3 is introduced, or more exactly as the lower edge 15 of the window pane 3 travels into the slit 14 in the catch 2 , pressed by the window pane 3 itself into the lowermost position which corresponds to a fully opened window once the window pane 3 is fitted and in which connection of window pane 3 and catch 2 can take place in the manner already described. Depending on the dimensions and relative arrangement of the different components of a window lift system of the described type, with other embodiments it can also be sufficient if the catch 2 is able to be positioned and fixed by the positioning and fixing means only in respect of two or three degrees of freedom.
A further embodiment of the invention is finally illustrated in FIG. 3 . In the window lifting device depicted there and arranged again on a panel part 1 of a door module, the means for positioning and fixing the catch 2 include, beside a lower stop 18 , an opening 20 in the panel part 1 and a corresponding opening 21 in the catch 2 , this corresponding opening 21 , which is indicated in a broken line in FIG. 3 , being designed merely as a depression on a side of the catch 2 facing the panel part 1 . The openings 20 and 21 are so arranged that they face one another when the catch 2 assumes its lowermost position which is indicated in FIG. 3 again by a dotted line. For positioning and fixing the catch 2 in the lowermost position, which serves as the fitting position during the fitting of the window pane 3 , a pin, which is not indicated in FIG. 3 , can be inserted from the dry side through the opening 20 in the panel part 1 into opening 21 . In the depicted embodiment, this pin is provided as a headless screw, the opening 20 in the panel part 1 being provided with a thread matching this headless screw. The catch 2 can therefore be fixed by the above-mentioned headless screw, produced for example from plastics material, being screwed through the opening 20 in the panel part 1 into the opening 21 in the catch 2 . After a window pane 3 has been fitted, i.e. after the introduction of the window pane 3 into the window lift system and connection of the window pane 3 with the catch 2 has taken place in the described manner, the headless screw can then be screwed back until the catch 2 is released and can later be moved up and down with the window pane 3 for opening and closing the window. The headless screw remaining in the opening 20 in the panel part then still serves to seal the opening 20 in the panel part 1 in order to prevent water penetrating into a dry region of the corresponding vehicle door. Removing the headless screw and then sealing the opening 20 with a plug would also be possible. It is possible to proceed in the same manner if, instead of the headless screw, a simple bolt is used as the pin.
In similar embodiments of the invention, a plurality of pins, preferably two, and a corresponding number of openings or depressions in the panel part 1 and in the catch 2 can be provided in order to fix the catch 2 in the described manner, preferably in a position which corresponds to a possible position of the catch 2 once the window pane is fitted. Differently from the embodiment depicted in FIG. 3 , this position does not necessarily have to correspond to the lowermost position of the catch 2 . In similar embodiments of the invention, provision can also be made for such a screw or such a pin not to be screwed or pushed through the panel part 1 into the catch 2 , but through the catch 2 into the panel part 1 . Finally, instead of a pin or a screw, another tool can be provided which engages through the opening 20 and can grasp and hold the catch 2 .
In the window lift systems illustrated in FIGS. 1 to 3 , in each case the window pane 3 is guided on one side by a single guide rail 11 . However, rail-free window lifting devices can also be embodied in a completely analogous manner. Finally, other embodiments of the invention can differ from the window lift systems depicted in the figures in that, instead of the single traction cable 5 , two independent pulling devices (for example cable pulls or chains) are provided, one of which forms the upwardly pulling end 8 and the other the downwardly pulling end 10 .
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A window lift system, especially for the side window of a motor vehicle, includes (i) a pulling device and (ii) a catch for a window pane, which can be moved up and down using the pulling device. The catch has a first fastening point for an upward pulling end of the pulling device and a second fastening point for a downward pulling end of the pulling device, which point is horizontally off-set from the first fastening point in the window pane plane when the window pane is fitted. The window lift system also includes (iii) an arrangement positioning and fixating the catch in terms of at least three degrees of freedom so that the catch can be maintained in a position that is defined in terms of the degrees of freedom even when the window pane is not yet fitted.
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BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present invention relates to a device for the collection of articles, such as waste, dirty laundry, and the like. The device is comprised of a carrying frame formed with a plurality of cutouts or cutouts, into which can be inserted in each case a bag-like receptacle produced from a plastic film, from a textile fabric, from paper, or the like. The receptacles are fastenable to the carrying frame.
[0002] It is known, for the collection of articles, in particular of garbage, to provide a metal or plastic container, into which there is inserted a bag-like receptacle which is produced from a plastic film, from a textile material or from paper. The articles are thereby introduced into the bag-like receptacle which, when it is filled, is then removed from the container and disposed of.
[0003] Insofar as a plurality of containers are provided next to one another, which are intended, for example, for receiving biowaste, glass, metal, plastics, and/or paper, a separation of the collected articles can thereby take place.
[0004] In prior art devices of this type, the bag-like receptacle inserted into the container is folded round outwardly with its upper edge around the upper edge of the container. There is therefore no need to fasten the bag-like receptacle to the container, since the bag-like receptacle serves, in particular, for protecting the container from being soiled by the collected waste, and the container serves for receiving or supporting the receptacle filled with articles.
SUMMARY OF THE INVENTION
[0005] It is accordingly an object of the invention to provide a device for collecting articles which overcomes the above-mentioned disadvantages of the heretofore-known devices and methods of this general type and which achieves a plurality of advantages.
[0006] On the one hand, the bag-like receptacles are to be capable of being disposed of at the same time as their contents and are to be reusable, but no carrying receptacle is to be required. For this purpose, the upper edges of the receptacles must be fastened in a carrying frame in a stable manner according to the requirements and, regardless of this, so as to be easily releasable.
[0007] On the other hand, the bag-like receptacles are to be fastened to the carrying frame in such a way that the latter is not soiled by the articles, which may be waste.
[0008] Further, it is to be possible to have the capability of filling the individual receptacles to different extents.
[0009] With the foregoing and other objects in view there is provided, in accordance with the invention, a device for collecting articles (waste, dirty laundry, etc.), comprising:
[0000] a carrying frame formed with a plurality of cutouts having surrounding edges formed with a clamping contour;
[0000] bag-type receptacles having upper edges for fastening to said carrying frame at said cutouts;
[0010] frame-shaped or ring-shaped, elastically deformable holding shackles being substantially closed on themselves and being configured for insertion into said cutouts, wherein said upper edges of said bag-like receptacles are fastened to said carrying frame by clamping between said holding shackles and said clamping contour on said carrying frame.
[0011] In other words, the above objects are achieved, according to the invention, in that the carrying frame is designed all-round, at the edgings surrounding the cutouts, with projecting strips, grooves or the like, into which frame-shaped or ring-shaped elastically deformable holding shackles assigned to the bag-like receptacles and at least virtually closed on themselves can be inserted, the upper edges of the bag-like receptacles being capable of being clamped between the holding shackles and the strips, grooves or the like provided on the carrying frame.
[0012] Preferably, the carrying frame is located within a clearance provided on the top side of a housing, in particular of a cabinet or the like, said carrying frame being capable of being lifted off from the housing or of being pivoted with respect to the latter.
[0013] According to a further preferred embodiment, a holding frame, against which the carrying frame comes to bear, is inserted into the cutout provided in the housing, in particular in the cabinet or the like. In this case, at least one part of the bars of the holding frame may be designed with an outwardly projecting web, which bears on the top side of the cabinet or the like, and with an inwardly projecting web, onto which the carrying frame comes to bear.
[0014] Further, the cutouts may be assigned at least one cover, wherein case this cover and/or the carrying frame may be pivotable on the housing. Further, the cover may be actuable by means of a hand lever or a foot lever.
[0015] Preferably, the housing is designed on one side wall with an orifice, in particular with an orifice closable by means of a door. Further, the carrying frame may be adjustable in an approximately horizontal direction with respect to the housing, for which purpose, in particular, a telescopic guide is provided. Finally, the carrying frame may be designed with upwardly projecting strips, on which a carrying shackle designed with a diametrically opposite profile can be placed, the upper edge of the bag-like receptacle being capable of being clamped between the carrying frame and the carrying shackle.
[0016] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0017] Although the invention is illustrated and described herein as embodied in a device for the collection of articles, such as waste, dirty laundry and the like, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0018] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 shows a first device according to the invention in a diagrammatic and exploded illustration;
[0020] FIG. 2 shows a device according to FIG. 1 in a further perspective illustration;
[0021] FIG. 3 is a partial sectional view of the device according to the invention taken along the line III-III of FIG. 2 ;
[0022] FIG. 4 is a partial, vertical section showing a variant of the device according to the invention;
[0023] FIG. 5 is a partial, vertical section showing a further variant of the device according to the invention;
[0024] FIG. 6 shows a second embodiment of a device according to the invention in an axonometric illustration;
[0025] FIG. 7 shows a third embodiment of a device according to the invention in an axonometric illustration;
[0026] FIG. 8 shows a fourth embodiment of a device according to the invention in vertical section and in a partially truncated illustration;
[0027] FIG. 9 shows a fifth embodiment of a device according to the invention, likewise in vertical section and in a partially truncated illustration;
[0028] FIGS. 10, 11 , and 12 are views corresponding to FIGS. 1, 2 , and 3 , respectively, of an embodiment of the invention with an additional holding frame;
[0029] FIG. 12A is a section of an enlarged detail of FIG. 12 ;
[0030] FIGS. 13-19 are views corresponding to FIGS. 4-6 , 8 , and 9 , of the embodiment of the invention with the additional holding frame.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a cabinet housing or cupboard 1 , the top side of which is designed as a carrying frame 2 which can be inserted into this and which is provided with four cutouts 21 , into which bag-like receptacles 4 for receiving articles can be inserted. For this purpose, the edges of the cutouts 21 are formed with a clamping contour, such as inwardly projecting strips 22 . Instead of the strips 22 , the inner edgings of the cutouts may be formed with grooves. The bag-like receptacles 4 are produced, for example, from a plastic film, from a textile fabric, or from paper.
[0032] The cutouts 21 of the carrying frame 2 are assigned elastically deformable holding shackles 3 which can be inserted into the cutouts 21 in such a way that they come to bear on the strips 22 . The holding shackles 3 have a frame-shaped design for their deformability, one of the legs 31 being interrupted, so that the holding shackles 3 can be reduced in size as a result of elastic deformation.
[0033] The holding shackles 3 are assigned the bag-like receptacles 4 which are drawn with their upper edge over the holding shackles 3 and are turned inward.
[0034] Finally, a cover 5 is provided, which is designed with a handle 51 and by means of which the cutouts 21 can be covered. Instead of a handle, for example, a suction cup or a gripping depression may also be provided.
[0035] According to the illustrations of FIGS. 2 and 3 , two of the holding shackles 3 are inserted into the carrying frame 2 , whereas two holding shackles 3 are not yet inserted. As is further evident from FIG. 3 , the carrying frame 2 lies on a strip 13 projecting inward from the inner walls of the cabinet 1 .
[0036] With reference to FIG. 4 , the cover 5 may be pivotally fastened to, or articulated at, the cabinet 1 by way of a hinge 52 . The carrying frame 2 may also be fastened pivotally to the cabinet 1 by means of a hinge.
[0037] According to FIG. 5 , each cutout 21 may be assigned a separate cover 5 a.
[0038] In the embodiments of a device according to the invention which are illustrated by means of FIG. 1 to 5 , the empty receptacles 4 are inserted through the perforations 21 into the cabinet 1 and their upper regions are clamped with respect to the carrying frame 2 by means of the holding shackles 3 and the strips 22 or the grooves provided in these, with the result that said receptacles are held in the carrying frame 2 . They may thereupon be filled with various articles.
[0039] As soon as the filled receptacles 4 are to be removed so that the articles contained in these can be disposed of, the holding shackles 3 are released from the strips 22 or grooves and taken off. The carrying frame 2 can thereupon be lifted off or pivoted up, with the result that the filled receptacles 4 can be lifted out of the cabinet 1 . Empty receptacles 4 can subsequently be inserted into the cabinet 1 again.
[0040] As illustrated further in FIG. 6 , the cabinet 1 may be designed on its front side with a door 11 . In this embodiment, the filled receptacles 4 do not need to be lifted out of the cabinet 1 as soon as the holding shackles 3 have been removed from the carrying frame 2 , but, instead, they can be taken out of the cabinet 1 laterally.
[0041] In the embodiment according to FIG. 7 , the carrying frame 2 can be moved out of the cabinet 1 laterally by means of a telescopic guide 12 , wherein the filled receptacles 4 can then be removed as soon as the holding shackles 3 have been lifted off from the carrying frame 2 . There is also shown a foot lever 53 or hand lever 53 for actuating the lid 5 . The lid 5 may be pivoted into the open position when the foot or hand lever 53 is actuated.
[0042] In the embodiment according to FIG. 8 , the carrying frame 2 is designed with upwardly open grooves 23 which are assigned U-profiled holding shackles 3 a . As soon as the empty receptacles 4 have been inserted into the cutouts 21 , their upper edges are introduced into the grooves 23 and are fastened to the carrying frame 2 by means of the holding shackles 3 a which are placed on them. As soon as the filled receptacles 4 are to be extracted from the cabinet 1 , the holding shackles 3 a are removed and the carrying frame 2 is lifted off upward or pivoted up. In this case, too, the orifices 21 are assigned covers 5 a.
[0043] The embodiment according to FIG. 9 differs from the embodiment according to FIG. 8 in that the carrying frame 2 is fastened to the cabinet 1 . So that in this case the filled receptacles 4 can be extracted more easily, the cabinet 1 may be designed with a lateral door.
[0044] It is additionally pointed out that the cutouts 21 may also be delimited in round or oval form, the holding shackles 3 having a corresponding shape. It is in this case critical, in any event, that the holding shackles 3 be elastically deformable, so that they can be inserted into the cutouts 21 , at the same time coming to bear on the strips 22 . In this case, the bag-like receptacles 4 are clamped between the holding shackles 3 and the cutouts 21 , as a result of which these receptacles are held in position even when they are partially or completely filled with articles.
[0045] Insofar as the carrying frame 2 is accessible only from above, the filled bag-like receptacles 4 are lifted out of the cabinet 1 upward. However, insofar as the carrying frame 2 is also accessible on its underside, the bag-like receptacles 4 may be drawn off downward as soon as the holding shackles 3 a have been released. A telescopic guide 12 according to the embodiment illustrated in FIG. 7 , by means of which the bag-like receptacles 4 can be displaced laterally with respect to the carrying frame 2 , makes it particularly easy to remove the filled bag-like receptacles 4 .
[0046] The cabinet 1 may also be designed with a roller blind or with a sliding door instead of a lateral cabinet door. Instead of the cabinet, the carrying frame may also be provided on a fold-in carrying stand.
[0047] A device of this type can be used, in particular, for the collection of garbage which is separated according to its material properties. It is also suitable, however, for the collection of other articles, such as articles of clothing.
[0048] As illustrated in FIG. 10 , there is also the possibility of providing, for fastening the carrying frame 2 to the cabinet 1 , an additional holding frame 14 , the side bars of which have in cross section a vertical web 14 a and two horizontal webs 14 b and 14 c from the latter. In this case, the upper horizontal web 14 b comes to bear on the top side of the cabinet 1 , the vertical web 14 a runs parallel to the edging 10 of the cabinet 1 , and the lower horizontal web 14 c projects inward from the holding frame 14 . The carrying frame 2 comes to bear on the web 14 c.
[0049] The particular advantage of this design is that the upper orifice of the cabinet 1 does not need to be designed with any strips or grooves which are complicated to produce. Instead, in an available piece of furniture, only one orifice which has the unprofiled edging 10 is to be produced. The additional holding frame 14 , which is prefabricated as an integral part of the entire device, serves for supporting the carrying frame 2 for the bag-like receptacles 4 .
[0050] FIG. 11 to 16 show the embodiments according to FIG. 2 to 6 and 8 , a holding frame 14 being additionally provided in each case. By means of such an additional holding frame 14 , a cabinet 1 or the like can be designed in a simple way with a device according to the invention at a later date, in that the cover plate of the cabinet 1 has produced in it a cutout, into which a device according to the invention designed with a holding frame 14 is inserted.
[0051] FIGS. 18 and 19 illustrate a variant of the embodiment according to FIGS. 16 and 17 , according to which the carrying frame 2 is designed with an inwardly projecting carrying strip 24 , on which the holding shackles 3 come to bear.
[0052] It is additionally pointed out that the covers 5 and 5 a may be designed at their edges with a sealing strip.
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A device for the collection of articles, such as waste, dirty laundry and the like, has a carrying frame with several cutouts, into which can be inserted in each case a bag-like receptacle produced from a plastic film, from a textile fabric, from paper or the like. The receptacles are fastenable to the carrying frame. The carrying frame is formed all-round, at the edgings surrounding the cutouts, with a clamping contour in the form of projecting strips, grooves, or the like, into which frame-shaped or ring-shaped, elastically deformable holding shackles assigned to the bag-like receptacles and at least virtually closed on themselves can be inserted. The upper edges of the bag-like receptacles can be clamped between the holding shackles and the clamping contour on the carrying frame.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to the field of dental cement compositions, and in particular to two-part glass ionomer compositions featuring longer shelf life, enhanced handling characteristics and improved strength.
[0003] 2. Description of the Related Art
[0004] The conventional Glass Ionomer compositions represent a two-part system, one part being in a liquid form and the other in a powder form. The liquid represents a solution of oligomers or copolymers of acrylic acid. The molecular weight of such polymers is usually in the range of 40,000 to 50,000 and their concentration may vary from about 40% to 60%. The powder is composed of fine alkaline glass particles. Its chemical composition usually includes silicon and aluminum oxides, calcium fluoride, and modifying additives, which may include aluminum, sodium or barium fluorides, alkaline or alkaline earth metal oxides, aluminum phosphate and zinc, zirconium or titanium oxides.
[0005] Powder/liquid systems are the least desirable forms of self (chemically) cured dental cements and restoratives. Maintaining proper proportion of the ingredients of the cement can be critical for reproducibly achieving acceptable properties of the cured material. It is extremely difficult, however, to meet such a requirement with powder/liquid systems, considering the small quantities of materials involved in the preparation of mixes for dental applications and the imprecise tools used for dispensing such materials.
[0006] Glass ionomer compositions can be particularly sensitive to variations in proportions of its components. Dental assistants and clinicians are accustomed to other types of cements and restoratives that do not require the materials to be dispensed in a high level of precision; therefore they can have little understanding of the differences in handling requirements when glass ionomer type materials are involved as compared to other materials. Imprecise dispensing may, however, have a detrimental effect on the mechanical properties, resistance to the oral environment, curing characteristics, ability to bond to dentin and tooth enamel, and oral tissue compatibility of the cured product.
[0007] Generally, an excess of liquid in the composition will result in slower setting of materials, greater susceptibility to deterioration when exposed to saliva, and/or greater potential for oral tissue irritation. On the other hand, an excess of powder causes mixes to be too dry and may not allow for sufficient working time. The consistency of such mixes may make them unsuitable for applications where flowability of the mix is mandatory, such as in a capacity as cavity liners, orthodontic band cements and crown and bridge cements. In addition, such formulations are likely to be excessively brittle after cured and their ability to bond to the tooth structure will be impaired.
[0008] Minor variations in the characteristics of the conventional glass ionomer liquid or powder, such as variations in the molecular weight of the polyacrylic acid and particle size of the glass, may render the originally designed dispensing system unsuitable. Moreover, changes in ambient temperature influence the viscosity and surface tension of the liquid. Consequently, variations in drop sizes, when the liquid is dispensed from a conventional dropper-type bottle, may affect the powder/liquid ratio and alter the consistency of the mix. The conventional way of dispensing powder with a scoop represents an intrinsically imprecise technique, as the bulk density of the powder may vary with time due to settling and the way the powder is handled (shaking, vibration, pounding, etc.). All these factors may affect the properties and, in some instances, the safety of the material, rendering its suitability for the intended purpose questionable.
[0009] Additional problems, related to variations in the particle size of the powder may also be encountered. Manufactured powders consist of blends of different size particles. Variations in particle size distribution among different batches of commercial products are virtually unavoidable. Larger particles tend to migrate to the bottom of the container, leaving finer particles on top. Using the same dispensing method for powders consisting of different-sized particles will result in mixes of varying consistencies and unpredictable working and setting times. Smaller sized glass particles will shorten the working time and result in mixes characterized by denser consistencies.
[0010] A common characteristic of prior art glass ionomer compositions is their undesirably short working time. In order to assure desirable properties of the cured cement, mixing of the components and completion of the application procedures should be accomplished before the blend starts to show signs of setting. However, preparation of powder/liquid mixes is time consuming, leaving clinicians with little latitude to complete the application within the allowed working time. Moreover, an operator's inexperience or haste may result in the operator preparing non-homogenous mixes with negative consequences on the characteristics of the cured product.
[0011] Powder/liquid systems are also undesirable from an economic point of view because substantial waste of the material is unavoidable. Dispensing of components generally cannot be accomplished in a way that closely approximates the amount of material the clinician needs, thus a large part of the dispensed material is frequently wasted.
[0012] To alleviate the shortcomings of powder/liquid versions of glass ionomers, one solution has been offered, derived from a technique used in packaging more expensive brands of dental amalgams. Such a system is comprised of a two-compartment capsule, separated by a breakable diaphragm. One of the compartments is filled with a measured amount of the powder, and the other with the liquid component of the glass ionomer formulation.
[0013] After the diaphragm is broken, the capsule is vigorously shaken for a specified period of time, using a vibrator type machine, producing relatively homogeneous mixes of more consistent quality. Such technique eliminates some of the shortcomings of the conventionally dispensed glass ionomer compositions, assuring better reproducibility of the properties of the cured cements and simplifying handling. However, it significantly increases the cost per application and the waste. Also, handling of the material, although much easier when compared to individually dispensing the powder and liquid components, still remains complex. The working time remaining after removal of the capsules from the vibrator is still inconveniently short.
[0014] Attempts to formulate glass ionomer compositions in a form different from the conventional powder/liquid system have brought, up to now, little success. Some advantages of glass ionomers include their ability to bond to the tooth structure without the necessity of acid etching, and to protect the teeth from decay due to a sustained release of fluoride. Preservation of these characteristics, combined with the need to meet requirements related to mechanical strength, curing characteristics and safety, has imposed severe restrictions on the chemical composition, concentration and physical form of the material components. Researchers were also severely limited in their options of incorporating various additives which, although otherwise highly desirable, could have a detrimental effect on the more critical properties of the cement.
[0015] Previous efforts to change the physical form of the components of glass ionomer materials have been made in order to make them more convenient to use, some of which resulted in modifications of their chemical compositions. These new formulations, while encompassing some of the original glass ionomer's components, have differed from the original concept of glass ionomers in important aspects, including their basic chemistry and curing mechanism. Consequently, many major advantages of glass ionomers, including their ability to bond to the tooth structure, to sustain a desirable level of fluoride release, and to prevent tooth decay, were severely compromised.
[0016] Most common examples of such modified formulations comprise blends of methacrylate monomers with glass ionomer-type powders used as fillers. They represent a light-cured one-component system or a self- (chemically-) cured two component system. Their mechanism of cure relies on the chain-forming (or -lengthening) action of ethylenically unsaturated methacrylate monomers, while the curing mechanism of unadulterated glass ionomers is based on the reaction of the carboxylic group in polyacrylic acid with alkaline sites of glass powder. This distinctive mechanism of curing and the presence of water in glass ionomer formulations seemed to be key for their ability to bond to the tooth structure and to provide sustained fluoride release.
[0017] Some of the shortcomings of the prior art glass ionomer systems were addressed in U.S. Pat. No. 5,965,632 which describes a two paste glass ionomer system comprising in one part a blend of 50%-95% of an aqueous solution of polyacrylic acid, or its blends or copolymers with other ethylenically unsaturated acids, thickened with inert inorganic fillers, and the second part comprising a blend of alkaline glass with water, thickened to a desired consistency.
[0018] Although the technology of this invention provided glass ionomer compositions featuring more convenient dispensing and handling when freshly made, its shortcomings include a limited shelf life due to gradually changing consistency (thickening) of the paste containing glass powder and relatively low mechanical strength of the cured material.
[0019] Some prior publications relating to the field of this invention include U.S. Pat. No. 5,965,632 issued Oct. 12, 1999 to Jan A. Orlowski et al., U.S. Pat. No. 5,520,922 issued May 28, 1996 to Oswald Gasser and Rainer Guggenberger, U.S. Pat. No. 5,520,725 issued May 28, 1996 to Kato-Shin-Ichi et al., U.S. Pat. No. 5,382,284 issued Jan. 17, 1995 to Thomas J. Arnold, U.S. Pat. No. 5,367,002 issued Nov. 22, 1994 to Huang Chim-The et al. and U.S. Pat. No. 5,063,257 issued Nov. 5, 1991 to Akahan Shoji et al.
SUMMARY OF THE INVENTION
[0020] In accordance with a preferred embodiment, there is provided a novel glass ionomer composition (e.g., dental cement) comprising first and second components or parts. The first part is preferably a paste or viscous liquid comprising an aqueous solution of polymers or copolymers of acrylic acid. Preferably the aqueous solution of polymers or copolymers of acrylic acid is present at 60% to 100% by weight of the total weight of the first part, and/or the polymers have molecular weights of about 35,000 to 75,000. The second part is preferably a paste comprising alkaline glass flux and water soluble/miscible monomers and/or pre-polymers (e.g. oligomers) of such monomers, having at least one —OH group per molecule. The alkaline glass flux preferably has an average particle size of about 0.2 to about 30 microns, and/or is present at about 50% to 90% by weight of the total weight of the second part. The water soluble/miscible monomers and/or pre-polymers of such monomers, having at least one —OH group per molecule are preferably present at about 10% to 50% by weight of the total weight of the second part. In a preferred embodiment, the second part further comprises one or more poly (C1-C4) alkyl methacrylate polymers, preferably polymethylmethacrylate, polyethylmethacrylate and/or copolymers of methyl- and ethyl-methacrylate, preferably having molecular weights of 100,000 to 1,500,000, and/or present at a total of up to 10% by weight, including 0.5% to 10%, 1% to 10% and 1% to 8% by weight.
[0021] In certain especially preferred embodiments, the new dental cements provide improved shelf life, strength and/or handling as compared to prior art materials, such as the two paste type glass ionomer cement described in U.S. Pat. No. 5,965,632. The present compositions preferably also allow for broad latitude in adjusting their characteristics to meet particular requirements. In one embodiment, the pastes may be dispensed by using a dual barrel type syringe device and/or blended in a static mixer attached to such a device.
[0022] Preferred embodiments herein are the result of one or more of the following unexpected and unforeseeable findings that allowed for development of glass ionomer compositions featuring desirable characteristics for the envisioned applications. One finding is the desirability of the absence, or virtual absence, of water in the part of the composition containing the glass ionomer powder. The presence of water in both parts of the prior art two paste system was deemed necessary to arrive at a workable composition featuring desirable characteristics and to meet the minimum requirements for the cured glass ionomer cement, including a sufficient range of working and curing times, adequate mechanical strength, ease of handling, longevity (shelf life), tolerance to ambient conditions, and/or resistance to oral environment. It was also desirable to preserve as many advantageous features of the conventional glass ionomer cements as possible, including their ability to bond to teeth (dentin and enamel) and to provide sustained fluoride release, for preventing the occurrence, or reoccurrence, of decays.
[0023] Another finding is the tolerance of preferred compositions to the presence of organic hydrophilic compounds at relatively high concentrations. Such compounds are employed herein as thickening and suspending agents, including in the part of the composition containing powdered alkaline glass. Unexpectedly, the presence of such a water soluble/miscible component does not substantially weaken the cured material, or cause its deterioration in a water environment. To the contrary, the cements containing such ingredients exhibit most desirable mechanical characteristics and resistance to moisture. Although not wishing to be bound by theory, it is theorized that this could be explained by the unexpected occurrence of a secondary side reaction of the unreacted group of polyacrylic acid with the hydroxy-groups of the hydrophilic additives, during the later phase of the curing process.
[0024] Furthermore, the present compositions preferably also have the ability to cure by light induced polymerization of ethylenically unsaturated components particularly acrylate and methacrylate monomers or prepolymers, in addition to the conventional glass ionomer curing mechanism of reaction between polycarboxylic acid(s) and alkaline glass.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Preferred embodiments as disclosed herein provide an ionomer composition comprising two components or parts, preferably in a viscous physical form, such as a paste or viscous liquid. All percentages stated herein are weight percentages based on total weight of the component in which it is present, unless otherwise stated.
[0026] The first component comprises an aqueous solution comprising polymers made from monomers comprising acrylic acid. These materials may be referred to herein as “polymers of acrylic acid” or “polymers comprising acrylic acid”, but it is to be understood that this means a polymer formed from the polymerization of monomer units, wherein the monomer units comprise acrylic acid. In some embodiments the polymer is a homopolymer and in other embodiments, other monomers may be present (such as to form a copolymer), preferably other ethylenically unsaturated acids such as itaconic acid and maleic acid, including in amounts ranging from about 1% to about 50%, including about 1% to 5%, and 5% to 10%. The first component preferably comprises about 60% to 100% by weight of an aqueous solution comprising polymers comprising acrylic acid, including about 60% to 90%, 70% to 90% or 70 to 80% by weight. In embodiments where more than one type of polymer solution is present, the stated preferred ranges correspond to the sum of the weights of each type present. The aqueous solution portion of the first component is itself a solution in which the polymer preferably makes up about 35%-70% by weight of the total weight of the aqueous solution, including about 48% to 63%, and 50% to 65% by weight. The polymers preferably have viscosity-based molecular weights in a range of about 30,000 to about 300,000, including about 30,000 to 75,000, and about 40,000 to 60,000.
[0027] In one embodiment, the polymer comprising acrylic acid may comprise an oligomer made from monomers comprising acrylic acid or a mixture of oligomers having different molecular weights. In another embodiment, the polymer comprising acrylic acid may include copolymers of acrylic acid with other ethylenically unsaturated organic acids. The oligomers comprising polyacrylic acid may be substituted, entirely or partially, by their copolymers with other ethylenically unsaturated organic acids, preferably maleic acid or itaconic acid.
[0028] In some embodiments, the first part or component contains more than one type of the polymers comprising acrylic acid. For example, the first component may comprise an aqueous solution of two or more polyacrylic acids of different molecular weights or a polyacrylic acid homopolymer and a polyacrylic acid/maleic acid copolymer. In another example, the first component can comprise an aqueous solution of two different copolymers of acrylic acid and ethylenically unsaturated organic acids, or an aqueous solution of a mixture of one kind of copolymer but present in two different molecular weights. Molecular weights referred to herein are viscosity-based molecular weights and are thus represent an aggregate or averaging of the molecular weights of the polymers in the solution said to have such molecular weight.
[0029] In some embodiments, the first component may further comprise preferably up to 30% by weight of inorganic filler (including about 1% to 30%, 5% to 25%, 10% to 25%, 10% to 20%, and 15 to 25% by weight), and/or preferably up to 10% by weight organic filler (including 1% to 10% and 2% to 8% by weight). The stated percentage ranges refer to the sum of all inorganic fillers present if one or more such fillers are present. Preferred inorganic fillers include quartz, glass, aluminum oxides, silica, and combinations thereof. Preferred organic fillers include powdered polymers such as polyethylene, polypropylene, polytetrafluoroethylene, polymethylmethacrylate, polyethylmethacrylate, nylon or any combination thereof. In one embodiment, the organic filler comprises methoxy polyethyleneglycol having a molecular weight of about 750. In another embodiment, the organic filler comprises a synthetic polypropylene wax. In addition, the first part or component of some embodiments may further comprise up to 20% by weight of tartaric acid, maleic acid, itaconic acid or any combination thereof, including 1% to 20%, 1% to 10%, and 2% to 6% by weight.
[0030] The second component preferably comprises about 50% to 90% by weight, including about 50% to 80%, 60% to 90%, 60% to 80% and 60 to 70% by weight, of a particulate glass flux (e.g., alkaline glass flux or powdered alkaline glass) in a liquid medium. The particulate glass flux preferably comprises silicon and aluminum oxides and calcium fluoride. It may optionally include one or more modifying additives, including aluminum, barium or sodium fluorides, alkaline or alkaline earth metal oxides, zirconium-, titanium- and zinc-oxides and aluminum phosphate, preferably at about 0.1% to 2% by weight including about 0.3% to 0.8%. In preferred embodiments, the alkaline glass particles have an average size of about 0.2 to about 30 microns, including about 0.2 to 4 microns.
[0031] The liquid medium portion of the second component or part preferably comprises about 10% to 50% by weight, including about 20% to 50%, 10% to 40%, 20% to 40% or 30 to 40% by weight, of a liquid medium (either a single liquid or the sum of one or more liquids). In preferred embodiments, the liquid medium is essentially anhydrous, meaning that there is no added water and preferably less than about 0.5%, including less than about 0.4%, 0.3%, 0.2%, 0.1%, 0.05, or 0.01% water by weight in the liquid medium. In other embodiments, the liquid medium contains very little water, preferably less than about 2% by weight, including less than about 1%, and about 1% to about 2%. In other embodiments, the second component may comprise more water, up to 12% water, including 2% to 10%, and 2% to 6%. The liquid medium preferably comprises water miscible acrylate or methacrylate monomers, or pre-polymers (e.g. oligomers) of such monomers, having at least one hydroxyl group per molecule. In preferred embodiments, the water miscible monomers or pre-polymers comprise hydroxyethylmethacrylate, hydroxypropylmethacrylate, glycerolmethacrylate, glyceroldimethacrylate, and combinations thereof.
[0032] In some embodiments, the second part further comprises up to 12% by weight of a total of one or more other kinds of water soluble polymers, including 2% to 12%, 2% to 10% and 1% to 8% by weight. Such materials can modify the rheological characteristics of the part and preserve homogeneity upon storage. Preferred water soluble polymers include polyalkalene glycols (e.g., polyethylene glycol and polypropylene glycol), polyalkalene-ether glycols (e.g., polytetramethylene-ether glycol) and any combination thereof. In one embodiment, the water soluble polymer comprises polytetramelylene-ether glycol having a molecular weight of about 600 to about 5,000, including about 800 to about 5,000, about 1,000 to about 5,000 and about 1,000 to about 3,000.
[0033] In still other embodiments, the second part or component comprises a total of preferably up to 10% by weight, including 0.5% to 10%, 0.5% to 7%, 1% to 10% and 1% to 8% by weight of one or more poly (C1-C4) alkyl methacrylate polymers, preferably polymethylmethacrylate, polyethylmethacrylate and/or copolymers of methyl- and ethyl-methacrylate, such polymers preferably having molecular weights of 100,000 to 1,500,000. These polymers may enhance the mechanical characteristics of the cured cement and prevent phase separation during storage. Unexpectedly, ionomer compositions disclosed herein tolerate the presence of these organic hydrophilic compounds, even at a relatively large concentration. Not only were the cured ionomer compositions of these embodiments not weakened by such additives, but, unexpectedly, they have shown advantageous mechanical characteristics and resistance to moisture. In one embodiment, inclusion of a methyl-/ethyl-methacrylate polymer increased the compressive strength of the cured material by 25% as compared to a formulation not including the polymer.
[0034] Other ingredients may be optionally incorporated in the first and/or second parts to enhance the physical properties, appearance, clinical performance, biocompatibility or shelf life of the compositions.
[0035] In some embodiments, the second component further comprises a total of preferably up to 20% by weight, including a total of 0.5% to 20%, 1% to 15%, 1% to 10% and 1% to 4%, of other ingredients. Other ingredients include suspending/thickening agents such as to achieve desirable consistency of a paste and to prevent sedimentation of the glass particles. Suspending/thickening agents include powdered inert glass, quartz, aluminum oxide, silica, zinc oxide or any combination thereof. In other embodiments, additives or other ingredients such as aluminum phosphate, sodium fluorides, barium fluorides, aluminum fluorides, alkaline or alkaline metal oxides, zinc oxide, zirconium oxide or titanium oxide may also be incorporated. Additives may have different or variable functions, such as: thickening/suspending agents, accelerators or retarders of the curing process, preservative, improving mechanical characteristics of cured material or its X-ray opacity, enhancing mineralization of teeth or their esthetics.
[0036] In some embodiments, the second part may include one or more light inducible polymerization activators, allowing for the material to cure as a result of two independent processes: (1) reaction between carboxylic acid(s) with alkaline glass, and (2) light induced polymeration of ethylenically unsaturated monomers or pre-polymers. Most frequently used polymerization activators are quinones and tertiary amines, exemplified by camphoroquinone, dimethyloaminoethyl methacrylate, triethylamine, 2-hydroxyethyl-diethylamine, triethenoloamine, and the like. In one embodiment, the second part comprises about 2% to 15% by weight, including about 5% to 10% by weight of one or more light curable monomers and/or about 0.3% to about 5% by weight, including about 1% to about 3%, of one or more light activated polymerization initiators (e.g. light inducible polymerization activator) that cause curing of monomers present in the second part. In some embodiments, the light inducible polymerization activator system may comprise 0.1 to 1% of camphoroquinone and 0.3 to 3.5% dialkylaminoalkylmethacrylate (e.g., dimethylaminoethylmethacrylate), both present in the second component.
[0037] In some embodiments, the first and second parts have different appearances, such as different or contrasting colors. Such coloration or shading can assist in achieving better control of the uniformity of the mixes. For certain dental applications, it is desirable that the cement composition after cure has an appearance resembling the color of the tooth. The requirement for various tooth color shades can be easily met by incorporating coloring agents, including pigments or dyes acceptable for intra-oral use, into one or both components. Particularly suitable coloring agents for the formulations include pigments based on iron oxides.
[0038] It is desirable, but not critical, that the two components of the system exhibit similar consistency, viscosity, and/or thixotropic behavior. This facilitates control over the ratios of the amounts dispensed and allows for using a dual barrel syringe dispensing system, including one equipped with a static mixer. Such device for dispensing the ionomer composition may offer time savings, avoidance of operator errors, and/or better control of working time, which can provide more consistent cured material characteristics. Depending on the design of a particular formulation, the first and the second components may be mixed at volumetric ratios of 1:4 to 4:1 (e.g., 1:4, 2:3, 3:2, 4:1, etc.), including at 1:1 ratio.
[0039] Examples of formulations and properties of the ionomer compositions are given below. These examples are provided for the purpose of illustration and for better understanding of the materials disclosed herein. They are presented, however, with no intention of limiting the invention as claimed.
EXAMPLE 1
[0040] The ionomer composition was formulated as follows. The first part was a paste having the following composition:
62% aqueous solution of polyacrylic acid, MW ˜50,000 74% Tartaric Acid 5% Quartz 20% Silica 1%
[0041] The second part was a paste having the following composition:
Alkaline glass powder 60% Hydroxyethylmethacrylate 33% Polytetramethylene-ether glycol, MW ˜2,000 6% Silica 1%
[0042] These two pastes were simultaneously dispensed in volumetrically equal proportions from a dual barrel syringe unit equipped with a static mixer. At 23° C., the working time of the mix was 90 seconds, and the setting time was 3.5 minutes. The compressive strength after cure was 64-71 MPa after 72 hours exposure to 37° C. at 100% humidity. The material in its uncured form has shown no signs of changes upon storage and the properties of the cured cement made from such aged compositions have also remained unchanged.
EXAMPLE 2
[0043] The ionomer composition was formulated as follows. The first part was a paste having the following composition:
50% aqueous solution of polyacrylic acid, MW ˜45,000 40% 65% aqueous solution of polyacrylic acid, MW ˜50,000 40% Polyacrylic acid, MW ˜100,000 1.5% Quartz 17% Silica 1.5%
[0044] The second part was a paste having the following composition:
Alkaline glass powder (<10μ) 66% Hydroxyethylmethacrylate 24% Polytetramethylene-ether glycol, MW ˜1,000 8.0% Silica 1.5%
[0045] These two pastes were mixed together in volumetrically equal proportions. At 23° C., the working time of the mix was 90 seconds, and the setting time was 210 seconds. The compressive strength of the material after exposure for 24 hours at 37° C. to 100% humidity was in excess of 65 MPa. The consistencies of the pastes allowed for easy dispensing from dual barrel syringes equipped with a static mixer. The pastes did not show any phase separation, changes in color or consistency after 1 month of storage at 37° C.
EXAMPLE 3
[0046] The ionomer composition was formulated as follows. The first part was a paste having the following composition:
63% aqueous solution of polyacrylic acid, MW ˜48,000 76% Silica 2% Fused quartz (<20μ) 20% Methoxypolyethyleneglycol, MW ˜750 2%
[0047] The second part was a paste having the following composition:
Alkaline glass powder 60% Hydroxypropylmethacrylate 32% Polytetramethylene-ether glycol, MW ˜2,000 4% Silica 1.6% Quartz 2.4%
[0048] These two pastes were mixed together in volumetrically equal proportions. At 23° C., the working time of the mix was 100 seconds, and the setting time was 240 seconds. The pastes remained unchanged after storage for 14 weeks at 23° C.
EXAMPLE 4
[0049] The ionomer composition was formulated as follows. The first part was a paste having the following composition:
50% aqueous solution of polyacrylic acid, MW ˜50,000 75% Tartaric acid 4% Synthetic polypropylene wax 8% Fused quartz (<20μ) 13%
[0050] The second part was a paste having the following composition:
Alkaline glass powder (<10μ) 61% Hydroxyethylmethacrylate 33% Polytetramethylene-ether glycol, MW ˜3,000 3.5% Silica 1.5% Germaben II (a preservative) 0.5% Zinc oxide 0.5%
[0051] The two pastes were mixed together in volumetrically equal proportions. At 23° C., the working time of the mix was 130 seconds, and the setting time was 240 seconds. Both pastes were stable upon storage at room temperature with respect to their consistencies and curing characteristics.
EXAMPLE 5
[0052] The glass ionomer composition was formulated as follows. The first part was a paste having the following composition:
48% solution of polyacrylic acid, MW ˜50,000 80% Tartaric acid 2% Silica 3% Fused quartz (<20μ) 15%
[0053] The second part was a paste having the following composition:
Alkaline glass powder (<4μ) 64% 66% Hydroxyethylmethacrylate 31% Methyl-/ethyl- methacrylate, copolymer, MW ˜600,000 1.5% Silica 1.5%
[0054] These two pastes were mixed in volumetrically equal proportions. At 23° C., the working time was 150 seconds and the setting time was 300 seconds. The compressive strength of the material after exposure for 24 hours at 37° C. to 100% humidity was in excess of 125 Mpa. The consistency allowed for easy dispensing from dual barrel syringes equipped with a static mixer.
EXAMPLE 6
[0055] The ionomer composition that provides a dual light/chemical curing mechanism was formulated as follows. The first part was a paste having the following composition:
60% aqueous solution of polyacrylic acid, MW ˜58,000 75% Quartz 20% Tartaric acid 5%
[0056] The second part was a paste having the following composition:
Alkaline glass powder (<10μ) 60% Polytetramethylene-ether glycol, MW ˜2,000-3,000 2.5% Silica 4% Hydroxyethyl methacrylate 22% 7,7,9-trimethyl-4,13 dioxo,3,4-dioxa-5,12 diaza-hexedecan-1,6- 9.5% diol dimethacrylate (common name: diurethane dimethacrylate) Camphoroquinone 0.5% Dimethylaminoethyl methacrylate 1.5%
[0057] The two pastes were mixed together in volumetrically equal proportions. At 23° C., the working time was 140 seconds, and the setting time was 300 seconds. When the mix was irradiated for 40 seconds using an Optilux 500™ dental curing light, the cured material was less brittle than its self cured only counterpart and a significant decrease in its solubility was also noticed, indicating the occurrence of polymerization of unreacted ethylenically unsaturated components.
[0058] The various compositions and methods described above provide a number of ways to carry out certain preferred embodiments. Of course, it is to be understood that not necessarily all objectives or advantages described may be achieved in accordance with any particular embodiment described or claimed herein. Thus, for example, those skilled in the art will recognize that the compositions may be made and the methods may be performed in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objectives or advantages as may be taught or suggested herein.
[0059] Furthermore, the skilled artisan will recognize the interchangeability of various features from different embodiments. Similarly, the various components and features discussed above, as well as other known equivalents for each such component or feature, can be mixed and matched by one of ordinary skill in this art to make compounds and perform methods in accordance with principles described herein.
[0060] Although the invention has been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that the invention extends beyond these specifically disclosed embodiments to other alternative embodiments and/or uses and obvious modifications and equivalents thereof. Accordingly, the invention is not intended to be limited by the specific disclosures of preferred embodiments herein.
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Disclosed is a novel glass ionomer type dental cement composition comprising a first component comprising an aqueous solution of polymers made from monomers comprising acrylic acid, and a second, preferably substantially anhydrous, component comprising alkaline glass flux in a medium comprising water soluble/miscible monomers or pre-polymers, of such monomers, having at least one —OH group per molecule. The compositions offer more convenient handling, excellent reproducibility of desired properties of the cured material, improved strength, and extended shelf life.
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BACKGROUND OF THE INVENTION
This application relates to bacteriocin compositions for use as enhanced broad range bactericides and methods of preventing and treating microbial infection.
Bacteriocins such as lysostaphin and nisin are proteins produced by bacteria that inhibit the growth of and sometimes kill bacteria closely related to the species of their origin. Lysostaphin is a bacteriocin that lyses and kills practically all known species of Staphylococcus, but is inactive against bacteria of other genera. Lysostaphin, isolated from culture filtrates of Staphylococcus simulans (NRRL B-2628) grown according to published references, is an endopeptidase which cleaves the polyglycine cross-links of the peptidoglycan found in the cell walls of Staphylococcus. Cultures of S. simulans grown under conditions which induce the production of lysostaphin are immune to the bacteriocin while the same cultures grown under conditions whereby lysostaphin is not produced are sensitive to the bacteriocin.
Lysostaphin is a naturally occurring bacteriocin secreted by a single known strain of S. simulans originally isolated and named Staphylococcus staphylolyticus by Schindler and Schuhardt. The production of lysostaphin by S. staphylolyticus has been described previously in U.S. Pat. No. 3,278,378 issued Oct. 11, 1966 and in Proceedings of the National Academy of Sciences, 51:414-421 (1964). The single organism S. staphylolyticus (NRRL B-2628) which produced lysostaphin was recently identified as a biovar of S. simulans by Sloan et al., Int. J. System. Bacteriol., 32:170-174 (1982). Since the name S. staphylolyticus is not on the Approved List of Bacterial Names, the organism producing lysostaphin has been redesignated as S. simulans.
Previously it was shown that the action of lysostaphin can be potentiated by penicillin and other antibiotics. See copending U.S. application No. 188,183 to Blackburn et al. filed Apr. 28, 1988.
Nisan, although sometimes referred to as a peptide antibiotic is more properly referred to as a bacteriocin. Nisin is produced in nature by various strains of the bacterium Streptococcus lactis. It is a food preservative used to inhibit the outgrowth of spores of certain species of Gram positive bacilli, including those arising from strains of Clostridium known to be responsible for Botulism food poisoning. A summary of nisin's properties appears in Hurst, Advances in Applied Microbiology, 27:85-123 (1981). The publication describes what is generally known about nisin. Nisin, produced by Streptococcus lactis, is commercially available as an impure preparation, Nisaplin™, (Aplin & Barret Ltd., Dorset, England)
Nisin belongs to the class of peptides containing lanthionine. Also included in that class are subtilin, epidermin, cinnamycin, duramycin, ancovenin, and Pep 5. These bacteriocin peptides are each produced by different microorganisms. However, subtilin obtained from certain cultures of B. subtilis, and epidermin obtained from certain cultures of Staphylococcus epidermidis, have molecular structures very similar to that of nisin, Hurst, pp. 85-86; and Schnell et al. Nature 333:276-278. Structurally similar, lanthionine containing peptide bacteriocins are believed to be effective in place of nisin in the present invention.
Nisin has been applied effectively as a preservative in processed cheese, and dairy products. The use of nisin in processed cheese products has been the subject of recent patents. See U.S. Pat. Nos. 4,584,199 and 4,597,972. The use of nisin to inhibit the outgrowth of certain Gram positive bacterial spores has been well documented. See Taylor, U.S. Pat. No. 5,584,199, and Taylor, U.S. Pat. No. 4,597,972, Tsai and Sandin, "Conjugal Transfer of Nisin Plasmid Genes from Streptococcus lactis 7962 to Leuconostoc dextranicum 181", Applied and Environmental Microbiology, p. 352 (1987); "A Natural Preservative", Food Engineering International, pp. 37-38 (1987); "Focus on Nisin", Food Manufacture, p. 63 (1987). Nisin is sometimes found naturally-occurring in low concentration in milk and cheese, and is believed to be completely non-toxic and non-allergenic to humans. Nisin has recently been recognized as safe by the FDA as a direct food ingredient in pasteurized cheese spread, pasteurized processed cheese spread and pasteurized or pasteurized processed cheese spread with fruits, vegetables, or meats. As nisin is proteinaceous, any residues in ingested foods are quickly degraded by digestive enzymes.
The general acceptance of nisin as a food preservative has been limited by the teaching that, as a bacteriocin, the activity of nisin was restricted to include only those Gram positive bacteria closely related to the bacterial species of its origin. Furthermore, nisin has not previously been shown to have bactericidal activity towards Gram negative bacteria. Since food contamination and spoilage result from a diversity of Gram positive and Gram negative bacteria, it is not surprising, therefore, that nisin has received only limited acceptance as a food preservative. Moreover, because of the heretofore restricted activity of nisin as a bacteriocin, its uses as such outside of the food area have not been indicated.
It has recently been demonstrated that a composition comprising nisin and non-bactericidal agents such as chelating agents and surfactants has bactericidal activity towards a wide range of Gram negative bacterial species and enhanced activity towards a broad range of Gram positive bacterial species. For instance Gram negative bacteria shown to be sensitive to the enhanced bactericide are Salmonella typhimirium, Escherichia coli, Klebsiella pneumoniae, Pseudomonas aeruginosa, Bacterioides gingivalis and Actinobacillus actinomycetescomitans. Gram positive bacteria shown to be sensitive to the enhanced bactericides are Staphylococcus aureus, Streptococcus mutans, Listeria monocytogenes, Streptococcus agalactiae and coryneform bacteria. See copending Blackburn et al., U.S. patent application entitled Nisin Compositions For Use as Enhanced, Broad Range Bactericides which is a continuation-in-part of U.S. patent application Ser. No. 209,861 filed June 22, 1988 which is hereby incorporated herein by reference.
SUMMARY OF THE INVENTION
It has now been found that the activity of bacteriocins such as lysostaphin and nisin can be surprisingly enhanced and the overall range and speed of their activity can be increased by combining the two bacteriocins. The properties of the novel bacteriocin compositions containing lysostaphin and nisin should also be further enhanced by the addition of chelating agents and/or surfactants which enhance and broaden the range of nisin and lysostaphin activity.
All the novel bacteriocin compositions of this invention comprise lysostaphin and nisin (herein "composition"). The bacteriocin composition becomes an enhanced broad range bactericide (hereinafter "bactericide") on being dissolved or suspended in a suitable carrier for example a solvent or suitable liquid, solid, or colloidal matrix. The novel bactericides contain lysostaphin in an amount sufficient to be effective as a bactericide towards Staphylococcus, and nisin is present in an amount sufficient to enhance the bactericidal effect of lysostaphin toward Staphylococci. Other compositions comprise lysostaphin, nisin, and a chelating agent and may also contain a surfactant. This composition in a carrier yields a novel bactericide wherein the lysostaphin and nisin are present in the same concentration range as in the lysostaphin/nisin composition and the chelating agent is present in an amount sufficient to enhance the bactericidal effect of nisin against both Gram positive and Gram negative bacteria. A still further composition comprises lysostaphin, nisin, and a surfactant. This composition in a carrier yields a novel bactericide wherein the surfactant is present in an amount sufficient to enhance the bactericidal effect of nisin and lysostaphin against Gram positive bacteria.
The compositions can be used directly or in carriers for treatment and prevention of bacterial contamination and infection by dissolving the composition in a suitable solvent or suspending in a suitable matrix and applying it to an affected area or by adding it to another composition to combat and prevent infection.
Most chemical disinfectants are too corrosive or otherwise too toxic to be used in foods and many medical applications, the majority of antibiotics act too slowly to be useful as disinfectants, and are not permitted in foods because of the risk of acquired antibiotic resistance that would attend such use. The novel bactericides are non-corrosive, non-toxic, suitable for use in foods and on open wounds, effective against antibiotic resistant bacteria and act rapidly against dividing or non-dividing bacteria, so as to be useful also as a disinfectant.
The compositions or the bactericides can be incorporated into ointments or coatings for the treatment of infections, wound dressings or surgical implants and other medications such as nasal instillations, oral rinses, disinfectant scrubs, wipes or lotions. The bactericides can be used for cleaning medical instruments and the like and in circumstances where environmental disinfection is desired but where chemical germicidals are precluded because of the risks of corrosive or otherwise toxic residues. The broad range bactericides are particularly suited for food related uses such as treatment of meat, especially poultry, eggs, cheese and fish or food packaging and handling equipment, and for the control and prevention of contamination of raw ingredients, processed foods and beverages by bacterial pathogens and other microbial spoilage organisms.
Unlike the activity of most broad spectrum germicidals which is compromised by the presence of complex organic matter, the bacteriocin compositions and bactericides of the present invention are effective in the presence of organic matter, such as milk or serum.
DETAILED DESCRIPTION OF INVENTION
The compositions of the claimed invention comprise lysostaphin and nisin, lysostaphin, nisin and a chelating agent, or lysostaphin, nisin, a chelating agent and a surfactant. To provide enhanced broad range bactericides, the compositions are dissolved in a suitable solvent or suspended in a suitable matrix. Compositions comprising lysostaphin, nisin, a chelating agent and/or a surfactant, dissolved in a suitable carrier for example an aqueous solvent or buffer or suspended in a suitable matrix, are believed to have broad range rapid bactericidal activity against both Gram positive and Gram negative bacteria.
Preferably the composition is dissolved in a liquid carrier or suspended in a liquid, colloidal or polymeric matrix such that lysostaphin is present in the bactericide in the range of 0.1 to 100 μg/ml and is enhanced by the presence of the bacteriocin nisin in the range of 0.1 to 300 μg/ml and the resulting bactericide is significantly more bactericidal towards Staphylococcus than lysostaphin alone. The total bactericidal activity of such a novel bactericide is believed to be further potentiated and effective against a broader range of both Gram negative and Gram positive bacterial species when the nisin in the bactericide is enhanced by a chelating agent as taught by copending application to Blackburn et al. entitled Nisin Compositions For Use as Enhanced, Broad Range Bactericides. The combination of lysostaphin, nisin and a chelating agent should also attain further broad range bactericidal activity by the addition of a surfactant as also taught by the Blackburn et al. application.
For example nisin is activated and enhanced toward a broad range of Gram positive bacteria by a chelating agent such as EDTA in the range of 0.1 to 20.0 mM. In the presence of EDTA, nisin has bactericidal activity against Gram negative organisms and its activity against Gram positive bacteria is enhanced and active over a wider pH range and towards a broader range of Gram positive bacteria. In addition the presence of a surfactant in the range of 0.01% to 1.0% in the bactericide improves the effectiveness of the nisin towards Gram positive bacteria. Suitable nonionic surfactants include, but are not limited to polyoxyalkylphenols (e.g. Triton X-100), polyoxyalkylsorbitans (e.g. Tweens), and glycerides (e.g. monolaurin and dioleates). Suitable ionic surfactants include, but are not limited to emulsifiers, fatty acids, quaternary compounds and anionic surfactants (e.g. sodium dodecyl sulphate) and amphoteric surfactants, for example, cocamidopropyl betaine.
Suitable carriers for the bactericides of the present invention include but are not limited to generally recognized aqueous buffers. Suitable matrices for suspension of the novel compositions of the present invention include but are not limited to organic solvents, colloidal suspension and polymers compatable with the bactericide.
Lysostaphin used in the invention can be produced by fermentation techniques wherein S. simulans is grown in liquid culture. Such fermentation techniques are described in U.S. Pat. No. 3,278,378 and in Proceedings of the National Academy of Sciences, 51:414-421 (1964). Various improvements in the production of lysostaphin by fermentation techniques have also been made as documented in U.S. Pat. Nos. 3,398,056, and 3,594,284. The latter two references disclose improvements in culture medium and inoculation techniques whereby the production of lysostaphin by fermentation can be accelerated and improved.
In addition, lysostaphin can be produced by recombinant microorganisms, including strains of Escherichia coli, Bacillus subtilus, and Bacillus sphaericus. A method for obtaining lysostaphin from microorganisms transformed by recombinant plasmids encoding the gene for lysostaphin is fully disclosed in U.S. patent application No. 034,464, which is a continuation-in-part of U.S. patent application No. 852,407. Both applications are incorporated herein by reference. Preferably, the lysostaphin is obtained from B. sphaericus strain 00, containing a recombinant plasmid which directs the synthesis of lysostaphin. This provides for production of high levels of lysostaphin substantially free from staphylococcal immunogenic contaminants and facile lysostaphin purification since the lysostaphin accumulates directly in the growth medium. B. sphaericus transformants containing plasmids pBC16-lL or pROJ6649-IL have been found to be particularly suited for this purpose, although other strains are also useful as a source of lysostaphin. These plasmids are fully described in the above-mentioned copending applications.
Produced by S. simulans during exponential growth, lysostaphin is first secreted as an inactive precursor that is processed extracellularly to the mature active bacteriocin by a protease produced in the stationary growth phase. In contrast to the natural production of lysostaphin, lysostaphin produced by a recombinant strain of B. sphaericus as described in U.S. patent application No. 034,464, accumulates extracellularly as the mature active protein during the exponential growth phase.
Nisin can be obtained commercially as an impure preparation, Nisaplin™ from Aplin & Barrett, Ltd., Dorset, England, and can be obtained by isolating naturally-occurring nisin from cultures of Streptococcus lactis and then concentrating the nisin by known methods. There are also reported methods for producing nisin using altered strains of Streptococcus. See Gonzalez, et al. U.S. Pat. No. 4,716,115 issued Dec. 29, 1987. It should also be possible to produce nisin by recombinant DNA. Nisin is a member of the family of lanthionine containing bacteriocins. It is believed that, due to the structural similarity, other lanthionine containing bacteriocins will be equally as effective as nisin in combination with lysostaphin.
The following non-limiting examples will further illustrate the invention and demonstrate the effectiveness of the new enhanced broad range bactericides. It is believed that since the degree and range of nisin activity are also enhanced by chelating agents, the compositions of lysostaphin, nisin and a chelating agent will also yield novel bactericides with enhanced bactericidal activity compared to compositions of lysostaphin and nisin alone.
All tests in the following examples were performed at 37° C. The efficacy of the enhanced broad range bactericides was determined by assaying bactericidal activity as measured by the percent bacterial survival after treatment with the bactericide. Generally, after incubation of a 10 7 cell per ml suspension of target species with the novel bactericide for specified lengths of time, bacteria were collected by centrifugation for 2 minutes. The bacterial pellet was washed free of the bactericide with a rescue buffer, termed herein Phage buffer (50 mM Tris-HCl buffer pH 7.8, 1 mM MgSO 4 , 4 mM CaCl 2 , 0.1M NaCl, and 0.1% gelatin), resuspended and serially diluted into Phage buffer, and 100 μl of the suspended bacteria were spread on nutrient agar plates. Surviving bacteria were determined by scoring colony forming units (CFU) after incubation for 24-48 hours at 37° C. An effective bactericide according to this invention is one which allows less than 0.1% of the initial viable count of the bacteria to survive.
EXAMPLE 1
Lysostaphin and Nisin
Staphylococcus aureus cells were suspended and incubated in milk at 37° C. for 2 hours with various concentrations of lysostaphin, nisin, or a combination of lysostaphin and nisin in the milk. The bactericidal efficacy of the bactericides was estimated by determining the percent survival of bacteria as described above. The results of such an experiment are given in Table 1.
TABLE 1______________________________________Bactericidal Activity of Lysostaphin, Nisin,and Their Combinations Towards Stachylococcus aureusLysostaphin Nisin μg/mlμg/ml 0 0.2 0.5 1.0 2.0 4.0______________________________________ % survival 2 hr.sup.a0 100 45 33 9 2.5 0.5 0.50.1 43 0.7 2.6 0.15 0.04 0.004 5.6 <10.sup.-31.0 <10.sup.-3 <10.sup.-4 -- -- <10.sup.-4 --______________________________________ .sup.a Initial viable counts: 5 × 10.sup.7 cfu/ml.
Nisin alone in milk has little practical bactericidal activity towards Staphylococci. Lysostaphin alone in milk is bactericidal towards S. aureus and can produce more than a five log reduction in viable cells at a concentration of 1.0 μg/ml. Lysostaphin, when combined with nisin in the milk, provides a composition which is a novel bactericide whereby the bactericidal activity of the bactericide is significantly and surprisingly superior to that of either bacteriocin alone and is more active than their anticipated additive effects. This is best illustrated at a limiting lysostaphin concentration (0.1 μg/ml) shown in Table 1. Thus, when the application of lysostaphin is limited by its available activity, a bacteriocin composition comprising lysostaphin with nisin in a suitable carrier such as milk in this example can be expected to provide an enhanced broad range bactericide.
EXAMPLE 2
Lysostaphin+Nisin+EDTA+Surfactant
The data in Table 2 illustrate the novel bactericide potency of a composition comprising lysostaphin, nisin, EDTA, and monoglyceride surfactant towards S. aureus and S. algalactiae in milk, a complex food medium. Previously, it was shown that low concentrations of EDTA potentiate the activity of nisin while higher concentrations of EDTA inhibited the activity of nisin, see the copending application to Blackburn, et al. In milk, higher concentrations of EDTA are less inhibitory to the bactericidal activity of the bacteriocin composition.
TABLE 2______________________________________Bactericidal Activity of Lysostaphin, Nisin,EDTA, and Monoglyceride in milk at 37° C. towardsStaphylococcus aureus and Streptococcus agalactiae 0.23 L 0.1 L 1.0 N 1.0 NSpecies 0.1% ML 1.0% ML Control.sup.c______________________________________ % Survival 2 hrS. agalactiae.sup.b 0.0001.sup.E 0.0007.sup.E 100(McDonald)S. aureus.sup.a 0.004.sup.E 0.002.sup.E 100(Newbould)______________________________________ N = Nisin μg/ml; L = Lysostaphin μg/ml; ML = monolaurin E = contained 50 mM EDTA a = S. aureus initial viable count: 8.1 × 10.sup.7 cells/ml b = S. agalactiae initial viable count: 6.6 × 10.sup.7 cells/ml c = no bacteriocin or monoglyceride
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Broad range bacteriocin compositions are provided. The compositions can be dissolved or suspended in a suitable solvent or matrix and are more active towards a broader range of bacteria than are any of the component parts. The dissolved or suspended compositions constitute enhanced broad range bactericides. The compositions include lysostaphin and a lanthionine containing peptide bacteriocin; lysostaphin, a lanthionine containing peptide bacteriocin and a chelating agent; and lysostaphin, a lanthionine containing peptide, a chelating agent and a surfactant. Each component is present in the enhanced broad range bactericide in sufficient amount such that the bactericide is more effective against staphylococci than is lysostaphin alone and is more effective at treating and preventing a broad range of microbial infections. Methods of treating bacterial infections using said compositions and bactericides are provided.
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CLAIM TO PRIORITY
[0001] The present application is a continuation of U.S. patent application Ser. No. 09/545,539, filed Apr. 7, 2000, and entitled “ACOUSTIC DOOR ASSEMBLY.” The identified patent application is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to doors and, more particularly, to doors incorporating enhanced sound isolation features.
BACKGROUND OF THE INVENTION
[0003] Acoustic doors are a significant element in the realm of performing arts centers, concert halls, broadcast studios, auditoriums, and movie theaters as well as in industrial applications where noise or voice privacy may be required. To effect noise or voice privacy, i.e., isolate absorb sound, it is important that a door be insulated, however, it is also important that the door seal tightly and, if possible, completely against its supporting frame.
[0004] However, many designs focus only on the structure of the door itself ignoring the involvement of the frame in obtaining effective sound absorption. For instance U.S. Pat. No. 4,998,598 describes an acoustic door wherein the door is comprised of multiple panels, each panel having three layers, two of which are high density materials such as hardboard; a door supporting frame is not discussed. Likewise, U.S. Pat. No. 5 , 416 , 285 describes an acoustical door wherein the door is comprised of multiple plies, the plies being separated by spacer networks; again, a door supporting frame and the additional sound absorption features it may provide in combination with the door is not discussed.
[0005] U.S. Pat. No. 5,371,987 does discuss an acoustic combination of a door and frame. Specifically, the '987 patent describes an acoustical door and frame system wherein the door is secured to the frame via a plurality of cam hinges that are spaced along the length of the door. Upon closing the door against the frame, the cam hinges lower the door to be positioned against an elastomeric seal that extends along the sides and top of the frame. The elastomeric seals are held in adjustable retainers for positioning of the seals to create optimum interference with the door and are compressed by the closing of the door.
[0006] The cam hinges used in the '987 patent help to move the door into a desired sealing position against the frame, however, because the hinges are spaced periodically along the door, complete support is not provided to the door allowing for the possibility of warpage in the position of the door and, therefore, the possibility of reduced sound isolation. Further, the use of an elastomeric seal, i.e., a soft and possibly porous seal, allows for the possibility of gaps between the door and frame and, therefore again, the possibility of reduced sound isolation.
[0007] In view of the above, there is a need for an acoustic door assembly that addresses the acoustic benefits that can be provided by the combination of a door and its supporting frame. Further, there is a need for an acoustic door and frame combination that is able to provide complete support to the door, thereby preventing warpage and the possibility of reduced sound isolation, and that is able to provide a seal between the door and frame that is not subject to gapping.
SUMMARY OF THE INVENTION
[0008] The needs described above are in large measure met by an acoustic door assembly of the present invention. The acoustic door assembly generally comprises a door, a frame and a hinge. The door of the assembly is an insulated, acoustic door having a predetermined length. The frame of the assembly is positioned proximate the door and is joined thereto by the hinge. The hinge is a continuous cam-lift hinge having a length that is substantially equivalent to the predetermined length of the door and is secured along the length of the door.
[0009] The insulated, acoustic door is preferably comprised of a first portion and a second portion where at least of a section of the first and second portion are separated by an insulating layer. The first portion is then crimped about the insulating layer to join the first portion of the door to the second portion of the door. The door also preferably includes a TEFLON® fabric-coated sweep and may or may not include a viewing window. The frame preferably includes a dual-magnetic seal to which the hinge is positioned externally.
[0010] A method of constructing an acoustic door assembly generally includes the steps of erecting a frame and securing an insulated, acoustic door to the frame through use of a continuous cam-lift hinge. The continuous cam-lift hinge has a length that is substantially equivalent to the length of the door and is secured to the door along that length.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a perspective view of an acoustic door assembly of the present invention that includes a frame, door, and hinge; the door is in a semi-open position.
[0012] [0012]FIG. 2 is a cross-sectional view of the acoustic door assembly wherein the door is in a closed position.
[0013] [0013]FIG. 3 is a perspective view of a first weldment of the frame of the acoustic door assembly.
[0014] [0014]FIG. 4 is a side view of the first weldment of FIG. 3.
[0015] [0015]FIG. 5 is a top view of the first weldment of FIG. 3.
[0016] [0016]FIG. 6 is a front view of a second weldment of the frame of the acoustic door assembly.
[0017] [0017]FIG. 7 is a cross-sectional view of the second weldment of FIG. 6.
[0018] [0018]FIG. 8 is a top view of the second weldment of FIG. 6.
[0019] [0019]FIG. 9 is a perspective view of a solid door and hinge of the acoustic door assembly.
[0020] [0020]FIG. 10 is a cross-sectional view of the door and hinge of FIG. 9.
[0021] [0021]FIG. 11 is a perspective view of the door and hinge of the acoustic door assembly wherein the door incorporates a window.
[0022] [0022]FIG. 12 is a cross-sectional view of the door and hinge of FIG. 11.
[0023] [0023]FIG. 13 is perspective view of a first portion of the hinge of the acoustic door assembly.
[0024] [0024]FIG. 14 is a side view of the first portion of the hinge of FIG. 13 prior to the winding of the hinge barrels.
[0025] [0025]FIG. 15 is a side view of the first portion of the hinge of FIG. 13 after the winding of the hinge joints.
[0026] [0026]FIG. 16 is a cross-sectional view of the first portion of the hinge of FIG. 13.
[0027] [0027]FIG. 17 is a perspective view of the mating portion of the hinge of the acoustic door assembly.
[0028] [0028]FIG. 18 is a side view of the mating portion of the hinge of FIG. 17 prior to the winding of the hinge joints.
[0029] [0029]FIG. 19 is a side view of the female portion of the hinge of FIG. 17 after the winding of the hinge joints.
[0030] [0030]FIG. 20 is a cross-sectional view of the female portion of the hinge of FIG. 17.
[0031] [0031]FIG. 21 provides a front and rear view of the acoustic door assembly of the present invention wherein the door incorporates a small window and is in the closed position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] An acoustic door assembly 10 of the present invention, is depicted in FIGS. 1 - 21 and provides the user with improved sound isolation qualities. In general, acoustic door assembly 10 comprises a frame 12 , an acoustic door 14 and a hinge 16 .
[0033] Frame 12 is a split steel frame having a first weldment, i.e., first portion 20 and a second weldment, i.e., second portion 22 . First weldment 20 of frame 12 is depicted in detail in FIGS. 3 - 5 . As shown, first weldment 20 includes a pair of side walls 24 and a top wall 26 that joins the tops of side walls 24 . Side walls 24 and top wall 26 incorporate a framing edge 28 that extends along the outer perimeter of each of walls 24 and 26 . A cross brace 30 extends between the lower inner comers of side walls 24 , and is included for shipping purposes only (removed upon installation of frame 12 ). One of side walls 24 incorporates a plurality of apertures 32 for insertion of rivet nuts 33 for the securing of hinge 16 to frame 12 .
[0034] Second weldment 22 of frame 12 is depicted in detail in FIGS. 6 - 8 . As shown, second weldment 22 includes a first side wall 34 , a second side wall 36 , and a top wall 38 joining first side wall 34 and second side wall 36 . Each of walls 34 , 36 , and 38 incorporates a framing edge 40 that extends along its outer perimeter. Further, top wall 38 includes a plurality of slots 39 that extend along its exterior; slots 39 are welding sites used to secure second weldment to first weldment 20 . Specifically, slots 39 are used to plug weld first weldment 20 to second weldment 22 ; additional welding to secure first weldment 20 and second weldment is provided 22 at the corners of the weldments 20 , 22 . Screws 41 , shown by hidden lines in FIG. 2, secure side walls 34 and 36 to side walls 24 of first weldment 20 .
[0035] First side wall 34 incorporates a first seal support rail 42 and a second seal support rail 44 . First seal support rail 42 is bounded by a side wall 46 , a rear wall 48 , and a looped side wall 50 . Second seal support rail 44 is bounded by a side wall 52 , a rear wall 54 , and a looped side wall 56 . Via the various wall configurations, shown most clearly in FIG. 7, a substantially-square chamber 58 is formed intermediate first seal support rail 42 and second seal support rail 44 .
[0036] Second side wall 36 also incorporates a first seal support rail 60 and a second seal support rail 62 . First seal support rail 60 is bounded by a side wall 64 , a rear wall 66 and a looped side wall 68 . Second support rail 62 is bounded by a side wall 70 , a rear wall 72 , and a looped side wall 74 . Via the various wall configurations shown most clearly in FIG. 7, a rectangularly shaped chamber 76 is formed intermediate first seal support rail 60 and second seal support rail 62 .
[0037] Referring to FIG. 2, additional detail regarding the sealing structure of frame 12 is provided. As shown, first seal support rail 42 and second seal support rail 44 of first side wall 34 are each provided with a unitary, extruded vinyl seal 79 that includes a clip portion 80 that is slid over support rails 42 and 44 . Each vinyl seal 79 further includes a central portion 82 that incorporates an air gap and an upper portion 84 that encases a magnet 85 . A substantially square foam absorber 86 is placed within chamber 58 and additional neoprene foam absorbers 88 are provided as indicated on FIG. 2. A layer of intumescent material 89 is provided proximate foam absorber 86 .
[0038] Likewise, first seal support rail 60 and second seal support rail 62 of second side wall 36 are each provided with a unitary, extruded vinyl seal 91 that includes clip portion 90 that is slid over support rails 60 and 62 . Each vinyl seal 91 further includes a central portion 92 that incorporates an air gap and an upper portion 94 that encases a magnet 95 . A rectangularly-shaped foam absorber 96 is placed within chamber 76 and additional foam absorbers 98 are provided as indicated on FIG. 2. A layer of intumescent material 99 is provided proximate foam absorber 96 .
[0039] With respect to foam absorbers 86 and 96 , they are comprised of open-cell urethane foam having two sides covered with non-woven cloth. Absorbers 86 and 96 are retained by interference-fit into chambers 58 and 76 and are captured by the geometry of the chamber. Pressure-sensitive adhesive may be applied to one or more of the surfaces of absorbers 86 and 96 , if desired, to prevent unauthorized removal of the absorbers. With respect to foam absorbers 88 and 98 , they are of a neoprene foam and are preferably adhered to frame 12 . Intumescent material layers 89 and 99 are provided to foam and expand when heated to prevent smoke and ignitable gases from getting past seals 84 and 94 and are also adhered to frame 12 .
[0040] Referring to FIGS. 9 and 10, door 14 in a solid configuration is depicted. As shown, door 14 includes a solid, outer leaf steel weldment 110 that is substantially planar in nature and a solid, inner leaf steel weldment 112 formed to include a pair of forward walls 114 , a pair of side walls 116 and a rear wall 118 joining side walls 116 . Outer leaf weldment 110 includes formed looping edges 120 that wrap about each of forward walls 114 crimping outer leaf weldment 110 to inner leaf weldment 112 . A layer of neoprene rubber insulation 122 is provided between looping edges 120 and forward walls 114 . Further, a recessed block of fiberglass insulation 124 is provided to the front and rear of inner leaf weldment 112 . The recessed blocks of fiberglass insulation 124 are separated by an insulating layer of air 126 . The lower portion of door 14 is provided with an adjustable height sweep 128 that is preferably coated in a TEFLON® fabric. Full length cam hinge 16 , described in further detail below, is shown in the open position and is secured to door 14 by welding.
[0041] Referring to FIGS. 11 and 12, door 14 incorporating a window 140 is depicted. Once again, door 14 includes an outer leaf weldment 142 and an inner leaf weldment 144 both incorporating an open window area 146 . Outer leaf weldment 142 is substantially planar in nature while inner leaf weldment 144 is formed to include a pair of forward walls 150 , a pair of side walls 152 and a rear wall 154 joining side walls 152 . Outer leaf weldment 142 is formed to include looping edges 156 that wrap about each of forward walls 150 thereby crimping outer leaf weldment 142 to inner leaf weldment 144 . A layer of neoprene rubber insulation 155 is provided between looping edges 156 and forward walls 150 . On either side of open window area 146 is provided an open-cell foam block 160 to provide sound absorption at the sides of open window area 146 . Blocks of fiberglass insulation 162 are provided, one to the front of inner leaf weldment 144 and one to the rear of inner leaf weldment 144 . The blocks of fiberglass insulation 162 are separated by an insulating layer of air 164 . The lower portion of door 14 is provided with an adjustable height sweep 166 that is preferably coated in a TEFLON® fabric. Full length cam hinge 16 , described in further detail below, is shown in the closed position and is secured to door 14 by welding.
[0042] With respect to window 140 , it is comprised of two panes of glass, one surface mounted to outer leaf weldment 142 and one to inner leaf weldment 144 . The edge of each pane of glass is surrounded by a u-channel rubber gasket 170 . A retaining strip 172 is placed over gasket 170 about the perimeter of window 140 and secured to door 14 with a plurality of button-head screws 174 . Each of screws 174 passes through outer leaf weldment 142 or inner leaf weldment 144 and threads into a pre-threaded weld nut 175 welded to the inner surface of the inner and outer leaf weldments 144 , 142 , as shown in FIG. 12. Window 140 may be of any suitable size and shape without departing from the spirit or scope of the invention, e.g., 20 inches by 64 inches as shown in FIGS. 1 and 11, 3 inches by 33 inches as shown in FIG. 21, etc.
[0043] Full-length cam hinge 16 is comprised of a first portion 180 , see FIGS. 13 - 16 , and a mating portion 181 , see FIGS. 17 - 20 , which extends the full length of door 14 . First portion 180 of cam hinge 16 is die-stamped to provide a plurality of barrels 182 and a barrel support 183 . Each of barrels 182 is provided with a first ramped end 184 and a second ramped end 186 , wherein second ramped end 186 additionally incorporates a notch 188 . Barrel support 183 is provided with a plurality of apertures 189 for the securing of cam hinge 16 to frame 12 with screws 190 , see FIG. 2. After the die-stamping of first portion 180 , the plurality of barrels 182 are rounded, see FIG. 15, to produce the cross-section of FIG. 16.
[0044] Mating portion 181 of full-length cam hinge 16 , FIGS. 17 - 20 , is also die-stamped to provide a plurality of barrels 194 and a barrel support 195 . Each of barrels 194 is provided with a first-ramped end 196 and a second ramped end 198 , wherein second ramped end 198 incorporates a notch 200 . After the die-stamping of mating portion 181 , the plurality of barrels 194 are rounded, see FIG. 19, to produce the cross-section of FIG. 20. Each of barrels 194 is positioned along barrel support 195 to mate with barrels 182 of first portion 180 such that first ramped end 184 mates with first ramped end 196 and second ramped end 186 mates with second ramped end 198 . A pin 202 secures first portion 180 to mating portion 182 . Rotation of mating portion 181 , which is fixed to door 14 by welding, relative to first portion 180 , which is fixed to frame 12 with screws, provides a lifting and a lowering, i.e., cam, action.
[0045] To assemble acoustic door assembly 10 , reference is made once again to FIG. 2 whereby it can be seen that first weldment 20 and second weldment 22 are joined to create frame 12 utilizing screws 41 , which are depicted with hidden lines. Additional insulating blocks 204 , of closed-cell urethane foam, are provided at the outer perimeters of frame 12 and are adhered to the inside of the frame. The user's door 14 of choice, e.g., with or without window 140 , is then secured to frame 12 by aligning apertures 189 of full-length cam hinge 16 with apertures 32 , frame 12 , and securing with screws 190 threaded into rivet nuts 33 . Referring to FIG. 1 (acoustic door assembly 10 in an open position) and FIG. 21 (acoustic door assembly 10 in a closed position, front and back), door 14 and frame 12 are preferably placed over a flat plate threshold 208 and are provided with a mortise style latch 209 and strike plate 210 .
[0046] In use, acoustic door assembly 10 provides the user with improved sound isolation qualities. Specifically, upon closing door 14 against frame 12 , see again FIG. 2, an uninterrupted dual magnetic seal 79 , 91 is provided on each side of door 14 wherein each side of rear wall 118 , 154 of inner leaf weldment 112 , 144 is in contact with one of magnetic seals 79 , 91 and each of looping edges 120 , 156 of outer leaf weldment 110 , 142 is in contact with one of magnetic seals 79 , 91 . A magnetic seal is especially effective in enhancing sound absorption of door 14 as a complete seal, e.g., essentially no air gaps, exist between magnetic seal 79 , 91 and metal door 14 . Air spring 82 helps to ensure a tight seal by compressing upon door 14 closing against frame 12 . Additional sound absorption is provided by the numerous foam portions, i.e., 86 , 88 , 96 , 98 , and 204 , within frame 12 itself as well as the foam and fiberglass layers, i.e., 124 , 160 , and 126 or 162 , 160 , and 164 , within door 14 .
[0047] Further sound absorption enhancement is provided by hinge 16 . The lifting, or cam, nature of hinge 16 ensures that door 14 is lowered into the appropriate position against frame 12 to ensure a substantially complete seal between frame 12 and door 14 as well as substantially complete sound isolation. The full-length nature of hinge 16 ensures complete support between door 14 and frame 12 thereby substantially eliminating any warpage between door 14 and frame 12 , and substantially eliminating the possibility of reduced sound isolation.
[0048] Because hinge 16 is outside of the magnetic sealing area, the magnetic field created between magnetic seals 79 and door 14 is not disturbed by hinge attachment brackets and hardware. The adjustable height sweep that is preferably coated in a TEFLON® fabric, 128 or 166 , also helps to maintain sound isolation. Upon opening of door 14 , cam lift hinge 16 lifts door 14 so that the sweep seal 128 , 166 lifts off the floor after a small amount of door swing. Thus, the seep seal 128 , 166 does not have to slide on the floor throughout the full travel of door 14 . As such, both sweep seal 128 , 166 and the user's floor suffer minimal wear. In the instance of door 14 incorporating window 140 , sound absorptive features are also provided. Specifically, open-cell foam 160 , u-channel rubber gasket, and retaining strip 172 help to improve sound absorption.
[0049] Utilizing the above-described embodiment, acoustic door assembly 10 of the present invention, with or without a window, is able to provide the user with a desirable STC rating of 49. STC stands for “sound transmission class” and is a single number rating derived from measured values of sound transmission loss (TL) in accordance with the American Society for Testing and Materials (ASTM) Eqo standards. TL through a door is a measure of its effectiveness in preventing the sound power incident on one side from being transmitted through it and radiated on the other side, taking into account the area of the door and the absorption in the receiving room. The STC provides a single number estimate of a door's performance for certain common sound reduction applications. A desirable fire rating of 45 minutes (door with 20 inch by 64 inch window) to one hour (solid door or door with 3 inch by 33 inch window) per UL 10 B is also provided by the present invention.
[0050] The present invention may be embodied in other specific forms without departing from the spirit of the essential attributes thereof; therefore, the illustrated embodiments should be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.
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An acoustic door assembly generally comprises a door, a frame and a hinge. The door of the assembly is an insulated, acoustic door having a predetermined length. The frame of the assembly is positioned proximate the door and is joined thereto by the hinge. The hinge is a continuous, cam hinge having a length that is substantially equivalent to the predetermined length of the door and is secured along the length of the door.
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This is a Continuation-In-Part application of U.S. Ser. No. 08/606,090 filed Feb. 23, 1996 now U.S. Pat. No. 5,779,676, which is a Continuation-In-Part of application U.S. Ser. No. 08/541,184, filed Oct. 11, 1995 now U.S. Pat. No. 5,776,103.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to fluid delivery devices. More particularly, the invention concerns an improved fluid delivery apparatus for precise subdermal delivery over time of medicinal liquids to an ambulatory patient, the device including novel reservoir filling means.
2. Discussion of the Prior Art
A number of different types of liquid dispensers for dispensing medicaments to ambulatory patients have been suggested. Many of the devices seek either to improve or to replace the traditional hypodermic syringe which has been the standard for delivery of liquid medicaments such as insulin solution.
Those patients that require frequent injections of the same or different amounts of medicament, find the use of the hypodermic syringe both inconvenient and unpleasant. Further, for each injection, it is necessary to first draw the injection dose into the syringe, then check the dose and, after making certain that all air has been expelled from the syringe, finally, inject the dose. This cumbersome and tedious procedure creates an unacceptable probability of debilitating complications, particularly for the elderly and the infirm.
One example of the urgent need for an improved liquid delivery device for ambulatory patients can be found in the stringent therapeutic regimens used by insulin-dependent diabetics. The therapeutic objective for diabetics is to consistently maintain blood glucose levels within a normal range much as the normally functioning pancreas would do by secreting a very low level of extremely fast-acting insulin at a basal rate into the blood stream throughout the day and night.
Consider the normal individual who doesn't have diabetes. A normal individual's cells require energy throughout the day just to maintain a basal metabolic rate. This energy is supplied to the cells by glucose that is transported from the bloodstream to the cells by insulin. When food is consumed, the blood glucose level rises and the pancreas responds by releasing a surge of fast-acting insulin. To mimic this natural process with individual injections, the individual would have to administer minuscule amounts of fast-acting insulin every few minutes throughout the day and night.
Conventional therapy usually involves injecting, separately, or in combination, fast-acting and slower-acting insulin by syringe several times a day, often coinciding with meals. The dose must be calculated based on glucose levels present in the blood. Slower-acting insulin is usually administered in the morning and evening to take advantage of longer periods of lower level glucose uptake. Fast-acting insulin is usually injected prior to meals. If the dosage of fast-acting insulin is off, the bolus administered may lead to acute levels of either glucose or insulin resulting in complications, including unconsciousness or coma. Over time, high concentrations of glucose in the blood can also lead to a variety of chronic health problems, such as vision loss, kidney failure, heart disease, nerve damage, and amputations.
A recently completed study sponsored by the National Institutes of Health (NIH) investigated the effects of different therapeutic regimens on the health outcomes of insulin-dependent diabetics. This study revealed some distinct advantages in the adoption of certain therapeutic regimens. Intensive therapy that involved intensive blood glucose monitoring and more frequent administration of insulin by conventional means, for example, syringes, throughout the day saw dramatic decreases in the incidence of debilitating complications.
The NIH study also raises the question of practicality and patient adherence to an intensive therapy regimen. A bona fide improvement in insulin therapy management must focus on the facilitation of patient comfort and convenience as well as dosage and administration schemes. Basal rate delivery of insulin by means of a convenient and reliable delivery device over an extended period of time represents one means of improving insulin management. Basal rate delivery involves the delivery of very small volumes of fluid (for example, 0.3-3 mL. depending on body mass) over comparatively long periods of time (18-24) hours). As will be appreciated from the discussion which follows, the apparatus of the present invention is uniquely suited to provide precise fluid delivery management at a low cost in those cases where a variety of precise dosage schemes are of utmost importance.
An additional important feature of the apparatus of the present invention is the provision of a novel reservoir filling means disposed on the underside of the base.
Another feature of the improved apparatus of the invention comprises a novel reservoir fill adapter means for permitting the reservoir of the device to be filled by filling means of different configurations.
Still another important aspect of the invention is the provision of a novel, dynamically-mounted delivery connection.
Because the embodiments of the invention described herein comprise improvements to the devices described in U.S. Ser. No. 08/606,090 filed Feb. 23, 1997, application Ser. No. 08/606,090 is hereby incorporated by reference in its entirety as though fully set forth herein.
Also relative to a complete understanding of the present invention is an earlier filed application by the present inventor, which is identified by the Ser. No. 08/541,184. This application, which was filed on Oct. 11, 1995 is also incorported by reference in its entirety as though fully set forth herein.
With regard to the prior art, one of the most versatile and unique fluid delivery apparatus developed in recent years is that developed by one of the present inventors and described in U.S. Pat. No. 5,205,820. The components of this novel fluid delivery apparatus generally include: a base assembly, an elastomeric membrane serving as a stored energy means, fluid flow channels for filling and delivery, flow control means, a cover, and an ullage which comprises a part of the base assembly.
Another useful liquid delivery device is that described in U.S. Pat. No. 5,514,097 issued to Knauer. The Knauer device comprises a medicament injection apparatus for subcutaneous or intramuscular delivery of a medicament which conceals the infusion needle behind a needle shroud. On apparatus activation, the needle is thrust forward, pushing the needle tip outside the needle shroud with enough force to puncture the skin. The needle is thus automatically introduced into the tissue at the proper needle/skin orientation. In the same action, the apparatus automatically dispenses an accurate pre-set dose.
U.S. Pat. No. 5,226,896 issued to Harris also describes a useful prior art device. This device comprises a multidose syringe having the same general appearance as a pen or mechanical pencil. The Harris device is specifically adapted to provide for multiple measured injections of materials such as insulin or human growth hormones.
Still another type of liquid delivery device is disclosed in U.S. Pat. No. 4,592,745 issued to Rex et al. This device is, in principle, constructed as a hypodermic syringe, but differs in that it enables dispensing of a predetermined portion from the available medicine and in that it dispenses very accurate doses.
The present invention seeks to significantly improve over the prior art by providing a novel fluid delivery device having unique filling and delivery means for filling the fluid reservoir of the device and for dispensing medicinal fluids therefrom.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an apparatus having a self-contained stored energy membrane for expelling fluids at a precisely controlled rate which is of a compact, laminate construction. More particularly, it is an object of the invention to provide such an apparatus which is of very low profile so that it can conveniently be used for the precise delivery of pharmaceutical fluids, such as insulin solution and the like, into an ambulatory patient at controlled rates over extended periods of time.
It is another object of the invention to provide an apparatus of the aforementioned character which is highly reliable and very easy-to-use by lay persons in a non-hospital environment.
Another object of the invention is to provide an apparatus of the character described in the preceding paragraphs which includes novel reservoir filling means for conveniently filling the fluid reservoir of the device.
Another object of the invention is to provide an apparatus of the character described which includes a novel fill adapter which permits filing of the reservoir of the apparatus only with filling means of a specific construction.
Another object of the invention is to provide an apparatus of the class described which further includes delivery means for precisely delivering medicinal fluids to the patient including the provision of a novel, dynamically mounted cannula assembly.
Another object of the invention is to provide an apparatus of the character described which, due to its unique construction, can be manufactured inexpensively in large volume by automated machinery.
Other objects of the invention are set forth in the co-pending United States application which are incorporated herein by reference and still further objects will become apparent from the discussion which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a bottom plan view of one form of the fluid delivery device of the present invention partly broken away to show internal construction.
FIG. 2 is a cross-sectional view taken along lines 2--2 FIG. 1.
FIG. 2A is an enlarged fragmentary, cross-sectional view of the area designated as 2A in FIG. 2.
FIG. 3 is an exploded, cross-sectional view of the device shown in FIG. 2.
FIG. 3A is an enlarged, cross-sectional view of an alternate form of flow rate control element of the invention.
FIG. 4 is an enlarged fragmentary, cross-sectional view of the area identified in FIG. 2 by the numeral 4.
FIG. 5 is a cross-sectional view taken along lines 5--5 of FIG. 4.
FIG. 6 is a generally perspective exploded view of one form of filling adapter of the invention and one type of filling syringe which is mateable with the filling adapter to permit controlled filling of the fluid reservoir of the device.
FIG. 6A is a side-elevational, cross-sectional view of the form of the syringe or fill device of the invention partially shown in FIG. 6 for use in filling the fluid reservoir of the embodiment of the delivery device shown in FIG. 2.
FIG. 6B is a view taken along lines 6B--6B of FIG. 6A.
FIG. 6C is a fragmentary, exploded cross-sectional view of a portion of the fill device shown in FIG. 6A.
FIG. 6D is a view taken along lines 6D--6D of FIG. 6C.
FIG. 7A is a cross-sectional view of an alternate form of fluid delivery device of the invention.
FIG. 7B is an exploded, cross-sectional view of the fluid delivery device shown in FIG. 7A illustrating the removal from the device of the fill adapter and the cannula cover.
FIG. 8 is a fragmentary, cross-sectional view of another embodiment of the fluid delivery device of the invention showing a fill adapter of a slightly different configuration.
FIG. 9 is a fragmentary, cross-sectional view similar to FIG. 8 but showing the filling syringe of this alternate embodiment mated with the alternate form of fill adapter.
FIG. 10 is an exploded, cross-sectional view of the embodiment of the invention shown in FIG. 8 illustrating the breaking away of the fill adapter following the reservoir filling step.
FIG. 11 is an enlarged, cross-sectional view of the syringe or filling device of this latest form of the invention.
FIG. 12 is a cross-sectional view of still another form of fluid delivery device of the invention which includes an alternate type of infusion means.
FIG. 13 is a cross-sectional view taken along lines 13--13 of FIG. 12.
FIG. 14 is a cross-sectional view taken along lines 14--14 of FIG. 12.
FIG. 15 is a greatly enlarged, cross-sectional view of the area of FIG. 12 identified by the numeral 15.
FIG. 16 is a cross-sectional view taken along lines 16--16 of FIG. 12.
FIG. 17 is fragmentary top plan view of the infusion means of this latest form of the invention.
FIG. 18 is a fragmentary top plan view of a portion of the flow control element of the infusion means shown in FIG. 17.
FIG. 19 is a cross-sectional view taken along lines 19--19 of FIG. 17 showing the infusion means connected to the patient.
FIG. 20 is a generally perspective view of the infusion cannula of the apparatus shown in FIG. 17.
FIG. 21 is a bottom plan view of another embodiment of the fluid delivery device of the invention.
FIG. 22 is a cross-sectional view taken along lines 22--22 of FIG. 21.
FIG. 23 is an exploded, cross-sectional view of the embodiment of the invention shown in FIG. 22.
FIG. 24 is an enlarged, generally perspective view of the dynamically mounted cannula assembly of the embodiment of the invention shown in FIG. 23.
FIG. 25 is an enlarged, generally perspective view of the protective sheath of the embodiment shown in FIG. 23 which covers a portion of the dynamically mounted cannula assembly.
FIG. 26 is a cross-sectional view taken along lines 26--26 of FIG. 21.
FIG. 27 is an exploded, cross-sectional view of the fill adapter assembly of the invention illustrated in FIG. 26.
FIG. 28 is a cross-sectional view taken along lines 28--28 of FIG. 27.
FIG. 29 is an enlarged, cross-sectional view of the fill port assembly of the embodiment of the invention shown in FIG. 26.
DESCRIPTION OF THE INVENTION
Referring to the drawings and particularly to FIGS. 1 through 6, one form of the fluid delivery device of the invention is there shown and generally designated by the numeral 30. This form of the invention, which is specially designed for subdermal infusion of selected medicaments, comprises a base 32 having an upper surface 34 including a generally dome shaped central portion 34a and a peripheral portion 34b circumscribing central portion 34a. As best seen in FIGS. 2 and 3, base 32 is also provided with a lower surface 36 to which a patient interconnection means or adhesive pad assembly 38 is connected. Pad assembly 38, which comprises a foam tape having adhesive on both sides, functions to releasably interconnect the device to the patient so as to hold it securely in place during the medicament delivery step. A peal-away member 38a covers the lower surface of the pad 38b.
A stored energy means cooperates with the upper surface 34 of base 32 to form a reservoir 40 (FIG. 2) having an inlet port assembly 42, which, in a manner presently to be described, is adapted to cooperate with a filling means for filling reservoir 40 with the medicinal fluid to be infused into the patient. The stored energy means is here provided in the form of at least one distendable membrane 44 which is superimposed over base 32. Membrane 44 is distendable as a result of pressure imparted on the membrane by fluids introduced into reservoir 40 via inlet port assembly 42 (FIG. 2). As membrane 44 is distended in the manner shown in FIG. 2, internal stresses will be established, which stresses tend to move the membrane toward a less distended configuration and in a direction toward upper surface 34 of base 32. Membrane 44 can be constructed from a single membrane or from multiple membranes which are overlayed to form a laminate construction.
Provided within the reservoir of the device, which is defined by the upper surface 34 of the base and a concave surface 46a of a cover means for covering the distendable membrane, is ullage defining means for providing ullage within the reservoir and for engagement with membrane 44 as the membrane moves toward its less distended starting configuration. The ullage defining means here comprises the previously identified, dome shaped central portion 34a of base 32. When the distendable membrane after being distended, tends to return toward its less distended configuration, fluid contained within the reservoir 40 will flow uniformly outwardly of the reservoir through the infusion means of the invention for infusing the medicinal fluids contained within the reservoir into the patient.
Superimposed over base 32 is the cover means, shown here as a rigid cover 46 which functions, through the use of novel sealing means, to sealably enclose membrane 44. The sealing means here comprises a pair of generally circular grooves 48 formed in peripheral surface 34b of base 32 and a pair of cooperating, generally circular shaped rim like protuberances 50 formed on the peripheral lower surface 46b of the cover 46. Protuberances 50 are receivable within grooves 48 in the manner shown in FIG. 2 and function to sealably clamp distendable membrane 44 between the cover and the base. A soft elastomer covering 47 is provided over the upper surface of cover 46 to make the device more patient friendly. More specifically, as shown in FIG. 2, covering 47 includes soft edges and corners 47a which prevent the edges and corners of the device from jabbing into the patient's flesh. Cover 47 also includes a soft, pliable overcover 47b. While several materials can be used for covering 47, materials such as a material sold under the name and style "Santoprene" by The Monsanto Company of St. Louis, Mo. has proven satisfactory for this purpose.
Examples of materials found particularly well suited for the construction of distendable membrane 44 include: silicone polymers (polysiloxanes) (high performance silicone elastomers made from high molecular weight polymers with appropriate fillers added). These materials are castable into thin film membranes and have high permeability (which allows maximum transport of vapor and gas), high bond and tear strength and excellent low temperature flexible and radiation resistance. Additionally, silicone elastomers retain their properties over a wide range of temperatures (-80° to 200° C.) are stable at high temperatures, and exhibit tensile strengths up to 2,000 lb./in 2 elongation up to 600%. Another suitable material for the stored energy membrane is natural and synthetic latex.
Manufacturers of materials suitable for use in construction of the distendable membrane include Dow Chemical, General Electric, B.P. Polymers, Mobay Chemical, Shell Oil Corp., Petrarch Systems, DuPont, Concept Polymers, Goodyear and Union Carbide Corp.
With respect to the structural cover 46 and base 32, these components can also be produced from a variety of materials including one of several polymer groups. The degree of hardness of these materials can range from soft, resilient or rigid, and the following polymers can be employed: Polypropylene (PP), Ultra high molecular weight polyethylene (UHMW PE), High density polyethylene (HDPE), Polyvinylidene Fluoride (PVDF), Ethylenevinyl acetate (EVA), Styrene Acrylonitrile (SAN), Polytetrafluoroethylene (PTFF). A suitable source of these materials is Porex Technologies of Fairburn, Ga. It is to be understood that other suitable materials well known to those skilled in the art can also be used, including a material sold by B.P. Chemicals International of Cleveland, Ohio, under the name and style "Barex". This material is a clear rubber modified Acroylonitrile Copolymer which has wide application in the packaging industry because of its superior gas barrier, chemical resistance and extrusion (thermoforming) and injection molding capabilities.
Referring particularly to FIGS. 2 and 3, the infusion means of this latest form of the invention for subdermal infusion of medicaments into the patient, can be seen to include, a downwardly extending hollow cannula 54 which is carried by a support member 56 that is received within a cavity 58 formed in base 32. Support member 56 also functions to support, within a cavity 55, flow control means for controlling the rate of fluid flow from reservoir 40 toward hollow cannula 54. This flow control means is here provided as a porous rate control frit 59 which can be constructed from a micro porous metal such as stainless steel. The frit can also be constructed from a porous ceramic or plastic material.
Referring to FIG. 3A, an alternate form of rate control assemblage is there shown. This unique assemblage is receivable within cavity 55 and comprises a plastic base 59a, a thin flow control wafer 59b superimposed over base 59a and a thin filter member 59c superimposed over wafer 59b. Wafter 59b includes an extremely small laser drilled aperture or microbore "MB". Base 59a, which includes a central fluid passageway 59d, can be constructed of numerous materials such as polycarbonate, acrylic, polypropylene and the like. Wafer 59b is preferably constructed from materials such as plastic films including polyester material. Filter member 59c is preferably constructed from materials such as polysolfone and polypropylene but other porous materials can also be used.
Hollow cannula 54 has an inlet end 55a and an outlet end 57 formed in a needle-like segment 54a which extends generally perpendicularly downward from the lower surface 36 of base 32. To protect cannula 54 from damage, a protective cover assembly 60 surrounds the cannula. As best seen in FIG. 3, cover assembly 60 includes spacer member 60a, a potting material 60b, and a sheath member 60c. At time of use the sheath member 60c can be broken away from the base portion 32 in the manner shown in the phantom lines of FIG. 2. For this purpose, a serration line 62 is formed between the body of the sheath member and a connector collar 60d which functions to interconnect the cover assembly 60 with the base 32.
Referring particularly to FIGS. 4, 5, and 6, one form of the novel filling means of the present invention is there illustrated. As previously mentioned, the filling means functions to controllably fill reservoir 40 with the medicinal fluid which is to be infused into the patient. In the present form of the invention, the filling means comprises a septum assembly, a filling syringe assembly and a novel fill adapter assembly. As best seen in FIG. 4, septum assembly 66 is sealably disposed within a fill port 67 formed in the intermediate portion of base 32 (see also FIGS. 2 and 3). Septum assembly 66 includes a septum housing 66a which is receivable within fill port 67 and an elastomeric, pierceable core 66b which is sealably disposed within an opening formed in septum housing 66a.
As shown in FIGS. 4, 5, and 6 septum housing 66a includes a non-circular, generally oblong shaped connector base 66c which functions to interconnect the fill adapter 68 of the invention with the septum assembly 66. Referring particularly to FIGS. 5 and 6, it is to be observed that fill adapter 68 includes connector means, comprising a base wall 68a having a non-circularly shaped opening 68b formed therein for receiving base 66c of the septum housing. With this construction, when the fill adapter is mated with the septum assembly and then rotated ninety degrees, the fill adapter will be securely located in place as shown in FIGS. 4 and 5.
As indicated in FIGS. 3, 4, and 6, fill adapter 68 includes an upper wall portion 68c, a lower wall portion 68d, and an intermediate wall portion 68e. For purposes presently to be described, intermediate wall portion 68e is generally oval shaped in cross section (see also FIGS. 5 and 6).
Also forming a part of the filling means of the present invention is a filling syringe assembly 72 which, as best seen in FIG. 6A, includes a vial like container 74 having a fluid reservoir 74a, a needle housing 76 closing fluid reservoir 74, and a double ended piercing needle 77 carried by needle housing 76. As indicated in FIG. 6, the collar portion 76a of needle housing 76 is also oval shaped and when correctly indexed is adapted to be closely received within oval shaped wall section 68e of fill adapter 68. With this novel arrangement, it is apparent that a conventional syringe having a circular shaped needle housing cannot be inserted into adapter 68 since the wall located between wall section 68d and 68e, would act as a stop to prevent complete insertion of the conventional syringe assembly into the adapter so that the needle portion thereof could pierce the elastomeric core 66b of the septum assembly 66. Also forming a part of the filling syringe of the present form of the invention is a needle protector cap 80 which is of the configuration shown in FIG. 6C and is adapted to be received over the piercing needle 77 to protect it from damage and contamination.
Turning particularly to FIGS. 6A and 6C, filling syringe 72 can be seen to comprise, in addition to the previously mentioned vial 74, needle housing 76, needle 77 and closure cap 80, an elongated housing assembly 82 which houses medicament vial 74. Housing assembly 82 includes a hollow housing 82a and a spacer sleeve 82b which insures a close fit of vial 74 within hollow housing 82a. As shown in FIG. 6A, the fluid reservoir 74a of vial 74 is sealed at one end by a pierceable closure septum 88 and is seated proximate its opposite end by an elastomeric plunger 89 which is telescopically movable along the length of reservoir 74a to expel fluid therefrom via needle 77. The needle housing 76, which supports needle 77 includes an internally threaded collar 76b which enables threadable interconnection with housing 82a in the manner shown in FIG. 6A so that the inwardly extending portion 77a of the needle will pierce closure septum 88 upon interconnection of the needle housing with hollow housing 82a. With this construction, portion 77b of needle 77 extends forwardly to enable the needle to pierce septum core 66b of septum assembly 66 upon mating the syringe assembly with adapter 68.
In using filling syringe assembly 72 to fill reservoir 40 of the delivery portion of the device, a protective cover 91 is pulled away from the bottom of adapter 68 (FIG. 4) and protective cap 60 is removed in the manner shown by the phantom lines of FIG. 2. Next, needle housing 76 along with needle 77 are telescopically inserted into adapter 68. By rotating the filling syringe to a position where oval collar 76a indexes with oval shaped wall section 68e of the adapter, the syringe can be urged inwardly of the adapter causing needle to pierce septum core 66b thereby placing reservoir 40 of the delivery device in fluid communication with reservoir 74a of medicament vial 74 (see the phantom lines of FIG. 2).
Also forming an important part of the filling syringe assembly 72 of the present form of the invention, pusher sleeve 92 which is telescopically receivable over housing 82 in the manner shown in FIG. 6A. Disposed internally of sleeve 92 is a pusher rod 94 which is adapted to engage plunger 89 and move it longitudinally of reservoir 74a as the pusher sleeve is moved from the first extended position shown in FIG. 6A to a position wherein a substantial portion of housing 82 is encapsulated within the sleeve. As sleeve 92 is moved toward the second position, plunger 89 will move inwardly of reservoir 74a causing fluid contained therein to flow toward reservoir 40 of the delivery device via hollow needle 77.
Turning next to FIGS. 7A and 7B, an alternate form of the fluid delivery device of the invention is there shown. This device is quite similar to that shown in FIGS. 1 through 6A and like numerals are used in FIGS. 7A and 7B to identify like components. The primary difference between the earlier described embodiment and the embodiment of FIGS. 7A and 7B resides in the differently configured cannula protective sheath identified in FIGS. 7A and 7B by the numeral 100. As best seen in FIG. 7B sheath 100 is generally cylindrical in shape and is smaller in diameter than sheath 60 of the earlier described embodiment. The outboard end of sheath 100 is closed by a generally hemispherically shaped closure wall 100a and the inboard end 100b is open. The inside diameter of open end 100b is such that it is closely receivable over the needle boss 56a of cannula assembly 56 to create an interference fit therewith. With this construction, when the reservoir of the device is filled and the adapter 68 removed from the base in the manner shown by the phantom lines of FIG. 7B, protective sheath 100 can be removed to expose cannula 54 by merely exerting a downward, separating force on the sheath body sufficient to separate it from boss 56a.
Referring to FIGS. 8 through 11, still another form of the fluid delivery device of the invention is there shown. This device is also very similar to that shown in FIGS. 1 through 6A and like numerals are used in FIGS. 8 through 11 to identify like components. The primary difference between the earlier described embodiments and the embodiment of FIGS. 8 through 11 resides in the differently configured filling adapter 104 and the filling means or filling syringe assembly 106 which mates therewith. As previously mentioned, the filling means functions to controllably fill the reservoir of the delivery portion of the device with the medicinal fluid which is to be infused into the patient. In this latest form of the invention, the filling means comprises a septum assembly 108 which is sealably disposed within fill port 110 formed in the intermediate portion of base 32 (see FIG. 8). Septum assembly 108 is quite similar to the previously described septum assembly 66 and includes a septum housing 108a which is receivable within fill port 110 and an elastomeric, pierceable, non-coring core 108b which is sealably disposed within an opening formed in septum housing 108.
Referring to FIG. 8, it is to be noted that fill adapter 104 includes a connector flange 104a which is fixedly connected as by adhesive bonding or the like to base 32 proximate fill port 110. Disposed between flange 104a and a cylindrical body section 104b is a serration 104c which permits body section 104b to be easily broken away from flange 104a leaving a smooth undersurface which is generally parallel with the lower surface of base 32 (see FIG. 10). Integrally formed with body section 104b is a cup-like syringe receiving section 104d which is adapted to telescopically receive the upper portion of syringe assembly 106 in the manner shown in FIG. 9. It is to be understood that, although the fill adapter is shown interconnected with the lower surface of the base of the device, it could also be connected to the side surfaces or to any other convenient surface.
Turning next to FIG. 11, the filling means or syringe assembly 106 is of similar construction to the previously described filling syringe 72 and includes a container or vial 112 having a fluid reservoir 112a, a needle housing 114, and a double ended piercing needle 116 carried by needle housing 114. As indicated in FIG. 11, the threaded collar 114a of the needle housing 114 is of a size and shape adapted to be closely received within cylindrically shaped wall section 104d of fill adapter 104 while end 114b of the needle housing is adapted to be closely receivable within section 104b of the fill adapter (FIG. 9). With this novel arrangement, the outboard end 114b of the needle housing is receivable within section 104b of the fill adapter as the collar portion 114b of the needle housing is inserted into adapter portion 104d. As illustrated in FIG. 9, insertion of the syringe assembly 106 into adapter 104 causes the needle portion of the syringe assembly thereof to pierce the elastomeric core 108b of the septum assembly 108 thereby opening fluid communication between reservoir 112a of the fill vial and the outlet 116a of hollow cannula 116. Also forming a part of the filling syringe of the present form of the invention is a needle protector cap 118 which is of the configuration shown in FIG. 11 and is adapted to be received over the piercing needle 116 to protect it from damage and contamination.
In addition to the previously mentioned needle housing 114, needle 116 and closure cap 118, the filling syringe assembly 106 also includes a housing assembly 120 which houses vial 112.
As before, reservoir 112a of vial 112 is sealed at one end by a septum assembly 88 and is sealed at its opposite end by an elastomeric plunger 89 which is telescopically movable along the length of reservoir 112a to expel fluid from the reservoir through hollow cannula 116. Septum assembly 88 and plunger 89 are of the construction as previously described. Needle housing 114, is threadably connected to hollow housing 120a and carries hollow needle 116 in the manner shown in FIG. 11 so that the inwardly extending portion 116b thereof will function to pierce the septum core 88 of the vial assembly when the needle housing is threadably coupled with hollow housing 120a. To insure a snug fit, spacer sleeve 120b is disposed between vial 112 and the interior wall of hollow housing 120a in the manner shown in FIG. 11.
In using filling syringe 106 to fill reservoir 40 of the delivery portion of the device, protective cap 118 is first removed and the needle housing 114 along with needle 116 are telescopically inserted into adapter 104. As the syringe assembly is urged inwardly of the adapter, needle 116 will pierce pierceable core 108b of the septum assembly thereby placing reservoir 40 of the delivery device in fluid communication with reservoir 112a of medicament vial 112. As the needle pierces core 108b, portion 114a of the needle housing will seat against a shoulder 104e formed on adapter 104 and portion 114b will be received within portion 104b of the adapter.
Also forming a part of the filling syringe assembly 106 is the previously described pusher sleeve 92 which is telescopically receivable over housing 120a. Disposed internally of housing 120a is a pusher rod 94 which, as before, is adapted to engage plunger 89 and move it longitudinally of reservoir 112a as the pusher sleeve is moved from the first extended position shown in FIG. 11 to a second position wherein a substantial portion of housing 120a is encapsulated within the sleeve. As sleeve 92 is moved toward the second position, plunger 89 will move inwardly of reservoir 112a causing fluid to flow toward reservoir 40 of the delivery device via hollow needle 116.
Turning next to FIGS. 12 through 20, still another form of the fluid delivery device of the invention is there shown and generally designated by the numeral 121. This device is similar in many respects to that shown in FIGS. 1 through 6A and like numerals are used in FIGS. 12 through 20 to identify like components. The primary difference between the earlier described embodiment and the embodiment of FIGS. 12 through 20 resides in the differently configured fill adapter and the totally different infusion means of the invention for infusing medicinal fluids into the patient. The details of construction of both of these novel features of the invention will presently be described.
As best seen in FIG. 12, this latest form of the invention comprises a base 122 having an upper surface 124 including a generally dome shaped central portion 124a and a peripheral portion 124b circumscribing central portion 124a. Base 122 is also provided with a lower surface 126 to which a patient interconnection means or adhesive pad assembly 128 of the general character previously described is connected.
A stored energy means cooperates with the upper surface 124 of base 122 to form a reservoir 130 having an inlet port 132, which is adapted to cooperate with a filling means of this latest form of the invention for filling reservoir 130 with the medicinal fluid to be infused into the patient. The stored energy means is here provided in the form of a laminate construction or assemblage 134 which is made up of a first and second distendable membrane 134a and 134b (FIG. 15) which are here shown as coated, for specialized biocompatibility purposes, with a flurosilicone barrier material 134c. Membrane assemblage 134 is distendable as a result of pressure imparted on the membrane by fluids "F" introduced into reservoir 130 through inlet port 132. As the membrane assemblage is distended in the manner shown in FIG. 12, internal stresses will be established, which stresses tend to move the assemblage toward a less distended configuration and in a direction toward base 122.
Provided within the reservoir of the device, which is defined by the upper surface of the base and a concave surface 136a of a cover means for covering the distendable membrane, is ullage defining means for providing ullage within the reservoir and for engagement with membrane assembly 134 as the assembly moves toward its less distended starting configuration. As before, the ullage defining means here comprises the dome shaped central portion 124a of base 122. When the distendable membrane assemblage, after being distended, tends to return toward its less distended configuration, fluid contained within the reservoir 130 will flow uniformly outwardly of the reservoir through the novel infusion means of the invention for infusing medicinal fluids into the patient.
Superimposed over base 122 is the cover means, shown here as a rigid cover 136 which is of the same general character as previously described and through the use of novel sealing means, to sealably enclose membrane 134. The sealing means is identical to that previously described in connection with the embodiment of the invention shown in FIGS. 1 through 6.
Referring particularly to FIGS. 12 and 13, the novel filling means of this latest form of the invention can be seen to comprise a septum assembly 140 which is sealably disposed within a fill port 142 formed in the intermediate portion of base 122 (see FIG. 12). Septum assembly 140 is somewhat similar to septum assembly 66 and includes an elastomeric pierceable core 140b which is sealably disposed within a core housing 140a.
As best seen in FIG. 12, septum assembly 140 is disposed proximate the upper end of a fill adapter 146 which in this form of the invention is connected to base 122 by means of a suitable potting compound "P" which fills the lower portion of fill port 142 and functions to hold a flange 146a formed on fill adapter 146 in position within the fill port.
As in the earlier described embodiments, fill adapter 146 includes a first reduced diameter portion 146b, a lower wall portion 146c, and an intermediate wall portion 146d. As indicated in FIG. 13, wall portion 146c defines, proximate its upper region 146e, a generally oval shaped opening 147 which, as before, will accept only filling syringes having the correct oval mating configuration.
Also forming a part of the filling means of this latest form of the invention is the previously illustrated and described filling syringe 72 (FIG. 6) which is identical in construction and use to that previously described and includes an oval shaped collar that is of a configuration that can be closely received within oval shaped opening 147 of fill adapter 146 (see also FIG. 6A). As before with this arrangement, a conventional syringe having a circular shaped needle housing cannot be fully inserted into adapter 146 since portion 146e would act as a stop and prevent insertion of the conventional syringe assembly into the adapter in a manner such that the needle portion thereof could pierce the elastomeric core 140a of the septum assembly.
As previously mentioned, the infusion means of the present form of the invention is totally different in construction and operation from that shown in FIGS. 1 through 11. More particularly, this novel infusion means here comprises an administration set having a subcutaneous infusion device 150 (FIG. 17) and connector means for operably interconnecting device 150 with the fluid reservoir 130 of the fluid delivery device. As best seen in FIGS. 16, 17, and 18, the connector means here comprises a connector boss 152 and a length of tubing 154 which interconnects device 150 with boss 152 (FIG. 17). Connector boss 152 is sealably received within a connector boss receiving port 156 formed in base 122 and cover 136 (FIG. 12) in a manner so as to place tubing 154 in communication with a flow passageway 158 formed in a flow plate 159 which is connected to base 122 by any suitable means such as sonic welding. For this purpose, sonic energy directors 159a are provided on plate 159 to aid in the sonic welding step (see FIGS. 14 and 16). Passageway 158 is, in turn, in communication with reservoir 130 via flow control means here provided as a rate control frit 160 which is housed within a cavity 162 formed in base 122 proximate the outlet 130a of reservoir 130. Frit 160 can be constructed from various materials including stainless steel, porous plastic or porous ceramics of the character available from Ball Brothers Company of Boulder, Colo. Frit 160 can also be constructed from a polyether ether Ketone (PEEK) material which is readily commercially available from Upchurch Scientific, Inc. of Seattle, Wash. and is more fully described in U.S. Pat. No. 5,651,931.
Turning particularly to FIGS. 19 and 20, the details of construction of the subcutaneous infusion device 150 is there shown. Device 150 here comprises a base 164 having upper and lower surfaces 164a and 164b and a generally circular shaped opening 166. Connected to base 164 is a cover 168. Cover 168 and base 164 cooperate to define an internal chamber 170 within which a generally spiral shaped cannula 172 is dynamically mounted. Cannula 172 includes a circuitously shaped body portion 172a which is disposed within chamber 170 and a stem portion 172b which is mounted between base 164 and cover 168 in a manner presently to be described. Cannula 172 also includes an outlet end, here provided in the form of a needle-like segment 172c, which extends generally perpendicularly downward from lower surface 164b of base 164 for subdermal infusion of medicinal fluids into the patient. For this purpose, segment 172c is provided with a sharp, pointed extremity 172d (see FIG. 20).
As shown in FIG. 19, stem portion 172b of the very small diameter spiral cannula 172 is encased within the inboard end 176a of fluid delivery tube 154 and the assembly thus formed is uniquely supported between a stem portion 168a of cover 168 (FIG. 17) and base 164 by a cannula encapsulation means shown here as a standard potting compound 177. Compound 177 rigidly supports the inboard end of tube 154 and portion 172b of the cannula so as to provide a secure interconnection of the cannula with base 164 and cover 168. As best seen in FIG. 20, portion 172b of the cannula is provided with a bend 172e to better secure the assemblage in place.
In using the device of this latest form of the invention, after the administration set has been suitably interconnected with the fluid delivery portion of the apparatus by means of delivery tube 154 in the manner shown in FIG. 17, infusion device 150 can be interconnected with the patient for subdermal delivery of fluids from the fluid delivery portion of the apparatus. This is accomplished by penetrating the patient's skin and tissue "S" with the point 172d of the infusion cannula in the manner shown in FIG. 19. In this regard, it is to be noted that an extremely important aspect of the infusion device 150 resides in the novel design of the circuitous cannula 172 and its unique interconnection with the base 164 and cover 168 of the infusion device. With the highly novel construction shown in the drawings, when the device is connected to the patient with the needle portion 172c of the cannula penetrating the patient's body, as, for example, the patient's abdomen, normal movement by the patient will permit the cannula to move within chamber 170 while the base remains completely stationary. Without this important feature, normal movements by the patient causing flexing of the muscle and tissue would cause irritation and discomfort to the patient. Additionally, such movements could cause the small diameter cannula to fail catastrophically or could cause separation of the device from the patient's skin. However, the novel and unique dynamic mounting of the cannula within chamber 170 positively prevents breaking of the fragile cannula and at the same time prevents irritation to the patient as a result of normal muscle flexing by the patient.
Referring next to FIGS. 21 through 28, yet another embodiment of the invention is there shown and generally designated by the numeral 180. The apparatus of this latest form of the invention is similar in some respects to the embodiment shown in FIGS. 1 through 6 save that in this latest embodiment, the infusion cannula is dynamically mounted to the base. This latest form of the invention, which is also specially designed for subdermal infusion of selected medicaments, comprises a base 182 having an upper surface 184 including a generally dome shaped central portion 184a and a peripheral portion 184b circumscribing central portion 184a. As best seen in FIGS. 22 and 23, base 182 is also provided with a lower surface 186 to which a patient interconnection means or adhesive pad assembly 188 is connected. As before, pad assembly 188, which comprises a foam tape having adhesive on both sides, functions to releasably interconnect the device to the patient so as to hold it securely in place during the medicament delivery step.
A stored energy means cooperates with the upper surface 184a of base 182 to form a reservoir 190 (FIG. 22) having an inlet port assembly 195 (FIG. 26), which, in a manner presently to be described, is adapted to cooperate with a filling means for filling reservoir 190 with the medicinal fluid to be infused into the patient. The stored energy means is here provided in the form of at least one distendable membrane 194 which is superimposed over base 182. Membrane 194 is distendable as a result of pressure imparted on the membrane by fluids introduced into reservoir 190 via an inlet port assembly 195 (FIG. 26). As membrane 194 is distended in the manner shown in FIG. 22, internal stresses will be established, which stresses tend to move the membrane toward a less distended configuration and in a direction toward base 182.
Provided within the reservoir of the device, which is defined by the upper surface of the base and a concave surface 196a of a cover means for covering the distendable membrane, is ullage defining means for providing ullage within the reservoir and for engagement with membrane 194 as the membrane moves toward its less distended starting configuration. As before, the ullage defining means here comprises the dome shaped central portion 184a of base 182. When the distendable membrane, after being distended, tends to return toward its less distended configuration, fluid contained within the reservoir 190 will flow uniformly outwardly of the reservoir through the infusion means of the invention for infusing medicinal fluids into the patient.
Superimposed over base 182 is the cover means, shown here as a rigid cover 196 which functions, through the use of novel sealing means, to sealably enclose membrane 194. The sealing means is identical to that described in connection with the embodiment of FIGS. 1 through 6 and comprises a pair of generally circular grooves 48 formed in peripheral surface 184b of base 182 and a pair of cooperating, circular rim like protuberances 50 formed on the lower surface 196b of cover 196. As before, protuberances 50 are receivable within grooves 48 in the manner shown in FIG. 22 and function to sealably clamp distendable membrane 194 between the cover and the base.
Referring particularly to FIGS. 22, 23, and 24, the infusion means of this latest form of the invention for subdermal infusion of medicaments into the patient can be seen to include a uniquely shaped, hollow cannula 200 which is dynamically mounted within an internal cavity 202 formed in base 182 (FIG. 23). As best seen in FIG. 24, cannula 200 includes a circuitously shaped body portion 200a, a portion of which is disposed within chamber 202. Cannula 200 also includes an outlet end, here provided in the form of a needle-like segment 200b, which extends generally perpendicularly downward from lower surface 186 of base 182 for subdermal infusion of medicinal fluids into the patient. For this purpose, segment 200b is provided with a sharp, pointed extremity 200c (see FIG. 22).
As shown in FIGS. 22, 23, and 24, inboard end portion 200d of the very small diameter spiral cannula 200, which forms the cannula inlet, is mounted within a generally cylindrically shaped housing 203 which houses the flow control means of the invention. This flow control means here comprises a porous frit 59 of the character previously described and a filter 204. Housing 203 is received within a bore 183 formed in base 182 (FIG. 23) so as to position the body portion 200a of the cannula within a cavity 207 provided in base 182 (FIG. 23). A potting compound 205 fills cavity 207 and functions to rigidly support the body portion of the cannula so as to provide a secure interconnection between the cannula and the base 182 and at the same time permits dynamic movement of the outboard end of the cannula within chamber 202.
Surrounding cannula 200 is a uniquely configured protective shroud 210 which has an upper portion 210a which closely receives portion 200a of the cannula and a lower portion 210b which surrounds portion 200b of the cannula. Upper portion 210a of shroud 210 forms an interference fit with the wall of chamber 202 so as to hold the shroud securely in place.
In this latest form of the invention, the filling means for filling reservoir 190 comprises a septum assembly 214 which is of similar construction to the previously described septum assembly. Septum assembly 214 is sealably disposed within a fill port 216 formed in the intermediate portion of base 182 (see FIG. 26). Septum assembly 214 includes a septum housing 214a which is receivable within fill port 216 and an elastomeric, pierceable core 214b which is sealably disposed within an opening formed in septum housing 214a.
As best seen in FIGS. 26 and 29, septum housing 214a includes a generally circular shaped connector base 215 which is receivable within fill port 216 so that housing 214a can be adhesively or sonically bonded to base 182. Referring to FIG. 26, it is to be noted that a fill adapter 218 is provided for use in filling reservoir 190. Fill adapter 218 includes an upper flange 218a which is also receivable within fill port 216 for engagement with connector base 215 of the septum housing for interconnecting the fill adapter with the septum housing and with the base 182 as by adhesive bonding. Fill adapter 218 also includes an upper portion 218b and an enlarged diameter portion 218c. Provided proximate the juncture of portions 218b and flange 218a is a serration 219 which permits portion 218b to be easily broken away from flange 218a.
Also forming a part of the filling means of the present invention is a filling syringe which is identical in construction and operation to filling syringe 106 shown in FIG. 11. In using the filling syringe 106 to fill reservoir 190 of the device of this latest form of the invention, protective cap 118 is first removed. Next, the tear away protective cover 218d which covers the open end of adapter 218 is removed by pulling on the pull tab 218e (FIGS. 21, 26, and 27). This done the needle housing 114 and needle 116 can be telescopically inserted into adapter 218. As the syringe assembly is urged inwardly of the adapter, needle 116 will pierce pierceable core 214b placing reservoir 190 of the device in fluid communication with reservoir 112a of medicament vial 112. Filling of reservoir 190 is accomplished in the manner previously described by urging vial adapter 92 forwardly over housing 120 so as to move plunger 89 forwardly of vial 112. (see FIG. 11).
In using the apparatus of this latest form of the invention, after reservoir 190 has been filled, portions 218b and 218c of the fill adapter are broken away from flange 218a along serrations 219 and cannula protective cap 210 is removed by gripping finger engaging ribs 210c so that the device can be interconnected with the patient. This is accomplished by penetrating the patient's skin and tissue "S" with the point 200c of the infusion cannula. When the device is thusly connected to the patient with the needle portion 200c of the cannula penetrating the patient's body, normal movement by the patient will once again permit the dynamically mounted cannula to move within chamber 202 while the base remains completely stationary thereby preventing irritation to the patient as a result of normal movement by the patient.
Having now described the invention in detail in accordance with the requirements of the patent statutes, those skilled in this art will have no difficulty in making changes and modifications in the individual parts or their relative assembly in order to meet specific requirements or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention, as set forth in the following claims.
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A fluid delivery device having a self-contained stored energy membrane for expelling fluids at a precisely controlled rate which is of a compact, laminate construction. The device also includes a novel adapter which is usable to fill the reservoir of the device using a compatable filling syringe apparatus which is mateable with the adapter.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention has to do with cereal serving bowls, such as bowls used for serving breakfast cereal and milk.
[0003] 2. Description of the State of the Art
[0004] Bowls of various sizes are used in the serving of breakfast cereals. The bowls will normally hold a quantity of cereal and a suitable liquid such as, but not limited to, milk.
[0005] It is known to provide bowls that have shapes augmenting the standard bowl shape. For instance, consider the following patents: “Cereal Bowl or the Like,” U.S. Des. 283,096; “Multi-Layered Cereal Bowl,” U.S. Des. 298,898; “Dish,” U.S. Pat. No. 1,520,402; “Cereal Bowl,” U.S. Pat. No. 2,207,417; “Cereal Bowl,” U.S. Des. 426,751 and “Milk and Cereal Bowl,” U.S. Pat. No. 5,676,275, all of these patents are herein incorporated by reference.
[0006] Although some of the bowls shown in the above patents are directed to the serving of cereal, none of the bowls encompass the advantages of the bowl presented herein. The bowls shown in the above patents have complex shapes that may prevent stacking of the bowls. The shape of the bowls may make the bowls difficult to clean and may subject the bowls to instability or fragility.
[0007] For instance, several of the bowls (see Des. 283,096; Des. 426,751; and U.S. Pat. No. 1,520,402) have a significant barrier between a first portion of the device and the portion where dry cereal is staged. Such a wall impedes the easy transfer of dry cereal from the cereal staging area into the milk-containing portion of the bowl.
[0008] The Roshau Des. 298,898 patent shows a complex structure that appears to be an unstable twin bowl unit whose method of use is not disclosed in the design patent. Its elevated bowl portion is deep with high walls and a broad base or floor that is significantly larger than the smaller bowl portion to which it is attached. This design may not be a free standing bowl. The elevated bowl portion may be heavier than the lower bowl portion especially when the extension is filled with dry cereal. To overcome this the lower bowl portion has been weighted to offset the weight of the upper bowl portion.
[0009] In one of the bowls mentioned above (Smith, U.S. Pat. No. 2,207,417) a hopper is provided. This design is impractical as cereal in the lowest section of the hopper will be in contact with milk in the bowl. This staged, now unintentionally milk-wetted cereal will be difficult to extract from the hopper element of the bowl resulting in a hopper outlet clogged with soggy cereal. Smith, the inventor of the cereal bowl of U.S Pat. No. 2,207,417; recognizes this as a problem and states that there will be little, if any, liquid entering the hopper portion. In general this may not be true as the level of milk in the hopper will be at the same level as the milk in the bowl. It is suggested in Smith that there be only a small depth of milk in the bowl, only to the bottom edge of the hopper, however, such a shallow depth of milk will allow for only enough milk for a small serving of cereal. There may not be enough milk in the bowl portion to accommodate the cereal in the bowl and still have enough milk to accommodate the rest of the cereal in the hopper, unless the amount of staged dry cereal is very small amount of cereal.
[0010] U.S. Pat. No. 5,676,275 is also a complex bowl as it has two detachable sections with one section provided with a perforated well that allows milk to enter the well. Dry cereal is then pushed into the well to expose the cereal to the milk in the well. This design is much more complex than the instant invention.
[0011] The applicant hereto provides a simpler and more elegant solution.
SUMMARY OF THE INVENTION
[0012] The present invention provides, among other things, a cereal bowl that has a trough on the main bowl portion of the cereal bowl. The trough is integral with the bowl portion of the cereal bowl. The trough section is designed to hold cereal in a staged placement before the dry cereal in the trough is exposed to milk, a suitable liquid, or a cereal wetting substance.
[0013] It is an object of the invention to provide a cereal bowl that will enhance the cereal eating experience.
[0014] It is another object of the invention to provide a trough on a bowl, the trough being sized to accommodate approximately half of the capacity of the bowl portion of the cereal bowl.
[0015] It is another object of the invention to allow the consumption of cereal in a cereal bowl while maintaining a quantity of cereal in a dry state in a trough integral with the main bowl portion of the cereal bowl.
[0016] It is also an object of the invention to keep a portion of a serving of cereal dry while a portion of the serving of cereal is submerged or floating in/on milk in a bowl.
[0017] It is also an object of the invention to provide a brand promotional graphic carried in, on, or integral with the bowl.
[0018] It is also an object of the invention to provide a cereal bowl that has a sloped interior floor and a flat exterior bottom.
[0019] It is also an object of the invention to provide a cereal bowl that has a sloped interior floor.
[0020] It is also an object of the invention to provide a cereal bowl having an interior surface that facilitates “spooning out” the last remaining cereal in the bowl after most of the cereal and milk have been removed from the bowl.
[0021] It is also an object of the invention to provide a cereal bowl that includes a cereal staging trough with the cereal bowl being stackable with one and more than one similar cereal bowls.
[0022] It is also an object of the invention to conserve the amount of milk used in a serving of cereal by allowing a first amount of cereal to be submerged in an ample supply of milk in the bowl portion of the cereal bowl, retrieving cereal from the bowl with a spoon leaving some of the milk in the bowl, and then “feeding” “staged” cereal into the milk containing section of the cereal bowl.
[0023] It is another object of the invention to provide a freestanding cereal bowl that resists tipping when the cereal bowl is resting on a flat surface.
[0024] The preferred embodiments of the invention presented here are described below in the drawings and detailed specification. Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given the plain, ordinary and accustomed meaning to those of ordinary skill in the applicable arts. If any other special meaning is intended for any word or phrase, the specification will clearly state and define the special meaning. Likewise, if a noun, term or phrase is intended to be further characterized or specified, such will include adjectives, descriptive terms or other modifiers in accordance with the normal precepts of English grammar. Absent use of such adjectives, descriptive terms or modifiers, it is the intent the nouns, terms or phrases be given their plain and ordinary English meaning to those skilled in the applicable arts.
[0025] Further, the use of the words “function,” “means” or “step” in the Specification is not intended to indicate a desire to invoke the special provisions of 35 U.S.C. 112, Paragraph 6, to define the invention. To the contrary, if the provisions of 35 U.S.C. 112, Paragraph 6 are sought to be invoked to define the inventions, the claims will specifically state the phrases “means for” or “step for,” and will also clearly recite a function, without also reciting in such phrases any structure, material or act in support of the function. Thus, even when the claims recite a “means for” or “step for” performing a defined function, if the claims also recite any structure, material or acts in support of that means or step, or that perform the function, then the intention is not to invoke the provisions of 35 U.S.C. 112, Paragraph 6. Moreover, even if the provisions of 35 U.S.C. 112, Paragraph 6 are invoked to define the claimed inventions, it is intended that the inventions not be limited only to the specific structure, material or acts that are described in the preferred embodiments, but in addition, include any and all structures, materials or acts that perform the claimed function as described in alternative embodiments, or that are well known present or later-developed, equivalent structures, material or acts for performing the claimed function.
BRIEF DESCRIPTION OF THE FIGURES
[0026] A more complete understanding of the present invention may be derived by referring to the detailed description when considered in connection with the following illustrative figures. In the figures, like reference numbers refer to like elements or acts throughout the figures.
[0027] FIG. 1 is a top view of the cereal bowl disclosed herein.
[0028] FIG. 2 is a cross sectional view through 2 - 2 of the cereal bowl shown in FIG. 1 .
[0029] FIG. 3 is a cross sectional view of a bowl having a sloped inner bottom portion.
[0030] FIG. 4 is a cross sectional view of a version of a bowl.
[0031] FIG. 5 is top view of a generally rectangular shaped bowl.
[0032] FIG. 6 is a cross sectional view through 6 - 6 of the bowl shown in FIG. 5 .
[0033] FIG. 7 is a cross sectional view of a rounded bowl similar to the bowl in FIG. 6 .
[0034] FIG. 8 is top view of a generally rectangular shaped bowl having two platforms.
[0035] FIG. 9 is a cross sectional view through plane 9 - 9 of FIG. 8 .
[0036] FIG. 10 is an alternative view of a smoothly contoured bowl similar to the bowl of FIG. 8 .
[0037] FIG. 11 is a top view of an alternative version of a cereal bowl.
[0038] FIG. 12 is a cross-sectional view of the bowl in FIG. 11 through plane 12 - 12 of FIG. 11 .
[0039] FIG. 13 is a top view of an alternative bowl incorporating the invention.
[0040] FIG. 14 is a cross-sectioned view through plane 14 - 14 of the bowl in FIG. 13
DETAILED DESCRIPTION OF THE INVENTION
[0041] In the following description, and for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various aspects of the invention. It will be understood, however, by those skilled in the relevant arts, that the present invention may be practiced without these specific details. In other instances, known structures and devices are shown or discussed more generally in order to avoid obscuring the invention. In many cases, a description of the operation is sufficient to enable one to implement the various forms of the invention. It should be noted that there are many different and alternative configurations of this invention. The full scope of the invention is not limited to the examples that are described below.
[0042] In one embodiment of the invention shown in FIG. 1 there is a cereal bowl, generally 10 , having a bowl portion 12 . The bowl portion has a bottom 14 and an upwardly extending wall 16 .
[0043] Integral with the bowl portion 12 at the top of the wall 16 is a trough portion 20 . The trough portion 20 is a shallow trough arranged to follow the curve or a portion of the circumference of the main bowl portion. In one embodiment of the cereal bowl, the trough 20 extends about one-fourth of the bowl circumference along and around the upper edge of the wall 16 . It, the trough portion 20 of the cereal bowl, generally 10 , can extend further than or less then one fourth of the way around the circumference of the bowl.
[0044] In one embodiment of the bowl the trough has an upwardly extending wall element. In this embodiment the upwardly extending wall element of the main body portion of the bowl and the upwardly extending wall element of the trough portion flow together to be interconnected and extend upwardly to similar elevations.
[0045] The horizontal ledge of the trough would be somewhat elevated above the bottom of the bowl to allow for the supply of milk to remain separated from the contents on the trough of the bowl.
[0046] The bowls presented here are “free standing.” That is each bowl is proportionately balanced, the bowl portion and the trough portions are proportionately balanced such that the bowls will not be unstable in use. The “free standing” bowls are intended to be stackable with bowls of similar shape.
[0047] The cereal bowl is designed to be a cereal bowl in which dry cereal is poured into the main bowl portion and into the trough portion of the bowl and an ample supply of milk or a suitable liquid is poured into the bowl portion 12 of the cereal bowl as is usually done.
[0048] In one embodiment of the bowl described here, the volume capacity of the trough portion of the bowl is generally about half of the volume of the bowl portion.
[0049] It is also contemplated that the cereal being put into the bowl and the cereal being put in the trough can be the same cereal, most usually a dry cereal product, or different foods, such as dry cereal and fruit or dry cereal and nuts.
[0050] FIG. 2 is a side elevation view of the bowl of FIG. 1 . In this figure the main bowl portion 12 is shown generally opposite the trough portion 20 of the bowl. The depth of the trough 20 from the top edge of the cereal bowl is seen at the right side of this figure. It can be seen in this figure, as well as in the other cross-sectioned views of bowls, that the trough portion 20 , has a generally flat, unobstructed bottom surface 18 and an upwardly extending wall portion. This will assist and allow for the unobstructed flow of cereal when the cereal consumer pushes the dry cereal from the trough portion 20 into the main bowl portion 12 of the cereal bowl.
[0051] Another embodiment of the cereal bowl is shown in FIG. 3 as a sloped floor cereal bowl generally 22 . In this embodiment, the floor 26 of the bowl is sloped to a lower point 30 so that milk or other suitable liquid will flow from portion 28 and gather in the lower point 30 of the cereal bowl. The thickness of the bottom of the main bowl portion would be slightly thinner at the lowest point 30 of the bottom of the bowl and thicker in other portions, such as area 28 , of the bottom of the main portion of the cereal bowl.
[0052] In the embodiments shown above, it is noted that the cereal bowl shapes allow the stacking of the bowls for storage, shipping, and staging. Furthermore, in the embodiments set forth herein, the trough portion of the cereal bowl will be smaller than the bowl portion of the cereal bowl. The volume of the trough would hold approximately no more than fifty percent of the volume of the main portion of the cereal bowl.
[0053] In each of the embodiments shown it can be seen that there is a flat bottom on the exterior surface of the cereal bowl. This flat bottom allows the bowl to be free standing such that the cereal bowl will not tip either when it is full, partially full, or empty. This stability is also facilitated by having the size, mass and location of the trough portion of the cereal bowls proportionately balanced with the main portion of the cereal bowl. That is, the trough portion of the cereal bowl can be made to be either lighter, or at least no heavier, than the main bowl portion of the cereal bowl.
[0054] The versatile nature of this invention allows for a number of different embodiments shown in FIGS. 4-14 . In various embodiments the bowl will have a main body portion and an attached trough. The main body will have a concave shape and an upwardly extending wall element and the trough will be integral with the upwardly extending wall. In another embodiment, the trough will be a horizontal ledge and will be attached to the upwardly extending wall at a point below the top of the wall. Yet another embodiment will have a trough that extends radially along the perimeter of the bowl. An alternative embodiment will be a bowl where the main portion has a round shape at the upper edge of the upwardly extending wall.
[0055] An additional embodiment will be a bowl where the main body portion has a bottom with an inner surface and an outer surface, and the two surfaces are generally parallel. A further embodiment will be a bowl having a bottom with an inner and outer surface, but the two surfaces will be non-parallel. An alternate version will be a bowl with a bottom portion composed of an inner and outer surface, and the outer surface will be generally horizontal.
[0056] Other embodiments the bowl would be rectangular, as shown in FIGS. 5-10 , rather than generally round in a top view. Furthermore, other non-circular top view bowl shapes, such as is shown for example in FIGS. 13 and 14 .
[0057] Further variations will be a bowl with a main body portion and attached trough where a graphic, such as the completely arbitrary example 30 , which is only an example and not the only graphic that can be used as would be understood, is shown in a dotted line presentation in FIG. 1 , is attached to the bowl. Other embodiments of this variation will have the graphic attached to the inner surface of the bottom of the bowl, the trough of the bowl, or the upwardly extending wall of the bowl. Another embodiment will have multiple graphics placed in two or more of the aforementioned locations. It is contemplated that the graphic can be a textual element, a trademark, a symbol, a picture, or the like, or any combination of graphics, text, and pictures. The bowl does not require the use of a graphic and any graphics may be left off the bowl.
[0058] FIG. 4 is similar to the bowl of FIG. 1 with the trough portion 20 extending more than one hundred and eighty degrees around the perimeter of the bowl.
[0059] FIGS. 5 , 6 and 7 show a generally rectangular bowl 32 having a flat surface 18 of the portion of the trough 20 similar to the bowl shown in FIG. 1 . The FIG. 7 version of this bowl has larger radius transitions between the floor of the bowl, the sidewalls and the other area of the trough portion as compared to FIG. 6 .
[0060] FIGS. 8 , 9 and 10 show another embodiment of a generally rectangular bowl 34 having a flat surface 18 of the portion of the trough 20 similar to the bowl shown in FIG. 5 . In this embodiment there are platforms 18 on two of the sides of the generally rectangular shape of the bowl section as can be seen in these figures. The FIG. 10 version of this bowl has larger radius transitions between the floor of the bowl, the sidewalls and the other area of the trough portion as compared to FIG. 9 .
[0061] FIGS. 11 and 12 show another version of the bowl. In this version the center bowl section 12 is somewhat rectangular and there are platforms 18 on two of the sides of the bowl as shown in FIGS. 11 and 12 . These platforms 18 may have a semicircular profile when viewed in the top view FIG. 11 .
[0062] FIGS. 13 and 14 is generally similar to the FIG. 1 embodiment with the difference being that the elevated trough is located entirely within the circumference of the bowl, or entirely inside the perimeter in the case of a bowl that is generally rectangular.
[0063] Several different shapes bowls are presented above. Round, square and rectangular shapes are the primary shapes but it is also possible to have other bowl shapes, such as, but not limited to triangular, octagonal or multiple-sided shapes comprising the perimeter shape of the bowl.
[0064] Due to the innovative structure of this invention, new methods of cereal preparation and consumption will be possible. One such method will allow a fresh crispy supply of dry cereal to be available without being mixed with the cereal being consumed. Beginning with a serving bowl having a bowl portion, the first method requires integrating a trough on an upwardly extending wall of the cereal serving bowl, placing a serving of cereal in the cereal serving bowl, and placing a second serving of cereal in the trough on the side of the cereal serving bowl. This method may be further refined by adding the additional step of moving dry, crispy cereal from the trough portion of the bowl to the main portion of the bowl when the cereal initially placed in the cereal-serving portion of the bowl has been consumed.
[0065] In summary the invention comprises a bowl having, but not limited too, a main body portion with a concave shape and an upwardly extending wall element and a trough integral with the upwardly extending wall portion of the bowl. This trough comprises a generally horizontal ledge having a first margin in communication with the upwardly extending wall element at a point below the top of the upwardly extending wall element and may extend radially outwardly along the perimeter of the bowl, or, in another embodiment, it extends radially inwardly along the perimeter of the bowl.
[0066] The main portion of the bowl can be of any general shape, such as, but not limited to a generally round, obround or curved shape at the upper edge of the upwardly extending wall element, a generally rectangular or square shape at the upper edge of the upwardly extending wall element, or, but not limited to, a multisided shape at the upper edge of the upwardly extending wall element.
[0067] The main body portion of the bowl comprises a bottom with an inner surface and an outer surface, the inner surface and the outer surface each being generally parallel to the other in one embodiment or generally non-parallel to the other in another embodiment. In either embodiment the bowl is proportionately balanced relative to the mass of the trough portion of the bowl. It has been found that when the capacity in volume of the tough portion of the bowl is approximately half the capacity in volume of the main body portion of the bowl the proportions of the bowl are about right for fulfilling its use. It has also been found that it is advantageous, and an object of this invention to have the bowls stackable with bowls having the same general shape.
[0068] Or stated another way, the invention herein is a bowl comprising a main body portion having a perimeter and a concave shape with an upwardly extending wall element. The bowl includes a trough integral with the upwardly extending wall portion of the bowl. This trough has a generally horizontal ledge with a first margin in communication with the upwardly extending wall element at a point below the top of the upwardly extending wall element. The trough element of the bowl may extend radially outwardly along the perimeter of the bowl, or, in another embodiment the trough may extend radially inwardly along the perimeter of the bowl. In either case the trough can be a generally flat unobstructed surface.
[0069] To use the bowl of the invention, where one of the objects is to ensure a supply of dry cereal is not initially mixed with a supply of dry cereal and ample supply of milk in a bowl. To accomplish this a partial serving of dry cereal and an ample supply of milk ARE is placed in the bowl portion of the serving bowl. A second partial serving of dry cereal is placed in the trough portion on the side of the bowl. The second serving of dry cereal is moved from the trough into the bowl portion of the bowl when a portion of the serving of dry cereal initially placed in the bowl portion of the bowl has been consumed from the bowl portion.
[0070] While the invention is described herein in terms of preferred embodiments and generally associated methods, the inventor contemplates that alterations and permutations of the preferred embodiments and methods will become apparent to those skilled in the art upon a reading of the specification and a study of the drawings.
[0071] Accordingly, neither the above description of preferred exemplary embodiments nor the abstract defines or constrains the invention. Rather, the claims variously define the invention. Each variation of the invention is limited only by the recited limitations of its respective claim, and equivalents thereof, without limitation by other terms not present in the claim.
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A bowl includes a main bowl portion and an ancillary portion or trough integral with the side of the bowl that is shaped to receive cereal or other food as a staging location before the food is maneuvered into the main bowl portion.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method for determining an energy yield loss of a first wind turbine of a wind farm comprising a plurality of wind turbines.
2. Description of Related Art
Particularly in the case of large wind farms it is desirable to offer a customer an energy yield guarantee instead of an availability guarantee. Here, in the case of a failure of a wind turbine, or respectively merely a reduced power output of a wind turbine, that is, a wind turbine that is operated in a reduced energy yield mode, it is however difficult to quantify the lost energy yield. Here, the lost energy yield is the difference between the actual possible energy yield in the case of an energy-optimized normal operating mode and the actual energy yield of a wind turbine, which is operated in a reduced energy yield mode or even fails, or respectively is operated without energy yield. It is, however, difficult to determine the actual energy yield that would be possible in an energy-optimized normal operating mode. For this purpose an exact wind strength profile based on location and time at the wind turbine, which is operated in a reduced energy yield mode, would have to be created which is impossible to do exactly, and can be approximated with known methods, such as for example, a nacelle anemometer or a plurality of nacelle anemometers in the region of the wind turbine, only in a very inaccurate way.
With an existing wind measurement mast in the proximity of the wind turbine or the wind farm, using an existing wind turbine power curve, the energy yield can be calculated with the assumption that the wind in the rotor plane corresponds to the wind at the measurement mast. This method is however based on the assumption that does not correspond to reality, and in particular in the case of wind farms, is also too imprecise. In addition, the approach to use the nacelle anemometer of the wind turbine operated in reduced energy yield mode is too imprecise, because the anemometer measurement is strongly distorted by the nacelle and possibly also the rotor blades of wind turbines, which are present in close proximity.
BRIEF SUMMARY OF THE INVENTION
It is the object of the present invention to specify a method for determining the energy yield loss of a first wind turbine of a wind farm comprising a plurality of wind turbines, wherein the first wind turbine is operated in a reduced energy yield mode, that allows a more accurate determination of the energy yield loss.
This object is solved by a method for determining an energy yield loss of a first wind turbine of a wind farm comprising a plurality of wind turbines, wherein the first wind turbine is operated in a reduced energy yield mode that is outside an energy-optimized normal operating mode, wherein a reduced energy yield of the first wind turbine is determined, wherein at least one second wind turbine is selected according to a pre-determinable criterion, wherein the energy yield of the at least one second wind turbine is determined, wherein depending upon the energy yield of the at least one second wind turbine an energy yield potential of the first wind turbine is determined and the difference between the energy yield potential of the first wind turbine and the determined reduced energy yield is formed.
The energy yield loss of the first wind turbine is then the difference between the energy yield potential of the first wind turbine and the determined reduced energy yield, thus in particular, the measured energy yield of the first wind turbine. An energy-optimized normal operating mode is understood to be an operating mode of a wind turbine which aims to generate an optimal quantity of energy, or respectively optimal power of the wind turbine. This is then, above a rated wind speed, the operating mode of the wind turbine at rated power, and below the rated wind speed is usually an operating mode in which the energy yield, or respectively the generated power, increases with increasing wind strength. Upon attaining the rated power then, a full load mode is attained, and before attaining the rated power, or respectively the rated wind speed, a partial load operating mode is attained, wherein the partial load operating mode also represents an energy-optimized normal operating mode. Customary characteristic curves are shown for example in image 14.5 on page 546 of the textbook by Erich Hau, entitled “Windkraftanlagen” (Wind Power Plants), 4th edition, Springer-Verlag, Berlin, Heidelberg.
The image 14.5 on page 546 of the textbook by Erich Hau shows multiple operating mode characteristic curves for the partial load and full load operating range in the rotor power characteristic diagram of a wind turbine. The rotor power coefficient is plotted over the tip speed ratio. The power, which is delivered by the wind turbine, figures in the rotor power coefficient, and the wind speed figures in the tip speed ratio. In this example embodiment, an operating characteristic curve is followed in which the pitch angle of the rotor blades of the wind turbine is set to 5° initially at high tip speed ratio, that is, at low wind speed (see the thick dotted line). From a certain tip speed ratio of approximately 12.5 onwards, the generator is switched on, that is, the wind turbine is then in partial load operating mode. Here, higher power is produced with increasing speed, wherein the pitch angle remains at 5°. Above the rated operating point, the wind turbine goes into full load operating mode, wherein with increasing wind strength the pitch angle is adjusted to greater angles. Above a cut-off wind speed with a pitch angle of approximately 27°, the wind turbine is switched off. There are also variants in which the wind turbine is not yet switched off at a cut-off wind speed, but rather, initially is further operated at reduced power with a greater rotor blade angle, or respectively, pitch angle in order to still produce power. This can also represent an energy-optimized normal operating mode. In the scope of the invention, an energy-optimized normal operating mode is therefore the example progression shown in the image 14.5 on page 546 in the textbook by Erich Hau. A reduced energy yield mode is a progression that lies below this characteristic curve, thus producing less energy, or respectively power, typically because a higher blade angle, or respectively pitch angle, is set.
Preferably, at least two second wind turbines are selected or are respectively selected, wherein the energy yield of the at least two second wind turbines is determined, wherein depending on the energy yields of the at least two second wind turbines an energy yield potential of the first wind turbine is determined. If the method is correspondingly expanded with at least two second wind turbines, a more accurate result of the determination of the energy yield potential of the first wind turbine is expected.
The at least one second wind turbine or the at least two second wind turbines is, or are, preferably operated in an energy-optimized normal operating mode.
Correspondingly, reference is also made to the document EP 0 847 496 B1, in which FIG. 1 shows characteristic curves which serve to specify for the operating control how to run, for instance, the power curve over the wind speed. With respective running, or respectively operating, of the wind turbine on the characteristic curve, the power over the wind speed shown in FIG. 1 , this is also an energy-optimized normal operating mode. With an operating mode of the first wind turbine which has a reduced energy yield mode, an operating mode would be provided which would be below the characteristic curve of the power over the wind speed. Here, in particular, this can preferably be a standstill or a powerless operation of the first wind turbine.
The method is in particular efficient when the energy yields of the at least two second wind turbines are interpolated, extrapolated, or averaged for the determination of the energy yield potential of the first wind turbine. In particular, averaging provides a realistic value for the energy yield potential of the first wind turbine. With this, in particular a weighted average value can also be used, when for example, a projection of the energy yield of the respective second wind turbines is known based on stored empirical values with determined environmental parameters, for instance the wind direction and/or the wind strength, which leads to an exact determination of energy yield potential of the first wind turbine. A projection can be preferably performed when it is known that with a predetermined environmental parameter, the energy yield of a second wind turbine is more similar than a further second wind turbine. A determination of the energy yield potential can be made particularly simply using interpolation. It can also make sense to extrapolate the corresponding energy yields of the at least two second wind turbines, in particular, when for certain environmental parameters, or respectively with at least one environmental parameter, a ratio of the energy yields of the at least two second wind turbines to the first wind turbine is known or respectively determined and/or saved.
The method is particularly preferred when this is performed automatically, in particular completely automatically. In the scope of the invention, completely automatically is understood to mean that the method is initiated completely automatically as soon as a first wind turbine is operated outside of an energy-optimized normal operating mode, i.e. in a reduced energy yield mode. Automatic comprises that the method is performed automatically after initiation by an operator.
Preferably the operation of the first wind turbine in a reduced energy yield mode is at standstill or powerless operation, for example rolling operation of the first wind turbine.
Preferably the wind farm is divided into at least a first and a second group of wind turbines, wherein the first wind turbine and the at least one second wind turbine are in the same group, or the first wind turbine and the at least two second wind turbines are in the same group. In this case, the criterion for the selection of the at least two second wind turbines is that the second wind turbines belong to the group to which the first wind turbine belongs.
Preferably the first group of wind turbines comprises wind turbines with freely inflowing wind and the second group of wind turbines comprises wind turbines with disrupted inflowing wind. The wind turbines with disrupted inflowing wind are wind turbines that are disrupted by further wind turbines with respect to the inflowing wind. A disruption arises for example due to a wake flow or wake turbulence of further wind turbines. Wind turbines with freely inflowing wind are for example those which, based on a predetermined wind direction, are the first wind turbines that are encountered by the wind. The wind turbines arranged behind these are typically wind turbines with disrupted inflowing wind because these lie in the turbulence zone of the wind turbines with freely inflowing wind.
If the first wind turbine belongs to the group of the wind turbines with freely inflowing wind, then at least one second wind turbine, or the at least two second wind turbines also belong to this group. Conversely, the second wind turbines belong to the group of the wind turbines with disrupted inflowing wind, when the first wind turbine also belongs to the group of wind turbines with disrupted inflowing wind. In this case, it is particularly preferable if an average value of the energy yields of the respective group of wind turbines is formed, and this average value from the second wind turbines from this group of wind turbines is applied as the energy yield potential of the first wind turbine. Which wind turbine belongs to the wind turbines with disrupted inflowing wind, and which belongs to the wind turbines with undisrupted inflowing wind, or respectively freely inflowing wind, depending on the wind direction, can be calculated according to a formula, which is specified in the scope of the following description of the figures. Preferably, all second wind turbines of the corresponding group are used for the determination of an average value of the energy yield in order to determine the energy yield potential of the first wind turbine.
Alternatively, or respectively additionally, preferably an energy yield ranking list of the wind turbines of the wind farm can be or has been formed. The energy yield ranking list concerns the energy yield, or respectively power yield, of the respective wind turbine in the energy-optimized normal operating mode, in order to be able to provide a respective comparison. The energy yield ranking list can be formed, or respectively measured, as a multidimensional matrix, in particular depending on different wind directions and/or different wind strengths.
By creating an energy yield ranking list it is possible in a particularly simple manner to determine an energy yield potential of the first wind turbine, for example in that the energy yield of one, or at least two, second wind turbines is considered in order to specify the energy yield potential of the first wind turbine. For this purpose, preferably the at least one second wind turbine or the at least two second wind turbines considered in the energy yield ranking list is or are neighboring the energy yield of the first wind turbine. Here, immediate neighbors can be considered as well as neighbors lying more remotely. Then, the energy yield potential of the first wind turbine can also simply be an average value of the wind yields of the neighboring second wind turbines, for example. In this case, the criterion for selecting the at least two second wind turbines is that they are energy yield neighbors to the first wind turbine. It should be considered that for forming the energy yield ranking list, preferably all wind turbines of the wind farm are not operated in a reduced energy yield load, but rather in an energy-optimized normal operating mode. The ranking list is preferably stored in the respective operating control system of the wind turbine, or respectively in a higher order control system for the wind farm.
As already mentioned, is preferable that the energy yield potential of the first wind turbine depends on at least one environmental parameter. The environmental parameter can be the wind direction, wind strength, air density, a predominant turbulence and/or a wind gradient.
Preferably only second wind turbines that are operated in an energy-optimized normal operating mode are used for determining the energy yield potential of the first wind turbine.
Preferably a comparatively low standard deviation of the determined effective power of the second wind turbine compared to at least one further second wind turbine is provided as a criterion for the selection of a second wind turbine, in particular an additional criterion. The corresponding second wind turbines, which have a standard deviation in energy yield, or respectively power yield, that is too large, are excluded for the determination of the energy yield potential of the first wind turbine, in order to correspondingly increase the accuracy of the determination of the energy yield potential of the first wind turbine.
Preferably, a matrix is or will be created which specifies the energy yield ranking list depending on the wind direction. Preferably, a matrix is or will be created which specifies the energy yield ranking list depending on a further environmental parameter. The matrix can have for example an energy yield ranking list for different wind directions in 5° intervals, or larger or smaller degree intervals. In addition, the matrix can additionally have the energy yield ranking list depending on the wind strengths in intervals of 1 m/s or more or less larger intervals. Additionally, the air density can be added as a further parameter in the matrix. The thusly resulting measured values are then respectively stored and can be adaptively and continuously modified and optimized depending on the prevailing environmental parameters. Preferably a continuously improving learning system results, with which very accurate an energy yield loss of a first wind turbine can be determined, or respectively calculated, based on neighboring wind turbines in terms of the energy yield.
Correspondingly, with the of division of the wind farm into at least two groups of wind turbines, the group division can also be performed depending on environmental parameters, such as the wind direction, wind strength, air temperature, wind gradients and/or wind turbulence, and possibly also atmospheric pressure, and the results can be stored in order to determine, or respectively to calculate, thusly adaptively and further refining a result that is as accurate as possible for the energy yield potential for the first wind turbine.
Further characteristics of the invention will become apparent from the description of the embodiments according to the invention together with the claims and the included drawings. Embodiments according to the invention can fulfill individual characteristics or a combination of several characteristics.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described below, without restricting the general idea of the invention, based on exemplary embodiments in reference to the drawings, whereby we expressly refer to the drawings with regard to the disclosure of all details according to the invention that are not explained in greater detail in the text. The figures show:
FIG. 1 is a plan view of a wind farm with 48 wind turbines with a specific wind direction;
FIG. 2 is a plan view of a wind farm with 48 wind turbines with a wind direction different than that illustrated in FIG. 1 ;
FIG. 3 is a schematic plan view of a further wind farm with 16 wind turbines;
FIG. 4 is a schematic illustration of the energy yield ranking list of the wind farm of FIG. 3 with a wind direction of 123°;
FIG. 5 is a schematic illustration of the energy yield ranking list of the wind farm of FIG. 3 with a wind direction of 340°; and
FIG. 6 is a simplified flowchart for forming an energy yield ranking list of wind turbines of a wind farm.
In the following figures, the same or similar types of elements or corresponding parts are provided with the same reference numbers so that a corresponding re-introduction can be omitted.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 schematically show a top view of a wind farm 51 with 48 wind turbines. In addition in FIG. 1 and in FIG. 2 , a wind 50 is shown with a corresponding schematically represented wind direction. It can be seen that the wind turbines which are provided with a black dot are wind turbines with freely incoming wind 50 , and the wind turbines which are provided with a gray triangle are wind turbines with disrupted incoming wind. In the case of FIG. 1 with a wind direction from the left in FIG. 1 according to the wind 50 , the wind turbines 1 , 2 , 3 , 4 , 5 , 7 , 9 , 11 and 13 encounter freely inflowing wind, and the other wind turbines in the wake turbulence of those wind turbines encountering freely inflowing wind and also the further wind turbines, are thus exposed to disrupted inflowing wind. Correspondingly, the wind turbines 1 , 6 , 7 , 20 , 21 , 29 , 36 , 41 , 42 , 46 , 47 and 48 in FIG. 2 with the wind direction of the wind 50 of the FIG. 2 , encounter freely inflowing wind, and the further wind turbines encounter disrupted inflowing wind, i.e. disrupted by further wind turbines.
Thus, the wind farm 51 according to FIGS. 1 and 2 is divided into two different groups of wind turbines depending on the wind direction. These are wind turbines which are not influenced by other wind turbines, and wind turbines which are influenced by other wind turbines. According to the invention, it is calculated for each wind direction, for example in increments of 1°, or larger or smaller increments, which wind turbines belong to which group. This can be specified in a first step according to the formula given in the document IEC 6140012-1:
α = 1 , 3 * arctan ( 2 , 5 * D n L n + 0 , 15 ) + 10
wherein α is an angle of a disrupted sector, D n is the rotor diameter of neighboring wind turbines that are operating, L n is the distance between the wind turbine to be determined and the neighboring turbine that is also in operation. As a second step, an orientation of the disrupted sector is given as follow:
β = { 90 - arctan ( ⅆ y ⅆ x ) f u ¨ r x 0 > x und y 0 > y 90 + arctan ( ⅆ y ⅆ x ) f u ¨ r x 0 > x und y 0 < y 270 - arctan ( ⅆ y ⅆ x ) f u ¨ r x 0 < x und y 0 < y 270 + arctan ( ⅆ y ⅆ x ) f u ¨ r x 0 < x und y 0 > y
wherein x 0 is the x-coordinate of the neighboring and operating wind turbine, y 0 is the y-coordinate of the neighboring and operating wind turbine, wherein the x and y-coordinates are also shown in the FIGS. 1 and 2 . Here, the x-coordinate is the abscissa and the y-coordinate is the ordinate. Correspondingly, x and y are the x-coordinate, or respectively the y-coordinate, of the wind turbine for which it is to be determined whether this wind turbine is disrupted by other wind turbines. dx is the distance along the abscissa between the wind turbine to be determined and the neighboring and operating wind turbine, and correspondingly dy is the distance along the ordinate in this regard. β is the angle between the wind turbine to be determined and the neighboring wind turbine compared to the north direction.
Finally, using the following formula:
γ = β - υ dir - α 2
it can be determined whether the respective wind turbine belongs to the disrupted wind turbines. This is the case if γ has a negative value. Here, γ is the disruption indication angle and v dir is the wind direction. These calculation steps are performed for all wind turbines that are in operation. Only the wind turbines that always have a positive γ belong to the first group of wind turbines, namely the wind turbines with freely inflowing wind. All others belong to the second group of wind turbines for which the wind is not freely inflowing.
In order to now determine the energy yield deficit of a wind turbine at standstill, or respectively operated in a reduced energy yield mode, the respective group division is performed, for example in a 10 minute average value of a wind direction, and the yield deficit of the nonoperational wind turbine, or respectively the wind turbine which is operated in a reduced energy yield mode, is specified as the average value of the energy yield of the further turbines of the corresponding group. Here, a 10 minute time interval can also be considered. For the case that the wind turbine 2 , with a wind direction according to FIG. 1 , for example, is at standstill, an average value of the energy yield of the wind turbines 1 , 3 , 4 , 5 , 7 , 9 , 11 and 13 is thus formed, and correspondingly the average value of the energy yields, or respectively the effective power, of these wind turbines over a 10 minute interval for example, is the energy yield potential for the wind turbine 2 . For the case that the wind turbine 2 is operated only at 50% power, or respectively energy yield, the difference between the possible power and the power actually created, is calculated. Correspondingly the wind turbine operated in a reduced energy yield mode can be a wind turbine from the group of wind turbines with disrupted inflowing wind, so that the energy yield potential of this first wind turbine is formed, for example, by an average value of the determined energy yields of the further wind turbines from this group.
The calculation of the group is calculated precisely to the degree, for example, for each 10 minute interval. The method according to the invention leads to remarkably good results even with complex wind farms, and can be refined also by a larger number of groups. For example, a group 3 can be provided which provides for multiple disruptions. With the embodiment according to FIG. 1 , a group 1 can be provided for example, which are the wind turbines which are represented as circles, a group 2 can be provided which includes the wind turbines 6 , 8 , 10 , 12 , 14 , 15 , 16 , 18 and 19 , and the group 3 represents the further wind turbines. It is possible that this can lead to improved and more accurate results. However, this is not necessarily the case because the complex disruption behavior in the wake of wind turbines, or respectively wind rotors, can also lead to contrary effects, which however depend on the wind direction and the design of the wind farm 51 .
FIG. 3 schematically shows a further wind farm in a schematic top view with an abscissa x and an ordinate y represented. Here, two wind arrows 50 are shown which are arranged at different angles, namely an angle of 123° and an angle of 340°, each relative to the wind direction from the north. Based on the wind farm 51 according to FIG. 3 , a ranking list of all wind turbines in the wind farm is to be created depending on their power, or respectively the energy yield and these are shown again depending on the wind direction. This ranking list serves in the case of a failure or a reduction of the energy yield of a wind turbine in order to determine possible energy partners from whose average value, or respectively weighted average value, or respectively by interpolation or extrapolation of the production power, the lost energy quantity can be derived.
The lost quantity of energy is the energy yield potential of a wind turbine at standstill, or respectively the difference of the energy yield potential to the reduced energy yield of this wind turbine, if this turbine is operated in a reduced energy yield mode. With this, fixed local wind turbines are not used as reference, thus wind turbines locally neighboring wind turbines, but rather wind turbines which are the closest in the energy production with given boundary conditions, i.e. given environmental parameters, for instance the wind direction or the wind strength, of the non-producing wind turbine, or respectively the wind turbine operated in the reduced energy yield mode. This embodiment of the invention has the advantage that it is very exact.
Correspondingly the ranking list can also be used for prioritizing maintenance work because only systems with lower yield at a correspondingly present wind direction for example can be serviced.
For the wind farm 51 from FIG. 3 with the 16 wind turbines an energy yield ranking list is created for each wind direction. This can be performed once and be continuously adapted for corresponding wind directions and/or wind strengths and/or other environmental parameters, such that in the case of changes to the wind turbines, for instance software updates, contamination of rotor blades, changes at the site for instance the felling of large trees, the energy yield ranking list 52 is respectively adapted. Here, the following data can be measured, or respectively provided, for instance the wind vane position which is made available, or respectively stored, preferably averaged for all wind vanes of each wind turbine from the energy farm 51 , the nacelle position of the respective wind turbine, an effective power, or respectively an energy yield of the respective wind turbine, and the status of the wind turbine whether this is in working or nonworking order. Here too, average values, for example a 10 minute average value, can be used.
A method for determining an energy yield ranking list 52 is shown schematically for example in FIG. 6 . At 100 , it is checked whether all wind turbines 1 to 16 are producing power, or respectively delivering an energy yield. At 110 , the averaged value of all wind vane positions is calculated. At 120 , the effective power of each wind turbine is measured in 10 minute averages; at 130 , the effective power of each wind turbine is normalized with the greatest effective power in the wind farm. The greatest effective power in the wind farm is an effective power not determined over 10 minutes, but rather a currently measured effective power. An effective power over a time average can also be provided, and also over a 10 minute average. The normalization occurs for each wind turbine in the wind farm. At 140 , the values corresponding to an n-tuple, for instance a 4-tuple, thus four-dimensional, are stored in a corresponding, in particular dynamic, matrix, for example a tuple comprising the wind direction, the number of the wind turbine, the normalized effective power and the number of the measurement, for example the n-th measurement, wherein n is an integer.
At 150 in FIG. 6 , a query is made whether the measurement method was performed n-times. The number n can be preset, and is, for example the number 5. However, n can also be 10 or 20. If the response to the question is that this is not the case (n), then the method restarts at 100 , and when the question is answered with yes (y), then at 160 the average value of each normalized effective power of each wind turbine and a corresponding standard deviation is formed.
At 170 , the ranking list is formed, which is represented for example in FIGS. 4 and 5 . Here, the normalized effective power is plotted on the ordinate and the number of respective wind turbines is plotted on the abscissa, wherein the sequence of the wind turbines is given by the energy yield, or respectively power yield. If a wind turbine has a standard deviation of the normalized effective power for the n-measurements that is too large, this wind turbine can be excluded from the ranking list.
The sorting of the ranking list 52 is according to the value of the normalized and averaged effective power. Here, the standard deviation reflects the reliability of the sequence. If the standard deviation values are above a limit value, the scattering is too large, and alternatively the next best reference system, or respectively neighboring wind turbine, should be selected if the standard deviation there is significantly lower.
FIG. 4 schematically shows an energy yield ranking list 52 with a wind direction of 123°, and FIG. 5 schematically shows an energy yield ranking list 52 with a wind direction of 340°. Both of these wind directions are indicated in FIG. 3 . A one-year evaluation of the respectively measured data for the wind farm of FIG. 3 provided the respective energy yield ranking list for the different wind directions. FIG. 4 and FIG. 5 are shown as an example.
If the turbine 7 fails, for example, with a wind direction of 123° (see FIG. 4 ) the energy neighbors 4 and 8 and possibly also 2 and 11 can be used for determining the energy yield deficit, or respectively the energy yield potential. The energy yields, or respectively effective powers, of these producing wind turbines can then be used in order to determine the energy yield potential of the wind turbine 7 . This can occur for example by forming an average value, or respectively interpolating or forming a weighted average value. With forming a weighted average value, for example, the energy yield of the wind turbines 4 and 8 would be evaluated as twice the strength of the energy yield of the wind turbines 2 and 11 .
With a wind direction of 340° (see FIG. 5 ) the immediate energy neighbors of wind turbine 7 are the wind turbines 6 and 13 , and the correspondingly somewhat further distanced energy neighbors, the wind turbines 11 and 5 . Correspondingly then, the energy yield potential of the wind turbine 7 can be determined using the energy yields of these wind turbines ( 11 and 5 , as well as 6 and 13 ). With this, the average value of the effective powers of the energy neighbors can be referred to for the relevant time of the standstill of a first wind turbine, in order to determine the energy quantity which the wind turbine 7 would have produced for example. Energy neighbors are preferably up to a maximum of 5 neighboring wind turbines in one direction.
A particularly advantageous method further provides that for the determination of the energy neighbors it is additionally checked whether the energy neighbor lies in the wake turbulence, or respectively the wake, of the first wind turbine (here turbine 7 ). This check can be performed analogously to the formulas which were specified above for determining the wind turbines of the group 2 . If the energy neighbor lies in the immediate wake, it is excluded from the calculation because it is to be expected that the energy yield changes significantly due to the failure of the first wind turbine. The next energy neighbor then is referred to for the method, possibly with consideration of a weighting factor. This embodiment significantly increases the method accuracy for wind farms in a level site. For wind farms at hilly sites, the result can also be more accurate, even without this additional check.
A strategy for prioritizing maintenance can also be derived. Planned standstill times, for instance, an annual maintenance or an oil change, can be performed, for example with wind 340°, preferably for turbine 4 or 8 , and not for turbine 12 or 14 .
All named characteristics, including those taken from the drawings alone, and individual characteristics, which are disclosed in combination with other characteristics, are considered individually and in combination as essential to the invention. Embodiments according to the invention can be fulfilled through individual characteristics or a combination of several characteristics.
REFERENCE LIST
1 - 48 wind turbine
50 wind
51 wind farm
52 energy yield ranking list
100 check, whether all wind turbines are producing
110 calculation of the average value of all wind vane positions
120 measurement of the effective power of each wind turbine in 10 minute intervals
130 normalization of the effective power of the wind turbine with the greatest power in the farm
140 storing the values in a four dimensional dynamic matrix, for example (wind direction/wind turbine/normalized effective power/n-th measurement)
150 query performed n times
160 form the average value and standard deviation
170 form the ranking list
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A method for determining an energy yield loss of a first wind turbine of a wind farm that includes a plurality of wind turbines. The first wind turbine is operated in a reduced energy yield mode that is outside an energy-optimized normal operating mode and a reduced energy yield of the first wind turbine is determined. At least one second wind turbine is selected according to a pre-determinable criterion. The energy yield of the at least one second wind turbine is determined and depending upon the energy yield of the at least one second wind turbine, an energy yield potential of the first wind turbine is determined. The difference between the energy yield potential of the first wind turbine and the determined reduced energy yield is formed.
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[0001] This application claims priority to U.S. provisional application Ser. No. 60/874,844, filed Dec. 14, 2006, the entire contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to methods of suppressing neuronal death, such as seen with so-called ischemia-related diseases and disorders, including for example neuronal and cardiac diseases due to sudden loss of oxygen, as well as longer-term degenerative diseases, such as Alzheimer's disease among others. The methods involve the use of inhibitors that act primarily in a simultaneous manner on the cyclin-dependent kinases, CDK4 and CDK6, an example of which is the compound, PD0332991 (Pfizer).
BACKGROUND OF THE INVENTION
[0003] The present invention is broadly directed to a new use of certain cyclin-dependent kinase (CDK) inhibitors, more particularly inhibitors of CDK4 and CDK6 together (CDK4/6), which have until now been shown useful only as antineoplastic agents. Such CDK4/6 inhibitors and their syntheses have been disclosed inter alia in U.S. Pat. No. 6,396,612. The present inventors have found that such compounds also have the characteristic of acting as neuroprotectants, and as such are useful in acute and chronic nervous system disorders and conditions and other diseases and disorders in which ischemia plays an essential role in the pathology.
[0004] Increasing evidence indicates that maintenance of neuronal homeostasis involves the activation of the cell cycle machinery in postmitotic neurons. Recently, the present inventors' studies have suggested that cell cycle activation is essential for DNA damage-induced neuronal apoptosis Accumulating evidence suggests that activation of the cell cycle machinery contributes to the demise of terminally differentiated neurons exposed to damaging stimuli (Kiruman, I. I., et al. 2004. Neuron. 41:549-561; Liu, D. X., and L. A. Greene. 2001. Cell Tissue Res. 305:217-228). In mitotic cells, the cell cycle machinery is a major contributor to the DNA damage response, acting through a complex set of mechanisms that repair the damage and coordinate cell division and apoptosis in a collective effort to preserve genomic integrity (Abraham, R. T. 2003. Bioessays. 25:627-630; Bernstein. C., et al. 2002. Mutat Res. 511:145-178; Rhind, N. and P. Russell. 2000. Curr Biol. 10:R908-R911). Accordingly, the processes of cell cycle regulation and DNA repair are functionally integrated, as evidenced by the fact that they use several common proteins (Slupphaug, G., et al. 2003. Mutat Res. 531:231-251). The protection of genomic integrity is a major challenge for cells, which are continuously exposed to genotoxic stress resulting from exogenous sources and from endogenous free radicals that arise from oxygen metabolism. Neurons are highly susceptible to oxidative stress due to their high rate of oxidative metabolism and low level of antioxidant enzymes (Brooks, P. J. 2000. Neurochem Int. 37:403-412). Consequently, oxidative stress represents a major cause of the neuropathology underlying a variety of neurodegenerative diseases (Sayre, L. M., et al. 2001. Curr Med Chem. 8:721-738). DNA damage is an important initiator of neuronal death in a wide variety of neuropathological conditions (Bogdanov, M., et al. 2000. Free Radic Biol Med. 29:652-658; Jenner, P. and C. W. Olanow. 1998. Ann Neurol. 44(3 Suppl 1):S72-84; Lovell, M., et al., 1999. J. Neurochem. 72:771-776). A connection between DNA damage and neurodegeneration is also illustrated by the neurological abnormalities that accompany defective DNA repair in various human syndromes such as ataxia telangiectasia and Cockayne syndrome (Rolig, R. L., and P. J. McKinnon. 2000. Trends Neurosci. 23:417-424).
[0005] Terminally differentiated neurons are transcriptionally active and retain the need to preserve the integrity of the transcribed genome throughout the life span, underscoring the importance of an adequate DNA damage response in these cells. Thus, the high metabolic rate and continuous exposure to oxidative stress make the control of genomic integrity a challenging but essential task for postmitotic neurons, as evidenced by the fact that defects in the DNA damage response lead to severe neurodegeneration.
[0006] While a number of studies have investigated the responses of proliferating cells to genotoxic agents, the DNA damage response in terminally differentiated neurons is poorly understood.
[0007] Research has shown that cell cycle activation plays an essential role in neuronal death. The suppression of cyclin-dependent kinases (CDKs), critical for cell cycle progression, is known to be neuroprotective in experimental models of stroke (Johnson K, et al. (2005). J. Neurochem. 93:538-548; Katchanov, J., et al. 2001. J. Neurosci. 21:5045-5053; Kruman, I. I., et al. 2004. Neuron. 41:549-561). For example, flavopiridol, a non-specific CDK inhibitor that inhibits all the CDKs, has been shown to be very potent in preventing neuronal apoptosis in vitro, and was protective in in vivo ischemia models (Ginsberg D. (2002). FEBS Lett. 529:122-125; Knockaert M, et al. 2002. Trends Pharmacol. Sci. 23:417-425).
[0008] However, the mechanism of the neuroprotection has not been well understood. The present inventors attribute this to that fact that prior work with CDK inhibitors has been done with agents that are not very specific to certain CDK complexes. For instance, flavopiridol has multiple cellular targets, including non-CDK-related kinases (Fry, D. W., et al. 2004. Mol Cancer Ther. 3:1427-1438).
[0009] The present invention elucudates for the first time that the specific inhibition of the CDK4/6 kinases is sufficient for preventing neuronal apoptosis. It has been hypothesized that the DNA damage response and associated apoptotic signaling in neurons are linked to cell cycle activation. While not being bound by a particular theory, with the present invention it is thought that neuroprotection occurs in neurons due to the action of a CDK4/6 inhibiting agent targeting and inhibiting cell cycle activation and, consequently, apoptosis.
[0010] The present invention thus provides a method for protecting neurons under exogenenous or physiological stress, and accordingly provides methods for treating acute and chronic neurological disease states, by the inhibition of CDK4/6.
[0011] While the present invention is primarily directed to agents that act on both CDK4 and CDK6 together, an agent that acts to inhibit one of these is alone is contemplated to be included herein.
[0012] Recently, we and others have shown that the DNA damage response in postmitotic neurons committed to apoptosis involves cell cycle-associated events (Klein, J. A., et al. 2002. Nature. 419:367-374; Kruman, I. I., et al. 2004. Neuron. 41:549-561). While these observations are in keeping with the notion that resting cells must activate cell cycle machinery in response to DNA damage to eliminate cells with non-repairable damage, the present invention, i.a., provides further evidence that the cell cycle machinery is involved in apoptotic signaling in postmitotic neurons.
SUMMARY OF THE INVENTION
[0013] Cyclin-dependent kinases (CDKs) are a family of serine/threonine protein kinases that regulate cell cycle progression upon complexing with their corresponding cyclin partner (Vermeulen, K., et al. 2003. Cell Prolif. 36:165-175). In general, pharmacological inhibition of CDK activity results in selective anti-proliferative effects on cycling cells (Gray, N., et al. 1999. Curr Med Chem. 6:859-875).
[0014] The neuronal effects of CDK4/6 inhibitors was discovered in the course of studying the DNA damage response of neurons under stress conditions. In neurons, mounting data suggest that the CDK/pRb/E2F pathway plays a prominent role in promoting neuronal cell death, and that CDK inhibitors have a neuroprotective effect (Katchanov, J., et al. 2001. J. Neurosci. 21:5045-5053; Meijer, L. and E. Raymond. 2003. Acc Chem Res. 36:417-425; Park, D. S., et al. 2000. Neurobiol Aging. 21:771-781). However, if the cell cycle machinery is involved in DNA repair, CDK suppression should block it.
[0015] This hypothesis was tested by employing RNAi directed against CDK4 and CDK6, two CDKs that are essential for cell cycle activation. By these studies, the present inventors demonstrated that the simultaneous inhibition of CDK4 and CDK6 activity actually blocked apoptosis, suggesting an important role for CDK4 and CDK6 in apoptotic signaling in postmitotic neurons. Thus, the data confirm the involvement of the cell cycle machinery in the neuronal apoptosis initiated by DNA damage.
[0016] Cell division cycle machinery is involved in the activation of the apoptotic cascade to eliminate cells that have incurred DNA damage (Bernstein. C., et al. 2002. Mutat Res. 511:145-178; Rhind, N. and P. Russell. 2000. Curr Biol. 10:R908-R911). The data presented here suggest that in postmitotic, terminally differentiated neurons, signaling through cell cycle components is also essential for the response to DNA damage; however, in contrast to cycling cells, which undergo growth arrest at specific checkpoints, DNA damage signaling in neurons is associated with activation of the cell cycle machinery.
[0017] This distinct response of neurons is thought to reflect the unique involvement of G1 cell cycle components in the activation of the neuronal DNA repair machinery.
[0018] While no pharmacological agents for neuroprotection are currently marketed, there are drugs approved for use in the therapy of chronic neurological conditions, which are glutamate receptor (NMDA) antagonists. Although there is evidence of ameliorating affects of such drugs in chronic CNS degenerative states, it does not appear that NMDA antagonists, alone, can provide substantial protection against ischemia, generally, especially in an acute situation.
[0019] A significant limitation of glutamate receptor antagonists as neuroprotectants against ischemic neurodegeneration is that they appear to insulate the neuron against degeneration only temporarily; they do not do anything to correct the energy deficit, or to correct other derangements that occur secondary to the energy deficit. Therefore, although these agents do provide some level of protection against ischemic neurodegeneration, the protection is only partial and in some cases may only be a delay in the time of onset of degeneration.
[0020] Since neurons begin to degenerate very rapidly after the onset of acute conditions such as ischemic injury, there is clearly a need for therapeutic agents that will actively protect neurons from further degeneration and death by, for example, suppressing apoptotic signaling. Such therapeutic agents could not only be used for acute instances of ischemia, but also preventing neuronal degeneration in chronic degenerative disorders, such as Alzheimer's and Parkinson's diseases on the basis of slowing down neuronal loss and neuronal degeneration.
[0021] Further, the compounds of the present invention can also be used to treat neurological disorders of the ear and eye that result from ischemic-like etiology, as well as diabetic neuropathies.
[0022] The development of therapeutic agents capable of preventing or treating the consequences of neuronal stress, whether acute or chronic, is highly desirable.
[0023] The present invention relates to methods of preventing and/or treating disorders resulting from neuronal stress conditions by administering to a patient in need of such treatment certain CDK4/6 inhibitors, such as PD 0332991, and pharmaceutically acceptable salts or prodrugs thereof:
[0024] The present invention is also directed to methods of treating, ameliorating, and/or preventing specific neuronal stress or ischemia-related conditions, including but not limited to treatment of neuronal damage following global and focal ischemia from any cause (and prevention of further ischemic damage), treatment or prevention of otoneurotoxicity and of eye diseases involving ischemic conditions (such as macular degeneration), prevention of ischemia due to trauma or coronary bypass surgery, treatment or prevention of neurodegenerative conditions such as amyotrophic lateral sclerosis (ALS), Alzheimer's disease, Parkinson's disease, and Huntington's chorea, and treatment or prevention of diabetic neuropathies.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 : Apoptotic death of cultured cortical neurons is induced by 100 μM but not 5 μM H 2 O 2 .
[0026] (A) Cultures were exposed for 24 h to either saline (Con), 5 μM H 2 O 2 or 100 μM H 2 O 2 and then stained with DNA-binding dye propidium iodide (PI). Note the nuclear DNA condensation and fragmentation in cultures exposed to 100 μM H 2 O 2 .
[0027] (B) Cultures were exposed to either saline (Con), 5 μM H 2 O 2 , or 100 μM H 2 O 2 during the indicated time periods and the dynamics of apoptosis in the cell populations were determined. The values are the means and SD (n=6); *p<0.01; **p<0.001.
[0028] (C) Immunoblot showing cleaved caspase-3 (19- and 17-kDa intermediates), fractin (cleaved β-actin; 32-kDa intermediate), cleaved Mcm3 (98-kDa intermediate), and non-cleaved Mcm2 in primary cortical neurons after the indicated time periods following exposure to either 5 or 100 μM H 2 02. Control (C) corresponds to untreated cultures. An extract from methyl methanesulfonate (MMS)-treated NIH/3T3 cells was included as positive control. Note the appearance of cleaved caspase-3, Mcm3 and 13-actin (fractin) in samples exposed to 100 μM H 2 O 2 .
[0029] FIG. 2 : DNA damage induced by H 2 02.
[0030] (A) Cultures were exposed to either 5 μM or 100 μM H 2 O 2 for the indicated periods of time. DNA damage was quantified by alkaline or neutral comet analysis in cortical neurons after the indicated time periods of incubation. Control (Con) represents untreated cells. As a positive control we used neurons exposed to 1 Gy of γ-irradiation. Note the higher levels of DNA damage in alkaline compared with neutral comet assay (different scales). Values are the means and SEM of determinations made in 3 cultures; *p<0.005; **p<0.001; #p<0.01; ##p<0.002.
[0031] (B) Micrographs showing immunoreactivity for γ-H2AX in cortical neurons treated for 6 h with vehicle (Con), 5 μM and 100 μM H 2 O 2 and visualized with FITC (488, green). Cells were co-stained with PI. Note the induction of γ-H2AX foci in cultures exposed to 5 μM and 100 μM before significant apoptotic death (6 h) in contrast to control culture.
[0032] FIG. 3 : A significant reduction in the extent of apoptosis in cells with silenced CDK4 and CDK6 expression.
[0033] (A) Successful knockdown of CDK4 and CDK6 expression by co-transfecting CDK4 and CDK6-specific siRNAs is shown by Western blot analysis.
[0034] (B) CDK4 and CDK6 expression in cortical neurons was knocked down, and susceptibility to 100 μM H 2 O 2 induced cell death (18 h of exposure) was studied. Neurons transfected with non-specific control RNAi and those treated with 100 μM H 2 O 2 were used as controls. Apoptosis was quantified in cortical cultures stained with Hoechst 33342 by calculating apoptotic nuclei. The values are the mean and SD (n=6); **p<0.001.
[0035] FIG. 4 : Pharmacological suppression of CDK4 and CDK6 by PD 0332991 significantly reduces the extent of apoptosis in cortical neurons treated with H 2 O 2
[0036] (A) PD 0332991 down-regulates phosphorylation of pRb in postmitotic neurons. Cultured cortical neurons were exposed either to saline, or 100 μM H 2 O 2 alone or after 12 h pretreatment with 1 μM PD 0332991 (PD) for 6 h and the pRB phosphorylation was determined by Western blot analysis. Control (Con)—untreated culture; G1—HeLa cells synchronized in G1 phase of the cell cycle.
[0037] (B) Apoptosis was quantified in cortical cultures exposed for 18 h to 100 μM H 2 O 2 after staining with Hoechst 33342 by calculating apoptotic nuclei. The values are the mean and SD (n=6); *p<0.002.
DETAILED DESCRIPTION OF THE INVENTION
[0038] The present invention provides for therapeutic treatment, amelioration or prevention of neuronal degeneration and/or neuronal death in acute or chronic conditions, whereby a subject in need thereof is administered an therapeutically effective amount of an agent that acts as an inhibitor of one or both of CDK4 and CDK6. Such an agent may act by interference of RNA or as a small molecule pharmacological drug. In a preferred embodiment, the agent is an inhibitor of both CDK4 and CDK6.
[0039] It is demonstrated herein that the specific suppression of CDK4 and CDK6 by RNA interference, or pharmacologically by PD 0332991(Pfizer), significantly reduces the extent of apoptosis in primary cortical neurons exposed to hydrogen peroxide. The results show that the suppression of CDK4 and CDK6 is sufficient for neuroprotection in vitro. The molecule, PD 0332991, has been shown to be effective in causing tumor regression in mice, and is currently being used in human clinical trials for cancer. The structure of PD 0332991 is:
[0000]
[0040] The present inventors have determined that, as a highly specific pharmacological inhibitor of CDK4 and CDK6 (aka “CDK 4/6”), the compound PD 0332991 exerts a neuroprotective effect in an oxidative DNA damage model of apoptosis due to the suppression of cell cycle reentry of neurons, essential for activating the apoptotic signaling. In this regard, PD 0332991 (a most preferred embodiment), as well as other agents that exhibit similar specificity in the inhibition of CDK4/6, have usefulness as therapeutic agents in such acute conditions as stroke, as preventatives in such instances as cardiac by-pass surgery, and as ameliorators or inhibitors of the progression of chronic neurological conditions, such as Alzheimer's, Parkinson's and ALS.
[0041] More particularly, the present invention contemplates that agents such as the exemplified PD 0332991 are useful in the treatment of the underlying ischemic causes of such diseases and conditions as: Alzheimer's disease; Parkinson's disease; ischemic states that are due to or result from such conditions as coronary artery bypass graft surgery; global cerebral ischemia due to cardiac arrest; focal cerebral infarction; cerebral hemorrhage; hemorrhage infarction; hypertensive hemorrhage; hemorrhage due to rupture of intracranial vascular abnormalities; subarachnoid hemorrhage due to rupture of intracranial arterial aneurysms; hypertensive encephalopathy; carotid stenosis or occlusion leading to cerebral ischemia; cardiogenic thromboembolism; spinal stroke and spinal cord injury; diseases of cerebral blood vessels (such as atherosclerosis and vasculitis); macular degeneration and other eye diseases such as retinopathies and glaucoma; myocardial infarction; cardiac ischemia; or superaventicular tachyarrhythmia. This list is not exhaustive, and one skilled in the art would understand that this invention is applicable to many physical ailments in which a physiologically ischemic condition prevails in the etiology—i.e., that a neuronal (esp.) or other cellular degeneration/cell death is at the root of the disease process, whether acute or chronic.
[0042] As described below, the present inventors investigated whether G1 (cell cycle) phase components contribute to the repair of DNA and are involved in the DNA damage response of postmitotic neurons. In terminally differentiated cortical neurons, treatment with toxic concentrations of hydrogen peroxide (H 2 O 2 ) caused non-repairable DNA double-strand breaks (DSBs) and the activation of G1 components of the cell cycle machinery. Importantly, neuronal apoptosis was attenuated if cyclin-dependent kinases CDK4 and CDK6, essential elements of G0→G1 transition, were suppressed. Our data suggest that G1 cell cycle components are involved in the DNA response and DNA damage-initiated apoptisis of postmitotic neurons.
[0043] With the present invention, it was shown that the cell cycle machinery is a key component of the DNA damage response and apoptotic signaling of postmitotic neurons. To show this, the present inventors investigated the effects of toxic concentrations of H 2 O 2 on postmitotic cortical neurons. The data indicate that oxidative stress elicited by exposure to toxic concentrations of H 2 O 2 induced the formation of non-repairable DSBs associated with activation of cell cycle machinery and neuronal apoptosis. Apoptosis was attenuated if the essential G1 cell components CDK4 and CDK6 were suppressed.
[0044] Such results are indicative of a way to therapeutically treat subjects (humans or other animals) to inhibit, ameliorate or prevent damage to cells, a particularly significant subset of which are neurons.
[0045] Thus, from the disclosure of the present invention, it will be apparent to the skilled artisan that agents such as those disclosed herein can be administered in a pharmaceutically and therapeutically appropriate manner to a patient in need of such intervention, whereby the patient is physically and clinically assisted in overcoming the effects of cell degeneration and cell death (esp. neuronal), and the patient's condition is ameliorated and (further) damage prevented.
[0046] It is surprising and unexpected that a compound such as PD 0332991 (and similarly acting compounds) is effective as a neuroprotectant against ischemic cellular insult, given that its only known use thus far has been proposed as an antineoplastic agent.
[0047] Thus, one of the embodiments of the present invention is directed to the amelioration of the effects of ischemic cellular insult, particular on nerve cells/tissue. The present invention also contemplates the prophylactic administration of compounds such as PD 0332991 in subjects suspected of a familial or genetic risk for developing a chronic neurodegenerative condition, such as Alzheimer's or Parkinson's disease.
[0048] Compounds useful in the present invention, CDK4/6 inhibitors (such as PD 0332991), and their syntheses have been disclosed inter alia in U.S. Pat. No. 6,396,612, and well known in the art.
[0049] In a further aspect, the invention is directed to pharmaceutical compositions of the CDK4/6 inhibitors (such as PD 0332991) useful in the methods of the invention. The pharmaceutical compositions of the invention comprise one or more of the compounds (or one of the compounds together with one or more different active ingredients) and a pharmaceutically acceptable carrier or diluent. As used herein “pharmaceutically acceptable carrier or diluent” includes any and all solvents, dispersion media, solid excipients (e.g., binders, lubricants, etc. typically used in solid oral dosage forms) coatings, antibacterial and antifungal agents, isotonic and absorption delaying agents, and the like that are physiologically compatible. The type of carrier can be selected based upon the intended route of administration.
[0050] In various embodiments, the carrier is suitable for intravenous, intraperitoneal, subcutaneous, intramuscular, topical, transdermal or oral administration. For example, pharmaceutically acceptable carriers include sterile aqueous solutions or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions or dispersion. The use of such media and agents for pharmaceutically active substances is well known in the art. Except insofar as any conventional media or agent is incompatible with the active compound, use thereof in the pharmaceutical compositions of the invention is contemplated. In all dosage forms, supplementary active compounds may be incorporated into the compositions as well.
[0051] Preferably, administration is oral, and may be of an immediate or delayed release. Such oral pharmaceutical compositions of the present invention are manufactured by techniques typically used in the pharmaceutical industry. Generally, the active agent(s) is/are preferably formulated into a tablet or capsule for oral administration, prepared using methods known in the art, for instance wet granulation and direct compression methods. The oral tablets are prepared using any suitable process known to the art. See, for example, Remington's Pharmaceutical Sciences, 18th Edition, A. Gennaro, Ed., Mack Pub. Co. (Easton, Pa. 1990), Chapters 88-91, the entirety of which is hereby incorporated by reference. Typically, the active ingredient, i.e., one or more of the CDK4/6 inhibitors, is mixed with pharmaceutically acceptable excipients (e.g., the binders, lubricants, etc.) and compressed into tablets. Preferably, such a dosage form is prepared by a wet granulation technique or a direct compression method to form uniform granulates. Alternatively, the active ingredient(s) can be mixed with a previously prepared non-active granulate. The moist granulated mass is then dried and sized using a suitable screening device to provide a powder, which can then be filled into capsules or compressed into matrix tablets or caplets, as desired.
[0052] In one such aspect, the tablets are prepared using a direct compression method. The direct compression method offers a number of potential advantages over a wet granulation method, particularly with respect to the relative ease of manufacture. In the direct compression method, at least one pharmaceutically active agent and the excipients or other ingredients are sieved through a stainless steel screen, such as a 40 mesh steel screen. The sieved materials are then charged to a suitable blender and blended for an appropriate time. The blend is then compressed into tablets on a rotary press using appropriate tooling.
[0053] Alternatively, the pharmaceutical composition is contained in a capsule containing beadlets or pellets. Methods for making such pellets are known in the art (see, Remington's, supra). The pellets are filled into capsules, for instance gelatin capsules, by conventional techniques.
[0054] Sterile injectable solutions can be prepared by incorporating a desired amount of the active compound in a pharmaceutically acceptable liquid vehicle and filter sterilized. Generally, dispersions may be prepared by incorporating the active compound into a sterile vehicle containing a basic dispersion medium. In the case of sterile powders for the preparation of sterile injectable solutions, the preferred methods of preparation are vacuum drying and freeze-drying, which will yield a powder of the active ingredient plus any additional desired ingredient from a previously sterile-filtered solution thereof.
[0055] The pharmaceutical compositions of the present invention may be administered by any means to achieve their intended purpose, for example, by oral, parenteral, subcutaneous, intravenous, intramuscular, intraperitoneal, transdermal, or buccal routes.
[0056] The active agent(s) in the pharmaceutical composition (i.e., one or more of the CDK-4/6 inhibitors) is present in a therapeutically effective amount. By a “therapeutically effective amount” is meant an amount effective, at dosages and for periods of time necessary, to achieve the desired therapeutic result of positively influencing the course of a particular disease state or acute condition. This terminology also contemplates and encompasses the therapeutic use of the compounds in a prophylactic manner, which may be of a lower dosage, and such an embodiment is included in the present invention. Of course, therapeutically effective amounts of the active agent(s) may vary according to factors such as the disease state, age, sex, and weight of the individual, and the ability of the agent to elicit a desired response in the individual. Dosage regimens may be adjusted to provide the optimum therapeutic response. A therapeutically effective amount is also one in which any toxic or detrimental effects of the agent are outweighed by the therapeutically beneficial effects.
[0057] The amount of active compound in the composition may vary according to factors such as the disease state, age, sex, and weight of the individual. Dosage regimens may be adjusted to provide the optimum therapeutic response. The specification for the dosage unit forms of the invention are dictated by and directly dependent on (a) the unique characteristics of the active compound and the particular therapeutic effect to be achieved, and (b) the limitations inherent in the art of compounding such an active compound for the treatment of sensitivity in individuals. It is contemplated that the dosage units of the present invention will contain the active agent(s) in amounts suitable for a dosage regimen of about the same as or, more preferably less than, those derivable from the studies in the Example, which are thought to be effective below its maximal tolerated dose.
[0058] The pharmaceutical compositions of the invention may be administered to any animal in need of the beneficial effects of the compounds of the invention. While the invention is primarily directed to human use, other mammals in which an ischemic disease or condition is suspected may be treated accordingly if so desired.
[0059] This invention is further illustrated by the following example, which is not intended to limit the present invention. The contents of all references, patents, and published patent applications cited throughout this application are specifically and entirely incorporated herein by reference.
EXAMPLE
Cortical Cell Cultures and Experimental Treatments
[0060] All experiments involving the use of animals were approved by the IACUC at the Georgetown University Medical Center, Washington, D.C. Primary cortical cell cultures were established from E18 Sprague-Dawley rats obtained from Jackson Laboratories.
[0061] The cells were plated according to procedures described earlier (Kruman, I. I., et al. 2004. Neuron. 41:549-561). Following dissociation by mild trypsinization and trituration, cells were seeded onto plastic dishes or chamber slides precoated with 0.025 μg/ml poly-L-lysine, at a density of 1.3×10 3 neurons/mm 2 in Neurobasal medium containing B-27 supplement, 1 mM HEPES, 2 mM glutamate and 0.001% gentamycin sulfate; fresh medium was replaced after 30 minutes.
[0062] All of the experiments were performed with 4-day-old cultures, a time during which ˜3% of the MAP-2-positive cells were in S phase (Kiruman, I. I., et al. 2004. Neuron. 41:549-561). A fresh stock of 1 mM hydrogen peroxide (H 2 O 2 ; Sigma) was prepared in Neurobasal medium for each experiment and added at the indicated concentrations (5 μM and 100 μM). Treatment with 1 μM PD 0332991 (obtained from Pfizer) was carried out for 12 h in complete medium; H 2 O 2 was added at the indicated times and doses.
[0063] Analysis of neuronal survival and apoptosis. Neuronal viability was assessed by quantifying apoptotic nuclei following the treatments. Cells were fixed and stained with DNA-binding dye propidium iodide (PI) (10 μg/ml; Sigma), and the percentage of cells with apoptotic nuclei was calculated as described previously (Kruman, I. I., et al. 2002. J. Neurosci. 22:1752-1762; Tenneti, L. and S. A. Lipton. 2000. J Neurochem. 74:134-142). Nuclear staining was viewed and photographed using a Zeiss fluorescence microscope. Apoptosis was also determined by immunoblot analysis for activated (cleaved) caspase-3 (polyclonal; 1 μg/ml; Upstate Cell Signaling Solutions), cleaved Mcm3 (polyclonal, 1:200; Santa-Cruz), Mcm2 (BM28; monoclonal; 1:200; BD Biosciences), and fractin (cleaved β-actin; 1:3000; Chemicon) in cellular extracts from corresponding neuronal 5 cultures. Extracts from methyl methanesulfonate (MMS)-treated NIH/3T3 cells were used as a positive control (Lakin, N. D. and S. P. Jackson. 1999. Oncogene. 18:7644-7655).
[0064] Immunoblot analyses. For total cell lysates, cortical neurons were lysed in ice-cold buffer consisting of 63 mM Tris, 2 mM EDTA, 2 mM EGTA, 2% sodium dodecyl sulfate, 10% glycerol, and a protease inhibitor cocktail (Sigma), pH 6.0. For the preparation of nuclear lysates (for analysis of cyclin D1 and γ-H2AX), cortical neurons were lysed in ice-cold buffer containing protease inhibitor cocktail (Sigma) and incubated with hydrochloric acid (0.2 M) on ice for 30 min.
[0065] After centrifugation, the acid-insoluble pellet was discarded and the supernatant was dialyzed against 200 ml 0.1 M acetic acid twice (1-2 h each time) and then dialyzed against water. As a positive control, we used extracts from HeLa cells synchronized in the G1 phase of the cell cycle (G1). HeLa cells were synchronized in mitosis by adding 0.1 μg/ml nocodazole. After 12 h, the mitotic cells were replated in nocodazole-free medium, and G1 cells were collected 3-5 hours later. Synchronization was monitored by flow cytometry.
[0066] Proteins (50 μg/lane) were size-separated by SDS-PAGE (10-15%), transferred to nitrocellulose membranes, and incubated for 30 min in the presence of 5% nonfat milk and incubated overnight at 4° C. with primary antibodies recognizing either γ-H2AX (monoclonal; 1 μg/ml; Upstate Cell Signaling Solutions), phospho RB at Ser 795 (polyclonal; 1:1000; Cell Signaling Technoogy), Rb (monoclonal, 1:2000; Cell Signaling Technology), Mcm3 (polyclonal; 1:200; Santa Cruz), Mcm2 (BM28 monoclonal; 1:500; BD Biosciences), cleaved caspase-3 (polyclonal; 1:1000; Cell Signaling Technology), and-fractin (cleaved β-actin; C-terminus polyclonal antibody; 1:3000; Chemicon). As a loading control we used anti-β-actin or anti-glyceraldehyde-3-phosphate dehydrogenase (GAPDH) antibodies.
[0067] Protein bands were visualized with horseradish peroxidase-conjugated secondary antibodies (1:3000; Jackson Immunological Research Laboratories Inc.) and enhanced using chemiluminescence (ECL kit, Amersham Corp.). Densitometric analysis of the blots were performed using the Kodak software ID 3.5.3 USB, and the intensity of the signal (normalized to the β-actin signals) was expressed as a ratio of the control signals.
[0068] siRNA preparation and transfection. siRNA oligonucleotides targeting CDK4 and CDK6 (SMARTpool reagents, Dharmacon), each representing a cocktail of four siRNAs directed against different regions of corresponding genes, were designed and used according to the manufacturer's guidelines. siRNA oligonucleotides targeting MAPK1 (Qiagen) was used as a control siRNA. Double-stranded siRNAs were generated by mixing the corresponding mixture of siRNA nucleotides to siRNA buffer (Dharmacon) to obtain a 50 μM solution. The reaction mixture was heated to 90° C. for 1 min and stored at −20° C. Transfection of RNA oligonucleotides was performed using the RNAi Starter Kit (Qiagen) according to the manufacturer's recommendations, with a final oligonucleotide concentration of 100 nM (for co-transfection of CDK4- and CDK6RNAi, 50 nM of each RNAi was used). After 24 h, the viability was examined and protein expression was assessed by Western blotting using primary antibodies recognizing either CDK4 (monoclonal; 1:250; BD Biosciences), CDK6 (monoclonal; 1:400; Biosource). All experiments were performed in triplicate.
[0069] Single Cell Gel Electrophoresis (Comet assay). DNA damage was assessed using the alkaline or neutral single-cell gel electrophoresis (comet assay) method (Kruman, I. I., et al. 2004. Neuron. 41:549-561; Kruman, I. I., et al. 2002. J Neurosci. 22:1752-176229). We used the neutral comet assay which is specific for detecting DSBs (Wojewodzka, M., et al. 2002. Mutat Res. 518:9-20). Following treatment, neurons were scraped and cell suspensions (˜10,000 cells) were embedded into 0.5% low melting agarose on slides (Trevigen, Gaithersburg, Md.). After treatment with cold lysis buffer (Trevigen) containing 1% Triton X-100 and 10% DMSO, the slides were incubated for 1 h in freshly prepared electrophoresis buffer, 300 mM sodium acetate, 100 mM Tris HCl, pH 8.3 (neutral comet assay) or 300 mM NaOH, 1 mM EDTA, pH>13 (alkaline comet assay). Then electrophoresis was performed at 14V and 60 mA for 1 h (neutral comet assay) or at 25V and 300 mA for 30 min (alkaline comet assay) at 8° C., stained with SYBR green (Trevigen), and analyzed using an Olympus BX51 fluorescent microscope and the comet assay image analysis software (Loats Associates Inc.). Nuclei with damaged DNA have the appearance of a comet with a bright head and a tail, where the tail represents the damaged DNA, which is often fragmented and its electrophoretic mobility is consequently greater. Nuclei with undamaged DNA appear round, with no tail. Images of 50 randomly selected cells were analysed from each slide. Data analysis was based on the mean population response or on the distribution of damage among cells. As a control of DSB formation we employed γ-irradiated cortical neurons. Cells were treated with 1 Gy of γ irradiation using an RS 2000 Biological irradiator (Rad Source Technologies, Inc.).
[0070] Immunofluorescence. Neurons grown on glass coverslips were fixed in freshly prepared 4% formaldehyde for 30 min at 4° C. and then permeabilized for 10 min in 0.5% Triton X-100 in 1% BSA prepared in PBS, blocked in 1% BSA for 1 h at room temperature, and incubated with the primary antibodies for 1 h at room temperature. We used the following specific antibodies: anti-y-H2AX (monoclonal; 1:500; Upstate Cell Signaling Solutions). As a counterstain, we used PI. Coverslips were mounted with Vectashield mounting medium (Vector Laboratories) and examined with a Nikon Eclipse E800 fluorescence microscope equipped with a Spot digital camera and software.
[0071] Statistical analyses. Statistical analyses were performed with Microsoft Excel and p values were obtained using ANOVA and Fisher's post-hoc test. A p value <0.05 was considered significant.
[0072] Results
[0073] To determine whether G1 cell cycle components are activated in terminally differentiated neurons subjected to DNA damage, the effects of oxidative stress produced by hydrogen peroxide (H 2 O 2 ) were first determined.
[0074] H 2 O 2 is generated as a product of normal metabolism, is a cell membrane-permeable precursor of various free radicals which have been suggested to contribute to neurodegeneration (Behl, C. 1999. Prog Neurobiol. 57: 301-323), and is known to generate double-strand breaks (DSBs) (Slupphaug, G., et al. 2003. Mutat Res. 531:231-251).
[0075] For culturing rat cortical neurons, we employed a previously reported method yielding >99% pure neuronal populations as assessed by immunofluorescent detection of neuron-specific MAP-2 (Kobayashi, S., et al. 2002. Nucleic Acids Res Suppl (2):283-284). By day 4 in culture, MAP-2-positive and GFAP-negative cultures were minimally (3%) contaminated by neuroblasts. The toxic (100 μM) and subtoxic (5 μM) concentrations of H 2 O 2 were chosen based on dose-response experiments to assess H 2 O 2 toxicity by counting cells with apoptotic nuclei (data not shown), as described earlier (Kruman, I. I., et al. 2002. J. Neurosci. 22:1752-1762).
[0076] Treatment of cortical neurons with 100 μM H 2 O 2 resulted in significant apoptotic death beginning by 9 h following exposure, as evidenced by the appearance of apoptotic nuclei in cultures stained with propidium iodide (FIG. 1 A,B) and cleaved caspase-3 intermediates (19 and 17 kDa, which serve as markers of caspase-3 activation during early apoptosis) as assessed by Western blot analysis ( FIG. 1C ). Extracts from methyl methanesulfonate (MMS)-treated NIH/3T3 cells were used as a positive control (Lakin, N. D. and S. P. Jackson. 1999. Oncogene. 18:7644-7655). Also, the appearance of cleaved β-actin fragment (a 32-kDa C11 terminus fragment) as assessed by Western blot analysis ( FIG. 1C ) is evidence of caspase3 activation which cleaves cytoskeletal proteins like β-actin during apoptosis (Salvesen, G. S. and V. M. Dixit. 1999. Proc Natl Acad Sci USA. 96: 10964-10967).
[0077] Treatment of cortical neurons with 100 μM but not 5 μM H 2 O 2 resulted in the cleavage of a nuclear substrate Mcm3 (a 98-kDa fragment), which is typical of early apoptosis, but not Mcm2 ( FIG. 1C ). These data are consistent with the previous notion that Mcm3, but not other members of the Mcm family of replicative proteins, is an early target in apoptotic proteolysis (Schwab, B. L., et al. 1998. Exp Cell Res. 238:415-421), suggesting that active destruction of Mcm3 inactivates the Mcm complex and serves to prevent untimely DNA replication events during the execution of the cell death program. In contrast to 100 μM H 2 O 2 , 5 μM H 2 O 2 did not induce apoptosis of cortical neurons by 24 h ( FIG. 1 ) or 48 h following exposure (data not shown). Collectively, our results based on using several independent apoptotic markers indicate that 100 μM H 2 O 2 is toxic for cultured cortical neurons. In order to test the hypothesis that cell cycle activation accompanies the formation of fatal DSBs in postmitotic neurons, we compared the effects of toxic and subtoxic concentrations of H 2 O 2 on DSB formation in cultured cortical neurons.
[0078] Changes in DNA damage depend on the concentration of DNA-damaging agent and on the exposure time and reflect a balance between DNA damage and DNA repair. We analyzed the lesions generated by H 2 O 2 using the single-cell gel electrophoresis (the comet assay), a sensitive method which has become standard for measuring DNA strand breaks in eukaryotic cells. The assay entails the gel electrophoresis of a small number of cells entrapped in a layer of low-density agarose.
[0079] The principle of the assay is based upon the ability of the denaturated DNA fragments to migrate out of the cell during electrophoresis. Nuclei with damaged DNA have the appearance of a comet with a bright head and tail, whereas nuclei with undamaged DNA appear round with no tail.
[0080] The ‘alkaline’ (pH 13) version of the comet assay detects a variety of different DNA lesions, including DSB and single strand breaks (SSB), as well as alkaline-labile sites (ALS) and incisions (Collins, A. R. 2004. Mol Biotechnol. 26:249-261). The ‘neutral’ (pH 8.3) version of the comet assay omits the DNA denaturation step, and therefore detects exclusively DSBs as they migrate in the electric field. (Wojewodzka, M., et al. 2002. Mutat Res. 518:9-20). The neutral comet assay has been shown to be a suitable tool for studying the induction and repair of radiation-induced DSBs (Olive, P. L., et al. 1991. Cancer Res. 51:4671-4676; Singh, N. P. and R. E. Stephens. 1997. Mutat Res. 383:167-175; Wojewodzka, M., et al. 2002. Mutat Res. 518:9-20). The neutral comet assay allows the measurement of DNA DSB but, because these lesions are much more toxic and less prevalent (they occur 25 to 40 times less frequently than SSBs), we expected to see much lower levels of DSBs compared to SSBs (Olive, P. L. 1999. Int. J. Radiat. Res. 75:395-405).
[0081] To differentiate between double-strand breaks and other types of DNA lesions, we performed two types of the comet assay, alkaline and neutral, and used γ-irradiation as a control of DSB formation, as described earlier (Kruman, I. I., et al. 2004. Neuron. 41:549-561; Morris, E. J., et al. 1999. Biotechniques. 26:282-283, 286-289; Olive, P. L., et al. 1991. Cancer Res. 51:4671-4676; Singh, N. P. and R. E. Stephens. 1997. Mutat Res. 383:167-175; Wojewodzka, M., et al. 2002. Mutat Res. 518:9-20).
[0082] Results of the neutral comet assay demonstrate significant increase of DNA damage (notably larger comet tails) in cells exposed to subtoxic 5 μM H 2 O 2 (6 h), as illustrated in FIG. 2A . The comparison of DNA damage by the alkaline and neutral comet assays in cortical neurons treated with 5 μM and 100 μM H 2 O 2 is shown in FIG. 2A . DNA damage was expressed in Olive Tail Moment (OTM) values, a commonly used parameter which represents the product of the amount of DNA in the tail and the distance between the centers of mass at the head and tail regions.
[0083] As expected, in contrast to alkaline version of the assay, the tail moments of the treated cells obtained with the neutral assay were smaller; however, this elevation was significant in cells that were tested 1 and 6 h after treatment with 5 μM H 2 O 2 compared to untreated control cells. Importantly, DNA damage significantly decreased in populations exposed to 5 μM but not 100 μM H 2 O 2 , as assessed by both the alkaline and neutral versions of the comet assay. These findings suggest that DNA damage induced by 5 μM H 2 O 2 is repairable, in contrast to DNA damage induced by 100 μM H 2 O 2 . As an additional measure of DSBs, we monitored the levels of phosphorylation of histone H2AX (γ-H2AX) at serine 139, which occurs at sites surrounding DSBs and can be determined by immunostaining.
[0084] Recent reports indicate that the dephosphorylation of γ-H2AX and dispersal of γ-H2AX foci in γ-irradiated cells correlate with DSB repair (MacPhail, S., et al. 2003. Int J Radiat Biol, 79:351-358; Nazarov, I., et al. 2003. Radiat Res. 160:309-317; Rothkamm, K. and M. Lobrich. 2003. Proc Natl Acad Sci USA. 100:5057-5062) and that these parameters provide a quantitative measure of DSB sites (Sedelnikova, O. A., et al. 2002. Radiat Res. 158:486-492). Thus, γ-H2AX foci reveal DSBs (Rothkamm, K. and M. Lobrich. 2003. Proc Natl Acad Sci USA. 100:5057-5062) and can be used as an indicator of the presence of DSBs. In order to relate the effects of treatment with 5 μM and 100 μM H 2 O 2 to neuronal death and survival upon DSB DNA damage, we determined the phosphorylation of H2AX in untreated cultures and in cultures exposed to both toxic and subtoxic H 2 O 2 concentrations. The extent of H2AX phosphorylation, assessed by immunofluorescence, revealed that the average number of γ-H2AX foci/cell was notably higher in treated cells ( FIG. 2B ). These data are consistent with the comet assay results ( FIG. 2A ), as well as with the ensuing apoptosis seen with 100 μM but not 5 μM H 2 O 2 ( FIG. 1 ).
[0085] Phosphorylation of H2AX, as well as increased OTM in the comet assay can be caused by apoptotic DNA fragmentation (Rogakou, E. P., et al. 2000. J Biol Chem. 275:9390-9395); however, since both DSBs precede apoptotic death, seen in neuronal cultures by 24 h of exposure to 100 μM H 2 O 2 ( FIG. 1 ), it appeared that either γ-H2AX formation or DNA damage as determined by the comet assay in those cultures preceded apoptosis. Therefore, 100 μM H 2 O 2 produced accumulative breaks that contributed to apoptosis.
[0086] As we showed previously, postmitotic neurons undergo DNA damage-initiated apoptosis after cell cycle activation, and cell cycle reentry was essential for the execution of DSB-mediated apoptosis initiated by the classical DSB inducers, y-irradiation and etoposide (Kruman, I. I., et al. 2004. Neuron. 41:549-561).
[0087] To confirm the role of cell cycle reentry in DNA damage-initiated neuronal apoptosis, we employed RNA interference (RNAi)-based methods to silence the expression of cyclin dependent kinases CDK4 and CDK6, two CDKs essential for cell cycle activation, and examined the influence of these interventions on H 2 O 2 -induced apoptosis (Davidson, M. K., et al. 2004. J Biol Chem. 279:50857-50863). Primary cortical neurons were co-transfected with CDK4 and CDK6-targeting siRNA, each representing a cocktail of four siRNA, directed against different regions of the corresponding transcripts (SMARTpool reagents, Dharmacon), or control siRNA. The simultaneous presence of multiple siRNAs elicits more effective gene silencing, while it minimizes off-target effects from each individual siRNA since they are used at lower concentrations (˜12.5 nM). At 24 h after transfection, cells were harvested and the expression of the CDKs was analyzed by Western blot analysis.
[0088] FIG. 3A demonstrates the marked reduction in CDK4 and CDK6 levels in cortical neurons at 24 h after transfection. Twenty-four h later, cells were treated with 100 μM H 2 O 2 and 18 h (when a significant number of apoptotic cells was expected, FIG. 1B ), apoptotic nuclei were assessed. We found a significant reduction in the extent of apoptosis in cells with silenced CDK4 and CDK6 ( FIG. 3B ). These findings support the notion that cell cycle reentry is essential for the activation of apoptotic program in differentiated neurons exposed to DSB DNA damage.
[0089] Treatment with PD 0332991, a highly specific inhibitor of CDK4 and CDK6 (Fry, D. W., et al. 2004. Mol Cancer Ther. 3:1427-1438), resulted in significant reduction in the extent of apoptosis in cells pretreated with PD 0332991 ( FIG. 4 B)
[0090] Collectively, these observations strongly suggest that activation of the cell cycle machinery is essential in apoptotic signaling in postmitotic neurons.
Experimental Conclusions
[0091] In this Example, evidence is provided that activation of the cell cycle machinery contributes to DNA damage-initiated neuronal apoptosis. To our knowledge, this study is the first to demonstrate that G1 cell cycle components are involved in DNA damage-initiated neuronal apoptosis.
[0092] In mitotic cells, the cell cycle machinery is a major contributor to the DNA damage response, a complex defense mechanism whose function is to eliminate the damaged DNA (DNA repair) or, alternatively, to eliminate the damaged cells via apoptosis (Bernstein. C., et al. 2002. Mutat Res. 511:145-178). The latter mechanism ensures that irreparable DNA modifications are not passed on to the progeny of damaged cells. Both DNA repair and apoptosis are coordinated with progression through the cell division cycle, together acting to preserve genomic integrity (Rhind, N. and P. Russell. 2000. Curr Biol. 10:R908-R911). Thus, in proliferating cells, an important role of the DNA damage response is to activate the cell cycle checkpoints (Shiloh, Y. 2003. Nat Rev Cancer. 3:155-168).
[0093] In neurons, by contrast, the DNA damage response was not expected to activate the cell cycle checkpoints, due to their postmitotic nature. However, accumulating evidence suggests that neurodegeneration is linked to a paradoxical reentry into the cell cycle (Liu, D. X., and L. A. Greene. 2001. Cell Tissue Res. 305:217-228). There is both in vitro and in vivo evidence of links between DNA damage and cell cycle reentry in dying postmitotic neurons (Klein, J. A., et al. 2002. Nature. 419:367-374, Kruman, I. I., et al. 2004. Neuron. 41:549-561), suggesting that both cell cycle activation and apoptosis are essential components of the DNA damage response. DNA repair is critical for the nervous system, as supported by the fact that hereditary diseases associated with defects in DNA repair defects are associated with neurological abnormalities and progressive neurodegeneration (Rolig, R. L., and P. J. McKinnon. 2000. Trends Neurosci. 23:417-424).
[0094] We found that DSBs in postmitotic neurons can arise from oxidative stress produced by H 2 O 2 and may result in apoptosis.
[0095] Our results indicate that the failure of DSB repair is linked to the onset of apoptosis.
[0096] In the above Example, the presence of non-repairable DNA DSBs in surviving neurons was accompanied by an activation of the cell cycle machinery and G0→G1 transition.
[0097] Our previous studies demonstrated that the cell cycle was activated in postmitotic neurons committed to DNA damage-initiated apoptosis (Kruman, I. I., et al. 2004. Neuron. 41:549-561). These observations, along with the present work, lead to a scientifically reasonable conclusion that cell cycle machinery plays a central role in the apoptotic signaling of neurons exposed to DNA damage, and that treatment with a highly specific inhibitor of CDK4 and CDK6 (in this instance, PD 0332991) results in significant reduction of the extent of apoptosis in cells pretreated with such an inhibitor.
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The present invention relates to methods of suppressing neuronal death, such as is observed with ischemia-related diseases and disorders, including neuronal and cardiac conditions arizing from a sudden loss of oxygen and/or energy loss, and degenerative diseases, such as Alzheimer's disease to name just one. The methods involve the use of inhibitors that act primarily in a simultaneous manner on the cyclin-dependent kinases, CDK4 and CDK6.
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BACKGROUND OF THE INVENTION
This invention relates to the art of hydraulic power units and, more particularly, to the piston-cylinder portion of such hydraulic units.
Particular utility of this invention is found in a power unit for controlling operation of a plow blade mounted on a vehicle, and the invention will be described herein with reference thereto. However, it will be appreciated that the invention has broader applications and may be used for controlling other devices.
Plow blades are often mounted on the front of a vehicle for the purpose of being pushed by the vehicle to clear snow, ice or other debris when the plow blade is lowered to a roadway. The plow blade is pivotally connected to a mounting frame secured to a frame portion of the vehicle and is also connected to a movable lift arm by a link chain. The lift arm is also supported by the mounting frame and is movable vertically, relative to the vehicle, to cause up and down movement of the plow blade relative to the roadway. A power unit is positioned between the mounting frame and the lift arm. The power unit generally includes a piston-cylinder unit which is functionally connected between the lift arm and mounting frame to cause the lift arm to raise when the piston is extended from within the cylinder, and to lower when the piston retracts into the cylinder. Usually, such retraction is caused by the weight of the plow blade after relieving the hydraulic pressure in the cylinder. In addition to the blade lifting and lowering piston-cylinder unit, the power unit for positioning the plow blade includes a motor-pump unit, and a number of control valves for additional hydraulic piston-cylinder units operable to achieve other blade displacement functions.
In this respect, the plow blade is usually power controlled for sideways angling as well as up and down movement. The additional piston-cylinder units mentioned above are provided on the plow blade unit for this purpose. U.S. Pat. No. 3,706,144 describes a device of the type discussed above and discloses an integral power unit assembly mounted at the front of a vehicle. The integral power unit advantageously incorporates the lift piston-cylinder, the motor-pump and the control valves in a unitary assembly. An integral power unit of this character is advantageous from the standpoint of compactness, and manufacturing and mounting ease and economy. One structural example of such a power unit is shown in U.S. Pat. No. 3,773,074. The disclosures of the above two patents are incorporated herein by reference.
While such an integral power unit lends itself to mounting on the front of a vehicle, by such mounting it is exposed to weather and other undesirable exterior factors. Some purchasers of plow blade arrangements prefer that the power unit components including the motor-pump and valves not be so exposed and, thus, specify that the hydraulic controls and motor-pump unit be internal to the vehicle, such as within the engine compartment. The location of a plow blade relative to a vehicle and the number of plow blades provided on the vehicle also has bearing upon location of the power unit components relative to the vehicle. In this respect, such an integral power unit heretofore had to be mounted on the vehicle front because of the structural relationship between the lift piston-cylinder and motor-pump units. Thus, use of the integral power unit was limited to front end mounting applications and, accordingly, all of the advantages of manufacturing and mounting economy and compactness were likewise limited. Prior to the present invention, specifications of a purchaser requiring a remote location for the controls of a plow blade power unit could not be met with an integral power unit of the character described above and required manufacturing an entirely different unit.
SUMMARY OF THE INVENTION
The present invention provides a modification applicable to the lift piston-cylinder of a power unit of the character described above which enables the power unit to be mounted other than on the front of a vehicle and thus operable to control blade movements from a remote location such as within the engine compartment. Advantageously, such a modification involves interchangeable parts in the basic integral power unit, whereby the latter can be readily adapted for mounting either on the vehicle front or remote therefrom. Basically, such interchangeability involves the lift piston-cylinder unit and, more particularly, a sleeve assembly interchangeable with piston and sleeve components of the unit to provide hydraulic fluid flow through the cylinder when the unit is not front mounted. Such fluid flow is directed from the cylinder to a lift piston-cylinder unit associated with the plow blade unit.
It is a principal object of the present invention to provide a modification for a hydraulic power unit for a vehicle mounted plow blade which provides increased versatility for the power unit.
A further object is the provision of a modification of the foregoing character which enables use of the power unit for direct or indirect blade displacement.
Another object is the provision of a modification of the foregoing character which enables selective use of the lift piston-cylinder of the unit for direct displacement of the piston associated therewith or for directing fluid flow to a remotely located piston-cylinder unit for displacement of the piston of the latter unit.
Yet another object is the provision of a modification of the foregoing character by which piston and piston sleeve components of the lift piston-cylinder of a power unit are replaced by an auxiliary sleeve assembly to convert the unit from one providing direct piston displacement to one providing fluid flow through the cylinder for use at a location remote from the power unit.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take physical form in a variety of parts and arrangements of parts, a preferred embodiment of which is described below and illustrated in the accompanying drawings which form a part hereof and wherein:
FIG. 1 is a pictorial view illustrating a prior art arrangement of a plow blade and a hydraulic power unit therefor mounted on the front of a vehicle, and which power unit includes a lift piston-cylinder for directly lifting and lowering the plow blade;
FIG. 2 is an elevational view, partially in section, of the lift piston-cylinder portion of the power unit shown in FIG. 1;
FIG. 3 is a cross-sectional elevation view of the sleeve assembly for modifying the power unit in accordance with the present invention;
FIG. 4 is an elevational view of the end wall and fitting portion of the sleeve assembly shown in FIG. 3;
FIG. 5 is an elevational view, partially in section, of a power unit modified in accordance with the present invention to include the sleeve assembly shown in FIG. 3; and,
FIG. 6 is a schematic illustration of the modified power unit in operable association with a plow blade.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings wherein the showings are for the purpose of illustrating a preferred embodiment of the invention only and not for the purpose of limiting the same, FIG. 1 shows a portion of the front of a vehicle 10 on which a standard plow blade 12 is mounted by means of an A-frame 14. Connection of A-frame 14 to a frame portion 16 of vehicle 10 is accomplished by pivot pins 18. Plow blade 12 is supported for pivotal movement horizontally relative to A-frame 14 by means of a blade mounting assembly 19 and is connected to the assembly 19 by pivot pins 20. Extending upwardly from frame portion 16 of the vehicle is a blade and power unit support frame 22. Movement of plow blade 12 is accomplished by and through a power unit, generally indicated by reference numeral 24, which is suitably mounted on support frame 22. Power unit 24 and the operation thereof is similar to that shown in U.S. Pat. No. 3,773,074 referred to herein. For the purpose of understanding the present invention, power unit 24 includes a lift piston-cylinder unit 26 which includes a piston rod or ram member 28 having its outer end pivotally connected to a lift arm 30. Lift arm 30 has one end pivotally connected by pin 32 to support frame 22, and the other end of lift arm 30 has one end of a chain 34 connected thereto. The other end of chain 34 is connected to A-frame 14. Vertical displacement of lift arm 30 in opposite directions about the axis of pin 32 by extension and retraction of piston rod 28 of the piston-cylinder unit raises and lowers plow blade 12 relative to a roadway under the vehicle. Power unit 24 further includes an electrically operated motor-pump unit 36 which pressurizes hydraulic fluid for use within piston-cylinder unit 26. Hydraulic cylinders 38 and 40 are mounted between A-frame 14 and blade mounting assembly 19 to angle plow blade 12 when actuated by power unit 24. In this respect, power unit 24 includes hydraulic control valves 42 and 44 which are connected to hydraulic cylinders 38 and 40, respectively, to provide actuation of the cylinders under the control of the power unit. Thus, the power unit provides all of the hydraulic system components and flow control devices in a compact unit mounted on the front of the vehicle.
FIG. 2 illustrates in greater detail the piston-cylinder unit 26 and motor-pump unit 36 of power unit 24. Motor-pump unit 36 includes an electric motor 46 and a gear type pump 48. Motor portion 46 is secured to gear pump 48 by elongated bolts 50 extending vertically through the motor housing and into threaded engagement with suitable threaded bores in the pump housing. A cover plate 52 is secured to the bottom of pump 48 such as by bolts 54, and the motor-pump unit is secured by bolts 58 to a base portion 56 providing a common base for all of the components of power unit 24. Piston-cylinder unit 26 includes an outer cylindrical housing member 60 positioned on base portion 56 and suitably sealed with respect thereto by seal 62. An inner cylindrical piston sleeve member 64 is located within housing member 60 and coaxial therewith. The lower end of sleeve 64 is received in a recess 65 in base 56 and is suitably sealed with respect thereto by a seal 66. Piston rod or ram member 28 extends into piston sleeve member 64 and is provided at its lower or inner end with a shank portion 70. Shank portion 70 receives a piston assembly defined by cylindrical members 72 and 74 having a sealing member 76 interposed therebetween. The piston assembly is retained on shank portion 70 by a nut 78.
Base portion 56 is provided with a recess 80 beneath the piston assembly in flow communication with the gear pump, as set forth more fully hereinafter, and housing member 60 and inner piston sleeve 64 are radially spaced from one another to provide a circumferential reservoir 82 for hydraulic fluid. A top or cover member 84 has a centrally located opening 85 therethrough slidably receiving the upper or outer end of piston rod 28. Suitable seals 86, 88 and 90 are provided in opening 85 around piston rod 28. A bearing washer 92 is also provided between the upper end of piston sleeve 64 and cover 84. Cover member 84 receives the upper ends of outer cylindrical member 60 and piston sleeve 64 and is suitably sealed with respect thereto by seals 94 and 95, respectively. Bolts 96 tightly clamp cover member 84 and base portion 56 together, with outer cylindrical member 60 and piston sleeve member 64 interposed therebetween.
Base portion 56 has a downwardly projecting lug portion thereon having a lateral opening 98 therethrough for mounting base portion 56 and thus power unit 24 on the front of a vehicle. The upper or outer end of piston rod 28 also has a lateral opening 100 therethrough for receiving a pin by which the piston rod is connected to lift arm 30 for raising and lowering of the plow blade. As mentioned above, recess 80 in base 56 is in fluid communication with gear pump 48 and, for this purpose, base 56 is provided with fluid passage 102. Reservoir space 82 is also in fluid communication with gear pump 48, by means of fluid passage 104 in base 56. An electrical terminal 106 is provided on motor 46 for connection with a suitable voltage source, such as the battery of the vehicle.
Piston-cylinder unit 26, with piston rod 28 and piston sleeve member 64 therein as described above, provides a first operational arrangement for power unit 24 by which piston rod 28 is adapted to be extended and retracted to directly raise and lower plow blade 12 through arm 30. In this respect, motor-pump unit 36 is operable to deliver hydraulic fluid from reservoir 82 through passage 104 to pump 48 and from the pump through passage 102 into recess 80 beneath the piston assembly on rod member 28. The hydraulic fluid under pressure displaces the piston assembly and thus piston rod member 28 upward in piston sleeve member 64, causing lift arm 30 to raise plow blade 12. When it is desired to lower the plow blade, hydraulic controls within pump 48 of the motor-pump unit connect fluid passages 102 and 104, thus allowing the pressurized fluid behind the piston to return to reservoir 82. As the pressurized fluid is released from behind the piston assembly, rod 28 moves downwardly within piston sleeve 64 causing lift arm 30 and the plow blade to be lowered. It will be appreciated from the foregoing description that the power unit must be mounted on the front of the vehicle to achieve blade raising and lowering functions.
In accordance with the present invention, a power unit as described above is adapted to be modified to provide a power unit of the same basic structure which is operable to deliver fluid to a point remote from the power unit, as opposed to delivering fluid under pressure behind the piston component as described above. Such a modification enables the basic power unit to be mounted remote from the front of a vehicle and to deliver fluid under pressure to a blade lift piston-cylinder assembly associated with the blade mounting frame.
In the embodiment disclosed, such modification is achieved by replacing the piston assembly and rod and piston sleeve 64 with the inner sleeve assembly 108 illustrated in FIG. 3. Sleeve assembly 108 includes a sleeve member 64' identical to piston sleeve member 64. The upper end of sleeve 64' is provided with an apertured end wall member 110 which is preferably secured to the inner surface of sleeve 64' as by welding. Sleeve 64' and member 110 provide a cavity 112 within the sleeve for the purpose set forth hereinafter. A central aperture 114 is provided axially through wall member 110 and is internally threaded as at 116 to receive an externally threaded nipple 118. Nipple 118 is cylindrical, has an outer surface 120 corresponding to the diameter of piston rod 28, and has an aperture 122 axially therethrough. The upper end of aperture 122 is internally threaded as at 124 for connection with fluid hose 126 by means of a threaded fitting 128. Since sleeve 64' is identical to piston sleeve 64 in the basic power unit, it will be appreciated that end wall 110 and nipple 118 can be preassembled, as shown in FIG. 4, and stored until such time as a basic unit is to be modified. Then, either the piston sleeve 64 from the unit to be modified, or a separate sleeve can be used to provide sleeve assembly 108 by attaching end wall member 110 thereto.
Sleeve assembly 108 is shown in FIG. 5 as replacing piston sleeve 64 and the piston rod and piston assembly of the basic power unit. The thus modified power unit is designated by the numeral 24', and component parts thereof corresponding to the basic power unit illustrated in FIG. 2 are identified by like numerals in FIGS. 2 and 5. As will be apparent from FIG. 5, sleeve 64' of sleeve assembly 108 is inserted into base portion 56 and is sealed with respect thereto by seal 66. Top cover 84 secures both outer cylindrical member 60 and inner sleeve member 64' to base portion 56 by means of bolts 96 therethrough, and outer member 60 and inner sleeve 64' are sealed with respect to cover 84 as at 94 and 95, respectively. As mentioned above, the exterior dimension of nipple 118 is the same as the exterior dimension of piston rod 28, whereby seals 86, 88 and 90 within opening 85 in cover 84 sealingly engage exterior surface 120 of the nipple. While sleeve member 64' is preferably of the same dimensions and shape as piston sleeve member 64', it should be understood that such dimension and shape of sleeve 64' is not critical. It is only necessary that the replacement sleeve be adequately supported between and sealed with respect to base 56 and cover 84. This can of course be achieved with other sleeve shapes and sizes, sleeve 64' being preferred in that it requires no modifications of the base, cover or seal arrangements.
With regard to the operation of the modified power unit shown in FIG. 5, hydraulic fluid under pressure is pumped by pump 36 from reservoir 82 through fluid passage 102 into recess 80 and thus into cavity 112 of sleeve 64'. The fluid then flows through sleeve member 64' and through aperture 122 of nipple 118 into hydraulic fluid hose 126. This enables the modified power unit 24' to be operable to raise and lower a plow blade from a location remote from the front of a vehicle. In this respect, as will be seen in FIG. 6, modified power unit 24' is located remotely from plow blade 12 and vehicle front frame portion 16 and could, for example, be mounted under the hood of the vehicle. Basically, the location of modified power unit 24' is dependent only upon particular specifications of the purchaser of the unit, as a result of considerations such as longevity of the power unit and appearance of the vehicle. Except for the removal of the power unit from the support frame 22, the latter and the plow assembly can be the same and, accordingly, like numerals are used in FIG. 6 to represent corresponding parts shown in FIG. 1. When using the modified power unit, a hydraulic piston-cylinder unit is mounted between support frame 22 and lift arm 30 to lift and lower the blade. In the embodiment illustrated, this unit includes a cylinder 134 pivotally connected to frame 22 by a pin 136, and a ram member 138 extending from the cylinder and having its outer end connected to lift arm 30 by a pin 140. Hose 126 from modified power unit 24' is connected to cylinder 134 behind the piston, not shown, on the inner end of ram member 138. While not shown in FIG. 6, it will be appreciated that the plow blade assembly includes hydraulic piston-cylinder units 38 and 40 and that the latter are operatively connected with the modified power unit as they are with the power unit shown in FIG. 1.
With further regard to FIGS. 5 and 6 and the operation of the modified power unit 24', fluid under pressure flows through hose 126 to hydraulic cylinder 134 to displace ram member 138 upwardly to elevate the plow blade. When the plow blade is to be returned to its original position, hydraulic controls within pump portion 48 of the motor-pump unit connect fluid passage 102 to fluid passage 104, thus allowing the hydraulic fluid to flow from sleeve cavity 112 to reservoir space 82. When the pressurized fluid is so released from cavity 112, the weight of the plow blade displaces ram member 138 inwardly of cylinder 134, thus to lower the blade.
While the structure of the preferred embodiment has been disclosed and described in detail, it will be appreciated that other embodiments can be made and that changes can be made in the preferred embodiment without departing from the invention. Accordingly, it is to be distinctly understood that the foregoing descriptive matter is to be interpreted as illustrative of the invention and not as a limitation.
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An arrangement for modifying a plow blade power unit of the type positioned between the mounting frame on the front of a vehicle and a plow blade lift arm, to a unit for creating pressurized fluid from a remote location. Modification enables a basically similar power unit to be utilized in both remote and direct operational environments with only minor substitution of interchangable parts. A piston-cylinder unit which enables direct lifting of a plow blade is replaced by a modified, but similar, cylindrical element for use in indirect lifting of a plow blade by fluid under pressure.
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BACKGROUND OF THE INVENTION
Fishing spearguns have not changed dramatically over the last century in that they continue to employ spearpoint shafts that are biased into a trigger release mechanism by a plurality of rubber bands, and a string line for retrieving the spearpoint and shaft after firing.
Of course, modern manufacturing techniques have made improvements which have affected somewhat the appearance of the speargun, its safety and ease of cocking and trigger pull. For example, the grip assembly now includes, in one embodiment of the assignee of the present invention, a one-piece plastic housing that forms the handle grip, the trigger guard, the butt support, the forepiece support and the housing for the trigger assembly.
The trigger assembly has been improved by providing it with a removable frame that permits the trigger assembly to be easily removed from the grip housing. This prior trigger assembly includes a one-piece plastic frame having an upper spearpoint shaft guide and spaced parallel lower frames that pivotally support both the trigger and a shaft latching bar.
The trigger assembly is also provided with a safety pawl operated by a knob on the outside of the grip housing.
Since these spearguns have remained basically unchanged, performance improvements, although they may appear small, contribute greatly to the popularlity of the speargun in this fascinating, competitive and still somewhat esoteric sport.
In these prior trigger assemblies, the latch bar and the trigger slidably engage one another and are constructed of the same material and after a period of use, the interengaging surfaces become scored causing trigger pull to become erratic which results in a jerking movement of the gun during firing throwing the spear off target.
Another problem in these prior trigger assemblies is that the safety mechanism requires the use of the fisherman's other hand, or more particularly, with the fisherman's left hand on the grip housing handle, he either has to operate the safety release with his right hand or take his left hand off the grip to release it.
It is a primary object of the present invention to ameliorate the problems noted above in spearguns, and particularly speargun trigger assemblies.
SUMMARY OF THE PRESENT INVENTION
In accordance with the present invention, a trigger assembly is provided for a speargun that has a left-right reversible safety operable with the trigger hand while on the grip, and an improved trigger pull achieved by engaging bearing surfaces on the latch bar and trigger.
Toward these ends, the present speargun is provided with a one-piece grip housing in the general shape of the housing of an automatic pistol that has an upper slot into which a trigger assembly is insertable. The trigger assembly has a plastic frame with an integral top tube that receives the proximal end of the spearpoint shaft, and parallel spaced depending walls that pivotally support the trigger, the latch bar, and a safety pawl.
The latch bar has an upwardly projecting shaft locking pawl substantially in line with the pivotal axis of the locking pawl, and this location has the effect of reducing the outward shaft torque on the latch bar, and hence the trigger, reducing trigger pull effort by at least 32%.
The latch bar has an elongated arm that rests on a shoulder on the trigger in the set or firing position. The latch bar is constructed of hardened 17-7 stainless steel, while the trigger is constructed of 302 stainless, or equivalents thereof, resulting in a significant difference in hardness and creating a bearing effect between the latch bar arm and the trigger shoulder eliminating the prior problem of scoring on these surfaces and thereby smoothing out trigger pull substantially.
The safety pawl, according to the present invention, is operated by a knob and shaft assembly projecting through the grip housing and the trigger frame. The knob has a radially extending finger that is positioned so that when the safety is "on" with the latch bar holding the spearpoint shaft in a firing position, this finger depends over the trigger blocking movement of the fisherman's index finger toward the trigger. This is especially important in spearguns because underwater conditions make it difficult to visually observe whether the safety is "on" or "off".
After recognizing a safety "on" condition, the fisherman, with his trigger hand on the housing grip, releases the safety with this index finger of his trigger hand by rotating the knob finger clockwise toward a horizontal position away from the trigger, rotating the safety pawl away from the trigger creating a firing condition.
The safety knob and shaft assembly is insertable through the safety pawl from either the right or left side of the grip housing permitting the safety to be used with the trigger hand on the grip for both right or left side spear fishermen.
Other objects and advantages of the present invention will appear more clearly from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a speargun with its safety in an "on" position;
FIG. 2 is an exploded perspective of the grip housing and trigger assembly arranged for left side shooting;
FIG. 3 is an exploded perspective of the same grip housing and trigger assembly arranged for right side shooting;
FIGS. 4, 5 and 6 are longitudinal sections of the trigger assembly respectively in the loading, safety "on" and firing positions;
FIG. 7 is an enlarged fragmentary side view of the grip housing illustrating the safety knob in a safety "on" position;
FIG. 8 is a top view of the grip housing shown in FIG. 7, and;
FIG. 9 is a partly fragmented top view of the grip housing showing the latching bar engaging the spearpoint shaft's proximal end.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings and particularly FIGS. 1 to 3, a speargun assembly 10 is illustrated according to the present invention generally including a grip housing 12, a trigger assembly 14, a butt rest 16 supported in grip housing 12 by butt extension 17, a wooden forepiece 19 supported in the forward end of grip housing 12, a muzzle piece 21 supported on forepiece 19, and a pair of bands 23 of natural rubber shown in their relaxed positions which are adapted to engage spearpoint shaft 24 in preparation for firing, which carries a spearpoint 26 at its distal end.
Bands 23 carry metal loops 28 adapted to engage in grooves 30 in the top of spearpoint shaft 24 as seen clearly in FIG. 4.
Referring again to FIG. 1, a line assembly 32 is provided for retrieving the spearpoint 26 and shaft after firing.
As seen in FIGS. 2 and 3, the grip housing 12 is a one-piece plastic molding in the general shape of an automatic pistol having a hollow handle 35, a trigger guard 36, and a tubular upper receiver 37, whose forward end supports forepiece 19 and rear end supports butt extension 17. Trigger assembly 14 is insertable into an elongated slot 38 in the top of receiver 37.
The trigger assembly 14 includes a reenforced nylon plastic frame 40 seen more clearly in FIGS. 4 to 6. Frame 40 is a one-piece plastic injection molding having an integral upper guide tube 41 that slidably receives proximal end 42 of spearpoint shaft 24. Frame 40 has a pair of parallel spaced depending side walls 43 and 44 that pivotally support trigger 45, latch bar 46, and safety pawl 48.
The latch bar 46 is a one-piece 17-7 hardened stainless steel part pivotally supported between walls 43 and 44 by a pin 49 that extends through walls 43 and 44 but not through receiver side walls 50, as seen in FIGS. 2 and 3 so that it does not have to be removed to remove trigger assembly 14 from receiver 37.
The latch bar 46 has a rectangular recess 52 that defines a reset pawl 53 extending into guide tube 41 through slot 54. Pawl 53 is engaged by the proximal end 42 of the spearpoint shaft as the shaft is loaded into the guide tube 41.
Recess 52 also defines a second pawl 55 on the latch bar that in its set position illustrated in FIG. 5 engages a shoulder 56 in a recess in the bottom of spearpoint shaft proximal end 42 to hold the spearpoint shaft in a firing ready position.
An important aspect of the present invention is that locking surface 58 of locking pawl 55 is vertically substantially in line with the side of pivot pin 49 which has the effect of reducing the torque on latch bar 46 caused by the spearpoint shaft in the loaded position illustrated in FIG. 5.
One-piece trigger 45 is constructed of 302 stainless steel and is pivotally mounted between trigger frame walls 43 and 44 by pin 61, and a leaf spring 63 is provided which engages shoulders on the latch bar and trigger to maintain them in engagement after firing as seen in FIG. 6.
The latch bar 46 has a forwardly extending arm 64 that engages a generally horizontal shoulder 65 on trigger 45 in the firing position of the latch bar illustrated in FIG. 5.
Another important aspect of the present invention is that because the latch bar 46 and the trigger 45 are constructed of substantially disparate hardness materials, the interengaging surfaces of shoulder 65 and the bottom surface of latch bar arm 64 create a bearing condition between the surfaces that substantially eliminates scoring of these surfaces and yields a vastly enhanced trigger pull.
As seen in FIGS. 2 and 3, a safety assembly 67 is provided that includes the pawl 48, spacing ring 68, spring 69, shaft 70 and operator knob 71.
Shaft 70 has a length sufficient to extend through spaced apertures 72 in side walls 43 and 44 and through receiver side walls 50 with one end projecting about 0.75 inches.
The inner end 73 of shaft 70 is deformed to prevent it from sliding through receiver side apertures 75. The opposite end 74 of shaft 70 carries a removable snap ring that retains ring 68, spring 69 and knob 71 on shaft 70.
Shaft 70 is freely slidable in receiver apertures 75 and trigger frame apertures 72 so that the entire trigger safety assembly 67 can be easily removed by removing the snap ring, ring 68, spring 69 and knob 71 from end 74 and sliding shaft 70 from the other side of the grip housing 12. In this way the safety assembly 67 can be mounted in either its left orientation illustrated in FIG. 2, or its right illustrated in FIG. 3 for left side or right side shooting.
As seen clearly in FIGS. 2, 3, 7 and 8, the safety operator knob 71 has a tapered radially extending integral arm or finger 76 that depends substantially over opening 77 in trigger guard 78 so that the fisherman readily engages it as he approaches trigger 45 with his trigger finger, as clearly seen in FIG. 7. With the trigger hand on the grip handle 35, safety finger or arm 76 is rotated from its "on" position illustrated in solid lines in FIG. 7, to the horizontal dotted line position with the trigger hand forefinger.
Referring to FIGS. 4, 5 and 6, spearpoint shaft 24 is loaded by inserting it into guide tube 41 engaging projection 54, rotating latch bar 46 counter-clockwise against the biasing force of spring 63 away from transverse trigger shoulders 81 and 82 permitting trigger 45 to pivot counter-clockwise to its position illustrated in FIG. 5 where latch bar arm 64 engages transverse trigger shoulders 65 and 84 stopping further counter-clockwise movement of trigger 54. In this position of latch bar 46, pawl 55 engages shaft shoulder 56 preventing outward movement of spearpoint shaft 24 from guide tube 41.
With his trigger hand forefinger, the fisherman engages safety arm 76 and rotates it from its FIG. 4 position to its FIG. 5 "on" position where safety pawl 48 engages trigger side 86 preventing trigger firing.
When commencing firing, the trigger hand forefinger again engages safety knob arm 76 and rotates it clockwise back to its horizontal position illustrated in FIG. 6, its "off" position, permitting trigger 45 to be pulled to its fired position illustrated in FIG. 6 permitting latch bar 46 to pivot clockwise releasing locking pawl 55 from shaft shoulder 56, permitting bands 23 to fire shaft 24 from the speargun.
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A trigger assembly for spearguns with a reversible safety and improved trigger pull. The safety has an operator that extends over the trigger area and is positioned so the fisherman's index finger can operate it while his hand is on the speargun grip.
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CROSS REFERENCE
[0001] This application is a divisional of U.S. application Ser. No. 10/918,882 filed on Aug. 16, 2004, which is incorporated by reference herein in its entirety.
BACKGROUND OF THE DISCLOSURE
[0002] 1. Field of the Invention
[0003] The present invention relates in general to garment securement devices, and particularly, to necktie holders for securing one's necktie to itself and to dress shirts.
[0004] 2. Background Art
[0005] Historically, garments worn by a person have been fastened together using buttons, belts, snaps, zippers, hook-and-loop fasteners, and the like. Permanent magnets have also been used to secure garments together, such as the magnetic button disclosed in U.S. Pat. No. 2,397,931 issued to Ellis, the magnetic button disclosed in U.S. Pat. No. 5,974,634 issued to Eisenpresser, and the magnetic attaching device disclosed in U.S. Pat. No. 5,732,451 issued to Mars. But permanent magnets made of traditional materials have not been capable of securely fastening multiple layers of clothing together due to their relatively weak magnetic field strengths. The emergence of high field strength permanent magnets in the marketplace has brought with them new utilitarian uses.
[0006] Neckties, in particular, have historically been secured to one's dress shirt using a broad array of spring clips, clasps, tacks, chains, and the like. However, conventional necktie holders such as these suffer from several shortcomings; namely, they may not be completely hidden from view, they may not have interchangeable decorative faceplates, they may not fixedly attach the necktie against the surface of the shirt, they may damage clothing by leaving a hole through the necktie and/or the shirt, and they may not permit easy separation of the ornamental end of the necktie from the shirt while simultaneously retaining the necktie holder.
[0007] In addition, conventional necktie holders can be dangerous for those persons who are required to wear a break-away necktie (i.e. clip-on tie) in their professions because conventional necktie holders are incapable of allowing the necktie to smoothly separate from the wearer's neck if the necktie were to become caught in machinery, for example.
[0008] Some necktie holders are known to include magnets as a means for securing a necktie to one's shirt. For example, U.S. Pat. No. 2,601,424 issued to Baker discloses a necktie holder having a composite faceplate incorporating both a magnet and a decorative plate in combination with a magnetic spring clip that is clamped onto person's shirt. However, Baker neither teaches nor suggests that all of the components of the necktie holder are completely hidden from view. Likewise, U.S. Pat. No. 6,216,275 B1 issued to Lee discloses a device for securing neckties that also incorporates a magnet. However, Lee neither teaches nor suggests a necktie holder capable of fixedly attaching the necktie to be in direct contact with the surface of the shirt.
[0009] Therefore, it would be desirable to provide a necktie holder that is completely hidden from view. It would also be desirable to provide a necktie holder that has interchangeable faceplates. It would also be desirable to provide a necktie holder that fixedly attaches the necktie against the surface of the wearer's shirt. It would also be desirable to provide a necktie holder that does not damage the wearer's clothing. It would also be desirable to provide a necktie holder for enhanced personal safety, yet all quick and easy separation of the necktie from the wearer's shirt to minimize damage to the necktie, as when washing hands or when eating a meal. It would also be desirable to provide a necktie holder that is retained by the wearer's clothing even when the necktie becomes separated from the wearer's shirt. It would also be desirable to provide a necktie holder that allows the necktie to move within a limited range dictated by the length of a tether, but which does not damage the wearer's clothing. It would also be desirable to provide a necktie holder that permits a single, seemingly unitary separation of the necktie from the wearer (if combined with a clip-on necktie) should the necktie become caught in machinery or otherwise pose harm to the wearer.
SUMMARY OF THE INVENTION
[0010] The present invention is directed to a magnetic device for securing a necktie to a wearer's shirt generally comprising a magnet that is magnetized to about Grade N35 and a faceplate that is magnetically attractable to the magnet. The magnet is preferably encased in a hard and durable coating for corrosion resistance.
[0011] In accordance with one aspect of the present invention, the magnet is positionable underneath at least a portion of the wearer's shirt, and the faceplate is likewise positionable within magnetic proximity to the magnet to cause releasable restraint of the necktie relative to the shirt at the location of the magnet. The magnet and the faceplate are preferably hidden from view. However, because the faceplate may be decorative in nature, the wearer may choose to install the faceplate on the front panel of the necktie for prominent display. The faceplate may be interchangeable with other faceplates of different ornamental design. The faceplate is optionally made of a rare Earth material magnetized to about Grade N35.
[0012] A method for using a magnet in combination with a faceplate for securing a necktie to a shirt is presented in accordance with another aspect of the present invention. The necktie comprises an ornamental end and a nonornamental end that is positioned behind a transverse piece of fabric secured to the rear portion of the ornamental end. The method comprises the steps of: (1) placing and holding the magnet underneath at least a portion of the shirt with one hand; (2) placing and holding the faceplate behind at least the transverse piece of fabric with the other hand; and (3) drawing the faceplate toward the magnet to become within magnetic proximity of one another to cause releasable fixation of the necktie relative to the shirt at the location of the magnet. The magnet may optionally be magnetized to about Grade N35 and may optionally be comprised of a rare Earth material that is encased in a hard and durable coating to protect it from corrosion. The coating on the magnet may optionally comprise at least nickel or epoxy. Placement of the faceplate behind the transverse piece of fabric may additionally occur between the ornamental end and the nonornamental end of the necktie.
[0013] Another method for using a magnet in combination with a faceplate for securing a necktie to a shirt is presented in accordance with one aspect of the present invention. The necktie comprises an ornamental end and a nonornamental end that is positioned behind a transverse piece of fabric secured to the rear portion of the ornamental end. The method comprises the steps of: (1) placing the magnet in a first pocket secured underneath a portion of the shirt; (2) placing the faceplate in a second pocket secured to the rear side of the ornamental end; and (3) drawing the necktie toward the shirt to cause the faceplate to become within magnetic proximity of the magnet to cause releasable fixation of the necktie relative to the shirt at the location of the magnet. As before, the magnet may optionally be magnetized to about Grade N35 and may optionally be comprised of a rare Earth material that is encased in a hard and durable coating to protect it from corrosion. The coating on the magnet may comprise at least nickel or epoxy. In addition, the second pocket may be secured between the transverse piece of fabric and the rear side of the ornamental end of the necktie.
[0014] Yet another method for using a magnet in combination with a faceplate for securing a necktie to a shirt is presented in accordance with one aspect of the present invention. The necktie comprises an ornamental end and a nonornamental end that is positioned behind a transverse piece of fabric secured to the rear portion of the ornamental end. The method comprises the steps of: (1) placing and holding the magnet underneath at least a portion of the shirt with one hand; (2) placing and holding the faceplate in front of the ornamental end of the necktie with the other hand; and (3) drawing the faceplate toward the magnet to become within magnetic proximity of one another to cause releasable fixation of the necktie relative to the shirt at the location of the magnet. In this aspect of the invention, the faceplate may be decorative for prominent display in front of the necktie, and the magnet may also be magnetized to about Grade N35.
[0015] Another method for using a magnet in combination with a faceplate for securing a necktie to a shirt is presented in accordance with one aspect of the present invention. The necktie comprises an ornamental end and a nonornamental end that is positioned behind a transverse piece of fabric secured to the rear portion of the ornamental end. The method comprises the steps of: (1) inserting a pin secured to the magnet through the shirt; (2) fastening a clasp to the pin to secure the magnet to the shirt; (3) placing and holding the faceplate in front of the ornamental end of the necktie; and (4) drawing the faceplate toward the magnet to become within magnetic proximity of one another to cause releasable restraint of the necktie relative to the shirt at the location of the magnet. In this aspect of the invention, the faceplate may be decorative for prominent display in front of the necktie, and the magnet may be magnetized to about Grade N35.
[0016] Yet another method for using a magnet in combination with a faceplate for securing a necktie to a shirt is presented in accordance with one aspect of the present invention. The necktie comprises an ornamental end and a nonornamental end that is positioned behind a transverse piece of fabric secured to the rear portion of the ornamental end. The method comprises the steps of: (1) inserting a bar through a buttonhole in the shirt, the bar being connected to a tether having a predetermined length and the tether being attached to the magnet; (2) supporting the tethered magnet with one hand; (3) placing and holding the faceplate in front of the ornamental end of the necktie with the other hand; and (3) drawing the faceplate toward the magnet to become within magnetic proximity of one another to cause releasable restraint of the necktie relative to the shirt to the extent of the length of the tether. As before, in this aspect of the invention, the faceplate is optionally decorative for prominent display in front of the necktie, and the magnet is optionally magnetized to about Grade N35.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective view according to one embodiment of the invention of a permanent magnet in combination with a faceplate attractable to the magnet.
[0018] FIG. 2 is a side view of the embodiment of FIG. 1 .
[0019] FIG. 3 is a detail perspective view of the embodiment of FIG. 1 showing the magnet and its protective outer coating.
[0020] FIG. 4 is a perspective view of the embodiment of FIG. 1 showing the magnet positioned behind the front panel of a shirt and showing the faceplate positioned behind a transverse piece of fabric (i.e. such as the manufacturer's label) on the back of a necktie.
[0021] FIG. 5 is a side view of the embodiment of FIG. 4 .
[0022] FIG. 6 is a perspective view of the embodiment of FIG. 1 showing the magnet and the faceplate positioned inside pockets fabricated in a shirt and a necktie, respectively.
[0023] FIG. 7 is a side view of the embodiment of FIG. 6 .
[0024] FIG. 8 is a perspective view according to another embodiment of the invention of a permanent magnet in combination with a decorative faceplate attractable to the magnet.
[0025] FIG. 9 is a side view of the embodiment of FIG. 8 .
[0026] FIG. 10 is a detail perspective view of the embodiment of FIG. 8 showing the magnet and its protective outer coating.
[0027] FIG. 11 is a front view of the embodiment of FIG. 8 .
[0028] FIG. 12 is a rear view of the embodiment of FIG. 8 .
[0029] FIG. 13 is a perspective view of the embodiment of FIG. 8 showing the magnet positioned behind the front panel of a shirt and showing the faceplate positioned in front of the necktie.
[0030] FIG. 14 is a side view of the embodiment of FIG. 13 .
[0031] FIG. 15 is a perspective view of an alternative embodiment of a permanent magnet having a pin and a clasp in combination with a decorative faceplate.
[0032] FIG. 16 is a side view of the embodiment of FIG. 15 .
[0033] FIG. 17 is a perspective view of yet another embodiment of a permanent magnet having a tether and a bar in combination with a decorative faceplate.
[0034] FIG. 18 is a side view of the embodiment of FIG. 17 .
DETAILED DESCRIPTION OF THE INVENTION
[0035] While this invention is susceptible of embodiment in many different forms, there are shown in the drawings and described in detail, certain preferred embodiments with the understanding that the present disclosure should be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiments so illustrated.
[0036] FIGS. 1-3 describe a generic magnet and faceplate combination as used in the present invention. Magnet 10 is preferably made from a rare Earth material 11 , such as Neodymium Iron Boron (NdFeB), sintered to form a permanent magnet of about Grade N35 (i.e. preferably a magnet having BHmax equal to about 33 to 35 Million Gauss Oersted energy units (MGOe), where BHmax is the maximum product of the induction (B) measured in Gauss units and the magnetic field strength (H) measured in Oersted units). Magnet 10 is encased by coating 14 to prevent corrosion of the underlying rare Earth substrate. Besides protecting rare Earth material 11 from corrosion, coating 14 is preferably made of at least nickel or epoxy to produce a hard and impact resistant outer surface for enhanced durability and longevity of the overall magnet 10 . Other materials, however, such as copper, tin, zinc, silver, gold and the like, are optionally available to protect rare Earth material 11 from corrosion, but may result in a higher cost or durability penalty.
[0037] While magnet 10 is preferably made of a rare Earth material, faceplate 12 is preferably made of any material attractable to magnet 10 to achieve the lowest cost without sacrificing functionality. However, faceplate 12 may optionally have magnetic properties of its own, and may even have physical and magnetic properties similar to that of magnet 10 .
[0038] Magnet 10 and faceplate 12 are each preferably relatively thin discs, as shown in FIGS. 1-3 , of about ½ inch diameter and about ⅛ inch thick to provide a relatively small and thin footprint and to yield a magnetic axial pull force of about 5 lbs. Alternatively, magnet 10 and/or faceplate 12 may be formed in the shape of a relatively thin square or rectangle of similar dimensions. Regardless of the geometry, magnet 10 should provide a magnetic axial pull force of no less than about 3 lbs to insure adequate margin exists to hold a necktie, and no greater than about 11 lbs to minimize the chances of personal injury or damage to clothing. Permanent rare Earth magnets having all of these properties, coatings and/or geometry are available at retail outlets such as www.kimagnetics.com or www.wondermagnetics.com, for example.
[0039] FIGS. 4-5 describe one embodiment of the present invention. Magnet 10 and faceplate 12 , in combination, can be used to noninvasively restrain a necktie relative to the wearer's shirt while simultaneously being completely hidden from view. For example, with nonornamental end 22 of necktie 24 already positioned behind transverse fabric (i.e. the manufacturer's label) 20 , itself secured along two edges to the back of ornamental end 26 to form a “hole” through which nonornamental end 22 is “threaded”, a user of the present invention holding magnet 10 in one hand and faceplate 12 in the other would first insert and hold magnet 10 between front shirt panel 16 and rear shirt panel 18 at a position proximate to the location of transverse fabric 20 when the necktie is comfortably worn and draped in front of the wearer. With the other hand, the user would then insert and hold faceplate 12 behind transverse fabric 20 . Next, the user would draw together magnet 10 and faceplate 12 to be within magnetic proximity with one another to cause transverse fabric 20 and front shirt panel 16 to lie fixedly in contact with one another between magnet 10 and faceplate 12 . Reversing this procedure allows the wearer to separate the garments from one another quickly and with relative ease. Notably, this embodiment as thus described is contemplated to work with varying thicknesses and/or layers of fabric. Therefore, faceplate 12 may optionally be inserted behind transverse fabric 20 and between ornamental end 26 and nonornamental end 22 of necktie 24 to cause transverse fabric 20 , nonornamental end 22 , and front shirt panel 16 to lie fixedly in contact with one another between magnet 10 and faceplate 12 .
[0040] FIGS. 6-7 describe another embodiment of the present invention. In this embodiment, the shirt and/or necktie manufacturer may provide pockets 28 , 29 to house one or both of magnet 10 and faceplate 12 so as to potentially be completely hidden from view while also enabling the necktie to be fixedly in contact with the surface of the shirt at the location of the holder. Pocket 28 is preferably positioned on the backside of front shirt panel 16 while pocket 29 is preferably positioned on the backside of ornamental end 22 of necktie 24 .
[0041] In this embodiment, pockets 28 , 29 are preferably sewn on only three sides (leaving the top seam open) to permit easy removal of magnet 10 and/or faceplate 12 from their respective garments to facilitate unencumbered ironing of the garments when needed. Though pockets 28 , 29 are illustrated in use together in this embodiment, it is contemplated that any combination of the embodiment of FIGS. 4-5 and FIGS. 6-7 is possible. Therefore, the present invention will work if magnet 10 is optionally inserted behind front shirt panel 16 and faceplate 12 is installed in pocket 29 . Likewise, the present invention will work if magnet 10 is installed in pocket 28 and faceplate 12 is optionally inserted behind transverse fabric 20 .
[0042] Preferably, with the nonornamental end 22 of necktie 24 behind transverse fabric (i.e. the manufacturer's label) 20 , itself secured along two edges to the back of ornamental end 26 to form a “hole” through which nonornamental end 22 is “threaded”, a user of this embodiment of the invention would first insert the magnet in pocket 28 secured underneath front shirt panel 16 . Next, the user would insert faceplate 12 in pocket 29 secured to the back of ornamental end 26 . Then, the user would draw necktie 24 toward front shirt panel 16 to cause magnet 10 and faceplate 12 to be within magnetic proximity with one another to cause transverse fabric 20 to lie fixedly in contact with front shirt panel 16 . Reversing this procedure allows the wearer to separate the garments from one another quickly, with relative ease, and with complete capture and/or retention of all components of the necktie holder of the present invention.
[0043] Instead of first preparing necktie 24 by “threading” nonornamental end 22 behind transverse fabric 20 , the user may optionally choose to first insert magnet 10 in pocket 28 (or faceplate 12 in pocket 29 , for that matter), then insert faceplate 12 in pocket 29 (or magnet 10 in pocket 28 ), before positioning nonornamental end 22 behind transverse fabric 20 and drawing necktie 24 toward front panel 16 .
[0044] FIGS. 8-12 illustrate another magnet and faceplate combination in which magnet 10 is used together with alternative faceplate 34 . Like faceplate 12 , faceplate 34 is preferably made of any material attractable to magnet 10 . However, the present invention will work even if faceplate 34 has physical and magnetic properties of its own, similar to that of magnet 10 .
[0045] Faceplate 34 is preferably decorative in nature for prominent display in front of a necktie, as opposed to being hidden from view as previously described in FIGS. 4-7 . But if a wearer no longer wishes to display decorative faceplate 34 , the wearer may optionally install faceplate 34 in the manner shown and described in FIGS. 4-7 .
[0046] Decorative faceplate 34 may include jewels or other similar decorative or precious metal items. In addition, faceplate 34 may also include engravings, etchings, geometric shapes, company logos or group affiliations, flags and insignia, awards, religious ornamentation and licensed characters, to name a few. In fact, an endless array of shapes, sizes, colors and indicia may be included on, with, and/or in faceplate 34 without interfering with the functionality of the device. The various designs of faceplate 34 are completely interchangeable with one another without inhibiting the functionality of the overall device.
[0047] FIGS. 13-14 describe another embodiment of the present invention where the necktie is fixedly placed into direct contact with the surface of the shirt at the location of the holder. Magnet 10 and faceplate 34 , in combination, can be used to noninvasively restrain a necktie relative to the wearer's shirt so as not to cause damage to either garment. For example, with nonornamental end 22 of necktie 24 already positioned behind transverse fabric (i.e. the manufacturer's label) 20 , itself secured along two edges to the back of ornamental end 26 to form a “hole” through which nonornamental end 22 is “threaded”, a user of this embodiment of the present invention holding magnet 10 in one hand and faceplate 34 in the other would first insert and hold magnet 10 between front shirt panel 16 and rear shirt panel 18 at a vertical position of their choice. Using the other hand, the user would then position and hold faceplate 34 in front of ornamental end 26 proximate the chosen location of magnet 10 . Next, the user would draw together magnet 10 and faceplate 34 to be within magnetic proximity with one another to cause necktie 24 (and its component ends 22 , 24 and possibly even transverse fabric 20 ) and front shirt panel 16 to lie fixedly in contact with one another between magnet 10 and faceplate 34 . Reversing this procedure allows the wearer to separate the garments from one another quickly and with relative ease. Of course, the present invention would also work if magnet 10 were installed in pocket 28 should it exist on the wearer's shirt.
[0048] FIGS. 15-16 describe yet another embodiment of the present invention. Magnet 10 includes pin 36 and clasp 38 to secure magnet 10 to at least front shirt panel 16 . Pin 36 may be attached to magnet 10 using any number of conventional means, including but not limited to, gluing, tack welding or brazing, or by an interference fit to the outer diameter of magnet 10 . Clasp 38 is any conventional clasp capable of being secured to pin 36 , such as through a mild friction fit.
[0049] A user of this embodiment of the present invention would first push pin 36 of magnet 10 through at least front shirt panel 16 (possibly even through an open buttonhole) at a vertical location chosen by the user. The user would then push clasp 38 onto pin 36 to securely restrain magnet 10 to at least front shirt panel 16 . With nonornamental end 22 of necktie 24 already positioned behind transverse fabric 20 , itself secured along two edges to the back of ornamental end 26 to form a “hole” through which nonornamental end 22 is “threaded”, the user would position faceplate 34 in front of ornamental end 26 of necktie 24 at approximately the same location as magnet 10 . Next, the user would draw together magnet 10 and faceplate 34 to be within magnetic proximity with one another to cause necktie 24 (and its component ends 22 , 24 and possibly even transverse fabric 20 ) and at least front shirt panel 16 to lie secured between magnet 10 and faceplate 34 . Reversing this procedure allows the wearer to separate the garments from one another quickly and with relative ease. Of course, this embodiment of the present invention would also work if faceplate 12 were substituted for faceplate 34 and installed as described in FIGS. 4-5 and FIGS. 6-7 (if pocket 29 should exist on the wearer's necktie).
[0050] Use of this embodiment of the present invention may cause a potentially undesirable hole to be formed in at least the front shirt panel 16 (unless the pin is pushed through an open button hole), however, it retains the advantages of quick disconnect of the necktie from the shirt, creates no undesirable holes in the necktie, includes a decorative faceplate, and has the added advantage of retention of magnet 10 to at least front shirt panel 16 regardless of the presence of faceplate 34 .
[0051] FIGS. 16-17 describe yet another embodiment of the present invention. Magnet 10 includes bar 40 and tether 42 to secure magnet 10 to at least front shirt panel 16 . Tether 42 is preferably made of conventional jewelry-grade materials and design, and may be attached to magnet 10 using any number of conventional means, including but not limited to, gluing, tack welding or brazing, or by an interference fit to the outer diameter of magnet 10 . One potential method of securing bar 40 to tether 42 is by threading the end of tether 42 through a hole formed through bar 40 .
[0052] A user of this embodiment of the present invention would first insert bar 40 through buttonhole 44 chosen by the user in front shirt panel 16 . Buttonhole 44 captures bar 40 as shown in FIGS. 17-18 and effectively retains magnet 10 to front shirt panel 16 whenever faceplate 12 or 34 is not actively engaged with magnet 10 . The size and geometry of the installed bar 40 and tether 42 combination do not inhibit the normal use of button 46 in buttonhole 44 .
[0053] With nonornamental end 22 of necktie 24 already positioned behind transverse fabric (i.e. the manufacturer's label) 20 , itself secured along two edges to the back of ornamental end 26 to form a “hole” through which nonornamental end 22 is “threaded”, a user of this embodiment of the present invention holding magnet 10 in one hand and faceplate 34 in the other would next position both pieces ( 10 and 34 ) on either side of necktie 24 . Next the user would draw together magnet 10 and faceplate 34 to be within magnetic proximity with one another to cause necktie 24 (and its component ends 22 , 24 and possibly even transverse fabric 20 ) to lie secured between magnet 10 and faceplate 34 . Reversing this procedure allows the wearer to separate the garments from one another quickly and with relative ease but with the added convenience of retention of magnet 10 to front shirt panel 16 . Most importantly, however, this embodiment allows for some limited movement of necktie 24 relative to front shirt panel 16 , up to the length of tether 42 . Of course, this embodiment of the present invention would also work if faceplate 12 were substituted for faceplate 34 and installed as described in FIGS. 4-5 and FIGS. 6-7 (if, for example, pocket 29 should exist on the wearer's necktie).
[0054] The present invention may also incorporate elements of FIGS. 15-16 and FIGS. 17-18 in still another embodiment (not shown). For example, clasp 38 may be mounted to the end of tether 42 , thereby replacing magnet 10 on the end of tether 42 . Tether 42 could be secured to front shirt panel 16 via bar 40 . A wearer of this clasp/tether combination may then use faceplate 12 or 34 in accordance with the teachings of FIGS. 4-7 and FIGS. 13-17 .
[0055] Besides that which has been shown and described for securing neckties to dress shirts, other uses of the present invention include securing socks together (even potentially during washing), replacing traditional securing means (i.e. pins and the like) in authentic cultural attire, replacing traditional shirt buttons, trouser closures, and cufflinks, holding a corporate badge or exposition name tag to one's outer garment, holding corsages or similar floral arrangements to one's lapel, securing strapless braziers to ladies' blouses, and as wardrobe clips to quickly and temporarily hold gowns or other garments in place on photographer's subjects.
[0056] As noted above, while faceplate 12 and faceplate 34 will work as shown and described even if they have similar physical and magnetic properties to that of magnet 10 , faceplate 12 and faceplate 34 are preferably nonmagnetic themselves. The reason is simple—the significant field strength presented by Grade N35 magnets or similar give rise to manufacturing issues that are minimized if faceplates 12 and 34 are nonmagnetic. Specifically, a magnetized faceplate may be difficult to silkscreen or otherwise process than a nonmagnetized faceplate because a magnetized faceplate would be attracted to the very machine used in processing it and potentially jam in the machinery. Therefore, processing operations for nonmagnetic faceplates 12 and 34 enhances manufacturability without sacrificing functionality of the invention.
[0057] The foregoing description and drawings merely explain and illustrate the invention, and the invention is not so limited as those skilled in the art who have the disclosure before them will be able to make modifications and variations therein without departing from the scope of the invention.
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An improved apparatus and method for holding garments, such as neckties, is disclosed. The device comprises a magnet, preferably made of a rare Earth material and magnetized to about Grade N35 or better, and a faceplate. In one embodiment, the magnet is positioned under at least a portion of the wearer's shirt while the faceplate is positioned on a portion of the wearer's necktie. The shirt and/or necktie may additionally include pockets for housing the magnet and/or faceplate. The faceplate may be decorative, and interchangeable, for prominent display in front of the necktie. Alternatively, the device may be configured to be completely hidden from view. Several means for retaining the magnet to the shirt upon separation of the garments are presented.
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FIELD OF THE INVENTION
[0001] The present invention relates to a lithium secondary battery and, more particularly, to a lithium secondary battery having improved overcharge characteristics as well as an electrical appliance utilizing the lithium secondary battery.
DISCUSSION OF THE RELATED ART
[0002] The rapid diffusion of portable electronic machines or appliances has created a demand for smaller and lighter batteries as their power source. Primary batteries that meet this demand are lithium primary cells having an anode of lithium metal which are small is size and light in weight and yet have a high capacity. Unfortunately, they cannot be used repeatedly by charging and hence they are limited in use. Secondary batteries such as lead batteries, nickel-cadmium batteries, and nickel-hydrogen batteries can be used repeatedly, but they are low in operating voltage because they rely on an aqueous electrolytic solution. Therefore, they are not suitable for use which requires high capacity, small size, and light weight.
[0003] Demand for a secondary battery having a high capacity, small size, and light weight has been met by the development of a practical lithium ion battery. It has found widespread use in portable electronic and communications machines and equipment, such as CAM coder, digital camera, cellular phone, and notebook computer. It has also found as a power source for hybrid cars and pure electric cars.
[0004] A lithium ion battery is characterized by its anode and cathode active materials made of a substance capable of occluding and releasing lithium ions. In principle, it works without requiring electrodeposition of lithium metal. Its anode and cathode may be made of a variety of substances capable of occluding and releasing lithium ions. Their combination permits one to design the battery capacity and working voltage as desired. For example, the cathode is practically made of a carbonaceous material. It is expected to be made of a Group IVA element or an oxide thereof, a lithium-transition metal composite nitride, or an organic compound such as polyacetylene. The anode is practically made of LiMn 2 O 4 or LiCoO 2 and will be made of LiNiO 2 , LiFeO 2 , or LiMnO 2 under developmental stage. A lithium ion battery formed from the above-mentioned anode active material and a carbonaceous material for the cathode undergoes charging by the following mechanism. The anode permits lithium to dissolve in an electrolytic solution composed of an organic solvent and a lithium salt (as en electrolyte) dissolved therein. The cathode (which is separated from the anode by a fine porous separator) causes the carbonaceous material to occlude (by intercalation) lithium ions from the electrolytic solution. Discharging proceeds in the reverse process, thereby delivering electrons to the external circuit.
[0005] The above-mentioned lithium ion battery has a designed battery capacity which is determined by the amount of lithium in the anode or the capacity of the cathode occluding lithium ions, whichever smaller. Charging in excess of this battery capacity is referred to as overcharging. In the overcharging state, the anode releases more lithium than it should keep, causing the active material to disintegrate, and the cathode receives excess lithium ions, causing lithium metal to separate out (a phenomenon called dendrite). This results in the battery increasing in voltage and temperature. Thus, overcharging of lithium batteries poses a problem with battery safety.
[0006] To address this problem, there has been proposed a method of inhibiting overcharging by causing the electrolytic solution to consume current when overcharging occurs. See, for example, Japanese Patent Laid-open Nos. 338347/1994, 302614/1995, 106835/1997, 17447/1994, 50822/1997, and 162512/1999. The proposed method consists of incorporating the electrolytic solution with an aromatic compound which has an oxidation potential which is higher than the anode potential (usually 4.1-4.3 V) at the time of charging. The object is achieved as the aromatic compound undergoes oxidation reaction, thereby consuming overcharging current and inhibiting reactions due to overcharging. This action is attributable to the oxidation reduction reaction of the π electron conjugated system of the aromatic compound.
[0007] The above-mentioned aromatic compound produces a good effect of inhibiting overcharging but has a disadvantage of deteriorating the cycle characteristics and storage characteristics of the battery.
[0008] In order to address this problem, there has been proposed a new compound, as disclosed in Japanese Patent Laid-open Nos. 156243/2000, 58112/2000, 58113/2000, 58114/2000, 58116/2000, and 58117/2000. The proposed compound produces a good effect but has a disadvantage because it contains many phenyl groups in the molecule and hence has a high molecular weight. The disadvantage is that the compound is low in solubility (and hence is limited in its amount that can be added to the electrolytic solution) and has an extended π electron conjugated system (to inhibit overcharging), with the result that consumption of overcharging current by each methyl group is low and the effect per unit amount added is poor.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to provide an electrolyte with a compound which has a high solubility and a low molecular weight. It is another object of the present invention to provide a lithium battery having improved safety owing to an electrolytic solution which effectively inhibits overcharging and has no adverse effect on storage characteristics. Further, another object of the present invention is to provide an electrical appliance utilizing the lithium secondary battery of the present invention.
[0010] According to the present invention, the above-mentioned object is achieved by a lithium secondary battery which is characterized in that its nonaqueous electrolytic solution contains a compound which is oxidized at a voltage higher than the charge end voltage of the lithium secondary battery and a compound which inhibits reactions at voltages lower than said charge end voltage.
[0011] The lithium secondary battery of the present invention is characterized in that it has a charge capacity of C 1 when it (in discharged state) is charged with constant current until a voltage V 1 of 1.2V is reached and it has a charge capacity of C 2 when it is charged further (at a voltage higher than V 1 ) until it cannot be charged any longer, with the ratio (4) of C 1 /C 2 being lower than 0.7.
[0012] The lithium secondary battery of the present invention achieves its good performance owing to the electrolytic solution which contains a fluorinated solvent represented by the chemical formula (1) below and an aromatic compound represented by the chemical formula (2) as an overcharge inhibiting substance.
Rf 1 —X—Rf 2 (1)
[0013] An overcharge inhibiting substance represented by the chemical formula (3) below produces a better effect.
[0014] The fluorinated solvent represented by the chemical formula (1), which is to be incorporated into the electrolytic solution, is exemplified by the following.
[0015] 2,2,2-trifluoromethyl ethyl ether,
[0016] 2,2,2-trifluoroethyl difluoromethyl ether,
[0017] 2,2,3,3,3-pentafluoropropyl methyl ether,
[0018] 2,2,3,3,3-pentafluoropropyl difluoromethyl ether,
[0019] 2,2,3,3,3-pentafluoropropyl 1,1,2,2-tetrafluoroethyl ether,
[0020] 1,1,2,2-tetrafluoroethyl methyl ether,
[0021] 1,1,2,2-tetrafluoroethyl ethyl ether,
[0022] 1,1,2,2-tetrafluoroethyl 1,1,2,2-trifluoroethyl ether,
[0023] 2,2,3,3,3-tetrafluoropropyl difluoromethyl ether,
[0024] 1,1,2,2-tetrafluoroethyl 2,2,3,3-trifluoroethyl ether,
[0025] Hexafluoroisopropyl methyl ether,
[0026] 1,1,3,3,3-pentafluoro-2-trifluoromethylpropyl methyl ether,
[0027] 1,1,2,3,3,3-hexafluoropropyl methyl ether,
[0028] 1,1,2,3,3,3-hexafluoropropyl ethyl ether,
[0029] 2,2,3,4,4,4-hexafluorobutyl difluoromethyl ether,
[0030] Methyl perfluoropropionate,
[0031] Methyl perfluorobutyrate,
[0032] Ethyl perfluorobutyrate,
[0033] Methyl perfluorooctanate,
[0034] Ethyl perfluorooctanate,
[0035] Ethyl difluoroacetate,
[0036] Ethyl 5H-octafluoropnetanoate,
[0037] Ethyl 7H-decafluoroheptanoate,
[0038] Ethyl 9H-decafluoronanoate,
[0039] Methyl 2-trifluoromethyl-3,3,3-trifluoropropionate,
[0040] Methyl nanofluorobutyl ether,
[0041] Ethyl nanofluorobutyl ether,
[0042] Propyl nanofluorobutyl ether, and
[0043] Butyl nanofluorobutyl ether.
[0044] Other solvents than fluorinated solvents include the following.
[0045] Cyclic or chain esters (such as ethylene carbonate, fluoropropylene carbonate, butylene carbonate, chloroethylene carbonate, fluoroethylene carbonate, difluoroethylene carbonate, trifluoromethylpropylene carbonate, vinylene carbonate, dimethylvinylene carbonate, dimethyl carbonate, ethylmethyl carbonate, diethyl carbonate, diphenyl carbonate, 1,3-propylene carbonate, and 2,2-dimethyl-1,3-propylene carbonate); cyclic or chain ethers (such as dimethoxy methane, 1,2-dimethoxyethane, diglyme, triglyme, 1,3-di-oxolane, tetrahydrofuran, and 2-methylterahydrofuran); γ-butyrolactone, sulfolane, methyl propionate, ethyl propionate, ethylene sulfide, dimethylsulfoxide, ethylmethylsulfoxide, diethylsulfoxide, methylpropylsulfoxide, and ethylpropylsulfoxide. They may be used alone or in combination with one another.
[0046] The electrolytic solution of the lithium battery contains a lithium salt as the supporting electrolyte.
[0047] Examples of the supporting electrolyte include LiPF 6 , LiBF 4 , LiClO 4 , LiSO 3 CF 3 , LiN(SO 2 CF 3 ), LiN(SO 2 CF 2 CF 3 ), LiC(SO 2 CF 2 CF 3 ) 3 , LiC(SO 2 CF 3 ) 3 , LiI, LiCl, LiF, LiPF 5 (SO 2 CF 3 ), and LiPF 4 (SO 2 CF 3 ) 2 .
[0048] They may be used alone or in combination with one another.
[0049] Examples of the overcharge inhibiting compound represented by the chemical formula 2 or 3 include the following.
[0050] 4-biphneyl acetate, phehyl propionate, 4-biphenyl benzoate, 4-biphenylbenzyl carboxylate, 2-biphenyl propionate, 1,4-diphenoxybenzene, 1,3-diphenoxybenzene, diphenyl ether, 3-phenxytoluene, anisole, 2-chloroanisole, 3-chloroanisole, 4-fluoroanisole, 4-chloroanisole, 4-bromoanisole, 2,4-difluoroanisole, 3,5-difluoroanisole, 2,4-dichloroanisole, 2,4-dibromoanisole, ethoxybenzene, 2,4-difluoroethoxybenzene, 2,4-difluoropropoxybenzene, 2,5-difluoroanisole, 2,6-difluoroanisole, 3,4-difluoroanisole, 3,5-fluoroanisole, 1,2-dimethoxybenzene, 1,2-dimethoxy-4-fluorobenzne, 1,2-dimethoxy-4-chlorobenzene, 1,2-diemthoxy-4-bromobenzene, 1,3-dimethoxy-5-bromobenzene, 2,4-dichlorotoluene, 2-chloroxylene, 4-chloro-o-xylene, and 4-bromo-m-xylene. Other examples include phenyltrimethylsilane, benzyltrimethylsilane, diphehylmethylsilane, diphenyldimethoxysilane, diphenylsilane, 4-methoxyphenylmethylsilane, and triphenylsilane.
[0051] The cathode of the lithium secondary battery may be formed from lithium metal, lithium-aluminum alloy, natural or artificial graphite, amorphous carbon, a composite material of carbon with a substance (such as silicon, germanium, and aluminum) which can be alloyed with lithium, or silicon oxide or tin oxide or a composite material thereof with carbon.
[0052] The anode of the lithium secondary battery may be formed from any of the following materials. A composite oxide of lithium with cobalt, nickel, or iron; a material incorporated with transition metal, silicon, germanium, aluminum, manganese, or magnesium; lithium manganate or a mixture thereof with lithium, transition metal, silicon, germanium, aluminum, manganese, or magnesium; or a material whose crystal is partly replaced by any of the above-mentioned materials.
[0053] The separator of the lithium secondary battery may be formed from a fine porous film of polymeric material such as polyethylene, polypropylene, vinylene copolymer, and polybutylene. The porous film may be used in the form of double-layered or triple-layered laminate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0054] The above advantages and features of the invention will be more clearly understood from the following detailed description which is provided in connection with the accompanying drawings.
[0055] [0055]FIG. 1 is a sectional view of the cylindrical lithium secondary battery in one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0056] Exemplary embodiment of the present invention will be described below in connection with the drawings. Other embodiments may be utilized and structural or logical changes may be made without departing from the spirit or scope of the present invention. Like items are referred to by like reference numerals throughout the drawings. The invention will be described in more detail with reference to the following examples which are not intended to restrict the scope thereof.
COMPARATIVE EXAMPLE 1
[0057] This comparative example is designed to evaluate the overcharging characteristics and storage characteristics. A cylindrical lithium secondary battery constructed as shown in FIG. 1 was produced in the following manner. For the cathode active material, a mixture was prepared from artificial graphite (mesophase microbeads) and PVDF as a binder in a ratio of 91:9 by weight. The mixture was dissolved in N-methylpyrrolidone (NMP for short) as a solvent to give a paste. This paste was applied to both sides of copper foil as a cathode current collector 1 . The coating was dried, pressed with heating, and vacuum-dried. In this way the cathode layer 2 was formed on both sides of the cathode current collector 1 . Thus there was obtained the cathode. For the anode active material, a mixture was prepared from lithium cobaltite, graphite as a conducting material, and PVDF as a binder in a ratio of 85:7:8 by weight. The mixture was dissolved in NMP as a solvent to give a paste. This paste was applied to both sides of aluminum foil as an anode current collector 3 . The coating was dried, pressed with heating, and vacuum-dried. In this way the anode layer 4 was formed on both sides of the anode current collector 3 . Thus there was obtained the anode. A cathode lead 5 and an anode lead 6 (both made of nickel foil) were attached by electric welding respectively to the uncoated parts of the cathode and anode. The cathode and anode, with a separator 7 interposed between them, were wound up. The outermost separator was fixed with a tape. The thus obtained electrode group was inserted into a battery can 10 of stainless steel, in such a way that the cathode lead 5 comes into contact with the bottom of the can, with a polypropylene insulator 8 interposed between them. The cathode lead 5 was connected by electric welding to the battery can 10 so as to form the cathode circuit. The anode lead 6 was connected by electric welding to the anode cap 12 , with an anode insulator 9 interposed between them. For the electrolytic solution, a mixed solvent was prepared from ethylene carbonate (EC) and dimethyl carbonate (DMC) in a ratio of 1:2 by volume. In this solvent was dissolved 1M (mol/dm −3 ) of LiPF 6 . (The composition of the electrolytic solution will be described as “1M LiPF 6 EC/DMC (1/2 by volume)” hereinafter.) The thus obtained electrolytic solution (about 4 ml) was poured into the battery can 10 through its opening. The cathode can 10 was mechanically crimped with an anode cap 12 (with a gasket 11 ). Thus there was obtained the cylindrical lithium secondary battery (cobalt-based battery) for Comparative Example 1. Incidentally, the anode cap 12 is equipped with a safety device which is a pressure switch CID (Current Interrupt Device, which opens the circuit at about 100 kPa) consisting of heat-sensitive resistance element PTC (Positive Temperature Coefficient, resistance trip temperature at about 80° C.) and aluminum foil circuit.
[0058] The thus obtained battery was charged at a constant current of 1 A and a constant voltage of 4.2 V, with the charge end current being 20 mA. Then the battery was discharged at a discharge current of 1 A, with the discharge end voltage being 3 V. In other words, V 1 was 4.2 V and the discharge voltage was 3 V. The charging-discharging cycle was repeated twice. Then the battery was charged until 4.2 V at a current of 1 A. The battery was charged further (for overcharging) at 1 A until charging was interrupted by the action of the safety device. It was found that the battery has a charging capacity C 1 of 1380 mAh when charged to 4.2 V and the battery has an overcharging capacity C 2 of 1300 mAh when overcharged until charging was interrupted by the safety device. It follows therefore that the safety effect (ξ) of the battery defined in the formula (4) below is 0.94.
Safety effect (ξ)=(Overcharging effect C 2 )/(Initial discharge capacity C 1 ) (4)
[0059] The smaller value of safety effect means that the battery is safe with a remote possibility of overcharging.
[0060] For evaluation of the initial discharge capacity S 1 , the battery prepared in the same way as above was charged at 1 A up to 4.2 V and then discharged at room temperature under the same conditions as mentioned above. The battery was charged again under the same conditions. The charged battery was allowed to stand at 60° C. for 10 days. After cooling to room temperature, the battery was discharged at 1 A. The battery was charged and discharged again and the recovered capacity was measured. The capacity after storage is designated as S 2 . The storage characteristic was evaluated according to the formula (5) below.
Storage characteristic (%)=(Recovered discharge capacity after storage S 2 )/(Initial discharge capacity S 1 )×100 (5)
[0061] The battery in Comparative Example 1 has a storage characteristic of 93%. The larger is this value, the better is the storage characteristic of the battery.
COMPARATIVE EXAMPLE 2
[0062] A cobalt-based battery was produced in the same way as in Comparative Example 1 except that the electrolytic solution (1M LiPF 6 EC/DMC (1/2 by volume)) contains 0.1 M of anisole (An for short hereinafter) dissolved therein. The resulting battery had an overcharging capacity of 1120 mAh and a safety effect (ξ) of 0.81. However, it had a storage characteristic of 72%, which is lower than that of the battery in Comparative Example 1.
EXAMPLE 1
[0063] An electrolytic solution was prepared from 1M LiPF 6 EC/DMC (1/2 by volume), 5 vol % of methyl perfluorobutyrate (HFE1 for short hereinafter) as a fluorinated solvent, and 0.1 M of An. This electrolytic solution was used to produce the same cobalt-based battery as in Comparative Example 1. The resulting battery had a charging capacity (up to 4.2 V) of 1395 mAh, but it had an overcharging capacity of 870 mAh. Therefore, the safety effect (ξ) of the battery was 0.62. This result indicates that the battery containing a specific fluorinated solvent (HFE1) in the electrolytic solution decreases in overcharge current capacity much more than that in Comparative Examples 1 and 2 even though An as an overcharge inhibiting agent is used in common. Moreover, the battery in this example had a storage characteristic of 82%, which is higher by 10% than that in Comparative Example 2.
EXAMPLE 2
[0064] An electrolytic solution was prepared from 1M LiPF 6 EC/DMC (1/2 by volume), 5 vol % of 2,2,3,3,3-tetrafluoropropyl difluoromethyl ether (HFE2 for short hereinafter) as a fluorinated solvent, and 0.1 M of An. This electrolytic solution was used to produce the same cobalt-based battery as in Comparative Example 1. The resulting battery had a charging capacity (up to 4.2 V) of 1410 mAh, but it had an overcharging capacity of 820 mAh. Therefore, the safety effect (ξ) of the battery was 0.58 (which is better than that in Example 1). This result indicates that the fluorinated solvent of ether structure added to the electrolytic solution improves further the effect of inhibiting overcharging. Moreover, the battery in this example had a storage characteristic of 86%, which is higher by 4% than that in Example 1. This suggests that the fluorinated solvent of ether structure also contributes to the storage characteristics.
EXAMPLE 3
[0065] An electrolytic solution was prepared from 1M LiPF 6 EC/DMC (1/2 by volume), 5 vol % of nanofluorobutyl methyl ether (HFE3 for short hereinafter) as a fluorinated solvent, and 0.1 M of An. This electrolytic solution was used to produce the same cobalt-based battery as in Comparative Example 1. The resulting battery had a charging capacity (up to 4.2 V) of 1390 mAh, but it had an overcharging capacity of 810 mAh. Therefore, the safety effect (ξ) of the battery was 0.58. This result indicates that the fluorinated solvent of ether structure produces the effect of inhibiting overcharging. Moreover, the battery in this example had a storage characteristic of 88%, which is higher by 2% than that in Example 1. This suggests that the nanofluorobutyl methyl ether greatly improves the storage characteristics.
COMPARATIVE EXAMPLE 3
[0066] A manganese-based battery was prepared in the same way as in Comparative Example 1 except that the anode active material was lithium manganate and the cathode active material was amorphous carbon (PIC from Kureha Chemical Industry Co., Ltd.), with the electrolytic solution remaining unchanged from 1M LiPF 6 EC/DMC (1/2 by volume). The resulting battery was measured for capacity by charging under the same condition (V 1 =4.2 V) as in Comparative Example 1. The battery was found to have a charging capacity of 920 mAh and an overcharging capacity of 850 mAh at 4.2 V and above. Therefore, the safety effect (ξ) of the battery was 0.94, and the storage characteristic of the battery was 94%.
COMPARATIVE EXAMPLE 4
[0067] A manganese-based battery was prepared in the same way as in Comparative Example 3 except that the electrolytic solution was replaced by the one consisting of 1M LiPF 6 EC/DMC (1/2 by volume) and 0.1M of An dissolved therein. The resulting battery was found to have a charging capacity of 910 mAh (up to 4.2 V) and an overcharging capacity of 720 mAh. Therefore, the safety effect (ξ) of the battery was 0.79, which means that the battery has better safety than that in Comparative Example 3. However, the storage characteristic of the battery was 67%, which is lower than that of the battery in Comparative Example 3.
EXAMPLE 4
[0068] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of An, and 5 vol % of HFE1. The resulting battery was found to have a charging capacity of 920 mAh (up to 4.2 V) and an overcharging capacity of 640 mAh. Therefore, the safety effect (ξ) of the battery was 0.70, which means that the battery has better safety than that in Comparative Example 4. Moreover, the storage characteristic of the battery was 72%, which is better than that of the battery in Comparative Example 4. This result suggests that the fluorinated solvent prevents the overcharging inhibiting agent (An) from lowering the storage characteristics even in the case of manganese-based battery.
EXAMPLE 5
[0069] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of An, and 5 vol % of HFE2. The resulting battery was found to have a charging capacity of 930 mAh (up to 4.2 V) and an overcharging capacity of 590 mAh. Therefore, the safety effect (ξ) of the battery was 0.63, which means that the battery has better safety than that in Example 4. Moreover, the storage characteristic of the battery was 81%, which is better than that of the battery in Example 4. This result suggests that the fluorinated solvent of ether structure prevents the overcharging inhibiting agent from lowering the storage characteristics even in the case of manganese-based battery.
EXAMPLE 6
[0070] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of 4-biphenyl benzoate (Bph for short hereinafter), and 5 vol % of HFE2. The resulting battery was found to have a charging capacity of 910 mAh (up to 4.2 V) and an overcharging capacity of 550 mAh. Therefore, the safety effect (ξ) of the battery was 0.60, which means that the battery has better safety than that in Example 4. In addition, the storage characteristic of the battery was 83%. This result suggests that the Bph does not greatly decrease the storage characteristics unlike the battery in Comparative Example 4.
EXAMPLE 7
[0071] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of 1,2-dimethoxybenzene (VL for short hereinafter), and 5 vol % of HFE2. The resulting battery was found to have a charging capacity of 910 mAh (up to 4.2 V) and an overcharging capacity of 580 mAh. Therefore, the safety effect (ξ) of the battery was 0.64, which means that the battery has better safety than that in Example 4. In addition, the storage characteristic of the battery was 81%. This result suggests that the VL does not greatly decrease the storage characteristics unlike the battery in Comparative Example 4.
EXAMPLE 8
[0072] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of 4-fluoroanisole (FAn for short hereinafter), and 5 vol % of HFE2. The resulting battery was found to have a charging capacity of 920 mAh (up to 4.2 V) and an overcharging capacity of 530 mAh. Therefore, the safety effect (ξ) of the battery was 0.58, which means that the battery has better safety than that in Example 4. In addition, the storage characteristic of the battery was 83%. This result suggests that the FAn does not greatly decrease the storage characteristics unlike the battery in Comparative Example 4.
EXAMPLE 9
[0073] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of 2,5-diphenylanisole (DFAn for short hereinafter), and 5 vol % of HFE2. The resulting battery was found to have a charging capacity of 910 mAh (up to 4.2 V) and an overcharging capacity of 510 mAh. Therefore, the safety effect (ξ) of the battery was 0.56, which means that the battery has better safety than that in Example 4. In addition, the storage characteristic of the battery was 81%. This result suggests that the DFAn does not greatly decrease the storage characteristics unlike the battery in Comparative Example 4.
EXAMPLE 10
[0074] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of 4-biphenylacetate (BphA for short hereinafter), and 5 vol % of HFE2. The resulting battery was found to have a charging capacity of 900 mAh (up to 4.2 V) and an overcharging capacity of 510 mAh. Therefore, the safety effect (ξ) of the battery was 0.57, which means that the battery has better safety than that in Example 4. In addition, the storage characteristic of the battery was 83%. This result suggests that the BphA does not greatly decrease the storage characteristics unlike the battery in Comparative Example 4.
EXAMPLE 11
[0075] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of phenyl propionate (PhP for short hereinafter), and 5 vol % of HFE2. The resulting battery was found to have a charging capacity of 900 mAh (up to 4.2 V) and an overcharging capacity of 520 mAh. Therefore, the safety effect (ξ) of the battery was 0.58, which means that the battery has better safety than that in Example 4. In addition, the storage characteristic of the battery was 82%. This result suggests that the PhP does not greatly decrease the storage characteristics unlike the battery in Comparative Example 4.
EXAMPLE 12
[0076] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of ethoxybenzene (EtOB for short hereinafter), and 5 vol % of HFE2. The resulting battery was found to have a charging capacity of 910 mAh (up to 4.2 V) and an overcharging capacity of 570 mAh. Therefore, the safety effect (ξ) of the battery was 0.63, which means that the battery has better safety than that in Example 4. In addition, the storage characteristic of the battery was 81%. This result suggests that the EtOB does not greatly decrease the storage characteristics unlike the battery in Comparative Example 4.
EXAMPLE 13
[0077] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of 4-bromoanisole (BrAn for short hereinafter), and 5 vol % of HFE2. The resulting battery was found to have a charging capacity of 920 mAh (up to 4.2 V) and an overcharging capacity of 560 mAh. Therefore, the safety effect (ξ) of the battery was 0.61, which means that the battery has better safety than that in Example 4. In addition, the storage characteristic of the battery was 81%. This result suggests that the BrAn does not greatly decrease the storage characteristics unlike the battery in Comparative Example 4.
[0078] The above-mentioned results are summarized in Table 1. As mentioned above, the combination of an aromatic compound and a fluorinated solvent produces the effect of inhibiting overcharging for both the cobalt/graphite carbon battery and the manganese/amorphous carbon battery and gives rise to batteries which decrease in capacity only a little during storage. In addition, it was found that the aromatic compound known as an overcharge inhibiting agent has its effect enhanced when used in combination with a fluorinated solvent. Of several fluorinated solvents, that of ether structure is most effective.
TABLE 1 Over- Charging charging Safety Storage Battery type capacity capacity effect character- Example No. Electrolytic solution (mAh) (mAh) (ξ) istic (%) LiCoO 2 / graphite carbon Comparative 1 M LiPF 6 EC/DMC = 1/2 1380 1300 0.94 93 Example 1 Comparative 1 M LiPF 6 EC/DMC = 1/2, An = 0.1 M 1390 1120 0.81 72 Example 2 Example 1 1 M LiPF 6 EC/DMC = 1/2, HFE1 = 5% + An = 0.1 M 1395 870 0.62 82 Example 2 1 M LiPF 6 EC/DMC = 1/2, HFE2 = 5% + An = 0.1 M 1410 820 0.58 86 Example 3 1 M LiPF 6 EC/DMC = 1/2, HFE3 = 5% + An = 0.1 M 1390 810 0.58 88 LiMn 2 O 4 / amorphous carbon Comparative 1 M LiPF 6 EC/DMC = 1/2 920 850 0.92 94 Example 3 Comparative 1 M LiPF 6 EC/DMC = 1/2, An = 0.1 M 910 720 0.79 67 Example 4 Example 4 1 M LiPF 6 EC/DMC = 1/2, HFE1 = 5% + An = 0.1 M 920 640 0.70 72 Example 5 1 M LiPF 6 EC/DMC = 1/2, HFE2 = 5% + An = 0.1 M 930 590 0.63 81 Example 6 1 M LiPF 6 EC/DMC = 1/2, HFE2 = 5% + Bph = 0.1 M 910 550 0.60 83 Example 7 1 M LiPF 6 EC/DMC = 1/2, HFE2 = 5% + VL = 0.1 M 910 580 0.64 81 Example 8 1 M LiPF 6 EC/DMC = 1/2, HFE2 = 5% + FAn = 0.1 M 920 530 0.58 83 Example 9 1 M LiPF 6 EC/DMC = 1/2, HFE2 = 5% + DFAn = 0.1 M 910 510 0.56 81 Example 10 1 M LiPF 6 EC/DMC = 1/2, HFE2 = 5% + BphA = 0.1 M 900 510 0.57 83 Example 11 1 M LiPF 6 EC/DMC = 1/2, HFE2 = 5% + PhP = 0.1 M 900 520 0.58 82 Example 12 1 M LiPF 6 EC/DMC = 1/2, HFE2 = 5% + EtOB = 0.1 M 910 570 0.63 81 Example 13 1 M LiPF 6 EC/DMC = 1/2, HFE2 = 5% + BrAn = 0.1 M 920 560 0.61 81
EXAMPLE 14
[0079] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of An, and 5 vol % of HFE3. The resulting battery was found to have a charging capacity of 920 mAh (up to 4.2 V) and an overcharging capacity of 560 mAh. Therefore, the safety effect (ξ) of the battery was 0.61, which means that owing to HFE3 as a fluorinated solvent the battery has better safety than that in Examples 4 and 5 which employs HFE1 or HFE2 as a fluorinated solvent. In addition, the storage characteristic of the battery was 85%. Thus the battery in this example is greatly improved over that in Example 4 or 5. This result suggests that an adequate selection of fluorinated solvents contributes to improvement in safety and storage properties.
EXAMPLE 15
[0080] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of PhP, and 5 vol % of HFE3. The resulting battery was found to have a charging capacity of 900 mAh (up to 4.2 V) and an overcharging capacity of 520 mAh. Therefore, the safety effect (ξ) of the battery was 0.58. This result suggests that PhP as an overcharge inhibiting agent contributes more to the battery safety when used in combination with HFE3 as a fluorinated solvent than when used in combination with HFE2 as a fluorinate solvent, as in Example 12. In addition, the storage characteristic of the battery in this example is 85%, which is much better than that in Example 11. Thus it was confirmed in this example that HFE3 produces its good effect even though the kind of the overcharge inhibiting agent is changed.
EXAMPLE 16
[0081] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of EtOB, and 5 vol % of HFE3. The resulting battery was found to have a charging capacity of 910 mAh (up to 4.2 V) and an overcharging capacity of 570 mAh. Therefore, the safety effect (ξ) of the battery was 0.63. This result suggests that EtOB as an overcharge inhibiting agent contributes more to the battery safety when used in combination with HFE3 as a fluorinated solvent than when used in combination with HFE2 as a fluorinate solvent, as in Example 12. In addition, the storage characteristic of the battery in this example is 86%, which is much better than that in Example 12. Thus it was confirmed in this example that HFE3 produces its good effect even though the kind of the overcharge inhibiting agent is changed.
[0082] The following examples demonstrate how the battery safety and storage characteristics vary depending on the main solvent of the electrolytic solution and the kind of the electrolyte.
EXAMPLE 17
[0083] In this example, DMC was replaced by ethyl methyl carbonate (EMC for short hereinafter). A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/EMC (1/2 by volume), 0.1M of An, and 5 vol % of HFE3. The resulting battery was found to have a charging capacity of 920 mAh (up to 4.2 V) and an overcharging capacity of 560 mAh. Therefore, the safety effect (ξ) of the battery was 0.60, which is equal to that of the battery in Example 14 which employs DMC as the solvent. The storage characteristic of the battery was 85%, which is equal to that of the battery which employs DMC as the solvent. This result suggests that EMC is as effective as DMC in safety and storage characteristics.
EXAMPLE 18
[0084] In this example, DMC was replaced by diethyl carbonate (DEC for short hereinafter). A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DEC (1/2 by volume), 0.1M of An, and 5 vol % of HFE3. The resulting battery was found to have a charging capacity of 900 mAh (up to 4.2 V) and an overcharging capacity of 520 mAh. Therefore, the safety effect (ξ) of the battery was 0.58, which is equal to that of the battery in Example 17 which employs EMC as the solvent. The storage characteristic of the battery was 84%, which is slightly inferior to that of the battery which employs DMC or EMC as the solvent but is superior to that of the battery in Example 5. This result suggests that the performance of the battery depends little on the solvent of the electrolytic solution.
EXAMPLE 19
[0085] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 PC (propylene carbonate), 0.1M of An, and 0.5 vol % of HFE3. The resulting battery was found to have a charging capacity of 890 mAh (up to 4.2 V) and an overcharging capacity of 490 mAh. Therefore, the safety effect (ξ) of the battery was 0.55. This result suggests that PC used alone for the electrolytic solution produces a better result than 1M LiPF 6 EC/DMC (1/2 by volume) used in Example 14. The storage characteristic of the battery was 86%, which is better than that of the battery in Example 14.
EXAMPLE 20
[0086] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 GBL (?-butyrolactone), 0.1M of An, and 0.5 vol % of HFE3. The resulting battery was found to have a charging capacity of 870 mAh (up to 4.2 V) and an overcharging capacity of 490 mAh. Therefore, the safety effect (ξ) of the battery was 0.55. This result suggests that the battery in this example which employs GBL alone for the electrolytic solution is superior to that in Example 14. The storage characteristic of the battery was 88%, which is better than that of the battery in Example 14.
EXAMPLE 21
[0087] In this example, the lithium salt was replaced by LiBF 4 . A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiBF 4 PC, 0.1M of An, and 0.5 vol % of HFE3. The resulting battery was found to have a charging capacity of 890 mAh (up to 4.2 V) and an overcharging capacity of 480 mAh. Therefore, the safety effect (ξ) of the battery was 0.54, which is better than that of the battery in Example 19. The storage characteristic of the battery was 87%, which is better than that of the battery in Example 19. This result suggests that in the case of a solvent consisting of PC alone, the electrolytic solution containing LiBF 4 is superior to that containing LiPF 6 .
EXAMPLE 22
[0088] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiBF 4 GBL, 0.1M of An, and 0.5 vol % of HFE3. The resulting battery was found to have a charging capacity of 890 mAh (up to 4.2 V) and an overcharging capacity of 480 mAh. Therefore, the safety effect (ξ) of the battery was 0.54, which is better than that of the battery in Example 19. The storage characteristic of the battery was 87%, which is better than that of the battery in Example 19. This result suggests that in the case of a solvent consisting of PC alone, the electrolytic solution containing LiBF 4 is superior to that containing LiPF 6 .
EXAMPLE 23
[0089] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiBF 4 EC/GBL/PC (1/1/1 by volume), 0.1M of An, and 0.5 vol % of HFE3. The resulting battery was found to have a charging capacity of 910 mAh (up to 4.2 V) and an overcharging capacity of 480 mAh. Therefore, the safety effect (ξ) of the battery was 0.53, which is better than that of the battery in Example 22. The storage characteristic of the battery was 89%, which is better than that of the battery in Example 22. This result suggests that the three-component solvent for the electrolytic solution also improves the safety and storage characteristics.
EXAMPLE 24
[0090] A manganese-based battery was prepared which contains an electrolytic solution consisting of 0.8M LiN(SO 2 CF 2 CF 3 ) (LiBETI for short hereinafter) and 0.2M LiBF 4 dissolved in BGL, 0.1M of An, and 0.5 vol % of HFE3. The resulting battery was found to have a charging capacity of 930 mAh (up to 4.2 V) and an overcharging capacity of 490 mAh. Therefore, the safety effect (ξ) of the battery was 0.53, which is better than that of the battery in Example 23. The storage characteristic of the battery was 87%.
EXAMPLE 25
[0091] A manganese-based battery was prepared which contains an electrolytic solution consisting of 0.2M LiPF 6 and 0.8M LiBF 4 dissolved in BGL, 0.1M of An, and 0.5 vol % of HFE3. The resulting battery was found to have a charging capacity of 940 mAh (up to 4.2 V) and an overcharging capacity of 490 mAh. Therefore, the safety effect (4) of the battery was 0.52, which is better than that of the battery in Example 23. The storage characteristic of the battery was 88%. This result suggests that a mixture of lithium salts tends to increase the charging capacity although its effect of improving the safety and storage characteristics remains almost unchanged.
[0092] The above-mentioned results are summarized in Table 2. As mentioned above, HFE3 as a fluorinated solvent improves the battery safety and storage characteristics more than HFE1 and HFE2. This holds true even when the composition of the electrolytic solution was changed.
TABLE 2 Over- Charging charging Safety Storage Battery type capacity capacity effect character- Example No. Electrolytic solution (mAh) (mAh) (ξ) istic (%) LiMn 2 O 4 / amorphous carbon Example 14 1 M LiPF 6 EC/DMC = 1/2, HFE3 = 5% + An = 0.1 M 900 520 0.58 85 Example 15 1 M LiPF 6 EC/DMC = 1/2, HFE3 = 5% + PhP = 0.1 M 910 570 0.63 86 Example 16 1 M LiPF 6 EC/DMC = 1/2, HFE3 = 5% + EtOB = 0.1 M 920 560 0.61 85 Example 17 1 M LiPF 6 EC/EMC = 1/2, HFE3 = 5% + An = 0.1 M 920 550 0.60 86 Example 18 1 M LiPF 6 EC/DEC = 1/2, HFE3 = 5% + An = 0.1 M 900 520 0.58 84 Example 19 1 M LiPF 6 PC, HFE3 = 0.5% + An = 0.1 M 890 490 0.55 86 Example 20 1 M LiPF 6 GBL, HFE3 = 0.5% + An = 0.1 M 870 490 0.56 88 Example 21 1 M LiBF 4 PC, HFE3 = 0.5% + An = 0.1 M 890 480 0.54 87 Example 22 1 M LiBF 4 GBL, HFE3 = 0.5% + An = 0.1 M 880 470 0.53 88 Example 23 1 M LiBF 4 EC/GBL/PC = 1/5/1, HFE3 = 0.5% + An = 910 480 0.53 89 0.1 M Example 24 0.8 M LiBF 4 0.2 M LiBETI GBL, HFE3 = 0.5% + An = 930 490 0.53 87 0.1 M Example 25 0.8 M LiBF 4 0.2 M LiPF 6 GBL, HFE3 = 0.5% + An = 940 490 0.52 88 0.1 M
EXAMPLE 26
[0093] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of phenyltrimethylsilane (PS1 for short hereinafter), and 5 vol % of HFE3. The resulting battery was found to have a charging capacity of 900 mAh (up to 4.2 V) and an overcharging capacity of 450 mAh. Therefore, the safety effect (ξ) of the battery was 0.50, which is best among all the batteries obtained in the foregoing Examples. The storage characteristic of the battery was 91%, which is best among all the batteries obtained in the foregoing Examples. This result suggests that the silicon compound (with a silyl group) used as the overcharge inhibiting agent greatly improves the battery safety and storage characteristics.
EXAMPLE 27
[0094] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of diphenylmethylsilane (PS2 for short hereinafter), and 5 vol % of HFE3. The resulting battery was found to have a charging capacity of 910 mAh (up to 4.2 V) and an overcharging capacity of 430 mAh. Therefore, the safety effect (ξ) of the battery was 0.47, which is best among all the batteries obtained in the foregoing Examples. The storage characteristic of the battery was 92%, which is best among all the batteries obtained in the foregoing Examples.
EXAMPLE 28
[0095] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of diphenylsilane (PS3 for short hereinafter), and 5 vol % of HFE3. The resulting battery was found to have a charging capacity of 920 mAh (up to 4.2 V) and an overcharging capacity of 430 mAh. Therefore, the safety effect (ξ) of the battery was 0.47, which is equal to that of the battery in Example 27. The battery in this Example has an improved charge capacity. The storage characteristic of the battery was 93%, which is best among all the batteries obtained in the foregoing Examples.
EXAMPLE 29
[0096] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of diphenyldimethoxysilane (PS4 for short hereinafter), and 5 vol % of HFE3. The resulting battery was found to have a charging capacity of 920 mAh (up to 4.2 V) and an overcharging capacity of 420 mAh. Therefore, the safety effect (ξ) of the battery was 0.46, which is best among all the batteries obtained in the foregoing Examples. The storage characteristic of the battery was 93%, which is equal to that of the battery in Example 28.
EXAMPLE 30
[0097] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1M of 4-methoxyphenyltrimethylsilane (PS5 for short hereinafter), and 5 vol % of HFE3. The resulting battery was found to have a charging capacity of 920 mAh (up to 4.2 V) and an overcharging capacity of 410 mAh. Therefore, the safety effect (ξ) of the battery was 0.465, which is best among all the batteries obtained in the foregoing Examples. The storage characteristic of the battery was 93%, which is equal to that of the batteries in Examples 28 and 29.
EXAMPLE 31
[0098] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiBF 4 EC/DMC (1/2 by volume), 0.1M of PS5, and 5 vol % of HFE3. The resulting battery was found to have a charging capacity of 910 mAh (up to 4.2 V) and an overcharging capacity of 390 mAh. Therefore, the safety effect (ξ) of the battery was 0.43, which is best among all the batteries obtained in the foregoing Examples. The storage characteristic of the battery was 93%, which is equal to that of the batteries in Examples 28 to 30. The result remained unchanged even though the lithium salt was replaced by LiBF 4 .
EXAMPLE 32
[0099] A manganese-based battery was prepared which contains an electrolytic solution consisting of 0.8M LiPF 6 0.2M LiBETI EC/DMC (1/2 by volume), 0.1 M of PS5, and 5 vol % of HFE3. The resulting battery was found to have a charging capacity of 920 mAh (up to 4.2 V) and an overcharging capacity of 410 mAh. Therefore, the safety effect (ξ) of the battery was 0.45, which is equal to that of the battery employing a compound having a silyl group. The storage characteristic of the battery was 94%, which is equal to that of the battery in Comparative Example 3.
EXAMPLE 33
[0100] A manganese-based battery was prepared which contains an electrolytic solution consisting of 0.8M LiBF 4 0.2M LiBETI EC/DMC (1/2 by volume), 0.1M of PS5, and 5 vol % of HFE3. The resulting battery was found to have a charging capacity of 930 mAh (up to 4.2 V) and an overcharging capacity of 420 mAh. Therefore, the safety effect (ξ) of the battery was 0.45, which is equal to that of the battery in Example 32 which employs a mixture of lithium salts.
EXAMPLE 34
[0101] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiBF 4 PC, 0.1M of PS5, and 0.5 vol % of HFE3. The resulting battery was found to have a charging capacity of 900 mAh (up to 4.2 V) and an overcharging capacity of 430 mAh. Therefore, the safety effect (ξ) of the battery was 0.48 and the storage characteristic was 92%. This result suggests that even a single solvent greatly improves the battery safety and storage characteristics compared with the battery in Example 21.
EXAMPLE 35
[0102] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiBF 4 GBL, 0.1M of PS5, and 0.5 vol % of HFE3. The resulting battery was found to have a charging capacity of 910 mAh (up to 4.2 V) and an overcharging capacity of 420 mAh. Therefore, the safety effect (ξ) of the battery was 0.46 and the storage characteristic was 92%. The battery in this example is much better in safety and storage characteristic than the battery in Example 22.
EXAMPLE 36
[0103] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiBF 4 EC/PC (1/2 by volume), 0.1M of PS5, and 0.5 vol % of HFE3. The resulting battery was found to have a charging capacity of 910 mAh (up to 4.2 V) and an overcharging capacity of 400 mAh. Therefore, the safety effect (ξ) of the battery was 0.44, which is best among all the batteries obtained in the foregoing Examples. The storage characteristic of the battery was as high as 93%.
EXAMPLE 37
[0104] A manganese-based battery was prepared which contains an electrolytic solution consisting of 1M LiBF 4 EC/GBL/PC (1/1/1 by volume), 0.1M of PS5, and 0.5 vol % of HFE3. The resulting battery was found to have a charging capacity of 920 mAh (up to 4.2 V) and an overcharging capacity of 390 mAh. Therefore, the safety effect (ξ) of the battery was 0.42, which is best among all the batteries obtained in the foregoing Examples. The storage characteristic of the battery was 93%, which also best among all the batteries obtained in the foregoing Examples.
[0105] The above-mentioned results are summarized in Table 3. As mentioned above, the phenylsilane compound as an overcharge inhibiting agent and HFE3 as a fluorinated solvent improve the safety and storage characteristics for lithium secondary batteries varying in the composition of the electrolytic solution.
TABLE 3 Over- Charging charging Safety Storage Battery type capacity capacity effect character- Example No. Electrolytic solution (mAh) (mAh) (ξ) istic (%) LiMn 2 O 4 / amorphous carbon Example 26 1 M LiPF 6 EC/DMC = 1/2, HFE3 = 5% + PS1 = 0.1 M 900 450 0.50 91 Example 27 1 M LiPF 6 EC/DMC = 1/2, HFE3 = 5% + PS2 = 0.1 M 910 430 0.47 92 Example 28 1 M LiPF 6 EC/DMC = 1/2, HFE3 = 5% + PS3 = 0.1 M 920 430 0.47 93 Example 29 1 M LiPF 6 EC/DMC = 1/2, HFE3 = 5% + PS4 = 0.1 M 920 420 0.46 93 Example 30 1 M LiPF 6 EC/DMC = 1/2, HFE3 = 5% + PS5 = 0.1 M 920 410 0.45 93 Example 31 1 M LiBF 4 EC/DMC = 1/2, HFE3 = 5% + PS5 = 0.1 M 910 390 0.43 93 Example 32 0.8 M LiPF 6 0.2 M LiBETI EC/EMC = 1/2, HFE3 = 5% 920 410 0.45 94 + PS5 = 0.1 M Example 33 0.8 M LiBF 4 0.2 M LiBETI EC/EMC = 1/2, HFE3 = 5% 930 420 0.45 94 + PS5 = 0.1 M Example 34 1 M LiBF 4 PC, HFE3 = 0.5% + PS5 = 0.1 M 900 430 0.48 92 Example 35 1 M LiBF 4 GBL, HFE3 = 0.5% + PS5 = 0.1 M 910 420 0.46 94 Example 36 1 M LiBF 4 EC/PC = 1/2, HFE3 = 0.5% + PS5 = 0.1 M 910 400 0.44 93 Example 37 1 M LiBF 4 EC/GBL/PC = 1/5/1, HFE3 = 0.5% + PS5 = 920 390 0.42 94 0.1 M
COMPARATIVE EXAMPLE 5
[0106] A battery of the same shape as in Comparative Example 4 was prepared in which the anode active material is LiNi 0.5 Mn 1.5 O 4 and the cathode active material is graphite carbon and the electrolytic solution is 1M LiPF 6 EC/DMC (1/2 by volume). This battery will be referred to as “5V-class Mn-graphite battery” hereinafter. This battery was charged under the condition of constant current and constant voltage (V 1 ) of 4.9 V. The charging voltage was set at 4.9 V because this battery has a high average discharge voltage. The current at the end of charging was 20 mA. The battery was discharged at a constant current of 1 A until the voltage decreased to 3.7 V. This charging and discharging cycle was repeated twice, and the charging capacity (C 1 ) and the overcharging capacity (C 2 ) were measured. It was found that the charging capacity (C 1 ) is 1100 mAh and the overcharging capacity (C 2 ) is 870 mAh and the safety effect (ξ) is 0.79. The storage characteristic is 89% (evaluated under the same condition as in Comparative Example 4).
EXAMPLE 38
[0107] A 5V-class Mn-graphite battery was prepared which contains an electrolytic solution consisting of 1M LiBF 4 EC/DMC (1/2 by volume), 0.1 M of An, and 5 vol % of HFE1. When evaluated under the same condition as in Comparative Example 5, the resulting battery was found to have a charging capacity of 1110 mAh and an overcharging capacity of 660 mAh. Therefore, the safety effect (ξ) of the battery was 0.6, which is lower by 0.19 than that of the battery in Comparative Example 5. The storage characteristic of the battery was 82%.
EXAMPLE 39
[0108] A 5V-class Mn-graphite battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1 M of An, and 5 vol % of HFE2. When evaluated under the same condition as in Comparative Example 5, the resulting battery was found to have a charging capacity of 1110 mAh and an overcharging capacity of 650 mAh. Therefore, the safety effect (ξ) of the battery was 0.59, which is lower by 0.01 than that of the battery in Example 38. The storage characteristic of the battery was 83%, which is 1% higher than that of the battery in Example 38.
EXAMPLE 40
[0109] A 5V-class Mn-graphite battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1 M of An, and 5 vol % of HFE3. When evaluated under the same condition as in Comparative Example 5, the resulting battery was found to have a charging capacity of 1120 mAh and an overcharging capacity of 630 mAh. Therefore, the safety effect (ξ) of the battery was 0.57, which is lower by 0.02 than that of the battery in Example 39. The storage characteristic of the battery was 85%, which is 2% higher than that of the battery in Example 39.
[0110] As mentioned above, the combined use of fluorinated solvent and overcharge inhibiting agent improves the safety effect and prevents the storage characteristics from decreasing also in the case of 5V-class Mn-graphite battery. In addition, ether-type fluorinated solvents are more effective than ester-type ones also in the case of 5V-class Mn-graphite battery.
EXAMPLE 41
[0111] A 5V-class Mn-graphite battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/GBL (1/2 by volume), 0.1 M of An, and 1 vol % of HFE3. When evaluated under the same condition as in Comparative Example 5, the resulting battery was found to have a charging capacity of 1120 mAh and an overcharging capacity of 580 mAh. Therefore, the safety effect (ξ) of the battery was 0.52, which is lower by 0.05 than that of the battery in Example 40. The storage characteristic of the battery was 86%, which is 1% higher than that of the battery in Example 40. This result suggests that the battery is improved in safety effect and storage characteristic when the solvent for electrolytic solution is switched from DMC to GBL.
EXAMPLE 42
[0112] A 5V-class Mn-graphite battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/GBL (1/2 by volume), 0.1 M of PS1, and 1 vol % of HFE3. When evaluated under the same condition as in Comparative Example 5, the resulting battery was found to have a charging capacity of 1120 mAh and an overcharging capacity of 550 mAh. Therefore, the safety effect (ξ) of the battery was 0.49, which is lower by 0.03 than that of the battery in Example 41. The storage characteristic of the battery was 87%, which is 1% higher than that of the battery in Example 41. This result suggests that PS1 (phenyltrimethylsilane) as the overcharge inhibiting agent contributes to safety and storage characteristic also in the case of 5V-class Mn-graphite battery.
EXAMPLE 43
[0113] A 5V-class Mn-graphite battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/GBL (1/2 by volume), 0.1 M of PS2, and 1 vol % of HFE3. When evaluated under the same condition as in Comparative Example 5, the resulting battery was found to have a charging capacity of 1110 mAh and an overcharging capacity of 510 mAh. Therefore, the safety effect (ξ) of the battery was 0.45, which is lower by 0.03 than that of the battery in Example 42. The storage characteristic of the battery was 88%, which is 1% higher than that of the battery in Example 42.
EXAMPLE 44
[0114] A 5V-class Mn-graphite battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/GBL (1/2 by volume), 0.1 M of PS3, and 1 vol % of HFE3. When evaluated under the same condition as in Comparative Example 5, the resulting battery was found to have a charging capacity of 1110 mAh and an overcharging capacity of 460 mAh. Therefore, the safety effect (ξ) of the battery was 0.41, which is lower by 0.05 than that of the battery in Example 43. The storage characteristic of the battery was 89%, which is equal to that of the battery in Comparative Example 5.
EXAMPLE 45
[0115] A 5V-class Mn-graphite battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/GBL (1/2 by volume), 0.1 M of PS4, and 1 vol % of HFE3. When evaluated under the same condition as in Comparative Example 5, the resulting battery was found to have a charging capacity of 1120 mAh and an overcharging capacity of 450 mAh. Therefore, the safety effect (ξ) of the battery was 0.40, which is lower by 0.01 than that of the battery in Example 44. The storage characteristic of the battery was 89%, which is equal to that of the battery in Comparative Example 5.
EXAMPLE 46
[0116] A 5V-class Mn-graphite battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/GBL (1/2 by volume), 0.1 M of PS5, and 1 vol % of HFE3. When evaluated under the same condition as in Comparative Example 5, the resulting battery was found to have a charging capacity of 1120 mAh and an overcharging capacity of 420 mAh. Therefore, the safety effect (ξ) of the battery was 0.38, which is lower by 0.02 than that of the battery in Example 45. The storage characteristic of the battery was 89%, which is equal to that of the battery in Comparative Example 5.
[0117] It is apparent from the foregoing results that the 5V-class Mn-graphite battery improves in safety and storage characteristic when PS1 (as the overcharge inhibiting agent) is replaced by any of PS2 (diphenylmethylsilane), PS3 (diphenylsilane), PS4 (diphenyldimethoxysilane), and PS5 (4-methoxyphenyltrimethylsilane).
TABLE 4 Over- Charging charging Safety Storage Battery type capacity capacity effect character- Example No. Electrolytic solution (mAh) (mAh) (ξ) istic (%) LiNi 0.5 Mn 15 O 4 /graphte carbon Comparative 1 M LiPF 6 EC/DMC = 1/2 1100 870 0.79 89 Example 5 Example 38 1 M LiPF 6 EC/DMC = 1/2, HFE1 = 5% + An = 0.1 M 1110 660 0.60 82 Example 39 1 M LiPF 6 EC/DMC = 1/2, HFE2 = 5% + An = 0.1 M 1110 650 0.59 83 Example 40 1 M LiPF 6 EC/DMC = 1/2, HFE3 = 5% + An = 0.1 M 1120 630 0.57 85 Example 41 1 M LiPF 6 EC/GBL = 1/2, HFE3 = 1% + An = 0.1 M 1120 580 0.52 86 Example 42 1 M LiPF 6 EC/GBL = 1/2, HFE3 = 1% + PS1 = 0.1 M 1120 550 0.49 87 Example 43 1 M LiPF 6 EC/GBL = 1/2, HFE3 = 1% + PS2 = 0.1 M 1110 510 0.46 88 Example 44 1 M LiPF 6 EC/GBL = 1/2, HFE3 = 1% + PS3 = 0.1 M 1100 460 0.41 89 Example 45 1 M LiPF 6 EC/GBL = 1/2, HFE3 = 1% + PS4 = 0.1 M 1120 450 0.40 89 Example 46 1 M LiPF 6 EC/GBL = 1/2, HFE3 = 1% + PS5 = 0.1 M 1120 420 0.38 89
COMPARATIVE EXAMPLE 6
[0118] A battery of the same shape as in Comparative Example 4 was prepared in which the anode active material is LiNi 0.5 Mn 1.5 O 4 and the cathode active material is amorphous carbon and the electrolytic solution is 1M LiPF 6 EC/DMC (1/2 by volume). This battery will be referred to as “5V-class Mn-amorphous battery” hereinafter. This battery was charged under the condition of constant current and constant voltage (V 1 ) of 4.9 V. The charging voltage was set at 4.9 V because this battery has a high average discharge voltage. The current at the end of charging was 20 mA. The battery was discharged at a constant current of 1 A until the voltage decreased to 3.7 V. This charging and discharging cycle was repeated twice, and the charging capacity (C 1 ) and the overcharging capacity (C 2 ) were measured. It was found that the charging capacity (C 1 ) is 940 mAh and the overcharging capacity (C 2 ) is 890 mAh and the safety effect (ξ) is 0.95. The storage characteristic is 87% (evaluated under the same condition as in Comparative Example 5).
EXAMPLE 47
[0119] A 5V-class Mn-amorphous battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1 M of An, and 5 vol % of HFE1. When evaluated under the same condition as in Comparative Example 6, the resulting battery was found to have a charging capacity of 950 mAh and an overcharging capacity of 660 mAh. Therefore, the safety effect (ξ) of the battery was 0.69, which is lower by 0.26 than that of the battery in Comparative Example 6. The storage characteristic of the battery was 81%.
EXAMPLE 48
[0120] A 5V-class Mn-amorphous battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1 M of An, and 5 vol % of HFE2. When evaluated under the same condition as in Comparative Example 6, the resulting battery was found to have a charging capacity of 960 mAh and an overcharging capacity of 650 mAh. Therefore, the safety effect (4) of the battery was 0.67, which is lower by 0.02 than that of the battery in Example 47. The storage characteristic of the battery was 82%, which is higher by 1% than that of the battery in Example 47.
EXAMPLE 49
[0121] A 5V-class Mn-amorphous battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/DMC (1/2 by volume), 0.1 M of An, and 5 vol % of HFE3. When evaluated under the same condition as in Comparative Example 6, the resulting battery was found to have a charging capacity of 960 mAh and an overcharging capacity of 630 mAh. Therefore, the safety effect (ξ) of the battery was 0.66, which is lower by 0.01 than that of the battery in Example 48. The storage characteristic of the battery was 84%, which is higher by 2% than that of the battery in Example 48.
[0122] As mentioned above, the combined use of fluorinated solvent and overcharge inhibiting agent improves the safety effect and prevents the storage characteristics from decreasing also in the case of 5V-class Mn-amorphous battery. In addition, ether-type fluorinated solvents are more effective than ester-type ones also in the case of 5V-class Mn-amorphous battery.
EXAMPLE 50
[0123] A 5V-class Mn-amorphous battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/PC (1/2 by volume), 0.1 M of An, and 0.5 vol % of HFE3. When evaluated under the same condition as in Comparative Example 6, the resulting battery was found to have a charging capacity of 940 mAh and an overcharging capacity of 560 mAh. Therefore, the safety effect (ξ) of the battery was 0.60, which is lower by 0.06 than that of the battery in Example 49. The storage characteristic of the battery was 85%, which is higher by 1% than that of the battery in Example 49. This result suggests that the battery improves in safety and storage characteristic when the solvent for electrolytic solution is switched from DMC to PC.
EXAMPLE 51
[0124] A 5V-class Mn-amorphous battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/PC (1/2 by volume), 0.1 M of PS1, and 0.5 vol % of HFE3. When evaluated under the same condition as in Comparative Example 6, the resulting battery was found to have a charging capacity of 950 mAh and an overcharging capacity of 520 mAh. Therefore, the safety effect (ξ) of the battery was 0.55, which is lower by 0.05 than that of the battery in Example 50. The storage characteristic of the battery was 87%, which is higher by 2% than that of the battery in Example 50. This result suggests that the battery improves in safety and storage characteristic when phenylsilane is used as the overcharge inhibiting agent.
EXAMPLE 52
[0125] A 5V-class Mn-amorphous battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/PC (1/2 by volume), 0.1 M of PS2, and 0.5 vol % of HFE3. When evaluated under the same condition as in Comparative Example 6, the resulting battery was found to have a charging capacity of 950 mAh and an overcharging capacity of 490 mAh. Therefore, the safety effect (ξ) of the battery was 0.52, which is lower by 0.03 than that of the battery in Example 51. The storage characteristic of the battery was 88%, which is higher by 1% than that of the battery in Example 51.
EXAMPLE 53
[0126] A 5V-class Mn-amorphous battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/PC (1/2 by volume), 0.1 M of PS3, and 0.5 vol % of HFE3. When evaluated under the same condition as in Comparative Example 6, the resulting battery was found to have a charging capacity of 940 mAh and an overcharging capacity of 470 mAh. Therefore, the safety effect (ξ) of the battery was 0.50, which is lower by 0.02 than that of the battery in Example 52. The storage characteristic of the battery was 88%.
EXAMPLE 54
[0127] A 5V-class Mn-amorphous battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/PC (1/2 by volume), 0.1 M of PS4, and 0.5 vol % of HFE3. When evaluated under the same condition as in Comparative Example 6, the resulting battery was found to have a charging capacity of 950 mAh and an overcharging capacity of 430 mAh. Therefore, the safety effect (ξ) of the battery was 0.45, which is lower by 0.05 than that of the battery in Example 53. The storage characteristic of the battery was 88%.
EXAMPLE 55
[0128] A 5V-class Mn-amorphous battery was prepared which contains an electrolytic solution consisting of 1M LiPF 6 EC/PC (1/2 by volume), 0.1 M of PS5, and 0.5 vol % of HFE3. When evaluated under the same condition as in Comparative Example 6, the resulting battery was found to have a charging capacity of 1120 mAh and an overcharging capacity of 420 mAh. Therefore, the safety effect (ξ) of the battery was 0.44, which is lower by 0.01 than that of the battery in Example 54. The storage characteristic of the battery was 88%.
[0129] It is apparent from the foregoing results that the 5V-class Mn-amorphous battery improves in safety and storage characteristic when PS1 (as the overcharge inhibiting agent) is replaced by any of PS2 (diphenylmethylsilane), PS3 (diphenylsilane), PS4 (diphenyldimethoxysilane), and PS5 (4-methoxyphenyltrimethylsilane).
TABLE 5 Over- Charging charging Safety Storage Battery type capacity capacity effect character- Example No. Electrolytic solution (mAh) (mAh) (ξ) istic (%) LiNi 0.5 Mn 15 O 4 / amorphous carbon Comparative 1 M LiPF 6 EC/DMC = 1/2 940 890 0.95 87 Example 6 Example 47 1 M LiPF 6 EC/DMC = 1/2, HFE1 = 5% + An = 0.1 M 950 660 0.69 81 Example 48 1 M LiPF 6 EC/DMC = 1/2, HFE2 = 5% + An = 0.1 M 960 650 0.67 82 Example 49 1 M LiPF 6 EC/DMC = 1/2, HFE3 = 5% + An = 0.1 M 930 630 0.68 84 Example 50 1 M LiPF 6 EC/PC = 1/2, HFE3 = 0.5% + An = 0.1 M 940 560 0.60 85 Example 51 1 M LiPF 6 EC/PC = 1/2, HFE3 = 0.5% + PS1 = 0.1 M 950 520 0.55 87 Example 52 1 M LiPF 6 EC/PC = 1/2, HFE3 = 0.5% + PS2 = 0.1 M 950 490 0.52 88 Example 53 1 M LiPF 6 EC/PC = 1/2, HFE3 = 0.5% + PS3 = 0.1 M 940 470 0.50 88 Example 54 1 M LiPF 6 EC/PC = 1/2, HFE3 = 0.5% + PS4 = 0.1 M 950 430 0.45 88 Example 55 1 M LiPF 6 EC/PC = 1/2, HFE3 = 0.5% + PS5 = 0.1 M 940 410 0.44 88
[0130] It has been demonstrated by Examples in the foregoing that the combined use of an overcharge inhibiting agent and a fluorinated solvent protects the lithium secondary battery from overcharging. (The fluorinated solvent enhances the action of the overcharge inhibiting agent and prevents the adverse effect of the fluorinated solvent on the storage characteristics.) The lithium secondary battery according to the present invention has a lower overcharge current than the conventional one by more than 20%. Therefore, it can be increased in capacity with safety. The first commercialized lithium secondary battery had a capacity of 1000 mAh; the capacity has increased to 2000 mAh since then. The increase in capacity is accompanied by danger. Assuming a safety effect of 0.9, the battery with a capacity of 1000 mAh has an energy of 17.1 kJ if overcharged up to 5V, whereas the battery with a capacity of 2000 mAh has an energy of 34.2 kJ if overcharged up to 5V. In other words, the latter battery has twice as much energy as the former battery. By contrast, the battery according to the present invention has a safety effect of, say, 0.6 and hence it has an energy of 28.8 kJ in its overcharged state even though it has a capacity of 2000 mAh. The magnitude of this energy is 1.68 times that of the battery with a capacity of 1000 mAh. In other words, if the safety effect is set at 0.6, the battery with an overcharge capacity of 2400 mAh will have the same energy of the conventional battery with an overcharge capacity of 2000 mAh which has a safety effect of 0.9. Thus according to the present invention, it is possible to increase the capacity of lithium batteries without impairing safety. Also, the present invention can be utilized in any electrical appliance as well. Note, an electrical appliance is defined to include any electrical object capable of utilizing a lithium secondary battery.
[0131] Although the invention has been described above in connection with exemplary embodiments, it is apparent that many modifications and substitutions can be made without departing from the spirit or scope of the invention. Accordingly, the invention is not to be considered as limited by the foregoing description, but is only limited by the scope of the appended claims.
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The present invention provides a lithium secondary battery comprising a nonaqueous electrolytic solution containing a compound which is oxidized at a voltage higher than a charge end voltage of the lithium secondary battery and a compound which inhibits reactions at voltages lower than said charge end voltage.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to methods and apparatus for high density magnetic tape recording and playback, and more particularly to methods and apparatus for high density magnetic tape recording and playback by means of a plurality of pairs of ferromagnetic laminations, each pair together defining a transducing gap and a larger gap, in which said larger gaps are successively scanned by one or more low reluctance bridging members, and thus fringing fluxes corresponding to successive elements of a video signal are produced in successive ones of said transducing gaps.
2. Description of the Prior Art
Methods and apparatus for high density video magnetic recording and playback are known in the prior art. For instance, it has been proposed to record video signals laterally rather than longitudinally of magnetic recording tape (see U.S. Pat. No. 2,517,808, issued to George C. Sziklai on Aug. 8, 1950). Such methods and apparatus have taken many forms, such as transducing heads rotating laterally, helically, etc., in relation to the longitudinal axis of the magnetic recording tape. In each of these cases, however, a high relative speed between the transducing head or heads and the magnetic recording tape is required, and this high relative speed causes excessive wear both of the tape and the transducing head. In particular, such head wear occurs in the area of the head gap, thus reducing the resolution of the recording and playback system. A high speed video tape recording system has been proposed in which a rotating bridging member bridges successive gaps in a corresponding plurality of magnetic circuits, each containing one transducing gap of a linear array of transducing gaps, whereby to transversely scan an associated magnetic recording tape and record thereupon, or read therefrom, successive signals corresponding to successive elements of a video signal (see U.S. Pat. No. 3,236,942). However, the minimum cross-sectional area of each of the several magnetic circuits of this prior art device is so small as to seriously limit the intensity of the dipoles which can be recorded upon the magnetic tape. Also, in this prior art device the magnetic recording tape must intersect all of said magnetic circuits, making recording from one side of the tape in accordance with the conventional practice impossible.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide methods and apparatus for high density magnetic recording and playback wherein tape wear and head wear are substantially reduced, by utilizing a stationary, laminated transducing head assembly.
Another object of the present invention is to provide methods and apparatus for high density magnetic recording and playback in which a plurality of magnetic circuits containing recording gaps are successively closed by mechanically moved low reluctance bridging means, and in which at the same time recording is done from one side of the tape only.
A further object of the present invention is to provide methods and apparatus for high density magnetic recording and playback by reluctance scanning in which the effects of cross-talk between adjacent magnetic circuits is reduced.
Other objects of the present invention will in part be obvious and will in part appear hereinafter.
The present invention, accordingly, comprises the several steps and the relation of one or more such steps with respect to each of the others, and the apparatus embodying features of construction, combinations of elements, and arrangements of parts which are adapted to effect such steps, all as exemplified in the following disclosure, and the scope of the present invention will be indicated in the appended claims.
In accordance with a principal feature of the present invention magnetic transducing heads are disclosed which comprise two cooperating stacks of ferromagnetic laminations, each lamination in one stack being paired with a lamination in the other stack to define a transducing gap and a larger gap.
In accordance with another principal feature of the present invention said transducing gaps are disposed in a rectilinear array, and the associated magnetic recording tape is moved past said array of transducing gaps, closely adjacent thereto, said array being disposed substantially transverse to the major longitudinal dimension of the magnetic recording tape.
In accordance with yet another principal feature of the present inventin said larger gaps lie in a common cylindrical surface, and a rotor is provided whereby one or more low reluctance bridging elements are moved repeatedly in the same direction past successive ones of said larger gaps, whereby to make if possible for current in an exciting coil linked with all of said magnetic circuits to produce recording fringing flux in successive ones of said transducing gaps.
For a fuller understanding of the nature and objects of the present invention, reference should be had to the following detailed description, taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the laminated pole structure of a magnetic transducing head embodying the present invention;
FIG. 2 is a vertical sectional view of a magnetic transducing head embodying the present invention taken on line 2--2 of FIG. 3;
FIG. 3 is a vertical sectional view of a magnetic transducing head embodying the present invention taken on line 3--3 of FIG. 2;
FIG. 4 illustrates one of the low reluctance bridging members of the embodiment of the present invention illustrated in FIGS. 2 and 3;
FIG. 5 is a partial sectional view of the rotor of the magnetic transducing head of a second embodiment of the present invention; and
FIG. 6 is a fragmentary view in section of the rotor of the magnetic transducing head of a third embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, there is shown the pole structure 10 of a magnetic transducing head embodying the present invention. Pole structure 10 consists of a plurality of pairs 12, 14, 16, etc., of ferromagnetic laminations. As best seen in FIG. 1, lamination pair 12 consists of a first lamination 12A and second lamination 12B; lamination pair 14 consists of a first lamination 14A and a second lamination 14B; lamination pair 16 consists of a first lamination 16A and a second lamination 16B; etc. By way of example only, the laminations of pole structure 10 may be 0.004 inches thick.
The lamination of pole structure 10 are maintained in the juxtaposition shown in FIG. 1 by conventional means (not shown) which are not part to the present invention.
Each pair of laminations shown in FIG. 1 defines, at the point of closest spacing between the laminations of the pair, a transducing gap. Thus, the laminations 12A and 12B of FIG. 1 define between the adjacent ends of their lower edges a transducing gap 12C. Similarly, the laminations 14A and 14B define between adjacent ends of their lower edges, as seen in FIG. 1, a transducing gap 14C; the laminations 16A and 16B define between the adjacent ends of their lower edges, as seen in FIG. 1, a transducing gap 16C; etc.
It will thus be understood by those having ordinary skill in the art, informed by the present disclosure, that the two stacks of laminations making up the pole structure 10 of FIG. 1 define between them a rectilinear array of closely juxtaposed transducing gaps 12C, 14C, 16C, etc.; the number of transducing gaps in said rectilinear array being equal to the number of pairs of laminations.
For clarity of description, the frontmost stack of laminations shown in FIG. 1, i.e., 12A, 14A, 16A, etc., will be designated by the reference numeral 18 herein; and the rearmost stack of laminations shown in FIG. 1, i.e., 12B, 14B, 16B, etc., will be designated by the reference numeral 20 herein. When, for example, it is desired to record on quarter inch magnetic tape, each stack 18, 20 will typically comprise 60 laminations.
Further, the rectilinear array of transducing gaps 12C, 14C, 16C, etc., described hereinabove, will sometime be referred to herein by the reference numeral 22.
As further shown in FIG. 1, the upper ends of all of the "A" laminations, i.e., the laminations of stack 18, are so located and configured as to lie in a common cylindrical surface 24. The cylindrical upper surface of lamination stack 18, i.e., the upper surfaces of the "A" laminations taken collectively, will sometimes be designated herein by the reference numeral 24A. The axis of the common cylindrical surface 24 will be designated herein by the reference numeral 24B.
As also shown in FIG. 1, the upper ends of all of the "B" laminations, i.e., the laminations of stack 20, are so located and configured as to lie in said common cylindrical surface 24. The cylindrical upper surface of lamination stack 20, i.e., the upper surfaces of the "B" laminations taken collectively, will sometines be designated herein by the reference numeral 24C.
Referring now to FIGS. 2 and 3, there is shown a magnetic transducing head 28 constructed in accordance with a first preferred embodiment of the present invention. Magnetic transducing head 28 comprises a pole structure 10 of the kind shown in FIG. 1 and described hereinabove. The parts of a pole structure 10 are referred to throughout the present specification by the same reference numerals used to designate those parts in FIG. 1. Thus, it will be seen that the rightmost lamination shown in FIG. 2 is lamination 12A of FIG. 1; the only stack of laminations shown in FIG. 2 is stack 18 of FIG. 1; etc. Similarly, while both of the stacks of laminations 18, 20 of the magnetic transducing head 10 of FIG. 1 are shown in FIG. 3, only two laminations are shown, viz., 12A and 12B, one from each stack.
As may be seen by comparisons of FIGS. 2 ad 3, a cylindrical rotor 30 is positioned above pole structure 10 in such manner that the cylindrical surface of rotor 30 is uniformly spaced from the cylindrical upper surface 24A of lamination stack 18, and from the cylindrical upper surface 24C of lamination stack 20, respectively, by very small gaps 32 and 32' (FIG. 2).
The main body 34 of rotor 30 is formed from nonmagnetic material. Main body 34 is irrotatably affixed to a shaft 36 for conjoint rotation therewith. Shaft 36 is journalled in a pair of bearings 38, 40 (FIG. 3) so that shaft 36 is coaxial with the common cylindrical surface 24 (FIG. 1) in which said cylindrical upper surfaces 24A and 24B lie, whereby the width of said gaps 32, 32' is maintained.
As may also be seen from FIG. 3, bearings 38 and 40 are fixedly positioned with respect to pole structure 10 by means of arms 42, 44, which are themselves affixed to pole structure 10 by means of mounting pads 46, 48. Arms 42 and 44 are joined together for additional rigidity by means of side frame members 50, 52. Arms 40, 42, side frame members 50, 52, and mounting pads 46, 48 in particular, will preferably be formed from non-magnetic material. Mounting pads 46 and 48 are affixed to lamination stacks 18 and 20, respectively, by means well-known to those having ordinary skill in the art.
As may also be seen by comparison of FIGS. 2 and 3, a low reluctance bridging member 54 (FIG. 4) is mounted in rotor 30. Bridging member 54 is so disposed in rotor 30 that it lies in a plane containing the axis of shaft 36, and that the outer ends 56, 58 (FIG. 4) of the two ears projecting from its main body portion are flush with the cylindrical surface of rotor 30.
As best seen in FIG. 2, three other low reluctance bridging members 60, 62, 64 are also mounted in rotor 30 and the four bridging members 54, 60, 62 and 64 are also mounted in rotor 30, and the four bridging members 54, 60, 62, 64 are equiangularly disposed about the axis of shaft 36. Bridging members 60, 62, 64 are substantially ientical to bridging member 54. All of the bridging members 60, 62, 64 are so disposed in rotor 30 as to contain a plane which itself contains the axis of shaft 36. Each of the bridging members 60, 62, 64 has a pair of tips or edge portions corresponding to tips or edge portions 56, 58 of bridging member 54, and the tips or edge portions of each bridging member 60, 62, 64 are flush with the cylindrical surface of rotor 30.
As best seen in FIG. 2, each of the bridging members 54, 60, 62, 64 is substantially equal in thickness to the ferromagnetic laminations 12A, 14A, 16A, etc., 12B, 14B, 16B, etc., of pole structure 10.
Thus, it will be seen that when rotor 30 is rotated, as by a motor 66 (FIG. 3), each bridging member is swept past the lamination pairs 12, 14, 16, etc., in succession, momentarily bridging the gap between the upper ends of the two laminations of each successive pair. Thus, bridging member 54 magnetically bridges the upper ends of each pair of laminations in pole structure 10 during the rotation of rotor 30 through 90 degrees, bridging member 60 then successively bridges the upper ends of each pair of laminations in pole structure 10 during the next 90 degress of rotation of rotor 30, etc.
It follows, then, that in the magnetic transducing head of FIGS. 2 and 3 the gaps between the upper ends of the pairs of laminations 12, 14, 16 etc., are successively bridged, in the same order, four times during each rotation of rotor 30.
Again comparing FIGS. 2 and 3, it will be seen that an exciting winding 68 surrounds all of the laminations of stack 18. Thus, it will be understood that when an exciting current, modulated for magnetic recording in the well-known manner, is passed through exciting winding 68, recording fringing flux will be produced in the transducing gap 12C if and only if the upper ends of laminations 12A and 12B are at that time bridged by one of the bridging members 54, 60, 62, 64. Similarly, exciting current in exciting winding 68 will induce recording fringing flux in transducing gap 14C if and only if one of the bridging members is bridging the upper ends of laminations 14A and 14B; exciting current in exciting winding 68 will induce recording fringing flux in transducing gap 16C if and only if one of the bridging members is bridging the gap between the upper ends of laminations 16A and 16B; etc.
Again comparing FIGS. 2 and 3 it will be seen that, in accordance with the principles of the present invention, a magnetic recording tape 70 is moved past magnetic transducing head 28 in the direction shown by arrow 72 (FIG. 3), the transverse dimension of tape 70 being maintained in registration with pole structure 10. Thus, it will be seen that during the motion of tape 70 past magnetic transducing head 30 to abovesaid rectilinear array 22 of transducing gaps is maintained transverse to magnetic recording tape 70, and extends substantially from edge to edge of magnetic tape 70.
It follows that if the speed of rotation of rotor 30 in the direction indicated by arrow 74 (FIG. 2) is synchronized with the rate of movement of recording tape 70 past rectilinear array 22 a signal applied to exciting winding 68 by way of current modulated in known manner for magnetic recording will be digitally recorded upon magnetic recording tape 70 in the form of successive linear arrays of magnetic dipoles, sometimes called "tracks", corresponding in strength to the mean amplitude of successive increments of the signal to be recorded. As will also be evident to those having ordinary skill in the art, informed by the present disclosure, these successive, closely spaced linear arrays of magnetic dipoles recorded on recording tape 70 will be substantially perpendicular to the edges of tape 70, i.e., make a very small angle therewith, when the speed of rotation of rotor 30 is high and at the same time the rate of advance of recording tape 70 is relatively low.
The provision of means for synchronizing the speed of advance of recording tape 70 with the speed of rotation of rotor 30 being well within the scope of those having ordinary skill in the art, such synchronizing means are not disclosed in detail herein. As an example only, direct current motor 66 may be synchronized with the operation of the tape transport mechanism (not shown) by means of a Motorola MC3302 Quad Comparator integrated circuit, designed to control small direct current motors by pulse width modulation, as shown and described in Motorola Application Note AN705; which comparator, referred to herein by the reference numeral 76, is supplied with error feedback signals by a suitable photoelectric shaft position encoder 78 over signal lines 80, 82; shaft position encoder 78 being irrotatably affixed to shaft 36 for conjoint rotation therewith. Comparator 76 will also be supplied with synchronizing signals for the tape transport mechanism by means of signal lines 84 and 86.
Alternatively, the synchronization of the rate of movement of recording tape 70 past magnetic transducing head 28 with the speed of rotation of rotor 30 may be accomplished by purely mechanical gearing means such as can be supplied by those having ordinary skill in the art without the exercise of invention.
Typically, in using the magnetic recording head of the present invention to record standard television signals on standard 2 inch recording tape the speed of movement of recording tape 70 past transducing head 28 may be 2 inches per second; in which case the speed of rotation of rotor 30 will be so selected as to record each raster line in 4 or 5 of said linear arrays of magnetic dipoles (or tracks) on recording tape 70.
Referring now to FIG. 5, there is shown an alternative mode of providing various degrees of magnetization of lamination pairs 12, 14, 16, etc., whereby to successively produce fringing fluxes of different intensities at recording gaps 12C, 14C, 16C, etc., and thus to successively produce corresponding dipoles in magnetic recording tape 70 in the abovesaid linear arrays or tracks.
In accordance with this first alternative mode of recording flux production, which is employed in at least two preferred embodiments of the present invention, exciting winding 68 is eliminated from the embodiment of FIGS. 2 and 3 and rotor 30 of FIGS. 2 and 3 is replaced by rotor 90, as shown in FIG. 5. With these exceptions, i.e., the elimination of exciting winding 68 and the replacement of rotor 30 with rotor 90, the parts of the magnetic transducing head 92 of the now to be described second preferred embodiment are substantially identical with the corresponding parts of the transducing head 28 of the first preferred embodiment (FIGS. 2 and 3), and all such like parts, as between the first preferred embodiment and the second preferred embodiment, will be referred to by the same reference numerals. Thus, the pole structure of the second preferred embodiment is substantially identical to the pole structure 10 of the first preferred embodiment (FIGS. 2 and 3), and will also be referred to by the reference numeral 10. Similarly, the rotor shaft of the second preferred embodiment is substantially identical to the rotor shaft 36 of the first preferred embodiment, and will also be designated by the reference numeral 36.
Referring particularly now to FIG. 5, it will be seen that rotor 90 comprises a cylindrical body 94 of insulating material. Rotor body 94 may be formed from the same insulating material as rotor body 34 of the first preferred embodiment, and will be of the same dimensions as rotor body 34.
Mounted in rotor body 94 are four low reluctance bridging members 96, 98, 100, 102 (only two shown). Bridging members 96, 98, 100, 102 are substantially identical to bridging member 54 of FIG. 4, and are equiangularly spaced about the axis of rotor 94 in the same manner in which bridging members 54, 60, 62, 64 are equiangularly spaced about the axis of rotor 30 of the first preferred embodiment. Similarly, the tips of bridging members 96, 98, 100, 102 are flush with the cylindrical surface of rotor 90, as the tips of bridging members 54, 60, 62, 64 are flush with the cylindrical surface of rotor 30. Thus, the tips 104, 106 of bridging member 98 can be seen in FIG. 5 to be flush with the surface of rotor 90.
Referring now to the lower portion of rotor 90 as shown in FIG. 5, in which a portion of rotor 90 is broken away to reveal bridging member 96, it will be seen that the narrow central portion of bridging member 96 is surrounded by a coil 108 of insulation-covered wire. As also there seen, coil 108 is provided with two leads 110, 112.
It is to be understood that in said second preferred embodiment each one of the other three equiangularly disposed bridging members 98, 100, 102 is provided with a winding corresponding to winding 108, and that each of these windings is provided with a pair of leads corresponding to leads 110 and 112.
As also seen in FIG. 5, the leads 110, 112 of winding 108 pass along shaft 36 and through bearing 38. Similarly, each pair of leads associated with one of the windings surrounding the narrow portion of one of the other bridging members 98, 100, 102 passes out of rotor 90, along shaft 36, and through bearing 38.
Affixed to the outer end of shaft 36 for conjoint rotation with rotor 90 is a commutating drum 116. Commutating drum 116 is formed from insulating material and bears on its face a plurality of conducting segments 118, 120, 122, 124, 126, 128, 130, 132, segments 126 and 128 are not being shown in FIG. 5. As seen in FIG. 5, leads 110 and 112 are connected, respectively, to segments 118 and 120 on the face of commutator drum 116. Similarly, the leads of the winding surrounding the narrow central portion of bridging member 98 are connected to conductive segments 122, 124 of commutator drum 116; the leads of the coil surrounding the narrow central portion of bridging member 100 are connected to the conductive segments 126 and 138 of commutator drum 116; etc.
As also shown in FIG. 5, a pair of brushes 134, 136, of well-known type, coact with commutator drum 116 in the well-known manner, brush 134 successively contacting segments 118, 122, etc., as shaft 36 rotates, and brush 136 successively contacting segments 120, 124, etc., as shaft 36 rotates. Brushes 134 and 136 are provided with leads 138 and 140, respectively.
As will now be evident to those having ordinary skill in the art, informed by the present disclosure, the commutation arrangement comprising commutator drum 116, brushes 134 and 136, etc., serves to pass a recording current from the recording current source connected to leads 138 and 140 to only one at a time of the windings 108, etc., surrounding the bridging members 96, 98, 100, 102, respectively, and to thus direct the recording current only to the one of these windings whose associated bridging member is scanning the lamination pairs 12, 14, 16, etc., of pole structure 10. Thus, it will be seen that these windings subserve the same function as winding 68 of the preferred embodiment.
Going now to FIG. 6, there is shown in part only a rotor 142 which is generally similar to rotor 90 of FIG. 5 but incorporates an additional feature of the present invention whereby the effect of crosstalk between adjacent ones of the lamination pairs of pole structure 10 is substantially reduced.
In rotor 142, as seen in FIG. 6, the central bridging member 144 is substantially identical in structure and function to bridging member 96 of rotor 90, and winding 148 is substantially identical in structure and function to winding 108 of rotor 90.
According to this additional feature of the present invention, a pair of additional bridging members 150, 152 are mounted in rotor 142 at the angle shown in FIG. 6, the tips of bridging members 150 and 152 lying very closely adjacent the tips of bridging member 144 and in the cylindrical surface of rotor 142.
As also seen in FIG. 6, the tips of bridging members 150 and 152 register with the pole structure laminations 154 and 156, which themselves lie on opposite sides of the pole structure lamination 158 shown in registration with bridging member 144.
As also seen in FIG. 6, auxiliary lamination 150 is provided with a winding 160 and auxiliary lamination 152 is provided with a winding 162. In accordance with this additional feature of the present invention, the crosstalk compensating windings 160 and 162 are wound or connected to winding 148 in such manner as to buck the effect of crosstalk from adjacent signal elements on the recording tape. This bucking effect may be compensated by proper shunting of windings 160 and 162, if those windings are connected in series, or may be adjusted by the interposition of series resistors 170, 172 if windings 160 and 162 are connected in parallel. Alternatively, the bucking effect may be adjusted by the proportioning of the number of turns in recording current winding 148 as against the numbers of turns in crosstalk compensating windings 160 and 162.
As will be evident to those having ordinary skill in the art, informed by the present disclosure, each of the other three bridging members of rotor 142 will be provided with additional bridging members and bucking windings corresponding to additional members 150, 152 and bucking windings 160, 162.
It is to be understood that the crosstalk compensating means shown in FIG. 6 and described in connection therewith may be incorporated in either the first preferred embodiment hereinabove described or the second preferred embodiment hereinabove described. The combination of the first preferred embodiment hereinabove described and the crosstalk compensating means of FIG. 6 is regarded herein as a third preferred embodiment of the present invention, and the combination of the second preferred embodiment hereinabove described with the crosstalk compensating means of FIG. 6 is regarded herein as a fourth preferred embodiment of the present invention.
It will thus be seen that the objects set forth above, among those made apparent from the preceeding description, are efficiently attained, and since certain changes may be made in the above constructions and the method carried out thereby without departing from the scope of the present invention it is intended that all matter contained in the above description or shown in the accompanying drawing shall be interpreted as illustrative only, and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
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Magnetic transducing heads are disclosed which include two stacks of ferromagnetic laminations. Each lamination in one stack is paired with a lamination in the other stack. At their closest point each pair of laminations defines a transducing gap. The stacks are so positioned that the transducing gaps form a linear array. The tops of the two stacks of laminations are so configured as to lie in a common cylindrical surface, the axis of the common cylindrical surface being perpendicular to the rectilinear array of transducing gaps, though not intersecting it. A cylindrical rotor is rotatably mounted so that its surface is very close to the cylindrical top surfaces of the two stacks. Four low reluctance bridging elements are mounted in the rotor and at or near its cylindrical surface. An exciting winding surrounds one stack of laminations. The method of the invention is carried out by rotating the rotor in synchronism with the movement of magnetic recording tape past the linear array of transducing gaps while passing recording current through the exciting winding, thus repeatedly positioning low reluctance bridging members across successive ones of the gaps between the tops of pairs of laminations in the same order, thereby repeatedly "switching on" the recording flux in successive ones of the transducing gaps in the same order.
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[0001] This Application claims the benefit of the filing date under 35 U.S.C. §119(e) of U.S. Provisional Application No. 61/832,599, filed on Jun. 7, 2013, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to the field of beverage dispensers, and more particularly to a modular valve assembly in which an array of valve modules are connected to a manifold for dispensing multiple different beverages through a single nozzle dispense point.
[0004] 2. Summary of the Invention
[0005] The present invention relates to a valve assembly for dispensing multiple beverages through a single nozzle dispense point. One aspect of the invention recognizes the need for a modular valve assembly that can easily be expanded to allow more types of beverages to be dispensed. A valve module has multiple fluid pathways and a flow control and shut-off component for controlling the flow of fluid through each pathway. A manifold is configured to receive at least one valve module, but may also be configured to receive multiple valve modules. Valve modules can easily be added to the manifold to expand the dispensing capacity of the valve assembly. The manifold also contains pathways for directing the fluid to a diffuser, which releases the fluid into a single nozzle dispense point.
DESCRIPTION OF THE FIGURES
[0006] FIG. 1 is a side perspective view of a valve module having two fluid pathways.
[0007] FIG. 2 is a top perspective view of a manifold.
[0008] FIG. 3 is a side perspective of a valve module, manifold, and nozzle connected to each other.
[0009] FIG. 4 shows a seal, syrup tips, diffuser and nozzle.
[0010] FIG. 5 shows an array of valve modules positioned within a housing.
DETAILED DESCRIPTION OF THE INVENTION
[0011] Referring now to the drawings, FIGS. 1-5 show an embodiment of the valve assembly. The valve assembly 50 , as in FIG. 5 , uses one or more valve modules 10 , as seen for example in FIG. 1 , to create an expandable array of valves capable of dispensing different beverages. Valve module 10 contains fluid pathways 11 , 12 , that may be interfaced to a manifold 20 . When a valve module 10 is connected to the manifold 20 , the fluid pathway(s) 11 , 12 of the valve module 10 interface with a corresponding pathway in the manifold 21 , 22 . The manifold 20 and manifold pathways 21 and 22 are show in greater detail in FIG. 2 . In this way, a fluid may travel through a fluid pathway 11 , 12 in the valve module 10 and into the corresponding pathway of the manifold 21 , 22 , which routes the fluid to a common dispense point 23 . At the common dispense point 23 , a diffuser 31 (as seen for example in FIG. 4 ) diffuses the fluid into a nozzle 32 , where the fluid may mix with other fluids to create a beverage. Flow control 13 , 14 and shut-off components 15 , 16 in the valve module control the amount of fluid that flows through the pathways. Although valve module 10 in FIG. 1 is shown having two sets of fluid pathways 11 , 12 , it is understood that each valve module 10 may have any number of pathways.
[0012] Referring specifically to FIG. 1 , the valve module 10 is shown as having two separate fluid pathways 11 , 12 . The fluid pathways 11 , 12 are not in communication with each other. Each fluid pathway 11 , 12 is controlled by a shut-off component 15 , 16 and a flow control component 13 , 14 . Together, the shut-off component 15 , 16 and the flow control component 13 , 14 control the rate (or completely stop the flow) of a fluid flowing through the fluid pathways 11 , 12 . Although the shut-off component 15 , 16 and the flow control components 11 , 12 are shown separately in the embodiment of FIG. 1 , it is also possible for a single component to control both the flow and the shut-off of a pathway.
[0013] In one embodiment, the shut-off component 15 , 16 may be a solenoid designed to be ¼ turn twist on, which requires no tools to remove, install, or service. The solenoid may use a 24v DC direct pull and plunger assembly, but alternatively a “hit and hold” solenoid using electronic controls could also be used. For the flow-control component, a differential pressure ceramic flow control may be used. In an alternate embodiment, the flow-control component may include stepper motor rotary controls that function on flow feedback.
[0014] The fluid pathways 11 , 12 are configured to interface with a manifold 20 (see FIG. 2 ) on one end, and with a backblock 51 (see FIG. 5 ) on the other end. The backblock 51 provides fluid which may flow through the fluid pathways 11 , 12 when the shut-off component 15 , 16 and flow control component 13 , 14 are in the open position. The backblock 51 may contain an interface to a fluid source. The backblock 51 may further include a heat exchanger for controlling the temperature of a fluid. An example thereof is disclosed in Applicant's U.S. Pat. App. 61/831,517, which is hereby incorporated in its entirety. The backblock 51 may be fastened to the housing using mating “dove-tail” fasteners 52 , 53 as see in FIG. 5 . More specifically, FIG. 5 shows a dovetail 52 on the backblock, and a mating receptacle 53 on the housing. Using mating dove-tail features to connect the housing to the backblock provides the added benefit being easily detachable for cleaning.
[0015] The fluid flowing from the backblock 51 into the valve module(s) 10 may be a branded beverage, or the fluid may be a beverage component, such as a syrup, concentrate, water, or carbonated water. The embodiment of FIG. 1 shows a valve module 10 having two fluid pathways 11 , 12 . But, a valve module 10 may have any number of fluid pathways. An advantage of using two fluid pathways per valve module is the ability to closely match the number of valves required by adding or removing valve modules.
[0016] Optionally, one or more of the valve modules may be in electronic communication with a CPU. Via the electronic communication, the CPU may be able to control either the valve module's shut off component and/or its flow control, thereby allowing the CPU to effectively control the volume and/or rate at which each of the valve modules dispenses a beverage. The valve modules may be controlled by a CPU, which receives a beverage recipe and drink size through an input, such as a touch screen or a conventional button, and operates the relevant valve modules 10 to dispense the required amount of each fluid. In other words, each valve module 10 contains a component of a beverage, and the CPU may operate the valve module(s) 10 to dispense the correct amount of each beverage component required to construct a beverage. The CPU may be in communication with a computer readable memory that uses non-transitory memory to store data representative of a beverage recipe. Thus, the CPU knows the correct amount of each beverage component that must be dispensed to construct a beverage. The CPU controls the opening and closing of the flow-control components 13 , 14 of each valve module 10 . Thus, the CPU may open any desired combination of valves for a predetermined time period to dispense the required quantity of each fluid.
[0017] FIG. 2 shows a manifold 20 which interfaces with the valve module 10 . In FIG. 3 , a manifold 20 and a valve module 10 are shown in the interfaced configuration. The manifold 20 used in this embodiment has five sets of two fluid pathways. Each set of these manifold pathways interfaces with the valve module fluid pathways when a valve module 10 is connected to the manifold. Thus, the manifold of FIG. 2 is capable of interfacing with five valve modules, where each valve module has two fluid pathways. It is understood that the manifold may be configured to receive any number of valve modules. Likewise, the housing 54 shown in FIG. 5 is configured to hold five valve modules, but may also be expanded according to a user's needs.
[0018] The manifold pathways 21 , 22 direct fluid to a common dispense point 23 . In the embodiment of FIG. 2 , the common dispense point 23 is positioned near the center of the manifold, but alternate configurations are also possible. Moreover, it is preferable, but not necessary, that each manifold pathway 21 , 22 have a slight downward slope from valve module interface to the common dispense point. A downward-sloping manifold pathway takes advantage of gravity to help move fluid to the common dispense point.
[0019] The manifold pathways 21 , 22 of FIG. 2 are not in fluid communication with each other. It is envisioned that the fluid pathways 11 , 12 of the valve module 10 , and by extension the manifold pathways 21 , 22 , can carry different flavored beverages or beverage components. Separating the manifold pathways 21 , 22 ensures that cross-contamination does not occur. Although there may be instances in which it is desirable to mix multiple beverages or beverages components (i.e. mixing a cherry concentrate with a cola beverage, or mixing a cola concentrate with carbonated water), the embodiment of FIG. 2 contemplates that such mixing should preferably occur in the nozzle.
[0020] In alternative embodiments, a subset of the manifold pathways 21 , 22 may be in fluid communication with each other. For example, it may be desirable to create a common manifold pathway that mixes uncarbonated water and carbonated water to create a mid-carbonated water.
[0021] At the common dispense point 23 , the manifold pathways 21 , 22 open into a diffuser 31 . The diffuser 31 is shown in FIG. 4 . The diffuser 31 is designed to cause fluids to disperse into the nozzle 32 . The various ridges and edges shown in the diffuser 31 of FIG. 4 have the effect of causing fluid to disperse evenly in the nozzle. The diffuser 31 provides the advantage of causing an even distribution of the fluid into the nozzle, which is beneficial because it enhances the mixing of multiple fluids. For example, where a cola and a cherry flavor are mixed in the nozzle 32 , the diffuser 31 enhances the mixing of the fluids. Similarly, the diffuser 31 enhances the mixing of beverage syrup or concentrate with water or carbonated water. In the embodiment of FIG. 3 , the diffuser 31 is designed to flow up to 4 ounces of water per second.
[0022] Moreover, syrup tips 33 (shown in FIG. 4 ) may be used to guide fluid from the manifold pathways 21 , 22 into the diffuser 31 . The use of syrup tips 33 provides the added benefit of reducing backsplash, and thus reducing the possibility of cross-contamination. Similarly, a seal 34 may be used to reduce potential leakage. In one embodiment, the seal 34 is a face-sealing silicon seal, which is easier to clean than typical 0 -ring and bore type assemblies.
[0023] FIG. 3 shows a valve module 10 and a nozzle 32 mounted to the manifold 20 . In operation, the valve module 10 and manifold 32 may be placed in a housing (not shown). Additional valve modules may be attached to the manifold in order to expand the dispense capability of the valve assembly.
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The invention relates to a valve dispensing system that can be used in a beverage dispenser. In particular, the valve dispensing system has individual valve module components that control the flow of a beverage or beverage component, and a plurality of valve module components may be combined to form a system capable of dispensing a plurality of beverages and/or beverage components.
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[0001] This application claims the benefit of the Korean Patent Application No. P2002-060705 filed on Oct. 4, 2002, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a crystallizing method, and more particularly, to a mask and method for crystallizing amorphous silicon. Although the present invention is suitable for a wide scope of applications, it is particularly suitable for improving fabrication productivity.
[0004] 2. Discussion of the Related Art
[0005] A liquid crystal display (LCD) device has been in the spotlight as a next generation high value display device because of its low power consumption and portability.
[0006] The liquid crystal display device is composed of an array substrate including thin film transistors, a color filter substrate, and a liquid crystal layer interposed between an array substrate and a color filter substrate. The liquid crystal display device displays images by using transmittance of light depending on the anisotropic refractive index of the liquid crystal layer.
[0007] An active matrix liquid crystal display (AMLCD) device, which includes a thin film transistor at each pixel as a switching device, has been widely used due to its high resolution and fast moving images.
[0008] In general, silicon has been used as an active layer of the thin film transistor. Especially, since polycrystalline silicon has a high field effect mobility and is optically stable, it has been widely used as an active layer of a thin film transistor for a liquid crystal display device having driving circuits and thin film transistors on the same substrate or for a display device that is much exposed to light.
[0009] Polycrystalline silicon may be formed through a high temperature process or a low temperature process. The high temperature process may be accomplished under the temperatures of about 1,000 degrees Celsius, which are much higher than the transition temperature of an insulating substrate, such as a glass substrate. Therefore, the high temperature process requires a quartz substrate that has a high heat resistance. However, the quartz substrate may not be cost effective for a substrate of thin film transistors. In addition, a polycrystalline silicon layer formed through the high temperature process has a high surface roughness and comprises fine grains.
[0010] Accordingly, a method of forming polycrystalline silicon, which includes depositing amorphous silicon that can be formed under low temperature conditions and crystallizing the amorphous silicon, has been researched and developed. The method of forming polycrystalline silicon includes a laser annealing method and a metal induced crystallization method.
[0011] Among these methods, in the laser annealing method, pulses of laser beams are irradiated on a substrate including an amorphous silicon layer, and melting and solidification of the irradiated amorphous silicon layer are repeatedly accomplished in 10 to 10 2 nanoseconds. Thus, damage to the substrate under the silicon layer may be minimized.
[0012] A method of crystallizing amorphous silicon will be described in detail with reference to the attached drawings.
[0013] [0013]FIG. 1 is a graph showing an energy intensity of a laser beam versus a grain size of crystallized silicon in a laser annealing method.
[0014] In FIG. 1, a first region of the graph is a partial melting regime. Only the surface of a silicon layer is melted by the energy intensity of the first region, thereby forming small grains.
[0015] A second region of the graph is a near-complete melting regime. Grains formed in the second region are larger than those in the first region because the grains laterally grow. However, sizes of the grains are non-uniform.
[0016] A third region of the graph is a complete melting regime, wherein an amorphous silicon layer is entirely melted by the energy intensity of the third region and fine grains are formed due to homogeneous nucleation.
[0017] Thus, in the laser annealing method, in order to form uniform and large grains, the energy intensity of the second region may be used, and irradiation times and overlapping ratios of the laser beams may be controlled.
[0018] Generally, grain boundaries of polycrystalline silicon interfere with currents and lowers the reliability of a thin film transistor. In addition, a breakdown of an insulating layer may occur because of a collision of electrons and a deterioration in the grains.
[0019] Accordingly, the formation of single crystalline silicon is important, and recently, a sequential lateral solidification (SLS) method has become of interest to solve the above problems. The SLS method takes advantage of the fact that silicon grains grow laterally from the boundary between the liquid silicon and the solid phase silicon. The SLS method can increase the size of the silicon grains by controlling the energy intensity of a laser beam and the irradiation range of the laser beam. The SLS method is disclosed in Robert S. Sposilli, M. A. Crowder, and James S. Im, Mat. Res. Soc. Symp. Proc. Vol. 452, 956-957, 1997. TFTs having channel areas of single crystalline silicon can be formed by the SLS method.
[0020] [0020]FIG. 2 is a schematic view showing the SLS crystallizing method using a laser annealing process according to the related art. In FIG. 2, a crystallizing mask 14 , which includes slits 12 spaced apart from each other, is disposed over a silicon layer 10 of an amorphous phase. A laser beam 16 is irradiated on portions A of the silicon layer 10 through the slits 12 of the crystallizing mask 14 . The laser beam 16 has an energy intensity that can completely melt the silicon layer 10 exposed to the laser beam 16 . Thus, the portions A of the silicon layer 10 corresponding to the slits 12 are completely melted. Then, a plurality of grains 18 grow laterally from the boundaries of the melted portions A of the silicon layer 10 , and the growth of the grains 18 stop at region B where the grains 18 meet each other. A width from one boundary of the portion A to the region B where the growth of the grains 18 stop may be referred to as length L of the grain 18 .
[0021] Although not shown in FIG. 2, the crystallizing mask 14 can be moved laterally so that the slit 12 may overlap one of the boundaries of the portion A. A laser beam is irradiated on the next portion of the silicon layer 10 , which overlaps the portion A, and the next portion is crystallized. Thus, larger grains are formed by repeatedly accomplishing the above processes.
[0022] The processes are performed until the length of the grain is about 10 micrometers (□), and the silicon layer including the grains may be used as an active layer of a thin film transistor, which has a channel of about 6 micrometers (□) in width.
[0023] [0023]FIG. 3 schematically shows a mask for crystallizing according to the related art.
[0024] As shown in FIG. 3, a plurality of blocking layers 22 spaced apart from each other is formed on a base substrate 20 . Spaces between the blocking layers 22 are defined as slits 24 . The base substrate 20 may be formed of quartz, and the blocking layers 22 may be formed of chromium (Cr), which reflects a laser beam. The blocking layers 22 may have a width of about 4 micrometers (□), and the slits 24 may have a width of about 2 micrometers (□).
[0025] [0025]FIG. 4 shows overlaps between shots of a laser beam in the SLS crystallizing process using the mask of FIG. 3. A profile of the laser beam at each shot relates to an energy intensity of the laser beam. FIG. 4 illustrates the region corresponding to only two slits of the mask for simplicity.
[0026] As shown in FIG. 4, a first laser shot is irradiated on the substrate 28 including an amorphous silicon layer 26 thereon, and a beam passing through the mask has two peaks corresponding to the slits. Second, third, and fourth laser shots are subsequently irradiated such that peaks of each laser shot overlap each other. At this time, the peaks overlap each other such that the overlapping portions between the peaks can have energy intensities higher than the melting point of the silicon layer 26 .
[0027] The peaks of the first laser shot to the fourth laser shot overlap each other with a fixed width because a position of the substrate 20 corresponding to the slit of the mask changes by moving the substrate in a first direction in FIG. 4. In FIG. 4 , a second direction, which is opposite to the first direction, indicates the growing direction of the grains.
[0028] Although not shown in FIG. 4, distance C between the two peaks of the first laser shot is closely connected to the width of the blocking layer 22 of the mask 20 of FIG. 3 (i.e., a space between the slits 24 of FIG. 3). Since the peaks of each laser shot must have the distance C therebetween to prevent them from overlapping each other, there is a limitation in reducing the width of the blocking layer 22 under 4 micrometers (□) according to the structure of the mask of the related art.
[0029] More particularly, in the SLS crystallizing process using the mask of the related art, if the peaks of a laser shot overlap each other, the silicon layer is melted non-uniformly because an overlapping portion between the peaks is large, and thus the grains do not grow completely. In addition, since a nucleation region is formed in the overlapping portion, characteristics of crystallization get worse. Therefore, the width of the blocking layer, that is, the space between the slits must be more than at least 4 micrometers (□) so that the peaks of each laser shot do not overlap each other, thereby providing a reliable process. However, there is a disadvantage in that the efficiency of the process is lowered due to an increase in the laser shots.
SUMMARY OF THE INVENTION
[0030] Accordingly, the present invention is directed to a mask and method for crystallizing amorphous silicon that substantially obviates one or more of problems due to limitations and disadvantages of the related art.
[0031] Another object of the present invention is to provide a mask and method for crystallizing amorphous silicon to form polycrystalline silicon having large grains.
[0032] A further object of the present invention is to provide a mask and method for crystallizing amorphous silicon for a reduced number of processes.
[0033] Additional features and advantages of the invention will be set forth in the description which follows and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0034] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, a method of crystallizing amorphous silicon includes forming an amorphous silicon layer on a substrate, placing a mask over the substrate including the amorphous silicon layer, and applying a laser beam onto the amorphous silicon layer through the mask to form a first crystallized region, the laser beam having an energy intensity high enough to completely melt the amorphous silicon layer, wherein the mask comprises a base substrate, a phase shift layer on the base substrate, having a plurality of first stripes having a first width separated by slits, and a blocking layer overlapping the phase shift layer, having a plurality of second stripes having a second width narrower than the first width, the second stripes being parallel to the first stripes.
[0035] In another aspect of the present invention, a mask for crystallizing amorphous silicon includes a base substrate, a phase shift layer on the base substrate, having a plurality of first stripes having a first width separated by slits, and a blocking layer overlapping the phase shift layer, having a plurality of second stripes having a second width narrower than the first width, the second stripes being parallel to the first stripes.
[0036] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiments of the invention and together with the description serve to explain the principle of the invention.
[0038] In the drawings:
[0039] [0039]FIG. 1 is a graph showing an energy intensity of a laser beam versus a grain size of crystallized silicon in a laser annealing method;
[0040] [0040]FIG. 2 is a schematic view showing the sequential lateral solidification (SLS) crystallizing method using a laser annealing process according to the related art;
[0041] [0041]FIG. 3 is a schematic cross-sectional view showing a mask for crystallization according to the related art;
[0042] [0042]FIG. 4 is a schematic view showing overlaps between shots of a laser beam in the SLS crystallizing method using the mask of FIG. 3;
[0043] [0043]FIG. 5 is a schematic view illustrating the principle of phase shift in a mask according to the present invention;
[0044] [0044]FIG. 6 is a plane view of a mask for crystallizing amorphous silicon according to the present invention;
[0045] [0045]FIG. 7 is a cross-sectional view taken along line VII-VII of FIG. 6;
[0046] [0046]FIG. 8 is a schematic view showing the energy intensity profiles of a laser beam irradiated through the mask of the present invention; and
[0047] [0047]FIG. 9 is a flow chart showing the SLS crystallizing method using the mask of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0049] [0049]FIG. 5 is a schematic view illustrating the principle of phase shift in a mask according to the present invention.
[0050] In FIG. 5, a first part 54 a of a laser beam 54 passes through a first portion M 1 of a mask 50 , where there is no layer, and a second part 54 b of the laser beam 54 permeates a second portion M 2 of the mask 50 , where there exists a phase shift layer 52 . Since the first part 54 a and the second part 54 b of the laser beam 54 go through different optical paths according to the existence of the phase shift layer 52 , there is a phase difference ΔΦ between the first part 54 a and the second part 54 b passing through the mask 50 . The phase difference ΔΦ is expressed as the following equation:
ΔΦ=2 π· d ( n− 1)·λ,
[0051] wherein, λ represents a wavelength of a light source, n is a refractive index of the phase shift layer 52 , and d represents a thickness of the phase shift layer 52 .
[0052] Thus, from the above equation, the phase of light can be shifted by about 180 degrees, for example, by controlling the thickness d of the phase shift layer 52 .
[0053] [0053]FIG. 6 is a plane view of a mask for crystallizing amorphous silicon according to the present invention. In FIG. 6, a phase shift layer 112 is formed in a first direction on a base substrate 110 . The phase shift layer 112 includes a plurality of first stripes, each of which has a first width W1. A blocking layer 114 is formed in the first direction, overlapping the phase shift layer 112 . The blocking layer 114 includes a plurality of second stripes, each of which has a second width W2. Spaces between adjacent phase shift layers 112 become a plurality of slits 116 , and each slit 116 has a third width W3.
[0054] Here, the second width W2 is narrower than the first width W1, thereby exposing both sides D of each first stripe of the phase shift layer 112 . The exposed sides D of the phase shift layer 112 causes a phase shift of a laser beam passing therethrough when the laser beam is irradiated, and thus profiles of the laser beam passing through the mask can have a stiff slope.
[0055] The first width W1 may generally be twice as wide as the third width W3 in the related art. However, the first width W1 may be smaller than or equal to the third width W3 in the present invention.
[0056] The mask of the present invention may be used for excimer laser.
[0057] [0057]FIG. 7 is a cross-sectional view taken along line VII-VII of FIG. 6.
[0058] As shown in FIG. 7, the phase shift layer 112 , which includes the plurality of first stripes, is formed on the base substrate 110 such that the first stripes are spaced apart from each other, and each first stripe has the first width W1. The blocking layer 114 , which includes the plurality of second stripes having the second width W2, is formed on the phase shift layer 112 , wherein the second width W2 is narrower than the first width W1, thereby exposing both sides D of each first stripe of the phase shift layer 112 by the blocking layer 114 . The spaces between the first stripes of the phase shift layer 112 become the slits 116 . The slits 116 have the third width W3.
[0059] The phase shift layer 112 may be formed of a material that can reverse the phase of light, such as MoSi x (molybdenum-silicide). The base substrate 110 may be formed of a high heat-resistant material, such as quartz, and the blocking layer 114 may be formed of a material that can block a light passage, such as chromium (Cr).
[0060] In the mask of the present invention, the third width W3 of the slit 116 may be within the range of about 1 to 3 micrometers (□), and the first width W1 of the phase shift layer 112 may be also within the range of about 1 to 3 micrometers (□). It may be beneficial that the third width W3 and the first width W1 are about 2 micrometers (□). Accordingly, in the present invention, the resolution of the mask for crystallizing can be improved due to a destructive interference of the beam profile by using the phase shift layer without changing the optical compensating apparatus for controlling the laser beam. Therefore, productivity in the SLS crystallizing method can be increased due to the mask having an improved resolution.
[0061] The exposed sides D of the phase shift layer 112 should have sizes enough so that the transmitted laser beam is reversed to have energy intensities larger than the melting point of a silicon layer.
[0062] [0062]FIG. 8 is a schematic view showing energy intensity profiles of a laser beam irradiated through the mask of the present invention.
[0063] In FIG. 8, a first laser shot is irradiated on a substrate 122 including an amorphous silicon layer 120 formed thereon, and a beam passing through the mask has two peaks, which corresponds to the slits of the mask. The peaks are spaced apart from each other without overlapping each other. Next, a second laser shot is irradiated, wherein a peak of the second laser shot overlaps the two peaks of the first laser shot.
[0064] In the SLS crystallizing method of the present invention, peaks of each laser shot do not overlap each other because profiles of the laser beam passing through the mask have stiff slopes due to destructive interference by using the phase shift layer. Therefore, the number of laser shots is decreased as compared to that in the related art. In addition, since the distance between the slits can be reduced and the number of slits can be increased, the resolution of the mask for crystallizing can be improved.
[0065] Accordingly, although the mask may have the resolution of about 2 micrometers (□), for example, the profiles of the laser beam do not overlap each other, and thus the growth of grains can be stable and reproducible.
[0066] In the present invention, the number of laser shots is not limited to two but decreased as opposed to the related art, thereby improving productivity of the SLS crystallizing process.
[0067] [0067]FIG. 9 is a flow chart showing a SLS crystallizing process using the mask of the present invention.
[0068] In step ST 1 , an amorphous silicon layer is formed by depositing amorphous silicon on an insulating substrate and dehydrogenating the amorphous silicon to improve crystallizing characteristics. Here, a buffer layer may be formed between the substrate and the amorphous silicon layer. The buffer layer may be formed of an insulating material such as silicon oxide (SiO 2 ).
[0069] In step ST 2 , the SLS crystallizing process is performed by using a laser. That is, a first shot of a laser beam is irradiated on the substrate including the amorphous silicon layer by using the mask having a phase shift layer, and a portion exposed to the laser beam is melted. Grains grow from the boundaries of the melted portion toward the middle of the melted portion, and thus a first crystallized region is formed. The next shot is irradiated, so that the transmitted laser beam overlaps the first crystallized region. Thus, a second crystallized region is formed.
[0070] In step ST 3 , a polycrystalline silicon layer is formed by repeatedly performing step ST 2 .
[0071] In the mask of the present invention, the blocking layer that is formed of chromium reflects the laser beam, and the phase shift layer formed of molybdenum silicide reverses the phase of the laser beam, reducing the intensity of the laser beam. Therefore, peaks of a laser shot can be separated without difficulty.
[0072] Additionally, the resolution of the mask for crystallizing can be improved, and thus productivity of the SLS crystallizing process can be increased.
[0073] It will be apparent to those skilled in the art that various modifications and variations can be made in the mask and method for crystallizing amorphous silicon of the present invention without departing from the spirit or scope of the inventions. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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A method of crystallizing amorphous silicon includes forming an amorphous silicon layer on a substrate, placing a mask over the substrate including the amorphous silicon layer, and applying a laser beam onto the amorphous silicon layer through the mask to form a first crystallized region, the laser beam having an energy intensity high enough to completely melt the amorphous silicon layer, wherein the mask comprises a base substrate, a phase shift layer on the base substrate, having a plurality of first stripes having a first width separated by slits, and a blocking layer overlapping the phase shift layer, having a plurality of second stripes having a second width narrower than the first width, the second stripes being parallel to the first stripes.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an air damper for generating a negative pressure in a head chip which is applicable to, for example, a printer or a facsimile, and to an ink jet head and an ink jet recording apparatus.
[0003] 2. Description of the Related Art
[0004] Up to now, an ink jet recording apparatus has been known in which an ink jet head for discharging ink from plural nozzles is employed to record characters and/or images on a recording medium. In this type of ink jet recording apparatus, an entirety of the desired area is printed by repeating the following operations. That is, a carriage mounted with the ink jet head is moved in a main scanning direction with respect to the recording medium while the ink is discharged from a nozzle of the ink jet head, thereby printing a dot pattern in a predetermined area; and after one main scanning operation ends, the recording medium is moved in a sub-scanning direction by a predetermined amount.
[0005] In a large ink jet recording apparatus, plural ink jet heads corresponding to respective ink colors are mounted to the carriage. This type of large ink jet recording apparatus in which the heads are mounted to the carriage and the carriage moves in the main scanning direction is called a “shuttle type recording apparatus”. The so-called shuttle type recording apparatus is structured such that, in order to perform a large amount of printing for a long period of time, an exchangeable large-capacity ink cartridge is incorporated in the apparatus and connected to the corresponding head through a tube to supply ink. In a method of supplying ink using a tube, when a carriage moves, the ink residing inside the tube moves therein in accordance with the movement of the carriage. When the ink moves, inertia is generated inside the head connected to the tube. Then, a differential pressure due to the inertia inside the head results in breakage of a meniscus that is formed by surface tension of the ink in a nozzle hole provided in a nozzle surface of the head. Thus, the ink cannot be discharged. In view of the above, a part called an “air damper” is generally mounted so as to relax the pressure fluctuation due to the inertia of the ink. In order to relax the pressure fluctuation, one side of the air damper is molded from a rigid body such as plastic to have a recessed portion for storing ink, and a film-shaped sheet is then bonded thereto by thermal welding or the like so as to seal the recessed portion. The film moves due to the pressure fluctuation of the ink in accordance with the movement of the carriage, thereby relaxing the pressure fluctuation of the ink.
[0006] If the large ink jet recording apparatus is employed, it is necessary to increase a length of the tube for supplying the ink from the ink cartridge. The longer tube increases a flow path resistance inside the tube to disturb flow of the ink. Also, if an outside air temperature becomes low, viscosity of the ink increases to harden the ink. Thus, smooth flow of the ink is hindered under only an ordinary suction pressure. There can be employed another method of supplying ink by providing a sub-tank in the vicinity of a head. However, a larger apparatus becomes necessary, which leads to higher costs.
[0007] Up to now, in order to fill the head with the ink, the following method has been employed. That is, a cap formed of rubber is brought in press contact with a nozzle plate of the head to seal an inside portion between the nozzle plate and the cap. Another tube is attached to an exhaust port provided to the cap which communicates with an external portion. Due to suction by a pump via the another tube, a negative pressure is generated inside a space between the cap and the nozzle plate. As a result, the head is filled with the ink via the tube from an ink cartridge. In this type of ink supplying method, the ink is sucked by only suction from the head side. Thus, if the longer tube is used, the head cannot be smoothly filled with the ink due to the generated flow path resistance.
[0008] In view of this, there has been proposed an additional method of filling the head with the ink such that the ink is forced to be pushed out from the ink cartridge side by another pump different from the above pump. However, if being pressurized from the ink cartridge side by using this method, the pressure increases inside the air damper attached to the head which relaxes the inertia of the ink inside the tube, so that the film bonded to the air damper by thermal welding or the like is ruptured due to the internal pressure in some cases.
SUMMARY OF THE INVENTION
[0009] In light of the above circumstances, the present invention has an object to provide a relatively simple structure in which ink can pressure-fill a head.
[0010] In order to solve the above problems, according to a first aspect of the present invention, there is provided an air damper including a reinforcement plate for preventing rupture of a film of the air damper.
[0011] According to a second aspect of the present invention, there is provided an air damper in which the reinforcement plate is formed of a transparent plastic plate.
[0012] According to a third aspect of the present invention, there is provided an air damper in which the reinforcement plate includes on its film side a recessed portion for accepting deformation of the film caused by fluctuation in the ink inside the air damper which is generated when the head moves.
[0013] According to a fourth aspect of the present invention, there is provided an air damper in which the reinforcement plate includes one or plural air holes for, in a case where a liquid surface inside the air damper fluctuates at the time of pressure fluctuation in accordance with the movement of a carriage, introducing air between the reinforcement plate and the film to relax the pressure fluctuation.
[0014] According to a fifth aspect of the present invention, there is provided an air damper in which the reinforcement plate is fixed to the air damper with plural screws.
[0015] According to a sixth aspect of the present invention, in any one of the first to fourth aspects, there is provided an air damper in which the reinforcement plate is fixed to the air damper by ultrasonic welding or the like.
[0016] According to a seventh aspect of the present invention, there is provided an air damper further including recessed portions formed in right and left side surfaces or three surfaces of the right and left side surfaces and another surface of a main body of the air damper, in which: the reinforcement plate includes undercut portions to be fitted to the recessed portions of the air damper; and the reinforcement plate is fixed by inserting the undercut portions into the recessed portions of the air damper.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In the accompanying drawings:
[0018] [0018]FIG. 1 is a schematic view showing an attachment part of an air damper of the present invention;
[0019] [0019]FIG. 2 is an exploded structural view showing a structure of the air damper of the present invention;
[0020] [0020]FIG. 3 is a perspective view showing an external shape of an ink jet head mounted with the air damper of the present invention;
[0021] [0021]FIG. 4 is an explanatory view showing how ink is pressure-supplied to the air damper of the present invention;
[0022] [0022]FIG. 5 shows one embodiment in a case where a reinforcement plate is attached to the air damper of the present invention; and
[0023] [0023]FIG. 6 shows another embodiment in the case where the reinforcement plate is attached to the air damper of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
[0025] [0025]FIG. 1 is a schematic view showing a part mounted with an air damper of the present invention, and FIG. 2 is an exploded structural view showing a structure of the air damper of the present invention. Further, FIG. 3 is a perspective view showing an external shape of an ink jet head mounted with the air damper.
[0026] As shown in FIGS. 1 to 3 , a head 1 in accordance with the present invention is composed of: a head chip 10 made of PZT; a nozzle plate 11 which is provided to a front end of the head chip 10 and has a hole for discharging ink; a flow path 12 for supplying the ink to an inside of the head chip 10 ; a base 13 for fixing respective parts; an air damper 14 ; and the like.
[0027] In an ink jet recording apparatus of the present invention, the ink is supplied to the head 1 by the following process. That is, a cap 20 formed of rubber is brought in press contact with the nozzle plate 11 of the head 1 to seal an inside portion between the nozzle plate 11 and the cap 20 . A tube 22 is attached to an exhaust port 21 provided to the cap 20 which communicates with an external portion. Due to suction by a not-shown pump via the tube 22 , a negative pressure is generated inside a space 23 between the cap 20 and the nozzle plate 11 . As a result, the head 1 is filled with the ink via a tube 25 from an ink cartridge 24 along the path shown by the arrows in FIG. 1.
[0028] An ink reservoir portion 16 of the air damper 14 is structured to be sealed by fixing a polyester film 15 or the like to an air damper main body over an entire surface of the ink reservoir portion 16 by thermal welding, ultrasonic welding, adhesion, or the like. As described above, in a case where the head 1 is filled with the ink, if an ink discharging portion of the head 1 is sealed with the cap 20 and the negative pressure is generated on a head 1 side, the ink in the ink cartridge 24 is made to flow into the air damper 14 via the ink tube 25 . If the air damper 14 is filled with the ink, the head 1 is next filled with the ink, the ink is then jetted from the nozzle plate 11 , and air inside the head 1 is pushed out from the exhaust port 21 of the cap 20 . As a result, preparation of printing is complete.
[0029] In the case where the ink has a high viscosity or the viscosity of the ink increases at a low temperature, a sufficient amount of ink cannot be supplied by an ordinary suction process. Such insufficient ink supply causes ink shortage and residual air inside the head 1 , so that the ink cannot be normally discharged from the head 1 . In this case, not only the suction process but also the following process may be employed. That is, as shown in FIG. 4, the cartridge 24 is directly pressurized in a direction shown by the arrow A to push out the ink. Alternatively, the tube 25 is pressed by a pump 26 to push out the ink from the tube 25 . Thus, the air damper 14 is rapidly filled with the ink, thereby making it possible to fill the head 1 with the ink.
[0030] In this case, if the ink reservoir portion 16 with only the film 15 is pressure-filled with the ink, the film 15 bulges toward the external portion. If the film 15 bulges to such an extent that a tension of the film 15 reaches or exceeds its maximum tension and an adhesive force at an adhesive boundary between the air damper 14 main body and the film 15 , the film 15 can be ruptured. Also, if the film 15 bulges at the time of pressurization, a pressure for pushing out the ink decreases and there is a case where efficient pressure-filling cannot be performed.
[0031] In order to suppress deficiency due to the bulging of the film 15 and transmit the pressure efficiently, as shown in FIG. 2, the air damper 14 of the present invention employs a structure in which a reinforcement plate 17 is fixed onto a not-shown film surface so as to prevent the film 15 from bulging. The reinforcement plate 17 can be formed of plastic or a metal plate. At the time of pressurization, a pressure of 1 to 2 atm is applied to the air damper 14 , so that the reinforcement plate 17 has rigidity enough to withstand the pressure at the time of pressure-filling of the ink. It is necessary that the reinforcement plate 17 formed of plastic has a thickness of 2 mm or more and the reinforcement plate 17 formed of a sheet metal has a thickness of 1 mm or more. For firm fixation, it is further necessary to use screws 18 and nuts 19 to fix the reinforcement plate 17 robustly. For this purpose, fixation holes 31 for fixing the reinforcement plate 17 are formed in the reinforcement plate 17 and the air damper 14 . Also, one or plural small holes 30 may be formed in the reinforcement plate 17 such that, in the case where a liquid surface inside the air damper 14 fluctuates at the time of pressure fluctuation in accordance with the movement of a carriage to thereby inhibit a movement of the film 15 , air is introduced between the reinforcement plate 17 and the film 15 , thereby making it possible to relax the pressure fluctuation. If respective structural parts disassembled as shown in FIG. 2 are reassembled, the head 1 according to this embodiment as shown in FIG. 3 is complete.
[0032] In this embodiment, the screws 18 and the nuts 19 are connected via the through holes 31 of the air damper 14 and the reinforcement plate 17 to fix the reinforcement plate 17 . However, it is also possible to fix the reinforcement plate 17 by using the air damper 14 main body insert-molded with nuts or using self-tapping screws. Alternatively, in another method, as shown in FIG. 5, U-shaped undercut portions 27 are formed in side surfaces of the reinforcement plate 17 while recessed portions 28 to be fitted to the undercut portions 27 are formed in the air damper 14 . Therefore, the undercut portions 27 may be inserted into the recessed portions 28 to fix the reinforcement plate 17 . Similarly in this method, the fixation may require use of screws in some cases.
[0033] Further, as another method of attaching the reinforcement plate 17 , as shown in FIG. 6, the reinforcement plate 17 may be fixed by ultrasonic welding or the like. In this case, the movement of the film 15 of the air damper 14 is regulated by the reinforcement plate 17 . Thus, a recessed portion 29 may be formed in the surface of the reinforcement plate 17 which opposes to the film 15 so that the film 15 can easily fluctuate. Note that, in this case, if the recessed portion 29 has a depth that is too large, the film 15 adheres to the recessed portion 29 of the reinforcement plate 17 or deforms due to the pressure at the time of pressurization. Thus, the depth of the recessed portion 29 is suitably set within the range of 0.3 to 1 mm.
[0034] As has been described above, according to the present invention, the head can be filled with the ink by pressurization and suction simultaneously. Also, in the case where the ink has a high viscosity or the viscosity of the ink increases at a low temperature, the head can be easily filled with the ink.
[0035] Hereinabove, the description has been made of the embodiments of the present invention. However, the present invention is not limited to the aforementioned structures and any modifications and variations may be made thereto without departing from the gist of the present invention as disclosed herein and claimed as appended herewith.
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Provided is a relatively simple structure in which ink can pressure-fill a head. In the structure, a reinforcement plate is attached to a film surface. Therefore, when the head is pressure-filled with the ink, a film of an air damper is not damaged by a pressure at the time when being pressurized. The attachment of the reinforcement plate suppresses bulging of the film, so that the pressure at the time of pressurization is efficiently transmitted to facilitate the ink supply. In addition, the pressurization can easily remove air from an inside of the head, thereby being capable of eliminating discharge failure in the head.
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BACKGROUND OF THE INVENTION
[0001] Polymeric electro-optic (EO) materials have demonstrated enormous potential for core application in a broad range of systems and devices, including phased array radar, satellite and fiber telecommunications, cable television (CATV), optical gyroscopes for application in aerial and missile guidance, electronic counter measure systems (ECM) systems, backplane interconnects for high-speed computation, ultrafast analog-to-digital conversion, land mine detection, radio frequency photonics, spatial light modulation and all-optical (light-switching-light) signal processing.
[0002] Nonlinear optic materials are capable of varying their first-, second-, third- and higher-order polarizabilities in the presence of an externally applied electric field or incident light (two-photon absorption). In telecommunication applications, the second-order polarizability (hyperpolarizability or β) and third-order polarizability (second-order hyperpolarizability or γ) are currently of great interest. The hyperpolarizability is related to the change of a NLO material's refractive index in response to application of an electric field. The second-order hyperpolarizability is related to the change of refractive index in response to photonic absorbance and thus is relevant to all-optical signal processing. A more complete discussion of nonlinear optical materials may be found in D. S. Chemla and J. Zyss, Nonlinear optical properties of organic molecules and crystals, Academic Press, 1987 and K.-S. Lee, Polymers for Photonics Applications I, Springer 2002.
[0003] Many NLO molecules (chromophores) have been synthesized that exhibit high molecular electro-optic properties. The product of the molecular dipole moment (μ) and hyperpolarizability (β) is often used as a measure of molecular electro-optic performance due to the dipole's involvement in material processing. One chromophore originally evaluated for its extraordinary NLO properties by Bell Labs in the 1960s, Disperse Red (DR), exhibits an electro-optic coefficient μβ˜580×10 −48 esu. Current molecular designs, including FTC, CLD and GLD, exhibit μβ values in excess of 10,000×10 −48 esu. See Dalton et al., “New Class of High Hyperpolarizability Organic Chromophores and Process for Synthesizing the Same”, WO 00/09613.
[0004] Nevertheless extreme difficulties have been encountered translating microscopic molecular hyperpolarizabilities (β) into macroscopic material hyperpolarizabilities (X (2) ). Molecular subcomponents (chromophores) must be integrated into NLO materials that exhibit: (i) a high degree of macroscopic nonlinearity; and, (ii) sufficient temporal, thermal, chemical and photochemical stability. Simultaneous solution of these dual issues is regarded as the final impediment in the broad commercialization of EO polymers in numerous government and commercial devices and systems.
[0005] The production of high material hyperpolarizabilities (X (2) ) is limited by the poor social character of NLO chromophores. Commercially viable materials must incorporate chromophores with the requisite molecular moment statistically oriented along a single material axis. In order to achieve such an organization, the charge transfer (dipolar) character of NLO chromophores is commonly exploited through the application of an external electric field during material processing which creates a localized lower-energy condition favoring noncentrosymmetric order. Unfortunately, at even moderate chromophore densities, molecules form multi-molecular dipolarly-bound (centrosymmetric) aggregates that cannot be dismantled via realistic field energies. As a result, NLO material performance tends to decrease dramatically after approximately 20-30% weight loading. One possible solution to this situation is the production of higher performance chromophores that can produce the desired hyperpolar character at significantly lower molar concentrations.
[0006] Attempts at fabricating higher performance NLO chromophores have largely failed due to the nature of the molecular architecture employed throughout the scientific community. Currently all high-performance chromophores (e.g., CLD, FTC, GLD, etc.) incorporate protracted “naked” chains of alternating single-double π-conjugated covalent bonds. Researchers such as Dr. Seth Marder have provided profound and detailed studies regarding the quantum mechanical function of such “bond-alternating” systems which have been invaluable to our current understanding of the origins of the NLO phenomenon and have in turn guided present-day chemical engineering efforts. Although increasing the length of these chains generally improves NLO character, once these chains exceed ˜2 nm, little or no improvement in material performance has been recorded. Presumably this is largely due to: (i) bending and rotation of the conjugated atomic chains which disrupts the 7-conduction of the system and thus reduces the resultant NLO character; and, (ii) the inability of such large molecular systems to orient within the material matrix during poling processes due to environmental steric inhibition. Thus, future chromophore architectures must exhibit two important characteristic: (i) a high degree of rigidity, and (ii) smaller conjugative systems that concentrate NLO activity within more compact molecular dimensions.
[0007] Long-term thermal, chemical and photochemical stability is the single most important issues in the construction of effective NLO materials. Material instability is in large part the result of three factors: (i) the increased susceptibility to nucleophilic attack of NLO chromophores due to molecular and/or intramolecular (CT) charge transfer or (quasi)-polarization, either due to high-field poling processes or photonic absorption at molecular and intramolecular resonant energies; (ii) molecular motion due to photo-induced cis-trans isomerization which aids in the reorientation of molecules into performance-detrimental centrosymmetric configurations over time; and (iii) the extreme difficulty in incorporating NLO chromophores into a holistic cross-linked polymer matrix due to inherent reactivity of naked alternating-bond chromophore architectures. Thus, future chromophore architectures: (i) must exhibit improved CT and/or quasi-polar state stability; (ii) must not incorporate structures that undergo photo-induced cis-trans isomerization; and (iii) must be highly resistant to polymerization processes through the possible full-exclusion of naked alternating bonds.
[0008] The present invention seeks to fulfill these needs through the innovation of fully heterocyclical anti-aromatic chromophore design. The heterocyclical systems described herein do not incorporate naked bond-alternating chains that are susceptible to bending or rotation. The central anti-aromatic conductor “pull” the molecule into a quasi-CT state; since aromaticity and non-CT states are both favorably low-energy conditions, charge transfer and aromaticity within the molecular systems described herein are set against each other within a competitive theater. This competitive situation is known as CAPP engineering or Charge-Aromaticity Push-Pull. As a result, the incorporation of anti-aromatic systems dramatically improves the conductive properties of the central π-conjugated bridge providing for smaller molecular lengths with significantly greater NLO property. Because all the systems described herein are aromatic in their CT state and quasi-aromatic in their intermediate quasi-polarized states, this structure is expected to dramatically improve polar-state stability. Furthermore, novel electronic acceptor systems are described herein which are expected to significantly improve excited-state and quasi-CT delocalization making the overall systems less susceptible to nucleophilic attack. The heterocyclical nature of all the systems described herein forbids the existence of photo-induced cis-trans isomerization which is suspected as a cause of both material and molecular degeneration. Finally, the invention provides for chromophoric systems that are devoid of naked alternating bonds that are reactive to polymerization conditions.
SUMMARY OF THE INVENTION
[0009] The present invention relates to NLO chromophores for the production of first-, second, third- and/or higher order polarizabilities of the form of Formula I:
[0000]
[0000] or an acceptable salt thereof; wherein
[0010] (p) is 0-6;
[0011] are independently at each occurrence a covalent chemical bond;
[0012] X 1-4 are independently selected from C, N, O or S;
[0013] Z 1-4 are independently N, CH or CR; where R is defined below.
[0014] D is an organic electron donating group having equal or lower electron affinity relative to the electron affinity of A. In the presence of π 1 , D is attached to the remainder of the molecule at two atomic positions X 1 and X 2 . In the absence of π 1 , D is attached to the remainder of the molecule at two atomic positions Z 1 and C 2 .
[0015] A is an organic electron accepting group having equal or higher electron affinity relative to the electron affinity of D. In the presence of π 2 , A is attached to the remainder of the molecule at two atomic positions X 3 and X 4 . In the absence of π 2 , A is attached to the remainder of the molecule at two atomic positions Z 4 and C 3 .
[0016] π1 comprises X 1 and X 2 and is absent or a bridge joining atomic pairs Z 1 and C 2 to X 1 X 2 and which provides electronic conjugation between D and an anti-aromatic system comprising C 1 , C 2 , C 3 , C 4 , Z 1 , Z 2 , Z 3 and Z 4 .
[0017] π 2 comprises X 3 and X 4 and is absent or a bridge joining atomic pairs C 3 and Z 4 to X 3 X 4 and which provides electronic conjugation between A and said anti-aromatic system.
[0018] R is independently selected from:
[0019] (i) a spacer system of the Formula II
[0000]
[0020] or an acceptable salt thereof; wherein
[0021] R 3 is a C 6 -C 10 aryl, C 6 -C 10 heteroaryl, 4-10 membered heterocyclic or a C 6 -C 10 saturated cyclic group; 1 or 2 carbon atoms in the foregoing cyclic moieties are optionally substituted by an oxo (═O) moiety; and the foregoing R 3 groups are optionally substituted by 1 to 3 R 5 groups;
[0022] R 1 and R 2 are independently selected from the list of substituents provided in the definition of R 3 , (CH 2 ) t (C 6 -C 10 aryl) or (CH 2 ) t (4-10 membered heterocyclic), t is an integer ranging from 0 to 5, and the foregoing R 1 and R 2 groups are optionally substituted by 1 to 3 R 5 groups;
[0023] R 4 is independently selected from the list of substituents provided in the definition of R 3 , a chemical bond (—), or hydrogen;
[0024] each Q 1 , Q 2 , and Q 4 is independently selected from hydrogen, halo, C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, nitro, trifluoromethyl, trifluoromethoxy, azido, —OR 5 , —NR 6 C(O)OR 5 , —NR 6 SO 2 R 5 , —SO 2 NR 5 R 6 , —NR 6 C(O)R 5 , —C(O)NR 5 R 6 , —NR 5 R 6 , —S(O) j R 7 wherein j is an integer ranging from 0 to 2, —NR 5 (CR 6 R 7 ) t OR 6 , —(CH 2 ) t (C 6 -C 10 aryl), —SO 2 (CH 2 ) t (C 6 -C 10 aryl), —S(CH 2 ) t (C 6 -C 10 aryl), —O(CH 2 ) t (C 6 -C 10 aryl), —(CH 2 ) t (4-10 membered heterocyclic), and —(CR 6 R 7 ) m OR 6 , wherein m is an integer from 1 to 5 and t is an integer from 0 to 5; with the proviso that when R 4 is hydrogen Q 4 is not available; said alkyl group optionally contains 1 or 2 hetero moieties selected from O, S and —N(R 6 )— said aryl and heterocyclic Q groups are optionally fused to a C 6 -C 10 aryl group, a C 5 -C 8 saturated cyclic group, or a 4-10 membered heterocyclic group; 1 or 2 carbon atoms in the foregoing heterocyclic moieties are optionally substituted by an oxo (═O) moiety; and the alkyl, aryl and heterocyclic moieties of the foregoing Q groups are optionally substituted by 1 to 3 substituents independently selected from nitro, trifluoromethyl, trifluoromethoxy, azido, —NR 6 SO 2 R 5 , —SO 2 NR 5 R 6 , —NR 6 C(O)R 5 , —C(O)NR 5 R 6 , —NR 5 R 6 , —(CR 6 R 7 ) m OR 6 wherein m is an integer from 1 to 5, —OR 5 and the substituents listed in the definition of R 5 ;
[0025] each R 5 is independently selected from H, C 1 -C 10 alkyl, —(CH 2 ) t (C 6 -C 10 aryl), and —(CH 2 ) t (4-10 membered heterocyclic), wherein t is an integer from 0 to 5; said alkyl group optionally includes 1 or 2 hetero moieties selected from O, S and —N(R 6 )— said aryl and heterocyclic R 5 groups are optionally fused to a C 6 -C 10 aryl group, a C 5 -C 8 saturated cyclic group, or a 4-10 membered heterocyclic group; and the foregoing R 5 substituents, except H, are optionally substituted by 1 to 3 substituents independently selected from nitro, trifluoromethyl, trifluoromethoxy, azido, —NR 6 C(O)R 7 , —C(O)NR 6 R 7 , —NR 6 R 7 , hydroxy, C 1 -C 6 alkyl, and C 1 -C 6 alkoxy;
[0026] each R 6 and R 7 is independently H or C 1 -C 6 alkyl;
[0027] T, U and V are each independently selected from C (carbon), O (oxygen), N (nitrogen), and S (sulfur), and are included within R 3 ;
[0028] T, U, and V are immediately adjacent to one another; and
[0029] W is any non-hydrogen atom in R 3 that is not T, U, or V; or
[0030] (ii) hydrogen, halo, C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, nitro, trifluoromethyl, trifluoromethoxy, azido, —OR 5 , —NR 6 C(O)OR 5 , —NR 6 SO 2 R 5 , —SO 2 NR 5 R 6 , —NR 6 C(O)R 5 , —C(O)NR 5 R 6 , —NR 5 R 6 , —S(O) j R 7 wherein j is an integer ranging from 0 to 2, —NR 5 (CR 6 R 7 ) t OR 6 , —(CH 2 ) t (C 6 -C 10 aryl), —SO 2 (CH 2 ) (C 6 -C 10 aryl), —S(CH 2 ) t (C 6 -C 10 aryl), —O(CH 2 ) t (C 6 -C 10 aryl), —(CH 2 ) t (4-10 membered heterocyclic), and —(CR 6 R 7 ) m OR 6 , wherein m is an integer from 1 to 5 and t is an integer from 0 to 5; said alkyl group optionally contains 1 or 2 hetero moieties selected from O, S and —N(R 6 )—, wherein R 5 , R 6 and R 7 are as defined above.
[0031] Another embodiment of the present invention refers to the compounds of Formula I wherein the π 1 conjugative bridge and C 2 and Z 1 of the anti-aromatic system are connected in a manner selected from the group consisting of:
[0000]
[0032] Wherein R is as defined above.
[0033] Another embodiment of the present invention refers to the compounds of Formula I wherein the electron donating group (D) and X 1 and X 2 of the π 1 conjugative bridge are connected in a manner selected from the group consisting of:
[0000]
[0034] And wherein R is as defined above.
[0035] Another embodiment of the present invention refers to the compounds of Formula I wherein the π 2 conjugative bridge and C 3 and Z 4 of the anti-aromatic system are connected in a manner selected from the group consisting of:
[0000]
[0036] Wherein R is as defined above.
[0037] Another embodiment of the present invention refers to the compounds of Formula I wherein the electron accepting group (A) and X 3 and X 4 of the π 2 conjugative bridge are connected in a manner selected from the group consisting of:
[0000]
[0038] wherein R is defined above independently at each occurrence; and, Acc is an electron accepting group selected from CN, NO 2 , SO 2 R and 0<n<5.
[0039] Another nonlimiting example of the invention includes the following chromophore:
[0000]
[0000] wherein R is defined above, independently at each occurrence.
[0040] Another nonlimiting example of the invention includes the following chromophore:
[0000]
[0000] wherein R is defined above, independently at each occurrence.
[0041] In this invention the term “nonlinear optic chromophore” (NLOC) is defined as molecules or portions of a molecule that create a nonlinear optic effect when irradiated with light. The chromophores are any molecular unit whose interaction with light gives rise to the nonlinear optical effect. The desired effect may occur at resonant or nonresonant wavelengths. The activity of a specific chromophore in a nonlinear optic material is stated as their hyper-polarizability, which is directly related to the molecular dipole moment of the chromophore.
[0042] In this invention, the term “halo,” unless otherwise indicated, includes fluoro, chloro, bromo or iodo. Preferred halo groups are fluoro, chloro and bromo.
[0043] The term “alkyl,” as used herein, unless otherwise indicated, includes saturated monovalent hydrocarbon radicals having straight, cyclic or branched moieties. It is understood that for cyclic moieties at least three carbon atoms are required in said alkyl group.
[0044] The term “alkenyl,” as used herein, unless otherwise indicated, includes monovalent hydrocarbon radicals having at least one carbon-carbon double bond and also having straight, cyclic or branched moieties as provided above in the definition of “alkyl.”
[0045] The term “alkynyl,” as used herein, unless otherwise indicated, includes monovalent hydrocarbon radicals having at least one carbon-carbon triple bond and also having straight, cyclic or branched moieties as provided above in the definition of “alkyl.”
[0046] The term “alkoxy,” as used herein, unless otherwise indicated, includes O-alkyl groups wherein “alkyl” is as defined above.
[0047] The term “aryl,” as used herein, unless otherwise indicated, includes an organic radical derived from an aromatic hydrocarbon by removal of one hydrogen, such as phenyl or naphthyl.
[0048] The term “heteroaryl,” as used herein, unless otherwise indicated, includes an organic radical derived by removal of one hydrogen atom from a carbon atom in the ring of a heteroaromatic hydrocarbon, containing one or more heteroatoms independently selected from O, S, and N. Heteroaryl groups must have at least 5 atoms in their ring system and are optionally substituted independently with 0-2 halogen, trifluoromethyl, C 1 -C 6 alkoxy, C 1 -C 6 alkyl, or nitro groups.
[0049] The term “4-10 membered heterocyclic,” as used herein, unless otherwise indicated, includes aromatic and non-aromatic heterocyclic groups containing one or more heteroatoms each selected from O, S and N, wherein each heterocyclic group has from 4-10 atoms in its ring system. Non-aromatic heterocyclic groups include groups having only 4 atoms in their ring system, but aromatic heterocyclic groups must have at least 5 atoms in their ring system. An example of a 4 membered heterocyclic group is azetidinyl (derived from azetidine). An example of a 5 membered heterocyclic group is thiazolyl and an example of a 10 membered heterocyclic group is quinolinyl. Examples of non-aromatic heterocyclic groups are pyrrolidinyl, tetrahydrofuranyl, tetrahydrothienyl, tetrahydropyranyl, tetrahydrothiopyranyl, piperidino, morpholino, thiomorpholino, thioxanyl, piperazinyl, azetidinyl, oxetanyl, thietanyl, homopiperidinyl, oxepanyl, thiepanyl, oxazepinyl, diazepinyl, thiazepinyl, 1,2,3,6-tetrahydropyridinyl, 2-pyrrolinyl, 3-pyrrolinyl, indolinyl, 2H-pyranyl, 4H-pyranyl, dioxanyl, 1,3-dioxolanyl, pyrazolinyl, dithianyl, dithiolanyl, dihydropyranyl, dihydrothienyl, dihydrofuranyl, pyrazolidinyl, imidazolinyl, imidazolidinyl, 3-azabicyclo[3.1.0]hexanyl, 3-azabicyclo[4.1.0]heptanyl, 3 H-indolyl and quinolizinyl. Examples of aromatic heterocyclic groups are pyridinyl, imidazolyl, pyrimidinyl, pyrazolyl, triazolyl, pyrazinyl, tetrazolyl, furyl, thienyl, isoxazolyl, thiazolyl, oxazolyl, isothiazolyl, pyrrolyl, quinolinyl, isoquinolinyl, indolyl, benzimidazolyl, benzofuranyl, cinnolinyl, indazolyl, indolizinyl, phthalazinyl, pyridazinyl, triazinyl, isoindolyl, pteridinyl, purinyl, oxadiazolyl, thiadiazolyl, furazanyl, benzofurazanyl, benzothiophenyl, benzothiazolyl, benzoxazolyl, quinazolinyl, quinoxalinyl, naphthyridinyl, and furopyridinyl. The foregoing groups, as derived from the compounds listed above, may be C-attached or N-attached where such is possible. For instance, a group derived from pyrrole may be pyrrol-1-yl (N-attached) or pyrrol-3-yl (C-attached).
[0050] The term “saturated cyclic group” as used herein, unless otherwise indicated, includes non-aromatic, fully saturated cyclic moieties wherein alkyl is as defined above.
[0051] The phrase “acceptable salt(s)”, as used herein, unless otherwise indicated, includes salts of acidic or basic groups which may be present in the compounds of the invention. The compounds of the invention that are basic in nature are capable of forming a wide variety of salts with various inorganic and organic acids. The acids that may be used to prepare pharmaceutically acceptable acid addition salts of such basic compounds of the invention are those that form non-toxic acid addition salts, i.e., salts containing pharmacologically acceptable anions, such as the hydrochloride, hydrobromide, hydroiodide, nitrate, sulfate, bisulfate, phosphate, acid phosphate, isonicotinate, acetate, lactate, salicylate, citrate, acid citrate, tartrate, pantothenate, bitartrate, ascorbate, succinate, maleate, gentisinate, fumarate, gluconate, glucaronate, saccharate, formate, benzoate, glutamate, methanesulfonate, ethanesulfonate, benzenesulfonate, p-toluenesulfonate and pamoate [i.e., 1,1′-methylene-bis-(2-hydroxy-3-naphthoate)] salts.
[0052] Those compounds of the invention that are acidic in nature are capable of forming base salts with various pharmacologically acceptable cations. Examples of such salts include the alkali metal or alkaline earth metal salts and particularly the sodium and potassium salts.
[0053] The term “solvate,” as used herein includes a compound of the invention or a salt thereof, that further includes a stoichiometric or non-stoichiometric amount of a solvent bound by non-covalent intermolecular forces.
[0054] The term “hydrate,” as used herein refers to a compound of the invention or a salt thereof, that further includes a stoichiometric or non-stoichiometric amount of water bound by non-covalent intermolecular forces.
[0055] Certain compounds of the present invention may have asymmetric centers and therefore appear in different enantiomeric forms. This invention relates to the use of all optical isomers and stereoisomers of the compounds of the invention and mixtures thereof. The compounds of the invention may also appear as tautomers. This invention relates to the use of all such tautomers and mixtures thereof.
[0056] The subject invention also includes isotopically-labelled compounds, and the commercially acceptable salts thereof, which are identical to those recited in Formulas I and II but for the fact that one or more atoms are replaced by an atom having an atomic mass or mass number different from the atomic mass or mass number usually found in nature. Examples of isotopes that can be incorporated into compounds of the invention include isotopes of hydrogen, carbon, nitrogen, oxygen, sulfur, fluorine and chlorine, such as 2 H, 3 H, 13 C, 14 C, 15 N, 18 O, 17 O, 35 S, 18 F, and 36 Cl, respectively. Compounds of the present invention and commercially acceptable salts of said compounds which contain the aforementioned isotopes and/or other isotopes of other atoms are within the scope of this invention. Certain isotopically-labelled compounds of the present invention, for example those into which radioactive isotopes such as 3 H and 14 C are incorporated, are useful in drug and/or substrate tissue distribution assays. Tritiated, i.e., 3 H, and carbon-14, i.e., 14 C, isotopes are particularly preferred for their ease of preparation and detectability. Further, substitution with heavier isotopes such as deuterium, i.e., 2 H, can afford certain advantages resulting from greater stability. Isotopically labelled compounds of Formula I of this invention can generally be prepared by carrying out the procedures disclosed in the Schemes and/or in the Examples and Preparations below, by substituting a readily available isotopically labelled reagent for a non-isotopically labelled reagent.
[0057] Each of the patents, patent applications, published International applications, and scientific publications referred to in this patent application is incorporated herein by reference in its entirety.
DETAILED DESCRIPTION OF THE INVENTION
[0058] The compounds of Formula I are useful structures for the production of NLO effects.
[0059] The first-order hyperpolarizability (β) is one of the most common and useful NLO properties. Higher-order hyperpolarizabilities are useful in other applications such as all-optical (light-switching-light) applications. To determine if a material, such as a compound or polymer, includes a nonlinear optic chromophore with first-order hyperpolar character, the following test may be performed. First, the material in the form of a thin film is placed in an electric field to align the dipoles. This may be performed by sandwiching a film of the material between electrodes, such as indium tin oxide (ITO) substrates, gold films, or silver films, for example.
[0060] To generate a poling electric field, an electric potential is then applied to the electrodes while the material is heated to near its glass transition (T g ) temperature. After a suitable period of time, the temperature is gradually lowered while maintaining the poling electric field. Alternatively, the material can be poled by corona poling method, where an electrically charged needle at a suitable distance from the material film provides the poling electric field. In either instance, the dipoles in the material tend to align with the field.
[0061] The nonlinear optical property of the poled material is then tested as follows. Polarized light, often from a laser, is passed through the poled material, then through a polarizing filter, and to a light intensity detector. If the intensity of light received at the detector changes as the electric potential applied to the electrodes is varied, the material incorporates a nonlinear optic chromophore and has an electro-optically variable refractive index. A more detailed discussion of techniques to measure the electro-optic constants of a poled film that incorporates nonlinear optic chromophores may be found in Chia-Chi Teng, Measuring Electro-Optic Constants of a Poled Film, in Nonlinear Optics of Organic Molecules and Polymers, Chp. 7, 447-49 (Hari Singh Nalwa & Seizo Miyata eds., 1997), incorporated by reference in its entirety, except that in the event of any inconsistent disclosure or definition from the present application, the disclosure or definition herein shall be deemed to prevail.
[0062] The relationship between the change in applied electric potential versus the change in the refractive index of the material may be represented as its EO coefficient r 33 . This effect is commonly referred to as an electro-optic, or EO, effect. Devices that include materials that change their refractive index in response to changes in an applied electric potential are called electro-optical (EO) devices.
[0063] An example compound of the Formula I may be prepared according to the following reaction scheme. R, in the reaction scheme and discussion that follow, is as defined above.
[0000]
[0064] Another example compound of the Formula I may be prepared according to the following reaction scheme. R, in the reaction scheme and discussion that follow, is as defined above.
[0000]
|
NLO chromophores of the form of Formula I:
and the commercially acceptable salts, solvates and hydrates thereof, wherein Z 1-4 , X 1-4 , π 1-2 , D and A have the definitions provided herein.
| 2
|
FIELD OF THE INVENTION
[0001] The invention relates particularly, but not exclusively, to an accumulator based, phase locked loop system, such as is typically used in a telecommunications system. However, the invention could equally be applied in other applications relying on a frequency synthesiser or a phase modulated signal source.
BACKGROUND OF INVENTION
[0002] Frequency synthesisers are an integral part of any modern communications system, especially any coherent system dependent upon a steady phase difference between each element in the communication network.
[0003] Advancing technology has made possible the use of adaptive beam steering using multiple antennas to provide a focused beam between transmitter and receiver systems, allowing the dual benefits of increased cell capacity with increased rejection of interfering signals. The ability to adjust the output phase of the frequency under digital base-band control is particularly useful as it can reduce the component count used in a transmitter system. Similarly a system which can accurately provide a phase modulated radio frequency signal offers the potential for higher levels of component integration.
[0004] Reference is made to FIG. 1 , which shows a known synthesiser generally designated by reference numeral 10 .
[0005] The synthesiser 10 comprises a phase detector 2 , a low-pass filter 4 , voltage controlled oscillator (VCO) 6 , a divider 8 , and an optional integer “R” divider 12 . A signal having a required output frequency is generated at the output of the VOC 6 .
[0006] Essentially there are two variants to this type of synthesiser, employing either fixed integer dividers or modulated dividers, by a suitably adjusted data stream, which constantly adjusts the integer divider value in the divider 8 . Modulated dividers are also known as fractional-N dividers. The parasitic modulation of the divider output signal is itself modulated by this modulated data stream to ensure the remainder of the phase locked loop can remove this parasitic modulation, whilst preserving the advantages it offers.
[0007] Both types of phase locked loops use a phase frequency detector 2 , which is commonly a digital element, to compare a fed back voltage controlled oscillator output with an incoming reference signal, to which the system is phase locked. The output of the phase frequency detector 2 can be a series of either current or voltage pulses, which are filtered by the loop filter 4 to give a small error voltage. This small error voltage complements the voltage pedestal at the output of the loop filter, ensuring the VCO remains phase locked. The error voltage is the correction voltage supplied to the VCO, to suppress the excess phase noise of this device to levels determined by the phase locked loop dynamic characteristics. The VCO is the device controlled by this negative feed back closed loop system. To provide a frequency translation back to the phase frequency detector 2 , for comparison with the reference signal, the series divider circuit is used. If fractional-n dividers are used, as shown in FIG. 1 , their mean division value can be adjusted to give an effective multiplication of the reference signal, hence allowing the phase locked system to change to different frequencies with respect to the reference signal.
[0008] Digital dividers have the net effect of raising the phase noise of the system because their dividing action in the feed back path of the system translates to a multiplication of PFD related noise in the through transfer characteristic of the phase locked loop.
[0009] Arrangements using digital dividers in their feed-back path offer limited noise performance preventing their simple implementation in new, more demanding, communication system applications.
[0010] Single loop fractional-N techniques, described earlier, have been adapted to improve on divider limitations by raising the sampling frequency seen at the digital phase frequency detector input to reduce these division values. However, a point is reached where the sampling frequency approaches half the synthesiser's output frequency (for a minimum division value of 2). Beyond this point only another 3 dB of improvement might be possible, although this still does not guarantee that the resulting in-band phase noise becomes acceptable.
[0011] Also known is the use of phase locked loops employing a mixer as a frequency translation element, in order to improve the in-band phase noise using a combination of analogue phase locked loops and direct digital synthesisers. In an alternative PLL arrangement, a mixer arrangement is used in place of the divider 8 . When mixers are used, additional signal sources are required to provide this frequency translation. Mixers do not raise the in-band phase noise levels, because their action is to subtract two signals in the feed back path, giving no change in phase at the mixer output, and hence no adverse effect to a system which tracks only phase. A phase locked loop using a mixer has a minimal multiplication of any spurious energy injected into the reference input.
[0012] The direct digital synthesisers provide the necessary frequency interpolation required for attaining the specified frequency steps at the phase locked loop output. Reference is made to the Qualcom application note AN2334-4, (1990) and U.S. Pat. Nos. 4,965,533, and 5,184,093 on the subject.
[0013] Alternatively the direct digital synthesiser is applied to the phase frequency detector input, with a consequent spurious degradation seen at the phase locked loop output.
[0014] A phase locked loop possesses a typical transfer characteristic of a band-pass system. This band-pass is filter characteristic is centred about the output VCO's signal, which at high frequencies (given the low loop bandwidths of the phase locked loop) represents a very high “Q” factor that cannot be achieved any other way.
[0015] The alternative to analogue phase locked loops, as described herein above, are direct digital synthesisers. Direct digital synthesisers are not phase locked systems, as they do not possess a feedback path between their output and inputs. They are capable of open loop operation because their all-digital nature guarantees repeatable outputs under all conditions. They do not suffer from the vagrancies of analogue systems. The basic concept of direct digital synthesisers remains unchanged from the original paper presenting the idea given in 1971. As shown in FIG. 2 , a direct digital synthesiser 20 is built up of three components; a digital (phase) accumulator 14 , a sine (or cosine) look-up table 16 , and a digital to analogue converter (DAC) 18 . External to the direct digital synthesiser 20 is an analogue low pass or band pass filter 22 . A reference clock 24 clocks the digital accumulator 14 and the DAC 18 .
[0016] The purpose of the digital accumulator 14 is to digitally integrate the digital input word provided on an input thereto, resulting in a ramp output at the required frequency. This defines the digital input word as a phase value equivalent to the phase difference over one accumulator clock period to give the required output frequency. Every time the accumulator overflows the “carry out” bit is ignored and the accumulator output re-starts it's integration sequence, giving an output word pattern resembling a ramp. The length of the digital accumulator 14 determines the phase resolution available for each accumulator clock cycle and hence the accuracy of the output frequency. Using this concept of phase increments, the required digital input word for a given output frequency can be calculated using the expression:
Input Accumulator Word = F Required × 2 Accumulator Length F Accumulator Clock
[0017] In a practical system the length of the accumulator data word exceeds the resolution of the following sine look up table, therefore only the “P” most significant bits are fed into the sine look up table. The value of “P” depends upon the combined width of the sine look up table and any compression circuitry used to mirror and invert the output of the sine look-up table output. It is the function of the sine look-up table 16 to convert the truncated accumulator equivalent phase value to a digital equivalent amplitude value, using a sine or cosine transfer characteristic. This digital amplitude is converted into an analogue signal level using a digital to analogue converter 18 clocked at the same frequency as the digital accumulator 14 . In some direct digital synthesiser designs additional pipelining circuitry may be added to overcome circuit settling times allowing higher frequencies of operation. There is no effect on the quality of the output signal, with such pipelining only a slight phase delay is incurred between a change in digital input to analogue output.
[0018] Direct digital synthesisers are comprised of all digital elements making them suitable for integration into a chip. However one major performance limitation is the digital-to-analogue converter at the output. This digital-to-analogue converter generates problems; reducing the spurious free dynamic range and raising the noise floor. To minimise these effects caused by sampling and aliasing during the digital-to-analogue converter operation, the passive reconstruction filter 22 is normally used to “clean-up” the signal before it is used in the remainder of the system it is employed to drive.
[0019] Direct digital synthesisers cannot operate at the required local oscillator frequencies of contemporary mobile communication systems with the necessary noise and spurious performance. Therefore in current known solutions direct digital synthesisers are combined with analogue or digital phase locked loop techniques, to perform the necessary up-conversion of their lower frequency signals.
[0020] As described hereinabove, any phase locked loop employing a digital divider in its feedback path possesses gain. Therefore any small direct digital synthesiser related spurious products would be subject to this gain, usually raising their level to unacceptable levels. Analogue loops using only a mixer in the feedback path have no such gain, giving a unity translation of input DDS spurious levels.
[0021] It is an aim of the present invention to provide a solution which overcomes the above-stated problems.
SUMMARY OF THE INVENTION
[0022] In accordance with the present invention, there is provided a phase locked loop comprising: a phase frequency detector for receiving as a first input a reference signal and for generating a control signal; a voltage controlled oscillator for receiving the control signal and for generating a signal defining an output frequency, a feedback path connecting the output signal to a second input of the phase frequency detector; and a digital accumulator for generating the reference signal under the control of an accumulator reference clock.
[0023] Preferably there is further provided a summer having a first input connected to the output of the phase frequency detector and an output connected to the input of the voltage controlled oscillator, and a digital to analogue converter having a first input connected to the output of the digital accumulator, a second input of the summer being connected to the output of the digital to analogue converter.
[0024] Preferably the digital to analogue converter is clocked by a clock signal derived from dividing the accumulator reference clock.
[0025] The digital to analogue converter may be connected to the digital accumulator via a latch. The latch may be clocked by the clock signal derived from the accumulator reference signal.
[0026] The accumulator reference clock may be divided on input to the accumulator. The digital to analogue converter may be connected to the digital accumulator via a look-up-table. The look-up-table may be one of either a sine look-up-table or a cosine look-up-table.
[0027] The phase detector circuit may receive a further reference signal from the digital accumulator.
[0028] The reference signal may be provided by the most significant bit of the digital accumulator, and the further reference signal is provided by at least one further bit of the digital accumulator.
[0029] The most significant bit may be provided to the phase detector via a divider, and the at least one further bit is provided to the phase detector by a latch. The latch may be clocked by a divided version of the accumulator reference clock.
[0030] The feedback path may be provided by a divider.
[0031] The accumulator reference clock may be provided by a reference clock generator.
[0032] The feedback path may be provided by a mixer. The mixer may receive as a first input the signal defining the output frequency and as a second input the accumulator reference clock. The accumulator reference clock may be generated by a further phase locked loop. The further phase locked loop may generate the accumulator clock as its output signal and receives a reference clock signal as the input reference signal. The digital accumulator may receive the accumulator reference clock, and the mixer receives a further accumulator reference clock. The accumulator reference clock and the further accumulator reference clock may be provided by first and second further phase locked loops.
[0033] The further phase locked loop circuit may comprise a reference divider for receiving a reference clock signal, a phase detector connected to receive the output of the reference divider, and a voltage controlled oscillator connected to receive the output of the phase detector, the output of the voltage controlled oscillator forming the second input to the mixer and the clock input for the digital accumulator, there further being a feedback path from the output of the voltage controlled oscillator to the phase detector of the reference generating circuit.
[0034] The feedback path may comprise a divider.
[0035] There may further be provided a low pass filter at the input to the voltage-controlled oscillator of the further phase locked loop.
[0036] The digital accumulator may receive as an input a digital frequency input word.
[0037] There may further be provided a low pass filter at the input of the voltage-controlled oscillator.
[0038] There may further be provided an IF filter at the output of the mixer.
[0039] A mobile communication system may include a phase locked loop as described. A mobile telephone handset may include a phase locked loop as described. An integrated circuit may include a phase locked loop as described.
[0040] The invention uses a variety of commonly available elements to derive a frequency synthesiser based system optimised for phase noise and lock time. Particular attention has been given to optimising the application of each element within the system so they serve their purpose without duplication. This invention relates to a variety of systems all using a digital accumulator core. The second part of this invention relates to using digital dividers to offset some of the limitations of this technique. The applicability of these dividers and their obvious advantages applies equally to other existing applications of direct digital synthesisers.
[0041] This invention offers both static phase coherency and dynamic phase adjustment.
BRIEF DESCRIPTION OF THE FIGURES
[0042] The invention will now he described with reference to the accompanying Figures, in which:
[0043] FIG. 1 illustrates a prior art phase locked loop;
[0044] FIG. 2 illustrates a prior art direct digital synthesiser;
[0045] FIG. 3 illustrates a simple phase locked loop in accordance with the present invention;
[0046] FIG. 4 illustrates a mix-down phase locked loop in accordance with the present invention;
[0047] FIG. 5 illustrates the phase locked loop of FIG. 3 with compensation;
[0048] FIG. 6 illustrates the phase locked loop of FIG. 4 with compensation;
[0049] FIG. 7 illustrates the phase locked loop of FIG. 3 with a digital divider;
[0050] FIG. 8 illustrates the phase locked loop of FIG. 4 with a digital divider;
[0051] FIG. 9 illustrates a combination of the phase locked loops of FIGS. 5 and 7 ;
[0052] FIG. 10 illustrates a combination of the phase locked loops of FIGS. 6 and 8 ;
[0053] FIG. 11 illustrates a direct digital synthesiser phase locked loop with a digital divider according to the present invention;
[0054] FIG. 12 illustrates a direct digital synthesiser mix-down phase locked look with a digital divider according to the present invention;
[0055] FIG. 13 illustrates a phase locked loop with a complex digital phase frequency detector according to the present invention; and
[0056] FIG. 14 illustrates a mix-down phase locked loop with a complex digital phase frequency detector according to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0057] Referring to FIG. 3 there is illustrated a first example implementation of the present invention in a simple phase locked loop. The simple phase locked loop refers to the PLL 10 of FIG. 1 . In accordance with the present invention, there is additionally provided a digital accumulator 26 and a phase locked reference clock source 28 . The digital accumulator 26 additionally receives frequency input word 30 . A single bit of the digital accumulator 26 , the most significant bit MSB on line 32 , forms the input to the PLL 10 . The input to the PLL 10 is the reference input to a single bit, digital phase frequency detector 2 . The required output frequency is generated on an output line 36 of the PLL 10 . It should be noted that the digital accumulator 26 and reference clock 28 of FIG. 3 correspond to the digital accumulator 14 and reference clock 24 of FIG. 1 .
[0058] Referring to FIG. 4 , there is shown a further example of the implementation of the present invention in a mix-down phase locked loop. Referring to FIG. 41 the mix-down phase locked loop includes the phase frequency detector 2 , low pass filter 4 and VCO 6 of the simple phase locked loop of FIG. 1 . The divider 8 of the phase locked loop of FIG. 1 is replaced by an IF filter 38 and a mixer 40 . The feedback input to the phase frequency detector 2 is provided from the required output frequency 36 via the mixer 40 and the filter 38 in series. A further input to the mixer 40 is provided on line 52 from a further voltage controlled oscillator 42 . A reference signal 54 provides an input to a divider 48 having a divider ratio of 1/R. The output of the divider 48 forms an input to a phase frequency detector 46 . The output of the phase frequency detector 46 is presented to a low-pass filter 44 , which drives the VCO 42 to generate the signal 52 . The signal 52 is additionally fed through a divider 50 having a divider ratio of 1/N to provide the second input to the phase frequency detector 46 . The signal on line 52 additionally provides a clock signal to the digital accumulator 26 , which is configured in the same way as the digital accumulator 26 of FIG. 3 . Thus in FIG. 4 the digital accumulator 26 receives a digital frequency input word 30 and generates a single signal providing the most significant bit stored in the digital accumulator 26 , on line 32 .
[0059] The synthesisers described herein in accordance with the invention with reference to FIGS. 3 and 4 use a digital accumulator to provide a correct frequency-interpolated output signal through the most significant bit of the digital accumulator 26 . This “most significant bit” signal MSB contains the correct mean frequency as well as a strong unwanted phase modulation, since the remainder of the phase information remains untouched in the phase accumulator. Normally, a direct digital synthesiser uses the “P” most significant bits available in the digital phase accumulator to drive the remainder of the device, preserving much of the available phase information.
[0060] With this simple scheme as illustrated in FIGS. 3 and 4 there is a problem associated with reducing the strong spur energy found at different, well defined input clock to output frequency ratios. This problem is due to the single most significant bit value only containing the phase values of 0° or 180° necessary to drive the single bit, digital phase frequency detector. To overcome this problem, in a preferred embodiment as described herein below, with reference to FIGS. 5 and 6 , the invention uses a combination of digital dividers and digital-to-analogue converters to compensate for this excess spur energy.
[0061] FIGS. 5 and 6 illustrate how the digital phase information available in the digital accumulator may be directly fed into a digital-to-analogue converter. The phase information may also be sub-sampled and fed into a digital-to- analogue converter to reduce the digital-to-analogue converters operating frequency at higher accumulator operating frequencies.
[0062] Referring to FIG. 5 , there is illustrated an example implementation of the simple phase locked loop of FIG. 3 according to the invention with a further modification to include phase compensation. Thus the arrangement of FIG. 5 further includes a latch 62 , a digital-to-analogue converter 60 and, as will be further described herein after, a divider 68 . A digital word is output from the digital accumulator on line 64 , representing the phase of the digital word stored in the digital accumulator 26 . The output digital word is latched into a latch 62 , which on its output provides a word 66 which forms an input to the digital-to-analogue converter 60 . The digital-to-analogue converter 60 provides an analogue signal on line 74 representing the phase of the digital word stored in the digital accumulator 26 . This analogue signal is provided to a summing unit 72 which removes the phase value from the signal at the output of the phase frequency detector 2 .
[0063] The latch 62 and digital-to-analogue converter 60 may be clocked directly by the clock signal on line 34 generated by the reference clock 28 . However in a preferable implementation of the invention, and as discussed in further detail herein below, the clock signal on line 34 may be divided by the divider 68 to generate a reduced clock on line 70 for clocking both the latch 62 and the digital-to-analogue converter 60 .
[0064] FIG. 6 illustrates an example implementation of the mixed-down phase locked loop of FIG. 4 according to the present invention with phase compensation included. The modification to FIG. 6 relative to FIG. 4 is identical to the modification of FIG. 5 relative to FIG. 3 , and therefore a detailed explanation to the modifications is not given here. It will be apparent from referring to FIG. 6 that the latch 62 , digital-to-analogue converter 60 , summing unit 72 , and divider 68 are introduced into the circuit of FIG. 4 in exactly the same manner as they are introduced into the circuit of FIG. 3 to provide phase compensation.
[0065] There are some integer frequencies at which the digital information being passed into the digital-to-analogue converter are not able to correctly compensate for the modulation available on the “MSB” data bit. To overcome this problem the divider 68 feeding the digital-to-analogue converter is adjusted for those frequencies.
[0066] The preferable lower frequency digital-to-analogue converter 60 , clocked by reduced clock signal 70 , serves to sub-sample the Phase information available in the digital accumulator and apply this information as a correction to the output of the phase frequency detector 2 in the analogue phase locked loop. For lower frequency applications, the digital-to-analogue converter need not sub-sample the accumulator's contents and the accumulator contents may be fed directly into the digital to analogue converter and the latch 62 and the divider 68 not utilised.
[0067] The data output from the sub-sampled digital accumulator 26 may, in a further modification, be fed through a simple passive-shaping look up table or active noise shaping element, to reduce the spurious energy parasitic to the digital to analogue conversion operation. This noise shaping entity could also use the most significant bit MSB as one of it's inputs.
[0068] One distinct advantage of digital accumulators is their inherent ability of produce absolute frequencies with frequency resolutions limited only by the accumulator length. Therefore as a means of minimising spur problems adjustable digital dividers can be additionally used to divide down the master clock frequency into the accumulator, as is illustrated by FIGS. 7 and 8 .
[0069] Referring to FIG. 7 there is illustrated the simple phase locked loop of FIG. 3 incorporating such an additional divider. As can be seen from FIG. 7 , a digital divider 80 is introduced between the reference clock 28 and the clock input of the digital accumulator 26 . Thus a divided clock signal is provided by the digital divider 80 on line 84 from the reference clock signal on line 34 . Referring to FIG. 8 there is similarly illustrated a modification to the mixed-down phased locked loop of FIG. 4 to include an additional divider. Again, the digital divider 80 is provided to divide down the clock signal 52 to provide a reduced clock signal 82 to the digital accumulator 26 .
[0070] It is necessary for the frequency word 30 programmed into the digital accumulator 26 to be modified to accommodate a division value D in the digital divider 80 of FIGS. 7 and 8 and still provide a final output frequency.
[0071] The digital divider 80 effectively changes the clock frequency driving the accumulator 60 , thereby altering the positions of the inter-multiplication products responsible for spurious products. This technique enables the strongest of these products to be avoided, but does not remove them in all cases. The modification to the formula given earlier above is:
Input Accumulator Word = F Required D × 2 Accumulator Length F Accumulator Clock
Where “D” is the preceding reference clock division value, i.e. the division value of the divider 68 .
[0073] Using the digital divider 80 , has the advantage of reducing the overall clock frequency of the digital accumulator 26 whilst still reducing the stronger spur levels of higher frequency accumulators. This is made possible because the divider 80 can be adjusted for each frequency to ensure the stronger accumulator spur “hot spots” are avoided.
[0074] Reducing the clocking frequency of the digital accumulator has the additional distinct advantage of reducing the overall system power during normal operation.
[0075] The advantageous divider as illustrated with reference to FIGS. 7 and 8 can be additionally and advantageously included in the phase compensation arrangements for FIGS. 5 and 6 . Referring to FIG. 9 , there is illustrated a preferable implementation of the simple phase locked loop arrangement with phase compensation as shown in FIG. 5 further incorporating the digital divider as shown in FIG. 7 . As can be seen from FIG. 9 , the effect of the digital divider in such an arrangement is to reduce the clock signal not only to the digital accumulator 26 , but additionally to the latch 62 and to the digital-to-analogue converter 60 .
[0076] Referring to FIG. 10 , there is similarly shown the introduction of the digital divider 80 of FIG. 8 introduced into the mix-down phase locked loop with compensation as shown in FIG. 6 . As for FIG. 9 , the digital divider 80 results in a reduced clock signal being applied to the digital accumulator 26 as well as the latch 62 and digital-to-analogue converter 60 . It will be apparent from the foregoing description and from referring to FIGS. 9 and 10 , that the clock signal applied to the latch 62 and the digital-to-analogue converter 60 is further reduced by the divider 68 when the divider 68 is utilised.
[0077] The position of the frequency spurs bears a simple relationship with the master clock (ie the reference clock 28 ) frequency, which can be calculated using the accepted inter-modulation formula:
Spur Frequencies=± N×F Accumulator ±M×F Digital Equivalent Output Frequency
Where N and M are integers.
[0079] What are the integers N and M—how are they derived/determined. The integers n and m range from negative to positive offsets. For example, n is kept at a particular integer value within the offsets, whilst m is varied across the offsets. This is done for every value of n, and in this way a graphical table of values can be established. In this way, the above equation may be used to predict where spur energies will fall for any given output frequency.
[0080] The principle of utilising a digital divider to reduce the clock frequency of the digital accumulator 26 and thereby minimise frequency spurs can also be applied to direct digital synthesisers. Referring to FIG. 11 , there is illustrated the simple phase locked loop with digital divider as shown previously in FIG. 7 further adapted to include a direct digital synthesiser for generating the input to the phase frequency detector 2 . Referring to FIG. 11 , the digital accumulator 26 generates an output word 104 which forms an input to sine look-up table 100 . The sine look-up table generates an output word 106 to a digital-to-analogue converter 102 which provides an analogue signal on line 108 to the phase frequency detector 2 . The implementation of such a direct digital synthesiser utilised in the digital accumulator 26 , the sine look-up table 100 , and the digital-to-analogue converter 102 is well known in the art.
[0081] Similarly referring to FIG. 12 , the mix-down phase locked loop including the additional divider for reducing the clock signal to the digital accumulator 26 of FIG. 8 is adapted as shown in FIG. 12 to include the sine look-up table 100 and the digital-to-analogue converter 102 to generate the signal on line 108 to the phase frequency detector 102 .
[0082] When the output frequency of the digital accumulator 26 is known to fall close to one of the problem frequencies, determined using the expression for spur frequencies stated above, the digital divider 80 is reprogrammed. This requires the digital accumulator 26 to also be reprogrammed to synthesise another frequency which is removed from the vicinity of the known problem frequency. Consequently, the output frequency of the digital accumulator 26 will be correct to drive the phase locked loop, but will possess lower unwanted spur energy.
[0083] In an alternative arrangement the digital-to-analogue converter 60 of FIGS. 5 and 6 (or FIGS. 9 and 10 ) could be replaced (or supplemented) using a suitable digital phase frequency detector which accepts a constant update of (sub-sampled) phase information from the digital accumulator 26 , as part of its operation.
[0084] Such an alternative arrangement is illustrated in FIGS. 13 and 14 . Referring to FIG. 13 , the direct digital synthesiser phase locked loop including the digital divider as shown in FIG. 11 is modified to Include a divider 110 and a complex digital phase frequency detector 112 and the latch 116 in place of the sine look-up table 100 and the digital-to-analogue converter 102 and the phase frequency detector 2 . Referring to FIG. 13 , the digital accumulator 26 outputs a digital word 104 to a latch 116 , which in turn provides digital word 118 to the complex digital phase frequency detector 112 . In addition the digital accumulator 26 outputs the most significant bit of the word stored therein on line 32 to the divider 110 which provides a divider signal on line 114 to the complex digital phase frequency detector 112 . The digital accumulator 26 is clocked by the reference clock signal on line 34 , the latch 116 is clocked by a divided reference clock signal, provided by the divider 68 dividing the reference clock signal on line 34 .
[0085] The direct digital synthesiser mix-down phase locked loop of FIG. 12 may be similarly adapted to include the latch 116 , divider 110 , and complex digital phase frequency detector 112 , as shown in FIG. 14 .
[0086] Digital phase information is continuously loaded into the phase frequency detector 112 , where the value is compared to the current phase offset it has determined allowing it to decide an output value. Using the more complex digital phase frequency detector 112 , it is possible to utilise more of the data values available in the digital accumulator without using (or supplementing) the DAC.
[0087] Important to the invention is the integration of each element's functionality within the system to avoid unnecessary duplication. Using only the digital accumulator 26 as shown in FIGS. 13 and 14 removes the high frequency digital-to-analogue converter 102 and sine look-up table 100 (and the optional reconstruction filter), all of which are difficult to implement at high clock speeds. Instead the analogue phase locked loop of FIGS. 13 and 14 acts like a parametric sine look-up table, high frequency digital-to-analogue converter and tracking reconstruction filter, by translating the phase information available in the digital accumulator 26 through the VCO 6 , within the analogue phase locked loop, to the required output frequency. The analogue phase locked loop acts as a self-oscillating sinusoidal output, as well as a high “Q” factor tracking reconstruction filter. One particular advantage is the output signal of the analogue phase locked loop is not limited to Nyquist sampling theory, as a direct digital synthesiser driven digital-to-analogue converter would be. Thereby an excellent signal-to-noise ratio is preserved. The total system becomes a digital and analogue hybrid circuit, using the easiest equivalent analogue or digital block necessary to complete the system.
[0088] In each of the above example implementations of the present invention a mix-down approach has been included with the digital divider approach. Using the mix down approach in the analogue phase locked loop removes sufficient closed loop gain reducing the amplification of digital phase/frequency detector noise and any residual spur energy. Therefore, in contrast to the low loop bandwidths used in standard phase locked loops, this loop requires a large loop bandwidth (which is ideal for very fast lock times) to minimise the overall phase noise profile seen at the output.
[0089] In the examples given hereinabove illustrating the invention being utilised in a mix-down approach, a single PLL is shown providing the clock signal to the accumulator 26 and the mixer 40 . However the invention is not limited to such an arrangement. In one alternative, the respective clock signals provided to the accumulator 14 and the mixer 40 may be provided by separate PLLs, each driven by a common reference signal.
[0090] For all the above examples the input to the digital accumulator 26 can be used for absolute phase adjustment of the analogue output signal. Alternatively it can be used for phase modulating this output signal to accurately reproduce any phase modulated output at much higher frequencies. This phase modulation capability could also be used to introduce noise shaping into the system to reduce the spur energy still further. Any sigma delta or noise dithering scheme could be employed.
[0091] It should be noted that the invention has been described herein with reference to particular examples. The invention is limited in its scope by the appended claims, and the applicability of the present invention may be broader than that as discussed above in the examples given.
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There is disclosed a phase locked loop comprising: a phase frequency detector for receiving as a first input a reference signal and for generating a control signal: a voltage controlled oscillator for receiving the control signal and for generating a signal defining an output frequency, a feedback path connecting the output signal to a second input of the phase frequency detector; and a digital accumulator for generating the reference signal under the control of an accumulator reference clock.
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RELATED APPLICATIONS
This appliction is a continuation of application Ser. No. 584,886, filed Feb. 29, 1985 and now abandoned, which was a continuation of application Ser. No. 446,994, filed Dec. 6, 1982 and now abandoned. Subject matter disclosed herein is also disclosed in my application Ser. No. 446,995, filed concurrently with application Ser. No. 446,994.
This invention relates to a method and apparatus for providing a fluid-tight seal between two concentric rigid members in order to seal the annulus between the two members against large fluid pressures. While more generally applicable, the invention is especially useful in sealing between concentric well members, as between a wellhead body and a casing hanger or between a wellhead body and a tubing hanger, particularly when such seals must be established remotely at a location under water.
BACKGROUND OF THE INVENTION
There are numerous requirements for sealing the annulus between two stationary concentric rigid members, with such applications usually requiring that the seal be effective against large fluid pressures. One such requirement which is increasingly difficult to satisfy is for sealing between concentric well members, as between a wellhead member and a casing string or between a wellhead member and one or more tubing strings, particularly when the seal is to be established by remote operations at considerable depth under water in an offshore well installation.
Historically, such seals have been established by elastomeric sealing elements, as seen for example in U.S. Pat. No. 3,268,241 to Castor et al, or by using so-called metal lip seals, as in U.S. Pat. No. 3,378,269 to Castor, or by using Laurent seals of the type shown for example in U.S. Pat. No. 2,687,229 to Laurent. The conditions under which such seals must operate have become increasingly severe, particularly in offshore well applications. Thus, specifications for offshore well installations now frequently require that such seals be effective against internal pressures at the wellhead of 15,000 p.s.i., and that capability frequently must be achieved under conditions of remote installation of the two concentric members and of the seal device itself. Particularly in the offshore well industry, there has been a trend away from elastomeric sealing elements toward metal-to-metal seals, with the metal-to-metal seal being viewed as a more dependable device over a long time period than seals depending upon elastomeric materials. However, conventional metal-to-metal sealing elements, such as the metal lip seals, depend upon elastic deformation of the sealing element, first mechanically and then in response to the pressure against which the seal is to act, and such devices have not always been dependably successful. Further, such devices must have a shape allowing the seal device to be elastically deformed under mechanical pressure applied by the parts being sealed, and this requirement has in some cases resulted in damage to the seal element, or the surfaces against which that element is to act, during remote installation of the seal element. There has thus been a continuing need for improvement, particularly when a metal-to-metal sealing action is needed.
OBJECTS OF THE INVENTION
It is accordingly a general object of the invention to provide a method and apparatus which will better serve the requirements for sealing between concentric well members and between other concentric rigid members.
Another object is to provide such a method and apparatus in which the seal element is of such dimension and shape that the seal element does not come into engagement with a critical surface, such as the surface portion of a bore wall against which the seal is to act, before the seal element is in place and ready to be activated.
A further object is to devise such a method and apparatus making it possible to bring the seal element into sealing engagement as a result of plastic deformation of the seal element.
Yet another object is to provide such a method and apparatus which makes possible remote sealing across an annulus between two rigid members with sealing being accomplished solely by a plastically deformed metal element in true metal-to-metal sealing fashion.
SUMMARY OF THE INVENTION
According to method embodiments of the invention, concentrically opposed surface portions are provided on the two rigid members, at least one of these surface portions being generally frustoconical and tapering longitudinally of the rigid members so that the two surface portions define an annular space tapering from a first end of larger radial width to a second end of smaller radial width. Into this space is preliminarily inserted a sealing ring which has a radial thickness which tapers axially. The direction of taper and the dimensions of the ring are such that, when preliminarily inserted, at least a leading portion of the ring substantially bridges the space between the annular surface portions of the rigid members but does not provide an effective seal. At least the leading portion of the sealing ring is of a material having good plastic deformation properties, low carbon steel in the annealed or normalized state being typical of such materials when a metal-to-metal seal is desired. While the two concentric rigid members are held against axial displacement, a large pressure is applied to the end of the ring which is of larger radial thickness, the pressure being uniformly distributed over the annular extent of the ring and directed axially toward the end of smaller radial thickness, the effect of the applied pressure being to force the ring to move further into the annular space in wedging fashion and to be plastically-deformed, as a result of the further movement relative to the rigid members and the tapering nature of the annular space, so that the plastically-deformed portion of the ring is forced into fluid-tight sealing engagement with the concentrically opposed surface portions of the rigid members. The seal member is then locked to one of the rigid members to retain the ring in its sealing position.
In particularly advantageous embodiments, one of the concentrically opposed surface portions is interrupted by a transverse annular shoulder facing toward the end of the annular space which is of smaller radial width, providing in effect an annular recess into which the material of the seal ring flows during movement of the ring to its final position. Thus, with the one of the concentrically opposed surface portions carried by the inner rigid member being frustoconical and uninterrupted, the outer surface portion can include a first right cylindrical portion of smaller diameter joined by the transverse shoulder to a second right cylindrical portion of slightly larger diameter.
Though application of pressure to force the seal ring to its final position and cause the desired plastic deformation can be accomplished in various ways, it is advantageous to so construct the seal ring that it can act as a piston, and to apply fluid under pressure to generate the necessary force for moving the seal ring relative to the concentric rigid members.
IDENTIFICATION OF THE DRAWINGS
FIG. 1 is a view, partly in vertical cross section and partly in side elevation, of an underwater well apparatus in which sealing across the annulus between a wellhead body and a casing hanger has been accomplished according to one embodiment of the invention;
FIGS. 2-4 are fragmentary cross-sectional views taken generally on lines 2--2, 3--3 and 4--4, FIG. 1, respectively;
FIG. 5 is a fragmentary vertical cross-sectional view, enlarged with respect to FIG. 1, showing the seal ring preliminarily inserted into the annular space between concentrically opposed surface portions of the wellhead body and casing hanger;
FIG. 6 is a view similar to FIG. 5 but showing the seal ring after reaching its final position, with plastic deformation having occurred; and
FIG. 7 is a view similar to FIG. 6 illustrating another embodiment in which the final stage of insertion of the seal ring is accomplished by a tool which is subsequently retrieved.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates one embodiment of the invention as applied to sealing across the annulus 1 between a wellhead lower body 2 and a casing hanger 3. The apparatus shown is part of a subsea well installation, with body 2 being secured to the upper end of an outer casing string 4, hanger 3 being supported on body 2 by a shoulder 5 seated on an annular series of segments 6 seated on a shoulder 7 on body 2, and with annulus 1 being in communication, in any suitable fashion, with the annulus between outer casing 4 and the casing (not shown) suspended from hanger 3.
Comparing FIGS. 1 and 5, it will be seen that most of annulus 1 is defined by the main bore wall 8 of body 2 and the main outer surface 9 of hanger 3, both of which are right cylindrical, with surface 9 being spaced inwardly from and concentric with wall 8. However, at the upper end of hanger 3, annulus 1 is defined by two concentrically opposed surface portions 10 and 11. Surface portion 10 is presented as part of the through bore of body 2 and includes an upper right cylindrical portion 12 and a lower right cylindrical portion 13, the latter being of slightly larger diameter than the former, portions 12 and 13 being joined by a transverse annular downwardly facing shoulder 14. Surface portion 11 forms part of the outer surface of hanger 3 and is uninterrupted and frustoconical, tapering upwardly and inwardly at a small angle. Thus, when hanger 3 has been landed on segments 6, surface portions 10 and 11 coact to define an annular space, indicated generally at 15, FIG. 5, which tapers from a larger radial width, at the top of hanger 3, to a smaller radial width, at the lower end of right cylindrical portion 13.
With hanger 3 and body 2 related in the manner just described, a seal ring, indicated generally at 16, is preliminarily inserted downwardly into space 15, this operation being carried out conventionally by use of a handling tool and handling string (not shown). Seal ring 16 includes an integral main body of material capable of exhibiting a significant plastic deformation, low carbon steel in the annealed or normalized state being a typical suitable material. In its initial form ring 16 has a right cylindrical outer surface 17 and an inner surface including a main frustoconical portion 18, tapering upwardly and inwardly at the same angle as surface portion 11 of hanger 3. The inner surface of the seal ring also includes a short right cylindrical portion 19 which extends upwardly from frustoconical portion 18 and joins a transverse annular downwardly directed shoulder 20. Shoulder 20 joins a short right cylindrical inner surface 21 which extends to the upper end face of the ring. The upper end face includes an outer frustoconical portion 22 which tapers upwardly and inwardly for a purpose hereinafter described.
In a location spaced from the lower end of the ring by a distance greater than the axial length of surface portion 13, outer surface 17 of the seal ring is interrupted by a transverse annular outwardly opening groove 25, FIG. 5. In a location significantly below that of groove 25, frustoconical inner surface portion 18 is interrupted by a transverse annular inwardly opening groove 26. Grooves 25 and 26 are interconnected by a circularly spaced series of bores 27, FIGS. 3 and 5. Grooves 25 and 26 and bores 27 accommodate an integral body of elastomeric material constituting both an annular outer elastomeric seal body 28 and an inner annular elastomeric seal body 29, seal bodies 28, 29 being interconnected by elastic material within bores 27. With the elastomeric material in its relaxed and undistorted state, body 28 completely fills groove 25 and body 29 not only completely fills groove 26 but also projects slightly inwardly beyond surface portion 18. Accordingly, as ring 16 is preliminarily inserted downwardly into space 15, seal body 29 is progressively compressed as a result of engagement with surface portion 11. Such compression causes elastomeric material to flow outwardly through bores 27 to increase the volume of elastomeric material in groove 25. As a result, the elastomeric material preliminarily seals between ring 16 and both surface portions 10 and 11 as soon as seal body 29 comes into good overlapping relation with the upper end of surface portion 11. Thus, preliminarily inserted as seen in FIG. 5, seal ring 16 is capable of action as a piston when pressure fluid is introduced within body 2.
As will be understood by those skilled in the well art, it is conventional to introduce pressure fluid into the wellhead, after seals have been installed, in order to test the seal or seals. According to the invention, this conventional practice is now employed to apply to the upper end portion of the preliminarily inserted seal ring 16 a large fluid pressure acting downwardly on and uniformly distributed over the annular extent of the ring. Since body 2 is rigidly supported, and hanger 3 is in turn rigidly supported on body 2 by shoulders 5 and 7 and segments 6, there can be no axial displacement of body 2 and hanger 3, and the effect of the applied fluid pressure is thus to force ring 16 downwardly further into annular space 15, in the manner seen by comparing FIGS. 5 and 6. At the start of such further displacement, the portion of ring 16 below elastomeric seal bodies 28, 29 substantially completely fills the annular space between surface portions 10 and 11 but does not seal therewith in acceptable fashion. However, since surface portions 10 and 11 converge downwardly, the remaining lower portion of annular space 15 is of inadequate width to accommodate the lower portion of ring 16 without deformation of the ring. Since the force applied downwardly on ring 16 by the pressure fluid is large in the context of the ability of the relatively ductile metal of ring 16 to resist plastic deformation, progressive movement of the ring downwardly into space 15 causes plastic deformation of the ring to such an extent that the ring completely fills the space between surface portions 13 and 11. Thus, metal of ring 16 in effect flows around shoulder 14, and as ring 16 reaches the final position seen in FIGS. 1 and 6, the lower portion of the ring has been forced into metal-to-metal sealing engagement not only with surface portion 11 but also with surface portion 13.
Installation of the seal can then be completed by installing a split locking ring 30, FIG. 1, between end face portion 22 of ring 16 and the upper side wall 31 of a transverse annular inwardly opening locking groove provided in body 2, ring 16 thus being locked against upward movement relative to body 2. Installation of locking ring 30 is accomplished by use of a conventional handling tool and string (not shown). With the locking ring installed as shown in FIG. 1, the combination of the locking ring and seal ring 16 serves to prevent upward movement of hanger 3 should excessive upwardly acting bore pressure occur.
Should need occur to retrieve seal ring 16, this can be accomplished by first removing locking ring 30 and then lowering a handling tool equipped to engage shoulder 20 of the seal ring and applying an upward strain on ring 16 adequate to deform the portion of ring 16 which is below shoulder 14.
Seal ring 16 extends as a complete, unbroken annulus which, at time of installation, is in an initial undistorted state such that the diameter of outer surface 17 of the ring is slightly smaller than the diameter of part 12 of surface portion 10. Part 12 of surface portion 12 is the smallest diameter to be traversed by ring 16 during its trip down for installation and the possibility of scoring or otherwise damaging outer surface 17 of the ring during the trip down is therefore minimized. Similarly, the diameter of part 13 of surface portion 10 is significantly larger than that of part 12, so that part 13, constituting the outer sealing surface in the final assembly, is protected from damage by tools and components passed through the wellhead before installation of the seal ring. It is to be noted that protection of the two active sealing surfaces 13 and 17 in this fashion is possible only because of the plastic deformation of the seal ring during the final stage of installation.
It is particularly advantageous to form ring 16 of a low carbon steel in the annealed or normalized condition. Thus, the steels identified by AISI numbers 1010, 1030 and 1040 are especially suitable. Austenitic steels, such as those of the AISI 300 series, in the annealed state are also suitable. Non-ferrous alloys, particularly the copper based and aluminum based alloys, can also be employed. Non-metallic materials, such as a composite of polymers with a combination of fillers with or without reinforcing fibers may be suitable for lower temperature and pressure applications. It will also be understood that only the portion of the seal ring which leads during insertion, such as the portion of ring 16 below the elastomeric seal bodies, need be of material capable of plastic deformation.
The Embodiment of FIG. 7
FIG. 7 illustrates an embodiment of the invention in which final insertion of the seal ring, to accomplish the necessary cold flow deformation, is accomplished by use of a tool rather than by introducing pressure fluid into the wellhead. Here, wellhead body 102 and casing hanger 103 again combine to define the annulus 101 to be sealed. The wellhead body again has a through bore and the wall of the through bore includes surface portion 110 which is opposed to surface portion 111 of the casing hanger after the hanger has been landed as described with reference to FIGS. 1-6. Surface portion 110 is identical to surface portion 10, FIGS. 1-6, and includes an upper right cylindrical part 112, a lower right cylindrical part 113 and a transverse annular shoulder 114 joining parts 112 and 113. Surface portion 111 is again frustoconical, tapering upwardly and inwardly.
In this embodiment, seal ring 116 is of the same general configuration as ring 16, FIGS. 1-6, but comprises a lower or leading portion 116a and an upper or trailing portion 116b, the two portions being rigidly interconnected in any suitable fashion. In the initial undistorted state of ring 116, the two portions 116a, 116b combine to present an outer surface 117 which is right cylindrical and of a diameter only slightly smaller than that of part 112 of surface portion 111, and a frustoconical inner surface 118 which tapers upwardly and inwardly at the same angle as does surface portion 111. Upper portion 116b of the seal ring has a transverse annular outwardly opening groove accommodating a circular series of arcuate latch segments 130 which are spring urged outwardly and can be constructed and arranged as described in detail in my U.S. Pat. No. 4,290,483. Body 102 is provided with a transverse annular inwardly opening locking groove 131 at the upper end of part 112 of surface portion 110, to receive segments 130 when the seal ring has been forced downwardly to its final active position. The upper end of portion 116b of the seal ring has a transverse annular downwardly facing shoulder 120, to cooperate with a handling and retrieving tool (not shown) and an upwardly directed flat transverse annular end face 122.
Initial downward insertion of seal ring 116 into the annular space defined by surface portions 110 and 111 is accomplished with a handling string and tool (not shown) in the manner referred to with reference to FIGS. 1-6, leaving the ring in an initial position similar to that shown in FIG. 5, with portion 116a of the ring being as yet undeformed and with latch segments 130 still above groove 131 and bearing on the bore wall of the wellhead body. In this embodiment, downward force is applied to the seal ring to accomplish final insertion by the tool indicated generally at 150. Tool 150 includes a main body 151 which is lowered by a handling string (not shown) and latched against upward movement relative to body 102, as by segments 152 which are constructed and arranged as described in my U.S. Pat. No. 4,290,483 to coact with a locking groove presented by body 102. An annular skirt 153 depends from body 151 and has a stationary seal ring 154 secured to the inner surface thereof. Coacting with skirt 153 and seal ring 154 is an annular piston indicated generally at 155 and presenting an upper outer surface portion 156, spaced inwardly from the skirt and slidably embraced by ring 154, and a lower outer surface portion 157 which is slidably embraced by the inner surface of the skirt below ring 154. An additional seal ring 158 is secured to and embraces the upper end portion of the piston and is slidably embraced by the surrounding portion of the skirt. O-rings or other suitable seals are provided, as shown, so that skirt 153 and piston 155 coact to define an upper expansible chamber 159 and a lower expansible chamber 160, suitable ducting (not shown) being provided for supply of pressure fluid selectively of the two expansible chambers. Supply of pressure fluid to chamber 159 drives piston 155 upwardly relative to tool body 151. Supply of pressure fluid to chamber 160 drives the piston downwardly, to the position shown in FIG. 7.
The lower end of piston 155 has a flat transverse annular downwardly directed end face 161 dimensioned to come into flush engagement with upper end face 122 of ring 116 as the piston moves downwardly. The dimensions of ring 116 and piston 155 are such that, when ring 116 is in its preliminarily inserted position, end face 161 of the piston comes into engagement with upper end face 122 of the seal ring before the downward stroke of the piston has been completed. The total excursion of the piston is such that completion of the downward stroke of the piston forces the seal ring downwardly to the fully inserted position shown in FIG. 7 and thereby results in cold-flow distortion of the lower portion 116a of the seal ring to the condition shown, that portion of the seal ring thus being in metal-to-metal sealing engagement with both surface portion 111 and part 113 of surface portion 110.
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Method and apparatus for establishing a seal across the annulus between two concentric rigid members to seal the annulus against large fluid pressures. A specially formed seal ring, advantageously of low carbon steel in the annealed state, is preliminarily inserted into the annular space between two concentrically opposed surfaces, then forced further into that annular space to force the sealing ring, with accompanying plastic deformation of a portion of the ring, into sealing engagement with both of the concentrically opposed surfaces.
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BACKGROUND OF THE INVENTION
The present invention pertains to a composite mattress system and, more particularly, to such a system which is primarily for institutional use, such as in hospitals, nursing homes and the like, and it is also adapted for domestic use, such as in convertible sofas. In institutional type mattresses, it is well-known that the supporting springs or pans on beds used in hospitals and similar institutions, require bending or flexing of the mattresses due to the supporting spring sections or pans being articulared and relatively movable between, for example, a relatively flat condition and one in which the mattress sections or pans are disposed at angular relationships, such as supporting the back of a patient at an angle to the horizontal, having the knees raised, or in some situations, even having the supporting sections of the bed disposed somewhat as a chair. All of these arrangements usually require that the mattress be capable of being folded along the lines where the springs or pans are flexibly connected for disposing the same in desired angular relationship, and in convertible sofas, similar or even more acute reverse folding also is required.
It also is a desirable factor that the mattresses be comfortable, even though subjected to bending at the articulated connection of the bed spring or pans, and in order to provide adequate comfort, it has been customary to employ mattresses of reasonable thickness, such as of the order of five or six inches or more. Attempting to bend or fold mattresses of this thickness however, presents problems, such as inability to conform closely to the angularly related sections, particularly at the location where the mattress is bent, or the mattress becomes puckered and over a period of time, becomes worn in the sections where it is bent. Further, if a mattress of the exemplary thickness referred to above is not used, and instead, a thinner mattress is employed which would readily be subjected to bending, the thin nature of such mattresses minimizes comfort to the occupant of the bed due to, for example, the mattress "bottoming-out", which is a term commonly known in the mattress industry and refers to the situation where the imposition of a weight, such as a human body upon the mattress, initially is cushioned but, depending upon the amount of the weight, said weight often compresses the mattress to an extent that no further resilience is offered and the support is the same as if the mattress were simply a rigid, immovable surface. The ideal arrangement is one in which when the weight applied to the mattress reaches stability, there is still at least a limited amount of further yieldability and a sensation of contacting an immovable surface is not present.
THE PRIOR ART
Many attempts have been made heretofore to solve the problem defined above, particularly in an effort to achieve suitable comfort, with the mattress being susceptible to bending and at least reasonably free from "bottoming-out". Some of the prior attempts are found in the following patents, as follows:
U.S. Pat. No. 3,663,973 to Spence, dated May 23, 1972, shows a cushion structure in the nature of a mattress in which two layers of non-porous gel have a Dacron mesh imbedded in the gel between the layers, said layers of gel being enclosed within a suitable cover of stockinette material and this, in turn, is enclosed in a waterproof casing, such as pure latex rubber.
U.S. Pat. No. 3,310,300 to Lawson, dated Mar. 21, 1967, discloses a load-bearing unit, such as used in a seating structure and comprises a metal frame across which a sheet of mesh of woven wool or other types of strands extend and at the edges thereof is secured to said frame. The mesh is disposed between a relatively thick upper portion and a thinner lower portion of foam plastic material and it appears that the mesh is embedded within the material rather than extending between two layers thereof.
U.S. Pat. No. 3,323,152 to Lerman, dated June 6, 1967, is directed to a body support comprising layers of polyurethane foam between which a perforated sheet of plywood 1/4 inch in thickness extends to stiffen the support, the layers of polyurethane being sealed at the edges but are not fixed to the sheet of plywood stiffener.
U.S. Pat. No. 3,553,749 to Majeske, dated Jan. 12, 1971, discloses an impact cushion of a laminated nature in which a low density, softer upper layer is connected by adhesive to a much thinner lower layer which is of a firmer high density foam plastic, the cushion primarily being intended for use as an impact means for unloading beer kegs from trucks, etc. A cover of vinyl sheeting or woven fabric, such as canvas, encloses the laminated foam plastic cushion structure.
U.S. Pat. No. 3,757,365 to Kretchmer, dated Sept. 11, 1973, discloses a pillow of polyurethane foam layers, the upper one being softer than the bottom layer, and the upper one being much thicker than the bottom layer, said layers being cemented together.
Lastly, U.S. Pat. No. 3,846,857 to Weinstock, dated Nov. 12, 1974, shows a multi-section variable density mattress comprising three zones of different densities, super-imposed upon a plywood base sheet, the lower foundation section comprising a plurality of members in end-to-end relationship, which include the plywood foundation and upon which a relatively thin foamed plastic sheet is attached, having a relatively high density for firmness. A composite mattress of upper and lower slabs, respectively of high density and low density for top firmness and lower softness is enclosed in the cover and disposed upon the foundation sections for articulation upon a hospital bed. The mattress is stated to be approximately six inches thick and the firm foam plastic slab upon the foundation plywood member is stated to be approximately two inches thick.
SUMMARY OF THE INVENTION
The basic objective of the present invention is to provide a mattress system which includes minimum thickness without sacrifice of comfort in order that the mattress readily may bend as, for example, when used in hospitals, the mattress readily will conform to an articulated bed structure, such as a relatively rigid series of articulated pans or link spring sections when disposed in various angular relationships to best suit the comfort or need of a patient. The mattress preferably is formed from two layers of foamed synthetic resin material which is of relatively low density for softness, said layers being either of the same or relatively close degrees of density and said layers are bonded to an intermediate sheet of mesh of highest tensile strength, one suitable type of material comprising Nylon for purposes of distributing the weight and particularly when concentrated loads are imposed upon the mattress especially by the buttocks of a human body, thereby aiding in minimizing said mattress to "bottoming-out", especially when the mattress is supported upon a bed in which sheet metal pans or link spring sections have relatively little yieldability.
Ancillary to the foregoing object, it is an additional object to support the aforementioned mattress upon a bottom pad of substantially less thickness than the mattress described above and preferably comprised of hingedly connected sections of preferably uniform thickness of much higher density foam synthetic resin to provide substantially greater firmness than the mattress and, in association with the mattress, affording still further capabilities of preventing, or at least minimizing, "bottoming-out" when the assembled mattress or top pad and said bottom pad are supported upon a bed structure affording little, if any, yieldability.
A further object of the invention is to adapt the mattress and bottom pad referred to above to institutional use, such as hospitals and nursing homes, or the like, but it is obvious that such a mattress system can be employed with equal facility for domestic purposes, such as in sofas convertible to a bed, which require substantial folding transversely into a plurality of overlying sections when in stored position within a sofa.
Foam mattresses of limited thickness, when placed on a relatively unyielding surface, tend to "bottom-out" easily due to being incapable of resisting further compression until the unyielding supporting surface actually provides the support for a human body. "Bottoming-out" has been minimized heretofore by increasing the thickness or increasing the density of the foam of the mattress. Increased thickness tends to give an unstable floating feeling when low density foam is used. Increased density reduces mattresses or upholstry confort because the foam surface does not conform easily to the irregular shape of the human body. Mattresses which use a layer of low density foam over a layer of high density foam have been marketed but have not proven superior or desirable over other forms of foam mattresses. As a result, most foam mattresses now in use have a minimum thickness of four or five inches. Foam mattresses of this type are used on institutional beds but many such beds still use interspring mattresses. For other hospital equipment, such as stretchers, operating tables, and the like, it is somewhat common to use foam mattresses of four inch thickness but only limited comfort is expected from such pads.
The thicker the mattress, the greater the weight, the more difficult to handle the same, the greater the cost of material, the more difficulty to conform to irregular or articulating forms and the lesser freedom for design purposes. Conversely, the thinner the mattress, the lighter the weight, the easier to handle, the lesser the cost of material, the easier to conform to irregular or articulating forms, and the greater possibility of design.
Designing mattresses for institutional use, such as in hospitals and nursing homes, presents specialized problems in view of the fact that bed surfaces articulate and bend at angles up to 60°. Thick mattresses are unable to conform to the bending of such bed surfaces and instead, they bend on a larger radius and this action tends to push the patient toward the foot of the bed, thus generating the requirement for increased bed length and greater areas in hospital rooms. A thinner mattress aids in overcoming this problem for either domestic or institutional use.
The weight of mattresses adds to the difficulty of making up the bed and changing sheets, cleaning the bed, moving the bed, and moving the mattress to decontamination areas. A light, relatively thin mattress helps to overcome these problems. Relatively thick mattresses also cause difficulty in achieving a low position for the bed to enable a patient to exit the bed safely; adds to the amount of material required to be used for bed linen; adds to the volume of hospital laundry needs; and tends to deform under weight more easily at the mattress edge, causing the patient to roll out of the bed. A thinner mattress obviates or minimizes most of the foregoing difficulties.
Ideally, a mattress, for either domestic sofa beds or institutional type beds, should have a limited thickness to allow the mattress to bend and conform closely to bed articulation and the same also should be capable of flexing in two directions, especially since most institutional beds afford a knee break which allows the foot end to drop from the horizontal and correspondingly, the part which supports the back of the patient normally extends angularly upward from a horizontal position, thereby bending oppositely from the foot end of the bed. The thickness should be sufficient to perform properly without any additional resiliency-providing backup and, due to the fact that link spring sections in institutional beds are difficult to clean, abrade mattresses and make mattress movement for transfer very difficult, metal pan sections of an articulated nature generally are preferred over link spring sections and, if desired, may be covered with layers of high density foam of very limited thickness or covered with seamless vinyl fabric.
In addition to a mattress system being used by patients while resting or sleeping, it is preferable that they also may be used as a transfer device, especially for transfer to radiology equipment and by making the mattress of radiolucent material, a patient need not be subjected to painful movement. Accordingly, interspring mattresses are unacceptable for such purposes and by employing non-metallic substances in the entire mattress system or at least in those are s which would be subjected to radiology equipment, such mattress systems will serve a dual function.
In addition to the above-described objects of the invention, particularly for purposes of providing a mattress system highly capable of meeting the requirements of minimum thinness without sacrifice of comfort, further objects of the invention are to cover the composite mattress or top pad with sheet material of water and stain resistant qualities, as well as being bacteria resistant and non-allergenic, one such suitable material being merchandised under the trademark "HERCULITE". It has been found, however, that such material has a certain amount of undesirable reaction with the foam plastic of the mattress layers, such as when formed from polyurethane, and in order to minimize or prevent such occurrence, barrier pads or layers of minimum thickness are disposed between at least the top and bottom cover areas and the adjacent surfaces of the foam plastic layers enclosed in said cover; one suitable type of barrier pad being a mixture of polypropylene glycol and toluene diisocyanate to render the cover compatible with the foam of the pads.
Still further, another objective of the invention is to provide appropriate handle structures, especially for the mattress composed of the composite layers of foam plastic, and one highly suitable form is to employ fabric tapes of limited width extending transversely between opposite sides of the mattress adjacent the mesh sheet between the upper and lower layers of foam synthetic resin, the opposite ends of said tape preferably extending beyond the side edges of the mattress and, if desired, may be arranged in loop form to facilitate the use thereof as handles and at least a pair of said tapes are employed in each mattress at longitudinally spaced positions therein.
One further object of the invention is to employ stabilizing mechanism between at least certain of the sections of the bottom pad of relatively firm foam synthetic resin and localized areas of the mattress and one highly satisfactory type of such stabilizing means comprises strips of non-metallic, interengageable and readily detachable plastic fastening means, one commercial variety thereof being sold under the tradename "VELCRO", said attaching means preferably being attached to the intermediate section of the bottom pad and the corresponding section of the mattress or top pad, preferably at the opposite ends of the intermediate sections of said pads, whereby when a human form is disposed upon the top and bottom pads in use, and either the back-supporting section or the leg-supporting section is moved angularly with respect to the intermediate, usually horizontal section, suitable movement of a sliding nature may occur between the mattress supporting means of the bed, such as metal pans, and the sections of the bottom pad which are disposed thereon, as well as between the corresponding end sections of the top and bottom pads.
Many of the foregoing objects also readily apply to mattresses for use in convertible sofas so that the relatively extreme bending of 180° extent may be accomplished while not sacrificing comfort when the mattress and sofa frame and extended for bed use. However, certain of the improvements may not necessarily apply to this type of domestic use.
Details of the foregoing objects and of the invention, as well as other objects thereof, are set forth in the following specification and illustrated in the accompanying drawings comprising a part thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of an exemplary arrangement of the top and bottom pads of the mattress system of the present invention supported upon articulated base members of a conventional nature on a hospital bed, the details of the bed being omitted in such view.
FIG. 2 is a perspective view of a mattress comprising the top pad of a mattress system embodying the principles of the present invention.
FIG. 3 is a perspective view of the bottom pad of the mattress system of the present invention and upon which the mattress of FIG. 2 is supported in use.
FIG. 4 is a fragmentary, somewhat diagrammatic disclosure, illustrating the distribution of said load upon the mattress of the invention shown in FIGS. 1 and 2.
FIG. 5 is an enlarged, fragmentary, vertical section of the mattress or top pad as shown in FIG. 2 and seen on the line 5--5 thereof.
FIG. 6 is an enlarged, fragmentary, vertical section of the bottom pad shown in FIG. 3 as seen generally on the line 6--6 thereof.
FIG. 7 is an end view of an exemplary illustration of the top mattress pad being folded in the manner in which such mattress is employed in a sofa bed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As set forth above, the principal purpose of the present invention is to provide a mattress highly adapted to be subjected to bending and/or folding, such as respectively found in institutional type beds such as hospitals, and also in sofa beds for domestic use. In order to accomplish this and simultaneously prevent "bottoming-out" to provide maximum comfort while minimizing the thickness of the mattress assembly in order to obtain the desired properties of bending and folding, a combination of different types of foamed plastics has been devised as described in detail hereinafter.
It also is preferred, especially for institutional type use, that mattresses be covered with flexible material that is water and stain resistant, as well as being anti-static, non-allergenic and also flame-retardant. In seeking a suitable covering material having the foregoing properties, one was selected which has been found to cause migration of plasticizer from certain types of desired foam plastics to be used in the body of the mattress and thus, it has been necessary to develop a suitable relatively thin barrier pad of foam plastic between such covering material and the foam body of the mattress to minimize or prevent such migration of plasticizer. All of this has been accomplished in the mattress described hereinafter, which employs the principles of the invention, in combination with certain structural features which have been included in order to provide maximum comfort with minimum thickness of the overall assembly and minimize, if not eliminate, "bottoming-out" of the assembly, especially when subjected to concentrated loads of normal amount.
Referring to the drawings, an exemplary illustration of an institutional type mattress embodying the present invention is shown in side elevation in FIG. 1. This mattress assembly comprises a composite type top pad 10 and a bottom pad 12, which is directly abutted by the top pad and, in conventional institutional type beds, such as in hospitals and the like, the superimposed top and bottom pads are supported upon either a plurality of hingedly-connected pans 14 or spring sections of conventional type employed in such institutional type beds. The composite top pad 10 is illustrated in detail in FIGS. 2, 4 and 5, while the bottom pad is shown in detail in FIGS. 3 and 6.
Referring to FIG. 4, in which an enlarged fragmentary transverse section of the top pad 10 is shown, and exemplary concentrated load 16 is shown, and the figure primarily is provided to show the disposition of forces from said load upon the composition of the composite top pad which is of special construction in accordance with the invention for purposes of distributing the forces of such concentrated load in a manner to contribute to the minimizing or elimination of "bottoming-out", which, as set forth hereinabove, is a term well-known in the mattress and upholstery trade. For example, when a mattress or cushion "bottoms-out", the load meets a relatively immovable surface, and no further cushioning effect exists. Contrarywise, the elimination of "bottoming-out" results in an applied load, such as a human body, not having the sensation of resilience or cushioning reaching zero effect. In other words, when the application of the load to the mattress comes to a rest position, there is still a sensation of further cushioning existing with respect to the load, and it is this sensation that the present invention has been devised to provide.
Part of the minimizing of "bottoming-out" is achieved by the top pad 10 and additional effect is provided by the bottom pad 12, whereby the two pads operate in conjunction with each other to achieve the desired ultimate result.
Considering the details of the top pad 10 as illustrated in FIG. 4, for example, it will be seen that said pad is composite, and is composed of an upper layer 18 of foam plastic having a density rating of preferably between HR17 and HR27, which densities are less firm than the density of the foam plastic employed in the bottom pad 12, which is set forth below, in detail. The upper layer 18 is superimposed upon a lower layer 20 of foam plastic, said layers preferably being of equal thickness, specific examples of which are set forth hereinafter. Sandwiched between the upper and lower layers 18 and 20 is a mesh layer 22, which is woven or otherwise formed from polypropylene filaments, said netting having a mesh preferably less than one-fourth inch in size and said netting and the adjacent surfaces of the upper and lower layers 18 and 20 are firmly bonded by appropriate cement compatible with the chemical composition of the foam plastic and mesh layer 22. By this construction, the upper and lower layers are united with each other. The function of the mesh layer is to assist in distributing compression of the upper layer of foam plastic 18 to the layer 20. To assist in such distribution and also provide maximum resilience, the plastic preferred to form the foam layers 18 and 20 comprises a mixture of polypropylene glycol and toluene diisocyanate. These compounds are furnished preferably in a 2:1 ratio and in addition, a suitable catalyst is mixed therewith, together with a plasticizer, such as silicone, conventional blowing agents and fire-retardants also being included in suitable proportion. Further to provide maximum resiliency, the foregoing composition includes a mixture of acrylonitrile and styrene in a proprietary formulation which provides the foamed plastic with maximum resilience, and in doing so renders said foamed plastic very expensive to produce, as compared with other foamed plastics that are employed in a less expensive type of mattress, which has inferior resilience.
The top pad 10 also is provided with a handle structure in the form of a single or a plurality of superimposed woven tapes 24, which extend between opposite sides of the mattress 10, as shown in FIG. 2, and loops of said tapes extend beyond the opposite sides of the mattress to provide appropriate loop-type handles 26. The tape 24 is applied incident to laminating the upper and lower layers 18 and 20 with each other and the mesh layer 22, and the same type of cement may be employed to effect connection of the tapes to the foam layers, as well as the mesh 22. Without restriction thereto, one type of tape which has been found to be highly appropriate is composed of 75% polyester and 25% Nylon.
In mattresses of institutional types, such as used in hospitals and the like, it is essential that the same be provided with a suitable cover. An exemplary cover 28 is shown in FIGS. 1, 2, 4 and 5. A preferred fabric for such cover comprises a commercial product sold under the trademark HERCULITE. Said fabric has a proprietary formulation but essentially is a woven open mesh fabric formed from polyvinyl chloride, reinforced with Nylon scrim, said open weaves crim being impregnated with the polyvinyl chloride and the product is provided with appropriate proprietary compounds and formulations to render the same flame-retardant, non-allergenic, anti-static and especially being water and stain resistant.
It has been found in practice that the highly desirable covering described above exhibits a tendency, when placed directly in contact with the foamed plastic from which the upper and lower layers 18 and 20 are formed, to effect migration of the plasticizer from the foam plastic and actually render the same relatively brittle. In view of the desirability, however, of using this type of covering with the plastic material of the upper and lower layers 18 and 20 without resulting in such migration of the plasticizer of the foam plastic, the present invention employs barrier layers 30 and 32 of foam plastic of limited thickness which essentially is the same basic formulation as that from which the upper and lower layers 18 and 20 are formed except that the acrylonitrile and styrene additives in said layers are not present in the barrier layers 30 and 32 in that it has been found that no noticeable migration of plasticizer in the barrier layers 30 and 32 occurs when in direct contact with the cover fabric 28.
The top and bottom sheets of the cover 28 are bent to extend along the sides of the composite body of the top pad 10 of the mattress assembly so as to meet substantially adjacent the edges of the mesh layer 22 and said side edges of the cover 28 are connected together, preferably detachably, by any suitable means, such as a conventional zipper 34, as shown in exemplary manner in FIGS. 1, 2 and 5.
For purposes of further aiding in distributing loads, especially concentrated loads, particularly for the purposes of minimizing or eliminating "bottoming-out" of the mattress assembly, an essential and very important component of the assembly comprises the bottom pad 12, details of which are best illustrated in FIGS. 3 and 6. As shown in FIG. 3, said bottom pad is composed of a plurality of articulated sections 36, 38, 40 and 42. Particularly when employed in institutional use, such as hospitals, the section 36 is the so-called leg section, and section 42 is the head or shoulder section, while the intermediate sections 38 and 40, which are shorter than the end sections 36 and 42, are illustrated in a common plane in the configurations shown in FIG. 1, but, in certain types of hospital beds, bending between the sections 38 and 40 is desired and the bed structures correspondingly are constructed to permit such bending between the sections. Spaces 44 of limited width are formed between the articulated sections of the bottom pad for purposes of providing hinges 46, which are composed of portions of the upper and lower sheets of the cover 48, which encloses the foam plastic body 50 of each of the sections 36, 38, 40 and 52. The hinges 46 may be formed either by stitching abutting portions of the upper and lower sheets of the cover together, or suitably cementing the same. Preferably, the cover 48 is formed from the same material as that of the cover 28 for the top pad 10, and the edges of the upper and lower sheets of said cover may be suitably connected, such as by stitching 52, shown in FIG. 6, or employing any other conventional connecting means.
The preferred and essential characteristic of the foam plastic body 50 of the bottom pad 12 is that it be substantially firmer than the layers 18 and 20 of the top pad 10, especially to minimize "bottoming-out" and, preferably, eliminating the same. Accordingly, the foam plastic selected is one that is identified as CS2045, which is much firmer than the upper and lower layers 18 and 20 of top pad 10 and has a density of approximately 2.0 lbs./cu.ft. Accordingly, due to the spreading of the application of a concentrated load by the top pad 10 and mesh layer 22 therein, as illustrated in FIG. 4, the much greater density and firmness of the bottom pad 12 provides a combination of related foam densities and physical construction in the assembled top and bottom pads that produces adequate comfort and minimal tendencies to "bottom-out" in a composite structure of minimum overall thickness, as follows:
By way of affording comparable dimensions and characteristics which are primarily exemplary and illustrative rather than being absolutely restrictive, sample mattresses embodying the present invention and affording the desired load distribution with maximum comfort and minimal thickness have the following dimensions:
The upper and lower layers 18 and 20 preferably are formed of HR17 and/or HR27 and are of similar thickness of substantially 11/2 inch each. The barrier pads are preferably approximately 1/4 inch thick and are formed of CS1530, which has a density of about 1.50 lbs/cu.ft., whereby the overall thickness of the top pad 10 is approximately 31/2 inches. HR17 has a density of about 1.90 lbs/cu.ft. and HR27 has a density of about 2.7 lbs/cu.ft. The bottom pad 12 which has a unitary foam plastic body 50 is preferably composed primarily of polyurethane which is approximately 11/2 inches thick. A conventional area size for institutional use in mattresses of this type comprises a width of 35 inches and a length of 80 inches. Also, the preferred linear distance between the pair of woven tapes 24 is 32 inches. As indicated, these dimensions are exemplary and may be varied within limited amounts. Similarly, while the upper and lower layers 18 and 20 of the top pad 10 have been indicated as preferably being of similar density, they need not be and, for example, the upper layer 18 may be formed of HR17 and the lower layer may be formed from HR27, or vice versa.
For comparison of firmness and softness of the layers of the top pad and the bottom pad, the HR ratings of 17 and 27 are relative to each other and CS2045 has a similar rating of 45, whereby it will be seen the bottom pad is about twice as firm as an average of the top pad layers.
In institutional use, one example of which is shown in FIG. 1, it will be seen that the top and bottom pads 10 and 12 are bent in accordance with the supporting means in which the sections of the hospital bed support, such as pans or springs, are disposed. Such bending may even be more accented than that illustrated in FIG. 1, such, for example, where the bottom pad and, correspondingly, the adjacent portions of the top pad, may be arranged so that the leg section 36 of the bottom pad may be depending substantially vertically, the intermediate sections 38 and 40 may be substantially horizontal, and the shoulder or head section 42 may be in a more upstanding position than shown in FIG. 1, or even vertical. However, when at least the top pad 10 is employed in a sofa bed for domestic purposes, as well as when either the top pad 10 or bottom pad 12, or both, are to be arranged compactly for sterilizing or other similar purposes, at least the top pad is disposed in an exemplary configuration, such as shown in side elevation in FIG. 7, and in which three sections of the mattress are disposed in directly overlying relationship, such as when the mattress is folded in stored position within a sofa or the sofa bed type. The thinness of the mattress, as indicated in exemplary manner above, permits such compact arrangement without deleteriously affecting the resilience and comfort afforded by the mattress. In view of the fact, however, that the space within which mattresses can be stored in such or similar manners in a sofa bed, it is essential that the mattress be relatively thin and under such circumstances employment of the bottom pad 12 and in conjunction with the top pad 10 is a sofa bed arrangement would probably render the folded and stored configuration too thick for such normal use, but it is not intended that this conclusion should rule out the possible employment of the bottom pad 12 of the type illustrated and described herein with the top pad 10 in sofa bed use if the normal cushion height of such sofa bed is sufficient to accommodate such folded section of both the top and bottom pads 10 and 12.
Particularly when the top and bottom pads 10 and 12 are employed in institutional use, it is desirable in accordance with the present invention to include stabilizing means between the same, especially to prevent relative movement therebetween in a longitudinal direction but also prevent relative movement in a transverse direction. Accordingly, as shown in FIGS. 1-3, one example of suitable stabilizing means is shown in the form of co-engageable strips of mechanical type connectors, one form of which is sold commercially under the tradename "VELCRO". It comprises areas of very small and short plastic fingers having hook-like configurations at the ends which are yieldable and when the fingers on opposite strips are compressed together, they co-engage and form a secure connection between the objects to which they are attached. When separation is desired, it is accomplished simply by pulling the strips away from each other, the yieldability of the hook-like ends on the fingers permitting such separation without injury to the same.
The exemplary illustration of co-engageable strips 54 and 56 attached respectively to the adjacent surfaces of pads 10 and 12 are of the type described above. They may be secured to said pads by sewing, cement, or any other suitable means. Also, such securing means between said pads are not to be considered restrictive but are merely exemplary both as to size and nature.
The foregoing description illustrates preferred embodiments of the invention. However, concepts employed may, based upon such description, be employed in other embodiments without departing from the scope of the invention. Accordingly, the following claims are intended to protect the invention broadly, as well as in the specific forms shown herein.
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A mattress assembly and system adapted for specialized use where bending is required and comprising a top pad formed of two layers of relatively soft foamed plastic between which a load-distributing mesh sheet is bonded to also secure said layers together, in combination with a bottom pad of much firmer foamed plastic coextensive with and underlying the top pad and capable of preventing the assembly and system of pads from bottoming-out. The bottom pad also is connected to the top pad in a manner to prevent relative longitudinal movement therebetween, especially when the assembly and system are bent at localized locations incident to the mattress support on a bed being similarly bent such as in hospital use and in domestic convertible sofas.
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TECHNICAL FIELD
[0001] The present invention relates generally to data protection, and more particularly to systems and methods for providing a message authentication code based on unimodular matrices.
BACKGROUND OF THE INVENTION
[0002] Since the beginning of the digital revolution, there has always been a concern that not all of the digital bits sent from point A to point B will arrive intact. This is because, whether malicious or non-malicious attacks, the digital information sometimes arrived in an altered state at its destination. Depending on the criticality of the transmitted data, the altered information could be inconsequential or might be of significant importance such as transferring one million dollars to a bank account instead of one hundred dollars to a bank account. Therefore, a means to verify and check data is required to ensure that what information was sent actually arrived in the same form. Additionally, especially in the banking example just mentioned, it is also highly desirable to ensure that the data came from a particular source. Thus, it is necessary to also have a means to verify and/or identify the sender of the information. Otherwise an individual could just send the information to the bank and transfer money into their account at will. Likewise, it is also desirable to hide, or encrypt, the information being sent so that other parties cannot view the data. All of these desirable characteristics for transmitted data tend to have equal importance for secure data transmissions in today's digital environment.
[0003] One way to ensure that data arrives exactly as it was sent is to provide information along with the transmitted data that provides a method to double check that all of the data bits have been received and, sometimes, even that they are in a particular order. This is often accomplished with a “checksum” value that is sent or appended to the transmitted data. This checksum can be as simple as the value of adding up all the bits or as complicated as a value that can indicate, to a high degree of probability, the order and value of all the digital bits. Thus, checksum methods can be quite complex, depending on the depth of checking required in a given circumstance. Critical data, for example, such as airplane flight control information, can require extremely thorough checksum values. Other means of ensuring data integrity can include sending redundant copies of the data and doing a data comparison at the receiving end. This is valid as long as the attacks to the data tend to be non-malicious and random. A malicious attack or a reoccurring error can affect all redundant copies of the data, yielding no means to adequately decide which data set is correct.
[0004] It is also desirable to be able to authenticate that data was sent by a particular party. Thus, when an email is received, for example, one assumes that it was sent from the party in the “from-line” of the email. However, as is common with email viruses, the virus sends emails to users in an address book of an infected computer and alters the from-line so that the emails appear to be from someone other than the virus program. Therefore, if the received communication is of a highly critical nature, the receiving party would like to be ensured that the email originated from the sender and not from anyone else. This is especially important in a business environment where the digital information is utilized to make business decisions and to conduct business transactions. It is also critical in medical settings such as transmitting drug prescriptions and medical information and the like.
[0005] As the digital age has progressed, it has become very easy to send, receive, and manipulate digital data. Although this digitally-provided power is typically utilized to enhance and enrich society, it can also be utilized to maliciously alter and/or intercept data. People, along with businesses, often tend to send information that is of a sensitive nature, and they do not want it to be disseminated to parties other than those to which the data was sent. Therefore, if the data is intercepted by a third party, they would like the data to be meaningless to that third party. This is typically done by encrypting data utilizing a “key.” The data can then only be unlocked by possessing and utilizing the digital unlock key. Generally, to gain more security, the encryption key is lengthened to contain more digital bits. The encrypting method can also become extremely complex in order to provide even more security for the transmitted data.
[0006] As technology has progressed in the aforementioned data protection areas, it has tended to somewhat merge into overlapping methods that provide data protection in multiple facets. Thus, an authentication method that verifies who the data was sent from is often also combined with an encryption scheme to hide the data from third parties. Likewise, an encryption scheme might also provide a data integrity scheme, and a data integrity scheme might also be utilized to verify who sent the digital data. Some current authentication schemes utilize “public keys” and “secret” or private keys to facilitate authentication. These methods often incorporate a “message authentication code” or MAC that is a hash value (a fixed length digital code) that is representative of the actual input data. The MAC is typically encrypted along with the data itself and sent to a party. The party then decrypts the data and generates a new MAC on the data. The received MAC and the new generated MAC are then compared to verify that the data is intact and can sometimes also be utilized to authenticate the sender of the information.
[0007] As society creates more and more digital information, the sizes of transmitted data also increase dramatically. Thus, despite advances in technology with regard to faster processors and better data management, the amount of digital information being sent can be immense. This creates a workload for digital protection schemes that can become overwhelming for a particular process. Typically, users will not tolerate lengthy delays after they command data to be transmitted. This additional time for providing data protection is seen as an encumbrance to this method of data transmission. Although a user deems the protection necessary, time constraints may cause a user to by-pass data protection in order to timely send out large amounts of data, exposing the data to interception/disclosure, spoofing, and alterations. Efficient, secure, and adjustable data protection schemes can provide businesses and individual users alike with the capability to expand beyond their current data size limitations without limiting their data protection due to intolerance of data protection overhead costs.
SUMMARY OF THE INVENTION
[0008] The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is not intended to identify key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.
[0009] The present invention relates generally to data protection, and more particularly to systems and methods for providing a message authentication code based on unimodular matrices. The invertibility of determinants of these types of matrices is leveraged to provide a universal hash function means with reversible properties and high speed performance. This provides, in one instance of the present invention, length controllable hash values comprised of vector pairs that can be processed as one instruction in a SIMD (single instruction, multiple data) equipped computational processor, where the vector pair is treated as a double word. By providing single instruction processible hash values, one instance of the present invention can compute the hash values at a 500 megabyte per second input data rate on a 1.06 gigahertz processor. The characteristics of the present invention permit its utilization in streaming cipher applications, and it can be utilized to provide key data to seed the ciphering process. Additionally, the present invention can utilize smaller key lengths than comparable mechanisms via inter-block chaining, can be utilized to double hash values via performing independent hash processes in parallel, and can be employed in applications that require its unique processing characteristics. Thus, the present invention provides a high performance hash value generation means that can also be utilized to facilitate cipher key seeding and utilized to facilitate other data protection schemes, such as, for example, checksumming and the like.
[0010] To the accomplishment of the foregoing and related ends, certain illustrative aspects of the invention are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles of the invention may be employed and the present invention is intended to include all such aspects and their equivalents. Other advantages and novel features of the invention may become apparent from the following detailed description of the invention when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a block diagram of a data transformation system in accordance with an aspect of the present invention.
[0012] FIG. 2 is another block diagram of a data transformation system in accordance with an aspect of the present invention.
[0013] FIG. 3 is a block diagram of a data encryption system in accordance with an aspect of the present invention.
[0014] FIG. 4 is a block diagram of a reversible data transformation system in accordance with an aspect of the present invention.
[0015] FIG. 5 is a graph illustrating the k-invertibility of A 50 in accordance with an aspect of the present invention.
[0016] FIG. 6 is a graph illustrating the k-invertibility of B t versus the log 1.5 t in accordance with an aspect of the present invention.
[0017] FIG. 7 is a flow diagram of a method of facilitating data transformation in accordance with an aspect of the present invention.
[0018] FIG. 8 is another flow diagram of a method of facilitating data transformation in accordance with an aspect of the present invention.
[0019] FIG. 9 is yet another flow diagram of a method of facilitating data transformation in accordance with an aspect of the present invention.
[0020] FIG. 10 is a flow diagram of a method of facilitating a data transformation value length in accordance with an aspect of the present invention.
[0021] FIG. 11 is a flow diagram of a method of facilitating inter-block chaining for a data transformation in accordance with an aspect of the present invention.
[0022] FIG. 12 is a flow diagram of a method of facilitating data encryption in accordance with an aspect of the present invention.
[0023] FIG. 13 illustrates an example operating environment in which the present invention can function.
[0024] FIG. 14 illustrates another example operating environment in which the present invention can function.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The present invention is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It may be evident, however, that the present invention may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing the present invention.
[0026] As used in this application, the term “component” is intended to refer to a computer-related entity, either hardware, a combination of hardware and software, software, or software in execution. For example, a component may be, but is not limited to being, a process running on a processor, a processor, an object, an executable, a thread of execution, a program, and/or a computer. By way of illustration, both an application running on a server and the server can be a computer component. One or more components may reside within a process and/or thread of execution and a component may be localized on one computer and/or distributed between two or more computers. A “thread” is the entity within a process that the operating system kernel schedules for execution. As is well known in the art, each thread has an associated “context” which is the volatile data associated with the execution of the thread. A thread's context includes the contents of system registers and the virtual address belonging to the thread's process. Thus, the actual data comprising a thread's context varies as it executes.
[0027] The present invention provides a MAC construction based on modular groups. Each input is embedded into a sequence of matrices with determinant ±1, the product of which yields a desired MAC . The invertibility and the arithmetic properties of the determinants of certain types of matrices are utilized for analysis and can be of interest in other applications. Algorithms to compute message authentication codes ( MAC S) are important in security applications, and the task of constructing them rigorously and efficiently is well-studied. Recent algorithms have utilized a secret key to map an input into a short binary string, and then secure the result with a block cipher or traditional secure hash. The present invention provides a method for the first step, the so-called universal hash function. It provides a construction based on modular groups that is competitive or better than other methods. The present invention can also be utilized with document indexing and retrieval, document integrity checking for databases and secure networks, and web search and server applications and the like.
[0028] In FIG. 1 , a block diagram of a data transformation system 100 in accordance with an aspect of the present invention is shown. The data transformation system 100 is comprised of a unimodular matrix-based data transformation component 102 that transforms input data X 104 and outputs data for applications such as authentication applications 106 , integrity applications 108 , and other applications 110 . The other applications 110 can be comprised of, but are not limited to, applications such as encryption, web search, and server applications and the like. In another instance of the present invention, the unimodular matrix-based data transformation component 102 can output data in the form of a message authentication code ( MAC ) for utilization with authentication applications 106 and/or integrity applications 108 and the like. Thus, the MAC not only provides an indication of who sent the data, but can also be utilized to determine if the input data X 104 has been altered. The unimodular matrix-based data transformation component 102 receives the input data X 104 and transforms it into a transformation value utilizing at least one secret key 112 and at least one public key 114 . The public key 114 can be comprised of public matrices with determinants of ±1. Generally, in one instance of the present invention, the unimodular matrix-based data transformation component 102 generates the transformation value in the format of a vector pair from a unimodular group employing the public matrices. Details of the processing of the input data X 104 are discussed infra.
[0029] Referring to FIG. 2 , another block diagram of a data transformation system 200 in accordance with an aspect of the present invention is illustrated. The data transformation system 200 is comprised of a unimodular matrix-based data transformation component 202 that receives input data X 204 and outputs MAC data 206 . The unimodular matrix-based data transformation component 202 is comprised of a hash mapping component 208 and an optional encryption component 210 . The hash mapping component 208 receives the input data X 204 and transforms the input data X 204 into a hash value utilizing keys 212 and a universal hash function with reversible properties. The resulting hash value can then be output as the MAC data 206 and/or it can be encrypted via the optional encryption component 210 and then output as an encrypted form of the MAC data 206 . The hash mapping component 208 maps the input data X 204 by processing it with keys 212 that provide authentication and/or data integrity characteristics and the like to the calculated hash value.
[0030] Looking at FIG. 3 , a block diagram of a data encryption system 300 in accordance with an aspect of the present invention is depicted. The data encryption system 300 is comprised of a MAC generation component 302 , a MAC encryption component 304 , and a cipher component 306 utilizing at least one key 308 . The data encryption system 300 receives input data X 310 , transforms and encrypts the input data X 310 , and then outputs encrypted data 312 . The encrypted data 312 is comprised of an encrypted form of the input data X 310 and an encrypted form of a MAC relating to the input data X 310 . In other instances of the present invention, the MAC can be appended to the encrypted form of the input data X 310 without being encrypted and/or the MAC generation component 302 can solely be utilized to seed the cipher component 306 . In the present instance of the present invention, the input data X 310 is received by both the MAC generation component 302 and the cipher component 306 . The MAC generation component 302 transforms the input data X 310 into a hash value utilizing unimodular matrices and outputs the hash value to the MAC encryption component 304 . Since the present invention's operations are invertible, they can be combined with authentication and encryption via employment of stream ciphers that utilize a final hash value to define a key for generation of a one-time pad. Thus, the MAC generation component 302 also produces seed data for the key 308 of the cipher component 306 . In this instance of the present invention, the cipher component 306 utilizes a function to encrypt the received input data X 310 in the form of y i =a i x i +b 1 , where a i and b i are random key words and a i x i is generated by the MAC generation component 302 . The cipher component 306 then outputs the encrypted form of the input data X 310 as a portion of the encrypted data 312 .
[0031] Turning to FIG. 4 , a block diagram of a reversible data transformation system 400 in accordance with an aspect of the present invention is shown. The reversible data transformation system 400 is comprised of a data converter component 402 and a data inverter component 404 . In other instances of the present invention, the reversible data transformation system 400 can be comprised solely of the data converter component 402 or solely of the data inverter component 404 . In this example of the present invention, the reversible data transformation system 400 receives input data X 406 and employs the data converter component 402 to transform it via a unimodular matrix-based transformation process into transformed data 408 . The transformed data is then received by the data inverter component 404 , and the transformation process is reversed, producing output data X 410 . The data converter component 402 is typically comprised of a unimodular matrix-based data transformation component. Thus, the transformed data can be a hash of the input data X 406 . Generally, a hash is defined as a one-way transformation of data into a fixed-length representation. However, the present invention provides a means to reverse the hash and derive relevant information as to the content of input data X 406 and/or characteristics related to authentication of the input data X 406 . This is a characteristic only provided by the present invention.
[0032] The unique qualities of the present invention are better perceived by understanding the context of the present invention. Algorithms to compute message authentication codes ( MAC ) are important in security applications, and the task of constructing them rigorously and efficiently has been a subject of many technological endeavors. An introduction can be found in Alfred J. Menezes, Paul C. van Oorschot, and Scott A. Vanstone; Handbook of Applied Cryptography; CRC Press, 1997.
[0033] Recent MAC algorithms utilize a secret key K to map an input X into a short binary string h=H K (X) of some fixed length [see, (J. Black, S. Halevi, H. Krawczyk, T. Krovetz, and P. Rogaway; UMAC: Fast and Secure Message Authentication; Lecture Notes in Computer Science, 1666:216-233, 1999), (S. Halevi and H. Krawczyk; MMH: Software Message Authentication in the Gbit/Second Rates; In Fast Software Encryption, pages 172-189, 1997), (Phillip Rogaway; Bucket Hashing and Its Application to Fast Message Authentication; Journal of Cryptology: the Journal of the International Association for Cryptologic Research, 12(2):91-115, 1999), (M. Bellare, R. Canetti, and H. Krawczyk; Keying Hash Functions for Message Authentication; Lecture Notes in Computer Science, 1109, 1996), (V. Shoup; On Fast and Provably Secure Message Authentication Based on Universal Hashing; Lecture Notes in Computer Science, 1109, 1996), and (M. H. Jakubowski and R. Venkatesan; The Chain and Sum Primitive and Its Applications to MACs and Stream Ciphers; In Advances in Cryptology—EUROCRYPT ' 98, volume 1403 of Lecture Notes in Computer Science, pages 281-293; Springer-Verlag, 1998 )].
[0034] After the mapping is completed, h is encrypted utilizing a block cipher. If the cipher acts as a random permutation, the encryptions of the hash values h i , . . . , h q of q distinct inputs X 1 , . . . , X q can not be distinguished from truly random outputs of the corresponding length, if the hash values h i =H K (X i ) are distinct. Thus, if a secure cipher is utilized, the collision properties of the hash function determine the security of the MAC . The main parameter of interest for a MAC algorithm is the collision probability Pr K [H K (X)=H K (X′)], where X and X′ are arbitrary and distinct inputs. If the collision probability is the inverse of the size of the range of the hash, regardless of the choice of inputs, the hash function is called a universal hash function (see, Carter and Wegman; New Hash Functions and Their Use in Authentication and Set Equality; Journal of Computer and System Sciences, 22(3):265-279, 1981). This approach has enabled construction families of hash functions with quantifiable collision probabilities that are remarkably fast in practice. The initial mapping X h and its collision probability is a focal point, and it is assumed for simplicity that all inputs have the same length and can be subdivided into blocks evenly.
[0035] To better understand the present invention's construction, it is helpful to review some earlier construction techniques. In one such technique, an evaluation MAC identifies an input message X=x 1 , . . . x m with a polynomial of degree m over a suitable field and computes the map α Σ i x i α i for a random α. Bernstein's hash 127 (D. Bernstein; Floating-point Arithmetic and Message Authentication; Draft available at http://cr.yp.to/papers/hash127.dvi) implements a polynomial evaluation hash utilizing floating-point operations in an efficient and platform independent manner.
[0036] Many MAC constructions utilize a standard iterative rule y i =f i (x i +y i−1 ), where y i are the intermediate values and various methods utilize different f i 's. In the evaluation MAC , f i (x)=f(x)=αx, the iteration is Horner's rule and y m is the final value. If one takes f i =f(x)=E K (x) to be a block cipher, one gets the CBC MAC [see, The Security of the Cipher Block Chaining Message Authentication Code (M. Bellare, J. Kilian, and P. Rogaway; Journal of Computer and System Sciences, 61(3):362-399, 2000) for an analysis and On Fast and Provably Secure Message Authentication Based on Universal Hashing (Shoup, 1996) for an efficient implementation].
[0037] The chain and sum method (Jakubowski and Venkatesan, 1998) doubles the length of the hash in a one-pass computation by outputting the pair (y i , Σy i ) . It is similar to the evaluation MAC , except it alternates two random affine transformations f and g of the form x ax+b. That is, f i =f for odd i, and f i =g for even i. To improve the present invention's collision probabilities, the summing method is utilized, which was employed in The Chain and Sum Primitive and Its Applications to MACs and Stream Ciphers (Jakubowski and Venkatesan, 1998) to obtain a pseudo-random permutation on X by further encrypting y 1 , . . . y t-2 with a one-time pad derived from (y t , Σ y i ) utilizing a stream cipher and encrypting (y t , Σ y i ) with a block cipher.
[0038] These methods work over a field, where operations are typically expensive on standard processors. Working instead with modulo 2 l is advantageous and the fastest MAC s utilize this method. However, the ring of integers modulo 2 l does not have the invertibility which is crucial for analysis. For example, for x≠x′, the function f(x)=αx+b over a field has an invertible output differential f(x)−f(x′)=α(x−x′) in the sense that it is uniformly distributed if α is randomly chosen. However, for modulo 2 l , this changes sharply. If 2 k |(x−x′)m, then 2 k |(y−y′), and if k=l−1 the output is distributed as a set of size 2 for a random odd α. The present invention constructs reversible transformations that are suitable for MAC and other applications. Proof for the present invention mimics the proof in the finite field case, except the present invention's equations involve coefficients from matrix groups.
[0039] UMAC (see, Black, Halevi, Krawczyk, Krovetz, and Rogaway, 1999) is an efficient MAC algorithm that achieves high speeds by utilizing SIMD instructions available on many CPUs for media processing. UMAC utilizes the iteration y i =f(x 2i , x 2i+1 )+y i−1 , where f(x 0 ,x 1 )=(x 0 +k 0 )·(x 1 +k 1 ). Here the k i are secret random words, and the multiplication is reduced at twice the word size of the x i . For example, the x i are 32 bits, and the y i 64 bits. In UMAC: Fast and Secure Message Authentication (see, id), it is shown that the reduction modulo powers of two, while not totally universal, is nearly so. Leveraging the media processing instruction set allows UMAC to achieve a rate faster than a byte per cycle, meaning gigabyte per second rates on today's processors.
[0040] Klimov and Shamir (see, A. Klimov and A. Shamir; A New Class of Invertible Mappings; Crypto 2001 Rump Session) constructed an elegant family of invertible mappings (modulo 2 l ) that combine arithmetic and boolean operations to get non-linear maps for utilization in cryptographic primitives. The present invention can incorporate these functions after they have been randomized and modified per the present invention to have suitable differential properties.
[0041] The present invention's inputs are broken into blocks of length t words, each of size l-bits. A given l-bit input x i is embedded into a 3×3 matrix B i over the ring of integers modulo 2 l by x i
x i ↦ [ A i v i 00 1 ] = : B i ,
where v i =f i (x i ) is a vector with two elements, and A i is a 2×2 matrix with det(A i )=±1; here the sequence of A i 's is fixed independent of the input x i . The A i sequence utilized by the present invention is periodic, so that the implementation can be unrolled and have a small code footprint. The function, f i (x), is defined by multiplication with random odd a i where a i and x are l bits, and the 2l bit result is viewed as a vector of two l-bit numbers. Thus f i (x) is invertible modulo 2 2l and can be implemented in one instruction utilizing the usual 2l-bit result of multiplication of two l-bit quantities.
[0042] For each block of input, the product
B = [ A z 00 1 ]
of these matrices B i is computed. The output of the present invention's hash value is the pair
( z , ∑ i = 1 i v i ) .
The collision probability is substantially near 2 −2l by utilizing the invertibility of A i and the arithmetic properties of the determinants of the matrices of the form
∏ i = j k A i - I
over (and not modulo 2 l ). The present invention offers simplicity and can also facilitate applications other than MAC s as well.
[0043] The present invention's construction can be viewed in a more general manner.
[0044] Let G=SL 2 and so that G is the group of unimodular matrices over multiplication, and H is the group of 2-dimensional vectors modulo 2 l over addition. The natural homomorphism taking elements of G to automorphisms of H via the matrix-vector product defines a semidirect product G H. The present invention's block hash is then an embedding of the input into G H by mapping x i to (A i , f i (x i )). The product of these elements is that over G H. Given appropriate f i , the present invention's construction can be generalized to larger matrices.
[0045] Many efficient MAC algorithms are available [see, (Shoup, 1996), (Halevi and Krawczyk, 1997), (Black, Halevi, Krawczyk, Krovetz, and Rogaway, 1999), (Rogaway, 1999), and (Bernstein). Several work by expanding a short key to a large key for an inner hash function utilizing a pseudo-random generator; the large key can amount to a fraction of the length to be hashed. However, the present invention's algorithm requires less key to be generated than algorithms such as UMAC . This is highly desirable in some applications.
[0046] Even though the present invention is slower than the fastest algorithm, UMAC (Black, Halevi, Krawczyk, Krovetz, and Rogaway, 1999), it is still very competitive and is even better than other algorithms. Unlike UMAC, however, the present invention's construction is interesting in its own right and can lend itself to other applications besides MAC S. Through optimization, the present invention can improve the speed of its algorithm and reduce the amount of key utilized.
[0047] The present invention's methods also provide a model for checksumming. Detailed infra, it is shown that any two inputs that collide within a block must differ in at least two locations. The collision probability of the present invention's MAC is much smaller if the input differs in at least three locations. While this is not substantially helpful in an adversarial context, when utilizing the present invention's MAC as a checksum, it can provide such a guarantee. Generalizing this notion, a d-semi-universal hash is defined to be one where the collision probability of two inputs that differ in d locations is nearly that of colliding with an independently chosen element of the range. The present invention's algorithm is a 3-semi-universal hash and more efficient variants can be d-semi-universal for larger d.
[0048] In order to fully appreciate the present invention, several conventions are utilized as follows. Fix a modulus m=2 l , for example, l=32. A word refers to an element of and a double word to an element of Hence, words can be thought of as l bit integers and double words as 2l bit integers. All operations take place over words, that is, over unless otherwise specified. The ability of modern processors to multiply two words to produce a double word in a single instruction is exploited; this operation is denoted as ×*. For x, y ε x×*y is in that is, the result is viewed as a two word vector. If necessary, the input is padded to consist of an integral number of words. For simplicity, an input consists of b blocks, each of which has a fixed block length of t words.
[0049] Typically data is processed by blocks. Thus, the present invention's construction is described for a map v that sends an input block X=x 1 , . . . , x t into l-bit hash value v=v(X). The block key consists of l-bit words a i , for 1 ≦i≦t; the same key is reused with each block. f i : is defined by f i (x)=a i ×*x. The present invention's algorithm utilizes fixed public matrices A 1 , . . . , A t . These can contain very small entries so that matrix products can be implemented very efficiently by addition and subtraction of words.
[0050] Let v i be the column vector of two words equal to f i (x i ). Define matrices B i , B and B 0 , which have the form
[ * * * * * * 0 0 1 ] ,
where
B 0 = [ 1 0 z 0 0 1 0 0 1 ] ,
and for i>0,
B i := [ A i v i 0 0 1 ] , B := B 0 · ∏ i = 1 t B i =: [ A z 0 0 1 ] ( Eq . 1 )
It is clear that B can be written as above; z is the first two components of the third column of B and A has determinant ±1. z 0 is an initial value for the block. Also computed is:
σ = σ 0 + ∑ i = 1 t v i ,
where σ 0 is another initial value for the block. The hash value is v(X)=(z, σ).
[0051] Other instances of the present invention can be employed to provide inter-block chaining. For example, assume the k th block is associated with two uniform hash functions F 1 (k) and F 2 (k) mapping double words to double words (the superscript is dropped if the block number is clear from the context). If (z′, σ′) is the output of a hashed block, this is chained to the next block by setting σ 0 =F 2 (σ′) and:
B 0 = [ 1 0 F 1 ( z ′ ) 0 1 0 0 1 ]
as the initial values for the next block. These inter-block functions can be repeated to save on key length, at some cost of security, which is detailed infra. The exact definition of these functions is not extremely important for these applications.
[0052] In other instances of the present invention, a hash value length can be doubled by performing an independent hash in parallel. Key words b i , 1≦i≦t are utilized, which are independent of the a i and set the functions g i , i≦t, to g(x)=b i ×*x. u i =g i (x i ) is defined and, as above, gets a map X H u(X) with the hash value u utilizing:
C i := [ A i u i 0 0 1 ] , C 0 := [ 1 0 u 0 0 1 0 0 1 ] ,
C := C 0 · ∏ i = 1 t C i =: [ A w 0 0 1 ] . ( Eq . 2 )
Also computed is
v = v 0 + ∑ i = 1 t u i .
The overall hash is now:
( v ( X ), u ( X ))=( z, σ, w, v ).
[0053] Thus, the present invention provides a lengthened transformation value or hash value with a collision probability that can be based on the following theorem.
[0054] Theorem 1: For t≦50, if H=(z, σ, w, v) and H′=(z′, σ′, w′, v′) are the hash values computed from two distinct inputs, then:
Pr[H=H′]≦ 2 −4l+20 ,
where the probability is taken over the choice of key.
This theorem follows directly from Lemmas 3 and 4 infra. It is noted that the theorem is not optimal, in that the choice for the matrices of Lemma 4 could be improved.
[0056] The analysis of the hash of a single block is focused upon first, and it is assumed that B 0=I for a 3×3 identity matrix. By repeated utilization of the identity:
[ A v 00 1 ] · [ B u 00 1 ] = [ AB Au + v 00 1 ] ;
in Equation (1):
z=v 1 +A 1 v 2 +A 1 A 2 v 3 + . . . +A 1 A 2 . . . A t−1 v i . (Eq. 3)
For two (not necessarily distinct) input blocks X and X′, X=x 1 , . . . , x t and X′=x′ 1 , . . . . , x′ t is written and v′ i =f i (x′ i ) is defined. z′ and σ′ are defined analogously to z and σ.
[0057] The following technical lemma relating the distributive law of ×* over vector subtraction is needed. In general, it is not true that a×*x−a×*x′=a×* (x−x′), and, thus, the operation is not linear. However, assuming x≠x′, a×*x−a×*x′ is nearly as likely to collide with any fixed value as a×*(x−x′).
[0058] Lemma 1. Given any fixed words x≠x′ and any fixed double word α=(α 1 , α 2 ),
Pr a [ ax * x - ax * x ′ = α ] ≤ 2 - ℓ + 2 ,
where the probability is taken over uniformly chosen odd words a ε
[0059] Proof: For this proof, let · denote the usual multiplication over double words. By abusing notation, a·x=y is written for a,x ε and y ε it is noted also in this case that there is no overflow, so that y=ax as integers. The crux of this lemma is the difference between subtraction over double words as integers modulo m 2 and subtraction over two-dimensional vectors modulo m. To make this distinction explicit, for an element x ε [x] is written as the vector corresponding x, so that [x] ε Then for double words y and z, if [y]−[z]=(w 1 , w 2 ), then [y−z]=(w 1 −c, w 2 ), where c is either 0 and 1 depending on whether there is a carry between the low and high words or not.
[0060] Let A be the set of all odd a that cause a collision, that is, for the fixed α=(α 1 , α 2 ), all a such that [a·x]−[a·x′]=α for x and x′ as in the statement of the lemma. Then for any a ε A, [a·x−a·x′]=(α 1 −c a , α 2 ), for c a =0 or 1. Given a, a′ ε A with c a =c a′ a·(x−x′)=a′·(x−x′) exists over the integers, so that as x≠x′, a=a′. Thus, A contains at most two elements, possibly one with carry 0 and possibly one with carry 1. As there are 2 l−1 choices for odd a, the chance of choosing one in A is at most 2·2 −l+1 =2 −l+2 , as required.
[0061] The hash function proper is now analyzed.
[0062] Lemma 2: If (z, σ)=(z′, σ′) for distinct inputs X and X′, then X and X′ differ in at least two locations.
[0063] Proof: Suppose not, so that x i =x′ i for all i≠j, and x j ≠x′ j for some j. Then σ−σ′=a j ×*x j −a j ×*x′ j . As a j is odd and hence an invertible map from σ≠σ′, contradicting (z, σ)=(z′, σ′).
[0064] It is now known that colliding inputs have at least two distinct words—however, which words these are, is not known. This is where computing the hash as a matrix product and sum helps. For example, if x and y are independently distributed over then 2x+y and 2y−x are independently distributed as well. Note, however, that x+y and x−y are not independently distributed; for example, they have the same parity. The difference between these two examples is that the former arises from the matrix
[ 2 1 - 1 2 ] ,
which is invertible over while the matrix of the latter is
[ 1 1 1 - 1 ]
has determinant −2, and so is not invertible over The relationship between the two components of the present invention's hash pair, z and σ, is similar, so that if the present invention's matrices are picked carefully, z and σ are independent.
[0065] Definition 1: A sequence of matrices (A 1 , . . . , A t ) is k-invertible if for any i<j, and Δ defined as:
Δ=det( A i . . . A j−1 − 1 ),
then Δ is nonzero, and if 2 k′ |Δ, then k′≦k.
[0066] For any interval I=(i, j), the matrix B=Π I A i −I of k-invertible A i is nearly invertible in the following sense. Let det(B)=s2 k′ for odd, nonzero s and k′≦k. Then Bx=α can be solved modulo 2 l−k uniquely and then there are 2 k solutions modulo 2 l . Thus the value k should be as small as possible.
[0067] Lemma 3: Assume that (A 1 , . . . , A t ) is k-invertible. Then for distinct inputs X≠X′, Pr {a i } [(z, σ)=(z′, σ′)]≦2 −2l+4+k , where f i (x)=a i ×*x.
[0068] Proof: Let δx i =x i −x′ i and δv i =f(x i )−f(x′ i )=a i ×*x′ i . By the Lemma 2, it can be assumed that there exists i<j such that δx i ≠0 and δx j ≠0. The analysis is now in terms of matrix equations over involving A i 's and δv i ; the inputs x i and x′ i are involved implicitly in a non-linear way which will by Lemma 1 will cost a factor of 2. By fixing all a r for r≠i,j:
Pr a i , a j [ ( z , σ ) = ( z ′ , σ ′ ) ] = Pr a i , a j [ A 1 … A i - 1 δ v i + A 1 … A j - 1 δ v j = α , δ v i + δ v j = β ] , ( Eq . 4 )
for appropriate fixed α and β. Rearranging (Eq. 4) for some fixed α′, it is equivalent to:
Pr a i , a j [ ( A i … A j - 1 - I ) δ v j = α ′ , δ v i + δ v j = β ] .
Let B=(A i . . . A j−1 −I), and let Δ=det B. As (A i , . . . , A j−1 ) are k-invertible, Δ=s·2 k′ for some odd s and k′≦k. As remarked above, Bδv j =α′ iff 2 k′ δv j =α* in for some fixed α* depending on α and B. As from Lemma 1 Pr a j [δv j =γ]≦2 −l+2 for any fixed γ, Pr a j [2 k′ δv j =α*]≦2 −l+2+k′ ≦2 −l+2+k (recall all operations are performed over ).
[0069] Finally, if the event 2 k δv j =α* occurs, then Pr a i [δv i +δv j =β]≦2 −l+2 , as δv i depends only on a i , independently from v j . Multiplying these probabilities gives the lemma.
[0070] The operation of the hash over several blocks is now considered. Let (z k , σ k ) be the output of the k th block, so that the initial values for the k+1 block are F 1 (k) (z k ) and F 2 (k) (σ k ). If the keys for the pair (F 1 (k) , F 2 (k) ) are new at each block, then the initial positions at each block are independent, utilizing the uniformity of the F i . Given two messages X 1 , . . . , X n and X′ 1 , . . . , X′ n , let i be the largest index of different blocks, so that X i ≠X′ i and X j =X′ j for j>i. Then H(X 1 , . . . , X n )=H(X′ 1 , . . . , X′ n ) iff (z i , σ i )=(z′ i , σ′ i ). If H(X 1 , . . . , X i−1 )=H(X′ 1 , . . . , X′ i−1 ), then the probability that (z i , σ i )=(z′ i , σ′ i ) is given in Lemma 3. Otherwise, by fixing all key bits but those for F r (i−1) , r=1,2, the probability that (z i , σ i )=(z′ i , σ′ i ) is equal to that of a collision in the F r (i−1) , which is smaller than that of Lemma 3. If it is desirable to save on key size, the F j (i) can be reused. A standard union-bound shows that the bit-security of the hash decreases linearly with the frequency of reuse.
[0071] The choice of the sequence A 1 , . . . , A t can be tailored to implementation requirements. Obviously there is a trade-off between finding k-invertible matrices for minimum k while ensuring that the matrix-vector products of the hashing algorithm can be efficiently computed. The implementations described infra utilize the families below. It should be noted that if the order of the matrices is changed, the determinants of interest may be identically zero.
[0072] Lemma 4. Define the following integer matrices of determinant ±1.
A 1 ′ = ( - 1 1 1 - 2 ) , A 2 ′ = ( 2 1 1 1 ) , and A 3 ′ = ( 1 3 1 2 ) .
[0073] This is now extended periodically into a longer sequence: A t =(A 1 , . . . , A t ) where A i+3s =A′ i . Then A 19 is 4-invertible, and A 50 is 6-invertible.
[0074] Proof: This can be verified by direct computation. A graph 500 of the k-invertibility of A 50 is shown in FIG. 5 . The y-axis is the largest k≧0 such that 2 k |det((Π i j A s )−I), where the interval {i . . . j} is given by the sequence number. The determinant is nonzero in all cases. Further exploitation of the noticeable structure in the graph 500 is possible.
[0075] Another family of matrices is now considered whose near-invertibility is not as good. However, these matrices have entries from {±1, 0}, yielding more efficient implementations. Some implementations of instances of the present invention suggest a 15% speed-up when utilizing these simpler matrices. It can also be shown that the determinants of interest are non-zero, if not nearly odd.
[0076] Lemma 5. Define the following matrices.
B 1 ′ = ( 1 1 1 0 ) , B 2 ′ = ( - 1 - 1 0 - 1 ) , B 3 ′ = ( 0 1 1 1 ) , and B 4 ′ = ( - 1 0 - 1 - 1 ) .
Set B i =B′ (i mod 4)+1 and B t =(B 1 , . . . , B t ). Then for any 1≦i≦j≦t, if M=Π i j B s , det(M−I)≠0.
This is a necessary condition for k-invertibility, though clearly it is insufficient in general. Experimentally, B t is roughly log 1.5 t-invertible. For t˜50, they are not as invertible as A 50 , so some instances of the present invention have not utilized them. FIG. 6 is a graph 600 illustrating the k-invertibility of B t versus the log 1.5 t as t is increased. The k-invertibility of B t (solid line 602 ) plotted against log 1.5 t (dashed line 604 ). Here the y-axis is the largest k such that 2 k |det((Π i j B s )−I), for all 1≦i≦j≦t, for the specified t.
[0078] Proof: For a matrix A, A≧0 if each entry of A is at least 0. A≦0 if −A≧0 and A≧A′ if A−A′≧0. |A| denotes the matrix whose entries are the absolute value of those of A.
[0079] In the notation of Lemma 5, note that:
X 1 = B 1 ′ B 2 ′ = B 2 ′ B 3 ′ = ( - 1 - 2 - 1 - 1 ) and X 2 = B 3 ′ B 4 ′ = B 4 ′ B 1 ′ = ( - 1 - 1 - 2 - 1 ) .
By examination, for all 1≦s≦4, det(B′ s −I)ε{−1,4} and hence nonzero, and Tr(B′ s )ε{1,−1} and is at least 1 in absolute value. For r=1,2, det(X r −I)=2≠0 and Tr(X r )=−2. Finally, det (B′ s X r −I)ε{−4,−3,6}. Hence, the analysis can proceed by induction and assume j−i>2. Set
M ′ = ∏ s = i j - 2 B s
and fix r so that M=M′ X r , and, by induction, it can be assumed that |Tr(M′)|≧2.
[0080] Since det(M)=±1, det(M−I)=det(M)+1−Tr(M), and det(M)+1=0 or 2, it will be enough to show that |Tr(M)|>2. Note that M≧0 or M≦0, for B s =±1·|B s |, so that M=±1·Π i j |B s |, and Π|B s |≧0. As M′≧0 or M′≦0, utilizing the same argument as for M, by examining X r , it can be seen that |M|≧|M′|.
[0081] One can label the off-diagonal elements of M′ by x and y, so that
Tr ( M )= Tr ( M′X r )=−(| Tr ( M ′)|+2 |x|+|y |),
if necessary by exchanging x and y. In a similar way as showing |M|≧|M′|, one can show |M′|>0, so thus |Tr(M)|≧|Tr(M′)|+1≧3, utilizing the inductive assumption on M′. Hence det(M−I)≠0, as required.
[0082] The present invention's hash methods can be adjusted to account for operating constraints of modern processors. In particular, instances of the present invention incorporate parallelization which is useful in processors that have SIMD operations. For example, the MMX™ brand type instruction set standard on Intel Pentium II™ brand and later processors can operate simultaneously on 32-bit words with a throughput of 2 per cycle. For brevity, a hash or MAC has s bits of security if the collision probability (over the choice of keys) on two distinct fixed messages is ≦2 −s . Utilizing A 50 , by Lemma 3 each hash gives 2·32−4−6=54 bits of security, utilizing 30 32-bit words of key per MAC per stream, plus the key for the inter-block chaining. As two MAC S are computed, the total security is 108 bits. Utilizing MMX™ brand type instructions on a 1.06 GHz Celeron™ brand type processor, this MAC was computed at a peak rate of 3.7 cycles per byte. An instance of the present invention can be implemented utilizing an optimized SSE2™ brand type algorithm. Performance of this instance of the present invention depends on the context of its utilization. Other instances of the present invention have implemented a hash utilizing a single stream, which gives 54 bits of security. This achieved a peak rate of 2.0 cycles per byte.
[0083] The present invention's methods are also competitive with UMAC on the length of a generated key. To maintain the security bounds of Lemma 3, each inter-block hash needs four 32-bit words of key per hash stream. Each of the present invention's blocks then requires 50·2 32-bit words of key. Thus, for an 8 Kbyte message, 42 inter-block hashes are required, for 5376 bits of key per hash stream. The total for an 8 Kbyte message and two hash streams is 13.6 Kbits of key. This compares with the UMAC implementation (see, J. Black, S. Halevi, H. Krawczyk, T. Krovetz, and P. Rogaway; UMAC home page, 2000; URL: http://www.cs.ucdavis.edu/˜rogaway/umac) which requires 8 Kbits of generated key to hash a message of any length to 60 bits of security.
[0084] This information is summarized with context from other algorithms in Table 1, where “P.I.” denotes an instance of the present invention. Data for other algorithms was taken from (Black, Halevi, Krawczyk, Krovetz, and Rogaway, 1999) and (Black, Halevi, Krawczyk, Krovetz, and Rogaway, 2000).
TABLE 1 MAC COMPARISONS Security Peak Rate Key Size Algorithm (Bits) (cycles/byte) (8 Kbyte Message) P.I. (two streams) 108 3.7 13.6 Kbits P.I. (one stream) 54 2.0 6.8 Kbits UMAC 60 0.98 8 Kbits SHA-1 80 12.6 512 bits
[0085] The proof k-invertibility of the present invention's matrix sequences is computational. However, it is not necessary for such sequences to be periodic. More complex families can improve the speed and the security of the present invention's hash. For example, a periodic sequence of 4×4 matrices of length 80 which is 4-invertible exists. The larger matrices can be utilized to consume twice as much input per iteration, and the longer sequence length means the inter-block chaining is less frequent, improving efficiency. Instances of the present invention with these implementations show this is 17% faster than the matrices of Lemma 4, and 2% faster than the matrices of Lemma 5, while providing more security than the other sequences.
[0086] Both the present invention's construction and UMAC benefit from the media processing instructions found on Pentium™ brand CPUs. Other platforms, such as those of AMD brand, or Intel's Itanium™ brand CPUs, have different advantages, including larger register files. These details can be exploited by the present invention to increase the relative performance between the present invention's MAC and UMAC .
[0087] Since the present invention's operations are invertible, they can be combined with authentication and encryption with stream ciphers. The idea is rather simple: utilize the final hash value to define a key for a stream cipher to generate a one-time pad. Instead of encrypting the input sequence x i , one encrypts y i =a i x i +b i , where a i and b i are random key words (the first quantity is the lower half of a v i in a step of the present invention's MAC ). As before, the hash value needs to be further encrypted. One needs to exercise caution here: if addition to b i were omitted, one can still observe correlations. This would be the case if the inputs x i end in many zeroes and RC4 is utilized (see, J. Golic; Linear Statistical Weaknesses in Alleged RC4 Keystream Generator; In Advances in Cryptology—EUROCRYPT ' 97, volume 1233 of Lecture Notes in Computer Science, pages 226-238; Springer-Verlag, 1997 and Ilya Mironov; Not So Random Shuffles of RC4; In Advances in Cryptology—CRYPTO 2002, Lecture Notes in Computer Science. Springer-Verlag, 2002). Masking of correlations in RC4 could yield improvements in the present invention.
[0088] The inter-block chaining can be further optimized by exploiting existing slack in the utilization of key. Almost twice as much key is utilized in inter-block hashing as is utilized for the blocks. Key reuse techniques such as a Toplitz shift (see, Black, Halevi, Krawczyk, Krovetz, and Rogaway, 1999) could address this problem. The utilization of a single pairwise independent hash could be sufficient.
[0089] In view of the exemplary systems shown and described above, methodologies that may be implemented in accordance with the present invention will be better appreciated with reference to the flow charts of FIGS. 7-12 . While, for purposes of simplicity of explanation, the methodologies are shown and described as a series of blocks, it is to be understood and appreciated that the present invention is not limited by the order of the blocks, as some blocks may, in accordance with the present invention, occur in different orders and/or concurrently with other blocks from that shown and described herein. Moreover, not all illustrated blocks may be required to implement the methodologies in accordance with the present invention.
[0090] The invention may be described in the general context of computer-executable instructions, such as program modules, executed by one or more components. Generally, program modules include routines, programs, objects, data structures, etc., that perform particular tasks or implement particular abstract data types. Typically, the functionality of the program modules may be combined or distributed as desired in various instances of the present invention.
[0091] The present invention's construction can be viewed in a general manner. In FIG. 7 , a flow diagram of a method 700 of facilitating data transformation in accordance with an aspect of the present invention is shown. The method 700 starts 702 by obtaining input data X, where X=x 1 , . . . , x t 704 . Let G represent a group of unimodular matrices over multiplication (G=SL 2 ) 706 . Let H represent a group of 2-dimensional vectors modulo 2 l over addition 708 . Define G H as the natural homomorphism taking elements of G to automorphisms of H via matrix vector products 710 . Input data X is then embedded into G H via mapping x i to (A i , f i (x i )) (product of elements over G H) to calculate the block hash, where A i is a 2×2 matrix with det(A i )=±1 and 1≦i≦t 712 . The block hash value is then output for input data X 714 , ending the flow 716 . Given an appropriate transformation function, f i , the present invention's construction can also be generalized to larger matrices.
[0092] Referring to FIG. 8 , another flow diagram of a method 800 of facilitating data transformation in accordance with an aspect of the present invention is depicted. The method 800 starts 802 by obtaining input data X, where X=x 1 , . . . , x t 804 . Input data X is then broken down into blocks of length t words, each of size l-bits 806 . A given l-bit input x i is then embedded into a 3×3 matrix B i over the ring of integers modulo 2 l by x i
x i ↦ [ A i v i 00 1 ] = : B i ,
where v i =f i (x i ) is a vector with two elements, A i is a 2×2 matrix with det(A i )=±1, and 1≦i≦t 808 . Here the sequence of A i 's is fixed independent of the input x i . The A i sequence utilized by this instance of the present invention is periodic, so that the implementation can be unrolled and have a small code footprint. The function, f i (x), is defined by multiplication with random odd a i , where a i and x are l bits, and the 2l bit result is viewed as a vector of two l-bit numbers. Thus, f i (x) is invertible modulo 2 2l and can be implemented in one instruction utilizing a 2l-bit result of multiplication of two l-bit quantities. For each block of input data X, the product
B = [ A z 00 1 ]
of these matrices B i is then computed 810 . The present invention then outputs a hash value pair
( z , ∑ i = 1 t v i )
812 , ending the flow 814 . The collision probability is substantially near 2 −2l by utilizing the invertibility of A i and the arithmetic properties of the determinants of the matrices of the form
∏ i = j k A i - I
over (and not modulo 2 l ). The present invention offers simplicity and can facilitate other applications besides MAC applications.
[0093] Turning to FIG. 9 , yet another flow diagram of a method 900 of facilitating data transformation in accordance with an aspect of the present invention is illustrated. Typically data is processed by blocks. Thus, this instance of the present invention's construction is described for a map, v, that sends an input data block X=x 1 , . . . , x t into l-bit hash value v=v(X). The method 900 starts 902 by obtaining input data block X, where X=x 1 , . . . , x t 904 . A block key is then provided 906 . The block key consists of l-bit words a i , for 1≦i≦t; the same key is reused with each block. f i : is then defined by f i (x)=a i ×*x 908 . This instance of the present invention's algorithm utilizes fixed public matrices A 1 , . . . , A t . These can contain very small entries so that matrix products can be implemented very efficiently by addition and subtraction of words. Let embedded vector, v i , be a column vector of two words equal to f i (x i ) 910 . Initialize 3×3 matrix, B 0 , with vector, z 0 , such that
B 0 = [ 1 0 z 0 0 1 0 0 1 ]
912 . Embed a unimodular 2×2 matrix, A i , and the embedded vector, v i , into a 3×3 matrix, B i such that
B i := [ A i v i 00 1 ]
914 . Calculate a 3×3 matrix, B, utilizing
B := B 0 · ∏ i = 1 t B i
916 . This provides a matrix in the form of
B := [ A z 00 1 ] ,
where A has determinant ±1. Let vector, z, be defined as the first two components of the third column of matrix, B 918 . Define a hash value component, σ, by
σ = σ 0 + ∑ i = 1 t v i ,
where σ 0 is an initial value for the input data block X 920 . Determine a hash value, v(X), utilizing v(X)=(z, σ) 922 . Output the hash value for the input data block X 924 , ending the flow 926 .
[0094] Moving on to FIG. 10 , a flow diagram of a method 1000 of facilitating a data transformation value length in accordance with an aspect of the present invention is shown. In this instance of the present invention, a hash value length is doubled by performing an independent hash in parallel. The method 1000 starts 1002 by obtaining input data block X, where X=x 1 , . . . , x t 1004 . A first block key, a i , and a second block key, b i , which is independent of the first block key, is then provided 1006 , where 1≦i≦t. Define g i , i≦t, to g(x)=b i ×*x 1008 . Let embedded vector, u i , be a 2-word column vector, u i =g i (x i ) 1010 . Initialize 3×3 matrix, C 0 , with vector, u 0 , such that
C 0 = [ 1 0 0 1 u 0 0 0 1 ]
1012 . Embed a unimodular 2×2 matrix, A i , and the embedded vector, u i , into a 3×3 matrix, C i such that
C i := [ A i u i 0 0 1 ]
1014 . Calculate a 3×3 matrix, C, utilizing
C := C 0 · ∏ i = 1 t C i
1016 . This provides a matrix in the form of
C := [ A w 0 0 1 ] ,
where A has determinant ±1. Let vector, w, be defined as the first two components of the third column of matrix, C 1018 . Define a hash value component, v, by
v = v 0 + ∑ i = 1 t u i
1020 , where v 0 is an initial value for the input data block X. Determine a first hash value, u(X), utilizing u(X)=(w, v) 1022 . Obtain a second hash value v(X)=(z, σ) via an instance of the present invention 1024 such as, for example, 20 the method described supra for FIG. 9 . Compute an overall hash value, H, utilizing H=(v(X), u(X))=(z, σ, w, v) hash value for the input data block X 1026 , ending the flow 1028 . For t≦50, if H=(z, σ, w, v) and H′=(z′, σ′, w′, v′) are the hash values computed from two distinct inputs, then the collision probability of the present invention is Pr[H=H′]≦2 −4l+20 , where the probability is taken over the choice of key.
[0095] In FIG. 11 , a flow diagram of a method 1100 of facilitating inter-block chaining for a data transformation in accordance with an aspect of the present invention is illustrated. The method 1100 starts 1102 by obtaining a first hash value, v′(X)=(z′, σ′), for an input block X 1104 . Uniform hash functions such as, for example, F 1 (k) and F 2 (k) , are then obtained for a k th input data block 1106 . The input data block X hash value is then chained to the k th input data block by setting σ 0 =F 2 (σ′) 1108 and
B 0 = [ 1 0 0 1 F 1 ( z ′ ) 0 0 1 ]
1110 for the k th input data block. A hash value for the k th input data block is then determined 1112 , ending the flow 1114 . The hash value for the k th input data block can then be utilized to chain a subsequent block and so forth. These inter-block functions can be repeated to save on key length, at some cost of security. The inter-block chaining can be further optimized by exploiting existing slack in the utilization of key. Almost twice as much key is utilized in inter-block hashing as is utilized for the blocks. Key reuse techniques such as a Toplitz shift (see, Black, Halevi, Krawczyk, Krovetz, and Rogaway, 1999) could address this aspect. The utilization of a single pairwise independent hash could be sufficient.
[0096] Looking at FIG. 12 , a flow diagram of a method 1200 of facilitating data encryption in accordance with an aspect of the present invention is depicted. Since the present invention's operations are invertible, they can be combined with authentication and encryption with stream ciphers. The method 1200 starts 1202 by obtaining input data block X, where X=x 1 , . . . , x t 1204 . Derive a unimodular matrix-based hash value per the present invention 1206 . Utilize at least a portion of hash value data employed during determination of the hash value to facilitate in defining a stream cipher key 1208 . Generate a one-time pad employing the stream cipher key 1210 . Encrypt input data block component x i (1≦i≦t) with function, y i , defined by y i =a i x i +b i , where a i and b i are random key words and a i is provided by the hash value data 1212 . The hash value is then encrypted 1214 . In other instances of the present invention, the hash value is not required to be encrypted and in still other instances of the present invention, the hash value data is only employed as a seed to a cipher process. The stream cipher and encrypted hash value ( MAC ) is then output 1216 , ending the flow 1218 . Typically, MAC S are appended to the data that they represent before the combined data is transmitted.
[0097] In order to provide additional context for implementing various aspects of the present invention, FIG. 13 and the following discussion is intended to provide a brief, general description of a suitable computing environment 1300 in which the various aspects of the present invention may be implemented. While the invention has been described above in the general context of computer-executable instructions of a computer program that runs on a local computer and/or remote computer, those skilled in the art will recognize that the invention also may be implemented in combination with other program modules. Generally, program modules include routines, programs, components, data structures, etc., that perform particular tasks and/or implement particular abstract data types. Moreover, those skilled in the art will appreciate that the inventive methods may be practiced with other computer system configurations, including single-processor or multi-processor computer systems, minicomputers, mainframe computers, as well as personal computers, hand-held computing devices, microprocessor-based and/or programmable consumer electronics, and the like, each of which may operatively communicate with one or more associated devices. The illustrated aspects of the invention may also be practiced in distributed computing environments where certain tasks are performed by remote processing devices that are linked through a communications network. However, some, if not all, aspects of the invention may be practiced on stand-alone computers. In a distributed computing environment, program modules may be located in local and/or remote memory storage devices.
[0098] As used in this application, the term “component” is intended to refer to a computer-related entity, either hardware, a combination of hardware and software, software, or software in execution. For example, a component may be, but is not limited to, a process running on a processor, a processor, an object, an executable, a thread of execution, a program, and a computer. By way of illustration, an application running on a server and/or the server can be a component. In addition, a component may include one or more subcomponents.
[0099] With reference to FIG. 13 , an exemplary system environment 1300 for implementing the various aspects of the invention includes a conventional computer 1302 , including a processing unit 1304 , a system memory 1306 , and a system bus 1308 that couples various system components, including the system memory, to the processing unit 1304 . The processing unit 1304 may be any commercially available or proprietary processor. In addition, the processing unit may be implemented as multi-processor formed of more than one processor, such as may be connected in parallel.
[0100] The system bus 1308 may be any of several types of bus structure including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of conventional bus architectures such as PCI, VESA, Microchannel, ISA, and EISA, to name a few. The system memory 1306 includes read only memory (ROM) 1310 and random access memory (RAM) 1312 . A basic input/output system (BIOS) 1314 , containing the basic routines that help to transfer information between elements within the computer 1302 , such as during start-up, is stored in ROM 1310 .
[0101] The computer 1302 also may include, for example, a hard disk drive 1316 , a magnetic disk drive 1318 , e.g., to read from or write to a removable disk 1320 , and an optical disk drive 1322 , e.g., for reading from or writing to a CD-ROM disk 1324 or other optical media. The hard disk drive 1316 , magnetic disk drive 1318 , and optical disk drive 1322 are connected to the system bus 1308 by a hard disk drive interface 1326 , a magnetic disk drive interface 1328 , and an optical drive interface 1330 , respectively. The drives 1316 - 1322 and their associated computer-readable media provide nonvolatile storage of data, data structures, computer-executable instructions, etc. for the computer 1302 . Although the description of computer-readable media above refers to a hard disk, a removable magnetic disk and a CD, it should be appreciated by those skilled in the art that other types of media which are readable by a computer, such as magnetic cassettes, flash memory cards, digital video disks, Bernoulli cartridges, and the like, can also be used in the exemplary operating environment 1300 , and further that any such media may contain computer-executable instructions for performing the methods of the present invention.
[0102] A number of program modules may be stored in the drives 1316 - 1322 and RAM 1312 , including an operating system 1332 , one or more application programs 1334 , other program modules 1336 , and program data 1338 . The operating system 1332 may be any suitable operating system or combination of operating systems. By way of example, the application programs 1334 and program modules 1336 can include a data transformation scheme in accordance with an aspect of the present invention.
[0103] A user can enter commands and information into the computer 1302 through one or more user input devices, such as a keyboard 1340 and a pointing device (e.g., a mouse 1342 ). Other input devices (not shown) may include a microphone, ajoystick, a game pad, a satellite dish, a wireless remote, a scanner, or the like. These and other input devices are often connected to the processing unit 1304 through a serial port interface 1344 that is coupled to the system bus 1308 , but may be connected by other interfaces, such as a parallel port, a game port or a universal serial bus (USB). A monitor 1346 or other type of display device is also connected to the system bus 1308 via an interface, such as a video adapter 1348 . In addition to the monitor 1346 , the computer 1302 may include other peripheral output devices (not shown), such as speakers, printers, etc.
[0104] It is to be appreciated that the computer 1302 can operate in a networked environment using logical connections to one or more remote computers 1360 . The remote computer 1360 may be a workstation, a server computer, a router, a peer device or other common network node, and typically includes many or all of the elements described relative to the computer 1302 , although, for purposes of brevity, only a memory storage device 1362 is illustrated in FIG. 13 . The logical connections depicted in FIG. 13 can include a local area network (LAN) 1364 and a wide area network (WAN) 1366 . Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet.
[0105] When used in a LAN networking environment, for example, the computer 1302 is connected to the local network 1364 through a network interface or adapter 1368 . When used in a WAN networking environment, the computer 1302 typically includes a modem (e.g., telephone, DSL, cable, etc.) 1370 , or is connected to a communications server on the LAN, or has other means for establishing communications over the WAN 1366 , such as the Internet. The modem 1370 , which can be internal or external relative to the computer 1302 , is connected to the system bus 1308 via the serial port interface 1344 . In a networked environment, program modules (including application programs 1334 ) and/or program data 1338 can be stored in the remote memory storage device 1362 . It will be appreciated that the network connections shown are exemplary, and other means (e.g., wired or wireless) of establishing a communications link between the computers 1302 and 1360 can be used when carrying out an aspect of the present invention.
[0106] In accordance with the practices of persons skilled in the art of computer programming, the present invention has been described with reference to acts and symbolic representations of operations that are performed by a computer, such as the computer 1302 or remote computer 1360 , unless otherwise indicated. Such acts and operations are sometimes referred to as being computer-executed. It will be appreciated that the acts and symbolically represented operations include the manipulation by the processing unit 1304 of electrical signals representing data bits which causes a resulting transformation or reduction of the electrical signal representation, and the maintenance of F data bits at memory locations in the memory system (including the system memory 1306 , hard drive 1316 , floppy disks 1320 , CD-ROM 1324 , and remote memory 1362 ) to thereby reconfigure or otherwise alter the computer system's operation, as well as other processing of signals. The memory locations where such data bits are maintained are physical locations that have particular electrical, magnetic, or optical properties corresponding to the data bits.
[0107] FIG. 14 is another block diagram of a sample computing environment 1400 with which the present invention can interact. The system 1400 further illustrates a system that includes one or more client(s) 1402 . The client(s) 1402 can be hardware and/or software (e.g., threads, processes, computing devices). The system 1400 also includes one or more server(s) 1404 . The server(s) 1404 can also be hardware and/or software (e.g., threads, processes, computing devices). The server(s) 1404 can house threads to perform transformations by employing the present invention, for example. One possible communication between a client 1402 and a server 1404 may be in the form of a data packet adapted to be transmitted between two or more computer processes. The system 1400 includes a communication framework 1408 that can be employed to facilitate communications between the client(s) 1402 and the server(s) 1404 . The client(s) 1402 are connected to one or more client data store(s) 1410 that can be employed to store information local to the client(s) 1402 . Similarly, the server(s) 1404 are connected to one or more server data store(s) 1406 that can be employed to store information local to the server(s) 1404 .
[0108] In one instance of the present invention, a data packet transmitted between two or more computer components that facilitates data protection is comprised of, at least in part, information relating to a data transformation system that utilizes, at least in part, at least one unimodular matrix to provide a transformation value for input data to facilitate in protection of the input data.
[0109] It is to be appreciated that the systems and/or methods of the present invention can be utilized in data protection transformation facilitating computer components and non-computer related components alike. Further, those skilled in the art will recognize that the systems and/or methods of the present invention are employable in a vast array of electronic related technologies, including, but not limited to, computers, servers and/or handheld electronic devices, and the like.
[0110] What has been described above includes examples of the present invention. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the present invention, but one of ordinary skill in the art may recognize that many further combinations and permutations of the present invention are possible. Accordingly, the present invention is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.
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The present invention leverages the invertibility of determinants of unimodular matrices to provide a universal hash function means with reversible properties and high speed performance. This provides, in one instance of the present invention, length controllable hash values comprised of vector pairs that can be processed as one instruction in a SIMD (single instruction, multiple data) equipped computational processor, where the vector pair is treated as a double word. The characteristics of the present invention permit its utilization in streaming cipher applications by providing key data to seed the ciphering process. Additionally, the present invention can utilize smaller key lengths than comparable mechanisms via inter-block chaining, can be utilized to double hash values via performing independent hash processes in parallel, and can be employed in applications, such as data integrity schemes, that require its unique processing characteristics.
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BACKGROUND
This disclosure is directed to vacuuming devices and, more particularly, to vacuuming devices that collect and filter contaminated fluid and the filtered fluid is subsequently discharged.
Vacuuming devices have been developed in a variety of designs, each to accomplish a specific task or set of tasks. One common configuration of a vacuuming device is a portable vacuum in which a canister, which may be a drum or other enclosed vessel, is used to collect material that is to be vacuumed. A flexible hose that terminates in a rigid wand or other tool is connected to the canister and the wand is placed in or near the material to be collected. Such devices typically include a vacuum pump that lowers the pressure within the sealed canister to below ambient, and the pressure differential causes material to be sucked through the collection hose and collected within the interior of the canister. Such portable devices may be used to vacuum and collect dry particulate material, fluids or a combination of fluids and particulate material.
Certain types of vacuuming devices may be adjusted to a vacuuming configuration, in which particulate material, a fluid or a combination thereof, is drawn through the collection hose and is retained within the canister, or to a discharge configuration, in which operation of the vacuum pump is reversed to pressurize the interior of the canister above ambient pressure. The pressurized interior forces the collected material, typically a fluid, out through the collection hose, or in some embodiments out through a second hose, thereby emptying the contents of the canister.
A common application for such vacuuming devices with reversible vacuum pumps is the collection and filtering of fluid that contains or is contaminated with particulate material. With such devices, the collection hose is first connected to a port that communicates with a collection filter within the canister. In the vacuuming or collecting mode, fluid with particulate material suspended in it is drawn through the collection hose and through the filter in the canister, which collects the particulate material suspended in the fluid. The filtered fluid is also retained within the canister. In a discharge mode, the collection hose is disconnected from a collection port, that port is closed off and the hose is connected to a second port that communicates with the interior of the canister and bypasses the filter. The vacuum pump is then adjusted to pressurize the interior of the canister. The filtered, collected fluid in the canister is then discharged through the hose.
There is a need for a liquid vacuuming and filtering device that is simple to operate and eliminates the need to adjust hoses when switching from a collection mode to a discharge mode.
SUMMARY
This disclosure is directed to a liquid vacuuming and filtering device and method. The device may be adjustable to a liquid collecting mode and to a liquid discharge mode without having to disconnect and reconnect the fluid collection hose. Moreover, the disclosed liquid vacuuming and filtering device may use the same, single hose both for collecting contaminated fluid and for discharging filtered fluid. Multiple hoses or discharge ports may not be needed.
In one aspect, the disclosed liquid vacuuming and filtering device may include a sealed container, a reversible vacuum pump communicating with an interior of the container, a two-way valve mounted on the container, a flexible hose connected to the valve, a filter positioned within the container and connected to the valve and a standpipe connected to the valve and extending within the container. In one aspect, the vacuum pump may be a reversible pneumatic pump. When the reversible pneumatic pump and the valve are adjusted to a filling configuration, and the flexible hose is placed at or in a fluid containing particulate material, the pump evacuates air from within the container to create a below-ambient pressure within the container. This partial vacuum may cause fluid to be drawn through the flexible hose, through the valve and into the filter within the container interior. The container interior fills with fluid and the filter may trap and collect the particulate material that was suspended in the fluid or was taken in through the hose along with the fluid.
The disclosed reversible vacuum pump and valve may be adjusted to a discharge configuration in which the reversible vacuum pump pressurizes the container interior to a pressure above ambient. In this configuration, the valve may be adjusted to create a fluid flow channel through the standpipe in the interior of the container, through the valve and out the flexible hose. The above-ambient pressure within the container may cause fluid within the container to flow through this channel and be discharged through the hose.
In this fashion, the disclosed liquid vacuuming and filtering device may be used to recondition cutting fluid or machine coolant that has become contaminated with particulate material such as dirt, metal particles and shavings. Operation of the device may draw such contaminated fluid from a sump through the flexible hose, valve and through the filter so that the particulate material may be collected within the filter and the filtered fluid fills the container. The device then may be adjusted to a discharge configuration and the filtered fluid returned to the sump through the flexible hose.
It is within the scope of the disclosure to utilize such a device in a number of other applications. For example, the device may be used to filter and recondition contaminated fluid from any sort of power transmission gear enclosure, such as an automobile transmission or differential, to filter and recondition contaminated fluid from equipment with oil or coolant reservoirs, to filter and recondition cooking oil, to clean ponds, to filter fluid taken from flooded vaults, and to collect and filter fluid from other waste containers.
It is also within the scope of this disclosure to utilize the disclosed device to clean up spills. In such applications, the hose may include a tool, such as a floor attachment, attached to its distil end that would facilitate vacuuming spilled fluid from, for example, a shop floor. The fluid may then be collected within the device and any particulate material filtered from the fluid. Disposal of the fluid and the particulate material thus would be facilitated.
In one aspect, the device may utilize a polyester bag filter that is removable and replaceable. Such a filter may be used with varying pore sizes, from 5 to 50 microns and larger, and down to 1 micron or less for applications to reclaim precious metals. It is also within the scope of the disclosure to utilize mesh filters made of other materials, such as metal.
Other objects and advantages of the disclosed device will be apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic, perspective view of one embodiment of the disclosed liquid vacuuming and filtering device, shown connected to a source of compressed air, and in which the interior of the container is partially broken away to reveal internal components;
FIG. 2 is a detail of the device of FIG. 1 , showing the tank lid and broken away to show the interior of the container;
FIG. 3 is a schematic, side elevation in section of the device of FIG. 1 , shown adjusted to a filling configuration; and
FIG. 4 is a schematic, side elevation in section of the device of FIG. 1 , shown adjusted to a discharge configuration.
DETAILED DESCRIPTION
An embodiment of the disclosed liquid vacuuming and filtering device, generally designated 10 , is shown in FIGS. 1 and 2 . The device 10 may include a container 12 , such as a standard 55-gallon drum. Other containers may be used, such as a 5-gallon or 30-gallon drum or a tank. Plastic containers may be used as well. Any container that is capable of being pressurized positively and negatively without leakage may be used.
The container 12 may include a container body 14 and a removable lid 16 . The lid 16 may be secured to the body by a drum latch ring 18 to form a sealed, substantially air-tight interior 20 .
A reversible vacuum pump 22 may be mounted on the lid 16 and may be attached to form a substantially air-tight seal with the lid. The pump 22 may include a shut-off valve 23 (see FIGS. 3 and 4 ), such as a float valve, that automatically shuts the valve off should the liquid level in the container 12 reach a predetermined maximum level and actuate the valve. This shut-off valve 23 may prevent overfilling the container 12 .
The pump 22 also may include a manually operated shut-off valve 24 . The shut-off valve 24 may be integrated with the pump, or as shown in FIG. 1 , may comprise a separate valve positioned upstream of the pump 22 . The pump 22 may be a reversible pneumatic pump, such as an EXAIR Model 6091 Reversible Drum Vac. If the pump 22 is pneumatically operated, the pump may be connected to a source of compressed air, generally designated 26 , by a supply line 28 , such as a flexible hose or rigid conduit. In such a configuration, the supply line 28 may be connected to the shut-off valve 24 , which in turn is connected to pump 22 . As shown in FIGS. 1 and 2 , the source of compressed air 26 may be a pressurized tank, as shown in FIG. 1 or it may be a compressor or other device for creating pressurized air. The preferred range of delivered compressed air is 80-100 psig. Alternatively, the pump 22 may be an electrically powered pump or blower.
The device 10 may include a flexible hose 29 that may optionally terminate in a tool 30 mounted or attached to its distal end. Tool 30 may be a rigid wand, as shown in FIG. 1 , or may be another tool, such as a floor vacuum attachment.
The device 10 also may include a valve, generally designated 32 , which may be a two-way valve. The valve 32 may be connected to the intake hose 29 at port 33 , which may be a barbed fitting. Valve 32 also may be a three-way valve, or a valve having more than three settings.
A filter 34 may be positioned within the interior 20 of the container 12 and connected to the valve 32 by an elbow 36 , which may be a female quick release elbow adaptor, which is connected to port 37 of the valve. As shown in FIGS. 1 and 2 , the filter 34 may be a porous filter bag, such as a polyester bag. The filter 34 may include a filter bag 38 and an adaptor 40 . The adaptor 40 may be connected to a quick-release adaptor 42 , such as a male quick release adaptor, that forms a part of the elbow 36 . The adaptor 40 may include a bulkhead fitting that forms a substantially air-tight seal with lid 16 .
The pore size of the filter bag 38 may vary, depending upon the particular application of the device 10 and the size range of the particulate material to be filtered from the fluid to be collected by the device 10 . For example, the bag 38 may have pores in the range of 1μ up to 125μ in size. Other forms of filter 34 may be employed, such as a mesh filter made of metal. Other shapes of filter 34 may be employed as well.
Also as shown in FIGS. 1 and 2 , the device may include a discharge pipe 44 , such as a standpipe that may comprise a section of PVC pipe. Alternatively, the discharge pipe 44 may be made of corrosion-resistant metal, metal coated or treated to be corrosion resistant, or a plastic other than PVC, such as nylon. The standpipe 44 may be connected to the valve 32 by a quick-release elbow adaptor 46 , such as a female quick release elbow adaptor, which may be attached to port 47 of the valve. Elbow adaptor 46 may include a quick-release adaptor 48 , such as a male quick release adaptor. Adaptor 48 may form a substantially air-tight seal with lid 16 . Alternatively, the discharge pipe 44 may pass through the body 14 of container 12 or through the bottom of the container and extend to valve 32 .
The method of operation of the device 10 is shown in FIGS. 3 and 4 . To place the device 10 in a filling configuration, as shown in FIG. 3 , the shut-off valve 24 is closed, which shuts off the flow of pressurized air to inactivate the reversible vacuum pump 22 . The knob 50 on the pump 22 is turned to adjust the pump to a configuration in which air is evacuated from the interior 20 of the container 12 . The handle 52 on two-way valve 32 is adjusted to connect the hose 29 with the filter bag 34 within the interior 20 of the container 12 . Thus, a continuous intake channel is formed that extends through the tool 30 , hose 29 , ports 33 and 37 of valve 32 , elbow 36 and quick-release adaptor 42 and filter 34 in the interior 20 of container 12 . The tool 30 , such as a wand shown in FIG. 3 , is placed within the contaminated fluid 54 in a vessel 56 , such as the sump shown in FIG. 3 .
The shut-off valve 24 is opened and the reversible pump 22 evacuates air from the interior 20 of the container 12 . This creates a below-ambient pressure condition within the container 12 so that fluid 54 is drawn through the wand 30 , hose 29 , valve 32 , elbow 36 and into the filter bag 34 . The particulate material 58 contained in the fluid 54 is collected in the filter bag 34 . The interior 20 of the container 12 then fills with filtered fluid 60 . It is preferable for an operator to move the wand around in the vessel 56 to make sure that all the contaminants are stirred up and drawn through the hose 29 with the fluid 54 and into the container 12 .
Once the vessel 56 is emptied, the shut-off valve 24 may be closed to stop the pump 22 and prevent overfilling or to prevent fluid or air from continuing to be drawn from the interior 20 of the container 12 . Alternatively, the device may be allowed to operate until the shut-off valve 23 is activated by the rising level of fluid 60 in the container 12 , which shuts off pump 22 . The container 12 is now filled with fluid 60 from which the particulate contaminants 58 have been removed.
As shown in FIG. 4 , to place the device 10 in a discharging configuration, shut off valve 24 preferably is in the closed position. The knob 50 then may turned on the reversible vacuum pump 22 so that the pump is adjusted to pressurize the interior 20 of the container 12 . The handle 52 of the valve 32 is adjusted to connect the standpipe 44 within the container 12 with the hose 29 . A continuous fluid discharge channel is thus formed that extends through standpipe 44 , elbow 46 and quick release 48 , ports 47 and 33 of valve 32 , and flexible hose 29 and tool 30 . The wand 30 is placed into the vessel 56 where clean, filtered fluid 60 from the interior 20 of the container 12 is desired. The shut-off valve 24 is opened, allowing pressurized air from source 26 (see FIG. 1 ) to activate the reversible vacuum pump 22 , which begins to pressurize the interior 20 of the container 12 . This above-ambient pressure condition in the interior 20 forces the filtered fluid 60 within the interior 20 to flow upwardly through the standpipe 44 , through elbow 46 , valve 32 , and through the hose 29 and wand 30 back into the vessel 56 , if desired. The vessel 56 then is refilled with the clean, filtered fluid 60 .
The standpipe 44 preferably is oriented substantially vertically within the container 12 and sized to open near the bottom of the interior 20 so that the container may be substantially completely emptied of filtered fluid 60 during fluid discharge operation. When the fluid 60 is discharged from the container 12 , the shut-off valve 24 may be adjusted to shut off the flow of compressed air from the source 26 ( FIG. 1 ) to the pump 22 , which stops the pump and the discharge of fluid 60 from the container 12 .
At this time, the latch ring 18 (see FIGS. 1 and 2 ) may be disengaged, which allows an operator to remove the lid 16 from the body 14 of the container 12 . The filter bag 34 may be removed from the adaptor 40 and the collected particulate material 58 emptied from the bag. In the alternative, the bag 34 may be discarded and replaced with a fresh bag.
In conclusion, the device 10 provides a means of vacuuming, filtering and returning filtered fluid to a source, such as a sump, without the necessity of disconnecting and reconnecting hoses. The device preferably is portable and may be mounted on a wheeled dolly (not shown), or may be provided in a stationary or wall-mounted form.
While the form of apparatus herein described and illustrated may constitute a preferred embodiment of the disclosed device, it is to be understood that this device is not limited to this precise form of apparatus, and that changes may be made therein without departing from the scope of the invention.
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A liquid vacuuming and filtering device may include a container having a sealed interior, a vacuum pump connected to the interior, a two-way valve connected to the interior, a flexible hose connected to the valve, a filter positioned within the interior and connected to the valve and a standpipe positioned within the interior and connected to the valve. The pump may be adjusted to a filling configuration, in which the pump evacuates the container interior to a pressure below ambient, causing fluid to be drawn through the hose, valve, and filter, which collects suspended particulates; or to a discharge configuration, in which the pump pressurizes the interior to a pressure above ambient, wherein the valve is adjusted to allow filtered fluid within the container to flow through the standpipe, valve and out through the hose.
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The present application is a divisional application of Ser. No. 07/483,995, filed Feb. 22, 1990, now U.S. Pat. No. 5,219,885, which is a continuation of Ser. No. 07/156,177 filed Feb. 16, 1988, and now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to prostaglandin E1 derivatives (PGE1 derivatives) as pharmacologically active agents and to pharmaceutical compositions--especially for transcutaneous (transdermal) application--which contain a PGE1 derivative.
DE-A-27 53 986 and the corresponding U.S. Pat. No. 4,205,178 disclose 6-keto prostaglandin E1 derivatives, especially the 6-keto PGE1 methyl ester.
A number of biological and pharmacological effects are described for these compounds. Various routes of administration are indicated for the various kinds of illnesses to be treated, e.g. oral, intravenous, subcutaneous, intra-arterial, buccal, rectal and intra-vaginal administration. Topical administration is described in connection with skin injuries or skin diseases at or near the site of the injury or disease.
6-keto prostaglandin E1 derivatives are also described in DE-A-28 40 032, in which the authors also refer to various forms of pharmacological activity and administration.
Prostaglandin E1 (PGE1) and 6-keto prostaglandin E1 (6-k PGE1) can be used for the treatment of several diseases. These diseases include peripheral occlusive diseases, complications in arteriosclerosis such as Meniere's disease or acute loss of hearing, acute myocardial infarctation, unstable angina pectoris, acute ischaemic strokes, impotence, bronchial asthma, impaired hair growth and rejection following kidney transplants; see H. Sinzinger and W. Rogatti, Prostaglandin E1 in atherosclerosis, Springer Verlag Berlin--Heidelberg--New York, 1986; S. Schrey, PGE1, Therapie der arteriellen Verschluβkrankheit, Universitatsdruckerei and Verlag Dr. C. Wolf und Sohn, Munich, 1985. PGE1 is used for the treatment of chronic arterial occlusive diseases in phase III and IV. This condition calls for intra-arterial or intravenous infusion which results in a severe limitation in the use of PGE1, as the infusion is not only a strain on the patient, but also involves a certain risk of arterial haemorrhage. Neither route of administration (i.a. and i.v.) is suitable for continuous therapy in ambulatory patient care. However, long-term administration would be most appropriate for these diseases. The oral adminstration of PGE1 is always problematic as either the very low bio-availability rules out such administration, or the typical undesired effects (nausea, vomiting, diarrhoea) are prohibitive due to the high concentration of the drug in the gastrointestinal tract when orally administered.
SUMMARY OF THE INVENTION
The object underlying the invention is to provide PGE1 and PGE1 derivatives as pharmaceutical compositions or pharmacologically -active agents. The PGE1 derivatives, which were especially developed as pharmacologically active agents for transcutaneous, transdermal adminstration, are absorbed by the skin and subsequently split by hydrolases into prostaglandin E1 or 6-keto PGE1 and alcohol. The PGE1 derivatives thus fulfill the requirements of the "Pro-Drug" Concept and avoid the disadvantages of PGE1 and 6-keto PGE1 when adminstered arterially, intravenously or orally.
The subject matter of the invention is therefore prostaglandin E1 derivatives of the general formula I ##STR1## in which R 1 is a hydrogen atom and R 2 is a C 1-4 alkyl residue, as pharmacologically active agents.
A further subject matter of the invention is a pharmaceutical composition containing a prostaglandin E1 derivative according to formula I.
Still a further subject matter of the invention is the use of prostaglandin E1 derivatives of general formula I, ##STR2## in which R 1 is a hydrogen atom (PGE1) or a carbonyl oxygen atom (6-k-PGE1) and R 2 is a C 1-4 alkyl residue for the preparation of a pharmaceutical composition to be administered transcutaneously.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows the absorption rate of PGE1 and PGE1 ethyl ester which has been determined as the cumulative urinary excretion following transcutaneous administration.
DETAILED DESCRIPTION
Specific examples of alkyl residues are the methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl and tertiary butyl group.
Due to the non-toxicity of the fragments, the preferred group R 2 is the ethyl group.
The preparation of the compounds of general formula I is carried out according to methods known per se via esterification of PGE1 and 6-k PGE1. The methyl and ethyl ester, for instance, are prepared by reacting the same with diazomethane or diazoethane; also see Ch. J. Sih et al., J. Am. Chem. Soc., Vol. 97 (1975), pp. 857 to 865.
The compounds of general formula I can be used to treat circulatory insufficiencies, for instance of the brain, the heart and the extremities, to inhibit platelet aggregation (thrombocyte aggregation), impotence and to treat allergic reactions such as bronchial asthma, rejection following transplantations and impaired hair growth. Typical examples of deficiencies in the cerebral blood supply are transitory cerebral ischaemia, acute loss of hearing, vertigo caused by circulatory insufficiencies and ischaemic strokes. Typical examples of deficiencies in the myocardial blood supply are angina pectoris and myocardial infarction. Typical examples of deficiencies in the blood supply of the extremities are periphal arterial circulatory insufficiencies in arteriosclerosis and Raynaud's disease and Raynaud's syndrom.
The compounds of general formula I can also be used to treat gastrointestinal ulcers and ulcers of the skin. Typical examples of gastrointestinal ulcers are ulcus ventriculi, duodenal ulcers and ulcerative colitis (Crohn's disease). A typical example of a skin ulcer is ulcus cruris. The compounds of general formula I have a cyto-protective effect. The cells exhibit increased resistance to noxious stimuli.
The compounds of general formula I can further be used to treat haematomas, especially surface haematomas.
In addition to transcutaneous (transdermal) administration, the compounds of general formula I can also be administered by inhalation, intravenously and intra-arterially and in each case incorporated into microsomes.
The preparation of pharmaceutical compositions is carried out according to conventional methods. For the preparation of pharmaceutical compositions to be administered transcutaneously, the compounds of general formula I can be mixed with a gel, ointment or liquid vehicle either with or without various solvents and stabilizers. The packages used are sprays, tubes, ampules and individual doses. Once applied to the skin either with or without an additional occlusive dressing, the active agent is absorbed.
The compounds of general formula I can also be placed either with or without stabilizers and solvents onto a plaster and can then be applied as such.
The conversion of the ethyl ester to PGE1 in the human body was demonstrated in the following way: an isotopically labelled PGE1 ethyl ester was applied in the manner described above. The isotopically labelled urinary metabolites were separated with HPLC and compared with the retention time of the main metabolite of PGE1 (7α-hydroxy-5,11-diketotetranorosta-1,20-dioic acid). It was found that after administration of the PGE1 ethyl ester, the main metabolite was identical to the main metabolite after administration of PGE1. This proves that the PGE1 ethyl ester is a pro-drug of PGE1.
The following examples illustrate the invention.
EXAMPLE 1
The preparation of prostaglandin E1 ethylester.
Excess diazoethane in diethyl ether (17 mg/ml; 0.3 mmol) is added to 500 μg PGE1 (1.31 μmol) in 500 μl ethanol under stirring and cooling. The reaction mixture is taken out of the cooler and is stirred until it reaches room temperature. Stirring is then continued for a further 30 minutes. The excess diazoethane and the ethanol are removed at room temperature by a stream of nitrogen. The product is purified by high-pressure liquid chromatography (RP 18).
In the same manner and with excess diazoethane, 500 μg of 6-keto PGE1 in 500 μl of ethanol are reacted and processed in diethyl ether. The ester is purified by high-pressure liquid chromatography (RP 18).
EXAMPLE 2
250 μg of prostaglandin E1 ethyl ester together with an isotopically labelled PGE1-ethyl-ester in 250 μl of ethanol were worked into 2 g of a gel vehicle of the composition as indicated below. The gel was applied to the upper arm and rubbed in for 1 minute. The application area was covered with a plastic foil.
One week later, 250 μg of prostaglandin E1 together with an isotopically labelled PGE1 in 250 μl of ethanol were mixed with 2 g of a gel vehicle of the composition as indicated below. It, too, was applied to the upper arm and rubbed in for 1 minute.
Measurement of the absorbed quantity was carried out by determining the isotopically labelled prostaglandin metabolites in the urine. For this, the total urine was collected in portions from the beginning of the application onwards. Four hours after the application, the plastic film was removed and the excess gel wiped off. As can be seen in FIG. 1, the absorption rate of PGE1 ethyl ester (23 %) was clearly better than that of PGE1 (approx. 4 %).
The gel vehicle was prepared according to the following recipe:
______________________________________Isopropanol 40.0 gDiisopropyl adipate 0.5 gCarbopol 940 2.0 gTrometamol 1.91 gPurified water ad 100.0 g______________________________________
The isopropanol can also be exchanged for ethanol.
The water, alcohol and diisopropyl adipate are mixed, the carbopol is dispersed in this mixture and left to swell. The gel is neutralized with the aqueous trometamol-solution.
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The invention describes prostaglandin E1 derivatives as pharmacologically active agents, and pharmaceutical compositions containing these compounds, especially for transcutaneous administration.
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RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 12/911,483, filed Oct. 25, 2010, which is a continuation of U.S. patent application Ser. No. 11/388,348, filed Mar. 24, 2006, the contents of which are incorporated by reference herein in their entirety.
BACKGROUND
The present invention is related to the field of data communications networks, and more particularly to data communications network management.
Network management encompasses a variety of activities with respect to communications networks, such as configuring, updating, monitoring and diagnosing network communications devices deployed within a network. In most instances the network communications devices, which are also referred to as “managed devices” herein, include hardware and software that supports these network management activities as well as an interface to a remote network management system of the managed network. While several such network management interfaces have been and continue to be used, one commonly used interface employs an open network management protocol known as the Simple Network Management Protocol (SNMP) along with a representation of network management data that conforms to an open specification known as the Structure of Management Information or SMI. Network management applications are deployed on a centralized network management system and engage in communications with the managed devices using the SNMP and SMI standards to carry out their network management tasks.
In particular, the SMI standards describe rules for writing abstract data collections referred to as Management Information Bases or MIBs. MIBs are specifications containing definitions of management information so that networked systems can be remotely monitored, configured, and controlled.
Although there are a wide variety of managed objects, for present purposes the focus is primarily on managed objects known as “interfaces”. In the context of data communications generally, “interface” refers to a logical relationship between two entities that operate at different hierarchical layers of a layered communications scheme. Typically, an “interface” refers to a communication layer beneath the network layer in the 7-layer OSI model. In the case of a point-to-point protocol (PPP) session being carried by an Ethernet VLAN, for example, involves a virtual interface layered atop a physical Ethernet interface.
In the context of SNMP and SMI, there is much content and structure pertaining to interfaces that are defined in a managed device. For example, a typical MIB includes an interfaces table that enumerates all the interfaces in a managed device and includes a variety of information about each of them, including such things as an interface type, a description, a speed, an address, administrative and operational status, counts of packets transferred and errors, etc. Additionally, the manner in which interfaces are identified in a MIB is itself the subject of standardization—there is an official list of interface “types” that have been assigned by the Internet Assigned Names Authority (IANA), and network management applications operate in part based on the use of standard interface types in MIBs.
Another pertinent type of managed object is an interface “stack”, which is a grouping of particular interfaces that together provide an interface between two entities that are separated in the hierarchical communications scheme. Continuing with the above example of a PPP session over an Ethernet VLAN, the virtual and physical interfaces are layered or “stacked” in that order.
It has been known to use a single data structure, referred to herein as an Interface Descriptor Block or IDB, to maintain various information pertaining to an “interface” as might be defined in a custom manner within a network communications device. Of particular pertinence here is the use of a single IDB by a software driver used in connection with an “interface” provided by a hardware interface module. A particular example might be a so-called “line card” for an optical communications link such as an Optical Carrier (OC)-x link, where x may have the value 8, 12, 48, etc. An internal interface provided by such a line card might be a single virtual tributary (VT) of a Synchronous Optical Network (SONET) connection, for example, and thus the “interface” may actually be a multi-layered interface including functionality at several hierarchical layers including a SONET Path layer and a SONET physical layer.
SUMMARY
Standards defining MIB modules for specific network interfaces typically describe how a particular type of network interface should relate to others in terms of interface stacking. As an example, one standard type of interface is a packet-over-SONET (‘POS’) interface, which is a packet-type of interface. It is expected from a standards perspective that a POS interface is part of an interface stack that also includes a SONET Path interface as well as a SONET physical-layer (line) interface. A network management application that is designed based on such an expectation may include corresponding internal dependencies. For example, if the network management application is tracing a communications path from end to end and collecting information about each interface along the way, upon discovering a POS interface it then looks for the underlying SONET Path and SONET physical layer interfaces that it expects. However, in the case that a managed device presents a multi-layered interface as a single managed object such as described above, the network management application will not be able to locate any of the underlying interfaces within the MIB for the managed device, because they are not present. The managed device is presenting the interface in a non-standard way to the network management application, and thus the network management application may not function correctly or provide usable results because its assumptions about the presentation of the network management information are not satisfied.
In accordance with the present invention, methods and apparatus are disclosed by which network management information can be presented in a standard way to a network management system by derivation from a non-standard representation maintained by a managed device, such as a single driver-maintained IDB for a multi-layered interface. The standards-related expectations of network management systems can be satisfied without requiring that software drivers for hardware interface modules themselves comply with the applicable network management standards. Thus, the disclosed techniques can be used in conjunction with existing drivers in a backwards-compatible manner, and can also be used even with new drivers to free the driver designer of the need to understand and comply with the pertinent network management standards.
According to a disclosed method, network management information about a multiple-layer network communications interface sub-stack is provided to a network management client. The network communications interface sub-stack has a non-standardized network management representation which omits network management information about an expected sub-layer interface of the network communications interface sub-stack.
The method includes establishing a standardized network management representation of the network communications interface sub-stack by use of an interface manager in conjunction a real driver and a pseudo driver. The real driver is associated with the network communications interface sub-stack as a whole, and the pseudo driver is associated with the expected sub-layer interface of the network communications interface sub-stack. The standardized network management representation includes the network management information about the expected sub-layer interface.
The interface manager is operative to receive a request from the network management client for the network management information about the expected sub-layer interface, and in response the request is passed from the interface manager to the pseudo driver. The pseudo driver obtains data maintained by the real driver corresponding to the requested network management information, and the data obtained by the pseudo driver is returned to the network management client in satisfaction of the request.
In another aspect, the standardized network management representation of the network communications interface sub-stack may be established by determining, based on a signature indicating a layered structure of the network communications interface sub-stack, whether the expected sub-layer interface of the network communications interface sub-stack exists. If the expected sub-layer interface is determined not to exist, then the expected sub-layer interface is created and a network management information base is populated with a sub-layer interface entry including (1) respective instance and type identifiers of the expected sub-layer interface and (2) one or more operational attributes of the expected sub-layer interface. The value of each operational attribute identically mirrors the value of a corresponding operational attribute of the network communications interface sub-stack as reflected in the non-standardized network management representation.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will be apparent from the following description of particular 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 is a block diagram of a data communications network including a network management system (NMS) and managed network devices;
FIG. 2 is a block diagram depicting an organization of network management functions within a managed network device as known in the art;
FIG. 3 (consisting of FIGS. 3A, 3B and 3C ) depicts various examples of multi-layered or “sub-stack” types of communications interfaces existing in a managed network device;
FIG. 4 is a block diagram depicting an organization of network management functions within a managed network device in accordance with the present invention;
FIG. 5 is a diagram depicting a multi-layered interface including explicitly defined sub-layer interfaces using the organization of network management functions of FIG. 4 ;
FIG. 6 is a flow diagram showing the overall operation of the organization of network management functions of FIG. 5 ; and
FIG. 7 is a diagram illustrating part of the operation of FIG. 6 having an iterative, reentrant characteristic.
DETAILED DESCRIPTION
FIG. 1 is a simplified depiction of a communications network from a network management perspective. A network management system (NMS) 10 is communicatively coupled to a plurality of managed network (NW) devices 12 , which may include switches, routers, bridges, modems, etc. Each NW device 12 includes a respective management information base (MIB) 14 containing a variety of configuration and operational information about the respective NW device 12 . The MIB 14 for a particular NW device 12 is not itself a physical data structure but rather a formalized, structured representation of data that may be distributed throughout the NW device 12 . The NMS 10 can control and monitor the configuration and operation of each NW device 12 by writing data to and reading data from the corresponding MIB 14 . In particular, the NMS 10 controls and monitors a variety of configuration and operational information concerning communications interfaces that exist within each NW device 12 , as described in more detail below. FIG. 1 also shows that a local console 15 may be connected directly to a NW device 12 for purposes of local management. Because such consoles 15 often employ command-line interfaces (CLIs) rather than more elaborate graphical user interfaces, a console 15 is sometimes referred to as the “CLI” from the perspective of the NW device 12 .
FIG. 2 shows an arrangement of pertinent software entities within a NW device 12 as known in the art. Much of the data that is represented within a MIB 14 , specifically interface-related data, is actually maintained by drivers 16 ′ that execute within a NW device 12 to control the operation of the hardware interface modules for the physical communications ports of the NW device 12 . Such modules are referred to as “physical layer interface modules” or “PLIMs” herein. A PLIM generally performs low-level, high-speed functions necessary to move data between a communications link (such as an Optical Carrier-12 (OC-12) link) and one or more high-speed data channels on a backplane or midplane of the NW device 12 . The drivers 16 ′ are part of an operating system executing within a NW device 12 to control its overall operation, including its interaction with the NMS 10 . An example of such an operating system is the Internetwork Operating System (IOS) sold by Cisco Systems, Inc. The drivers 16 ′ may maintain interface-related information in the form of interface description blocks (IDBs) 18 ′, which are described in more detail below.
Also shown in FIG. 2 are a set of management information clients 20 ′ that require access to the network-management-related information maintained by the drivers 16 ′. Examples of clients 20 ′ include one or more MIB systems (MIB SYS) 22 ′, one or more event receivers (EVENT RCVR) 24 ′ and the interface to the console 15 (shown as CLI 26 ′). In operation, a client such as a MIB SYS 22 ′ communicates with the drivers 16 ′ to access the underlying data elements that are represented by the MIB variables exposed to the NMS 10 . Thus, if the NMS 10 performs an SNMP GET of a MIB variable, the MIB SYS 22 ′ of the NW device 14 responds by interrogating the appropriate driver 16 ′ and/or IDB 18 ′ to read the actual data value represented by the MIB variable, such as a packet counter, interface description, etc.
In the prior-art configuration depicted in FIG. 2 , the clients 20 ′ are essentially in direct communication with the drivers 16 ′ for purposes of accessing network management information including the information maintained within the IDBs 18 ′. This organization is problematic from several perspectives. Development of new drivers 16 ′ and/or clients 20 ′ may be unduly complicated, for example because the burden of managing MIB data falls too heavily on driver developers who are not familiar with the detailed operation of network management. Also, existing clients 20 ′ and drivers 16 ′ may not adequately support functional and compliance testing of the MIBs 14 that they support. Existing software has also come to include numerous dependencies on particular types of NW devices 12 and/or particular types of PLIMs, making it increasingly difficult to migrate to new MIB definitions as well as to diagnose operational problems when existing MIBs are in use. These problems can manifest themselves in the form of conformance and consistency issues that negatively affect the development and deployment of network management applications and that can increase the cost to a manufacturer of product support for the NW devices 12 . The presently disclosed methods and apparatus address these problems by introducing an explicit interface manager as described below which provides for normalized access to interface-related network management data. The interface manager can be implemented as a common part and interface-specific extensions for implementation efficiency, and can have specific support for “legacy” drivers 16 ′ that have not been designed or adapted for use with the interface manager.
The interfaces-related data in the MIB 14 resides in several particular sub-structures, all of which are part of an “interfaces group” defined in the MIB standards, such as Request for Comments (RFC)2863. An “interfaces table” represents all the interfaces of a NW device 14 as a sequence of “interface entries”, each of which in turn is a collection of a variety of data elements for a particular interface. These data elements include things such as an index (unique identifier), description, type, address, status, operational variables, etc. It should be noted that interface types are subject to textual conventions defined by an interface type MIB published by the Internet Assigned Names Authority (IANA). The interfaces group also includes an “interface stack table” which describes the interface stacks within the scope of managed entity such as a NW device 14 . Each conceptual row in this table describes a connection in a graph representing an interface stack. Each table entry identifies a connection by a pair of interface indexes, one representing a “superior” (higher level) interface and the other representing a “subordinate” (lower-level) interface, in the order specified. Thus, a connection flows from superior to subordinate interface. The interface stack table can be used by network management software to identify the stack relationships of interfaces, which can be useful for certain types of operations, including path-tracing and isolation during the process of diagnosing operational problems. There is also an “inverted” interface stack table which describes the same interface-stack graph using entries that have the interface indexes lexically reversed, making it easier for network management software to traverse the graph from bottom to top when necessary.
Historically, driver objects representing interfaces often do not cleanly map to the notion of an interface as defined by the interfaces MIB and interface-specific MIBs. Consider an interface on an OC-12 Packet-Over-SONET (POS) PLIM configured to use a High-Level Data Link Control (HDLC) type of encapsulation. An interface driver for such a POS PLIM might maintain a single IDB 18 ′ containing information at the encapsulated packet level, the SONET Path level, and the SONET physical layer. A standardized interface type that might be selected for this OC-12 POS interface would necessarily be incomplete and/or misleading, because it would not capture the non-standard multiple-layer structure. This contrasts with the expectations of the interfaces MIB and a specific SONET MIB known as SONET-MIB, which together mandate an interface stack having three distinct MIB-identified interfaces, namely a topmost POS interface, a next-layer SONET Path interface, and a bottom-most SONET physical layer interface.
It can be generalized that driver objects representing such non-standard, multi-layered interfaces map to interface “sub-stacks” rather than to a single interface. In the above example, the IDB 18 ′ representing the OC-12 POS interface can be mapped to an interface sub-stack including distinct POS, SONET Path, and SONET physical-layer interfaces, where each of these is a standardized IANA interface type. FIGS. 3A, 3B and 3C illustrate several examples of such mappings. FIG. 3A shows the structure of an interface object 28 that has the non-standard type POS-FRAME-RELAY. This object might be presented, for example, by an interface driver for a port of an OC-12 POS PLIM that employs frame relay encapsulation. As shown, the POS-FRAME-RELAY object 28 actually includes functionality at three different layers, including a frame relay encapsulation layer 30 , a SONET path transport layer (SONET PATH) 32 , and a SONET line or physical layer (SONET) 34 . FIG. 3B illustrates an interface object 36 that may be created for a T1 (DS1) PLIM that provides frame relay encapsulation, and thus may be identified as the non-standard type DS1-FRAME-RELAY. FIG. 3C shows an interface object 38 that may represent the use of frame relay, DS1 and SONET virtual tributaries (VTs) of a channelized OC-12 PLIM and having the non-standard type SERIAL-FRAME-RELAY.
In all three cases of FIG. 3 , the topmost layer is FRAME RELAY and thus each interface object 28 , 36 and 38 might be represented in a prior-art network management environment as being of the standardized type FRAME RELAY. Such a common identification of very different multi-layered interfaces can present problems for network management applications that attempt to operate according to published standards.
It will be noted in the foregoing description that a distinction is drawn between the type of each multi-layered interface (such as the POS FRAME RELAY type of interface object 28 ) and the type of each sub-layer (e.g., SONET Path layer 32 ), which is standardized. In accordance with the presently disclosed technique, the non-standard terms POS FRAME RELAY, DS1-FRAME-RELAY, and SERIAL-FRAME-RELAY are taken to be “signatures” of the respective multi-layered interface objects. These signatures are used as described below to create explicit representations of all the standard-type sub-layers. The resulting MIB representations of these interface objects are compliant with the relevant standards, so that the operational assumptions of network management applications are satisfied and the applications perform better. The use of interface signatures in this manner allows a network device to guarantee the representation of all standard required interfaces with respect to network management.
FIG. 4 shows an improved organization of the functions/software pertaining to the management of interfaces in a managed system such as that of FIG. 1 . An explicit interface manager 40 is interposed between a set of clients 20 and a set of drivers 42 . The drivers 42 are divided into two types referred to for convenience herein as “real” drivers 16 and “pseudo” drivers 44 . The real drivers 16 are similar to drivers 16 ′ of FIG. 2 , i.e., they control the operation of real hardware and/or software interfaces that transmit and receive data communications packets. The real drivers 16 include corresponding IDBs 18 represented by associated “signatures” such as described above. The pseudo drivers 44 are used in the creation, destruction and use of pseudo interfaces that are used to provide a more standardized view of the NW devices 12 from a network management perspective, to avoid the type of problems described above with reference to FIG. 2 . The actual implementation of any real driver 15 or pseudo driver 44 will generally depend on the particular operating system with which it operates.
The interface manager 40 maintains an interface database 46 and acts as a common control point between the management clients 20 and the drivers 42 . It exposes a set of client services to the management clients 20 for the purpose of retrieving and modifying managed data associated with interfaces. It also exposes a set of driver services to the interface drivers 42 for the purpose of creating/destroying interfaces, retrieving managed data, validating and modifying configuration data, posting status, and signaling events and alarms. The interface manager 40 depends on the pseudo drivers 44 to manage sub-layer interfaces as described in more detail below.
With respect to the interface manager 40 , any pseudo driver 44 behaves very much like any real driver 16 , with the exception that the interface(s) handled by each pseudo driver 44 do(es) not transmit or receive packets. One other potential distinction between the pseudo drivers 44 and the real drivers 16 is that the pseudo drivers 44 may interact with the interface manager 40 in a client-like manner as indicated by connection 48 . This operation is described in more detail below.
The drivers 42 are all included within the operating system of the NW device 12 in a conventional fashion, e.g. as part of a bootstrapping process and/or in a “plug and play” fashion upon insertion of a PLIM. The interface types of the pseudo drivers 44 generally conform to published standards such as the above-mentioned IANA types (SONET, SONET Path, etc.). For reasons described below, the interface “signatures” used by each real driver 16 (e.g. POS driver 16 - 1 ) must generally be unique across a particular operating system implementation.
FIG. 5 illustrates an exemplary outcome of the combined operations of the interface manager 40 and drivers 42 (including pseudo drivers 44 ) as described below. A multiple-layer interface object 28 having a signature of POS-FRAME-RELAY, for example, is represented within a MIB 14 as three distinct, standard-type interfaces. The topmost interface 50 of type FRAME RELAY is maintained by a real driver 16 that actually implements all the packet-moving functionality of the entire POS-FRAME-RELAY object 28 . Also included are a SONET Path pseudo interface 52 and a SONET (physical layer) pseudo interface 54 that are utilized for network management purposes only. In particular, the pseudo interfaces 52 and 54 provide a standardized “sub-stack” representation of the multi-layered object 28 that is much more consistent with the needs and expectations of standard network management applications such as might be used in the network management system 10 ( FIG. 1 ).
FIG. 6 illustrates the process by which network management information is made accessible and actually accessed using the organization shown in FIG. 4 . In step 56 , the drivers 42 (including both the real drivers 16 and the pseudo drivers 44 ) register with the interface manager 40 . By this registration the interface manager 40 becomes aware of the existence and type of each driver 42 as well as how to communicate with it. In step 58 , a real driver 16 creates a multi-layered or sub-stack type of interface, such as the POS-FRAME-RELAY interface 28 , and invokes a “Create Interface” service of the interface manager 40 . These actions may occur, for example, when a boot process of the NW device 12 invokes a POS real driver 16 to create a static interface corresponding to its physical ports supported by the NW device 12 . Alternatively, the insertion of a PLIM may invoke the POS real driver 16 to create static interface(s) corresponding to physical port(s) supported by the PLIM.
When invoking the Create Interface service of the interface manager 40 , a driver 42 provides the following information:
Interface Handle—an opaque value uniquely identifying the interface being created. This value will typically be a reference to the driver object representing the interface. Master Interface—the interface index of the interface functioning as the “master” of the interface being created. The concept of a master interface is described below. Interface Signature—an opaque value uniquely identifying the type of multi-layered or sub-stack interface being created (e.g., POS-FRAME-RELAY). Interface Name—a descriptive string assigned to the interface by the CLI 15 ( FIG. 1 ). Interface Description—a string assigned to the interface by the system. The interface manager 40 requires this value to be globally unique and persistent across restarts. Subordinate Interface—the interface index associated with the interface that is “subordinate” to the interface being created, i.e., beneath this interface in the sub-stack (if one exists).
Note that it is assumed that drivers 42 create interface stacks in a bottom-up manner, i.e., they create lower-level interfaces first and then build up higher-level interfaces.
In step 60 of FIG. 6 , the interface manager 40 and the pseudo drivers 44 cooperate to create interface entries in the interface database 46 for the interface being created. These interface entries are available as MIB objects to the MIB clients 22 , and are also available to other types of clients 20 . In the case of a sub-stack type of interface, there will be interface entries for the top-level interface (e.g. FRAME RELAY 50 of FIG. 5 ) and the sub-layer interfaces (e.g. SONET Path 52 and SONET 54 ) as necessary. The details of this cooperative operation are described below.
In step 62 , a management client 20 requests a read or write of a MIB data element, for example in response to an SNMP GET or SET command issued by the NMS 10 of FIG. 1 . The interface manager 40 responds by forwarding the request to the appropriate driver 42 . In step 64 , the driver 42 responds by satisfying the request. In the case of a real driver 16 which actually maintains the data underlying the MIB data element, it can either update the data (in the case of a write) or return the data to the interface manager 40 for forwarding on to the requesting client 20 (in the case of a read). The operation of a pseudo driver 44 involves a level of indirection as now described.
As mentioned above, the sub-layer interfaces maintained by pseudo drivers 44 do not transmit or receive packets. Thus, the sub-layer interfaces by their nature are not represented in exactly the same way as are real interfaces. The representation of sub-layer interfaces relies in part on the notion of a “master” interface, which is used by a pseudo driver 44 to derive a representation of a sub-layer interface. As an example, a pseudo driver 44 can equate the operational status of a sub-layer SONET path to that of the master POS interface. More specifically, the pseudo driver 44 may derive the SONET path's operational status from the driver object (e.g., a IDB 18 ) representing the interface sub-stack of which the sub-layer interface is a part.
In some cases, the master interface may be the top-most interface in the interface sub-stack containing the sub-layer interface. This would be the case in the examples of FIG. 3 . In other cases, the master interface may be the subordinate interface to the interface sub-stack. For example, it may be desirable for the pseudo driver 44 to equate the operational status of a SONET path to that of the underlying SONET physical layer interface. More specifically, the pseudo driver derives the SONET path's operational status from the driver object (IDB 18 ) representing the SONET physical layer interface. There may be a variety of approaches that a pseudo driver 44 might use to derive a representation for a pseudo interface. As a general matter, the interface index for a pseudo interface should not be in any way dependent on a master interface; interface indexes should be allocated and managed for pseudo interfaces in the same way as for real interfaces. The interface type will be that of the sub-layer, e.g. SONET Path. Data elements such as the interface description and operational status might simply be equal to the corresponding values of the master interface, or in appropriate cases a null value.
The interface manager 40 can query the pseudo driver 44 for managed data relating to a pseudo interface through an Interface Data Get function that is registered by the pseudo driver 44 . In supporting this function, the pseudo driver 44 may need to derive certain managed data from elsewhere, as discussed above, and in such cases requires access to managed data maintained by the associated master interface. A pseudo driver 44 can obtain access to this managed data in one of two ways:
1. Client Services of the Interface Manager 40 —This is the connection 48 in FIG. 4 in which the pseudo drivers 44 act as clients of the interface manager 40 . That is, a pseudo drive 44 can request access to data maintained by a real driver 16 in the same manner as the clients 20 . These services might be the most straightforward to employ. However, they add to the overhead of the interface manager 40 and may present a performance issue.
2. Driver Callbacks—The pseudo drivers 44 may have access to “callback” functions of the real drivers 16 that provide a direct method for accessing managed data relating to the master interface. To utilize such a technique, a pseudo driver 44 must identify the real driver 16 maintaining the master interface and the signature of the master. Second, the pseudo driver 44 needs to determine the appropriate callbacks. Finally, to use these callbacks, the pseudo driver 44 must determine the interface handle of the master interface. All of these actions can be supported by providing appropriate services within the system.
FIG. 7 illustrates the detailed operation of steps 58 and 60 of FIG. 6 for a specific example, namely the layered POS-FRAME-RELAY interface 28 of FIG. 5 . At the top are shown the interface manager 40 as well as three drivers 42 : a POS real driver 16 - 1 , a SONET Path pseudo driver 44 - 1 , and a SONET pseudo driver 44 - 2 . Time progresses in the vertical downward direction, and thus the operation of each driver 16 - 1 , 44 - 1 , 44 - 2 and the interface manager 40 is shown in a corresponding vertically oriented operation box 66 , 68 , 70 , and 72 . The operation box 72 of the interface manager 40 includes sub-boxes 72 - 1 and 72 - 2 for reasons described below.
Interface creation starts with the POS real driver 16 - 1 , as described above with reference to step 58 of FIG. 6 . After the POS driver 16 - 1 has created or initialized the IDB 18 for a POS-FRAME-RELAY interface, the following operations ensue:
1. The POS interface driver 16 - 1 invokes a Create Interface service of the interface manager 40 (shown at 74 ). 2. The interface manager 40 creates an interface entry 76 in the MIB interfaces table with a standardized IANA type of ‘pos’. This entry corresponds to the frame relay interface 50 of FIG. 5 . As part of this operation, the interface manager 40 allocates an interface index to the new interface entry. 3. The interface manager 40 then determines whether it is necessary to create any sub-layer interfaces to provide the standardized MIB representation that may be needed by the clients 20 . The details of this determination are described below. If no sub-layer interface is needed, then the interface manager 40 merely returns the value of the interface index to the requestor for its future use in accessing the interface entry. If one or more sub-layer interfaces is needed, then the interface manager 40 initiates the creation of such sub-layer interfaces. In the example of FIG. 7 , sub-layer interfaces for the SONET Path and the SONET physical layer (SONET) are required, and thus the interface manager 40 proceeds to have them created. 4. In the example of FIG. 7 , the interface manager 40 first invokes the SONET Path sub-layer interface pseudo driver 44 - 1 (operation box 68 ) to create a sub-layer pseudo interface to represent the SONET Path underlying the frame relay interface 50 . This operation is indicated at 78 . 5. The SONET path sub-layer interface pseudo driver 44 - 1 creates a sub-layer pseudo interface, which as mentioned above has all the attributes of a real interface except that it does not handle packet traffic. Part of the creation of the sub-layer pseudo interface is to establish how it will be represented to the MIB clients 20 , as discussed above with reference to FIG. 6 . Then as shown at 80 , the SONET Path pseudo driver 44 - 1 invokes the Create Interface service of the interface manager 40 in order to register this new interface with the network management system. Note that this action represents a reentrance into the interface manager 40 —the Create Interface service of the interface manager 40 is being invoked again before the first invocation 74 has completed. Thus, the Create Interface service of the interface manager 40 is preferably implemented in a reentrant manner to support the iterative creation of sub-layer pseudo interfaces. 6. This first reentrance into the interface manager 40 is indicated by operation box 72 - 1 . As part of this operation, the interface manager 40 creates an interface entry 82 in the MIB interfaces table with a standardized IANA type of ‘sonetPath’. This entry corresponds to the SONET Path sub-layer interface 52 of FIG. 5 . 7. The above steps 4 - 6 are now repeated for the SONET sub-layer interface 54 of FIG. 5 . The operations are indicated at 84 and 86 and the resulting interface entry at 88 . It will be appreciated that the operation box 72 - 2 represents a second reentrance into the interface manager 40 and the deepest level of nesting or iteration of the overall process. 8. As generally indicated at 90 , the interface manager 40 and the various drivers 16 - 1 , 44 - 1 and 44 - 2 then “unwind” from the nesting. Specifically, at 92 the interface manager 40 passes an interface index for the SONET interface entry 88 to the SONET pseudo driver 44 - 2 for its future use in accessing the interface entry 88 . At this point the operations of the interface manager 40 represented by operation box 72 - 2 are complete. At step 94 the SONET pseudo driver 44 - 2 provides an indication to the interface manager 40 that the SONET sub-layer interface 54 has been created. This indication is handled in the context of operation box 72 - 1 of the interface manager 40 . Specifically, the interface manager 40 now creates a stack relationship between the SONET interface entry 88 and the SONET Path interface entry 82 , by making an appropriate addition to the interfaces stack table of the MIB 14 . At 96 and 98 , operations are performed between the interface manager 40 and the SONET Path pseudo driver 44 - 1 that are analogous to the operations 92 and 94 respectively, and after which the interface manager 40 makes an analogous addition to the interfaces stack table to create a stack relationship between the SONET Path interface entry 82 and the POS interface entry 76 . At 100 the interface manager 40 passes the interface index for the POS interface entry 76 to the POS real driver 16 - 1 for its future use in accessing the interface entry 76 , and the entire interface creation process is complete.
As mentioned above, part of the operation of the Create Interface service of the interface manager 40 is to determine whether there is a sub-layer interface that should be created. It does this based on the signature of the interface being created as well as the type of subordinate interface as reported by the requesting driver. If the subordinate interface is of an appropriate type based on the interface signature, then no sub-layer interface is needed. But if the subordinate interface is an inappropriate type, indicating that a required sub-layer is missing, then the interface manager 40 takes steps to have the missing sub-layer interface created. It should be noted that the driver 42 may use a “null” value to indicate that there is no subordinate interface. Whether the subordinate interface is “appropriate” is dependent on the interface signature or type. Recall that a POS-FRAME-RELAY sub-stack, for example, should include frame relay, SONET path, and SONET sub-layers. If a driver 42 creates a POS-FRAME-RELAY interface and reports a null subordinate interface, this indicates to the interface manager 40 that the SONET path and SONET sub-layer interfaces are missing. When interface sub-stacks have been properly formed as described herein, only the lowest-level pseudo interface (e.g., SONET) properly has a null value for its subordinate interface. In the process of FIG. 7 , the invocation 74 by the POS driver 16 - 1 will have an inappropriate null value for the subordinate interface, which indicates to the interface manager that there are missing sub-layers. In contrast, the invocation 86 by the SONET pseudo driver 44 - 2 has an appropriate null value—the SONET sub-layer 54 is a physical layer and thus should have no subordinate interfaces—and thus the interface manager 40 can conclude in response that no additional sub-layers are needed.
As mentioned above, the interface manager 40 may be implemented as a common part and a plurality of “extensions”, where the common part supports generic operations (such as providing access to packet counters) and the extensions support operations that are more specific to particular interface types. In such a case, there is necessarily a software interface (application programming interface or API) between the common part and the extensions for purposes of signaling the forwarding of requests to the extensions and the return of results by the extensions. In particular, the common part may be the primary actor responding to a Create Interface request of a driver 42 for purposes of registering a newly created interface and determining whether any sub-layer interfaces are to be created. In the case that a sub-layer interface is needed, then the common part would signal the appropriate extension, which would in turn invoke the appropriate pseudo driver. The subsequent reentrance into the interface manager 40 by the pseudo driver would be via the extension in the first instance, which would then signal back up to the common part.
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 method of providing network management information about a multiple-layer network communications interface sub-stack to a network management client includes establishing a standardized network management representation by use of an interface manager and a real driver and a pseudo driver, receiving a request from the network management client for network management information about an expected sub-layer interface, and in response to the request obtaining, by the pseudo driver, data maintained by the real driver corresponding to the requested network management information, and returning the data obtained by the pseudo driver to the network management client in satisfaction of the request.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. provisional application No. 60/175,629, filed Jan. 12, 2000, the entire contents of which are incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates to a hydraulically operated attachment for a front-end loader. The invention is designed specifically for attachment to smaller construction vehicles such as skid steer loaders. The present invention is directed to a concept for a new soil excavation implement and bucket attached to the skid steers and similar size tractors that will enable the skid steers to be used to excavate in virgin soils or similarly compacted earth while avoiding the problems described above. The overall function of this inventive excavation implement and bucket is to perform small earth moving work which is comprised of cutting, transporting, dumping and grading materials. It is not intended for loading trucks.
[0005] 2. Description of the Related Art
[0006] Skid steer loaders are relatively small hydraulic wheel loaders with a lifting boom that can be easily fitted with a variety of attachments by means of a lock-on mechanism commonly known as a quick-tach. In addition to the lifting action of the boom there is a dumping pivot action on the boom end. When equipped with a bucket the skid steer loader may be used for digging, pulverizing material, transporting material, and grading.
[0007] In addition to a variety of types of buckets, there are many other attachments which may be affixed to the lifting boom such as trenchers, augers, brooms, rototillers, vibratory rollers, cold planers, jack hammers, back hoes, etc. Attachments such as rototillers and augers, are powered by hydraulic motors in addition to the boom lift and dump actions These motors are generally driven by oil pumped from the skid steer loader hydraulic system through quick disconnect hose connections.
[0008] There has been rapid development of accessory power attachments for a skid steer machine. The skid steer machines as known generally have a surplus of hydraulic power for use with any desired type of accessory. As equipped with digging buckets, and operating like a conventional wheel loader, skid steers consume only a small fraction of their available horsepower. The majority of the total horsepower is available for the powered attachments. So as with basic tractors, skid steers are power dense, relative to their size.
[0009] Therefore, skid steers are basically a multi-function powered unit, capable of performing a wide variety of tasks. However, the performance of the skid loader is typically reduced during work such as in the digging of established soil. In these instances the skid loaders have more than enough horsepower for this task, however, they simply don't have sufficient traction to excavate established soil. A skid loader used for digging established soil may experience difficulties such as the spinning of tires which dig pockets and pile up mounds. As the loader runs over these obstructions, it is bounced and pitched which further hampers traction as well as interfering with the ability to control the cutting process of the bucket. There are many small scale excavating jobs which allow access to nothing larger than a skid steer, yet the digging capability of the skid steer is not sufficient for the task. Often, in these cases, back hoes are used for the digging and the skid steer loader is used to transport and grade the excavated-material.
BRIEF SUMMARY OF THE INVENTION
[0010] This invention provides for a unique skid steer bucket which is equipped with a powered cutter reel, set crosswise, and positioned ahead of the bucket floor cutting edge. The reel cutter may have many rectangular knives which strike the ground flatwise, like paddles. The reel turns in a climb cutting rotation to the ground. In other words, the top of the reel moves forward so that the bottom is cutting soil and throwing the soil back into the bucket from the bottom side of the reel. There may be some cases where it would be preferable to reverse the reel rotation so that it throws the soil over the top, and consequently, higher into the bucket.
[0011] The cutting reel may be mounted in a pair of shock resistant sealed bearings positioned on each side of the bucket. At one end of the reel shaft is located a roller chain sprocket with a roller chain or other connection means running to the rear of the bucket just outside of the bucket end wall. At the rear of the bucket, the chain connects to a drive sprocket of a hydraulic motor.
[0012] In at least one embodiment of the invention the hydraulic motor is enclosed in a protective housing positioned within the confines of the bucket. The hydraulic motor may be powered from the tractor auxiliary or high flow hydraulic system through the use of quick disconnect hose couplings. The operator control for the reel drive motor allows the cutter reel to be engaged forwardly, stopped, or reversed. If necessary, a speed control may be added to the motor.
[0013] The basic bucket floor cutting edge follows directly behind the cutting reel, at approximately the same elevation as the cut path of the cutting reel. However the bucket cutting edge does not cut virgin earth, it merely serves as an apron to receive the earth that is kicked off of the reel. The actual floor of the cut pass may be made exclusively by the knives of the spinning cutter reel. The cutting reel generally does not cut the end zones located outside of the bucket which are occupied by the bearings and especially the chain and sprocket. So the structure that supports and protects the bearings and sprocket must plow through the ground without the aid of the cutting reel.
[0014] A piercing point is positioned forwardly to each of the bearing support structures where the piercing points function as plows to reduce the force required to penetrate the undisturbed soil. These points may have a wide variety of characteristics. In at least one embodiment of the invention the points may be chisel shaped, set flat to the ground, and may be a few inches wide so that they cut and lift the soil just ahead of the bearing support structures. The chisels cut the form of the comers where the cut pass sides meet the cut pass floor. In addition to the bottom cutting chisels, the piercing points may be fitted with side cutting knives. Together, the side knife and bottom chisel of each piercing point shears each corner of the cut pass, forcing the material upward and inward, making it accessible to the cutter reel.
[0015] The two corner piercing points pierce and lift the undisturbed soil just ahead of the cutter reel end bearings. The reaction to the lifting action tends to suck the bucket deeper into the ground. This downward pull of the bucket is countered by the climbing rotation of the reel cutter which tends to lift the bucket upward. As these two forces work against each other, they combine into a third resultant force direction that tends to pull the bucket forward, adding to the piercing force of the points. In this way, the cutter reel not only breaks the soil encountered as the tractor pushes it forward, but adds to the push of the tractor by pulling itself forward, into the soil.
[0016] Usually the size of a skid steer bucket is limited by the tractor's ability to force it to cut, and the potential instability of lifting a loaded bucket for placement of aggregate within a truck. The use of the cutter reel on a bucket provides for a cutting force from an independent powered cutter as opposed to forward penetration of a bucket cutting edge, and because a bucket equipped with a cutter reel is not intended to be lifted high for loading trucks, its capacity can be relatively higher, thus maximizing its transport function. Therefore, this new bucket may have a capacity of one cubic yard or more when used on mid to large size skid steer loaders.
[0017] Compared to typical skid steer buckets, this new bucket cutter reel combination permits use of a taller and shorter bucket from front to back. The cutter reel preferably throws soil high enough to fill a taller bucket. The throwing of soil preferably places the center of mass of the load as close as possible to the tractor to reduce forward tipping forces which may result from the cantilevered load weight on the tractor.
[0018] In operation, this bucket cutter reel combination is advanced into the cut with the cutter reel under full power. The cuter reel throws the soil up, into the bucket, pulverizing it in the process. If the cutter reel encounters a rock that is too large to pass between the cutter reel center shaft and the bucket cutting edge, the cutter reel will simply stall actuating an operation circuit into bypass. An operator may then toggle the cuter reel to reverse, thereby unjamming the clog. If the obstruction is too large, the operator must work around it.
[0019] Once the bucket is full, it may be elevated a sufficient distance to clear the ground, whereupon the cutter reel may be disengaged. The bucket may be moved to the dumping location and tipped to the dump position to disperse transported material. Material may either be dumped in one pile or dumped while moving in order to spread it over a desired area. During the dump cycle, the soil maybe further pulverized by running the cutter reel, allowing the soil to pass through the cutter reel as it falls out of the bucket. This second pass of material through the rotating cutter facilitates production of a uniform rate of dumping which aids the grading and finishing process.
[0020] As previously explained, the purpose of the cutter reel is to reduce the tractive effort needed to fill the bucket, however, a second benefit is the inevitable soil pulverization. Soil pulverization facilitates a bucket being filled without voids for efficient transportation, and the pulverized soil is easier to spread and grade. During the grading process, the bucket may be set in the cutting position (with the bucket floor flat to the ground), with the cutter running in reverse. The cutter may then kick the soil ahead for further pulverization while having the effect of dozing the soil forward as a means of transport and/or spreading. This technique may be used for light cutting in virgin earth whereby the soil is cut and kicked forward by the cutting reel, forming a heap which is being constantly reground as it is pushed forward. This process is called dynamic dozing.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0021] A detailed description of the invention is hereafter described with specific reference being made to the drawings in which:
[0022] [0022]FIG. 1 is a perspective view of an embodiment of the invention;
[0023] [0023]FIG. 2 is a close-up partially cut-away perspective view of the embodiment shown in FIG. 1;
[0024] [0024]FIG. 3 is a reverse partially cut-away perspective view of the embodiment shown in FIG. 2;
[0025] [0025]FIG. 4 is a top down view of an embodiment of the invention;
[0026] [0026]FIG. 5 is a side view of an embodiment of the invention depicted in its operational environment; and
[0027] [0027]FIG. 6 is an alternative perspective view of an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The present invention, as may be seen in FIG. 1 is referred to as a self loading bucket or dog bucket and is indicated generally at 10 . Dog bucket 10 further comprises a bucket 12 of a skid loader such as a Bobcat® or a tractor.
[0029] The bucket 12 includes a frame 14 comprising a floor 16 , a back wall 18 , and a pair of side walls 20 and 22 . The bucket 12 may be composed of a variety of materials but is typically steel or an alloy thereof. The side walls 20 and 22 include shock resistant sealed bearing supports 24 for rotatably mounting the shaft 26 of a cutter real 28 . Alternatively, the side walls 20 , 22 , may each include an aperture adapted to receive the shaft 26 where the shock resistant sealed bearing supports 24 are positioned adjacent to and exterior of the side walls 20 , 22 . In another alternative embodiment, one set of shock resistant bearing supports 24 may be positioned forwardly of the leading edge of each of the respective side walls 20 , 22 . Side wall 20 includes a drive mechanism 70 which includes a roller chain sprocket 30 provided at one end of the cutter reel 28 , a drive sprocket 32 , and one or more support sprockets 72 . The drive mechanism 70 may be integral with and/or releasably secured to the exterior of the side wall 20 . In the embodiment shown the drive mechanism 70 is chain driven by drive chain 54 . Alternatively, the drive chain 54 may be replaced with a belt drive and/or other drive mechanism to impart rotation to the cutter reel 28 during use of the self-loading bucket 10 . The drive sprocket 32 is in mechanical communication with a hydraulic motor 34 (shown in FIG. 2) and is generally positioned at the back and to the interior of the bucket 12 . Alternatively, the hydraulic motor 34 may be positioned to the rear of the bucket 12 and affixed to the exterior of the back wall 14 . In this embodiment, the drive sprocket 32 is preferably positioned proximate to the side wall 20 and rearwardly to the back wall 18 . The hydraulic motor 34 is preferably powered by the tractor auxiliary hydraulic flow system (not shown). The bucket floor 16 extends to the front 36 of bucket 12 to form a cutting edge 38 . The cutting edge 38 may serve as an apron to receive soil thrown into the bucket 12 from the cutter real 28 .
[0030] The powered cutter reel 28 is positioned forwardly to the cutting edge 38 of the bucket floor 16 . The cutter reel 28 has a shaft 26 and a plurality of digging members 40 which function like paddles for removal of soil. The digging members 40 may include a variety of shapes and sizes as well as arrangements. In the embodiment shown the digging members 40 may be characterized as a plurality of rectangular knives. The cutter reel 28 may be rotated in a clockwise manner such that the paddles 40 cut downward into the soil and throw soil backwards into the bucket 12 . The direction of the cutter real 28 may be reversed for the purpose of dislodging blockages or dispersing soil from within the bucket 12 onto the ground or for other purposes as may be desired.
[0031] The cutter real 28 and the components thereof are typically constructed from metal such as steel or an alloy thereof, however, other materials may also be utilized such as, titanium, iron, etc.
[0032] The cutter real 28 is adapted for operation via a drive such as the hydraulic motor 34 , as may best be seen in FIG. 2. The hydraulic motor 34 is preferably in fluid communication with the auxiliary hydraulic system of the skid loader (not shown) by way of hydraulic feed lines 42 which may be equipped with quick connect/disconnect ends 44 , such as may be seen in FIG. 3.
[0033] As may be seen in FIG. 2 the hydraulic motor 34 may be positioned within the bucket 12 . However, in order to protect the motor 34 from dirt and debris which would other wise fill the bucket 12 during use, the hydraulic motor 34 is preferably contained in a protective housing or motor house 46 , such as may be seen in FIG. 1.
[0034] In the embodiment shown in FIGS. 1 and 2, the motor house 46 is located in a back corner of the bucket 12 , against the floor 16 , the back wall 18 and side wall 20 , as such, the motor house 46 may be a three sided structure which completely covers the motor 34 and may be welded and/or bolted to the adjacent bucket surfaces 16 , 18 and 20 . Alternatively, one or more cleats 48 , such as may be seen in FIG. 2, may be pre-welded into the bucket 12 . The housing 46 may then also be bolted and/or welded to the cleat 48 as shown.
[0035] As indicated above, the hydraulic motor 34 may be hydraulically powered by hydraulic feed lines 42 which lead from the hydraulic motor 34 to the hydraulic fluid pumping system of the skid steer loader. As may be seen in FIG. 3, the hydraulic lines 42 extend from the hydraulic motor through an opening 50 in the back wall 18 of the bucket 12 . The hydraulic lines 42 may extend several feet from the motor. In order to protect the hydraulic lines 42 from potential damage the lines 42 may be enclosed in-part by a hose duct or guard 52 . The hose duct 52 encloses the lines 42 as they pass out of the opening 50 and extend along the back wall 18 of the bucket 12 . The hose duct 52 may be constructed from any type of suitable protective material, including but not limited to, steel, particularly light gauge steel. The hose duct 52 may be bolted and/or welded to the bucket 12 .
[0036] The hydraulic motor 34 , shown in FIG. 2, is engaged to the drive sprocket 32 which is depicted in FIGS. 1 and 3. The hydraulic motor 34 , may be engaged to the drive sprocket 32 by a shaft 80 which preferably passes through the side wall 20 proximate to the hydraulic motor 34 . Alternatively, the hydraulic motor 34 may be positioned rearwardly to the back wall 18 . If the hydraulic motor 34 is positioned rearwardly to the back wall 18 then the drive sprocket 32 is also required to be positioned rearwardly to the back wall 18 . In the embodiment shown, the drive sprocket 32 is operatively engaged to the roller chain sprocket 30 by a drive chain 54 . While the embodiment of the cutter real 28 is chain driven via a hydraulic motor 34 , in alternative embodiments the cutter real 28 may be directly hydraulically driven, belt driven, or shaft driven as may be desired.
[0037] Turning back to FIG. 1, it may be seen that each of the side walls 20 and 22 may also include a piercing point 56 . Each piercing point 56 may be integral to the bucket frame 14 or may be welded and/or bolted thereon. The piercing points 56 extend horizontally from the front 36 of the bucket 12 . The piercing points 56 may include a chisel shaped edge 58 which is designed to cut and lift the soil ahead of bearing supports 24 . In addition, side cutting knives/plows 60 , as may best be seen in FIG. 4, also force soil upwardly and inwardly away from the bearing supports 24 . Alternatively, a standard bucket 12 may be utilized for retrofitting to include the frame 14 and cutter reel 28 . In this embodiment, the frame 14 includes forwardly located piercing points 56 where one piercing point 56 is preferably positioned to each side wall 20 , 22 forwardly of, and proximate to, the cutting edge 38 .
[0038] In FIG. 4, a cover or bonnet 62 may be seen mounted to the frame 14 . The bonnet may be welded and/or bolted, or otherwise fastened to the bucket frame 14 . The bonnet 62 is a light weight enclosure that is placed on the bucket 12 to provide greater soil containment ability. Because the bonnet 62 is not subjected to active soil digging or pushing pressures, the bonnet may be made of a variety of materials such as steel, but may also be made of lighter weight materials such as aluminum or even plastic. In general, as may be seen in FIGS. 4 and 5, the bonnet 62 includes a pair of upwardly and inwardly extending angled sides 82 and upwardly and forwardly extending back wall 64 and a horizontally extending roof 84 as engaged to the back wall 64 and angled sides 82 . In general, the bonnet 62 may be in the shape of a standard non-modified production bucket for a skid or front end loader. It should be noted that other shapes may be utilized for the bonnet 62 at the discretion of an individual. In general, the bonnet 62 may be secured to the top of the frame 14 and back wall 18 through the use of bolts and nuts and/or welding. Alternatively, any desired type of permanent and/or releasable mechanical fastener may be utilized to secure the bonnet 62 to the frame 14 and the back wall 18 at the discretion of an individual. The back wall 64 of the bonnet 62 may include a window or grate 66 to allow the tractor or skid loader operator the ability to see into the bucket 12 and visually monitor the load and the cutting action of the cutter real 28 . Alternatively, where the bonnet 62 is constructed of plastic, the plastic may be clear to provide a clear line of sight from the operator into the bucket 12 .
[0039] In an alternative embodiment of the invention, the bonnet 62 my extend forward to act as a guard for the cutter real 28 . Alternatively, a separate guard assembly may be attached to the frame 14 to partially cover the cutter real 28 thereby preventing accidental contact with the cutter blades 40 from above.
[0040] Turning to FIG. 5, the dog bucket 10 is depicted in operation. During operation, the action of the dog bucket 10 causes the bucket 12 to be sucked into the ground. This action is countered by the climbing forces resulting from the rotation of the reel 28 which in combination pull the bucket 12 forwardly through the soil 68 . The piercing points 56 and side cutting knives/plows 60 also move soil 68 inwardly along the drive mechanism 70 and bearings 24 into the interior of the bucket 12 . The rotating action of the cutter reel 28 and knives/paddles 40 function to break apart established soil for movement into the bucket 12 . The bucket floor 16 cutting edge 38 is therefore provided with the ability to have an enhanced depth for removal of soil.
[0041] In an alternative embodiment as may be depicted in FIG. 6, the frame 14 may be mechanically secured to a standard bucket 12 of a skid or front end loader. The frame 14 in this embodiment is generally formed of a first cutter reel support 90 and a second cutter reel support 92 . The first and second cutter reel supports 90 , 92 may be respectively secured to the side walls 20 , 22 by the use of bolts and/or welding or any other secure mechanical fasteners. The first cutter reel support 90 preferably includes the features of the roller chain sprocket 30 , drive sprockets 32 , drive mechanisms 70 , and support sprockets 72 as earlier described.
[0042] The first and second cutter reel supports 90 , 92 preferably each include the bearing supports 24 for support of the shaft 26 and cutter reel 28 as earlier described. In addition, each of the first and second cutter reel supports 90 , 92 each preferably include a piercing point 56 , chisel shaped edge 58 , and knife plows 60 as earlier described.
[0043] In this embodiment, a standard skid or front end loader bucket 12 is modified or retrofitted to include the first and second cutter reel supports 90 , 92 and cutter reel 28 .
[0044] The first side wall 20 is therefore required to receive at least one aperture to accommodate the shaft 80 of the hydraulic motor 34 as engaged to the drive sprocket 32 . A second aperture may also be required for receipt of the bearing supports 24 and shaft 26 as connected to the roller chain sprocket 30 and cutter reel 28 . Alternatively, the first cutter reel support 90 may be secured to the side wall 20 by welding and/or bolts and nuts where the first cutter reel support 90 includes the bearing supports 24 positioned within an aperture for support of the shaft 26 as connected to the roller chain sprocket 30 and cutter reel 28 which are preferably positioned forwardly of the leading edge of the side walls 20 , 22 . It should be noted that the second cutter reel support 92 is preferably attached in an identical location relative to the side wall 22 . The side wall 22 may therefore be required to include an aperture to receive bearing supports 24 and shaft 26 of the cutter reel 28 .
[0045] The hydraulic motor 34 in this embodiment is preferably positioned interior to the bucket 12 proximate to the side wall 20 and back wall 18 as earlier described.
[0046] The other features as identified herein may also be preferably included for retrofit of a standard skid or front end loader bucket 12 to accommodate the attachment of the cutter reel 28 excavation accessory as illustrated and disclosed herein.
[0047] In addition to being directed to the embodiments described above and claimed below, the present invention is further directed to embodiments having different combinations of the features described above and claimed below. As such, the invention is also directed to other embodiments having any other possible combination of the dependent features claimed below.
[0048] The above examples and disclosure are intended to be illustrative and not exhaustive. These examples and description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the attached claims. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims attached hereto.
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A digging attachment for a skid steer loader which comprises a bucket, a shaft mounted cutter reel and a drive means. The drive means is operatively connected to the bucket and the powered cutter reel. The powered cutter reel includes a plurality of digging members which may be rotated about the shaft of the cutter reel when the drive means is activated so as to dig into soil and draw the soil into the bucket.
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CLAIM PRIORITY
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/418,774 filed Oct. 15, 2002.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a retractor blade which is adjustably connected to a retractor shaft, and more particularly, to a retractor blade connected to a retractor shaft with a ball socket connection allowing free movement while limiting the range of motion of the retractor blade relative to the retractor shaft.
DETAILED DESCRIPTION OF RELATED ART
[0003] Co-pending and co-owned patent application Ser. No. 10/113,663 shows a multi-position ratchet mechanism for connecting a retractor blade to a ring, which is incorporated by reference. The 10/113,663 application is not prior art, but the development of the technology disclosed in that application assisted the applicant in determining that a need existed for the invention disclosed herein.
[0004] The new clamp allows for a retractor blade to be connected by a retractor shaft to the clamp when the clamp is connected to a ring, when the clamp is pivoted downwardly into the wound or from left to right relative to the ring, a fixably mounted retractor blade connected to the retractor shaft as has been traditionally done in the prior art and shown in U.S. Pat. No. 4,354,763, does not maintain the retractor blade in a substantially perpendicular alignment relative to the direction of retraction. The retractor blade is most effective when the majority of the surface area is against tissue (i.e., perpendicular to the direction of retraction) so that proper retraction can occur.
[0005] Accordingly, with the development of the multi-positioning clamp as described in U.S. patent application Ser. No. 10/113,663, a need has arisen for improved connection intermediate the retractor blade and the retractor shaft so that the intimate contact with the retractor blade against the tissue may be maintained in spite of the angular relationship of the retractor shaft relative to the multi-position ratchet mechanism, or other angularly adjustable clamp.
SUMMARY OF THE INVENTION
[0006] A need exists for an improved connector intermediate a retractor blade and retractor shaft so that an optimal amount of retractor blade may be maintained against tissue in spite of the angular position of the retractor shaft relative to a clamp connecting the retractor shaft to a ring.
[0007] A need also exists for an improved retractor blade assembly which is free to rotate to an optimal retraction position when the retractor shaft is not necessarily oriented along a vector oriented in the direction of retraction.
[0008] Another need exists for the ability to maintain the retractor blade perpendicular to the direction of retraction when the retractor shaft is not optimally oriented for such retraction.
[0009] Accordingly, a retractor assembly is comprised of a retractor blade connected by a stem to a connector and the retractor shaft. The retractor shaft is preferably connected to a ring, which is not necessarily circular, by a rotatable and/or pivoting clamp. The connector allows for the self adjustability of the angle of the retractor blade relative to the retractor shaft as the angle of the retractor shaft relative to the ring is adjusted at the clamp. The connector is preferably a pivoting type connector, but others could also be employed.
[0010] Since rings are typically located proximate an elevation of the incision, in the preferred embodiment a limited travel is allowed in the up and down direction. The side to side, or lateral travel, of the retractor shaft relative to the stem connected to the retractor blade in the preferred embodiment is about 120° range of motion so the connector allows for the pivoting of the retractor blade relative to the retractor shaft sufficient to account for an offset of the retractor blade relative to the ring in the direction of the retraction.
[0011] It is preferred that the type connection connect the retractor blade to the retractor shaft while allowing the desired range of motion of the ball retractor blade relative to the retractor shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings in which:
[0013] [0013]FIG. 1 is a top perspective view of a retractor blade assembly having a retractor blade connected to a retractor shaft with a connector in accordance with the preferred embodiment of the present invention;
[0014] [0014]FIG. 2 is a side perspective view of the shaft portion of the retractor blade assembly shown in FIG. 1;
[0015] [0015]FIG. 3 is a top perspective view of a flange clevis of the retractor blade assembly shown in FIG. 1;
[0016] [0016]FIG. 4 is a top perspective view of a pivot flange of the retractor blade assembly shown in FIG. 1;
[0017] [0017]FIG. 5 is a side perspective view of a blade attachment boss of the retractor blade assembly shown in FIG. 1; and
[0018] [0018]FIG. 6 is a practical application of the use of the retractor blade in conjunction with the retractor shaft and connected in accordance with the present invention with one location option shown in phantom.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] Accordingly, FIG. 1 shows an assembly 10 of the preferred embodiment. The assembly 10 is comprised of a retractor blade 12 having a stem or shoulder 14 . The assembly 10 also has a retractor shaft 16 . The retractor shaft 16 and the retractor blade 12 are joined at connector 18 which is preferably a pivoting type connection. Other connectors like a ball and socket type connection could also be utilized.
[0020] A description of the component parts is helpful to understand the anticipated positioning in order to show the capabilities of the assembly 10 shown in FIG. 1 and FIG. 6. The retractor shaft 16 is preferably equipped with a plurality of angled cuts 34 which allow for a clamp 48 as shown in FIG. 6 to ratchetly or otherwise retain the retractor shaft 16 at a desired position relative to a ring 46 or other appropriate structure. The shaft 16 preferably has a substantially square cross section along a majority of its length with a connection 36 at a distal end 38 .
[0021] The pivoting connection is preferably constructed having a flange clevis 20 which connects to the retractor shaft 16 with a pin 22 . The flange clevis 20 connects to a pivot flange 24 which pivots about pin 26 as shown in FIG. 1. Preferably the flange clevis 20 can pivot at least 60 degrees, if not 90 degrees to either side of shaft axis 17 . In other embodiments, ranges of +/−30 degrees or +/−45 degrees may also be utilized.
[0022] [0022]FIG. 4 shows the pivot flange 24 apart from the assembly 10 shown in FIG. 1. The pivot flange 24 has an extension 28 which is received in bore 30 of blade attachment boss 32 which connects with the pivot flange 24 as well as with a shoulder 14 of a retractor blade 12 as shown in FIG. 1.
[0023] The connection 36 is in the form of a post with a bore 40 extending therethrough as shown in FIG. 1.
[0024] The distal end 38 of the shaft 16 is illustrated in FIG. 1 is inserted into receiver 42 shown in phantom in FIG. 3. Pin 22 shown in FIG. 1 extends through a hole 44 and bore 40 of the connector 36 to retain the shaft 16 relative to the flange clevis 20 as shown in FIG. 1. It is anticipated that this will be a rigid and non-moveable connection, however, in alternative embodiments, this may not necessarily be the case.
[0025] [0025]FIG. 3 shows the flange clevis 20 having a slot 50 which receives hub 56 of pivot flange 24 shown in FIG. 4. The hub may have a circular circumference or, as illustrated in FIG. 4, may be configured with stops 60 , 62 which when installed in the slot 50 as shown in FIG. 1, cooperate with the slot 50 to prevent rotation of the hub 56 of more than about 60 degrees to the left or right of shaft axis 17 about rotation axis 60 . In other embodiments, the slot 50 may work to restrict the angular movement of the hub 56 independent of stops 60 , 62 on a hub or other structure. In other embodiments, the hub 56 may be constructed so that 90 degrees or more to the left and right of the shaft axis 17 may be allowed. Pin 26 retains the hub 56 in the slot 50 as shown in FIG. 1 while allowing the hub 56 to pivot. Other connections like a ball and socket joint may be utilized to accomplish this retention and movement capability. It should be understood that the term “pin” is a generic term and can be utilized to mean screw, post or other connection device.
[0026] The extension 28 of the pivot flange 24 is received within the bore 30 of the blade attachment boss 32 as shown in FIG. 1. A pin 68 extends through bore 64 in the extension as well as through side slots 66 which not only accommodates the pin 68 , but also allows for pivoting about tilting axis 70 , at least to a limited degree such as less than about plus or minus twenty degrees relative to shaft axis 17 . Tilting axis 70 is preferably perpendicular to as well as spaced from rotation axis 60 .
[0027] The shoulder 14 of the blade 12 is captured within the mouth 72 of the blade attachment boss 32 and, depending on the tolerances of the shoulder 14 relative to the mouth 72 , a connector pin 74 may assist in retaining the shoulder 74 in the mouth 72 .
[0028] While the clamp 48 is substantially illustrated as a box in FIG. 6, it could have sufficient more structure as shown in co-pending U.S. patent application Ser. No. 10/133,663 or other clamp configurations which show how the retractor shaft 16 can be configured to rotate relative to ring 46 about axes 52 , 54 . The pivoting of a retractor shaft 16 into an incision to direct a retractor blade 12 into a wound has been done, however, the retractor blade has been traditionally rigidly connected to the retractor shaft 16 in the prior art.
[0029] Accordingly, as the clamp 48 rotates the retractor shaft 16 downwardly, the tissue contact surface 76 shown in FIG. 1 would be angled at a similar angle as the downward tilt of the retractor shaft 16 relative to the ring 16 at the clamp about the axis 52 in a prior art retractor. Accordingly, the connector 18 allows for the tissue contact surface 76 to be maintained adjacent to tissue 58 (and perpendicular to the direction of retraction) as shown in FIG. 6, even when the retractor shaft 16 is downwardly rotated about axis 52 .
[0030] Additionally, when the clamp 48 rotates about axis 54 relative to the ring 46 and/or the clamp 48 is positioned so that the plane extending through axis 54 and retractor shaft 16 does not intersect a plane perpendicular to the tissue contact surface 76 extending through stem 14 , the tissue contact surface 76 may be still maintained contact with the tissue 58 since the slot 50 allows for the side to side rotation, pivoting or swiveling of the hub 56 about the rotation axis 60 , and thus the stem 14 and tissue contact surface 56 of the retractor blade 12 so that it maintains optimal contact with tissue 58 as shown in FIG. 5.
[0031] In the preferred embodiment, the hub 56 is free to pivot about rotation axis 60 as necessary within slot 50 , however in other embodiments, the slot 50 may be configured to lock the hub 56 in a desired position, if necessary. The pin 68 is also free to move within side slots 66 in the preferred embodiment to allow up and down movement about tilting axis.
[0032] Rings 46 known in the art are not necessarily circular in their circumference, and some rings may then be substantially linear. Furthermore, there are a plurality of different kinds of clamps 48 apart from those described and illustrated in co-pending application Ser. No. 10/113,663 which could utilize the assembly 10 shown and described herein.
[0033] Although most retractor shafts 16 have a square cross section along a linear length, other cross sectional shapes could also be utilized in accordance with the present invention. Furthermore, depending on a particular anticipated uses and angular relationship of the shoulder 14 relative to retractor shaft 16 , the angular travel both laterally (i.e., from side to side as well as top to bottom) may be adjusted. This is believed to assist in maintaining the tissue contact surface 56 in an incision against tissue 58 . While the preferred top to bottom range of motion is less than +/−30° and more particularly about +/−20 degrees, and the preferred range of side to side motion is about 1200 , these angles may be restricted and/or expanded depending on the particular needs of the retractor system and assembly 10 utilized.
[0034] Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
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A retractor clamp assembly includes a clamp positionable about a support ring. A retractor shaft extends from the clamp and has a connector at the end with a retractor blade connected thereto by a stem. The connector is preferably equipped with a first slot limiting the side to side angular range of motion of the retractor blade stem relative to the retractor shaft, and a second slot limiting the top to bottom range of motion of the retractor blade stem relative to the retractor shaft. This allows the retractor blade to be maintained and/or positioned in an optimum position relative to retracted tissue while allowing the retractor shaft to be selectively positioned by a user.
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FIELD OF THE INVENTION
This invention generally relates to the art of electrical connectors and, particularly, to a system for terminating the metallic shield of a high speed cable, such as the metallic braid of the cable.
BACKGROUND OF THE INVENTION
A typical high speed cable includes a center conductor or core surrounded by a tube-like inner dielectric. A shield is disposed outside the inner dielectric for shielding and/or grounding the cable. The shield typically is a tubular metallic braid. However, one or more longitudinal conductive wires have also been used and are commonly called "drain wires." An insulating jacket surrounds the composite cable outside the shield.
Various types of connectors are used to terminate high speed cables. The connectors typically have contacts which are terminated to the center conductor or core of the cable. The connectors also have one form or another of a terminating member for terminating the metallic shield of the high speed cable, usually for grounding purposes. A typical system in such connectors terminates the metallic shield to the terminating member by soldering. Other systems use crimping procedures to crimp at least a portion of the terminating member securely to the metallic braid for commoning purposes.
With the ever-increasing miniaturization of the electronics in various industries, such as in the computer and telecommunications industries, along with the accompanying miniaturization of electrical connectors, considerable problems have been encountered in terminating miniature high speed cables, particularly in terminating the metallic shield of the cable. For instance, the outside diameter of a small coaxial cable may be on the order of 0.090 inch. The outside diameter of the inner dielectric surrounding the conductor/core may be on the order of 0.051 inch, and the diameter of the center conductor/core may be on the order 0.012 inch. Coaxial cables having even smaller dimensional parameters have been used.
The problems in terminating such very small coaxial cables often revolve around terminating the metallic shield of the cable. For instance, if soldering methods are used, applying heat (necessary for soldering) in direct proximity to the metallic shield can cause heat damage to the underlying inner dielectric and, in fact, substantially disintegrate or degrade the inner dielectric. If conventional crimp-type terminations are used, typical crimping forces often will crush or deform the inner dielectric surrounding the center conductor/core of the cable.
The above problems are further complicated when the metallic shield of the high speed cable is not terminated to a cylindrical terminating member, but the shield is terminated to a flat terminating member or contact. For instance, it is known to terminate the tubular metallic shield or braid of a coaxial cable to a flat ground circuit pad on a printed circuit board. This is accomplished most often by simply gathering the tubular metallic braid of the coaxial cable into a twisted strand or "pigtail" which, in turn, is soldered to the flat ground pad on the circuit board.
Another example of terminating the metallic shield or braid of a coaxial cable to a flat ground member is shown in U.S. Pat. No. 5,304,069, dated Apr. 19, 1994 and assigned to the assignee of the present invention. In that patent, the metallic braids of a plurality of coaxial cables are terminated to a ground plate of a high speed signal transmission terminal module. The conductors/cores of the coaxial cables are terminated to signal terminals of the module.
In terminating the tubular metallic shields or braids of high speed cables to flat ground contact pads as in a printed circuit board, or to a planar ground plate as in the above-referenced U.S. patent, or to any other flat or non-tubular terminating member, various design considerations should be considered as has been found with the present invention. It should be understood that there is a transition zone created where the center conductor/core of the high speed cable goes from a "controlled environment"wherein the conductor/core is completely surrounded by the tubular metallic shield or braid, to an "uncontrolled environment" where the braid is spread away from the conductor/core for termination to the non-tubular terminating member. It is desirable that this transition zone be held to as small an area as possible and as short a length (i.e., longitudinally of the cable) as possible. Preferably, the metallic shield or braid should be terminated over an area (or at least at two points) approximately 180° apart in relation to the center conductor/core of the cable. Preferably, the flat terminating member should overlap or at least extend to the point where the metallic shield or braid is separated from its tubular configuration surrounding the conductor/core of the cable. Still further, it is desirable that the metallic shield or braid of any given high speed cable be terminated on the same side of the flat terminating member as the center conductor/core of the cable.
The present invention is directed to solving the above-identified problems and satisfying as many of the above-identified design parameters as possible in an improved system for terminating the metallic shield of a high speed cable to a terminating member, such as a ground plate.
SUMMARY OF THE INVENTION
An object, therefore, of the invention is to provide a new and improved method of terminating the metallic shield of a coaxial cable, as well as a terminating member for the shield of the cable.
In the exemplary embodiment of the invention, the method includes providing an exposed portion of the metallic shield of a high speed cable and a conductive terminating member with a plurality of positioning arms formable from an open position to a closed position. The metallic shields are soldered to the positioning arms while the arms are in their open positions. The arms then are formed to their closed positions to properly position the high speed cable.
Preferably, the metallic shield is spread away from the inner dielectric of the cable prior to the soldering step. This further ensures that the heat from the soldering process does not damage the dielectric.
As disclosed herein, the conductive terminating member is formed with a blade portion having a pair of the opposed positioning arms at opposite edges of the blade portion for positioning a pair of coaxial cables therebetween. A pair of the opposed positioning arms provided on each opposite side of the blade portion. The blade portion is generally planar with the positioning arms being generally coplanar therewith when in the open positions of the arms. After soldering, the arms are formable to their closed positions generally perpendicular to the planar blade portion to define channels within which the coaxial cables finally are positioned.
Other objects, features and advantages of the invention will be apparent from the following detailed description taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of this invention which are believed to be novel are set forth with particularity in the appended claims. The invention, together with its objects and the advantages thereof, may be best understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements in the figures and in which:
FIG. 1 is a perspective view of an electrical connector of a type in which the invention is applicable;
FIG. 2 is a fragmented vertical section taken generally along line 2--2 of FIG. 1;
FIG. 3 ,is a perspective view of a stamped metal blank from which the terminating member or ground plate is formed;
FIG. 4 is a perspective view of the ground plate with the positioning arms in their open position, and with the metallic shield of one of the coaxial cables being soldering to one of the arms;
FIG. 5 is a view similar to that of FIG. 4, but showing a second coaxial cable having the metallic shield thereof being soldered to a second positioning arm on the same side of the terminating member;
FIG. 6 is a view similar to that of FIG. 5, but showing the two positioning arms being bent to their closed positions moving the terminated coaxial cables therewith;
FIG. 7 is a view similar to FIG. 5, but showing the terminating member flipped over for soldering the metallic shields of two additional coaxial cables to the remaining two positioning arms on the opposite side of the terminating member;
FIG. 8 is a view similar to that of FIG. 7, but with the remaining two positioning arms bent upwardly of the terminating member; and
FIG. 9 is a perspective view of the terminal module of the connector, including the subassembly of FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in greater detail, and first to FIGS. 1 and 2, the invention is embodied in a shielded electrical connector, generally designated 10, which is a hybrid electrical connector for terminating both the conductors of slower data transmission lines and the conductors of high speed or high frequency transmission lines. In particular, electrical connector 10 includes a dielectric housing 12 (FIG. 2) mounting a plurality of data transmission terminals 14 (FIG. 1). A conductive shield, generally designated 16, substantially surrounds dielectric housing 12 and has a shroud portion 18 projecting forwardly about the mating ends of data transmission terminals 14. A two-piece backshell (not shown substantially in conformance with that shown in U.S. Pat. No. 5,358,428, dated Oct. 25, 1994) projects rearwardly of housing 12 and shield 16. An overmolded boot 20 includes an integral cable strain-relief 22 that is in engagement with a composite electrical cable 24 which includes both the data transmission lines and the high speed or high frequency transmission lines. A pair of thumb screws 26 project through the overmolded boot and include externally threaded forward distal ends 26a for securing the connector to a complementary mating connector, panel or other structure.
As seen best in FIG. 2, a high speed signal transmission terminal module, generally designated 30, is inserted into a passage 31 in dielectric housing 12 from the rear thereof. The terminal module includes a pair of identical terminal blocks 30a and 30b which clamp a ground plate, generally designated 32, therebetween. Each terminal block includes a post 34 and a recess. The post from each terminal block extends from each terminal block through a hole or slot 44 (FIG. 3) in the ground plate and into a recess in the other terminal block to secure terminal blocks 30a and 30b to ground plate 32 as a subassembly. Once this subassembly is inserted into passage 31 in housing 12 as shown in FIG. 2, the terminal blocks are effective to clamp the ground plate therebetween. The terminal module is held within the dielectric housing by ramped latches 36, on each terminal block.
Each terminal block 30a and 30b is overmolded about at least one high speed signal terminal 38. The contact ends of a pair of the terminals 38, along with the forward end of ground plate 32, are shown projecting forwardly of the connector in FIG. 1, within the surrounding shroud portion 18 of shield 16. The rear ends 38a of terminals 38 are terminated to the center conductor/cores 52 of a plurality of coaxial cables, generally designated 40 in FIG. 2. The invention is particularly directed to the manner of termination of the metallic shields 56 of the coaxial cables to ground plate 32, as described below.
More particularly, FIG. 3 shows a blank, generally designated "B," stamped from conductive sheet metal material and from which ground plate 32 is formed. Blank "B" is generally T-shaped and includes a leg or stem portion 42 which will form a blade portion for ground plate 32. The blade portion includes an aperture 44 through which posts 34 (FIG. 2) of terminal blocks 30a and 30b extend. A pair of wings or arms 46 project outwardly at one end of leg 42 generally at each opposite edge thereof. These wings will form the positioning arms of the ground plate, as will be seen hereinafter. Lastly, barbs or teeth 49 are stamped at the opposite edges of blade portion 42 to facilitate holding the subassembly of the ground plate and terminal blocks 30a and 30b within the housing.
Reference now is made to FIG. 4 wherein wings 46 of blank "B" in FIG. 3 now will be referred to as two pairs of positioning arms 50a and 50b. The pair of positioning arms 50a are at the extreme end of ground plate 32 opposite blade portion 42. The pair of positioning arms 50b are located slightly forward of arms 50a . If desired, the arms 50a and 50b could be spaced inwardly from the end of ground plate 32 so that the ground plate extends along cable 40 at the point where the metallic shield 56 of the cable is separated from the inner dielectric layer 54.
In essence, ground plate 32 is provided with a pair of opposed positioning arms 50a at opposite edges of the plate for positioning a pair of coaxial cables, as well as providing a pair of the opposed positioning arms 50a and 50b on each opposite side of the plate. One pair 50a is located at the extreme rear distal end of blade portion 42, and the other pair 50b is located slightly spaced longitudinally forward of the first pair. With this structure, the ground plate can terminate from one to four coaxial cables depending on the specifications of the connector. In some computer applications, three cables may be used to carry the red, green and blue chroma signals for a monitor. A fourth cable might be used for flat screen monitors for carrying the pixel clock timing signals.
FIG. 4 also shows that each of the coaxial cables 40 typically includes a center conductor or core 52 surrounded by a tube-like inner dielectric 54. A metallic shield in the form of a tubular metallic braid 56 surrounds inner dielectric 54. An insulating jacket 58, as of plastic or the like, surrounds metallic braid 56 to form the overall composite coaxial cable 40. It can be seen that center conductor/core 52 of coaxial cable 40 has been stripped to expose a given length thereof which is soldered to the inner end 38a (FIG. 9) of one of the high speed signal transmission terminals 38 (FIG. 2). The outer insulating jacket 58 of the cable also has been cut-back to expose a given length of the metallic shield 56. Therefore, the exposed shield can be soldered to one of the gripping arms 50a or 50b of ground plate 32.
Still referring to FIG. 4, after ground plate 32 has been stamped from a stock of sheet metal material, the metallic shield 56 of one of the coaxial cables 40 is pulled away or spread from dielectric 54 and placed on top of one of the end-most positioning arms 50a as seen in FIG. 4. Since the metallic shield of the coaxial cable shown herein comprises a metallic braid, the braid is spread across the one positioning arm 50a , preferably from the distal end or tip of the arm to approximately the center of the blade portion 42 of ground plate 32. Dielectric 54 and conductor/core 52 also can be bent upwardly as shown in FIG. 4 to further separate the metallic braid from the inner dielectric. The dielectric then is soldered to the one positioning arm, as at "S." It should be understood that by separating the metallic braid from the inner dielectric, as shown, the heat required for the soldering process can be isolated from the inner dielectric to prevent any damage thereto.
FIG. 5 shows the next step in the process, wherein the metallic braid 56 of a second coaxial cable 40' is soldered to the other end-most positioning arm 50a. Again, the inner dielectric is bent upwardly, and the metallic shield is spread over the arm prior to soldering.
After metallic shields 56 of coaxial cables 40 and 40' are soldered to positioning arms 50a as shown in FIG. 5, inner dielectric members 45 are straightened back to their original linear configuration and the positioning arms are bent upwardly as seen in FIG. 6 relative to blade portion 42 of ground plate 32. Preferably, the positioning arms are bent generally perpendicular to the blade portion to form a generally U-shaped channel for positioning the coaxial cables therebetween as seen in FIG. 6. Arms 50 are preferably slightly longer than the diameter of inner dielectric 54. The width of blade portion 42 at the rear thereof is at least as large as twice the diameter of inner dielectric 54. Therefore, two cables may be positioned on each side of blade portion 42. In this configuration, the shield of each coaxial cable extends circumferentially approximately 180° about the center conductor/core of the cable. In other words, a line extending between opposite ends of the soldered metallic braid will also pass approximately through center conductor 52.
The next step in the process is to repeat the steps of FIGS. 4 and 5 for two additional coaxial cables 40" and 40'" with respect to the other two positioning arms 50b as seen in FIG. 7. In particular, ground plate 32 and the terminated coaxial cables 40 and 40' are turned over, the inner dielectric 54 of each coaxial cable 40" and 40'" is bent upwardly, and metallic shields 56 of coaxial cable 40"and 40'" is soldered to positioning arms 50b as clearly shown in FIG. 7.
After the metallic shields of coaxial cables 40"and 40'" are soldered to positioning arms 50b, the inner dielectric members are straightened back to their original linear configurations, and the positioning arms are bent generally perpendicular to blade portion 42 of ground plate 32 as shown in FIG. 8. Like positioning arms 50a, positioning arms 50b form a generally U-shaped channel 42 to position coaxial cables 40" and 40'" therewithin. Preferably, blade portion 42 extends rearwardly beyond, or at least overlaps, the point where the metallic shields discontinue their cylindrical configurations inside jackets 58 and start to become spread out over arms 50a and 50b.
Once the subassembly of FIG. 8 is fabricated, including the soldering procedures, this subassembly is assembled to terminal blocks 30a and 30b and high speed signal transmission terminals 38 to form terminal module 30 as shown in FIG. 9 and described above in relation to FIG. 2. Center conductors/cores 52 of the coaxial cables are connected, as by soldering, welding or otherwise securing to the inner ends 38a of terminals 38 (FIG. 9), with terminal blocks 30a and 30b clamping blade portion 42 of ground plate 32 therebetween, as shown in FIG. 2 and described above. The terminal module then is mounted within dielectric housing 12 as shown in FIG. 2.
The concepts of the invention have been shown and described herein in conjunction with terminating the metallic shield of the coaxial cable to a terminating member 32 in the form of a ground plate 42. However, it should be understood that the concepts of the invention are equally applicable for terminating the metallic shield 56 to other types of terminating members, such as electrical terminals themselves.
It will be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein.
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A method is disclosed for terminating the metallic shield of a high speed cable. The method includes the steps of providing a cable with an exposed portion of the metallic shield of the cable and a conductive terminating member having a plurality of positioning arms. Each arm is formable from an open position to a closed position. The metallic shields are soldered to a positioning arm while the arm is in its open position. Each arm is formed to its closed position to properly position the high speed cables.
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PRIORITY
This application claims priority through U.S. Provisional Application No. 61/135,974 filed by Henry B. Wallace on Jul. 25, 2008 for “Low Capacitance Audio Cable.”
BACKGROUND OF THE INVENTION
1. Field of the Invention
The cable connection method is a method of connecting to conductors within a triaxial electrical cable, without completely severing the cable, allowing compact, low cost connections to be made while having the added benefit of strain relief of the cable around the connection point and even within the cable itself.
2. Description of the Prior Art
Coaxial cables have been in use for many years. A common problem is connecting to a coaxial cable to access the signal on the inner conductor of the cable without completely severing the cable. Many inventions have been created to aid the goal of connecting to coaxial cables, typically by puncturing or removing part of the outer shield and insulation to access the inner conductor. These will be reviewed, and their applicability in connecting to triaxial cables evaluated.
For the purposes of reference, a triaxial cable is considered to have a first center conductor, an inner tubular shield conductor situated around the first center conductor and separated from it by a dielectric material (with optional semi-conductive outer layer for handling-noise suppression), an outer tubular shield conductor situated around the inner shield conductor and separated from it by an additional dielectric material, and an overall insulating layer.
Edlen, et al. (U.S. Pat. No. 2,694,182, Nov. 9, 1954) discloses a coaxial cable tap that pierces the outer insulator, shield and inner insulator to contact the center conductor using a hinged clamp assembly. Peripheral probes contact the shield to connect it electrically to other coaxial cables. While this performs suitably with coaxial cables, triaxial cables have and additional conducting layer that would require impractical piercing parts to connect to each conductor, such piercing parts being specially insulated and demanding critical positioning.
A functionally similar method is disclosed in Rheinfelder (U.S. Pat. No. 3,543,222, Nov. 24, 1970), and consists of a coaxial cable tap that pierces the outer insulator, shield and inner insulator to contact the center conductor and route its signal to one or more other coaxial cables. For triaxial cable connection, this is impractical, as cited for Edlen, above.
Rheinfelder (U.S. Pat. No. 3,625,623, Dec. 7, 1971) describes a method of accessing the conductors in a coaxial cable using a boring tool situated radially with respect to the central axis of the cable. Such a boring method adequately exposes the center conductor in a coaxial cable, but would not adequately also expose the inner shield conductor in a triaxial cable such that it could be easily connected to.
Down, et al. (U.S. Pat. No. 4,738,009, Apr. 19, 1988) discloses a coaxial cable tap that removes a semicircular section of the cable, then connects to the shield and center conductor using a clamping shell assembly. This method and assembly results in a coaxial cable tap construct that appears from the drawings to be approximately 10 to 15 times the cable diameter in length, which is unacceptably large. However, removal of a semicircular section of a triaxial cable would allow access to all three conductors and connection thereto.
The prior art is concerned with making connections to coaxial cables as are typically used in cable television distribution and radio frequency systems, where the connections must be made without interrupting service to customers, and where the impedance of the completed connection must not disturb the signals or system. In the case of a connection being made during factory assembly of a product, interruption of service is not an issue, and simpler methods may be used. With audio cables and systems, the characteristic impedance of the cable and connections is not important. While the prior art regarding coaxial cable taps provides some direction, it does not provide a solution that affords compact, low cost, strain relieved connections to audio triaxial cable.
After an electrical connection is made to a cable, it is also important to stabilize the connection against physical damage and encroaching moisture and contaminants. This is typically done with a sealing gasket or potting (encapsulating) operations. Of interest here are strain reliefs formed using epoxy or other potting compounds, as opposed to discrete molded plastic strain reliefs or seals.
For example, Jenets (U.S. Pat. No. 6,439,929, Aug. 27, 2002) discloses a standard strain relief application: “Often times, these terminating backshells are intended to be filled with a potting compound, such as at non-conductive epoxy or the like, which will protect soldered wire joints from the environment and to prevent corrosion, while at the same time providing some degree of strain relief to soldered wire joints.” Similar disclosure is found in Burger, et al. (U.S. Pat. No. 6,146,196, Nov. 14, 2000): “After termination, the back end of the coaxial contact system would be potted with epoxy to further lock in place and to provide strain relief.”
Takahashi, et al. (U.S. Pat. No. 5,679,008, Oct. 21, 1997) describes a similar strain relief: “It is preferable that the vinyl jackets 54 of the coaxial cables 5 are fixed to the circuit boards 41 with epoxy resin in order to reinforce the attachment of the coaxial cables 5 , providing strain relief.”
The prior art is replete with examples of the use of epoxy resins as stabilizing, sealing, and strain relief agents when used in the construction of cable connections. However, not disclosed is the possibility and express intention that the epoxy used in the potting process wicks into the cable along the interfaces between the various members of the cable's structure, cures there, and provides strain relief actually within the structure of the cable itself.
Bryant, et al. (U.S. Pat. No. 7,430,881, Oct. 7, 2008) discloses an optical fiber termination means where epoxy wicks into a tube around a fiber: “ . . . the pigtail 102 may be heated to wick epoxy up through the maria 205 . The protective sleeve 203 may then be reinserted and the epoxy allowed to cure (e.g., via UV curing), thus providing strain relief and securing the protective sleeve 203 without interfering in the optical path.” However, there is no disclosure of the epoxy wicking into the structure of the fiber to provide a strain relief, and all strain relief is external to the fiber.
McNeel (U.S. Registration No. H113, published Aug. 5, 1986) discloses an electrical cable termination and sealing method: “A select epoxy resin 84 , such as type CN-874 manufactured by Mereco Company infills housing 82 , surrounding the ends of the pins and sockets such as 52 and 60 within flanges 72 , the laced wire conductors 66 and 68 , brace stem 76 , and a predetermined length of cable 14 . The epoxy resin 84 forms a watertight seal within housing 82 and reacts chemically with cable 14 firmly anchoring it within the housing.” Here there is still no disclosure of epoxy encapsulant wicking into the structure of the cable and forming a strain relief.
Objects and Advantages of the Cable Connection Method
Several objects and advantages of the cable connection method are:
1. Connections to the triaxial cable can be made in a small space, typically two to four diameters of the cable in length. 2. No elaborate clamping or shell arrangement is needed, and the frame for encapsulation of the connection may be inexpensive plastic. 3. Connections to the cable may be easily wired by soldering wires to the exposed conductors of the cable. 4. The entire connection area is potted in epoxy, which then wicks into the cable, creating a strain relief. 5. The assembly method requires no high tolerance machined parts or expert assembly skills, and can be accomplished with inexpensive materials. 6. The completed connection is impervious to moisture and contaminants.
SUMMARY OF THE INVENTION
The cable connection method is a method of connecting to conductors within a triaxial electrical cable, without completely severing the cable, resulting in compact, low cost connections with strain relief and contaminant resistance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a drawing of a typical method of connection of two triaxial cables to a printed circuit board (PCB).
FIG. 2 is a drawing of a typical stripping profile of a triaxial cable.
FIG. 3 is a drawing illustrating an alternative, compact method of accessing the conductors within a triaxial cable.
FIG. 4 is a drawing illustrating another view of the conductors within a triaxial cable after removal of a section of the cable.
FIG. 5 is a drawing illustrating connection of a triaxial cable to a PCB using the compact method of conductor access.
FIG. 6 is a drawing illustrating the potting of the exposed area of a triaxial cable and connected PCB, and the wicking action that provides strain relief to the cable.
DETAILED DESCRIPTION
This application involves connecting to the three conductors of a triaxial cable, typically connecting those conductors to a PCB for some signal processing operation, for example a driven shield capacitance reduction scheme. In the past, such a connection was made as in FIG. 1 , which shows a first triaxial cable 100 , a second triaxial cable 101 , each having a first center conductor 103 , an inner shield conductor 105 situated around the first center conductor 103 and separated from it by a dielectric material 104 , and an outer shield conductor 107 situated around the inner shield conductor 105 and separated from it by a yet additional dielectric material 106 , with an overall insulating layer 108 . Identically stripped lengths of each cable are shown, though various lengths and arrangements may be used depending upon the application. A PCB 102 receives soldered connections 109 to the cable conductors, either the conductors themselves or using additional lead wires, as shown in Scholz, et al. (U.S. Pat. No. 5,151,050, Sep. 29, 1992), FIG. 3 , and in the specification: “The ground braid 34 is electrically connected to a corresponding terminal 28 by means of a wire 35 surrounding the ground braid 34 and soldered thereto.”
Such an assembly is labor intensive to construct in that the cables 100 and 101 must be precisely stripped (all stray braid conductors accounted for and restrained), and each of six conductors must be soldered to the PCB 102 .
Another disadvantage of the method if FIG. 1 is that the size of the assembly is large. FIG. 2 illustrates the stripping profile of a typical audio triaxial cable, where length “L” 110 is typically 1.5 cm to 2 cm. Thus for an inline connection the length would be at least 3 cm. The cables may be overlapped to some extent to reduce that dimension, but such overlap increases the width required on the PCB.
It would be better to tap the cable in some way that saves labor and space.
While many methods exist for tapping or connecting to coaxial cable, such methods do not directly apply to triaxial cables due to the additional shield conductor. Tapping elements that pierce the triaxial cable would have to be constructed with fine dimensions in order to contact a single conductor of the three, especially regarding the two inner conductors. Such tapping elements would also have to be positioned with great precision to avoid shorting to other conductors, and to make contact as intended.
Coaxial cable tapping methods are also generally designed to not disturb the impedance of the coaxial cable because they carry radio frequency (RF) energy. Any impedance perturbations on an RF coaxial cable, for example, in a cable television system, can produce line reflections that foul signal delivery to the customer. Thus coaxial RF tapping methods must be precise and as noninvasive as possible.
With audio cables, the impedance of the cable is relatively unimportant, especially for low-level signal cables. This permits other, less stringent methods to be used to tap or access the signals on the cable. This also allows optimization of other parameters, such as the space occupied by the tap arrangement.
The present cable connection method is not affected by the existence or lack of the noted optional semi-conductive layer within a triaxial cable, and as such this feature is not considered further except to say that it should be trimmed properly in the preparation of any connection assembly, which is standard procedure in the prior art.
PREFERRED EMBODIMENT
Referring to FIG. 3 , to access the conductors in a triaxial cable 111 it is acceptable to remove a section from the side of the cable. This may be done by grinding, milling, or cutting, or by using another prior art method, as in Down, et al., but with the improvement that the center conductor is exposed in the process. (The method disclosed in Down, et al. leaves the center conductor fully enveloped in dielectric.) Cooling the cable before the removal process helps stiffen the cable and attain a cleaner cut. Such methods work as well on triaxial cable as on coaxial cable, and exposes all three conductors in a semicircular exposed area 120 of extent on the order of the diameter of the cable, typically less than 5 mm for an audio cable. A length 121 of center conductor 103 is exposed in this process, but the conductor is not completely severed.
Another view of the exposed semicircular area 120 is shown in FIG. 4 . All three conductors of triaxial cable 111 are available for connection, including first center conductor 103 , inner shield conductor 105 , and outer shield conductor 107 , as designated in FIG. 1 .
Referring to FIG. 5 , after the semicircular section of cable 111 is removed, creating an exposure 120 , it is a simple matter to solder wires 130 onto the three cable conductors and connect them to a PCB 131 . The wires 130 may also be attached to the three cable conductors using mechanical pressure or conductive adhesive. Since this is an application for an audio signal cable, and the currents flowing are generally much less than 1 milliamp RMS, the wires may be of fine gauge.
It is also feasible to use conductors captured in a connector at fixed spacing, instead of discrete wires. Such conductors may be soldered to the three cable conductors, or maintained in contact using physical pressure or conductive adhesive.
FIG. 6 shows the assembly after being potted with epoxy, for example MG Chemicals type 832 B. The critical feature here, unexpected and not disclosed in the prior art, is that the epoxy 143 wicks into the internal structure of the cable 111 through exposure 120 to a distance of 1 cm-2 cm, providing a strain relief 140 inside the cable 111 after the epoxy cures. The internal structure of the cable consists of the components of the cable within the outer layer 108 (not shown in FIG. 6 ). Such wicking generally occurs to a greater extent along the outer shield 107 , which is acceptable because a strain relief there will protect cable structures within. The cable 111 is shown exiting a plastic or metal potting enclosure 142 through apertures 141 in the walls, the apertures fitting the cable 111 snugly. Each aperture 141 does not compress the cable 111 as in a typical mechanical strain relief. Thus the epoxy wicks inside the cable 111 past the wall of the enclosure 142 .
Note that the potting enclosure and wall are not strictly required, and the epoxy wicks into the cable in any case, providing some strain relief against flexure of the cable where it enters the main mass of cured epoxy.
With this assembly technique, a strain relief 140 is created without the need for discrete rubber or plastic strain relief parts, and the strain relief is contained within the cable 111 and is not visible. The net effect is that the cable 111 is stiffer near the enclosure wall 142 , retarding wire breakage near the wall as the cable 111 is repeatedly flexed.
The epoxy 143 wicking action also serves to reinforce the exposed section of the cable 120 where the semicircular wedge has been removed (the dashed oval in FIG. 6 ). This restores the cable 111 to a useful and sufficient tensile strength in the vicinity of the connection area. Enhanced wicking and strain relief may be had by potting the assembly under vacuum to draw more of the epoxy into the cable structure. It should be understood that this operation might include positive pressure as needed, depending on the specific configuration of the equipment.
Note that the references to strain relief with regard to potting cable assemblies in the prior art assume that the entire mechanical advantage of the potting compound occurs entirely on the outer surface of the cable, and the exposed conductors and insulators thereof. No statement of the advantage of the wicking of the epoxy into the cable is made, and this potential benefit is neglected.
Marketing by applicant of an audio cable featuring the cable connection method, after the filing of U.S. Provisional Application No. 61/135,974, has been successful. The audio cables have been praised by professional musicians, and the cables have withstood the typical abuse received from working musicians without failure.
The specific configuration of the embodiments discussed should not be construed to limit implementation of this cable connection method to those embodiments only. The techniques outlined are applicable to embodiments in other physical formats, using various methods of exposing the conductors in the triaxial cable, using various connection methods to the conductors in the cable, and using various potting compounds. The cable connection method is functional with a broad range of electrical cable, not just coaxial or triaxial cable. These techniques, structures and methods find applicability outside the realm of audio cables. Therefore, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.
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The cable connection method is a method of connecting to conductors within a triaxial electrical cable, without completely severing the cable, allowing compact, low cost connections to be made while having the added benefit of strain relief of the cable around the connection point and even within the cable itself.
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BACKGROUND OF THE INVENTION
The present invention relates in general to a bathtub cleaning system, and more particularly, to a self-cleaning system for bathtubs and the like having a cleaning and rinse cycle controlled by a mixing control valve.
Lavatories, such as bathtubs, showers and the like, often require daily cleaning due to health and general sanitation standards. This is particularly true of bathtubs found in hotels and motels which must be cleaned on a daily basis. Heretofore, the task of cleaning such bathtubs have been accomplished by manual labor. As a result of the increasing cost of manual labor and the undesirability of performing such tasks, attempts have been made to improve the cleaning operation of these bathtubs.
In particular, the prior art has addressed the problem of the daily cleaning of public and private restroom facilities which have included cleaning the commodes, bathtubs, showers, walls, etc. Such attempts have included the design of cleaning machines and complicated cleaning systems suspended from the ceiling. However, these systems have not gained commercial acceptance due to their expense and cumbersome use.
Accordingly, there is an unsolved need for a self-cleaning system which is economical and easy to use for cleaning bathtubs and the like.
SUMMARY OF THE INVENTION
It is broadly an object of the present invention to provide a bathtub self-cleaning system which fulfills one or more of the foregoing requirements of bathtub cleaning systems and which overcomes or avoids one or more of the foregoing disadvantages from the use of the prior art restroom facility cleaning systems. Specifically, it is within the contemplation of the present invention to provide a bathtub self-cleaning system which automatically cleans bathtubs without the necessity of any manual scrubbing thereof.
A further object of the present invention is to provide a bathtub self-cleaning system which provides a cleaning cycle and a rinse cycle from a common mixing control valve.
A still further object of the present invention is to provide a bathtub self-cleaning system which is adapted to combine a predetermined amount of a concentrate with a dilutent to form a cleaning solution for use during a cleaning cycle.
A still further object of the present invention is to provide a bathtub self-cleaning system which supplies a cleaning agent and rinse at a predetermined rate to a mixing chamber within a mixing control valve to form a cleaning solution for cleaning the walls of a bathtub.
A yet still further object of the present invention is to provide a bathtub self-cleaning system for cleaning the surfaces of the confining walls of a bathtub in an uncumbersome and inexpensive manner.
In accordance with one embodiment of the present invention, there is provided a system for cleaning the walls of a bathtub. The system includes a plurality of spray nozzles adapted to be arranged to distribute a cleaning solution and dilutent over the walls of a bathtub to be cleaned. A fluid conduit means is provided to communicate with each of the spray nozzles for supplying the cleaning solution and dilutent thereto from a control means. The control means is constructed and arranged to combine a concentrate with the dilutent to provide the cleaning solution for use in cleaning the walls of the bathtub during a first cycle and to provide the dilutent for rinsing the walls of the bathtub during a second cycle.
Further in accordance with the above embodiment, the control means includes a first chamber for supplying a quantity of concentrate, a second chamber for supplying a quantity of dilutent and a third chamber for combining a quantity of concentrate supplied from the first chamber with a quantity of dilutent supplied from the second chamber to form the cleaning solution.
Still further in accordance with the above embodiment, the first and second chambers include an orifice member having an opening of predetermined size to supply a predetermined quantity of concentrate and dilutent from the first and second chambers into the third chamber.
Further in accordance with the present invention there is provided a cleaning system for a bathtub including a series of spray nozzles adapted to be arranged around the walls of the bathtub. The spray nozzles have piston elements movable between a first stored position and a second operative position. A fluid conduit means is provided to communicate with each of the spray nozzles for supplying a solution thereto. Control means are provided for supplying the solution to the fluid conduit means. The spray nozzles are constructed and arranged to move the piston elements from the first position to the second position in response to the solution for distributing the solution over the walls of the bathtub during a first interval and to move the piston elements from the second position to the first position at the end of the first interval.
Still further in accordance with the present invention, there is provided a mixing control valve for combining a concentrate with a dilutent to provide a diluted solution. The control valve is construced from a body having an inlet, an outlet and first, second, and third chambers. The first chamber is provided to supply a quantity of concentrate and the second chamber to supply a quantity of dilutent to the third chamber. The third chamber is in communication with the first and second chambers for combining a quantity of concentrate from the first chamber with a quantity of dilutent from the second chamber to provide the diluted solution. The inlet is arranged in communication with the first and second chambers for supplying the dilutent thereto and the outlet with the third chamber for supplying the dilute solution therefrom.
Further in accordance with the last mentioned embodiment, there is provided an injection port communicating directly with the first chamber for introducing the concentrate therein from a storage bottle.
BRIEF DESCRIPTION OF THE DRAWINGS
The above description as well as further objects, features and advantages of the present invention will be more fully understood by reference to the following detailed description of a presently preferred, but nonetheless illustrative bathtub self-cleaning system in accordance with the present invention when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a front elevation of a bathtub self-cleaning system installed on a bathtub showing a plurality of pop-out spray nozzles connected to a manifold for supplying a cleaning solution and rinse from a mixing control valve;
FIG. 2 is a perspective elevation of the bathtub as shown in FIG. 1 having a plurality of apertures for installing the spray nozzles as shown in FIG. 1;
FIG. 3 is a partial, cross-sectional, side elevation showing the mixing control valve as shown in FIG. 1 installed to the wall of the bathtub and having means for injecting a cleaning agent therein;
FIG. 4 is a cross-sectional elevation taken along lines 4--4 of FIG. 3 showing the mixing control valve having a first cleaning agent chamber, a second rinse chamber and a third mixing chamber for combining the cleaning agent with the rinse to form a cleaning solution;
FIG. 5 is a cross-sectional elevation of a pop-out spray nozzle as shown in FIG. 1 having horizontal and verticle spray orifices; and
FIG. 6 is a cross-sectional elevation of the spray nozzle, as shown in FIG. 5 in an operative popped-out position, for supplying the cleaning solution to the wall of the bathtub.
DETAILED DESCRIPTION
Referring specifically to the drawings, there is shown in FIG. 1, a bathtub self-cleaning system constructed according to one embodiment of the present invention and generally designated by reference numeral 100. Although the system 100 is shown with reference to a bathtub 102, it is to be understood that such a system may be incorporated into a shower, a swimming pool or the like. The system 100 is constructed to include a plurality of pop-up spray nozzles 104, a fluid conduit or manifold 106 and a mixing control valve 108 having an injection port 118. In addition, the system 100 can be provided with an external check valve 110 and a manually or solenoid activated supply valve 112.
As shown in FIG. 1, the spray nozzles 104 are secured around the walls of the bathtub 102 within apertures 114 (see FIG. 2). The spray nozzles 104 are positioned to distribute a cleaning solution and a dilutent such as rinse water over selected surface portions of the walls of the bathtub 102 during a cleaning and rinse cycle. The manifold 106 communicates with each of the spray nozzles 104 to supply the cleaning solution and rinse thereto from the control valve 108. The manifold 106 can be located below the upper lip of the bathtub 102 to position it out of eyesight upon installation. The control valve 108 is secured adjacent to the wall of the bathtub 102 in alignment with aperture 116 (see FIG. 2).
The construction of the control valve 108 will now be described with reference to FIGS. 3 and 4. Referring specifically to FIG. 3, the control valve 108 is secured to the bathtub 102 via the injection port 118. The injection port 118 is constructed from a hollow tubular nipple 120 having external threads. One end of nipple 120 is secured within the body of the control valve 108. The other end is secured to the wall of the bathtub 102 by a wall fitting 122 having internal threads for engaging the external threads of nipple 120. Wall fitting 122 includes a central opening 124 in communication with the opening at the end of nipple 120. Wall fitting 122 is secured to the bathtub 102 within aperture 116 by a locknut 126. A resilient flexible check valve 128 having a variable orifice is located within opening 124 of the wall fitting 122 and extends inward into nipple 120. The operation of the injection port 118 will be described hereinafter with reference to the operation of the bathtub self-cleaning system.
Referring to FIG. 4, the control valve 108 is constructed from a body 130 having a first concentrate or cleaning agent chamber 132, a second dilutent or rinse chamber 134 and a third mixing chamber 136. Secured within one end of the cleaning agent chamber 132 is a flow control orifice member 138 having a restricted opening 140 of predetermined size. Likewise, secured within one end of the rinse chamber 134 is an orifice member 142 having a restricted opening 144 of predetermined size. The openings 140, 144 within orifice members 138, 142 provide direct communication from the cleaning agent chamber 132 and rinse chamber 134 to the mixing chamber 136. Orifice members 138, 142 can be constructed permanently within the cleaning agent chamber 132 and rinse chamber 134 or can be constructed from a replaceable body to alloy for the easy changing of the size of openings 140, 144.
An inlet 146 is located at one side of the control valve 108 to provide a supply of rinse to the rinse chamber 134 and cleaning agent chamber 132 by interconnecting passageway 148. An outlet 150 is located at one end of the control valve 108 in communication with the mixing chamber 136. The injection port 118 communicates directly with the cleaning agent chamber 132 via nipple 120 and check valve 128. Plugs 152 are secured within one open end of the cleaning agent chamber 132, rinse chamber 134 and mixing chamber 136 to provide internal access thereto. The plugs 152 allow for the cleaning of the cleaning agent chamber 132, rinse chamber 134 and mixing chamber 136, in addition to allowing replacement and repair of orifice members 138, 142.
The construction of the pop-out spray nozzles 104 will now be described with reference to FIGS. 5 and 6. The spray nozzles 104 are constructed of a body 154 having a cavity 156 therein. The body 154 has an open end extending through aperture 114 within the bathtub 102 and is secured thereto by a cap 158 having a central opening therein. A gasket 160 provides a leak proof seal between the internal region of cap 158 and the open end of the body 154.
A hollow piston nozzle element 162 is slidably located within cavity 156 between a first stored position (see FIG. 5) and a second operative position (see FIG. 6). The piston nozzle element 162 includes a flange 164 at one end and one or more orifices 166, 168 provided at the other end. The end of the piston nozzle element 162 containing orifices 166, 168 is arranged for sliding engagement within the central opening of cap 158. A spring 170 is provided in the cavity 156 between the gasket 160 and flange 164 of the piston nozzle element 162 to bias the flange 164 against a retaining lip 172 constructed in the body 154. The manifold 106 is connected to the body 154 of the spray nozzles 104 to provide a supply of cleaning solution and rinse to the cavity 156 and orifices 166, 168.
The operation of the bathtub self-cleaning system in accordance with the present invention will now be described with reference to FIGS. 1 and 3-6. A concentrated cleaning agent such as a detergent 174 is supplied within a squeeze bottle 176 having an injection tube 178 at one end. A predetermined quantity of detergent 174 is introduced into the cleaning agent chamber 132 of the control valve 108. This is accomplished by inserting the injection tube 178 through the flexible check valve 128 via central opening 124 in the injection port 118. As the injection tube 178 engages the internal portions of the check valve 128, the check valve is forced open to allow continued insertion of the injection tube to communicate with the cleaning agent chamber 132. Once a sufficient quantity of detergent 174 has been introduced into the cleaning agent chamber 132, the injection tube 178 is withdrawn and the check valve 128 closes, retaining the detergent therein.
The rinse is supplied to the inlet 146 of the control valve 108 from a suitable source of cold, hot or tepid water. Opening of valve 112 manually or by activation of the solenoid supplies the rinse to the rinse chamber 134 and cleaning agent chamber 132 via passageway 148. Check valve 110 prevents contamination of the rinse source with detergent 174 during operation of the system 100. The rinse is supplied to the mixing chamber 136 from the rinse chamber 134 at a controlled rate through the opening 144 in the orifice member 142. In a like manner, the detergent 174 is supplied to the mixing chamber 136 at a controlled rate through the opening 140 in the orifice member 138. The detergent 174 and rinse combine in the mixing chamber 136 to provide the diluted cleaning solution for use at outlet 150 of the control valve 108. In one embodiment, the orifice member 142 in the rinse chamber 134 provides a flow rate of 2.75 gallons per minute of rinse and the orifice member 138 in the cleaning agent chamber 132 provides a controlled flow rate of 0.25 gallons per minute of detergent 174.
The cleaning solution is supplied to each of the spray nozzles 104 through the manifold 106. The cleaning solution enters cavity 156 within each spray nozzle 104 and impinges upon flange 164 of the piston nozzle elements 162. As shown in FIG. 5, the piston nozzle elements 162 are normally biased by the spring 170 in a first stored position such that the end containing the orifices 166, 168 is flush with the outer surface of cap 158 and the other end having flange 164 is biased against the retaining lip 172 of the body 154. As shown in FIG. 6 the pressure of the cleaning solution forces the piston nozzle elements 162 to compress spring 170 such that the orifices 166, 168 at the end of the piston nozzle elements protrude beyond the outer surface of cap 158.
In one embodiment, those spray nozzles 104 which are provided along the side walls of the bathtub 102 include an orifice 166 having a horizontal spray pattern for cleaning the opposite sidewalls of the bathtub and a second orifice 168 having a downward spray pattern for cleaning the adjacent sidewall. Those spray nozzles 104 located at the opposite ends of the bathtub 102 are provided with a single orifice 168 having a downward spray pattern for cleaning the adjacent endwalls. It is to be understood by those skilled in the art that other spray patterns may be incorporated with the present invention for spraying the cleaning solution and rinse over the walls of the bathtub 102.
The cleaning solution is sprayed over the walls of the bathtub 102 until the detergent 174 has been consumed from the cleaning agent chamber 132, thus ending the cleaning cycle. Subsequently, the rinse is supplied to the spray nozzles 104 to remove any residual cleaning solution and dirt from the walls of the bathtub 102 during a rinse cycle. The rinse cycle continues until valve 112 is turned off isolating the control valve 108 from the rinse supply, i.e., water source. As shown in FIG. 5 when valve 112 is turned off, spring 170 forces the piston nozzle elements 162 to return to their first stored position having their ends flush with the outer surface of cap 158. The duration of the cleaning cycle can be altered by changing the size of opening 140 in the orifice member 138 located in the cleaning agent chamber 132. Likewise, the concentration of the cleaning solution can be altered by changing the size of opening 144 in the orifice member 142 located in the rinse chamber 134.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and application of the present invention. Thus, it is to be understood that numerous modifications may be made in the illustrative embodiments and other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. For example, the cleaning solution can be supplied to the manifold by using an aspirator to remove a predetermined quantity of detergent from a concentrate supply source for mixing with the dilutent flowing through the aspirator. A valve at the outlet to the concentrate supply source can be closed to allow pure rinse to flow through the aspirator and be sprayed on the walls of the bathtub. Cycle times for cleaning and rinse can be automatically adjusted by solenoid activated valves positioned within the bathtub self-cleaning system. In addition, the detergent may be eliminated from the control valve to provide only the dilutent for use in accordance with the bathtub self-cleaning system of the present invention.
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A bathtub self-cleaning system includes a series of pop-out spray nozzles designed to be arranged about the confining walls of a bathtub and the like. The spray nozzles are connected by a manifold to a combined concentrate and dilutent mixing control valve. The control valve serves to initially mix the dilutent such as water with the concentrate such as a detergent to provide a diluted cleaning solution. Subsequently, the control valve discharges the cleaning solution via the manifold through the spray nozzles. The spray nozzles when popped-out are directed at the surfaces of the confining walls for their cleaning by the cleaning solution. Upon consumption of the concentrate within the mixing control valve, only dilutent is discharged therefrom to rinse the confining walls of residual cleaning solution or dirt. In this manner, a bathtub may be automatically cleaned without the necessity of any manual scrubbing thereof.
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REFERENCE TO RELATED APPLICATIONS
This patent application claims the benefit of U.S. Provisional Application No. 61/750,659 filed on Jan. 9, 2013, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a framing and sheathing system for manufacturing wall panels, and more particularly to a semiautomatic system for framing and sheathing wall panels.
2. Description of Related Art
The vast majority of new construction requires framing of the wall panels. Framing and sheathing jobs can be time consuming and potentially dangerous. In addition to the inconvenience and safety issues themselves, this can cause a job to become expensive. It can be particularly challenging to do a high quality job within specific time and money budgets using currently available methods. This often requires workers to work at a speed that decreases accuracy and precision when framing.
Therefore there is a need to have an improved framing and sheathing system that can help workers to work at a fast speed without compromising accuracy and precision when framing walls.
In view of the above, it is the principal object of the present invention to provide an improved framing and sheathing system which can manufacture wall panels at a fast speed yet without compromising accuracy and precision.
A further object is to provide an improved system which requires a minimum amount of manual intervention.
Yet another object is to provide a framing and sheathing system that produces wall panels at a competitive cost relative to the wall panels produced by the conventional techniques.
SUMMARY OF THE INVENTION
The present invention describes a system for framing and sheathing walls. The system comprises a framing jig, sheathing jig, computer, carriage, photoelectric eyes, pneumatic or hydraulic rams, solenoids and other triggers, stops, controls, switches, and banks of nail guns. The system can be quickly or automatically adjusted for building walls with various sized studs, stud spacing, and for building walls of varying height. The framing system allows automated nailing without any operator input. The system helps to automate the framing process, which increases speed, accuracy, and decreases wasted materials. This quickly and safely produces squared panels with precise stud placement by means of a framing jig and stud brackets, reducing the time needed to assemble walls by more than 70%.
In an exemplary embodiment of the present invention, there are disclosed a semiautomatic framing and sheathing system comprising a framing jig for framing a wall panel using a top plate, bottom plate and studs and a sheathing jig for attaching sheathing to the framed wall panel.
The system further comprises two parallel horizontal plate holders including a top plate holder to hold the top plate and a bottom plate holder to hold the bottom plate, the bottom plate holder being parallel to and spaced apart from the top plate holder, two parallel horizontal nail gun tracks including a top nail gun track above the top plate holder and a bottom nail gun track below the bottom plate holder, two parallel horizontal bars for mounting stud brackets including a top stud bracket bar below the top plate holder and a bottom stud bracket bar above the bottom plate holder, a plurality of spaced apart stud brackets removably attached to the stud bracket bars to hold the studs in place, a nailing device secured to and running the length of the horizontal nail gun tracks, four parallel vertical tubes attached to the plate holders having wheels to support the framing jig, and two pneumatic rams each connecting with two of parallel vertical tubes to adjust a distance between the two plate holders whereby adjusting a height of the wall panel. The stud brackets are removably and rigidly attached to the stud bracket bars in predetermined locations at a regular interval for conventional wall panels and can be detached and reattached to the stud bracket bars at different locations to adjust the space between studs.
The system further comprises two parallel horizontal carriage support rails including a top carriage support rail above the top plate holder and a bottom carriage support rail below the bottom plate holder, a motorized carriage supported by and extending between the two parallel carriage support rails, having two ends each having rollers to slide over each of the two carriage support rails and two separate parallel vertical nail gun tracks extending between the two ends, and—a nailing device including a plurality of nail guns secured to and running the length of the vertical nail gun tracks.
The more important features of the invention have thus been outlined in order that the more detailed description that follows may be better understood and in order that the present contribution to the art may better be appreciated. Additional features of the invention will be described hereinafter and will form the subject matter of the claims that follow.
Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
The foregoing has outlined, rather broadly, the preferred feature of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention and that such other structures do not depart from the spirit and scope of the invention in its broadest form.
BRIEF DESCRIPTION OF THE DRAWINGS
Other aspects, features, and advantages of the present invention will become more fully apparent from the following detailed description, the appended claim, and the accompanying drawings in which similar elements are given similar reference numerals.
FIG. 1 shows a top view of the framing jig and other parts for framing a wall panel of the semiautomatic framing and sheathing system of the present invention.
FIG. 2 shows a side view of nail gun tracks with attached nail guns and photoelectric eyes of the present invention of FIG. 1 .
FIG. 3 shows an isometric view of the framing jig and other parts for framing a wall panel of the semiautomatic framing and sheathing system of the present invention.
FIG. 4 shows a top view of the framing jig and other parts for framing a wall panel of the semiautomatic framing and sheathing system according to another embodiment of the present invention wherein the wall panel is on top of the framing jig.
FIG. 5 shows a top view of the sheathing jig and carriage of the system according to the present invention.
FIG. 6 shows a side view of nail gun bars of the system in FIG. 5 .
FIG. 7 shows an isometric view of the sheathing jig and carriage of the system according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 , there is shown an overhead view of the present invention. The device is comprised of a semiautomated framing system for use in construction of wall panels for residential construction. The system uses individual nail guns or banks of 40 or more pneumatic nail guns automatically controlled by photoelectric eyes, valves, solenoid triggers, rams and computers.
The system 100 comprises a framing jig 10 . Referring to FIG. 1 , there is shown a top view, of the framing jig 10 and parts involving in the process of framing wall panels according to one embodiment of the present invention. The system comprises a framing jig 10 which may be constructed from angle iron and square tubing. The system 100 further comprises a pair of horizontal angle iron plate holders including a top 11 and bottom 12 plate holders that run parallel to each other holding the top and bottom plates of a wall panel in place. The system 100 further comprises a pair of nail gun tracks which run horizontally and parallel to one another including a top nail gun track 15 which is above the top plate holder and a bottom nail gun track 16 which is below the bottom plate holder. The pair of nail gun tracks provides a place to attach a nailing device 17 for each 16″ or 24″ OC stud. The system 100 further comprises a pair of horizontal and parallel bars for mounting stud brackets including a top bar 21 which is below the top plate holder and a bottom 22 bar which is above the bottom plate holder. The system 100 further comprises a nailing device 17 . The system 100 further comprises stud brackets 19 (see FIG. 2 ) which are designed to hold the studs in place.
Referring to FIG. 2 there is shown a side view of nail gun tracks with attached nail guns 15 , 16 , nail guns 17 , and stud bar 21 , 22 with brackets 19 of the present invention. The system further comprises photoelectric eyes 25 or mechanical stops near the nail gun to sense the presence of the studs. The system 100 further comprises four vertical square tubes 13 that utilize either wheels 14 or stands. These tubes can attach to the plate holders 11 , 12 . Rollers 14 easily move the framed wall panel to the sheathing jig 40 . See FIG. 2 Diagonal braces can be added to strengthen the frame.
To better illustrate the system, referring to FIG. 3 there is shown an isometric view of the framing jig 10 and other parts of the system 100 involving in framing. The system 100 further comprises pneumatic or hydraulic rams 23 , each connecting to two parallel vertical supports 13 across the top and bottom plate holders 11 , 12 to adjust the distance between the two plate holders whereby adjusting the height of the wall.
In one embodiment, the stud brackets are of U-shape. In one embodiment, the location where the stud brackets 19 are attached to the stud bracket bars are predetermined so that a worker does not need to measure and mark the location of the studs on the top and bottom plates and thus can save time for framing wall panels. The brackets may be rigidly affixed to the bracket bars at regular intervals. The regular intervals between the brackets may be fixed at any of a number of common dimensions employed in framing for the spaces between studs. For example, a common spacing would be 16 and/or 24 inches on center. However, in another embodiment, the stud brackets 19 may be detached from and repositioned at or slid to different locations along the stud bracket bars to achieve a different spacing, so that the space between studs can be adjusted.
In one embodiment, the nailing device 17 includes 40 or more nail guns as shown in FIGS. 1 and 3 . The location where the nail guns attached to the nail gun tracks are predetermined. The nail guns may be rigidly attached to the nail gun tracks at regular intervals corresponding to the intervals of the stud brackets so that the nail guns can appropriately apply nails to fasten the studs to the plates. In this embodiment, each nail guns may be controlled by corresponding photoelectric eyes. When the photoelectric eyes sense the presence of a stud, it activates the corresponding nail guns. When the photoelectric eye senses an open area, as in a window, it deactivates the nail gun.
Referring to FIG. 5 there is disclosed another embodiment of the framing jig of the present invention. In this embodiment, the nailing device 17 includes two nail gun banks with photoelectric eyes 25 . Each nail gun bank with the photoelectric eye is attached to each end of a carriage 27 which slides along the nail gun tracks and apply nails to fasten studs to the plates when the photoelectric eyes sense the presence of a stud, it activates the corresponding nail gun. When the photoelectric eye senses an open area, as in a window, it deactivates the nail gun.
The system 100 further comprises a sheathing jig 40 . Referring now to FIG. 5 , there is shown an overhead view of the sheathing jig 40 and carriage with two nail gun tracks 41 . The sheathing jig 40 utilizes the framing jig in FIGS. 1 and 2 for its base. The system further comprises a pair of horizontal angle iron plate holders including a top 43 and bottom 44 plate holders that run parallel to each other holding the top and bottom plates of a framed wall in place. The system 100 further comprises a pair of horizontal carriage rails 45 , 46 which run parallel to and outside the top and bottom plate holders. It means the top carriage rail locates above the top plate holder and the bottom carriage rail locates below the bottom plate holder.
The system 100 further comprises a motorized carriage 41 which is supported by and extending between the two parallel carriage support rails. The motorized carriage has two ends 47 each having a roller 48 (as indicated in dashed line to show a transparent view) to slide over each of the two carriage support rails 45 , 46 as well as two separate parallel vertical nail gun tracks 49 extending between the two ends 47 .
The motorized carriage 41 extends between the two carriage support rails 45 , 46 , meaning the motorized carriage 41 spans the height of the wall plus the possible sheathing overlaps on the top and bottom of the wall panel. The system further comprises nail guns 51 . The carriage 41 supports two separate nail gun tracks 49 with attached nail guns 51 that run the height of the wall, operating separately or together. The nail gun tracks slide vertically for 6″, 4″ or 2″ edge nailing and horizontally for double studs (see FIG. 6 ). The carriage 41 moves sideways across the panel stopping to nail field and edges. When the carriage 41 reaches the end of the panel, the carriage returns in the opposite direction nailing sheathing to the bottom, top, and crown plates (and where applicable the top and bottom of windows and the top of door).
To better illustrate the system for sheathing a framed wall, referring to FIG. 7 there is disclosed an isometric view of the sheathing jig 40 and carriage with two nail gun tracks 41 .
While there have been shown and described and pointed out the fundamental novel features of the invention as applied to the preferred embodiments, it will be understood that the foregoing is considered as illustrative only of the principles of the invention and not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are entitled.
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The present invention describes a system for framing and sheathing wall panels. The system comprises a framing jig, sheathing jig, computer, carriage, photoelectric eyes, pneumatic or hydraulic rams, solenoids and other triggers, controls, switches, and banks of nail guns. The system can be quickly or automatically adjusted for building walls with various sized studs, stud spacing, and for building walls of varying height. The system helps to automate the framing process, which increases speed, accuracy, and decreases wasted materials. This quickly and safely produces squared panels with precise stud placement by means of a framing jig and stud brackets, reducing the time needed to assemble walls.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to toothbrushes and more particularly pertains to a toothbrush which may be reduced in size for travel or storage and which has a replaceable bristle head thereon.
2. Description of the Prior Art
The use of travel type toothbrushes is known in the prior art. More specifically, such brushes heretofore devised and utilized for the purpose of brushing teeth are known to consist basically of familiar, expected and obvious structural configurations, notwithstanding the myriad of designs encompassed by the crowded prior art which have been developed for the fulfillment of countless objectives and requirements. Such brushes have been provided with replaceable heads and some have provisions for folding, coming apart or otherwise reducing in size. Typical of such brushes are those illustrated in U.S. Pat. Nos. 4,850,074; 4,866,809; 4,543,679; 5,144,712; and Des. 323,745.
In this respect, the toothbrush according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides a device primarily developed for the purpose of reducing to a very small travel or storage size having a long-lasting permanent handle and a replaceable toothbrush head removably connected thereto.
Therefore, it can be appreciated that there exists a continuing need for new and improved toothbrushes which can be miniaturized when not in use. In this regard, the present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of toothbrushes now present in the prior art, the present invention provides an improved toothbrush construction wherein the same can be utilized for easy adjustment to a storage or travel size. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved toothbrush which has all the advantages of the prior art devices and none of the disadvantages.
To attain this, the present invention can be briefly described as a toothbrush comprising a multi-section telescoping stainless steel tubular handle and means to pivotally connect a replaceable toothbrush head thereto.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved toothbrush which has all the advantages of the prior art brushes and none of the disadvantages.
It is another object of the present invention to provide a new and improved toothbrush which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved toothbrush which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved toothbrush which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such brushes economically available to the buying public.
Still another object of the present invention is to provide a new and improved toothbrush having a long-lasting permanent handle and a replaceable bristle head therefor.
Yet another object of the present invention is to provide a new and improved collapsible toothbrush.
Even still another object of the present invention is to provide a new and improved telescoping handle toothbrush.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a perspective view of a prior art toothbrush having a removable brush head thereon.
FIG. 2 is a perspective view of yet another prior art device showing a folding toothbrush.
FIG. 3 is a perspective view of the toothbrush of the present invention in open position for use.
FIG. 4 is a perspective view of the toothbrush of FIG. 3 in collapsible position for storage or travel.
FIG. 5 is a detail plan side view of the head portion of the toothbrush of FIG. 3.
FIG. 6 is a sectional view on line 6--6 of FIG. 3.
FIG. 7 is an exploded perspective view of the brush head and the means for removably connecting it to the handle of the toothbrush of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIG. 3 thereof, a new and improved toothbrush embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, it will be noted that the toothbrush 10 comprises four elements, a telescoping handle section 11, a brush head 12, means 13 to connect the head 12 to the handle 11 and a hanger member 14. Handle section 11 consists of a plurality of small diameter short telescoping tubular members 15 frictionally engaging one with another and made of stainless steel, thin wall tubing. This permits the unit 10 to be collapsed into a very short format as is shown in FIG. 4 for storage or travel purposes while the frictional engagement keeps the handle extended until deliberately collapsed. Since such handle 11 is formed of stainless steel members 15 it is extremely durable and long lasting. The brush head 12 is of a much shorter life (dentists usually recommend changing brushes every three months or so) and accordingly is considered for the purposes of this invention to be a disposable item. Preferably it is constructed of plastic with synthetic bristles 16 and, as described in connection with FIGS. 5 and 7 is easily replaceable on handle 11. Hanger member 14 (also of stainless steel) permits hanging the brush unit 10 up after use if desired.
FIG. 4 illustrates the travel mode for the unit 10. Sections 15 of handle 11 are telescoped, one within another, to form a very small package, not much larger than the head 12 of unit 10. This drawing also illustrates that head 12 is pivotally mounted to the end 17 of handle 11 as is shown in more detail below.
FIGS. 5 and 7 illustrate the connection of handle 11 to brush head 12. Extending axially from the end 17 of handle 11 is a plug member 18 threaded into such end 17 of the tubular section 15. Such plug member 18 carries thereon a pair of laterally projecting circular cross-sectioned pins 19 and 20. These are not axially aligned but have one pin 20 vertically disposed above and horizontally displaced from the other pin 19. Pin 20 serves as a stop to hold head 12 at the correct angle for brushing when the brush 10 is in use. This is accomplished by providing brush head 12 with a projecting cam member 21 which slidably engages alongside the flat portion 22 of plug end and has an aperture 23 therein to fit over pin 20. Projecting from cam member 21, and defined by a spiral outer perimeter shape of the cam member, is a flat stop plate section 24 which, when brush head 12 is pivoted on pin 20, comes into engagement with top pin 19 preventing further rotation of head 12. These components are most clearly visible in FIG. 7 which also shows the threaded end 25 of plug 18. When brush head 12 is considered due for replacement, head 12 is slipped off pin 20 and replaced with a new head of the same construction.
FIG. 6 illustrates the telescoping arrangement of segments 15 in handle member 11. It will be noted that angled detents 26 are provided at the ends of each tube segment 15, such detents 26 engaging when the handle is extended and preventing separation of segments 15 from each other.
As to the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A toothbrush comprising a multi-section telescoping stainless steel tubular handle and rotating connector to pivotally connect a replaceable toothbrush head thereto.
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FIELD OF THE INVENTION
The present invention relates to aminocarbonate compounds and their use as catalysts for the production of urethane polymers and/or urea polymers.
BACKGROUND OF THE INVENTION
Catalysts for the production of polyurethanes are known (see J. H. Saunders and K. C. Frisch, Polyurethanes Chemistry and Technology, 1962, p. 73 ff.). Said catalysts are organic, organometallic and inorganic compounds. From the group of organic compounds particularly tertiary amines, e.g. bis(dimethylaminoethyl)ether (U.S. Pat. No. 3,400,157), aminoorthoester (U.S. Pat. No. 3,786,029) and β,β'-dimorpholinodiethylester (DE 2 138 403) are used. Examples for metal Catalysts are Sn(II)/Sn(IV) salts or Fe(III) salts (DE 3 938 203 A1).
However, the catalysts used at present have many disadvantages. A great number of amines, e.g. bis(dimethylaminoethyl)ester, have a very unpleasant odor which is disadvantageous both during the production of polyurethanes and in the processing of polyurethane materials produced with the aforesaid catalysts. Furthermore, it has hitherto been impossible to definitely infer the odor and the properties as catalysts for the production of polyurethanes from the chemical structure of a compound.
Another criterion for the classification of a catalyst is the equilibrium between its activity and the isocyanate-alcohol reaction and the isocyanate-water reaction. When comparing amine catalysts of similar chemical structures, e.g. bis(dimethylaminoethyl)ether and dimethylaminopropyldimethylaminoethylether, an extension by only one methylene group will result in a significant drop in activity and, above all, in a considerable shift in the catalytic impact on the isocyanate-water reaction toward the isocyanate-alcohol reaction. A catalyst having a strong blowing activity will thus degenerate into a medium-active gelling catalyst (see N. Malwitz et el., Proceedings of the 30th Annual Polyurethane Technical/Marketing Conference, Oct. 15-17, 1986, p. 338-353).
Therefore, in order to reduce the odor of amine catalysts, amine compounds having high molecular weights and, incidental thereto, low vapor pressures have been used. However, since such compounds present low mobilities and, thus, low activities, great quantities are required for production.
Moreover, according to the prior art, the odor is reduced by using amino catalysts with substituents having isocyanate-reactive hydrogen atoms. Examples for such catalysts are dimethylethanolamine and dimethylaminopropylamine. In JP-A-59 191 743 the products obtained by reaction of polyamine with carbonates as polyurethane catalysts have been described. A great disadvantage of the prior art is that the amino catalysts remain in the polyurethane which, as is generally known, may catalyze the back reaction of the urethane groups or urea groups and would deteriorate the hydrolysis and ageing resistance.
Therefore, it was the object of the present invention to provide novel compounds which are suitable as catalysts for the production of polyurethanes and/or polyureas while avoiding or reducing the aforementioned disadvantages.
SUMMARY OF THE INVENTION
In accordance with the present invention the problem is solved by providing aminocarbonate compounds corresponding to the following general formula (I) ##STR1## wherein R 1 and R 2 are equal or different and R 1 comprises a tertiary amino group and also R 2 comprises a tertiary amino group, or constitutes methyl, a branched or unbranched alkyl group of 2 to 20 carbon atoms, phenyl or an alkyl-substituted phenyl group of up to 20 carbon atoms and, preferably, alkyl of 1 to 3 carbon atoms or phenyl.
R 1 and R 2 , if also R 2 comprises a tertiary amino group, is (are) preferably a group corresponding to the following general formula (II) ##STR2## wherein Z 1 and Z 2 are equal or different and each constitutes methyl or a branched or unbranched alkyl group of 2 to 6 carbon atoms or together form a morpholine o group or a piperazine group corresponding to the following general formulas (III) and (IV), respectively, ##STR3## wherein the groups R 3 and R 4 and the groups R 5 and R 6 are equal or different and each constitutes hydrogen and/or an alkyl group of 1 to 2 carbon atom, and R 7 is hydrogen or an alkyl group of 1 to 2 carbon atoms, and Y constitutes an unbranched or branched alkylene of 2 to 10 carbon atoms or an unbranched or branched alkyl ether of 2 to 10 carbon atoms and 1 to 3 oxygen atoms.
The compounds of the invention have surprising characteristics when used as catalysts:
they have sufficiently high activities
they have low odors
they can be prepared from inexpensive starting materials
The catalysts of the invention do have a slightly lower activity than known compounds of similar structures, but the basic characteristic is unchanged. For instance, the balance between blowing and gelling catalysis of the catalyst of the invention, bis(dimethylaminoethyl)carbonate (I) corresponds to that reached when using bis(dimethylaminoethyl)ethers. The dimorpholinoethylcarbonate catalyst (II) of the invention, like β,β'-dimorpholinodiethylether, only influences the isocyanate-water reaction. It is advantageous, in accordance with the present invention, that the catalysts I and II of the invention are almost odorless.
DETAILED DESCRIPTION OF THE INVENTION
In the general formula (I) for the compounds of the invention ##STR4## R 1 and R 2 constitute equal or different groups, R 1 comprising a tertiary amino group. If R 2 does not comprise a tertiary amino group, R 2 preferably is --CH 3 , --C 2 H 5 , C 3 H 7 or phenyl. If R 1 and/or R 2 contain a tertiary amino group corresponding to the general formula (II), ##STR5## Y preferably constitutes an alkylene of 2 to 4 carbon atoms. If Y is a branched or unbranched alkyl ether, the same preferably has 2 to 4 carbon atoms and 1 oxygen atom.
Z 1 and Z 2 preferably constitute alkyl of 1 to 3 carbon atoms, particularly methyl.
Z 1 and Z 2 together may form a morpholine derivative or a piperazine derivative corresponding to the general formula (III) and (IV), respectively, ##STR6## wherein the groups R 3 to R 7 preferably constitute hydrogen atoms and/or methyl.
The compounds of the invention can be provided by reacting amino alcohols with alkyl carbonates.
Examples for amino alcohols as appropriate starting materials are N,N,-di-methylmethanolamine, N,N-dimethylethanolamine, N,N-dimethylpropanolamine, N,N-dimethylbutanolamine as well as the corresponding N,N-diethyl compounds and N,N-dipropyl compounds, hydroxymethylmorpholine, hydroxyethylmorpholine, hydroxypropylmerpholine, hydroxybutylmorpholine, 1-N,N-dimethylamino-1,2-dimethyl-2-hydroxyethane, 1-N,N-dimethylamino-1-methyl-1-hydroxymethane, 1-N,N-dimethylamino-1,2,4,5-teramethyl-3-oxa-5-hydroxypentane, 2-morpholinylethan-1-ol, 2-(3,5-dimethylmorpholinyl)-ethan-1-ol, 2-piperazinylethan-1-ol, 2-(1-N-methylpiperazinyl)-ethan-1-ol, 2-(1-N-methyl-3,5-dimethylpiperazinyl)-ethan-1-ol, hydroxyethoxyethylmorpholine, hydroxyethoxyethylpiperazine, 1-(1-N-methylpiperazinyl)-3-oxa-5-hydroxypentane as well as compounds corresponding to the following general formulas (V) and (VI), ##STR7## wherein R 19 and Y have the aforementioned meanings.
The alkyl carbonates preferably comprise an alkyl group of 1 to 3 carbon atoms. Lewis bases are appropriate for accelerating the reaction. Said bases are metals, preferably from the main groups I and II of the periodic system, hydroxy compounds of said metals or tertiary amines.
The compounds of the invention are appropriate for the production of solid or cellular polyurethanes. Said catalysts of the invention may be used alone or in combination with commercial catalysts which are suitable for the production of polyurethanes. The commercial catalysts may be chosen from the group of tertiary amines, carboxylic acid salts, phosphorus compounds and metal compounds.
Examples for commercial catalysts are the following amine catalysts: triethylenediamine, bis(dimethylaminoethyl)ether, dimethylcyclohexylamine, dimethylbenzylamine, dimethylethanolamine, N-methylmorpholine, N-ethylmorpholine, dimorpholinodiethylether, tetramethylhexamethylenediamine, 2-methyl-2-azanorbornane, 2-(hydroxyethoxyethyl)-2-azanorbornane, 2-(2-dimethylaminoethoxy)-ethanol, 3-dimethylaminopropyl-diisopropanolamine, bis(3-dimethylaminopropyl)-isopropanolamine and 2-dimethylaminoethyl-3-dimethylaminopropylether.
Examples for commercial metal catalysts are the following: metal salts, preferably tin, of a carboxylic acid and mixed alkyl derivatives and carboxylic acid derivatives of a metal. For instance, dibutyl tin dilaurate, dibutyl tin diacetate, diethyl tin diacetate, tin dioctoate and mixtures thereof are appropriate.
Furthermore, a foam stabilizer, e.g. from the group of silanes or siloxanes, may be added (U.S. Pat. No. 3,194,773).
In the production of foamed polyurethanes using the compounds of the invention as catalysts polyisocyanates may be used, e.g. hexamethylene diisocyanate, phenylene diisocyanate, toluylene diisocyanate, isophorone diisocyanate, naphthylene diisocyanate and 4,4'-diphenylmethane diisocyanate. In particular, 2,4-toluylene diisocyanate or 2,6-toluylene diisocyanate as well as mixtures thereof are appropriate. Other suitable polyisocyanates are commercially available mixtures, known as `crude MDI`, which contain approx. 60 % of the 4,4'-diphenylmethane diisocyanate and other isomers or analogous, higher-molecular polyisocyanates. Mixtures of toluylene diisocyanate and 4,4'-diphenylmethane diisocyanate and the polyisocyanates known as `crude MDI` are also particularly appropriate. In addition, `prepolymers` of the aforementioned polyisocyanates which are comprised of the reaction products of polyisocyanates and polyether polyols or polyester polyols are suitable.
The polyol component which is capable of reacting with the polyisocyanates may be a polyester polyol or a polyether polyol. Suitable polyols are polyalkylene polyols or polyester polyols. Particularly appropriate polyalkylene polyols include polyalkylene oxide polymers, e.g. polyethylene oxide polymers and polypropylene oxide polymers as well as mixed polymerized polyethylene polymers and polypropylene oxide polymers. Starting compounds for said polyalkylene polyols are for instance ethylene glycol, propylons glycol, 1,3-butanediol, 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, diethylene glycol, dipropylene glycol, pentaerythritol, glycerol, diglycerol, trimethylolpropane, cyclohexane diol, sucrose and saccharose.
Suitable polyester polyols include the products obtained by the reaction of dicarboxylic acids with an excess of diols, e.g. adipic acid with ethylene glycol or butanediol or by the reaction of lactones with an excess of a diol, e.g. caprolactone and propylene glycol.
The following examples are illustrative of this invention.
EXAMPLE 1
Bis(dimethylaminoethyl)carbonate (I)
Into a flask equipped with a reflux cooler, a water separator and a dropping funnel, there were charged 113.5 grams (1.25 moles) of dimethyl carbonate. The substance was heated to 80° C. A solution of 1.4 grams (0.025 moles) of potassium hydroxide in 225.0 grams (2.5 moles) of dimethylethanolamine was then added in drops over a period of 30 minutes. The methanol formed during the reaction was removed by azeotropic distillation using cyclohexane as an entraining agent.
After 24 hours the liquid phase was distilled off from the precipitate. The clear solution thus obtained was distilled under oil pump vacuum (0.1 Torr). The temperature at the bottom was 110° C. Fraction 1 (head temperature 30°-45° C.) contained approx. 60% of the desired compound, while fraction 2 (head temperature 73° C.) contained approx. 98% thereof. The total yield was 35% of theoretical. After purifying distillation (0.05 Torr) bis(dimechylaminoethyl)carbonate (I) was obtained in 99.2% purity (head temperature 61° C., boiling point of I: 61° C., yield: 34% of theoretical).
EXAMPLE 2
Dimorpholinoethylcarbonate (II)
Into a flask equipped as described hereinbefore, there were charged 329.0 grams (2.5 moles) of hydroxyethylmorpholine. Dissolved therein were then 6.0 grams (0.1 mole) of potassium hydroxide. Thereafter 35 ml of cyclohexane were added. The solution was heated to 90° C. 121.5 grams (1.35 moles) of dimethyl carbonate were added in drops within 10 minutes. After a reaction time of 36 hours the batch was filtered and then distilled under oil pump vacuum (0.1 Torr). After removing three low-boiling fractions, the desired product was obtained at a head temperature of 160°-63° C. The yield was 55% of theoretical. After purifying distillation (0.3 Torr) dimorpholinoethylcarbonate (II) was obtained in 98.9% purity (head temperature: 181° C., boiling point of II: 181° C., yield 54% of theoretical).
EXAMPLE 3
Use of the compounds I and II prepared as described in Examples 1 and 2 as catalysts in combination with a tin catalyst for the production of flexible polyurethane (PUR) foam.
The flexible PUR foam was prepared using the handmix technique. First, component A comprised of an appropriate polyol, a foam stabilizer, a tin catalyst, the amine catalyst of the invention and water as blowing agent was stirred for 50 seconds with a high-performance stirrer at 1,000 r.p.m. The adequate amount of an appropriate polyisocyanate (component B) was then added. Stirring was continued for 7 seconds at 2,500 r.p.m. The foamable mixture was poured into a cubic mold (edge length: 27 cm). The rise curves were recorded by a measuring system coupled to an ultrasonic measuring probe. The cream times, rise times and rise heights were determined from the rise curves.
The following foam formulation was used:
______________________________________Polyol (1) 100.0 gramsIsocyanate (2) 59.0 gramsWater 5.0 gramsStabilizer (3) 1.0 gramTin catalyst (4) 0.2 gramAmine catalyst see Table 1Index 106(isocyanate/polyol ratio)______________________________________ (1) branched polyol having an OH number of 45 to 50 and an average molecular mass of 3,400 g/mole (2) toluylene diisocyanate comprised of 80% 2,4isomers and 20% 2,6isomers (3) polyether siloxane (4) tin dioctoate
TABLE 1______________________________________Foaming Characteristics Cream Quantity Time Rise Time Density TemperatureCatalyst pphp! s! s! kg/m.sup.2 ! °C.!______________________________________DMDEE (1) 0.2 16 104 26.5 22II*. 0.2 17 112 25.2 22CD (2) 0.1 7 59 23.6 30I* 0.1 12 87 24.8 30I* 0.2 10 77 24.1 30Mixture A 0.2 7 73 19.7 30Mixture B.sup.+ 0.2 7 75 19.8 30Mixture B.sup.+ 0.15 8.5 77 19.9 30Mixture B.sup.+ 0.1 9 79 19.7 30Mixture B.sup.+ 0.05 9 81 19.2 30Mixture A 0.2 18 103 21.1 20Mixture B.sup.+ 0.2 18 105 21.2 20TD 100 (3) 0.2 16 74 20.3 21CD (2) 0.2 12 58 20.0 21I* 0.2 15 104 21.1 21______________________________________ (1) DMDEE = dimorpholinodiethylether **dimorpholinoethylcarbonate according to the invention (2) CD = bis(dimethylaminoethyl)ether *bis(dimethylaminoethyl)carbonate according to the invention (3) TD 100 = triethylenediamine Mixture A 12 percent by weight of TD 100, 19 percent by weight of dimethylethanolamine, 14 percent by weight of CD, 55 percent by weight of dipropylene glycol Mixture B.sup.+ according to the invention: 24 percent by weight of the catalyst as defined in Example 1, 12 percent by weight of TD 100, 19 percent by weight of dimethylethanolamine, 45 percent by weight of dipropylene glycol
EXAMPLE 4
Use of compound II prepared as described in Example 2 as catalyst for the production of flexible polyurethane (PUR) foam.
The flexible PUR foam was prepared using the handmix technique. First, component A comprised of an appropriate polyol, a foam stabilizer, the amine catalyst and water as blowing agent was stirred for 30 seconds with a high-performance stirrer at 1,000 r.p.m. The adequate amount of an appropriate polyisocyanate (component B) was then added. Stirring was continued for 5 seconds at 2,000 r.p.m. The foamable mixture was poured into a cubic mold (edge length: 27 cm). The rise curves were recorded by a measuring system coupled to an ultrasonic measuring probe. The cream times, rise times and rise heights were determined from the rise curves.
The following foam formulation was used:
______________________________________Polyol (1) 100.0 gramsIsocyanate (2) 20.8 gramsIsocyanate (3) 24 8 gramsStabilizer (4) 1.0 gramWater 3.7 gramsAmine co-catalyst (5) 0.4 gramAmine catalyst see Table 2______________________________________ (1) polyester polyol having an OH number of 57 to 63 and an average molecular weight of 2,400 g/mole (2) toluylene diisocyanate comprised of 80% of 2,4isomer and 20% of 2,6isomer (3) toluylene diisocyanate comprised of 65% of 2,4isomer and 35% of 2,6isomer (4) polyether siloxane (5) dimethylbenzylamine
TABLE 2______________________________________Foaming Characteristics Quantity Cream Time Rise Time DensityCatalyst pphp! s! s! kg/m.sup.3 !______________________________________N-Methylmorpholine 3.0 15 82 33.3Dimethylpiperazine 1.0 15 67 28.2II** 4.0 19 110 33.5______________________________________ **dimorpholinoethylcarbonate of the invention
EXAMPLE 5
Use of the compounds prepared as described in Examples 1 and 2 as catalysts for the production of polyurethane (PUR) rigid foam.
The PUR rigid foam was prepared using the handmix technique. First, component A comprised of an appropriate polyol, a foam stabilizer, water and the amine catalyst was stirred for 50 seconds with a high-performance stirrer at 1,000 r.p.m. The adequate amount of a physical blowing agent was then added and stirred for 10 seconds at 1,000 r.p.m. Thereafter, the adequate amount of an appropriate polyisocyanate (component B) was added. Stirring was continued for 7 seconds at 2,500 r.p.m. The foamable mixture was poured into a cubic mold (edge length: 27 cm). The rise curves were recorded by a measuring system coupled to an ultrasonic measuring probe. The cream times, rise times and rise heights were determined from the rise curves.
The following foam formulation was used:
______________________________________Polyol (1) 100.0 gramsIsocyanate (2) 126.0 gramsWater 2.0 gramsStabilizer (3) 1.5 gramsBlowing agent (4) 31.0 gramsAmine catalyst see Table 3Index 105______________________________________ (1) polyol: branched polyol having an OH number of 6.77 mmol/g (2) isocyanate: mixture of isomers of the diphenylmethane diisocyanate with an NCO content of 7.5 mmol/g (3) polyether siloxane (4) Frigen R 11 (CC13F)
TABLE 3______________________________________Foaming Characteristics Quantity Cream Time Rise Time DensityCatalyst pphp! s! s! kg/m.sup.3 !______________________________________Mixture C + 8 25 128 24.1Mixture D + 4 10 220 23.5Mixture E + 4 34 321 23.2Mixture F + 8 30 137 24.3Mixture G + 4 10 253 24.6Mixture H + 4 38 414 24.2I* 4 60 600 24.7II** 4 180 620 42.6TD 100 (1) 2 32 159 24.5CD (2) 2 10 256 24.5DMCHA (3) 2 43 394 24.0without catalyst -- >400 unmeasurable --______________________________________ + according to the invention *bis(dimethylaminoethyl)carbonate according to the invention **dimorpholinoethylcarbonate according to the invention (1) TD 100 = triethylenediamine (2) CD = bis(dimethylaminoethyl)ether (3) DMCHA = dimethylcyclohexylamine Mixture C 1.0 mg of catalyst I of the invention as defined in Example 1, 1.0 g of triethylenediamine (TD 100), 2.0 g of dipropylene glycol Mixture D 1.0 g of catalyst I of the invention as defined in Example 1, 1.0 g of bis(dimethylaminoethyl)ether (CD) Mixture E 1.0 g of catalyst I of the invention as defined in Example 1, 1.0 mg of dimethylcyclohexylamine (DMCHA) Mixture F 1.0 g of catalyst II of the invention as defined in Example 2, 1.0 g of triethylenediamine (TD 100), 2.0 g of dipropylene glycol Mixture G 1.0 g of catalyst II of the invention as defined in Example 2, 1.0 g of bis(dimethylaminoethyl)ether (CD) Mixture H 1.0 g of catalyst II of the invention as defined in Example 2, 1.0 mg of dimethylcyclohexylamine (DMCHA)
EXAMPLE 6
Use of the compounds prepared as described in Examples 1 and 2 as catalysts for the production of solid polyurethanes.
The polyurethane casting resin was prepared by mixing component A comprised of an appropriate polyol, additives, e.g. heavy spar, a zeolite for binding the water, and the catalyst with component B consisting of an appropriate polyisocyanate. For the characterization, the pot life, the demolding time and the temperature of the PUR casting resin when reaching the pot life were determined.
The following PUR casting resin formulation was used:
______________________________________Polyol (1) 100.0 gramsIsocyanate (2) 35.0 gramsCatalyst see Table 4______________________________________ (1) trifunctional polyether polyol based on propylene oxide adducts to trimethylol propane, hydroxyl groups content = 11.3%, viscosity (20° C.): 600 mPa · s (2) 4,4methylenediphenylisocyanate having an NCO content of 31.0%, viscosity (20° C.): 110 mPa · s
TABLE 4______________________________________Characteristics of the PUR Casting Resin Temperature/ Demolding Quantity Pot Life Pot Life TimeCatalyst pphp! minutes! °C.! minutes!______________________________________Mixture K 0.25 11 70 60I* 0.4 10 71 60II** 0.4 40 42 90without catalyst -- >50 36 150______________________________________ Mixture K: 17.4 percent by weight of 2methyl-2-azanorbornane, 60 percent by weight of β,βdimorpholinodiethylether, 22.6 percent by weigh of 2ethylhexanoic acid *bis(dimethylaminoethyl)carbonate according to the invention **dimorpholinoethylcarbonate according to the invention
The polyurethanes prepared with the catalysts of the invention were odorless. The odor was significantly lower than that of prior art products when using the catalysts of the invention in combination with amine co-catalysts. The amine odor then detectable was attributable to the co-catalysts.
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Diaminocarbonate compounds are disclosed which are particularly suitable as low-odor catalysts for the production of solid or cellular urethane polymers and/or urea polymers. The compounds are obtainable by reacting amino alcohols with alkyl carbonates.
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BACKGROUND OF THE INVENTION
This invention relates to new organic compounds useful as pharmaceutical agents. The novel compounds of the present invention are antiatherosclerotic agents capable of ameliorating atherosclerosis by counteracting the formation or development of atheromatous lesions in the arterial wall of mammals. The invention also relates to the chemical synthesis of the novel compounds disclosed herein. In addition, the invention pertains to novel pharmaceutical compositions for the utilizaiton of these compounds in the treatment of disease in mammals. Further, the invention contemplates methods for treating atherosclerosis in a manner designed to prevent, arrest, or reverse the course of the disease.
Atherosclerosis is a form of arteriosclerosis characterized by lipid accumulation in and thickening of the arterial walls of both medium- and large-sized arteries. Arterial walls are thereby weakened, and the elasticity and effective internal size of the artery is decreased. Atherosclerosis is the most common cause of coronary artery disease and is of great medical importance since the occlusion of medium- and large-sized arteries diminishes the supply of blood to vital organs such as the heart muscles and the brain. The sequelae to atherosclerosis include ischemic heart disease, heart failure, life-threatening arrythmias, senility, and stroke.
The fact that cholesterol is a major component of atherosclerotic lesions or plagues has been known for more than 100 years. Various researchers have studied the role of cholesterol in lesion formation and development and also, more importantly, whether lesion formation can be prevented or lesion development arrested or reversed. Atheromatous lesions have now been shown [Adams, et al., Atherosclerosis, 13, 429 (1974)] to contain a greater quantity of esterified as opposed to unesterified cholesterol than the surrounding undiseased arterial wall. The intracellular esterification of cholesterol with fatty acids is catalyzed by the enzyme "Fatty acyl CoA: cholesterol acyl transferase" or ACAT, and the accumulation and storage of cholesterol esters in the arterial wall is associated with increased levels of this enzyme [Hashimoto and Dayton, Atherosclerosis, 28, 447 (1977)]. In addition, cholesterol esters are removed from the cells at a slower rate than unesterified cholesterol [Bonjers and Bjorkerud, Atherosclerosis, 15, 273 (1972) and 22, 379 (1975)]. Thus, inhibition of the ACAT enzyme would diminish the rate of cholesterol esterification, decrease the accumulation and storage of cholesterol esters in the arterial wall, and prevent or inhibit the formation and development of atheromatous lesions. The compounds of the present invention are very potent inhibitors of the ACAT enzyme. Thus, these compounds are useful for controlling and normalizing the cholesterol ester content of mammalian arterial walls. In contrast to the serum hypocholesterolemic agents which are well known in the art to merely lower cholesterol in the blood stream, the compounds of this invention decrease the accumulation and storage of the cholesterol in the arterial walls of mammals. Further, the compounds of this invention inhibit the formation or development of atherosclerotic lesions in mammals. The exact mechanism by which these compounds exhibit this antiatherosclerotic activity is not known, and the invention should not be construed as limited to any particular mechanism of antiatherosclerotic action.
SUMMARY OF THE INVENTION
This invention relates to new organic compounds and more particularly is concerned with aralkanamidobenzoic acids and analogs thereof which may be represented by the following structural formula: ##STR1## wherein A is selected from the group consisting of: ##STR2## B is selected from the group consisting of a chemical bond and, when A is >CH--, also from an optionally branched or unbranched C 1 -C 4 alkylene group; R is selected from the group consisting of hydrogen, C 1 -C 4 alkyl, phenyl, and phenyl substituted with X; X represents one or more substituents independently selected from the group consisting of hydrogen, C 1 -C 4 alkyl, hydroxy, C 1 -C 4 alkoxy, halo, and nitro; Y represents one or more substituents independently selected from the group consisting of hydrogen, C 1 -C 4 alkyl, hydroxy, C 1 -C 4 alkoxy, halo, trifluoromethyl, nitro, amino, acetamido, acetyl, formyl, cyano, carboxy, C 1 -C 4 carboalkoxy, carboxamido, sulfonamido, --CO 2 CH 2 CO 2 C 2 H 5 , --CO 2 CH 2 CO 2 CH 3 , and --CO 2 CH 2 CO 2 H; and the pharmaceutically-acceptable salts thereof.
Preferred embodiments of the invention relate to those compounds wherein A and B taken together represent two carbon atoms joined by either a single or double bond: that is, A is >CH-- and B is --CH 2 -- or A is >C--CH-- and B is a chemical bond. Of these, the more preferred are the compounds wherein R is phenyl substituted with X, and X is chloro, methyl, or methoxy. Of the latter, the most preferred are those compounds wherein Y is hydrogen, carboalkoxy, carboxy, or an alkali metal salt thereof.
Representative specific embodiments involve, for example, 4-[3,3-bis-(p-chlorophenyl)propionamido]benzoic acid; 4-[3,3-bis-(p-tolyl)propionamido]benzoic acid; 4-[3,3-bis-(p-methoxyphenyl)propionamido]benzoic acid; ethyl 4-[3,3-bis-(p-chlorophenyl)propionamido]benzoate; ethyl 4-[3,3-bis-(p-tolyl)propionamido]benzoate; ethyl 4-[3,3-bis-(p-methoxyphenyl)propionamido]benzoate; sodium 4-[3,3-bis-(p-chlorophenyl)propionamido]benzoate; sodium 4-[3,3-bis-(p-tolyl)propionamido]benzoate; sodium[3,3-bis(p-methoxyphenyl)propionamido]benzoate; 4-[3,3-bis-(p-chlorophenyl)-acrylamido]benzoic acid; 4-[3,3-bis-(p-chlorophenyl)acrylamido]benzoate; 4-[3,3-bis-(p-tolyl)acrylamido]benzoate; ethyl 4-[3,3-bis-(p-methoxyphenyl)acrylamido]benzoate; 3,3-bis-(p-chlorophenyl)acrylanilide; 3,3-bis-(p-tolyl)acrylanilide; 3,3-bis-(p-methoxyphenyl)acrylanilide; 3,3-bis-(p-chlorophenyl)propionanilide; 3,3-bis-(p-tolyl)propionanilide; 3,3-bis-(p-methoxyphenyl)propionanilide. Additional specific embodiments include the compounds of Examples 47-58, 60-66, and 68-73.
With reference to the above formula, the invention contemplates as novel compounds per se only those analogs wherein Y is not hydrogen or chloro, A is >CH--, and B is a chemical bond; since two of the compounds of this class are known in the art. Although bis-(p-chlorophenyl)acetanilide and bis-(p-chlorophenyl)aceto-4-chloroanilide are known --O. Grummitt and D. Marsh, J. Am. Chem. Soc., 71, 4156 (1949)--no specific use is reported for either.
This invention also relates to a method of reducing the cholesterol ester content of an arterial wall in a mammal in need of such treatment which comprises administering to said mammal a cholesterol ester-reducing amount of a compound as recited above.
This invention further relates to a method of inhibiting atherosclerotic lesion development in a mammal in need of such treatment which comprises administering to said mammal an atherosclerotic lesion development-inhibiting amount of a compound as recited above.
This invention still further relates to a pharmaceutical composition suitable for reducing the cholesterol ester content of an arterial wall in a mammal in need of such treatment which comprises a cholesterol ester-reducing amount of a compound as recited above and a non-toxic, pharmaceutically-acceptable carrier.
Further still, this invention relates to a pharmaceutical composition suitable for inhibiting atherosclerotic lesion development in a mammal in need of such treatment which comprises an atherosclerotic lesion development-inhibiting amount of a compound as recited above and a non-toxic, pharmaceutically-acceptable carrier.
Finally, this invention relates to a process for preparing compounds as recited above which comprises reacting an acid derivative of the formula: ##STR3## with an aniline of the formula: ##STR4## or reacting a carbonyl compound of the formula: ##STR5## with a phosphonate ester of the formula: ##STR6## wherein R, X, A, B, and Y are as defined hereinabove; J is selected from the group consisting of halo, C 1 -C 4 alkoxy, and C 1 -C 4 alkanoyloxy; and Q is selected from the group consisting of C 1 -C 4 alkyl and phenyl.
DETAILED DESCRIPTION OF THE INVENTION
Many of the compounds of this invention are prepared by reactions of aralkanoyl or aralkenoyl halides with substituted anilines, for example, treatment of 3,3-bis-(p-chlorophenyl)acryloxy chloride with ethyl 4-aminobenzoate yields ethyl 4-[3,3-bis-(p-chlorophenyl)acrylamido]benzoate. Often these reactions are conducted at or below room temperature; however, in certain cases elevated temperatures are required. These reactions may be carried with or without an added acid acceptor, such as triethylamine, using organic solvents such as dichloromethane, chloroform, or tetrahydrofuran. Certain of the products of this type of reaction may be further transformed to yield other compounds of the invention. Examples of such further transformations are the alkaline hydrolysis of ethyl 4-[3,3p-bis-(p-chlorophenyl)acrylamido]benzoate which yields 4-[3,3-bis-(p-chlorophenyl)acrylamido]benzoic acid and the catalytic hydrogenation of ethyl 4-[3,3-bis-(p-chlorophenyl)acrylamido]benzoate which yields ethyl 4-[3,3-bis-(p-chlorophenyl)propionamido]benzoate.
Many of the aralkanoyl and aralkenoyl halides required for the above-described reacitons were not previously known. Their preparation is accomplished by a variety of methods. Certain aralkenoyl halides are obtained by the Wadsworth-Emmons reaction of triethylphosphonoacetate with a benzophenone followed by alkaline hydrolysis and acid halide formation. These Wadsworth-Emmons are conducted at temperatures from 0° C. to 50° C. in ether solvents such tetrahydrofuran or 1,2-dimethoxyethane for periods of 1 to 25 hours. An example of this sequence of reactions is the Wadsworth-Emmons reaction of triethylphosphonoacetate with 4,4'-dichlorobenzophenone which yields ethyl 3,3-bis-(p-chlorophenyl)acrylate. Hydrolysis of this acrylate ester with sodium hydroxide affords 3,3-bis-(p-chlorophenyl)acrylic acid. Treatment of this acrylic acid with thionyl chloride yields 3,3-bis-(p-chlorophenyl)acryloyl chloride. Aralkanoyl halides corresponding to the aralkenoyl halides may be obtained by catalytic hydrogenation of the intermediate acrylate esters or acrylic acids followed by transformations similar to those just described for these esters and acids. Thus, catalytic hydrogenation of ethyl 3,3-bis-(p-chlorophenyl)acrylate followed by alkaline hydrolysis and acid halide formation affords 3,3-bis-(p-chlorophenyl)propionyl chloride. Similarly, catalytic hydrogenation of 3,3-bis-(p-chlorophenyl)acrylic acid followed by treatment with thionyl chloride yields 3,3-bis-(p-chlorophenyl)propionyl chloride.
Other methods useful for the synthesis of aralkanoic and aralkenoic acid intermediates are, first, alkylation of benzophenones with dianions derived from alkanoic acids followed by dehydration and, if required, catalytic hydrogenation. An example of the preparation of both an aralkenoic and an aralkanoic acid by this method is the reaction of 4,4'-dimethylbenzophenone with the dianion of acetic acid to yield 3-hydroxy-3,3-bis(p-tolyl)acrylic acid. Further, catalytic hydrogenation of this acid affords the corresponding aralkanoic acid, 3,3-bis-(p-tolyl)propionic acid. A second method useful for the preparation of certain aralkanoic acids is the Friedel-Crafts alkylation of activated aromatic compounds. An example is the reaction of anisole with 4-methoxycinnamic acid to yield bis-3,3-(p-methoxyphenyl)-propionic acid.
Certain of the compounds of this invention are prepared directly by the reaction of substituted diethyl phosphonoacetanilides with benzophenones. The requisite substituted diethyl phonsphonoacetanilides are prepared as follows. Treatment of bromoacetyl bromide with a substituted aniline yields a substituted bromoacetanilide. Reaction of the bromoacetanilide with triethylphosphite affords the substituted diethyl phosphonoacetanilide required for reaction with a benzophone. An example of this series of reactions is the acylation of ethyl 4-aminobenzoate to yield ethyl 4-bromoacet anilide followed by reaction with triethyl phosphite to yield ethyl 4-[(diethylphosphono)acetamido]benzoate. Reaction of this diethylphosphonoacetanilide with 4,4'-diethylbenzophenone then affords ethyl 4-[3,3-bis-(p-tolyl)acrylamido]benzoate directly. If the saturated analog is desired, catalytic hydrogenation of this ester may be used to obtain ethyl 4-[3,3-bis-(p-tolyl)propionamido]benzoate.
The compounds of the present invention are generally obtained as crystalline solids having characteristic melting points and spectra. They are appreciably soluble in many organic solvents but are generally less soluble in water. Those compounds which are carboxylic acids may be converted to their alkali metal and alkaline earth salts by treatment with appropriate metal hydroxides, and these salts exhibit increased water solubility.
The preparation and properties of the compounds of this invention will be described in greater detail in conjunction with the specific examples shown below.
The compounds of the present invention were tested for their ability to inhibit the enzymatic esterification of cholesterol according to the following procedure:
Rat adrenals were homogenized in 0.2M monobasic potassium phosphate buffer, pH 7.4, and centrifuged at 1,000 times gravity for 15 minutes at 5° C. The supernatant, containing the microsomal fraction, served as the source of the cholesterol-esterifying enzyme, fatty acyl CoA: cholesterol acyl transferase (ACAT). A mixture comprising 50 parts of adrenal supernatant, 10 parts of albumin (BSA) (50 mg./ml.), 20 parts of oleoyl CoA ( 14 C-0.4 μCi), 3 parts of test compound, and 500 parts of buffer was pre-incubated at 37° C. for 10 minutes. After treatment with 20 parts of oleoyl CoA ( 14 C-0.4 μCi), the mixture was incubated at 37° C. for 10 minutes. A control mixture, omitting the test compound, was prepared and treated in the same manner. The lipids from the incubation mixture were extracted into an organic solvent and separated by thin-layer chromatography. The cholesterol ester fraction was counted in a scintillation counter. This procedure is a modification of that described by Hashimoto, et al., Life Scie., 12 (Part II), 1-12 (1973).
The results of this test on representative compounds of this invention appear in Table I. The final concentration of the test compound was 5.2 μg./ml., and the effectiveness of the compound is expressed as percent inhibition of the ACAT enzyme compared to control values.
TABLE I______________________________________ %COMPOUND INHIBITION______________________________________4-(p-Chlorocinnamamido)benzoic acid, ethyl 51ester4-(p-chlorocinnamamido)benzoic acid 414-(p-Chlorohydrocinnamamido)benzoic acid, 30ethyl ester4-(p-Chlorohydrocinnamamido)benzoic acid 334-[3,3-Bis(p-chlorophenyl)acrylamido]benzoic 91acid4-[3,3-Bis(p-chlorophenyl)propionamido]ben- 94zoic acid, ethyl ester4-[3,3-Bis(p-chlorophenyl)acrylamido]benzoic 93acid, ethyl ester4-[3,3-Bis(p-chlorophenyl)propionamido]ben- 71zoic acid4-(p-Methylhydrocinnamamido)benzoic acid, 25ethyl ester4-(p-Methoxyhydrocinnamamido)benzoic acid, 28ethyl ester4-(p-Methoxycinnamamido)benzoic acid, ethyl 53ester4-(p-Methoxycinnamamido)benzoic acid 204-(p-Chlorophenyl)hexanamidobenzoic acid 183-[3,3-Bis(p-chlorophenyl)acrylamido]benzoic 94acid, methyl ester2-[3,3-Bis(p-chlorophenyl)acrylamido]benzoic 71acid, methyl ester3-[3,3-Bis(p-chlorophenyl)acrylamido]benzoic 98acid2-[3,3-Bis(p-chlorophenyl)acrylamido]benzoic 32acid4-[3,3-Bis(p-chlorophenyl)acrylamido]benzoic 88acid, ethyl glycolate ester4-(p-chloro-β-phenylcinnamamido)benzoic acid, 92ethyl ester4-[3,3-Bis(p-fluorophenyl)acrylamido]benzoic 74acid, ethyl ester4-[3,3-Bis(p-fluorophenyl)acrylamido]benzoic 79acid4-(p-Chloro-β-phenylcinnamamido)benzoic acid 774-(3,3-Diphenylacrylamido)benzoic acid 664-(3,3-Diphenylacrylamido)benzoic acid, 40ethyl ester4-[3,3-Di-(p-tolyl)acrylamido]benzoic acid, 97ethyl ester4-(p-Methyl-β-phenylcinnamamido)benzoic acid, 88ethyl ester4-(p-Methyl-β-phenylcinnamamido)benzoic acid 804-(p-Chloro-β-methylcinnamamido)benzoic acid, 74ethyl ester4-(p-Chloro-β-methylcinnamamido)benzoic acid 714-[3,3-Di-(p-tolyl)acrylamido]benzoic acid 893,3-Bis(p-chlorophenyl)-4'-cyanoacrylanilide 964' -Acetyl-3,3-bis(p-chlorophenyl)acrylanilide 864-[3,3-Bis(p-methoxyphenyl)acrylamido]benzoic 78acid4-(3,4-Dichlorophenyl-β-methylacrylamido)ben- 74zoic acid, ethyl ester4-[3,3-Bis(p-methoxyphenyl)acrylamido]benzoic 97acid, ethyl ester4-[3,3-Bis(p-bromophenyl)acrylamido]benzoic 96acid, ethyl ester4-[3,3-Bis(p-bromophenyl)acrylamido]benzoic 90acid4-(4-Chloro-3-nitro-β-phenylcinnamamido)ben- 94zoic acid, ethyl ester4-[2,2-Bis-(p-chlorophenyl)acetamido]benzoic 86acid, ethyl ester4-[2,2-Bis-(p-chlorophenyl)acetamido]benzoic 71acid4-[6-(p-chlorophenyl)hexanamido]benzoic acid, 42ethyl esterN--Phenyl-3,3-bis(4-methoxyphenyl)propionamide 91N--(p-Chlorophenyl)-3,3-bis(4-methoxyphenyl) 91propionamideN--(p-Bromophenyl)-3,3-bis(4-methoxyphenyl) 79propionamideN--(p-Fluorophenyl)-3,3-bis(4-methoxyphenyl) 92propionamideN--(p-Nitrophenyl)-3,3-bis(4-methoxyphenyl) 94propionamideN--(p-Tolyl)-3,3-bis(4-methoxyphenyl)propion- 97amideN--(p-Methoxyphenyl)-3,3-bis(4-methoxyphenyl) 58propionamideN--(p-Cyanophenyl)-3,3-bis(4-methoxyphenyl) 94propionamideN--(p-Trifluroromethylphenyl)-3,3-bis(4-meth- 92oxyphenyl)propionamideN--(p-Acetylphenyl)-3,3-bis(4-methoxyphenyl) 82propionamideN--(p-Carboethoxyphenyl)-3,3-bis(4-methoxy- 91phenyl)propionamideN--(p-Carboxyphenyl)-3,3-bis(4-methoxyphenyl) 45propionamideN--Phenyl-3,3-bis(p-tolyl)propionamide 82N-(p-Chlorophenyl)-3,3-bis(p-tolyl)propion- 89amideN--(p-Fluorophenyl)-3,3-bis(p-tolyl)propion- 92amideN--(p-Cyanophenyl)-3,3-bis(p-tolyl)propion- 90amideN--(p-Tolyl)-3,3-bis(p-tolyl)propionamide 66N--(p-Carboethoxyphenyl)-3,3-bis(p-tolyl) 95propionamideN--(p-Trifluoromethylphenyl)-3,3-bis(p-tolyl) 94propionamideN--Phenyl-3,3-bis(p-ch1orophenyl)propionamide 50N--(p-Fluorophenyl)-3,3-bis(p-chlorophenyl) 67propionamideN--(p-Tolyl)-3,3-bis(p-chlorophenyl)propion- 36amideN--(p-Cyanophenyl)-3,3-bis(p-chlorophenyl) 96propionamideN--(p-Acetylphenyl)-3,3-bis(p-chlorophenyl) 95propionamideN--(p-Trifluoromethylphenyl)-3,3-bis(p-chloro- 35phenyl)propionamide______________________________________
When the compounds are employed for the above utility, they may be combined with one or more pharmaceutically-acceptable carriers, e.g., solvents, diluents, and the like, and may be administered orally in such forms as tablets, capsules, dispersible powders, granules, suspensions containing, for example, from about 0.5% to 5% of suspending agent, syrups containing, for example, from about 10% to 50% of sugar, and elixirs containing, for example, from about 20% to 50% ethanol, and the like, or parenterally in the form of sterile injectable solutions or suspensions containing from about 0.5% to 5% suspending agent in an isotonic medium. These pharmaceutical preparations may contain, for example, from about 05up to about 00% of the active ingredient in combination with the carrier, more usually between 5% and 60% by weight.
The antiathermosclerotic effective dosge of active ingredient employed for the reduction of cholesterol ester content in the arterial walls of a mammal may vary depending on the particular compound employed, the mode of administration, and the severity of the condition being treated. In general, however, satisfactory results are obtained when the compounds of the invention are administered at a daily dosage of from about 2 milligrams to about 500 milligrams per kilogram of animal body weight, preferably given in divided doses two to four times a day, or in sustained release form. For most large mammals, the total daily dosage is from about 100 milligrams to about 5,000 milligrams, preferably from about 100 milligrams to 2,000 milligrams. Dosage forms suitable for internal use comprise from about 25 to 2,500 milligrams of the active compound in intimate admixture with a solid or liquid pharmaceutically-acceptable carrier. This dosage regimen may be adjusted to provide the optimal therapeutic response. For example, several divided doses may be administered daily or the dose may be proportionally reduced as indicated by the exigencies of the therapeutic situation. A decided practical advantage is that these active compounds may be administered orally as well as by intravenous, intramuscular, or subcutaneous routes if necessary. Solid carriers include sterile water, polyethylene glycols, and edible oils such as corn, peanut, and sesame oils, as are appropriate to the nature of the active ingredient and the particular form of administration desired. Adjuvants customarily employed in the preparation of pharmaceutical compositions may be advantageously included, such as flavoring agents, coloring agents, preserving agents, and antioxidants, e.g., vitamin E, ascorbic acid, BHT, and BHA.
The preferred pharmaceutical composition from the stand-point of ease of preparation and administration are solid compositions, particularly tablets and hard-filled or liquid-filled capsules. Oral administration of Compound I is preferred.
These active compounds may also be administered parenterally or intraperitoneally. Solutions or suspensions of these active compounds as a free base or pharmacologically-acceptable salt can be prepared in water suitably mixed with a surfactant such as hydroxypropylcellulose. Dispersions can also be prepared in glycerol, liquid polyethylene glycols, and mixtures thereof in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
The pharmaceutical forms suitable for injectable use include sterile aqueous solutions or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions or dispersions. In all cases, the form must be sterile and must be fluid to the extent that easy syringability exists. It must be stable under the conditions of manufacture and storage and must be preserved against the contaminating action of microorganisms such as bacteria and fungi. The carrier can be a solvent or dispersion medium containing, for example, water, ethanol, polyol (e.g., glycerol, propylene glycol,, and liquid polyethylene glycol), suitable mixtures thereof, and vegetable oils.
EXAMPLE 1
4-(p-Chlorocinnamamido)benzoic acid, ethyl ester
To a solution of 20 g. of p-chlorocinnamic acid in 200 ml. of benzene is added dropwise 43 g. of thionyl chloride. The solution is refluxed for 5 hours, cooled, and evaporated. The residue is dissolved in benzene, and the solution evaporated to yield 21.8 g. of p-chlorocinnamoyl chloride.
The 21.8 g. of p-chlorocinnamoyl chloride is dissolved in 250 ml. of dichloromethane. To this is added, with stirring, a solution of 35.7 g. of ethyl 4-aminobenzoate in 250 ml. of dichlormethane. The mixture is stirred overnight, then 300 ml. of water are added, stirring is continued for 30 minutes, and the solid is collected by filtration and dried. This solid is boiled in 600 ml. of ethanol and 100 ml. of chloroform, filtered, and the volume reduced to 450 ml., giving a solid, 15.0 g. of which is recrystallized from a mixture of 800 ml. of ethanol and 250 ml. of chloroform by boiling to a volume of 250 ml., giving 13.57 g. of the desired product as off-white crystals, m.p. 203°-204° C.
EXAMPLE 2
4-(p-Chlorocinnamamido)benzoic acid
A solution of 7.1 g. of p-(p-chlorocinnamamido)benzoic acid, ethyl ester and 1.6 g. of potassium hydroxide in 50 ml. of 95% ethanol is stirred at 75° C. overnight. A 25 ml. portion of water and 200 mg. of potassium hydroxide are added, and stirring is continued at 75° C. for 1.5 hours. The mixture is then diluted with 150 ml. of water, adjusted to pH 3 with 37% hydrochloric acid, and the precipitate is collected and dried. The solid is boiled in 100 ml. of methyl cellosolve, cooled, and the solid is collected, washed with ethanol, and dried, giving 5.51 g. of the desired product as a white powder, m.p. 333°-336° C. (dec.).
EXAMPLE 3
4-(p-Chlorohydrocinnamamido)benzoic acid, ethyl ester
A mixture of 30.0 g. of 4-(p-chlorocinnamamido)benzoic acid, ethyl ester, 500 mg. of 10% palladium on carbon, and 150 ml. of tetrahydrofuran is hydrogenated in a Parr apparatus, over a 2 hour period, repressurizing until hydrogen uptake is complete. The mixture is filtered, and the filtrate is evaporated. The solid is crystallized from 175 ml. of ethanol, giving 26.8 g. of the desired product as white crystals, m.p. 163°-165° C.
EXAMPLE 4
4-[3,3-Bis(p-chlorophenyl)acrylamido]benzoic acid, ethyl ester
A solution of 48.52 g. of bis-β,β-(p-chlorophenyl)acrylic acid and 60 g. of thionyl chloride in 250 ml. of benzene is stirred at reflux for 4 hours. The solution is cooled and then evaporated. The residue is dissolved in benzene and the solution evaporated to yield 41.8 g. of bis-β,β-(p-chlorophenyl)acryloyl chloride.
This 41.8 g. of bis-β,β-(p-chlorophenyl)acryloyl chloride is dissolved in 250 ml. of dichloromethane, and to the stirred solution is slowly added a mixture of 24.3 g. of benzocaine and 14.8 g. of triethylamine in 250 ml. of dichloromethane. This mixture is stirred for 2 hours, then refluxed for one hour, cooled and washed with 300 ml. of 10% hydrochloric acid. The acid wash is in turn washed with 100 ml. of dichloromethane. The combined organic layers are washed with 100 ml. of brine and evaporated. The residue is boiled in 250 ml. of ethanol, then 200 ml. of chloroform are added, the solution is filtered, and the filtrate is boiled down to a volume of 250 ml. The resulting solid is washed with 400 ml. of ethanol, and 6 g. is recrystallized from 50 ml. of acetone, giving 4.89 g. of the desired product as white crystals, m.p. 207°-209° C.
EXAMPLE 5
4-(p-Methylhydrocinnamamido)benzoic acid, ethyl ester
A solution of 65 g. of p-methylcinnamic acid, 1 g. of palladium on carbon catalyst, and 200 ml. of tetrahydrofuran is hydrogenated in a Parr apparatus at an initial pressure of 50 p.s.i., overnight. The mixture is filtered and the filtrate is evaporated, giving 65.2 g. of 3-(4-methylphenyl)propionic acid.
A solution of 27 g. of 3-(4-methylphenyl)propionic acid and 58.7 g. of thionyl chloride in 550 ml. of benzene is refluxed for 5 hours. The benzene is evaporated, and the residue is recrystallized form benzene, giving 29.8 g. of 3-(4-methylphenyl)propionyl chloride.
A solution of 15 g. of 3-(4-methylphenyl)propionyl chloride in 100 ml. of dichloromethane is created with stirring with a solution of 15 g. of benzocaine and 9.13 g. of triethylamine in 100 ml. of dichloromethane. The mixture is stirred overnight, then washed with 100 ml. each of 10% hydrochloric acid, water, and brine, then dried with magnesium sulfate, and evaporated to yield a solid. This solid is crystallized from 200 ml. of acetonitrile and dried in vacuo, giving 22.08 g. of the desired product, m.p. 154°-155° C.
EXAMPLE 6
4-(p-Methoxyhydrocinnamamido)benzoic acid, ethyl ester
A solution of 27.4 g. of p-methoxyhydrocinnamic acid and 59.7 g. of thionyl chloride in 550 ml. of benzene is refluxed for 5 hours, then cooled, and evaporated. The residue is dissolved in benzene and the solution evaporated to yield 30.0 g. of p-methoxyhydrocinnamoyl chloride.
A solution of 13.73 g. of benzocaine and 11.56 ml. of triethylamine in 100 ml. of ether is slowly added to a stirred solution of 15 g. of p-methoxyhydrocinnamoyl chloride in 100 ml. of ether. The mixture is stirred overnight, 250 ml. of dichloromethane are added, and the mixture is extracted with 200 ml. of water, then 200 ml. of 10% hydrochloric acid, dried over magnesium sulfate, and evaporated to yield a solid. This solid is crystallized from 200 ml. of toluene, giving 21.4 g. of the desired product as white crystals, m.p. 134°-135.5° C.
EXAMPLE 7
4-(p-Methoxycinnamamido)benzoic acid, ethyl ester
A solution of 30 g. of p-methoxycinnamic acid and 66.1 g. of thionyl chloride in 550 ml. of benzene is refluxed for 5 hours. The solvent is evaporated, and the residue is dissolved in benzene and the solution evaported to yield 33.09 g. of p-methoxycinnamoyl chloride.
To a solution of 10 g. of p-methoxycinnamoyl chloride in 200 ml. of dichloromethane is slowly added a solution of 0.24 g. of benzocaine and 7.1 ml. of triethylamine in 200 ml. of dichloromethane. The mixture is stirred for 19 hours, then the organic layer is washed with 200 ml. of 10% hydrochloric acid followed by 200 ml. of brine, dried over magnesium sulfate, and condensed to a solid. This solid is crystallized from 100 ml. of ethanol, giving 10.6 g. of the desired product as yellow crystals, m.p. 163°-165.5° C.
EXAMPLE 9
4-[3,3-Bis(p-chlorophenyl)acrylamido]benzoic acid, sodium salt
A mixture of 19.1 g. of 50% sodium hydride in oil dispersion in 2.2 liters of diethyl ether is stirred in a cold water bath, and 89.3 g. of 4-(2-phosphonoacetamido)benzoic acid, triethy ester are added in portions (exothermic). The solution is stirred for 1/2 hour, 100 g. of 4,4'-dichlorobenzophenone are added, and the mixture is stirred overnight. The solution is decanted form the brown oil and residue, evaporated to near dryness, and saved. The brown residue is stirred vigorously with 500 ml. of dichloromethane. The above residue after evaporation is boiled briefly with 500 ml. of dichlormethane. Both organic solutions are decanted, combined, washed with water, then brine, and evaporated to yield a solid. This solid is dissolved in 1 liter of dichloromethane, filtered, and extracted with two 250 ml. portions of water. The solution is dried and evaporated to yield 125.1 g. of bis(4-chlorophenyl)acrylic acid, ethyl ester.
The above ester is dissolved in 800 ml. of ethanol and 80 ml. of water, and 29 g. of potassium hydroxide are added. The solution is refluxed for one hour, cooled, and avaporated to a residue which is dissolved in 2 liters of water, filtered through celite, and adjusted to pH 2 with concentrated sulfuric acid. The mixture is added to 1 liter of boiling dichloromethane. The dichloromethane layer is separated, dried white hot, filtered, and evaporated, giving 98.0 g. of bis(4-chlorophenyl)acrylic acid.
A 105.6 g. portion of bis(4-chlorophenyl)acrylic acid is added to 800 ml. of toluene. A 140 ml. portion of thionyl chloride is added over a 5 minute period, and the mixture is stirred at 80° C. for 5 hours. The toluene is evaporated, and the residue is dissolved in toluene, and the solution is evaporated to yield 121.0 g. of bis(4-chlorophenyl)acryloyl chloride.
A solution of 15 g. of bis(4-chlorophenyl)acryloyl chloride in 100 ml. of tetrahydrofuran is cautiously added to a solution of 30 g. of benzocaine in 400 ml. of tetrahydrofuran and stirred for 48 hours. The reaction is diluted with 1 liter of water. The resulting oil is decanted, and the water layer is extracted with two 200 ml. portions of dichloromethane. The combined oil and extracts are washed with 200 ml. of 10% hydrochloric acid. The dichloromethane layer is separated, dried over magnesium sulfate, and evaporated to yield a solid. This solid is crystallized from 500 ml. of acetic acid, giving 15.0 g. of 4-[3,3-bis(p-chlorophenyl)acrylamido]benzoic acid.
dTo a hot solution of 10 g. of 4-[3,3-bis(p-chlorophenyl)acrylamido]benzoic acid in 300 ml. of alcohol is added 5 ml. of 10N sodium hydroxide solution. The mixture is cooled, the precipitate is collected, washed with ethanol, and dried in vacuo, giving 9.75 g. of the desired product as a yellow powder, m.p. 365°-370° C. (dec.).
EXAMPLE 9
3-[3,3-Bis(p-chlorophenyl)acrylamido]benzoic acid, methyl ester
A solution of 20.0 g. of bis(4-chlorophenyl)acryloyl chloride in 150 ml. of dichloromethane is added to a stirred solution of 10.3 g. of methyl 3-aminobenzoate and 12.2 ml. of triethylamine in 150 ml. of dichloromethane. This solution is stirred under reflux for 3 hours and then at room temperature overnight and evaporated. The residue is stirred with 300 ml. of boiling acetone, filtered white hot, and the filtrate is chilled. The resulting solid is collected and dried in vacuo, giving 13.8 g. of the desired product as a white solid, m.p. 155°-159° C.
EXAMPLE 10
2-[3,3-Bis(p-chlorophenyl)acrylamido]benzoic acid, methyl ester
A solution of 20.0 g. of bis(4-chlorophenyl)acryloyl chloride in 150 m. of dichloromethane is added to a stirred solution of 10.3 g. of methyl 2-aminobenzoate and 12.2 ml. of triethylamine in 150 ml. of dichloromethane. This solution is stirred under reflux for 3 hours, then overnight at room temperature, and evaporated. The residue is stirred with 300 ml. of boiliing acetone, filtered white hot, and chilled. The resulting solid is collected and dried in vacuo, giving 15.6 g. of the desired product as a white solid, m.p. 141°-143° C.
EXAMPLE 11
4-[p-Chloro-β-(p-chlorophenyl)cinnamamido]benzoic acid, ethyl glycolate ester
A slurry of 13.03 g. of 4-[3,3-bis(p-chlorophenyl)acrylamido]benzoic acid, sodium salt, 14.7 g. of ethyl chloroacetate, and 50 ml. of hexamethylphosphortriamid is heated at 75° C. for 16 hours. The mixture is diluted with 50 ml. of water and cooled to 2° C. The resulting solid is collected, washed with water, dried, and recrystallized from a mixture of 130 ml. of toluene and 20 ml. of hexane, giving 7.3 g. of the desired product as a white solid.
Similarly prepared from methyl chloroacetate is 4-[p-chloro-β-(p-chlorophenyl)cinnamido]benzoic acid, methyl glycolate ester. Alkaline hydrolysis of the latter affords 4-[p-chloro-β-(p-chlorophenyl)cinnamido]benzoic acid.
EXAMPLE 12
4-(p-Chloro-β-phenylcinnamamido)benzoic acid, ethyl ester
A solution of 96 ml. of bromoacetyl bromide in 800 ml. of dichloromethane is added, during one hour, to a stirred solution of 165 g. of ethyl 4-aminobenzoate and 165 ml. of triethylamine in 1 liter of dichloromethane white maintaining the temperature at 0° C. The solution is then stirred at room temperature for 20 hours and the extracted with water, dried, and evaporated. The residue is crystallized from 2 liters of toluene and dried, giving 223 g. of 4-(bromoacetamido)benzoic acid, ethyl ester.
A mixture of 146 g. of the above ester, 230 ml. of triethylphosphite, and 800 ml. of toluene is stirred and heated at 105°-110° C. for 2 hours, then cooled, and the solvent is evaporated at 50° C. The residue is reevaporated three times from 400 ml. of hexane. The solid is triturated with 300 ml. of hexane and air dried, giving 170 g. of 4-(2-phosphonoacetamido)benzoic acid, triethyl ester.
To a suspension of 2.04 g. of sodium hydride [(50% suspension in oil) washed with 30 ml. of hexane] in 70 ml. of dry dimethoxyethane is added portionwise 8.6 g. of 4-(2-phosphonoacetamido)benzoic acid triethyl ester over 2 minutes. The mixture is stirred for 20 minutes, then 5.42 g. of 4-chlorobenzophenone is added. This mixture is refluxed for 31/2 hours, cooled, and 300 ml. of water are added. The mixture is extracted with two 150 ml. portions of dichloromethane. The organic extracts are stripped to dryness. The residue is dissolved in acetone, then hexane is added to turbidity. The solid is collected, washed with hexane, dissolved in 15 ml. of hot acetonitrile and filtered. The filtrate is refrigerated, and the resulting solid is collected, washed with hexane, and dried, giving 820 mg. of the desired product as a white solid, m.p. 173°-175° C.
EXAMPLE 13
4-[3,3-Bis(p-fluorophenyl)acrylamido]benzoic acid, ethyl ester
To a suspension of 3.28 g. of sodium hydride [(50% in oil) washed with 2×40 ml. of hexane] in 30 ml. of dimethylformamide is added dropwise a solution of 6.86 g. of 4-(2-phosphonoacetamido)benzoic acid, triethyl ester in 30 ml. of dimethylformamide. The mixture is stirred for 20 minutes, then 4.36 g. of 4,4'-difluorobenzophenone are added, and stirring is continued for one hour. The mixture is then heated at 60°-70° C. for one hour, cooled, and 200 ml. of water is cautiously added. The mixture is stirred and cooled for 45 minutes; then the solid is collected, washed with water, and dried at 60° C. overnight. This solid is dissolved in 35 ml. of acetonitrile, filtered, and chilled overnight. The resulting solid is collected, washed with hexane, and dried, giving 3.7 g. of the desired product, m.p. 161°-163° C.
EXAMPLE 14
4-(p-Chloro-β-phenylcinnamamido)benzoic acid
To a suspension of 3.75 g. of hexane-washed sodium hydride (50% in oil) in 30 ml. of moist dimethylformamide is added dropwise a solution of 8.6 g. of 4-(2-phosphonoacetamido)benzoic acid, triethyl ester in 30 ml. of dimethylformamide. The mixture is stirred for 20 minutes, then 5.42 g. of 4-chlorobenzophenone are added, and this mixture is heated at 50°-70° C. for 2 hours. The mixture is cooled, 150 ml. of water is cautiously added, and stirring and cooling are continued for 30 minutes. The resulting solid is removed by filtration. The filtrate is acidified with concentrated hydrochloric acid, using ice bath cooling, and the resulting solid is collected, washed with water, and dried. This solid is then dissolved in 70 ml. of hot toluene, filtered, and the filtrate is chilled. The resulting solid is collected, washed with toluene, dried, dissolved in 40 ml. of hot acetonitrile, filtered, and chilled. The resulting solid is collected, washed with acetonitrile, and dried, giving 1.52 g. of the desired product, m.p. 220°-223° C.
EXAMPLE 15
4-(3,3-Diphenylacrylamido)benzoic acid
To a suspension of 7.2 g. of hexane-washed sodium hydride (50% in oil) in 30 ml. of moist dimethylformamide is added dropwise a solution of 17.15 g. of 4-(2-phosphonoacetamido)benzoic acid triethyl ester in 40 ml. of dimethylformamide. The mixture is stirred for 25 minutes, then 9.11 g. of benzophenone are added, and the mixture is heated at 60°-70° C. for 1.5 hours. The mixture is cooled, 250 ml. of water are cautiously added, and cooling and stirring are continued for 30 minutes. The mixture is filtered, the filtrate is cooled, acidified with concentrated hydrochloric acid, and the solid is collected and crystallized from 100 ml. of hot acetonitrile, giving 3.25 g. of the desired product as light yellow needles, m.p. 222°-224° C.
EXAMPLE 16
p-(3,3-Diphenylacrylamido)benzoic acid, ethyl ester
To a suspension of 1.44 g. of hexane-washed sodium hydride in 30 ml. of dry hexamethylphosphortriamide is added slowly a dry solution of 3.43 g. of 4-(2-phosphonoacetamido)benzoic acid triethyl ester in 30 ml. of hexamethylphosphortriamide. The mixture is stirred for 20 minutes, 1.82 g. of benzophenone are added, and the mixture is heated at 65° C. for 1.5 hours, then cooled and cautiously diluted with 250 ml. of water. This mixture is cooled in an ice bath and stirred for 30 minutes; then the solid is collected, washed with water, and dried. This solid is crystallized from 50 ml. of hot acetonitrile, giving 1.58 g. of the desired product, m.p. 166°-169° C.
EXAMPLE 17
4-[3,3-Di-(p-tolyl)acrylamido]benzoic acid, ethyl ester
To a solution of 5.76 g. of hexane-washed sodium hydride (50% in oil) in 40 ml. of dry hexamethylphosphortriamide is added, dropwise, a solution of 13.72 g. of 4-(2-phosphonoacetamido)benzoic acid triethyl ester in 100 ml. of dry hexamethylphosphortriamide. The mixture is stirred for 20 minutes, then 8.41 g. of 4,4'-dimethylbenzophenone are added. This mixture is heated at 70° C. for 4 hours, cooled, and cautiously diluted with water to a total volume of 1,300 ml. This mixture is extracted with two 400 ml. portions of ether. The ether extracts are combined, washed with water, dried over anhydrous magnesium sulfate, and evaporated to dryness. The residue is dissolved in 50 ml. of hot acetone, filtered, and the filtrate is diluted with hexane and cooled, giving a solid which is collected, washed with a mixture of acetone and hexane, and dried at 50° C., giving 5.0 g. of the desired product, m.p. 151°-154° C.
EXAMPLE 18
4-(p-Methyl-β-phenylcinnamamido)benzoic acid, ethyl ester
The proceduere of Example 16 is repeated, substituting 7.85 g. of 4-methylbenzophenone for the 4,4'-dimethylbenzophenone. The aqueous dilution of the cooled reaction mixture is extracted six times with ether giving 12.0 g. of a yellow oil. This oil is purified by preparative high pressure liquid chromatography, using a silica gel column, 12% ethylacetate in hexane as the solvent at a flow rate of 100 ml./minute. Fractions 7, 8, and 9 are combined, giving 5.8 g. of the desired product as a light yellow solid, m.p. 122°-124° C.
EXAMPLE 19
4-(p-Chloro-β-methylcinnamamido)benzoic acid, ethyl ester
To a solution of 4.32 g. of hexane-washed sodium hydride (50% in oil) in 30 ml. of hexamethylphosphortriamide is added, dropwise, a dry solution of 10.29 g. of 4-(2-phosphonoacetamido)benzoic acid, triethyl ester in 75 ml. of hexamethylphosphortriamide. The mixture is stirred 20 minutes, then 4.64 g. of 4'-chloroacetophenone are added, and this mixture is heated at 65°-70° C. for 4 hours. The mixture is cooled, cautiously diluted with 1 liter of water and extracted with three 250 ml. portions of ether. The ether extracts are combined, washed with saturated aqueous sodium chloride, dried over anhydrous magnesium sulfate, stirred with diatomaceous earth, and filtered. The filtrate is evaporated, and the residue is crystallized from acetonitrile. A 2.5 g. portion is recrystallized from a mixture of acetone and hexane, giving 1.66 g. of the desired product, m.p. 150°-152° C.
EXAMPLE 20
4-[3,3-Bis(p-chlorophenyl)propionamido]benzoic acid, sodium salt
A solution of 4.17 g. of sodium methoxide in 80 ml. of methanol is added to a mixture of 32.0 g. of 4-[3,3-bis(p-chlorophenyl)propionamido]benzoic acid in 500 ml. of methanol. The solution is filtered, then evaporated in vacuo, and dried at 50° C., giving 33.0 g. of the desired product as a white solid.
EXAMPLE 21
3,3-Bis(p-chlorophenyl-4'-cyanoacrylanilide
A mixture of 9.0 g. of bis(4-chlorophenyl)acrylic acid and 9.0 ml. of thionyl chloride is stirred for 24 hours and then evaporated to a yellow oil. This oil is dissolved in 50 ml. of dichloromethane and added to a stirred mixture of 3.54 g. of 4-aminobenzonitrile and 8.31 ml. of triethylamine in 50 ml. of dichloromethane. This solution is stirred under reflux for 4 hours and then evaporated. The residue is stirred with 250 ml. of boiling acetone, filtered, and the filtrate is concentrated to 100 ml. and allowed to cool. The solid is collected, dried, and recrystallized from 80 ml. of acetonitrile, giving 4.59 g. of the desired product as a light yellow solid, m.p. 228°-230° C.
EXAMPLE 22
4'-Acetyl-3,3-bis(p-chlorophenyl)acrylanilide
A 9.0 ml. portion of thionyl chloride is added to a solution of 9.0 g. of bis-(4-chlorophenyl)acrylic acid in 25 ml. of dichloromethane (exothermic). The solution is stirred for 4 hours under reflux and then evaporated to an oil. A solution of this oil in 50 ml. of dichloromethane is added in portions to a stirred solution of 4.05 g. of p-aminoacetophenone and 8.31 ml. of triethylamine in 50 ml. of dichloromethane (exothermic). This solution is stirred under reflux for 2 hours, then at room temperature overnight, and evaporated. The residue is stirred with 250 ml. of boiling acetone, filtered while hot, and the filtrate is concentrated to 100 ml., allowed to cool, and reflitered. This filtrate is evaporated, and the residue is crystallized from 220 ml. of acetonitrile. The resulting solid is again crystallized from 100 ml. of acetonitrile. Concentration of the filtrate to 40 ml. and chilling yields 320 mg. of the desired product as a light yellow solid, m.p. 213°-215° C.
EXAMPLE 23
4-[3,3-Bis(p-methoxyphenyl)acrylamido]benzoic acid, ethyl ester
To a suspension of 7.2 g. of hexane-washed sodium hydride (50% in oil) in 150 ml. of dry hexamethylphosphortriamide is added 22.3 g. of 4-(2-phosphonoacetamido)benzoic acid, triethyl ester, under argon. The mixture is stirred for 10 minutes, then 14.54 g. of 4,4'-dimethoxybenzophenone are added. The mixture is heated at 65°-70° C. for 5 hours, and allowed to stand overnight. The mixture is filtered through a celite pad. The pad is washed with water, then two 200 ml. portions of ether, then three 200 ml. portions of ethyl acetate. The ethyl acetate extracts are combined, dried over magnesium sulfate, and evaporated to dryness. The residue is crystallized from 50 ml. of hot acetonitrile giving 6.0 g. of solid. A 3.2 g. portion of this solid is purified by preparative high pressure liquid chromatography, using a silica gel column and the solvent system 30% ethyl acetate in hexane. Fractions 10-13 are combined, stripped to dryness, and the residue is dissolved in dichloromethane. This solution is filtered, hexane is added to the filtrate, and the solid is collected, washed with hexane, and dried, giving 1.7 g. of the desired product as a white solid, m.p. 156°-159° C.
EXAMPLE 24
4-(3,4-Dichlorophenyl-β-methylacrylamido)benzoic acid, ethyl ester
To a suspension of 4.32 g. of hexane-washed sodium hydride (505 in oil) in 150 ml. of dry hexamethylphosphortriamide under nitrogen is added 13.72 g. of 4-(2-phosphonoacetamido)benzoic acid triethyl ester. The mixture is stirred 20 minutes, then 5.67 g. of 3',4'-dichloroacetophenone are added. The mixture is heated at 65°-70° C. for 6 hours, cooled to 5° C., and cautiously diluted with 400 ml. of water. The mixture is filtered through a pad of celite. The pad is then washed with 250 ml. of ether followed by ethyl acetate. The ethyl acetate extract is dried, evaporated to dryness, and the residue is crystallized from acetonitrile, giving 3.2 g. of the desired product, m.p. 149°-150° C.
EXAMPLE 25
4-[3,3-Bis(p-bromophenyl)acrylamido]benzoic acid, ethyl ester
To a suspension of 0.9 g. of hexane-washed sodium hydride (50% in oil) in 40 ml. of dry hexamethylphosphortriamide under argon is added 2.7 g. of 4-(2-phosphonoacetamido)benzoic acid triethyl ester. The mixture is stirred for 5 minutes, then 2.0 g. of 4,4'-dibromobenzophenone are added. The mixture is heated at 70°-75° C. for 4 hours, cooled to 10° C., and cautiously diluted with 60 ml. of water. This mixture is stirred and cooled for 1/2 hour. The solid is collected, washed with water, and dried. A 1.5 g. portion is dissolved in 50 ml. of acetone, filtered, and hexane is added to the filtrate until turbid. The mixture is chilled, and the solid is collected, washed with hexane, and dried, giving 320 mg. of the desired product as a white solid, m.p. 207°-208° C.
EXAMPLE 26
4-(4-Chloro-3-nitro-β-phenylcinnamamido)benzoic acid, ethyl ester
To a suspension of 3.0 g. of hexane-washed sodium hydride (50% in oil) in 100 ml. of dry hexamethylphosphortriamide under argon is added 8.92 g. of 4-(2-phosphonoacetamido)benzoic acid triethyl ester. The mixture is stirred 5 minutes, then 5.23 g. of 4-chloro-3-nitrobenzophenone are added. This mixture is heated at 70° C. for 2 hours, cooled to 10° C., and cautiously diluted with 350 ml. of water and stirred for 1/2 hour. The mixture is filtered through a pad of celite. The pad is washed with water followed by 400 ml. of ethyl acetate. The ethyl acetate extract is washed with water, dried over anhydrous magnesium sulfate by preparative high pressure liquid chromatography on a silica gel column using ethyl acetate:hexane (25:75) as the solvent system and a flow rate of 100 ml./minute. Eighteen fractions are collected. The like fractions are pooled and stripped to dryness. A 2.71 g. portion of the residue is crystallized from 30 ml. of absolute ethanol giving three crops. The third crop comprises 120 mg. of the desired product.
EXAMPLE 27
4-[3,3-Bis(p-chlorophenyl)propionamido]benzoic acid, ethyl ester
A 30.2 g. portion of 4-[3,3-(p-chlorophenyl)acrylamido]benzoic acid, ethyl ester is hydrogenated as described in Example 3, giving 25.97 g. of the desired product, m.p. 152°-155° C.
The ethyl esters of certain of the compounds of this invention are converted to the corresponding acid derivatives by the procedures of Example 2, using either potassium hydroxide or sodium hydroxide as base. The products of this reaction are listed in Table II.
TABLE II__________________________________________________________________________ExampleStarting Material Product M.P. °C.__________________________________________________________________________28 4-(p-Chlorohydrocinnamamido)- 4-(p-Chlorohydrocinnamam- 273-275benzoic acid, ethyl ester ido)benzoic acid29 4-[3,3-Bis(p-chlorophenyl)- 4-[3,3-Bis(p-chlorophenyl)- 258-259acrylamido]benzoic acid, acrylamido]benzoic acidethyl ester30 4-[3,3-Bis(p-chlorophenyl)- 4-[3,3-Bis(p-chlorophenyl)- 280-282propionamido]benzoic acid, propionamido]benzoic acidethyl ester31 4-(p-Methoxycinnamamido)- 4-(p-Methoxycinnamamido)- 289-291benzoic acid, ethyl ester benzoic acid32 3-[3,3-Bis(p-chlorophenyl)- 3 - [3,3-Bis(p-chlorophenyl)- 211-215acrylamido]benzoic acid, acrylamido]benzoic acidethyl ester33 2-[3,3-Bis(p-chlorophenyl)- 2-[3,3-Bis(p-chlorophenyl)- 230-232acrylamido]benzoic acid, acrylamido]benzoic acidethyl ester34 4-[3,3-Bis(p-fluorophenyl)- 4-[3,3-Bis(p-fluorophenyl)- 245-247acrylamido]benzoic acid, acrylamido]benzoic acidethyl ester35 4-(p-Methyl-β-phenylcinnamam- 4-(p-Methyl-β-phenylcinna- 221-223ido)benzoic acid, ethyl ester mamido)benzoic acid36 4-(p-Chloro-β-methylcinnamam- 4-(p-Chloro-β-methylcinna- 273-276ido)benzoic acid, ethyl ester mamido)benzoic acid37 4-[3,3-Di-(p-tolyl)acrylamido]- 4-[3,3-Di-(p-tolyl)acryla- 238-240benzoic acid, ethyl ester mido]benzoic acid38 4-[3,3-Bis(p-methoxyphenyl)- 4-[3,3-Bis(p-methoxyphen- 237-239acrylamido]benzoic acid, yl)acrylamido]benzoic acidethyl ester39 4-[3,3-Bis(p--bromophenyl)- 4-[3,3-Bis(p-bromophenyl)- 259-261acrylamido] benzoic acid, acrylamido]benzoic acidethyl ester__________________________________________________________________________
EXAMPLE 40
4-[6-(p-Chlorophenyl)hexanamido]benzoic acid
To a solution of 101 g. of ethyl adipate in 500 ml. of benzene is slowly added 120 ml. of thionylchloride. The mixture is refluxed for 4.5 hours, cooled, and evaporated. The residue is evaporated three times from 500 ml. of benzene, giving 113 g. of ethyl adipoyl chloride as a yellow liquid.
A solution comprising 155 g. of aluminum chloride in 200 ml. of tetrachloroethane and 77 ml. of chlorobenzene is cooled to 3° C. in an ice bath. The 113 g. of ethyl adipoyl chloride is added slowly over a period of 3 hours, washing the oil in with small portions of tetrachloroethane and keeping the temperature below 5° C. The mixture is refrigerated overnight, then warmed to 50° C. into 1.5 liters of ice and water containing 200 ml. of 37% hydrochloric acid. The oil is drawn off, and the aqueous layer is washed with two 500 ml. portions of ether. The oil and ether extracts are combined, washed with water, then brine, dried, and evaporated, giving 159.1 g. of ethyl 5-(p-chlorobenzoyl)valerate.
To a solution of the 159 g. of the valerate in 400 ml. of ethanol is slowly added 80 g. of 85% potassium hydroxide. The mixture is allowed to stand 1/5 hour, 100 ml. of water are added, and the solution is stirred at reflux for 2 hours. The solution is cooled, the ethanol is evaporated, and the residue is dissolved in 1 liter of water, adjusted to pH 1 with 37% hydrochloric acid, and the solid is collected. Two crystallizations from ethanol give 69.5 g. of 5-(p-chlorobenzoyl)valeric acid.
A 55 g. portion of zinc is placed in a flask. To this is added 5.4 g. of mercuric chloride, 90 ml. of water, and 3 ml. of concentrated hydrochloric acid. The mixture is stirred for 5 minutes, and the solution is decanted. To this solution is sequentially added 35 ml. of water, 80 ml. of 37% hydrochloric acid, 45 ml. of toluene, and 35 g. of 5-p-(chlorobenzoyl)valeric acid. The mixture is stirred at reflux for 24 hours with the addition of 25 ml. portions of 37% hydrochloric acid after 6, 12, and 18 hours. The reaction is cooled and diluted with 100 ml. of water. The organic layer is separated and saved. The aqueous layer is extracted with two 100 ml. portions of ether. The organic layers are combined, dried, and condensed to an orange oil. This oil is distilled through a Kugelrohr apparatus. The distillate is dissolved in 100 ml. of ethanol, 500 mg. of 10% palladium on carbon are added, and the mixture is hydrogenated at 40 p.s.i. for one hour in a Parr apparatus. The catalyst is removed by filtration and the filtrate is evaporated, giving 25.2 g. of 6-(p-chlorophenyl)hexanoic acid.
A solution of 15 g. of 6-(p-chlorophenyl)hexanoic acid and 14 ml. of thionyl chloride in 200 ml. of benzene is refluxed for 6 hours, then cooled, the solvent is evaporated and the residue dissolved in benzene, and the solution is evaporated to yield 16.7 g. of 6-(p-chlorophenyl)hexanoic acid chloride as an oil.
To a solution of 11.7 g. of this acid chloride in 100 ml. of dichloromethane is added a solution of 15.8 g. of benzocaine in 100 ml. of dichloromethane. The mixture is stirred for 4 hours, then washed with 100 ml. of 10% hydrochloric acid, 100 ml. of water, dried, filtered through magnesol, and evaporated to yield a solid. This solid is crystallized from 150 ml. of toluene, giving 14.98 g. of 4-6-(p-chlorophenyl)hexanamidobenzoic acid, ethyl ester.
This ester (7.61 g.) is reduced to the desired product by the procedure of Example 2, giving 5.54 g. of white crystals, m.p. 218°-220° C.
EXAMPLE 41
4-[5,5-Bis(p-chlorophenyl)-2,4-pentadienamido]benzoic acid, ethyl ester
A slurry of 22 g. of hexane-washed sodium hydride (50% in oil) in 500 g. of hexamethylphosphortriamide is stirred at 32° C. while 96.5 g. of 4,4'-dichlorobenzophenone and a solution of 125 g. of triethyl 4-phosphonocrotonate in 500 ml. of hexamethylphosphortriamide are added. After one hour the temperature is raised to 75° C., and stirring is continued overnight. The mixture is cooled, diluted with 500 ml. of water, and extracted with three 500 ml. portions of ether. The ether extracts are combined, dried over magnesium sulfate, and concentrated to a solid. This solid is dissolved in 300 ml. of ether and chromatographed on 600 g. of silica gell, eluting eith 2 liters of ether. The ether is concentrated in vacuo to an oil which is triturated with 100 ml. of hexane, giving 59.1 g. of ethyl 5,5-bis(p-chlorophenyl)pent-2,4-dienoate.
To a suspension of 20 g. of the above ester in 50 ml. of ethanol is added a solution of 3.8 g. of potassium hydroxide in 150 ml. of water. The mixture is refluxed for 6 hours, filtered while hot, acidified with 7 ml. of concentrated hydrochloric acid, and then cooled in ice. The solid is collected, washed with water, and dried, giving 10.0 g. of 5,5-bis(p-chlorophenyl)-2,4-pentadienoic acid.
A mixture of 13.0 g. of the above acid and 35 ml. of thionyl chloride is stirred overnight, evaporated to dryness, and concentrated twice from 50 ml. of dichloromethane. The solid is dissolved in 100 ml. of dichloromethane, and a mixture of 6.8 g. of ethyl p-aminobenzoate, 100 ml. of dichloromethane, and 11 ml. of triethylamine is added dropwise over 30 minutes. The solution is stirred overnight, filtered, and concentrated in vacuo. The residue is dissolved in acetone, heated to boiling, filtered, cooled, and refiltered. This filtrate is concentrated to a solid. A 10.0 g. portion of this solid is chromatographed on a silica gel, eluting with dichloromethane, and collecting 500 ml. fractions. Fractions 15-20 are combined and recrystallized from dichloromethane and then dried giving a white solid. This solid is recrystallized several times from ether, giving the desired product as an off-white solid, m.p. 216°-218° C.
EXAMPLE 42
4-[5,5-Bis(p-chlorophenyl)-2,4-pentadienamido]benzoic acid
A mixture of 4.0 g. of p-[5,5-bis(p-chlorophenyl)-2,4-pentadienamido]benzoic acid, ethyl ester, 40 ml. of ethanol, and 10 ml. of 1N sodium hydroxide is heated at reflux for 4 hours, filtered while hot, 15 ml. of 1N hydrochloric acid are added, and the mixture is cooled in ice. The solid is collected, washed with water, dried and recrystallized from ethanol, giving 3.1 g. of the desired product, m.p. 273°-276° C.
EXAMPLE 43
4-[2,2-Bis(p-chlorophenyl)acetamido]benzoic acid, ethyl ester
A mixture of 49.5 g. of 1,1'-(2,2,2-trichloroethylidene)bis[p-chlorobenzene], 400 ml. of diethylene glycol, and a solution of 63 g. of potassium hydroxide in 35 ml. of water is heated at reflux for 6 hours, then cooled, and poured slowly into 1 liter of cold water with stirring. The solution is filtered, and the filtrate is warmed to 90° C. and stirred with 2 g. of charcoal for 10 minutes. The solution is filtered, made acidic with 55 ml. of concentrated sulfuric acid, and refrigerated for 6 hours. The solid is collected and crystallized from ethanol:water (100:75), giving 28.0 g. of bis(p-chlorophenyl)acetic acid.
To a stirred solution of 23.55 g. of bis(p-chlorophenyl)acetic acid in 250 ml. of benzene is added dropwise 33.1 g. of sulfonyl chloride. The mixture is refluxed 5 hours, the solvent is evaporated, and the residue is evaporated from three 250 ml. portions of benzene, giving 26.06 g. of bis(p-chlorophenyl)acetyl chloride as an oil. To this oil is added a solution of 27.7 g. of benzocaine. The mixture is stirred overnight, filtered, washed with 200 ml. each of 10% hydrochloric acid, saturated sodium bicarbonate solution, water, and brine, dried over magnesium sulfate, and evaporated. The residue is crystallized twice from 200 ml. of ethanol, giving 25.76 g. of the desired product as colorless needles, m.p. 171°-172° C.
EXAMPLE 44
4-[2,2-Bis(p-chlorophenyl)acetamido]benzoic acid
A mixture of 6.0 g. of p-[2,2-bis(p-chlorophenyl)acetamido]benzoic acid, ethyl ester, 920 mg. of potassium hydroxide, and 50 ml. of 95% ethanol is stirred at 75° C. for 9 hours, cooled, diluted with 100 ml. of water, and the pH is adjusted to 2.0 with 37% hydrochloric acid. The precipitate is collected, washed with water, dried and recrystallized from 100 ml. of ethanol, giving 2.78 g. of the desired product as colorless crystals, m.p. 272°-274° C.
EXAMPLE 45
4-[6-(p-Chlorophenyl)hexanamido]benzoic acid, ethyl ester
A mixture of 150 g. of aluminum chloride, 200 ml. of dichloromethane, and 84.2 g. of chlorobenzene is cooled in an ice bath to 30° C.; then 108.1 g. of ethyl adipoyl chloride are added dropwise with stirring, maintaining the temperature at less than 50° C. The mixture is refrigerated overnight, then warmed slowly to 50° C., and poured slowly into a stirred mixture of 200 ml. of 37% hydrochloric acid and 1,200 g. of crushed ice. When the ice melts, the organic layer is separated and saved. The aqueous layer is extracted with two 500 ml. portions of ether. The ether extracts are combined with the original organic layer, washed with 300 ml. of water, then 500 ml. of brine, dried over magnesium sulfate, and evaporated to a solid. This solid is recrystallized from 300 ml. of methylcyclohexane, giving 78.4 g. of 5-(p-chlorobenzoyl)valeric acid, ethyl ester.
A 139.3 g. portion of 5-chlorobenzoyl valeric acid, ethyl ester (prepared as described above) is dissolved in 400 ml. of 95% ethanol. An 80 g. portion of potassium hydroxide and 75 ml. of water are added, and the mixture is refluxed for 3 hours. The solution is cooled, poured into 1.2 liters of water, and the pH is adjusted to 1 with 37% hydrochloric acid. The solid is collected, dried, and crystallized from 400 ml. of toluene, giving 70.0 g. of 5-p-chlorobenzoyl valeric acid.
A mixture of 55 g. of mossy zinc, 5.4 g. of mercuric chloride, 90 ml. of water, and 3 ml. of concentrated hydrochloric acid is stirred for 5 minutes, and the solution is decanted. To the residue is suquentially added 35 ml. of water, 80 ml. of 37% hydrochloric acid, 45 ml. of toluene, and 30.0 g. of 5-p-chlorobenzoylvalerica cid. This mixture is refluxed at 115° C. for 28 hours, with the addition of 25 ml. of concentrated hydrochloric acid at 6 hour intervals. The solution is cooled, diluted with 100 ml. of water, and the organic layer is separated and saved. The aqueous layer is extracted with three 100 ml. portions of ether. The ether extracts and organic layer are combined, washed with 100 ml. of water, then 100 ml. of brine, dried over magnesium sulfate, and evaporated to an oil. This oil is distilled on a Kugelrohr apparatus collecting the fraction that boils at 160°-170° C. (60 mm.), giving 22.0 g. of 6-(p-chlorophenyl)hexanoic acid as an oil. To a solution of 19.0 g. of this oil in 200 ml. of benzene is added dropwise 33.1 g. of sulfonyl chloride. The mixture is refluxed 5 hours, cooled, and evaporated three times from 250 ml. of benzene, to yield 21.09 g. of brown liquid. This liquid is dissolved in 200 ml. of dichloromethane, and a solution of 28.4 g. of benzocaine in 200 ml. of dichloromethane is added, and the mixture is stirred overnight. The mixture is filtered, and the filtrate is extrcted with 100 ml. of 10% hydrochloric acid, 100 ml. of saturated sodium bicarbonate solution, and 100 ml. of brine; then it is dried over magnesium sulfate and evaporated to a solid. The solid is boiled in 400 ml. of toluene, treated with 1 g. of charcoal, filtered, and boiled down, giving 23.0 g. of crystalline solid. A 4.1 g. portion of this solid, 100 mg. of 10% palladium on carbon, and 50 ml. of ethyl acetate are hydrogenated in a Parr apparatus giving, after crystallization from toluene, 3.81 g. of the desired product as colorless crystals, m.p. 107°-108° C.
The final catalytic hydrogenation is necessary to convert ethyl p-[6-(p-chlorophenyl)hex-5-enamido]benzoate, an impurity present in the product, to the desired product. This impurity arises from 6-(p-chlorophenyl)hex-5-enoic acid, a by-product formed during the preparation of the intermediate 6-(p-chlorophenyl)hexanoic acid, and thus the catalytic hydrogenation may alternatively be performed on the intermediate itself.
EXAMPLE 46
3,3-Bis(4-methoxyphenyl)propionic acid
A mixture of 10 g. of p-methoxycinnamic acid and 100 ml. of 85% phosphoric acid is stirred at approximately B 75° C. while 6.07 g. of anisole is added for about 24 hours thereafter. The mixture is allowed to cool, then is poured into ice water, and is filtered. The solid is crystallized from hexane-methylene chloride to yield 16.2 g. of 3,3-bis(4-methoxyphenyl)propionic acid as a white solid, m.p. 132°-134° C.
Amides prepared from 3,3-bis(4-methoxyphenyl)propionic acid by the method of Example 1 are shown in Table III.
TABLE III______________________________________EXAMPLE PRODUCT M.P. °C.______________________________________47 N--Phenyl-3,3-bis(4-methoxyphenyl) 168-171 propionamide48 N--(p-Chlorophenyl)-3,3-bis(4-meth- 165-168 oxyphenyl)propionamide49 N--(p-Bromophenyl)-3,3-bis(4-meth- 171-173 oxyphenyl)propionamide50 N--(p-Fluorophenyl)-3,3-bis(4-meth- 154-156 oxyphenyl)propionamide51 N--(p-Nitrophenyl)-3,3-bis(4-meth- 119-122 oxyphenyl)propionamide52 N--(p-Tolyl)-3,3-bis(4-methoxyphe- 157-159 nyl)propionamide53 N--(p-Methoxyphenyl)-3,3-bis(4-meth- 203-205 oxyphenyl)propionamide54 N--(p-Cyanophenyl)-3,3-bis(4-meth- 144-145 oxyphenyl)propionamide55 N--(p-Trifluoromethylphenyl)-3,3-bis 171-173 (4-methoxyphenyl)propionamide56 4'-[3,3-Bis(4-methoxyphenyl)propion- 158-161 amido]acetophenone57 Ethyl 4'-[3,3-bis(4-methoxyphenyl) 150-151 propionamido]benzoate58 4'-[3,3-Bis(4-methoxyphenyl)pro- 250 dec pionamido]benzoic acid______________________________________
EXAMPLE 59
3,3-Bis(p-tolyl)propionic acid
A suspension of 1.6 g. of lithium aluminum hydride and 250 ml. of ether is stirred at reflux while 30 g. of 4,4'-dimethylbenzophenone is added and for 4 hours thereafter. Unreacted hydride is decomposed by the addition of aqueous sodium hydroxide solution, and the mixture is filtered. The filtrate is extracted with ether, and the extract is dried and evaporated to yield 28.1 g. of 4,4'-dimethylbenzhydrol, m.p. 69°-70° C.
An ether solution of the 28.1 g. of 4,4'-dimethylbenzhydrol is treated with anhydrous hydrogen chloride and stirred at about 25° C. Evaporation followed by crystallization from petroleum ether affords 24.4 g. of 4,4'-dimethylbenzhydryl chloride as a white solid.
A mixture of 11.5 g. of sodium hydride (60% in mineral oil) and 250 ml. of tetrahydrofuran is treated with a solution of 38.4 g. of diethyl malonate in 100 ml. of tetrahydrofuran followed by 16.0 g. of sodium iodide and 25.0 g. of 4,4'-dimethylbenzhydryl chloride. The mixture is stirred for 24 hours at 25° C. and then poured into ice and extracted with ether. The dried extract is evaporated, and the residue is crystallized from hexanemethylene chloride to yield 26.1 g. of diethyl 2-(4,4'-dimethylbenzhydryl)malonate, m.p. 74°-75° C.
A mixture of 2.95 g. of this diester, 10 ml. of ethanol, and 10 ml. of 5N sodium hydroxide solution is stirred under reflux for 3 hours and evaporated. A solution of the residue in water is acidified and filtered to yield 2.35 g. of 2-(4,4'-dimethylbenzhydryl)malonic acid, m.p. 188°-191° C.
A 2.2 g. sample of this diacid is heated until it melts; the heating is continued for 5 minutes thereafter. The material is crystallized from ethanol to yield 1.51 g. of 3,3-bis(p-tolyl)propionic acid, m.p. 44°-46° C.
Amides prepared from 3,3-bis(p-tolyl)propionic acid by the method of Example 1 are shown in Table IV.
TABLE IV______________________________________EXAMPLE PRODUCT M.P. °C.______________________________________60 N--Phenyl-3,3-bis(p-tolyl)propion- 143-146 amide61 N--(p-Chlorophenyl)-3,3-bis(p-tolyl) 153-155 propionamide62 N--(p-Fluorophenyl)-3,3-bis(p-tolyl) 131-134 propionamide63 N--(p-Cyanophenyl)-3,3-bis(p-tolyl) 163-166 propionamide64 N--(p-Tolyl)-3,3-bis(p-tolyl)propion- 180-183 amide65 Ethyl 4'-[3,3-bis(4-methylphenyl) 164-166 propionamido]benzoate66 N--(p-Trifluoromethylphenyl)-3,3-bis 157-160 (p-tolyl)propionamide______________________________________
EXAMPLE 67
3,3-Bis(4-chlorophenyl)propionic acid
A 38.4 g. quantity of sodium hydride (50% in mineral oil) is washed with hexane to remove the mineral oil and then stirred with 2.0 l. of tetrahydrofuran at 10° C. while 158 ml. of triethyl phosphonoacetate is added during 15 minutes followed by 167 g. of 4,4'-dichlorobenzophenone. The solution is then stirred at 25° C. for 20 hours. The mixture is evaporated, and the residue partitioned between methylene chloride and water. The organic layer is dried and evaporated to yield 201 g. of ethyl 3,3-bis(4-chlorophenyl)acrylate, m.p. 58°-61° C.
A solution of 32.1 g. of this ester in 250 ml. of cyclohexane is treated with 1.6 g. of platinum oxide and shaken under 40 p.s.i. of hydrogen for about 6 hours. The mixture is filtered and the filtrate evaporated. The residue is crystallized from ethanol to yield 22.8 g. of ethyl 3,3-bis(4-chlorophenyl)propionate, m.p. 48°-52° C.
A solution of 25.0 g. of this ester and 9.6 g. of
A solution of 25.0 g. of this ester and 9.6 g. of potassium hydroxide in 200 ml. of 95% aqueous ethanol is stirred under reflux for 4 hours, allowed to cool, and poured into ice water. The mixture is acidified with 6N hydrochloric acid and filtered. The solid is recrystallized from acetonitrile to yield 22.0 g. of 3,3-bis(4-chlorophenyl)propionic acid as a white solid, m.p. 190°-193° C.
Amides prepared from 3,3-bis(p-chlorophenyl)propionic acid by the method of Example 1 are shown in Table V.
TABLE V______________________________________EXAMPLE PRODUCT M.P. °C.______________________________________68 N--Phenyl-3,3-bis(p-chlorophenyl)pro- 207-209 pionamide69 N--(4-Fluorophenyl)-3,3-bis(p-chloro- 193-196 phenyl)propionamide70 N--(4-Tolyl)-3,3-bis(p-chlorophenyl) 233-235 propionamide71 N--(4-Cyanophenyl)-3,3-bis(p-chloro- 190--192 phenyl)propionamide72 N--(4-Acetylphenyl)-3,3-bis(p-chloro- 146-148 phenyl)propionamide73 N--(4-Trifluoromethylphenyl)-3,3-bis 181-184 (p-chlorophenyl)propionamide______________________________________
No effort has been made to optimize the yields obtained in the aforementioned Examples.
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This disclosure describes novel substituted aralkanamidobenzoic acids and analogs thereof. These compounds are useful pharmaceutical agents for ameliorating atherosclerosis by inhibiting the formation and development of atherosclerotic lesions in the arterial wall of mammals.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2002-357143, filed Dec. 9, 2002, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image search technique for searching an image database storing images, for desired images.
2. Description of the Related Art
Known methods of searching for an image can be roughly classified into two types.
According to a first search method, images are provided with keywords that reflect the contents of the images. Then, during a search, an image provided with a keyword equivalent to one input by a user is extracted from an image database and presented to the user.
A problem with this search method is that the operation of providing each image with an appropriate keyword is not easy. Furthermore, if the user is different from the person who has provided the keywords, the reference keyword may not match the corresponding keyword used in the image database even though the two keywords are conceptually the same. Thus, this method may fail to search for appropriate images.
According to a second search method, a search is carried out utilizing attribute values that quantify the physical characteristics of images such as their colors, shapes, or textures. The attribute values of a reference image are compared with those of a searched image to extract a similar image from the image database. This image is then presented to the user as a search result.
With this method, since the attribute values extracted on the basis of a predetermined algorithm are not necessarily the same as those of an equivalent image human beings expect to obtain, the similarity between the searched image and the reference image may often be low in terms of human senses. Consequently, it has been pointed out that this method has a low detection accuracy.
To avoid these problems, the following technique has been proposed. For a set of images in a database which are provided with the same keyword, characteristic amount vectors and importance levels are determined. Then, the keyword is converted into an attributed value. The database is then searched for an image on the basis of this attribute value (Jpn. Pat. Appln. KOKAI Publication No. 2002-140332).
However, with this search method, images must be provided with keywords. Thus, much labor is required to provide the keywords. Furthermore, the distribution of the characteristic amount vectors of images with the same keyword is not ensured to be sufficiently localized on a characteristic space. Consequently, similar images cannot always be retrieved accurately.
As an alternative, the following technique has been proposed. A search is carried out using keywords assigned to images. Then, a similarity search is executed using the attribute values of images obtained results (Jpn. Pat. Appln. KOKAI Publication No. 10-289240).
However, this search method also uses keywords. It is a heavy burden to provide images with keywords. Moreover, images having the same keyword may have markedly different image attribute values. Accordingly, a decrease in search accuracy cannot always be avoided even though a search for a similar image is executed on the basis of attribute values.
BRIEF SUMMARY OF THE INVENTION
An image search program according to a first aspect of the present invention allows a computer to execute a symbol providing step of determining whether predetermined images are similar to or dissimilar from first images and storing symbols for each of the predetermined images in data regions which are categories, in association with one first image, each symbol representing similarity or dissimilarity, a reference-image retrieving step of retrieving some of the first images stored in a storage section, which are similar to a reference image, thereby retrieving primary selected images, an accumulating step of accumulating the values of the symbols stored in each category, for secondary selected images included in the primary selected images and being more similar to the reference image than the remaining primary selected images, a category selecting step of selecting some of the categories, each having accumulated a symbol value greater than the other categories, thereby selecting a first number of categories, and a symbol-provided image retrieving step of retrieving some of the first images having symbols representing similarity and stored in a second number of categories included in the first number of categories.
An image search program according to a second aspect of the present invention allows a computer to execute a reference-image retrieving step of retrieving at least one second image selected from first images stored in a storage section, which is similar to a reference image, an image-displaying step of displaying an index image obtained by reducing the second image retrieved, an image-selecting step of causing a person who wants to retrieve images to select at least one third image similar to the reference image, in accordance with the index image displayed, and a symbol-providing step of storing symbols in data regions which are categories provided for the reference image, in association with the third image selected, each symbol representing similarity or dissimilarity.
A storage medium according to the first aspect of the present invention stores a computer readable program allowing a computer to execute a symbol providing step of determining whether predetermined images are similar to or dissimilar from first images and storing symbols for each of the predetermined images in data regions which are categories, in association with one first image, each symbol representing similarity or dissimilarity, a reference-image retrieving step of retrieving some of the first images stored in a storage section, which are similar to a reference image, thereby retrieving primary selected images, an accumulating step of accumulating the values of the symbols stored in each category, for secondary selected images included in the primary selected images and being more similar to the reference image than the remaining primary selected images, a category selecting step of selecting some of the categories, each having accumulated a symbol value greater than the other categories, thereby selecting a first number of categories, and a symbol-provided image retrieving step of retrieving some of the first images having symbols representing similarity and stored in a second number of categories included in the first number of categories.
A storage medium according to the second aspect of the present invention stores a computer readable program allowing a computer to execute a reference-image retrieving step of retrieving at least one second image selected from first images stored in a storage section, which is similar to a reference image, an image-displaying step of displaying an index image obtained by reducing the second image retrieved, an image-selecting step of causing a person who wants to retrieve images to select at least one third image similar to the reference image, in accordance with the index image displayed, and a symbol-providing step of storing symbols in data regions which are categories provided for the reference image, in association with the third image selected, each symbol representing similarity or dissimilarity.
An image search apparatus according to the first aspect of the present invention comprises a symbol providing section which determines whether predetermined images are similar to or dissimilar from first images and stores symbols for each of the predetermined images in data regions which are categories, in association with one first image, each symbol representing similarity or dissimilarity, a reference-image retrieving section which retrieves some of the first images stored in a storage section, which are similar to a reference image, thereby retrieves primary selected images, an accumulating section which accumulates the values of the symbols stored in each category, for secondary selected images included in the primary selected images and being more similar to the reference image than the remaining primary selected images, a category selecting section which selects some of the categories, each having accumulated a symbol value greater than the other categories, thereby selects a first number of categories, and a symbol-provided image retrieving section which retrieves some of the first images having symbols representing similarity and stored in a second number of categories included in the first number of categories.
An image search apparatus according to the second aspect of the present invention comprises a reference-image retrieving section which retrieves at least one second image selected from first images stored in a storage section, which is similar to a reference image, an image-displaying section which displays an index image obtained by reducing the second image retrieved, an image-selecting section which causes a person who wants to retrieve images to select at least one third image similar to the reference image, in accordance with the index image displayed, and a symbol-providing section which stores symbols in data regions which are categories provided for the reference image, in association with the third image selected, each symbol representing similarity or dissimilarity.
An image search method according to the first aspect of the present invention comprises a symbol providing step of determining whether predetermined images are similar to or dissimilar from first images and storing symbols for each of the predetermined images in data regions which are categories, in association with one first image, each symbol representing similarity or dissimilarity, a reference-image retrieving step of retrieving some of the first images stored in a storage section, which are similar to a reference image, thereby retrieving primary selected images, an accumulating step of accumulating the values of the symbols stored in each category, for secondary selected images included in the primary selected images and being more similar to the reference image than the remaining primary selected images, a category selecting step of selecting some of the categories, each having accumulated a symbol value greater than the other categories, thereby selecting a first number of categories, and a symbol-provided image retrieving step of retrieving some of the first images having symbols representing similarity and stored in a second number of categories included in the first number of categories.
An image search method according to the second aspect of the present invention comprises a reference-image retrieving step of retrieving at least one second image selected from first images stored in a storage section, which is similar to a reference image, an image-displaying step of displaying an index image obtained by reducing the second image retrieved, an image-selecting step of causing a person who wants to retrieve images to select at least one third image similar to the reference image, in accordance with the index image displayed, and a symbol-providing step of storing symbols in data regions which are categories provided for the reference image, in association with the third image selected, each symbol representing similarity or dissimilarity.
Advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention, and together with the general description given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a block diagram showing the configuration of an image search apparatus to which an image search method according to the present invention is applied;
FIG. 2 is a diagram showing associations among functions of the image search apparatus which are used to register original images;
FIG. 3 is a flowchart schematically showing a process procedure used to register original images;
FIG. 4 is a diagram showing the configuration of index data;
FIG. 5 is a diagram showing associations among functions of the image search apparatus which are used to provide a symbol to an original image;
FIG. 6 is a flowchart schematically showing a process procedure used to provide a symbol to an original image;
FIG. 7 is a diagram showing the configuration of a symbol area;
FIG. 8 is a diagram showing associations among functions of an image search method according to a first embodiment;
FIG. 9 is a flowchart schematically showing the process procedure of the image search method according to the first embodiment;
FIG. 10 is a diagram illustrating an adding method;
FIG. 11 is a diagram showing associations among functions of an image search method according to a second embodiment; and
FIG. 12 is a flowchart schematically showing the process procedure of the image search method according to the second embodiment.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a block diagram showing the configuration of an image search apparatus to which an image search method according to the present invention is applied. An image to be searched for will hereinafter be referred to as an “original image”.
An image search apparatus 1 includes an image processing section 4 , an attribute processing section 5 , a symbol processing section 6 , an image database 8 , and a buffer memory 9 .
The image processing section 4 deals with image data. The attribute processing section 5 deals with attribute data on images. The symbol processing section 6 deals with a symbol indicating whether or not an image belongs to a certain category. The image database 8 is a storage region for original images. The buffer memory 9 is a storage region for other data.
The image processing section 4 is provided with an image input section 11 , an index image creating section 12 , an image display section 13 , and an image selecting section 14 .
The image input section 11 loads an original image from an image input apparatus (not shown) into the image search apparatus 1 . The index image creating section 12 creates an index image that is a reduced image of the original image stored in the image database 8 . The image display section 13 displays the index image or the original image on a display device (not shown). The image selecting section 14 supports an image selecting operation performed by a user.
The attribute processing section 5 is provided with an attribute processing section 18 , an attribute analyzing section 19 , and a similarity calculating section 20 .
The attribute processing section 18 determines attribute values for an original image. The attribute analyzing section 19 belongs to the attribute processing section 18 and extracts various attribute values from the original image. The similarity calculating section 20 calculates an index for determining whether or not images are similar to each other, on the basis of the attribute values.
The symbol processing section 6 is provided with a symbol providing section 23 , a symbol adding section 24 , and a symbol searching section 25 .
The symbol providing section 23 provides the same symbol to all the original images selected by the image selecting section 14 when determining that the original images are similar to a reference image on the basis of an index image displayed on the image display section 13 . If the original image is similar to the reference image, then for the reference image, for example, “1” is provided at a particular digit of data associated with the original image. If the original image is not similar to the reference image, for example, “0” is provided to the same digit of the data. The symbol adding section 24 executes a symbol adding calculation on the plurality of original images. The image searching section 25 searches for an original image with a predetermined symbol indicating “1”.
The image database 8 is provided with an original image region 28 , an index image region 29 , and an index data region 30 .
The original image area 28 stores original images to be searched for. The index image region 29 stores index images obtained by reducing the sizes of original images. The index data region 30 stores the original images, addresses used to access the index images, information on the original images such as their attribute values.
The buffer memory 9 comprises a reference image memory 33 storing reference images used as references for image searches and a candidate index memory 34 storing, for example, the storage addresses of original images selected in an intermediate stage of a search.
Now, operations of the present image search apparatus 1 will be described.
As an operation performed in a preparation stage, a user registers original images in the image search apparatus 1 .
FIG. 2 is a diagram showing associations among functions of the image search apparatus which are used to register original images. FIG. 3 is a flowchart schematically showing a process procedure used to register original images.
At step S 1 , the image input section 11 loads the original images from the image input apparatus (not shown). Then, the image input section 11 stores the loaded original images in the original image region 28 of the image database 8 . The image input section 11 activates the attribute processing section 18 .
At step S 2 , the attribute processing section 18 sets an initial value “1” to a control variable P, and activate the P-th attribute analyzing section 19 .
At step S 3 , the P-th attribute analyzing section 19 determines the P-th attribute value for the loaded original images. Here, the attribute values of the original images include numerical data items representing colors, shapes, textures, and the like expressed in the original images. Accordingly, the attribute values as used herein refer to amounts expressed by quantification for physical components such as colors and shapes and textures are not values based on sensuous elements based on human subjectivities.
At step S 4 , the attribute processing section 18 stores the attribute values P determined by the P-th attribute analyzing section 19 , in an attribute value area of index data 37 saved in the index data region 30 .
FIG. 4 is a diagram showing the configuration of the index data 37 .
The index data 37 is provided with an image ID 37 a , an original image address 37 b , an index image region address 37 c , an attribute value area 37 d , and a symbol area 37 e.
The image ID 37 a identifies an original image. The original image address 37 b stores an address in the original image area 28 at which the original image is stored. The index image region address 37 c stores an address in the index image region 29 at which an index image that is a reduced image of the original image is stored. The attribute area 37 d stores a plurality of attribute values of the original image. The symbol area 37 e stores a symbol for a category provided to the original image as well as the total number of symbols.
Here, the “category” refers to a data region used to identify an image determined by the user to be visually the same as a certain image. The category is defined for each reference image, described later. When the original image belongs to the J-th category, this means that it is visually similar to the J-th reference image presented by a requester. In this case, a “symbol J” in the symbol area 37 e is 1.
At step S 5 , it is checked whether or not a predetermined number N of attribute values have all been determined. If the result of the check in step S 5 is No, that is, the predetermined number N of attribute values have not been determined, then at step S 6 , the control variable P is counted up. Then, the processing in steps S 3 to S 4 is repeated.
If the result of the check in step S 5 is Yes, that is, the predetermined number N of attribute values have been determined, then at step S 7 , the index image creating section 12 creates an index image that is a reduced image of the original image. The index image creating section 12 stores the index image in the index image region 29 and updates the index image address 37 c of the index data 37 .
At step S 8 , it is checked whether or not all the original images have been registered. If the result of the check in step S 8 is No, that is, there remain any images to be registered, then the processing in steps S 1 to S 7 is repeated.
If the result of the check in step S 8 is Yes, that is, all the images have been registered, the image registering process is ended. All the original images need not be registered at a time but the registration of an original image may be repeated.
Subsequently, the user provides a symbol to each of the original images registered in the image search apparatus 1 . Here, the “symbol” used in the present invention is a concept which is similar to a conventional keyword but is broader and higher than the keyword. That is, the keyword represents a characteristic of an image on the basis of a “word”. However, the “symbol” does not conceptualize the image using a word, but groups it on the basis of its visual identity. When images are determined to be the same, they are said to belong to the same category, with “1” stored in the same digit in the symbol area 37 . The digits in the symbol area 37 e other than the one indicating the number of symbols represent the respective categories.
FIG. 5 is a diagram showing associations among functions of the image search apparatus which are used to provide a symbol to an original image. FIG. 6 is a flowchart schematically showing a process procedure used to provide a symbol to an original image.
At step S 11 , the user prepares a reference image used as a reference for providing a symbol to each original image. Here, the reference image replaces the conventional keyword. The process described below provides the original image with a symbol indicating whether or not it is similar to the reference image.
At step S 12 , the image input section 11 loads the reference image from the image input apparatus (not shown). Then, the image input section 11 stores the loaded reference image in the reference image memory 33 of the buffer memory 9 .
At step S 13 , the similarity calculating section 20 retrieves the reference image from the reference image memory 33 . The similarity calculating section 20 then calculates the previously described attribute values for the reference image. That is, in accordance with the procedure in steps S 3 and S 4 , described previously, the similarity calculating section 20 obtains a plurality of attribute values processed by the attribute analyzing section 19 .
At step S 14 , the similarity calculating section 20 identifies original images similar to the reference image on the basis of the index data 37 stored in the index data region 30 . Similarity is determined by comparing the reference image with the original image for a plurality of attribute values 1 to M. For example, the original image can be determined to be similar to the reference image if a function is set which uses the attribute values 1 to M as parameters and if the reference image and the original image have similar function values.
At step S 15 , the image display section 13 retrieves the index images of the original images sequentially identified in the order of decreasing similarity level, from the index image region 29 . The image display section 13 then displays a predetermined number of index images on a display device (not shown). The image display section 13 then outputs an instruction urging the user to make selection.
At step S 16 , the user views the displayed index images, determines any of the original images to be similar to the reference image, and selects them. The user may select one or more images. Alternatively, the user may choose not to select any original images. The image selecting section 14 supports the selecting operation performed by the user and loads information on the selected image.
At step S 17 , the symbol providing section 23 provides a symbol in the symbol area 37 e of the index data 37 for the selected original image.
FIG. 7 is a diagram showing the configuration of the symbol area 37 e . The symbol providing section 23 adds 1 to the “number of symbols” in the symbol area 37 e for the selected original image, to obtain M. The symbol providing section 23 also describes a number “1” at the position of a newly provided “symbol M”. Furthermore, the symbol providing section 23 adds 1 to the “number of symbols” in the symbol area 37 e for the original image which has not been selected, to obtain M. The symbol providing section 23 describes a number “0” at the position of a newly provided “symbol M”.
At step S 18 , if one type of reference image can be provided with a plurality of symbols, it is checked whether or not all the symbols have been provided.
Even with one type of reference image, if the image contains a plurality of subjects, then the respective subjects can be provided with different marks. Furthermore, even if the image contains only one subject, it can be provided with a plurality of symbols by varying the viewpoint. For example, one subject can be provided with a plurality of symbols by considering its color and form to be different features. Then, if the result of the check in step S 18 is No, the processing in steps S 16 and S 17 is repeated.
If the result of the check in step S 18 is Yes, then at step S 19 , it is checked whether or not the symbol providing operation has been finished. For example, it is checked whether or not the symbol providing process has been finished for all the reference images.
If the result of the check in step S 19 is No, that is, there remain any reference images to be processed, the processing in steps S 13 to S 17 is repeated. If the result of the check in step S 19 is Yes, that is, the symbol providing process has been finished for all the reference images.
In the present embodiment, the symbols “1” and “0” are used. However, the present invention is not limited to this aspect. The symbols may be letters or special symbols and need not particularly be meaningful. Furthermore, it is unnecessary to know what reference images the symbols 1 to M indicate. In this point, the present invention essentially differs from the keyword system, in which each keyword requires a particular meaning and content.
Furthermore, the present embodiment is characterized in that similarity is not only quantitatively determined on the basis of the attribute values but the result for similarity to the reference image subjectively determined by the user is loaded as a symbol. In general, the similarity of images depends significantly on subjective elements. Then, by configuring the present image search apparatus 1 so that similarity is determined on the basis of not only mechanical determinations based on digitized data but also the user's determinations, it is possible to provide results similar to the subjectivity of the user using the present image search apparatus 1 .
Moreover, in the present embodiment, each time a reference image is loaded and a symbol providing process is executed, the number described in the “number of symbols”, shown in FIG. 7 is incremented by one. Then, the data area used to provide the symbol, that is, the category increases. This means that the symbol information characterizing images grows as more reference images are loaded. Consequently, it is expected that search accuracy increases consistently with the number of times the image search apparatus is used.
On the other hand, the present embodiment is characterized by using no keywords. However, steps S 11 to S 17 can be applied to keyword provisions for the conventional keyword search. By providing the same keyword to the images selected in steps S 11 to S 16 , it is possible to provide keywords more easily than in the case in which each image is provided with a keyword.
Now, description will be given of an image search method according to a first embodiment of the present invention.
FIG. 8 is a diagram showing associations among functions of the image search method according to the first embodiment. FIG. 9 is a flowchart schematically showing the process procedure of the image search method according to the first embodiment.
At step S 21 , the user prepares a reference image similar to an image to be searched for. The image input section 11 loads the reference image from the image input apparatus (not shown). Then, the image input section 11 stores the loaded reference image in the reference image memory 33 of the buffer memory 9 . Instead of being loaded from the image input apparatus (not shown), the reference image may be selected from those already stored in the reference image memory 33 . Alternatively, any of the original images stored in the original image region 28 may be selected as a reference image.
At step S 22 , the similarity calculating section 20 retrieves the reference image from the reference image memory 33 . The similarity calculating section 20 then calculates the previously described attribute values for the reference image. That is, in accordance with the procedure in steps S 3 and S 4 , described previously, the similarity calculating section 20 obtains a plurality of attribute values processed by the attribute analyzing section 19 .
At step S 23 , the similarity calculating section 20 identifies original images similar to the reference image on the basis of the index data 37 stored in the index data region 30 .
Similarity is determined on the basis of the magnitude of similarity determined as a function of a plurality of attribute values 1 to N for each of the reference and original images. For example, the attribute values 1 to N of the reference image are combined together to obtain an attribute vector V for the reference image. Likewise, an attribute vector Uh is determined for the h-th original image. Then, a similarity level Dh is calculated using Equation (1).
Dh =( Uh−V )·( Uh−V ) (1)
Dh in Equation (1) denotes the square of the Euclidean distance between the attribute vectors of the h-th original image and the attribute vector of the reference image, and is an index for similarity. That is, the similarity level increases with decreasing distance.
Furthermore, by weighting each characteristic amount to calculate the distance to obtain an attribute value, it is possible to correct the difference in characteristic (for example, color and shape) between the attribute values to obtain a more appropriate similarity index.
In this case, a weight vector indicating the weight applied to each characteristic amount is defined as W. Then, the similarity level Dh is expressed by Equation (2).
Dh =( W*Uh−W*V )·( W*Uh−W*V ) (2)
The weight may be the inverse of the variance of each attribute value sample determined from a large number of sample images.
The operator “·” indicates the inner product of vectors shown in Equation (3).
W·V=W 1 ×V 1 +W 2 ×V 2+ . . . + WN×VN (3)
The operator “*” is a vector operator that generates a vector with elements composed of values obtained by multiplying respective elements of each of the two vectors by different weights.
W*V =( W 1× V 1, W 2× V 2, . . . , WN×VN ) (4)
Then, the similarity calculating section 20 sequentially sorts the index data 37 on the plurality of identified original images (hereinafter referred to as “primary selected images”) in the order of decreasing similarity level. The similarity calculating section 20 then stores the index data 37 in the candidate index memory 34 as candidate index data.
At step S 24 , the symbol adding section 24 retrieves the index data 37 from the candidate index memory 34 , for the K most similar ones of the primary selected images. Then, the symbol adding section 24 adds up all the data provided to the same symbol in the symbol area 37 e . In the present embodiment, the data is “1” or “0”.
FIG. 10 is a diagram illustrating an adding method.
FIG. 10 shows the symbol area 37 e , corresponding to the K most similar original images Image 1 to K. The symbol adding section 24 adds data for each of the symbols 1 to M. That is, for each of the symbols 1 to M, the number of original images similar to the category represented by that symbol is determined. The results of the additions are shown at the bottom of FIG. 10 .
At step S 25 , the symbol adding section 24 selects T symbols having the largest values as a result of the addition. If T=3, the symbols 3 , 4 , and M are selected as shown in FIG. 10 .
This means that the original images determined to be very similar to the reference image often comprise the characteristics indicated by the symbols 3 , 4 , and M. That is, the original images comprising the characteristics indicated by the symbols 3 , 4 , and M are presumably likely to be similar to the reference image.
At step S 26 , the symbol searching section 25 searches for original images for which at least S of the T selected symbols are “1”, on the basis of the index data 33 . The images searched for on the basis of the symbols are those of the original images which have not been selected as the primary elected images. That is, in addition to the original images selected on the basis of the attribute values, the original images searched for on the basis of the symbols are extracted as images similar to the reference image. The method of thus selecting images on the basis of symbols is called a symbol search method.
At step S 27 , the image display section 13 displays index images of the primary selected images and of the images extracted using the symbol search method, on the display device (not shown) as search results.
According to the search method of the first embodiment, the attribute-value-based search and the symbol search are combined together to search for similar images. This enables the search accuracy to be increased. That is, the search based on attribute values determines similarity on the basis of physical components such as colors and shapes. Accordingly, human beings do not always find similarity in similar images selected using only the above references. Thus, by also applying the symbol search method of determining similarity utilizing sensuous elements based on human subjectivities, it is possible to reduce failures to detect similar images to improve the search accuracy.
Now, description will be given of an image search method according to a second embodiment according to the present invention.
FIG. 11 is a diagram showing associations among functions of the image search method according to the second embodiment. FIG. 12 is a flowchart schematically showing the process procedure of the image search method according to the second embodiment.
At step S 31 , the user prepares a reference image similar to an original image to be searched for. The image input section 11 loads the reference image from the image input apparatus (not shown). Then, the image input section 11 stores the loaded reference image in the reference image memory 33 of the buffer memory 9 . Instead of being loaded from the image input apparatus (not shown), the reference image may be selected from those already stored in the reference image memory 33 . Alternatively, any of the original images stored in the original image region 28 may be selected as a reference image.
At step S 32 , the similarity calculating section 20 retrieves the reference image from the reference image memory 33 . The similarity calculating section 20 then calculates the previously described attribute values for the reference image. That is, in accordance with the procedure in steps S 3 and S 4 , described previously, the similarity calculating section 20 obtains a plurality of attribute values processed by the attribute analyzing section 19 .
At step S 33 , the similarity calculating section 20 identifies original images similar to the reference image on the basis of the index data 37 stored in the index data region 30 . Similarity is determined in a manner similar to that used in the first embodiment.
Then, the similarity calculating section 20 sequentially sorts the index data 37 on the plurality of identified primary selected images in the order of decreasing similarity level. The similarity calculating section 20 then stores the index data 37 in the candidate index memory 34 .
At step S 34 , the image display section 13 displays index images of the primary selected images on the display device (not shown) as search results.
At step S 35 , the user views the displayed index images, determines a plurality of images (one or zero image may also be possible) to be similar to the reference image, and selects them. The image selecting section 14 supports the selecting operation performed by the user and loads information on the selected image.
At step S 36 , the symbol adding section 24 retrieves the index data 37 from the candidate index memory, for the original images selected by the user. Then, the symbol adding section 24 adds up all the data provided to the same symbol in the symbol area 37 e . The adding method is similar to the one used in the first embodiment. Accordingly, its detailed description is omitted.
At step S 37 , the symbol adding section 24 selects T symbols having the largest values as a result of the addition.
At step S 38 , the symbol searching section 25 searches for original images for which at least S of the T selected symbols are “1”, on the basis of the index data 33 . The images searched for on the basis of the symbols are those of the original images which have not been selected as the primary elected images.
At step S 39 , the image display section 13 displays index images of the primary selected images and of the original images extracted using the symbol search, on the display device (not shown) as search results.
According to the search method of the second embodiment, similar images are selected from primary selected images on the basis of human subjectivities. Then, the symbol search method is applied on the basis of the selected images. This further improves the accuracy of the search for similar images based on the symbol search.
As described above, according to the present embodiment, the concept of the “symbol” is introduced. Accordingly, required labor can be sharply reduced compared to the conventional operation of providing keywords. Furthermore, the provided symbols need not be keywords. This avoids troubling the user about selecting keywords during a search. Moreover, the symbol search is used with the conventional method of searching for similar images. This improves the accuracy of the search for similar images.
The functions described in the above described embodiments cannot only be configured using hardware but can also be implemented by using software to load programs describing the functions into a computer. Alternatively, the functions may be configured by properly selecting software or hardware.
Moreover, the functions can be implemented by loading programs stored in a storage medium (not shown), into a computer. Here, the storage medium according to the present embodiment may use any storage form provided that it can store programs and that a computer can read data from it.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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An image search program allowing a computer to execute a reference-image retrieving step of retrieving at least one second image selected from first images stored in a storage section, which is similar to a reference image, an image-displaying step of displaying an index image obtained by reducing the second image retrieved, an image-selecting step of causing a person who wants to retrieve images to select at least one third image similar to the reference image, in accordance with the index image displayed, and a symbol-providing step of storing symbols in data regions which are categories provided for the reference image, in association with the third image selected, each symbol representing similarity or dissimilarity.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a method of and an arrangement for designing of tubular round knitted articles produced on a flat knitting machine.
[0002] Due to constantly increasing personal costs, a trend for producing knitted articles for which after the production of the knitting machine no additional fabrication works are needed has been observed. These knitted articles are usually tubular round final products which are produced with the use of the possibilities of modern electronically controlled, fully automatic flat knitting machines. The sleeve and body trunk parts of such a tubular round final article are first formed as separate tubular round knitted articles, before the sleeves must be connected to the body trunk part. Starting from this position, three individual tubular round knitted articles are knitted further as a single tubular round knitted article. Then shoulder shapes, neck portions and in some cases collars are knitted to them. The knitted article is therefore completely formed by the flat knitting machine. After this no seams must be closed any longer, and as a rule only the initial and the end thread portions are cleaned manually.
[0003] In the tubular round final articles which are formed of several parts, in order to produce very complex knitted articles correspondingly large numbers of knitting data for controlling the flat knitting machine must be provided. This no longer can be done manually. The European patent document EP 0 763 615 B1 discloses a device and a method for designing a round knitted article for a flat knitting machine, in which first a pattern for the knitted article is placed. Subsequently, a contour of the knitted article is selected by selection of contour shapes stored on the device and dimensional data for the front and rear parts as well as the sleeves are provided. After this manually for each individual contour region a knitting process description is produced, which depends on the pattern structures available in the corresponding contour region. Then, based on the knitting process description, the device automatically generates the control data for the flat knitting machine.
[0004] This known method makes possible a high automation degree during designing of tubular round final knitted articles. However, it has some disadvantages. The knitted articles can not have any arbitrary contours, but they can have only those contours which are contained in the selection stored in the device. Since the knitting process descriptions depend on the contour and the pattern in the corresponding contour region, it is necessary for each pattern structure occurring inside the contour to provide its own knitting process description, which is very expensive. Manual changes which are performed after the manufacture of the design are not transferred automatically to the original pattern representation, so that no visual control of the performed changes is possible. Furthermore, with the known method after the manufacture of the total design a close to reality representation of the knitting device can be visualized, but not the intermediate stages of designing, for example during the pattern association to a sleeve or the like.
SUMMARY OF THE INVENTION
[0005] Accordingly, it is an object of the present invention to provide method of and device for designing tubular round knitted articles produced on a flat knitting machine, which avoid the disadvantages of the prior art.
[0006] More particularly, it is an object of the present invention to provide a method of and device for designing a tubular round knitted articles, which are user-friendlier than the known solutions and allow a higher automation degree.
[0007] In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a method of designing of tubular round knitted articles on a flat knitting machine with at least one front part and at least one rear part, which comprises the following steps:
[0008] preparation of a knitting pattern for each front part and each rear part as well as in some cases further knitted parts such as pockets, independently from the shape of the knitted piece by means of an inputting and indicating device and storing the pattern data,
[0009] describing the contour of each front part and each rear part by means of the inputting and indicating device and storing the contour data,
[0010] fixing the contour portion of the knitted parts on which a connection with another knitted part must be produced, and storing the data of this contour portion,
[0011] assembling the contours of the knitted parts to a total knitted piece and determining a sequence of knitting rows, with which the total knitted piece is producible,
[0012] for each knitted part indicating the knitting pattern and the contour on the indicating device, by means of the inputting device displacing the contour onto the knitting pattern until the knitting pattern fills the contour in a desired manner,
[0013] indicating the total knitted piece with the selected and stored knitting pattern-and contour data for the individual knitted part,
[0014] determining the knitting information for each knitting row for providing the total knitting piece in accordance with the pattern and contour data of the knitting parts.
[0015] The knitting information for each knitting row can be converted into knitting data for a flat knitting machine and thereby one or several flat knitting machines can be controlled for producing the tubular round knitting article.
[0016] With the inventive method only a few steps can be performed manually. They are limited to the perforation of a knitting pattern for each knitted part, the fixing of the contours of the knitted part as well as the connection portion of the individual knitted parts, and the introduction of the knitting pattern into the contour of the corresponding knitted part. When these data are provided, then automatically the required sequence of knitting rows is generated for production of the total knitting piece as well as the knitting information for each individual knitting row. Correction possibilities both of the pattern and the contour are possible in each designing stage. During a correction of the pattern or the contour of the total knitted piece, moreover the made changes can be provided automatically in the stored pattern and the contour data of the corresponding individual knitted part. Also, after a correction, the individual representations of the knitted parts and the representation of the total knitted piece coincide with one another.
[0017] The knitted patterns can be designed preferably in the loop formation representation or in the thread running representation. From the data for one individual representation type the data for another representation type can be calculated, so that the knitted pattern in each design stage of the knitted article is indicatable in both representation types. Further advantages are provided when in the case of the loop formation representation a reality-close approximately three-dimensional representation of all elements of the knitted piece, such as loops, tucks and floating is provided.
[0018] A tubular round knitted article is composed of at least three knitting plates, one for the front part and one for the rear part. With pocket-and/or special patterning, further knitting planes can be produced. In accordance with a preferable variant of the inventive method, the individual knitted parts are associated with one or several planes of the total knitted piece. It is advantageous when also each knitting element, such as loops, tucks, floatings of one knitted part are associated with one of the knitting planes. Thereby for the user it is clear, in which plane the corresponding knitting elements are formed.
[0019] For facilitating the designing of the knitting pattern for the knitted parts, portions from a knitting pattern can be stored as individual modules, which at different locations of the pattern or during designing of the knitting patterns of another knitted parts can be again utilized. A significant facilitation of this modular technique is moreover also possible when the modules with the new use at other locations can be joined with a loop technique correctly in the surrounding knitting pattern, and if necessary, an adaptation of the knitting article plane association to the individual knitting elements of the module can be performed.
[0020] The fixing of the contour portions of the knitted parts, on which a connection with another knitted part might be produced, can be performed so that the starting and end points of the portion and the type of the connection are determined for example with or without performing a longitudinal compensation between the knitted parts and can be stored.
[0021] The invention also deals with an arrangement for designing tubular round knitted articles produced on a flat knitting machine with at least one front part and at least one rear part, that has at least one storage device for the designing data, at least one indicating device for representation of design formations of the knitted article and at least one inputting device for producing and changing the design former, wherein in accordance with the present invention it has at least one device for assembling the contours of the at least one front part and the at least one rear part in accordance with a manually inputtable connection steps and for calculating the knitted rows required for production of the contour of the total knitted piece, as well as for calculating the knitting information for each knitting row of the total knitted article in accordance with the pattern-and contour data of the individual knitted parts.
[0022] The arrangement also has a device for converting the knitting information of each knitting row into a knitting data for a flat knitting machine. In accordance with a preferable embodiment, the indicating device can be formed so that simultaneously loop formation and thread running representations of the knitted article or the knitted article parts are reproducible.
[0023] Further decisive advantages, in particular during correction of the knitted product production, are produced when the arrangement during change of one or the both representation types simultaneously changes the other representation.
[0024] For facilitating the knitting pattern production, the arrangement can be provided with devices for combining several knitting elements of a thread running-or loop formation representation to modules and storing devices for storing the modules. Furthermore, the devices for loop-technically correct insertion of modules in an available knitting pattern, for reducing and increasing, for multiplying and for inverting of modules can be provided.
[0025] The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] [0026]FIG. 1 is a principle view of an inventive designing arrangement together with a flat knitting machine and a tubular round final knitted article;
[0027] [0027]FIGS. 2 a and 2 b are views showing a partial view of a front side of a tubular round knitted article in stitch formation representation and a thread running representation correspondingly;
[0028] [0028]FIGS. 3 a - 3 c are views showing two stitch formation representations and a thread running representation of a portion of a rear part of a tubular round knitted article;
[0029] [0029]FIGS. 4 a and 4 b are views showing a joint representation of the front and the rear parts from FIGS. 2 and 3 in a loop formation representation and a thread running representation;
[0030] [0030]FIGS. 5 a and 5 b are views showing representation of the front part of FIG. 2 in a loop formation representation and a thread running representation, which clearly show the knitting production;
[0031] [0031]FIGS. 6 a and 6 b are views showing a thread running representation of a pattern and a knitting module inserted in the pattern;
[0032] [0032]FIGS. 7 a - 7 c are views showing a loop formation representation of a braid pattern of the front and rear part of a tubular round knitted article;
[0033] [0033]FIG. 8 is a view showing a representation of contours of different knitted parts of a tubular round knitted article;
[0034] [0034]FIG. 9 is a principle view of the definition of connecting points of two knitted parts;
[0035] [0035]FIG. 10 is a view showing a representation of a knitting row sequence on an example of a sleeve and a body trunk part with a V-section on the front part;
[0036] [0036]FIG. 11 is a principle view showing the introduction of a pattern of a knitting pattern in different knitted parts;
[0037] [0037]FIGS. 12 a - 12 c are views showing different representations of a total knitted article composed of individual knitted parts.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] [0038]FIG. 1 shows a designing arrangement for producing a tubular round final knitted article 9 by means of a flat knitting machine 8 . The designing arrangement has a computing and storage device 1 , a keyboard 2 as a first inputting device, a graphic tablet 4 as a second inputting device, and an image screen 3 as an indicating device. A printer 5 and an external mass storage 6 are connected to the computing and storage device 1 .
[0039] FIGS. 2 - 7 show various pattern representation-and design possibilities of an inventive method and an inventive arrangement.
[0040] [0040]FIG. 2 a shows a loop formation representation of a section of the outer view of a front side of a right smooth tubular round knitted article. The loops 10 of the front part are right loops, and in FIG. 2 a are shown as in the final knitted article. FIG. 2 b shows the thread running representation corresponding to FIG. 2 a wherein the loops 10 here are formed on the front needle bed V.
[0041] [0041]FIG. 3 a shows the inner view of the rear part of a right smooth tubular round final knitted article. The loops 11 are left loops and formed, as in the thread running representation in FIG. 3 b , on the rear needle bed H. FIG. 3 shows the outer view of the rear part of the tubular round knitted article. Here the loops 11 are shown as right loops.
[0042] [0042]FIG. 4 a shows in the general view the front-end rear part from FIGS. 2 a and 3 a as a loop formation representation in a combined view. The right loops 10 of the front part belong to the first plane 100 of the total knitted product and the loops 11 to the second plane 200 . In this example a right smooth tubular round knitted article has only two knitting planes, the first knitting plane 100 for the front part and the second knitting plane 200 for the rear part. FIG. 2 b shows the thread running representation corresponding to FIG. 4 a . The loops 10 are formed on the front needle V and the loops 11 of the rear part are formed on the rear needle bed H.
[0043] [0043]FIG. 5 a shows a further type of the representation of the front part of FIG. 2 a in the loop formation representation, wherein the loops 10 are shown as they actually are suspended in the needles of the front needle bed. FIG. 5 b illustrates that the loops 10 are knitted only with each second needle of the front needle bed V. It can be seen that the loops 10 in FIG. 5 a are pulled further from one another than the loops 10 in the representation of FIG. 2 a , which is a reality-closed representation of the front part and does not consider the knitting-technical production of the knitted article.
[0044] [0044]FIGS. 6 a and 6 b illustrate the binding of a knitting module 25 in a knitting pattern 26 . The knitting pattern 26 in the rows 101 - 104 contains knitting instructions for the first plane of the knitted product and in the rows 201 - 205 contains data for the second plane of the knitted article. The module 25 contains knitting informations 101 ′- 104 ′ for a single knitting plane. FIGS. 6 b illustrates how with insertion of the module 25 into the knitting pattern 26 automatically an adaptation of the module 25 in the both different knitting planes 100 and 200 is performed. Since the module 25 contains only data for the first plane of the knitted article, the rows of the second plane 201 - 205 remain unchanged. For the rows 101 - 104 , the module 25 contains data that in each its row left loops must be formed.
[0045] For enabling formation of mainly left loops in the row 101 , automatically the row 101 ′ generated, in which the fifth loop from left is transferred to the rear needle bed H. Also automatically a row 101 ″ is produced, in which the left loops are transferred back from the rear needle bed to the front needle bed. In an identical way, for the row 102 a row 102 ′ is generated. Also, the row 102 ″/ 102 ′ is automatically produced. Here the left loops are transferred back from the rear needle bed to the front needle bed, and the fourth loop is transferred from left to the rear needle bed, so that it can form a left loop in the rows 103 and 104 . In a similarly automatically produced row 104 ″ then the fourth loop is transferred back from left to the front needle bed V.
[0046] [0046]FIG. 7 a shows a 2×2 braid in the representation for a first knitting plane. The loop train 15 , 16 which raises to the right upwardly forms the intersecting visual side, and the loop train 17 raising to the left upwardly is covered. The illustrated knitting plane can be for example the outer front plane. FIG. 7 b shows the braid of FIG. 7 a in a representation for the second knitting plane of a tubular round knitted product, as seen from the front side of the knitted product. The second plane can be for example the inner side of the rear part. The braid train 15 ′, 16 ′ is now covered and raises to the left, and the loop train 17 ′, 18 ′ raises to the right and is not visible. In FIG. 7 c the knitted product is shown from the rear side. FIG. 7 c shows also the braid which is seen from the outer side of the rear part. The loop trains 15 ″, 16 ″ and 17 ″, 18 ″ are mirror inverted with respect to the orientation in FIG. 7 a.
[0047] [0047]FIG. 8 shows the contours of a front part 24 , a rear part 23 , as well as two sleeves 21 , 22 . The parts 21 - 24 can be selected completely arbitrarily by a designer.
[0048] [0048]FIG. 9 shows an example for fixing of contour portions on which a body trunk part 30 and a sleeve 31 must be connected with one another. This is performed by fixing the initial and end points 32 , 33 , 34 on the body trunk part 30 and corresponding initial and end points of the connecting portions 32 ′, 33 ′ and 34 ′ on the sleeve 31 . In the region between the points 32 / 32 ′ and 33 / 33 ′, the sleeve is suspended on the body trunk part and simultaneously production knitting rows for the sleeve are produced. Between the points 33 / 33 ′ and 34 / 34 ′ the sleeves are suspended only on the body trunk part and no loop rows for the sleeve 31 are produced any longer.
[0049] [0049]FIG. 10 shows example as an on the front part 30 and the sleeve 31 of FIG. 9, the sequence of criteria, in accordance with which a knitting row sequence is provided. 40 identifies the starting knitting row both of the body trunk part 30 and the sleeve 31 . At the knitting row 41 , the separate production of the body trunk part 30 and the sleeve 31 starts, and simultaneously the binding of the sleeve 31 to the body trunk part 30 starts. Both parts as well as the other not shown sleeves are further knitted from this position as a single tubular round knitted product. At the position 42 an interruption of the tubular knitted product is performed at the front part for the production of a V portion. On the position 43 the sleeve 31 comes to end in correspondence with a contour description. The position 44 identifies the last production knitting row of the sleeve 31 in correspondence with the knitting process. The row 45 is the last body trunk row, in which the sleeve 31 is bound to the body trunk part 30 . In the knitting row 46 an interruption of the tubular knitted product on the rear side of the body trunk part 30 is performed for producing a neck back section. Reference numeral 47 identifies the last produced knitting row.
[0050] In accordance with the sequence of knitting rows shown in FIG. 10, in the inventive method the introduction of the knitting pattern is performed, which were before generated for the knitting parts, in the contours of the sleeves 31 , 32 as well as the body trunk part 30 . The contours 30 - 32 are displaced on the pattern field 50 so long until the individual pattern elements 51 and 52 are arranged on the right position in the corresponding knitting part 30 - 32 as shown in FIG. 11.
[0051] Subsequently the total knitted piece can be indicated in different representation types as shown in FIG. 12. FIG. 12 a shows the standard representation of a total knitted piece 60 , wherein the knitting rows for the sleeves 62 and 63 are identified starting from the sleeve connection with the body trunk part 31 , 61 . When on a knitted part no loops are formed, while on the other knitted parts loops are formed, then in the corresponding knitted part a knitted row is identified with a definite color 65 which forms the background of the knitted article. In the shown example the non-formation of loops is identified with a white color. FIG. 12 b shows a variant of the illustration of FIG. 12 a , wherein the knitting rows for the sleeves 62 and 63 are released from the body trunk and indicated in a vertical direction parallel to the body trunk part 61 . FIG. 12 c corresponds to FIG. 12 b wherein however with the sleeves 62 and 63 the illustration of individual knitting rows in which no loops are formed for the sleeves 62 and 63 is dispensed with. It is to be understood that from the total knitted piece also a reality-close loop formation representation can be indicated, to test the design results based on purely optical criteria.
[0052] It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of methods and constructions differing from the types described above.
[0053] While the invention has been illustrated and described as embodied in method of and device for designing of tubular round knitted articles produced on a flat knitting machine, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
[0054] Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
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A method of and an arrangement for designing tubular round knitted products on a flat knitting machine operates with the fine automation degree and a plurality of representing, designing and correcting possibilities.
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[0001] This application claims the benefit of priority to U.S. provisional application having Ser. No. 61/238488 filed on Aug. 31, 2009. This and all other extrinsic materials discussed herein are incorporated by reference in their entirety. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
FIELD OF THE INVENTION
[0002] The field of the invention is marketing infrastructure.
BACKGROUND
[0003] A great many different programs have been used over the years to incentivize consumers to purchase products and services. No matter how the program is implemented, however, the program must have some way of covering its costs.
[0004] In what is referred to herein as “free” discount programs, a discount card, book or other indicia is provided to consumers without any direct payment on the part of consumers for the indicia. In many such cases the programs generate revenue by tying in the discounts to purchase of some other goods or services. Examples include issuance of American Automobile Assn. (AAA®) cards, Benesaver® cards for discount plastic surgery, and pharmacy discount cards to consumers that purchase medical insurance. In other cases free discount programs generate revenue by tying the discounts to rebates or other payments from service providers utilized by the consumers. Thus, for example, programs that mail out free discount coupons often generate revenue by charging service providers for advertising in the coupons.
[0005] In what is referred to herein as “paid” discount programs, a discount card, book or other indicia is provided to consumers only upon direct payment on the part of consumers for the indicia. As with the free discount programs, paid discount programs may or may not be tied to the purchase of something else from the program's seller. For example, discount stores such as Costco® charge for memberships, and additional revenue is realized from purchases at the stores. The Entertainment Book™ and the Student Advantage™ card charge for the discount books and cards, respectively, but neither typically receive any further revenue when those cards are used to make purchases.
[0006] In that latter case, where paid programs receive no further revenue when the discounts are taken, there is little incentive (and possibly little funds) for the program to keep track of consumer transactions that utilize the discount. Indeed, to the best knowledge of the current applicant, the only known paid discount programs that track transactions related to consumers' use of the discounts all require some sort of extra purchase on the part of the consumers.
[0007] Thus, there is still a need for a paid discount program that doesn't require additional purchases on the part of consumers, but that does track consumer transactions that utilize the discount.
SUMMARY OF THE INVENTION
[0008] The inventive subject matter provides apparatus, systems and methods in which a discount program is provided that does not require a consumer to purchase anything else from a seller to benefit from the program. The discount program advantageously allows consumers to receive discounts on first and second disparate services provided by respective first and second unrelated entities.
[0009] As used herein, “disparate services” means services in different fields that are not normally provided by the same service provider (e.g., dental services and massage therapy). As used herein, “unrelated entities” means entities having no parent-child or sibling relationship, and that no more than a 5% common ownership. Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary
[0010] In preferred embodiments, at least one of the disparate services is an elective medical service, which is used herein to mean a service that is not medically essential, but legally requires the provider (in the jurisdiction in which the service is being provided) to have one or more of the following degrees: M.D. (Doctor of Medicine), D.O. (Doctor of Optometry), D.D.S. (Doctor of Dental Surgery), D.M.D. (Doctor of Dental Medicine), D.P.M. (Doctor of Podiatric Medicine), D.C. (Doctor of Chiropractic), N.D. (Naturopathic Doctor), and an M.S. or Ph.D. in Psychology. In California, for example, elective medical services include Botox® and other cosmetic injections, elective plastic surgery, LASIK surgery, some teeth whitening procedures, and braces for teeth.
[0011] In other contemplated embodiments, at least one of the disparate services is a beauty-spa service. As used herein, “beauty-spa” services means beauty services (e.g., hair, nails, and skin services), spa services (e.g., massages, facials, etc.), non-prescription exercise-related services (e.g., personal trainers and gym memberships), and nutrition-related services (e.g., non-prescription dietary supplements).
[0012] It is contemplated that discount programs could be sold through any suitable channels, including especially insurance agents that handle health policies. Of particular interest are the thousands of commissioned independent insurance agents, which can collectively provide a vast, pre-existing sales and marketing infrastructure.
[0013] One aspect of the inventive subject matter includes providing systems and methods in which: (1) a seller sells addition of a consumer to a discount program discount program; (2) without requiring the consumer to purchase anything else from the seller to benefit from the program; (3) the program allows consumers to receive discounts on first and second disparate services provided by respective first and second unrelated entities; and (4) there is a computer infrastructure that tracks transactions related to the consumer's use of the discount program.
[0014] Although a discount program could add a consumer without delivering a discount card, book or other indicia to that consumer, consumers would likely receive some sort of card indicia. As used herein, “card indicia” means a tangible item that contains at least one piece of identifying information (e.g., consumer number, name, etc.) related to the card's owner, or identifies a group to which the card's owner belongs. Preferred cards have a magnetic stripe and/or embossed lettering. Additionally or alternatively, consumers could receive discount books of coupons, which the consumers could either use themselves, or pass along to friends or acquaintances, and thereby enticing others to join the program.
[0015] All suitable manner of computer infrastructures can be used to track transactions related to consumers' use of a discount program. Contemplated computer infrastructure includes one or more consumer relationship management (“CRM”) systems, which preferably have at least one server capable of storing and processing data related to discount card transactions, and one or more user interfaces (e.g., consumer interface, seller (vendor) interface, service provider interface, advertiser interface, management interface, etc.). Consumer interfaces could be used, for example, to allow consumers to activate the program, manage their accounts, and find service providers. It is also contemplated that the CRM system could be coupled to a social network to allow consumers to coordinate visits to service providers, and suggest product to their friends. Among other things, the computer infrastructure would likely maintain name and contact information for consumers, purchase history, as well as keeping track of one-year or other expiration periods.
[0016] The CRM system can optionally be configured to track traffic to vendors, and could also be configured to track member satisfaction. In some contemplated embodiments, the CRM system could be provided free to vendors.
[0017] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWING
[0018] FIG. 1 is a diagram illustrating an embodiment of a method of implementing a discount program.
DETAILED DESCRIPTION
[0019] Throughout the following discussion, numerous references will be made regarding servers, services, interfaces, engines, platforms, or other systems formed from computing devices. It should be appreciated that the use of such terms is deemed to represent one or more computing devices having at least one processor configured to execute software instructions stored on a computer readable media. For example, a server can include a computer operating as a web server, database server, or other type of computer server in a manner to fulfill described roles, responsibilities, or functions. One should appreciate that the deployment of the disclosed subject matter provides a platform that reduces an amount of processing time for managing aliases or distribution lists. Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.
[0020] As shown in FIG. 1 , insurance agents or other sellers of the program could be provided with an electronic interface 110 that allows them to perform various functions related to the discount program including, for example, signing up and activating new consumers, following up with previous purchasers of the discount program, and monitoring their sales of the discount program over time. In some contemplated embodiments, sellers could activate the discount program through one or more insurance networks. Through the seller interface or separately, sellers could be supplied with various reports, including monthly revenue generated by their sales of the discount program, the number of consumers that purchased services during a specified time period, etc.
[0021] The service provider interface 120 could be accessed via a web browser, or by software installed on service providers' computers. Advantageously, use of such interface 120 could be leased to service providers. Contemplated uses of the interface 120 by the service providers could include verifying consumer's status in the program, recording consumers' visits and the services and products provided to those consumers, scheduling appointments, tracking program consumer visits and spending habits, and referring consumers to other service providers. For example, a cosmetologist that sees a mole while cutting a consumer's hair could refer that consumer to a dermatologist. For such referrals, service providers could receive commissions, fees, or other benefits. Through the service provider interface 120 , or separately, service providers could be supplied with the number of consumers residing within a specified distance from the service providers, revenue generated by the consumers and other analysis of the visits of consumers.
[0022] As an added benefit, the CRM system could optionally include a database populated with contact and other information of service providers not yet affiliated with the program. A contract or other registration form could then be pre-populated with information from the database to simplify the process of registering new service providers.
[0023] In addition to the interfaces discussed above, preferred systems also include a management interface 140 that allows internal management of various aspects of the discount program. For example, the management interface 140 could allow for program activation, monitoring of sales of the program by sellers, and monitoring of consumers' spending and usage of the program by service provider, region, demographic, etc.
[0024] In a preferred aspect of the present invention, the CRM system 100 includes an analytics engine 160 configured to analyze all aspects of the transactions involving the discount program. Contemplated analysis could be conducted, for example, within a single field of service providers and/or among disparate service providers. Thus, for example, the analytics engine 160 could be used to provide meaningful data regarding the behavior and trends of consumers across disparate services. This would advantageously allow for marketing of services to consumers and other consumers across such disparate services, which has traditionally been impracticable. Such cross marketing would allow service providers to substantially increase their consumer base.
[0025] It is contemplated that the resulting reports, presentations, or other results of the analytics engine 160 could be viewed through one of the interfaces discussed above and/or an analysis interface.
[0026] Preferred CRM systems advantageously have the ability to track the spending of each program consumer (e.g., service providers visited, amounts spent at each service provider, and which services/products were provided). Such information allows for directed marketing to consumers, both individually and by one or more demographics. In addition, such information could be used to obtain new sellers and service providers, to negotiate discounts provided by various service providers, and to determine the cost of the discount program.
[0027] A recommendation engine 150 could also be provided that uses the consumers' purchase histories across the disparate services to make useful recommendations of products and services to consumers. Thus, for example, instead of merely recommending a different spa treatment for consumers who purchased a spa treatment, the recommendation engine 150 could recommend an elective medical service that is commonly undertaken by consumers who purchased that spa treatment. Such recommendations are preferably presented to consumers via the card owner's interface, though other mediums are contemplated (e.g., email, flyers, etc.).
[0028] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.
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Methods for implementing a discount program directed to reducing costs to a consumer for first and second disparate services provided by first and second unrelated entities are described. A seller can sell addition of the consumer to the discount program, without requiring the consumer to purchase anything else from the seller to benefit from the program.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of parent application Ser. No. 11/255,361, filed on Oct. 21, 2005, now U.S. Pat. No. 7,348,432 which claims the benefit of U.S. Provisional Application 60/622,580, filed on Oct. 27, 2004, both of which are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
The present invention is directed to novel pyridine imidazoles and aza-indole derivatives, the pharmaceutical compositions containing them and their use in the treatment or prevention of disorders and diseases mediated by agonists and antagonists of the progesterone receptor. The clinical usage of these compounds are related to hormonal contraception, the treatment and/or prevention of secondary dysmenorrhea, amenorrhea, dysfunctional uterine bleeding, uterine leiomyomata, endometriosis; polycystic ovary syndrome, carcinomas and adenocarcinomas of the endometrium, ovary, breast, colon, prostate, or minication of side effects of cyclic menstrual bleeding. Additional uses of the invention include stimulation of food intake.
BACKGROUND OF THE INVENTION
Intracellular receptors are a class of structurally related proteins involved in the regulation of gene proteins. Steroid receptors are a subset of these receptors, including the progesterone receptors (PR), androgen receptors (AR), estrogen receptors (ER), glucocorticoid receptors (GR) and mineralocorticoid receptors (MR). Regulation of a gene by such factors requires the intracellular receptor and a corresponding ligand which has the ability to selectively bind to the receptor in a way that affects gene transcription.
Progesterone receptor modulators (progestagens) are known to play an important role in mammalian development and homeostasis. Progesterone is known to be required for mammary gland development, ovulation and the maintenance of pregnancy. Currently, steroidal progestin agonists and antagonists are clinically approved for contraception, hormone replacement therapy (HRT) and therapeutic abortion. Moreover, there is good preclinical and clinical evidence for the value of progestin antagonists in treating endometriosis, uterine leiomyomata (fibroids), dysfunctional uterine bleeding and breast cancer.
The current steroidal progestagens have been proven to be quite safe and are well tolerated. Sometimes, however, side effects (e.g. breast tenderness, headaches, depression and weight gain) have been reported that are attributed to these steroidal progestagens, either alone or in combination with estrogenic compounds.
Steroidal ligands for one receptor often show cross-reactivity with other steroidal receptors. As an example, many progestagens also bind to glucocorticoid receptor. Non-steroidal progestagens have no molecular similarity with steroids and therefore one might also expect differences in physicochemical properties, pharmacokinetic (PK) parameters, tissue distribution (e.g. CNS versus peripheral) and, more importantly, non-steroidal progestagens may show no/less cross-reactivity to other steroid receptors. Therefore, non-steroidal progestagens will likely emerge as major players in reproductive pharmacology in the foreseeable future.
It was known that progesterone receptor existed as two isoforms, full-length progesterone receptor isoform (PR-B) and its shorter counterpart (PR-A). Recently, extensive studies have been implemented on the progesterone receptor knockout mouse (PRKO, lacking both the A- and B-forms of the receptors), the mouse knockoutting specifically for the PR-A isoform (PRAKO) and the PR-B isoform (PRBKO). Different phenotypes were discovered for PRKO, PRAKO and PRBKO in physiology studies in terms of fertility, ovulation uterine receptivity, uterine proliferation, proliferation of mammary gland, sexual receptivity in female mice, sexual activity in male mice and infanticide tendencies in male mice. These findings provided great challenge for synthetic chemists to construct not only selective progesterone receptor modulator (SPRM), but also PR-A or PR-B selective progesterone receptor modulator.
SUMMARY OF THE INVENTION
The present invention provides novel pyridine imidazoles and aza-indole derivatives of the formula (I) or (II):
wherein
R 1 and R 2 are independently selected from the group consisting of hydrogen, alkyl, cycloalkyl, aralkyl or heteroaryl-alkyl; wherein the cycloalkyl, aralkyl or heteroaryl-alkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, —SH, —S(alkyl), SO 2 (alkyl), NO 2 , CN, CO 2 H, —OR C , —SO 2 —NR D R E , —NR D R E , NR D —SO 2 —R F , -(alkyl) 0-4 -C(O)NR D R E , (alkyl) 0-4 -NR D —C(O)—R F , -(alkyl) 0-4 -(Q) 0-1 -(alkyl) 0-4 -NR D R E ;
wherein R C is selected from the group consisting of alkyl, cycloalkyl, cycloalkyl-alkyl, aryl, aralkyl, heteroaryl, heteroaryl-alkyl, heterocycloalkyl and heterocycloalkyl-alkyl; wherein the cycloalkyl, cycloalkyl-alkyl, aryl, aralkyl, heteroaryl, heteroaryl-alkyl, heterocycloalkyl or heterocycloalkyl-alkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, —SH, —S(alkyl), SO 2 (alkyl), NO 2 , CN, CO 2 H, R C , —SO 2 —NR D R E , NR D R E , NR D —SO 2 —R F , -(alkyl) 0-4 -C(O)—NR D R E , -(alkyl) 0-4 -NR D —C(O)—R F , -(alkyl) 0-4 -(Q) 0-1 -(alkyl) 0-4 -NR D R E ,
wherein Q is selected from the group consisting of O, S, NH, N(alkyl) and —CH═CH—;
wherein R D and R E are each independently selected from the group consisting of hydrogen and alkyl; alternatively R D and R E are taken together with the nitrogen atom to which they are bound to form a 4 to 8 membered ring selected from the group consisting of heteroaryl or heterocycloalkyl; wherein the heteroaryl or heterocycloalkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, carboxy, amino, alkylamino, dialkylamino, nitro or cyano;
wherein RF is selected from the group consisting of hydrogen, alkyl, cycloalkyl, cycloalkyl-alkyl, aryl, aralkyl, heteroaryl, heteroaryl-alkyl, heterocycloalkyl and heterocycloalkyl-alkyl; wherein the cycloalkyl, aryl, heteroaryl, heteroaryl-alkyl, heterocycloalkyl or heterocycloalkyl-alkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, carboxy, amino, alkylamino, dialkylamino, nitro or cyano;
R 3 is selected from the group consisting of halogen, CF 3 , hydroxy, R C , nitro, cyano, SO 2 (alkyl), —C(O)R G , —C(O)OR G , —OC(O)R G , —OC(O)OR G , —OC(O)N(R G ) 2 , —N(R G )C(O)R G , —OSi(R G ) 3 —OR G , —SO 2 N(R G ) 2 , —O-(alkyl) 1-4 -C(O)R G , —O-(alkyl) 1-4 -C(O)OR G , aryl and heteroaryl, wherein aryl or heteroaryl is optionally substituted with one or more substituents independently selected from alkyl, halogenated alkyl, alkoxy, halogen, hydroxy, nitro, cyano, —OC(O)-alkyl or —C(O)O-alkyl;
wherein each R G is independently selected from hydrogen, alkyl, aryl, aralkyl; wherein the alkyl, aryl or aralkyl group is optionally substituted with one or more substituents independently selected from alkyl, halogenated alkyl, alkoxy, halogen, hydroxy, nitro, cyano, —OC(O)-alkyl or —C(O)O-alkyl;
alternatively two R G groups are taken together with the nitrogen atom to which they are bound to form a heterocycloalkyl group; wherein the heterocycloalkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, carboxy, amino, alkylamino, dialkylamino, nitro or cyano;
R 4 is selected from the group consisting of hydrogen, acetyl, SO 2 (alkyl), alkyl, cycloalkyl, aralkyl or heteroaryl-alkyl; wherein the cycloalkyl, aralkyl or heteroaryl-alkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, —SH, —S(alkyl), SO 2 (alkyl), NO 2 , CN, CO 2 H, —OR C , —SO 2 —NR D R E , —NR D R E , NR D —SO 2 —R F , -(alkyl) 0-4 -C(O)NR D R E , (alkyl) 0-4 -NR D —C(O)—R F , -(alkyl) 0-4 -(Q) 0-1 -(alkyl) 0-4 -NR D R E ,
wherein R C is selected from the group consisting of alkyl, cycloalkyl, cycloalkyl-alkyl, aryl, aralkyl, heteroaryl, heteroaryl-alkyl, heterocycloalkyl and heterocycloalkyl-alkyl; wherein the cycloalkyl, cycloalkyl-alkyl, aryl, aralkyl, heteroaryl, heteroaryl-alkyl, heterocycloalkyl or heterocycloalkyl-alkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, —SH, —S(alkyl), SO 2 (alkyl), NO 2 , CN, CO 2 H, R C , —SO 2 —NR D R E , NR D R E , NR D —SO 2 —R F , -(alkyl) 0-4 -C(O)NR D R E , -(alkyl) 0-4 -NR D —C(O)—R F , -(alkyl) 0-4 -(Q) 0-1 -(alkyl) 0-4 -NR D R E ,
wherein Q is selected from the group consisting of O, S, NH, N(alkyl) and —CH═CH—;
wherein R D and R E are each independently selected from the group consisting of hydrogen and alkyl; alternatively R D and R E are taken together with the nitrogen atom to which they are bound to form a 4 to 8 membered ring selected from the group consisting of heteroaryl or heterocycloalkyl; wherein the heteroaryl or heterocycloalkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, carboxy, amino, alkylamino, dialkylamino, nitro or cyano;
wherein R F is selected from the group consisting of hydrogen, alkyl, cycloalkyl, cycloalkyl-alkyl, aryl, aralkyl, heteroaryl, heteroaryl-alkyl, heterocycloalkyl and heterocycloalkyl-alkyl; wherein the cycloalkyl, aryl, heteroaryl, heteroaryl-alkyl, heterocycloalkyl or heterocycloalkyl-alkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, carboxy, amino, alkylamino, dialkylamino, nitro or cyano;
or a pharmaceutically acceptable salt thereof.
The compounds of this invention may contain an asymmetric carbon atom and some of the compounds of this invention may contain one or more asymmetric centers and may thus give rise to optical isomers and diastereomers. While shown without respect to stereochemistry in Formula 1 and 2, the present invention includes such optical isomers and diastereomers as well as the racemic and resolved, enantiomerically pure S and R stereoisomers dn pharmaceutically acceptable salts thereof.
Illustrative of the invention is a pharmaceutical composition comprising a pharmaceutically acceptable carrier and any of the compounds described above. An illustration of the invention is a pharmaceutical composition made by mixing any of the compounds described above and a pharmaceutically acceptable carrier. Illustrating the invention is a process for making a pharmaceutical composition comprising mixing any of the compounds described above and a pharmaceutically acceptable carrier.
Exemplifying the invention are methods of treating a disorder mediated by one or more progesterone receptors in a subject in need thereof comprising administering to the subject a therapeutically effective amount of any of the compounds or pharmaceutical compositions described above.
Illustrating the invention is a method of contraception comprising administering to a subject in need thereof co-therapy with a therapeutically effective amount of a compound of formula (I) with an estrogen or estrogen antagonist.
Another example of the invention is the use of any of the compounds described herein in the preparation of a medicament for treating: (a) dysfunctional bleeding, (b) endometriosis, (c) uterine leiomyomata, (d) secondary amenorrhea, (e) polycystic ovary syndrome, (f) carcinomas and adenocarcinomas of the endometrium, ovary, breast, colon, prostate, (g) minication of side effects of cyclid menstrual bleeding and for (h) contraception and i) stimulation of food intake in a subject in need thereof.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is further directed to a compound of formula (I) or (II):
wherein R 1 , R 2 , R 3 and R 4 are as herein defined, useful for the treatment of disorders mediated by an progesterone receptor. More particularly, the compounds of the present invention are useful for the treatment and prevention of disorders mediated by the progesterone-A and progesterone-B receptors. More preferably, the compounds of the present invention are tissue selective progesterone receptor modulators.
The compounds of the present invention are useful in the treatment of disorders associated with the depletion of progesterone, hormone sensitive cancers and hyperplasia, endometriosis, uterine fibroids, osteoarthritis and as contraceptive agents, alone or in combination with a estrogen or a partial estrogen antagonist.
The compounds of the present invention are useful in the treatment of disorders associated with the depletion of progesterone, secondary amenorrhea, dysfunctional bleeding, uterine leiomyomata, endometriosis; polycystic ovary syndrome, carcinomas and adenocarcinomas of the endometrium, ovary, breast, colon, prostate, or minication of side effects of cyclid menstrual bleeding. and as contraceptive agents, alone or in combination with a estrogen or restrogen antagonist.
In an embodiment of the present invention R 1 , R 2 are both methyl groups. In another embodiment of the present invention R 1 , R 2 are connected by —(CH 2 ) 4 — to form a 5-membered spiro ring. In another embodiment of the present invention R 1 , R 2 are connected by —(CH 2 ) 5 — to form a 6-membered spiro ring.
In an embodiment of the present invention R 3 is selected from halogen, CN, CF 3 , NO 2 or SO 2 (alkyl) group. In another embodiment of the present invention R 3 is selected from aryl, heteroaryl groups, wherein aryl or heteroaryl groups are mono-, di-, or tri-substituted by halogen, NO 2 , CF 3 , CN, O(alkyl).
In an embodiment of the present invention R 4 is selected from hydrogen, acetyl or SO 2 (alkyl), lower alkyl, aralkyl, heteroarylalkyl.
For use in medicine, the salts of the compounds of this invention refer to non-toxic “pharmaceutically acceptable salts.” Other salts may, however, be useful in the preparation of compounds according to this invention or of their pharmaceutically acceptable salts. Suitable pharmaceutically acceptable salts of the compounds include acid addition salts which may, for example, be formed by mixing a solution of the compound with a solution of a pharmaceutically acceptable acid such as hydrochloric acid, sulfuric acid, fumaric acid, maleic acid, succinic acid, acetic acid, benzoic acid, citric acid, tartaric acid, carbonic acid or phosphoric acid. Furthermore, where the compounds of the invention carry an acidic moiety, suitable pharmaceutically acceptable salts thereof may include alkali metal salts, e.g., sodium or potassium salts; alkaline earth metal salts, e.g., calcium or magnesium salts; and salts formed with suitable organic ligands, e.g., quaternary ammonium salts. Thus, representative pharmaceutically acceptable salts include the following:
acetate, benzenesulfonate, benzoate, bicarbonate, bisulfate, bitartrate, borate, bromide, calcium edetate, camsylate, carbonate, chloride, clavulanate, citrate, dihydrochloride, acetate, edisylate, estolate, esylate, fumarate, gluceptate, gluconate, glutamate, glycollylarsanilate, hexylresorcinate, hydrabamine, hydrobromide, hydrochloride, hydroxynaphthoate, iodide, isothionate, lactate, lactobionate, laurate, malate, maleate, mandelate, mesylate, methylbromide, methylnitrate, methylsulfate, mucate, napsylate, nitrate, N-methylglucamine ammonium salt, oleate, pamoate (embonate), palmitate, pantothenate, phosphate/diphosphate, polygalacturonate, salicylate, stearate, sulfate, subacetate, succinate, tannate, tartrate, teoclate, tosylate, triethiodide and valerate.
The present invention includes within its scope prodrugs of the compounds of this invention. In general, such prodrugs will be functional derivatives of the compounds which are readily convertible in vivo into the required compound. Thus, in the methods of treatment of the present invention, the term “administering” shall encompass the treatment of the various disorders described with the compound specifically disclosed or with a compound which may not be specifically disclosed, but which converts to the specified compound in vivo after administration to the patient. Conventional procedures for the selection and preparation of suitable prodrug derivatives are described, for example, in “Design of Prodrugs”, ed. H. Bundgaard, Elsevier, 1985.
As used herein, the term “progestogen antagonist” shall include mifepristone, J-867 (Jenapharm/TAP Pharmaceuticals), J-956 (Jenapharm/TAP Pharmaceuticals), ORG-31710 (Organon), ORG-32638 (Organon), ORG-31806 (Organon), onapristone and PRA248 (Wyeth).
As used herein, unless otherwise noted, “halogen” shall mean chlorine, bromine, fluorine and iodine.
As used herein, unless otherwise noted, the term “alkyl” whether used alone or as part of a substituent group, include straight and branched chain compositions of one to eight carbon atoms. For example, alkyl radicals include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, t-butyl, pentyl and the like. Unless otherwise noted, “lower” when used with alkyl means a carbon chain composition of 1-4 carbon atoms. Similarly, the group “-(alkyl) 0-4 -”, whether alone or as part of a large substituent group, shall be the absence of an alkyl group or the presence of an alkyl group comprising one to four carbon atoms. Suitable examples include, but are not limited to —CH 2 —, —CH 2 CH 2 —, CH 2 —CH(CH 3 )—, CH 2 CH 2 CH 2 —, —CH 2 CH(CH 3 )CH 2 —, CH 2 CH 2 CH 2 CH 2 —, and the like.
As used herein, unless otherwise noted, “alkoxy” shall denote an oxygen ether radical of the above described straight or branched chain alkyl groups. For example, methoxy, ethoxy, n-propoxy, sec-butoxy, t-butoxy, n-hexyloxy and the like.
As used herein, unless otherwise noted, “aryl” shall refer to unsubstituted carbocyclic aromatic groups such as phenyl, naphthyl, and the like.
As used herein, unless otherwise noted, “aralkyl” shall mean any lower alkyl group substituted with an aryl group such as phenyl, naphthyl and the like. Suitable examples include benzyl, phenylethyl, phenylpropyl, naphthylmethyl, and the like.
As used herein, unless otherwise noted, the term “cycloalkyl” shall mean any stable 3-8 membered monocyclic, saturated ring system, for example cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl and cyclooctyl.
As used herein, unless otherwise noted, the term “cycloalkyl-alkyl” shall mean any lower alkyl group substituted with a cycloalkyl group. Suitable examples include, but are not limited to cyclohexyl-methyl, cyclopentyl-methyl, cyclohexyl-ethyl, and the like.
As used herein, unless otherwise noted, the terms “acyloxy” shall mean a radical group of the formula —O—C(O)—R where R is alkyl, aryl or aralkyl, wherein the alkyl, aryl or aralkyl is optionally substituted. As used herein, the term “carboxylate” shall mean a radical group of the formula —C(O)O—R where R is alkyl, aryl or aralkyl, wherein the alkyl, aryl or aralkyl is optionally substituted.
As used herein, unless otherwise noted, “heteroaryl” shall denote any five or six membered monocyclic aromatic ring structure containing at least one heteroatom selected from the group consisting of O, N and S, optionally containing one to three additional heteroatoms independently selected from the group consisting of O, N and S; or a nine or ten membered bicyclic aromatic ring structure containing at least one heteroatom selected from the group consisting of O, N and S, optionally containing one to four additional heteroatoms independently selected from the group consisting of O, N and S. The heteroaryl group may be attached at any heteroatom or carbon atom of the ring such that the result is a stable structure.
Examples of suitable heteroaryl groups include, but are not limited to, pyrrolyl, furyl, thienyl, oxazolyl, imidazolyl, purazolyl, isoxazolyl, isothiazolyl, triazolyl, thiadiazolyl, pyridyl, pyridazinyl, pyrimidinyl, pyrazinyl, pyranyl, furazanyl, indolizinyl, indolyl, isoindolinyl, indazolyl, benzofuryl, benzothienyl, benzimidazolyl, benzthiazolyl, purinyl, quinolizinyl, quinolinyl, isoquinolinyl, isothiazolyl, cinnolinyl, phthalazinyl, quinazolinyl, quinoxalinyl, naphthyridinyl, pteridinyl, and the like.
As used herein, unless otherwise noted, the term “heteroaryl-alkyl” shall mean any lower alkyl group substituted with a heteroaryl group. Suitable examples include, but are not limited to pyridyl-methyl, isoquinolinyl-methyl, thiazolyl-ethyl, furyl-ethyl, and the like.
As used herein, the term “heterocycloalkyl” shall denote any five to seven membered monocyclic, saturated or partially unsaturated ring structure containing at least one heteroatom selected from the group consisting of O, N and S, optionally containing one to three additional heteroatoms independently selected from the group consisting of O, N and S; or a nine to ten membered saturated, partially unsaturated or partially aromatic bicyclic ring system containing at least one heteroatom selected from the group consisting of O, N and S, optionally containing one to four additional heteroatoms independently selected from the group consisting of O, N and S. The heterocycloalkyl group may be attached at any heteroatom or carbon atom of the ring such that the result is a stable structure.
Examples of suitable heteroaryl groups include, but are not limited to, pyrrolinyl, pyrrolidinyl, dioxalanyl, imidazolinyl, imidazolidinyl, pyrazolinyl, pyrazolidinyl, piperidinyl, dioxanyl, morpholinyl, dithianyl, thiomorpholinyl, piperazinyl, trithianyl, indolinyl, chromenyl, 3,4-methylenedioxyphenyl, 2,3-dihydrobenzofuryl, and the like.
As used herein, unless otherwise noted, the term “heterocycloalkyl-alkyl” shall mean any lower alkyl group substituted with a heterocycloalkyl group. Suitable examples include, but are not limited to piperidinyl-methyl, piperazinyl-methyl, piperazinyl-ethyl, morpholinyl-methyl, and the like.
When a particular group is “substituted” (e.g., cycloalkyl, aryl, heteroaryl, heterocycloalkyl), that group may have one or more substituents, preferably from one to five substituents, more preferably from one to three substituents, most preferably from one to two substituents, independently selected from the list of substituents. Additionally when aralkyl, heteroaryl-alkyl, heterocycloalkyl-alkyl or cycloalkyl-alkyl group is substituted, the substituent(s) may be on any portion of the group (i.e. the substituent(s) may be on the aryl, heteroaryl, heterocycloalkyl, cycloalkyl or the alkyl portion of the group.)
With reference to substituents, the term “independently” means that when more than one of such substituents is possible, such substituents may be the same or different from each other.
Under standard nomenclature used throughout this disclosure, the terminal portion of the designated side chain is described first, followed by the adjacent functionality toward the point of attachment. Thus, for example, a “phenylC 1 -C 6 alkylaminocarbonylC 1 -C 6 alkyl” substituent refers to a group of the formula
Abbreviations used in the specification, particularly the Schemes and Examples, are as follows
Ac
Acetyl group (—C(O)—CH 3 )
DCM
Dichloromethane
DMF
Dimethyl formamide
ERT
Estrogen replacement therapy
Et
ethyl (i.e. —CH 2 CH 3 )
EtOAc
Ethyl acetate
FBS
Fetal bovine serum
HPLC
High pressure liquid chromatography
HRT
Hormone replacement therapy
MeOH
Methanol
Ph
Phenyl
TEA or Et 3 N
Triethylamine
THF
Tetrahydrofuran
TsOH
Toluene sulfonic acid
The term “subject” as used herein, refers to an animal, preferably a mammal, most preferably a human, who has been the object of treatment, observation or experiment.
The term “therapeutically effective amount” as used herein, means that amount of active compound or pharmaceutical agent that elicits the biological or medicinal response in a tissue system, animal or human that is being sought by a researcher, veterinarian, medical doctor or other clinician, which includes alleviation of the symptoms of the disease or disorder being treated. Wherein the present invention directed to co-therapy comprising administration of one or more compound(s) of formula I and a progestogen or progestogen antagonist, “therapeutically effective amount” shall mean that amount of the combination of agents taken together so that the combined effect elicits the desired biological or medicinal response. For example, the therapeutically effective amount of co-therapy comprising administration of a compound of formula I and progestogen would be the amount of the compound of formula I and the amount of the progestogen that when taken together or sequentially have a combined effect that is therapeutically effective. Further, it will be recognized by one skilled in the art that in the case of co-therapy with a therapeutically effective amount, as in the example above, the amount of the compound of formula I and/or the amount of the progestogen or progestogen antagonist individually may or may not be therapeutically effective.
As used herein, the term “co-therapy” shall mean treatment of a subject in need thereof by administering one or more compounds of formula I with a progestogen or progestogen antagonist, wherein the compound(s) of formula I and progestogen or progestogen antagonist are administered by any suitable means, simultaneously, sequentially, separately or in a single pharmaceutical formulation. Where the compound(s) of formula I and the progestogen or progestogen antagonist are administered in separate dosage forms, the number of dosages administered per day for each compound may be the same or different. The compound(s) of formula I and the progestogen or progestogen antagonist may be administered via the same or different routes of administration. Examples of suitable methods of administration include, but are not limited to, oral, intravenous (iv), intramuscular (im), subcutaneous (sc), transdermal, and rectal. Compounds may also be administered directly to the nervous system including, but not limited to, intracerebral, intraventricular, intracerebroventricular, intrathecal, intracisternal, intraspinal and/or peri-spinal routes of administration by delivery via intracranial or intravertebral needles and/or catheters with or without pump devices. The compound(s) of formula I and the progestogen or progestogen antagonist may be administered according to simultaneous or alternating regimens, at the same or different times during the course of the therapy, concurrently in divided or single forms.
As used herein, the term “composition” is intended to encompass a product comprising the specified ingredients in the specified amounts, as well as any product which results, directly or indirectly, from combinations of the specified ingredients in the specified amounts.
One skilled in the art will recognize that it may be necessary and/or desirable to protect one or more of the R 3 and/or R 4 groups at any of the steps within the process described above. This may be accomplished using known protecting groups and know protection and de-protection reagents and conditions, for example such as those described in Protective Groups in Organic Chemistry , ed. J. F. W. McOmie, Plenum Press, 1973; and T. W. Greene & P. G. M. Wuts, Protective Groups in Organic Synthesis , John Wiley & Sons, 1991.
Compounds of formula (I) may be prepared according to the process outlined in Scheme (I).
More particularly, a suitably substituted compound of formula (II), wherein X is halogen, CN, CF 3 , NO 2 , or SO 2 (alkyl), a known compound or compound prepared by known methods, is reacted with a compound of formula (III), a known compound, in an organic solvent such as acetone, THF, 1,4-dioxane, ethyl ether and the like, at a temperature in the range of about 0° C. to about 30° C., to yield the corresponding compound of formula (IV). The cyclization of compound IV and alkyl iodide (V) or alkyl diiodide (VI) can be affected under the organic base such as NaOMe, NaOEt, KOtBu, NaOtBu and the like or inorganic base, such as NaOH, KOH, Na 2 CO 3 , NaHCO 3 , K 2 CO 3 , Cs 2 CO 3 , KF and the like; in the presence of organic solvent, such as MeOH, EtOH, iPrOH, tBuOH at a temperature in the range of about 0° C. to 100° C., to yield the corresponding compound of formula (VII).
Preferably, compound of formula (VII), wherein X is Br or I, a compound made from Scheme I, can react further with aryl or heteroaryl boronic acid of formula R 3 B(OH) 2 , a known compound or a compound prepared from known methods, under the palladium (0) or palladium (+2) catalysts, such as Pd(PPh 3 ) 4 , Pd(OAc) 2 with PPh 3 , PdCl 2 (PPh 3 ) 2 , or PdCl 2 (dppf) 2 and the like, in the presence of inorganic base, such as K 2 CO 3 , Na 2 CO 3 , KOAc, K 3 PO 4 , NaOAc, Cs 2 CO 3 , and the like, in the organic solvent such as 1,4-dioxane, THF, toluene, with small amount of water; at a temperature in the range of 0 to 125° C., to yield the corresponding compound of formula (VIII).
Preferably, compound of formula (X), a known compound prepared according to the procedure described in WO2003/082868, was deprotonated under an organic base, such as nBuLi, LDA, NaHMDS and the like, in the aprotice solvent such as THF, ether, or hexane at a temperature in the range of −78° C. to −40° C.; the anion was then reacted with iodide of formula R 1 I or R 2 I or diiodide of formula I—(R 1 —R 2 )—I to generate the compound of formula (XI).
TABLE 1
(I)
ex. #
R 1 , R 2
R 3
MF
1-C3
Spirocyclohexane
Br
C 12 H 13 BrN 2 O
3
Spirocyclohexane
3-Cl-phenyl
C 18 H 17 ClN 2 O
1-C1
Dimethyl
Br
C 9 H 9 BrN 2 O
2
Dimethyl
3-Cl-phenyl
C 15 H 13 ClN 2 O
4
Dimethyl
3-CN-phenyl
C 16 H 13 N3O
5
Dimethyl
Cl
C9H9ClN2O
6
Spirocyclohexyl
Cl
C12H13ClN2O
7
Dimethyl
3,5-di-F-phenyl
C15H12F2N2O
8
Dimethyl
3-NO 2 -phenyl
C15H13N3O3
9
Dimethyl
3-CF 3 -phenyl
C16H13F3N2O
10
Dimethyl
2,4-di-F-phenyl
C15H12F2N2O
11
Dimethyl
3,5-di-CF 3 -phenyl
C17H12F6N2O
12
Dimethyl
3-MeO-phenyl
C16H16N2O2
13
Dimethyl
3-F-phenyl
C15H13FN2O
14
Dimethyl
2-Cl-phenyl
C15H13ClN2O
1-C2
spirocyclopentane
Br
C11H11BrN2O
15
spirocyclohexane
3-F-phenyl
C18H17FN2O
16
spirocyclohexane
3-MeO-phenyl
C19H20N2O2
17
spirocyclohexane
3,5-di-CF 3 -phenyl
C20H16F6N2O
18
spirocyclohexane
3-NO2-phenyl
C18H17N3O3
19
spirocyclohexane
3-CF 3 -phenyl
C19H17F3N2O
20
spirocyclohexane
3-CN-phenyl
C19H17N3O
21
spirocyclohexane
3,5-di-F-phenyl
C18H16F2N2O
22
spirocyclohexane
3,4-di-Cl-phenyl
C18H16C12N2O
23
spirocyclohexane
2,4-di-F-phenyl
C18H16F2N2O
24
spirocyclopentane
3-Cl-phenyl
C17H15ClN2O
25
spirocyclopentane
3-CN-phenyl
C18H15N3O
26
spirocyclopentane
3-F-phenyl
C17H15FN2O
27
spirocyclopentane
3-NO 2 -phenyl
C17H15N3O3
28
spirocyclopentane
3,4-di-Cl-phenyl
C17H14Cl2N2O
29
spirocyclopentane
3,5-di-CF 3 -phenyl
C19H14F6N2O
30
spirocyclopentane
3-Cl-4-F-phenyl
C17H14ClFN2O
TABLE 2
(I)
Ex. #
R 1 , R 2
R 3
MF
31
Spirocyclohexane
3-F-phenyl
C 23 H 21 FN 2 O 3 S
32
Dimethyl
3-F-phenyl
C 23 H 21 ClN 2 O 3 S
It is intended that the definition of any substituent or variable at a particular location in a molecule be independent of its definitions elsewhere in that molecule. It is understood that substituents and substitution patterns on the compounds of this invention can be selected by one of ordinary skill in the art to provide compounds that are chemically stable and that can be readily synthesized by techniques known in the art as well as those methods set forth herein. It is further intended that when m is >1, the corresponding R 4 substituents may be the same or different.
The compounds of the present invention can be used in the form of salts derived from pharmaceutically or physiologically acceptable acids or bases. These salts include, but are not limited to, the following salts with inorganic acids such as hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid and as the case may be, such organic acids as acetic acid, oxalic acid, succinic acid, and maleic acid. Other salts include salts with alkali metals or alkaline earth metals, such as sodium, potassium, calcium or magnesium in the form of esters, carbamates and other conventional “pro-drug” forms, which, when administered in such form, convert to the active moiety in vivo.
This invention includes pharmaceutical compositions comprising one or more compounds of this invention, preferably in combination with one or more pharmaceutically acceptable carriers and/or excipients. The invention also includes methods of contraception and methods of treating or preventing maladies associated with the progesterone receptor, the methods comprising administering to a mammal in need thereof a pharmaceutically effective amount of one or more compounds as described above wherein R is alkyl, aryl, heteroary or alkylaryl group.
The progesterone receptor antagonists of this invention, used alone or in combination, can be utilized in methods of contraception and the treatment and/or prevention of benign and malignant neoplastic disease. Specific uses of the compounds and pharmaceutical compositions of invention include the treatment and/or prevention of uterine myometrial fibroids, endometriosis, genign prostatic hypertrophy; carcinomas and adenocarcinomas of the endometrium, ovary, breast, colon, prostate, pituitary, meningioma and other hormone-dependent tumors. Additional uses of the present progesterone receptor antagonists include the synchronization of the estrus in livestock.
When used in contraception the progesterone receptor antagonists of the current invention may be used either alone in a continuous administration of between 0.1 and 500 mg per day, or alternatively used in a different regimen which would entail 2-4 days of treatment with the progesterone receptor antagonist after 21 days of a progestin. In this regimen between 0.1 and 500 mg daily doses of the progestin (e.g. levonorgestrel, trimegestone, gestodene, norethistrone acetate, norgestimate or cyproterone acetate) would be followed by between 0.1 and 500 mg daily doses of the progesterone receptor antagonists of the current invention.
The progesterone receptor agonists of this invention, used alone or in combination, can also be utilized in methods of contraception and the treatment and/or prevention of dysfunctional bleeding, uterine leiomyomata, endometriosis; polycystic ovary syndrome, carcinomas and adenocarcimomas of the endometrium, ovary, breast, colon, prostate. Additional uses of the invention include stimulation of food intake.
When used in contraception the progesterone receptor agonists of the current invention are preferably used in combination or sequentially with an estrogen agonist (e.g. ethinyl estradiao). The preferred dose of the progesterone receptor agonist is 0.01 mg and 500 mg per day.
This invention also includes pharmaceutical compositions comprising one or more compounds described herein, preferably in combination with one or more pharmaceutically acceptable carriers or excipients. When the compounds are employed for the above utilities, they may be combined with one or more pharmaceutically acceptable carriers, or excipients, for example, solvents, diluents and the like and may be administered orally in such forms as tablets, capsules, dispersible powders, granules, or suspensions containing, for example, from about 0.05 to 5% of suspending agent, syrups containing, for example, from about 10 to 50% of sugar, and elixirs containing, for example, from 20 to 50% ethanol, and the like, or parenterally in the form of sterile injectale solutions or suspensions containing from about 0.05 to 5% suspending agent in an isotonic medium. Such pharmaceutical preparations may contain, for example, from about 25 to about 90% of the active ingredient in combination with the carrier, more usually between about 5% and 60% by weight.
The effective dosage of active ingredient employed may vary depending on the particular compound employed, the mode of administration and the severity of the condition being treated. However, in general, satisfactory results are obtained when the compounds of the invention are administered at a daily dosage of from about 0.5 to about 500 mg/kg of animal body weight, preferably given in divided doses two to four times a day, or in a sustained release from. For most large mammals, the total daily dosage is from about 1 to 100 mg, preferably from about 2 to 80 mg Dosage from suitable for internal use comprise from about 0.5 to 500 mg of the active compound in intimate admixture with a solid or liquid pharmaceutically acceptable carrier. This dosage regimen may be adjusted to provide the optimal therapeutic response. For example, several divided doses may be administered daily or the dose may be proportionally reduced as indicated by the exigencies of the therapeutic situation.
These active compounds may be administered orally as well as by intravenous, intramuscular, or subcutaneous routes. Solid carriers include starch, lactose, dicalcium phosphate, microcrystalline cellulose, sucrose and kaolin, while liquid carriers include sterile water, polyethylene glycols, non-ionic surfactants and edible oils such as corn, peanut and sesame oil, as are appropriate to the nature of the active ingredient and the particular form of administration desired. Adjuvants customarily employed in the preparation of pharmaceutical compositions may be advantageously included, such as flavoring agents, coloring agents, preserving agents, and antioxidants, for example, vitamin E, ascorbic acid, BHT and BHA.
The preferred pharmaceutical compositions from the standpoint of ease of preparation and administration are solid compositions, particularly tablets and hardfilled or liquid-filled capsules. Oral administration of the compounds is preferred.
These active compounds may also be administered parenterally or intraperitoneally. Solutions or suspensions of these active compounds as a free base or pharmacologically acceptable salt can be prepared in water suitably mixed with a surfactant such as hydroxylpropylcellulose. Dispersions can also be prepared in glycerol, liquid, polyethylene glycols and mixtures thereof in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
The pharmaceutical forms suitable for injectable use include sterile aqueous solutions or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions of dispersions. In all cases, the form must be sterile and must be fluid to the extent that easy syringe ability exits. It must be stable under conditions of manufacture and storage and must be preserved against the contaminating action of microorganisms such as bacterial and fungi. The carrier can be a solvent or dispersion medium containing, for example, water, ethanol (e.g., glycerol, propylene glycol and liquid polyethylene glycol), suitable mixtures thereof, and vegetable oil.
The following non-limiting examples illustrate preparation and use of the compounds of the invention.
EXAMPLE 1
A. 2-Amino-5-bromo-1-ethoxycarbonylmethyl-pyridinium; bromide
2-Amino-5-bromopyridine (10.88 g, 62.9 mmol) was dissolved in acetone (65 mL). To this solution was added ethyl bromoacetate (7.7 mL, 69.2 mmol). The solution was heated to reflux overnight under nitrogen. The reaction mixture was cooled and an off-white solid was filtered off. The solid was washed with acetone and dried to provide title compound as an off-white solid (13.74 g, 64%). 1 H NMR (DMSO-d 6 ) δ 8.91 (s, 2H), 8.42 (d, J=2.2 Hz, 1H), 8.09 (dd, J=2.2 and 9.5 Hz, 1H), 7.10 (d, J=9.5 Hz, 1H), 5.11 (s, 2H), 4.21 (q, J=7.1 and 14.2, 2H), 1.26 (t, J=7.1, 3H); MS (m/e): 259 (MH + ).
B. 6-Bromo-imidazo[1,2-a]pyridin-2-one
To a solution of 2-Amino-5-bromo-1-ethoxycarbonylmethyl-pyridinium; bromide (2.86 g, 8.4 mmol) in methanol (30 mL) was added sodium methoxide (25 wt %, 2.5 mL, 10.1 mmol). The reaction mixture was stirred at room temperature overnight under argon. The reaction mixture was diluted with water and then extracted three times with ethyl acetate. The organic extracts were washed with brine, dried over magnesium sulfate, filtered, evaporated to yield a tan solid. The crude material was purified by column chromatography eluting with 3, 5, and 10% methanol/dichloromethane. The product was obtained as a brown solid (56 mg, 3%). 1 H NMR (CDCl 3 ) δ 7.85 (s, 1H), 7.67 (dd, J=1.6, 9.5 Hz, 1H), 7.07 (d, J=9.5 Hz, 1H), 4.52 (s, 2H); MS (m/e): 215 (MH + ); HRMS: calc'd MH + for C 7 H 5 BrN 2 O 212.9672. Found 212.9664.
C1. 6-Bromo-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one
A solution of 2-Amino-5-bromo-1-ethoxycarbonylmethyl-pyridinium; bromide (6.11 g, 17.97 mmol) in 100 mL of ethanol was prepared followed by sodium ethoxide (21 wt %, 20.5 mL, 54.9 mmol). After one hour, iodomethane was added (2.3 mL, 37.7 mmol) and the reaction was stirred at room temperature overnight. The solvent was evaporated and the residue was taken up in dichloromethane. The mixture was filtered and the filtrate was purified by column chromatography eluting with 5% methanol/dichloromethane. The product was obtained as a tan solid (1.07 g, 25%). 1 H NMR (CDCl 3 ) δ 7.73 (s, 1H), 7.67 (dd, J=1.8 and 9.4 Hz, 1H), 7.13 (d, J=9.4 Hz, 1H), 1.59 (s, 6H); MS (m/e): 241 (MH + ).
C2. 6-Bromo-3,3-spiro[cyclopentane]-imidazo[1,2-a]pyridin-2-one
6-Bromo-imidazo[1,2-a]pyridin-2-one (0.211 g 1 mmol), NaOMe (25% in MeOH, 0.26 g, 1.2 mmole), was stirred in MeOH (5.0 mL). 1,4-Diiodobutane (0.310 g, 1.0 mmol) was added slowly. This was stirred at ambient temperature for 16 hours. The reaction mixture was diluted with water and then extracted three times with ethyl acetate. The organic extracts were washed with brine, dried over magnesium sulfate, filtered, evaporated to yield a tan solid. The crude material was purified by column chromatography eluting with 5% methanol/dichloromethane. The product was obtained as a white solid (20 mg, 20%). Several runs with different scale was carried out and the best yield is 50%. 1 H NMR (CDCl 3 ) δ 7.68 (s, 1H), 7.62 (d, 1H, J=12 Hz), 7.04 (d, 1H, J=12 Hz), 2.52-1.83 (m, 8H); MS (m/e): 267 (MH + ).
C3. 6-Bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
A solution of 2-Amino-5-bromo-1-ethoxycarbonylmethyl-pyridinium; bromide (4.66 g, 13.70 mmol) in 80 mL of ethanol was prepared followed by sodium ethoxide (21 wt %, 15.4 mL, 41.11 mmol). After one hour, 1,5-diiodopentane was added (2.2 mL, 15.07 mmol) and the reaction allowed to proceed overnight. The reaction mixture was diluted with water and then extracted three times with ethyl acetate. The organic extracts were washed with brine, dried over magnesium sulfate, filtered, evaporated to yield a tan solid. The crude material was purified by column chromatography eluting with 5% methanol/dichloromethane. The product was obtained as an orange solid (1.15 g, 30%). 1 H NMR (CDCl 3 ) δ7.73 (d, J=1.8 Hz, 1H), 7.63 (dd, J=2.2 and 9.4 Hz, 1H), 7.07 (d, J=9.0 Hz, 1H), 2.35-2.24 (m, 2H), 2.01-1.96 (m, 2H), 1.88-1.81 (m, 1H), 1.75-1.64 (m, 4H), 1.46-1.37 (s, 1H); MS (m/e): 282 (MH + ).
EXAMPLE 2
6-(3-Chloro-phenyl)-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one
To a round-bottom flask was added 6-bromo-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one (60 mg, 0.25 mmol), 3-chlorophenylboronic acid (39 mg, 0.25 mmol), potassium carbonate (69 mg, 0.25 mmol), Pd(PPh 3 ) 4 (29 mg, 0.025 mmol), dioxane (5 mL) and water (1 mL). The mixture was heated at reflux until the starting material was consumed monitored by HPLC-MS. The solution was cooled and water was added. The reaction mixture was extracted twice with ethyl acetate and the combined organic layers were dried, filtered and concentrated. The residue was purified by column chromatography eluting with 5% methanol/dichloromethane to provide the desired product as an off-white solid (43 mg, 63%). 1 H NMR (CDCl 3 ) δ 7.84 (dd, J=1.8 and 9.1 Hz, 1H), 7.74 (s, 1H), 7.46-7.27 (m, 5H), 1.64 (s, 6H); MS (m/e): 273 (MH + ); HRMS: calc'd MH + for C 15 H 13 ClN 2 O 273.0794. Found 273.0800.
EXAMPLE 3
6-(3-chloro-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 71% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohepane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.81 (dd, J=2.1 and 9.2 Hz, 1H), 7.76 (d, J=1.4, 1H), 7.45-7.33 (m, 3H), 7.25-7.23 (m, 2H), 2.40-2.30 (m, 2H), 2.05-2.00 (m, 2H), 1.91-1.86 (m, 1H), 1.78-1.71 (m, 4H), 1.49-1.42 (m, 1H); MS (m/e): 313 (MH + ).
EXAMPLE 4
3-(3,3-Dimethyl-2-oxo-2,3-dihydro-imidazo[1,2-a]pyridin-6-yl)-benzonitrile (JNJ-27385696)
The title product was prepared in 12% yield as a yellow solid according to the procedure described in Example 2 using 3-cyanophenylboronic acid as starting material. 1 H NMR (CDCl 3 ) δ 7.82 (dd, J=2.1 and 9.2 Hz, 1H), 7.76-7.69 (m, 4H), 7.61 (m, 1H), 7.31 (d, J=9.3 Hz, 1H), 1.65 (s, 6H); MS (m/e): 264 (MH + ); HRMS: calc'd MH + for C 16 H 13 N 3 O 264.1137; found 264.1130.
EXAMPLE 5
6-Chloro-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 44% yield according to the procedure described in Example 1-C1, starting from 5-chloro-pyridin-2-ylamine. 1 H NMR (CDCl 3 ) δ 7.62 (d, J=2.2 Hz, 1H), 7.57 (dd, J=2.3 and 9.5 Hz, 1H), 7.16 (d, J=9.5 Hz, 1H), 1.59 (s, 6H); MS (m/e): 197 (MH + ).
EXAMPLE 6
6-Chloro-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 14% yield according to the procedure described in Example 1-C3, starting from 5-chloro-pyridin-2-ylamine. 1 H NMR (CDCl 3 ) δ 7.63 (t, J=1.8 and 0.4 Hz, 1H), 7.53 (dd, J=2.3 and 9.4 Hz, 1H), 7.11 (dd, J=0.4, 9.4 Hz, 1H), 2.36-2.25 (m, 2H), 2.00-1.96 (m, 2H), 1.88-1.81 (m, 1H), 1.75-1.63 (m, 4H), 1.46-1.36 (m, 1H); MS (m/e): 237 (MH + ).
EXAMPLE 7
6-(3,5-Difluoro-phenyl)-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one (JNJ-27446913)
The title product was prepared in 73% yield as a yellow solid according to the procedure described in Example 2 using 3,5-difluorophenylboronic acid as starting material. 1 H NMR (CDCl 3 ) δ 7.81 (dd, J=2.1 and 9.2 Hz, 1H), 7.77 (d, J=1.4 Hz, 1H), 7.29 (d, J=0.6 Hz, 1H), 7.02-6.98 (m, 2H), 6.90-6.84 (m, 1H), 1.64 (s, 6H); MS (m/e): 275 (MH + ); HRMS: calc'd MH + for C 15 H 12 FN 2 O 275.0996. Found 275.1009.
EXAMPLE 8
3,3-Dimethyl-6-(3-nitro-phenyl)-imidazo[1,2-a]pyridin-2-one (JNJ-27504646)
The title product was prepared in 37% yield as a yellow solid according to the procedure described in Example 2, using 3-nitrophenylboronic acid as starting material. 1 H NMR (400 MHz, CDCl 3 ) δ 8.35 (t, J=2.0 Hz, 1H), 8.30-8.27 (m, 1H), 7.89 (dd, J=2.1 and 9.2 Hz, 1H), 7.83-7.80 (m, 2H), 7.70 (t, J=8.0 Hz, 1H), 7.33 (d, J=9.3 Hz, 1H), 1.66 (s, 6H); MS (m/e): 284 (MH + ); HRMS calc'd MH + for C 15 H 13 N 3 O 3 284.1035. Found 284.1028.
EXAMPLE 9
3,3-Dimethyl-6-(3-trifluoromethyl-phenyl)-imidazo[1,2-a]pyridin-2-one (JNJ-27512277)
The title product was prepared in 73% yield as an off-white solid according to the procedure described in Example 2, using 3-trifluoromethylphenylboronic acid as starting material. 1 H NMR (CDCl 3 ) δ 7.86 (dd, J=2.1 and 9.2 Hz, 1H), 7.76 (s, J=1.5 Hz, 1H), 7.70-7.61 (m, 4H), 7.30 (d, J=9.2, 1H), 1.65 (s, 6H); MS (m/e): 307 (MH + ); HRMS: calc'd MH + for C 16 H 13 F 3 N 2 O 307.1058. Found 307.1052.
EXAMPLE 10
6-(2,4-Difluoro-phenyl)-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one (JNJ-27518738)
The title product was prepared in 65% yield as a white solid according to the procedure described in Example 2 using 2,4-di-fluorophenylboronic acid as starting material. 1 H NMR (CDCl 3 ) δ 7.78-7.74 (m, 2H), 7.37 (m, 1H), 7.28-7.26 (m, 1H), 7.05-6.95 (m, 2H), 1.62 (s, 6H); MS (m/e): 275 (MH + ); HRMS: calc'd MH + for C 15 H 12 FN 2 O 275.0996. Found 275.1008.
EXAMPLE 11
6-(3,5-Bis-trifluoromethyl-phenyl)-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one (27518803)
The title compound was prepared in 75% yield according to the procedure described in Example 2, starting from 3,5-di-trifluoromethylphenyl boronic acid. 1 H NMR (CDCl 3 ) δ 7.93-7.91 (m, 3H), 7.88-7.86 (m, 2H), 7.33 (dd, J=1.8 and 8.4 Hz, 1H), 1.67 (s, 6H); MS (m/e): 375 (MH + ).
EXAMPLE 12
6-(3-Methoxy-phenyl)-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 54% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one and 3-methoxyphenyl boronic acid. 1 H NMR (CDCl 3 ) δ 7.86 (dd, J=2.1 and 9.2 Hz, 1H), 7.73 (d, J=1.5 Hz, 1H), 7.43-7.39 (m, 1H), 7.28-7.25 (m, 1H), 7.05 (m, 1H), 6.97-6.94 (m, 2H), 3.88 (s, 3H), 1.63 (s, 6H); MS (m/e): 269 (MH + ).
EXAMPLE 13
6-(3-Fluoro-phenyl)-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 72% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.84 (dd, J=2.1 and 9.2 Hz, 1H), 7.75 (d, J=1.6 Hz, 1H), 7.49-7.43 (m, 1H), 7.29-7.24 (m, 2H), 7.19-7.10 (m, 2H), 1.64 (m, 6H); MS (m/e): 257 (MH + ).
EXAMPLE 14
6-(2-Chloro-phenyl)-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 46% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.77-7.73 (m, 2H), 7.55-7.51 (m, 1H), 7.40-7.32 (m, 3H), 7.28-7.23 (m, 1H), 1.62 (s, 6H); MS (m/e): 273 (MH + ).
EXAMPLE 15
6-(3-Fluoro-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 39% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.81 (dd, J=2.1 and 9.2 Hz, 1H), 7.77 (d, J=1.4, 1H), 7.50-7.40 (m, 1H), 7.25-7.23 (m, 2H), 7.18-7.10 (m, 2H), 2.40-2.30 (m, 2H), 2.05-2.00 (m, 2H), 1.91-1.81 (m, 1H), 1.77-1.71 (m, 4H), 1.50-1.38 (m, 1H); MS (m/e): 297 (MH + ).
EXAMPLE 16
6-(3-Methoxy-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 67% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.83 (dd, J=2.1 and 9.2 Hz, 1H), 7.77 (d, J=1.4 Hz, 1H), 7.40-7.38 (m, 1H), 7.24-7.22 (m, 1H), 7.04-7.02 (m, 1H), 6.97-6.95 (m, 2H), 3.88 (s, 3H), 2.40-2.30 (m, 2H), 2.05-2.00 (m, 2H), 1.92-1.80 (s, 1H), 1.77-1.68 (m, 4H), 1.50-1.38 (m, 1H); MS (m/e): 309 (MH + ).
EXAMPLE 17
6-(3,5-Bis-trifluoromethyl-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 35% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.93-7.79 (m, 5H), 7.30-7.28 (m, 1H), 2.40-2.36 (m, 2H), 2.06-2.01 (m, 2H), 1.92-1.88 (m, 1H), 1.82-1.72 (m, 4H), 1.50-1.38 (m, 1H); MS (m/e): 415 (MH + ).
EXAMPLE 18
6-(3-nitro-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 8% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 8.34 (t, J=1.9 Hz, 1H), 8.29-8.26 (m, 1H), 7.88-7.79 (m, 3H), 7.69 (t, J=7.9, 1H), 7.31-7.26 (m, 1H), 2.45-2.30 (m, 2H), 2.10-2.00 (m, 2H), 1.93-1.83 (m, 1H), 1.81-1.70 (m, 4H), 1.50-1.40 (m, 1H); MS (m/e): 324 (MH + ).
EXAMPLE 19
6-(3-trifluoromethyl-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 65% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.84 (dd, J=2.2 and 9.2 Hz, 1H), 7.78 (d, J=1.4 Hz, 1H), 7.69-7.62 (m, 4H), 7.28-7.25 (m, 1H), 2.39-2.32 (m, 2H), 2.05-2.00 (m, 2H), 1.91-1.86 (m, 1H), 1.80-1.71 (m, 4H), 1.47-1.43 (m, 1H); MS (m/e): 347 (MH + ).
EXAMPLE 20
6-(3-cyano-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 47% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.82-7.79 (m, 2H), 7.77-7.70 (m, 3H), 7.28-7.26 (m, 1H), 7.28-7.26 (m, 1H), 2.38-2.30 (m, 2H), 2.05-2.01 (m, 2H), 1.91-1.87 (m, 1H), 1.80-1.71 (m, 4H), 1.49-1.43 (m, 1H); MS (m/e): 304 (MH + ).
EXAMPLE 21
6-(3,5-Difluoro-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 36% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.78-7.75 (m, 2H), 7.23 (s, 1H), 7.00-6.97 (m, 2H), 6.90-6.84 (m, 1H), 2.40-2.23 (m, 2H), 2.05-1.95 (m, 2H), 1.91-1.81 (m, 1H), 1.77-1.65 (m, 4H), 1.50-1.37 (m, 1H); MS (m/e): 315 (MH + ).
EXAMPLE 22
6-(3,5-Dichloro-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 48% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.79-7.76 (m, 1H), 7.69-7.64 (m, 1H), 7.58-7.53 (m, 1H), 7.49-7.45 (m, 1H), 7.31-7.23 (m, 2H), 2.38-2.30 (m, 2H), 2.04-2.00 (m, 2H), 1.90-1.85 (m, 1H), 1.79-1.65 (m, 4H), 1.50-1.38 (m, 1H); MS (m/e): 347 (MH + ).
EXAMPLE 23
6-(2,4-Difluoro-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 48% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.81 (s, 1H), 7.75-7.72 (m, 1H), 7.40-7.33 (m, 1H), 7.25-7.22 (m, 1H), 7.08-6.95 (m, 2H), 2.37-2.28 (m, 2H), 2.05-2.02 (m, 2H), 1.87-1.84 (m, 1H), 1.75-1.71 (m, 4H), 1.45-1.39 (m, 1H); MS (m/e): 315 (MH + ).
EXAMPLE 24
6-(3-chloro-phenyl)-3,3-spiro[pentane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 60% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclopenane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.80 (dd, J=2.1 and 9.2 Hz, 1H), 7.73 (d, J=1.6 Hz, 1H), 7.45-7.39 (m, 3H), 7.34-7.31 (m, 1H), 7.25-7.23 (m, 1H), 2.53-2.48 (m, 2H), 2.20-2.16 (m, 2H), 2.05-1.94 (m, 4H); MS (m/e): 299 (MH + ).
EXAMPLE 25
6-(3-cyano-phenyl)-3,3-spiro[pentane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 31% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclopenane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.80 (dd, J=2.2 and 9.2 Hz, 1H), 7.75-7.68 (m, 4H), 7.62 (t, J=7.7 Hz, 1H), 7.28 (s, 1H), 2.55-2.48 (m, 2H), 2.22-2.18 (m, 2H), 2.06-1.95 (m, 4H); MS (m/e): 290 (MH + ).
EXAMPLE 26
6-(3-Fluoro-phenyl)-3,3-spiro[pentane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 58% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclopenane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.81 (dd, J=2.0 and 9.1 Hz, 1H), 7.74 (d, J=1.8 Hz, 1H), 7.49-7.43 (m, 1H), 7.27-7.22 (m, 2H), 7.17-7.10 (m, 2H), 2.54-2.48 (m, 2H), 2.21-2.14 (m, 2H), 2.08-1.94 (m, 4H); MS (m/e): 283 (MH + ).
EXAMPLE 27
6-(3-nitro-phenyl)-3,3-spiro[pentane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 48% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclopenane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 8.33 (t, J=2.0 Hz, 1H), 8.29-8.27 (m, 1H), 7.87 (dd, J=2.1 and 9.2 Hz, 1H), 7.83-7.68 (m, 2H), 7.70 (t, J=8.0 Hz, 1H), 7.30 (d, J=9.2 Hz, 1H), 2.54-2.49 (m, 2H), 2.22-2.18 (m, 2H), 2.07-1.97 (m, 4H); MS (m/e): 310 (MH + ).
EXAMPLE 28
6-(3,4-Dichloro-phenyl)-3,3-spiro[pentane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 58% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclopenane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.77 (dd, J=2.1 and 9.2 Hz, 1H), 7.72 (m, 1H), 7.57-7.53 (m, 2H), 7.30-7.23 (m, 2H), 2.53-2.47 (m, 2H), 2.21-2.14 (m, 2H), 2.08-1.94 (m, 4H); MS (m/e): 331 (MH − ).
EXAMPLE 29
6-(3,5-Bis-trifluoromethyl-phenyl)-3,3-spiro[pentane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 80% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclopenane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.93 (s, 1H), 7.88 (s, 2H), 7.84-7.79 (m, 2H), 7.30-7.28 (m, 1H), 2.54-2.48 (m, 2H), 2.23-2.16 (m, 2H), 2.09-1.97 (m, 4H); MS (m/e): 401 (MH + ).
EXAMPLE 30
6-(3-Chloro-4-fluoro-phenyl)-3,3-spiro[pentane]-imidazo[1,2-a]pyridin-2-one
The title compound was prepared in 44% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclopenane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.76 (dd, J=2.1 and 9.2 Hz, 1H), 7.70 (d, J=1.4 Hz, 1H), 7.49 (dd, J=2.3 and 6.7 Hz, 1H), 7.34-7.22 (m, 3H), 2.53-2.47 (m, 2H), 2.22-2.12 (m, 2H), 2.07-1.94 (m, 4H); MS (m/e): 317 (MH + ).
EXAMPLE 31
A. 5-(3-Fluoro-phenyl)-1,3-dihydro-pyrrolo[2,3-b]pyridin-2-one
The title compound was prepared in 32% yield according to the procedure described in Example 2, starting from 5-bromo-1,3-dihydro-pyrrolo[2,3-b]pyridin-2-one (prepared according to the procedure described in WO2003082868, Page 33) and 3-fluoro-phenyl boronic acid. 1 H NMR is the same as the one reported in WO2003082868, page 34.
B. 5-(3-Fluoro-phenyl)-3,3-dimethyl-1,3-dihydro-pyrrolo[2,3-b]pyridin-2-one
A solution of 5-(3-Fluoro-phenyl)-1,3-dihydro-pyrrolo[2,3-b]pyridin-2-one (91 mg, 0.40 mmol) in THF (8 mL) was cooled to between −10 and −30° C. under argon. To this solution was added n-butyllithium (0.34 mL, 0.84 mmol) followed by N,N,N′,N′-tetramethylenediamine (0.13 mL, 0.84 mmol). The solution was stirred at −10° C. for 0.5 hours. Iodomethane was added (0.05 mL, 0.84 mmol) and the solution was allowed to warm to room temperature overnight. The reaction mixture was diluted with water and then extracted three times with ethyl acetate. The organic extracts were washed with brine, dried over magnesium sulfate, filtered, evaporated to yield a tan solid. The crude material was purified by column chromatography eluting with 40% ethyl acetate/hexanes. The product was obtained as off-white solid (23 mg, 22%). 1 H NMR (CDCl 3 ) δ 8.74 (s, 1H), 8.36 (d, J=1.9 Hz, 1H), 7.62 (d, J=2.0 Hz, 1H), 7.46-7.41 (m, 1H), 7.33 (d, J=7.8 Hz, 1H), 7.24-7.23 (m, 1H), 7.11-7.06 (m, 1H), 1.48 (s, 6H); MS (m/e): 257 (MH + ).
EXAMPLE 32
5-(3-Fluoro-phenyl)-3,3-spiro[cyclohexane]-1,3-dihydro-pyrrolo[2,3-b]pyridin-2-one
The title compound was prepared in 24% yield according to the procedure described in Example 30B, starting from 5-(3-Fluoro-phenyl)-1,3-dihydro-pyrrolo[2,3-b]pyridin-2-one and 1,5-diiodopentane. 1 H NMR (CDCl 3 ) δ 9.40 (s, 1H), 8.37 (s, 1H), 7.87 (d, J=1.9 Hz, 1H), 7.47-7.38 (m, 1H), 7.33 (d, J=7.8 Hz, 1H), 7.24-7.23 (m, 1H), 7.11-7.06 (m, 1H), 1.99-1.67 (m, 10H); MS (m/e): 297 (MH + ).
EXAMPLE 33
In Vitro Test
T47D human breast cancer cells are grown in RPMI medium without phenol red (Invitrogen) containing 10% (v/v) heat-inactivated fetal bovine serum (FBS; Hyclone), 1% (v/v) penicillin-streptomycin (Invitrogen), 1% (w/v) glutamine (Invitrogen), and 10 mg/mL insulin (Sigma). Incubation conditions are 37 □C in a humidified 5% (v/v) carbon dioxide environment. For assay, the cells are plated in 96-well tissue culture plates at 10,000 cells per well in assay medium [RPMI medium without phenol red (Invitrogen) containing 5% (v/v) charcoal-treated FBS (Hyclone) and 1% (v/v) penicillin-streptomycin (Invitrogen)]. Two days later, the medium is decanted and the compounds are added in a final concentration of 0.1% (v/v) dimethyl sulfoxide in fresh assay medium. Twenty-four hours later, an alkaline phosphatase assay is performed using a SEAP kit (BD Biosciences Clontech, Palo Alto, Calif.). Briefly, the medium is decanted and the cells are fixed for 30 minutes at room temperature with 5% (v/v) formalin (Sigma). The cells are washed once with room temperature Hank's buffered saline solution (Invitrogen). Equal volumes (0.05 mL) of 1× Dilution Buffer, Assay Buffer and 1:20 substrate/enhancer mixture are added. After 1-hour incubation at room temperature in the dark, the lysate is transferred to a white 96-well plate (Dynex) and luminescence is read using a LuminoSkan Ascent (Thermo Electron, Woburn, Mass.).
TABLE 3
(I)
Ex. #
R1, R2
R4
% inh.
1-C3
Spirocyclohexane
Br
3
Spirocyclohexyl
3-Cl-phenyl
104%
1-C1
Dimethyl
Br
53%
2
Dimethyl
3-Cl-phenyl
15%
4
Dimethyl
3-CN-phenyl
19%
5
Dimethyl
Cl
31%
6
Spirocyclohexyl
Cl
42%
7
Dimethyl
3,5-di-F-phenyl
40%
8
Dimethyl
3-NO 2 -phenyl
33%
9
Dimethyl
3-CF 3 -phenyl
17%
10
Dimethyl
2,4-di-F-phenyl
29%
11
Dimethyl
3,5-di-CF 3 -phenyl
19%
12
Dimethyl
3-MeO-phenyl
3.1%
13
Dimethyl
3-F-phenyl
14%
14
Dimethyl
2-Cl-phenyl
0%
1-C2
spirocyclopentane
Br
35%
15
spirocyclohexane
3-F-phenyl
0%
16
spirocyclohexane
3-MeO-phenyl
01%
17
spirocyclohexane
3,5-di-CF 3 -phenyl
04%
18
spirocyclohexane
3-NO 2 -phenyl
98%
19
spirocyclohexane
3-CF 3 -phenyl
97%
20
spirocyclohexane
3-CN-phenyl
96%
21
spirocyclohexane
3,5-di-F-phenyl
99%
22
spirocyclohexane
3,4-di-Cl-phenyl
88%
23
spirocyclohexane
2,4-di-F-phenyl
96%
24
spirocyclopentane
3-Cl-phenyl
1%
25
spirocyclopentane
3-CN-phenyl
2%
26
spirocyclopentane
3-F-phenyl
2%
27
spirocyclopentane
3-NO 2 -phenyl
86%
*28
spirocyclopentane
3,4-di-Cl-phenyl
22%
29
spirocyclopentane
3,5-di-CF 3 -phenyl
25%
30
spirocyclopentane
3-Cl-4-F-phenyl
21%
*% activation: 93.82% @ 3000 nM, EC50 = 1950 nM.
TABLE 4
(II)
Ex. #
R 1 , R 2
R 3
% inh.
IC 50 (nM)
31
Spirocyclo
3-F-phenyl
92% @ 10 uM
4484
hexane
95% @ 3 uM
32
Dimethyl
3-F-phenyl
58% @ 10 uM
7027
58% @ 3 uM
EXAMPLE 34
While the foregoing specification teaches the principles of the present invention, with examples provided for the purpose of illustration, it will be understood that the practice of the invention encompasses all of the usual variations, adaptations and/or modifications as come within the scope of the following claims and their equivalents.
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The present invention is directed to novel heteroatom containing tetracyclic derivatives, pharmaceutical compositions containing them and their use in the treatment of disorders mediated by one or more estrogen receptors. The compounds of the invention are useful in the treatment of disorders associated with the depletion of estrogen such as hot flashes, vaginal dryness, osteopenia and osteoporosis; hormone sensitive cancers and hyperplasia of the breast, endometrium, cervix and prostate; endometriosis, uterine fibroids, osteoarthritis and as contraceptive agents, alone or in combination with a progestogen or progestogen antagonist.
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RELATED APPLICATION
This application relates to an application in the name of the same inventor entitled “MOTOR PUMP”, and filed of even date herewith, and assigned U.S. Ser. No. 12/136,873, filed on Jun. 11, 2008 and now issued as U.S. Pat. No. 8,008,500. This co-pending application is hereby incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The present invention relates in general to an improved bearing for use with a motor driven pump. The present invention is directed to an improved bearing material that can be particularly used in constructing bearings for a canned motor pump.
BACKGROUND OF THE INVENTION
Canned motor pumps are widely used to circulate water in heating and plumbing systems. Examples of canned motor pumps are found in U.S. Pat. Nos. 4,990,068 and 5,549,459. Canned motor pumps are lubricated by the fluid being pumped which typically is water. These pumps are commonly referred to as water lubricated pumps. The pumps are typically driven by an electric motor and the rotor of the motor, as well as the pump impeller, are mounted on a common shaft. An inherent feature of canned motor pumps is that all rotating parts are immersed in the fluid being pumped. Because of that they generally do not require any dynamic seals such as packings or mechanical seals. Since the shaft is immersed in the fluid being pumped, it follows that the bearings supporting the shaft are also immersed in the fluid, usually water. It is a common practice to use sleeve bearings, as opposed to ball bearings, in canned motor pumps.
When constructing sleeve bearings, it is desired to achieve a hydrodynamic operating condition, i.e., complete separation of the shaft and the bearing by a fluid film. From a practical point, this is not consistently possible, particularly with small bearings and a lubricant of very low viscosity, such as water. Therefore, what actually occurs is so-called mixed-film lubrication where some contact between shaft and bearing remains and thus some rubbing is constantly present. For this reason, it is important that shaft and bearing materials are carefully selected so that they are compatible and do not undergo excessive wear.
Early pumps used in heating systems utilized shafts made of hardened stainless steel and bearings made of bronze (either solid or sintered). This combination worked well as long as the water (and thus the bearing lubricant) was clean. However, many heating systems suffer from galvanic corrosion due to the presence of copper (in pipes) and iron (in the boiler). The galvanic corrosion product is magnetite (chemical formula Fe 3 O 4 ) which is very hard and abrasive. It precipitates out in the form of very fine particles which easily find their way into the bearing clearance where they have often caused severe wear of the stainless steel shaft. Even when hardened to the maximum possible extent, stainless steel is still softer than magnetite. To overcome this problem, shafts made of very hard ceramics such as alumina ceramic (chemical formula Al 2 O 3 ) have been used. Unfortunately, the combinations of a bronze bearing and a ceramic shaft resulted in so-called “galling,” i.e., the transfer of bronze from the bearing to the shaft, thus destroying the bearing. In the past the bronze of the bearing has been replaced by carbon-graphite (i.e. the bearing system then includes a ceramic shaft and carbon-graphite bearing). An example of the use of carbon-graphite at a bearing surface is found in U.S. Pat. No. 5,549,459. This arrangement provided an improved bearing system. However, carbon-graphite bearings are very expensive.
Accordingly, it is an object of the present invention to provide an improved bearing system that provides a more durable bearing surface, while at the same time providing a bearing system that is relatively inexpensive, particularly in comparison to carbon-graphite bearings.
Another object of the present invention is to provide an improved bearing that is particularly adapted for use in a canned motor pump.
SUMMARY OF THE INVENTION
To accomplish the foregoing and other objects, features and advantages of the present invention there is provided a bearing that is used in a motor pump in which a liquid is not only pumped by means of an impeller driven by the motor, but also is used to lubricate components of the motor pump including the motor pump shaft. The bearing is for supporting the shaft at at least one location of the shaft. The bearing constructed of a bronze material having added thereto a small amount of graphite.
In accordance with other aspects of the present invention the small amount of graphite is in a range of 1% to 10% of the total material comprising the bearing; alternatively the small amount of graphite is in a preferred range of 2.5% to 5% of the total material comprising the bearing; the bearing is constructed using a sintering technique that defines a porosity of the bearing; the graphite is mixed as a powder with a bronze powder prior to sintering or the graphite is impregnated into the bronze after sintering; the motor pump is a canned motor pump and the liquid is the fluid being pumped.
In accordance with another embodiment of the present invention there is provided a method of forming a sleeve type bearing for use in a motor pump in which a liquid is not only pumped by means of an impeller driven by the pump, but also is used to lubricate components of the motor pump including the motor pump shaft. The method comprises the steps of: providing a main bearing component as a bronze powder; providing a small amount of an additive as a graphite powder; wherein the small amount of the additive is less than 10% of the total material of the combined powders; mixing the bronze and graphite powders together to form a composite material; and heating the mixed composite material to form the sleeve type bearing.
In accordance with still other aspects of the present invention the heating step includes sintering the powder mixture; the small amount of graphite is in a range of 1% to 10% of the total material comprising the bearing; the small amount of graphite is in a range of 2.5% to 5% of the total material comprising the bearing; the motor pump is a canned motor pump and the liquid is the fluid being pumped.
In accordance with still a further embodiment of the present invention there is provided a method of forming a sleeve type bearing for use in a motor pump in which a liquid is not only pumped by means of an impeller driven by the pump, but also is used to lubricate components of the motor pump including the motor pump shaft. The method comprises the steps of: providing a main bearing component as a bronze powder; providing a small amount of an additive as a graphite powder; wherein the small amount of the additive is less than 10% of the total material of the combined powders; heating the bronze powder to form the sleeve type bearing; and adding the small amount of graphite to the formed sleeve type bearing.
In accordance with other aspects of the present invention the heating step includes sintering the bronze powder; the graphite is added by impregnating the graphite into the bronze bearing; the small amount of graphite is in a range of 1% to 10% of the total material comprising the bearing; the small amount of graphite is in a range of 2.5% to 5% of the total material comprising the bearing; the motor pump is a canned motor pump and the liquid is the fluid being pumped.
DESCRIPTION OF THE DRAWINGS
Numerous other objects, features and advantages of the present invention should now become apparent upon a reading of the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a cross sectional view through a canned motor pump that uses the improved bearing of the present invention;
FIG. 2 is an axial cross-sectional view of the cartridge assembly in FIG. 1 ; and
FIG. 3 is a cross-sectional view taken along line 3 - 3 of FIG. 2 .
DETAILED DESCRIPTION
Reference is now made to the cross-sectional views shown in FIGS. 1 and 2 . FIG. 1 is a cross sectional view taken through a canned motor pump, and that uses the improved bearing of the present invention. FIG. 2 is an axial cross-sectional view of the cartridge assembly in FIG. 1 . It is to be understood that this particular canned motor pump is only shown by way of illustration, and that other canned motor pump structures, or any other motor pump structures may also use the bearing described herein. Furthermore, the principles of the present invention may also apply to other motor and/or pump constructions, and may apply to different locations therein where the improved bearing of the present invention can be used.
The pump illustrated in FIGS. 1 and 2 has been covered in the co-pending application. FIG. 1 is a cross sectional view of a motor pump which is characterized by excellent alignment and field serviceability. FIGS. 1 and 2 show further details of this pump including the pump housing 38 , the motor housing 40 , the front bearing support 42 , as well as sleeve bearings 44 A and 44 B. Within the motor housing 40 is disposed the stator 46 and adjacent thereto the rotor 48 . A sleeve 50 is shown supported between the rotor and stator. The support plate 52 secures the assembly to the pump housing. An O-ring 53 or other elastomeric member is provided between the shaft 54 and the bearing support 42 . The shaft 54 holds the rotor and is supported by the two bearings 44 A, 44 B. The front end of the shaft 54 supports the pump impeller 56 . A thrust washer 45 is preferably provided between bearing 44 A and the rotor assembly. The rear bearing 44 B is mounted in the sleeve 50 and the bearing support 42 , to which front bearing 44 A is mounted, is fitted to the sleeve 50 . Refer to FIG. 2 . In the disclosed pump structure the liquid is illustrated at 36 (see FIG. 1 ), flowing through the pump itself.
In FIG. 2 it is also noted that the bearing support member is preferably constructed with a reverse bend as at 39 in FIG. 2 where, at one side the bearing 44 A is mounted, while the opposite side forms the pilot section 42 A. Both of these sides are preferably cylindrical. The pilot section 42 A is adapted for insertion into the corresponding pilot section 50 A of the sleeve 50 . There is thus formed an interface surface between the respective pilot sections 42 A, 50 A extending along dimension L in FIG. 2 .
In accordance with the present invention, rather than providing a press-fit between the bearing support 42 and the sleeve 50 , there is provided a pilot section P of the sleeve (see FIG. 2 ) that has an undulating, wavy shape, instead of a plain circular or cylindrical shape. In this regard refer to the cross-sectional view of FIG. 3 for an illustration of the shape of the sleeve along the length 50 A corresponding to the pilot section P. The undulating shape is dimensioned so that a diameter touching the inside low points K (six of them in FIG. 3 ) of the sleeve length 50 A in FIG. 3 is smaller than the outside diameter D of the pilot section L (see FIG. 2 ) of the bearing support 42 . In this way, when pushing the rotor sub-assembly into the sleeve assembly in order to obtain the cartridge illustrated in FIG. 2 , the waves or undulations are caused to flatten out to conform to the pilot diameter D of the bearing support 42 . The section P preferably extends beyond the section L to assure that there is proper contact between the components. Although reference has been made to contact points, as at K in FIG. 3 , because this wave pattern extends along the entire length of the pilot section P ( 50 A) the contact is actually along a line that runs parallel to the shaft axis.
This combination of the wavy or undulating surface of the sleeve with the cylindrical nature of the bearing support thus provides essentially a clearance-less assembly. The wavy shape of the length 51 A of the sleeve 50 functions as a radial spring. The sleeve length 50 A preferably has a wall thickness in a range on the order of 0.006 to 0.020 inch. Because of the relative thinness of the sleeve wall, particularly along the section 50 A, the spring forces are relatively small, allowing ready insertion and removal of the assembly by hand.
The discovery of the present invention is that the addition of a relatively small amount of graphite to a bronze bearing results in a bearing structure that is characterized by improved durability and essentially an elimination of the afore-mentioned “galling”. This provides an improved bearing structure at relatively low cost. It has been discovered that by mixing a certain amount of graphite powder with bronze powder and then using the sintering process, bearings can be produced which have proven to work successfully with ceramic shafts, i.e., ceramic shafts are not abraded by magnetite and the addition of graphite to the bronze inhibits the transfer of bronze material to the shaft.
It has been discovered that the addition of as little as 1.0% graphite is sufficient to provide the desired effect. The upper limit on the percentage is at the point where the strength of the bronze matrix of the mix is sufficiently lowered to become a problem. Too much graphite makes the bearing too brittle. The preferred range of percentage of graphite is 1.0% to 10%, and most preferred range is of 2.5% to 5%.
The graphite may be combined with the bronze in basically two different ways. Both techniques include a sintering process. First, a graphite powder may be mixed with a bronze powder in the amounts indicated above, followed by the sintering (heating) process. In addition to mixing graphite with the bronze powder prior to sintering, bearings can be impregnated with graphite after the sintering process has been completed. It should be noted that sintered materials are porous and it is thus possible to impregnate the plain bronze material even after it has been sintered.
Thus, in accordance with the present invention there is the discovery that one can use the combination of graphite and bronze to produce sintered bearings, either by pre-mixing graphite and bronze prior to the sintering process or by impregnation of porous sintered bronze bearings with graphite subsequent to the sintering process. The sintered bronze material is commercially available from Keystone Carbon Company. The material is designated C-62.
Having now described a limited number of embodiments of the present invention it should now be apparent to one skilled in the art that numerous other embodiments and modifications thereof are contemplated a falling within the scope of the present invention. For example, in the embodiment that is disclosed, such as in FIG. 3 , there are six valleys (point K). However, greater than or fewer than six may be used. The preferred number of points K is three. The disclosed embodiment also has the undulations on the outer sleeve. However, in an alternate embodiment of the invention the undulations may be in the bearing support member such as along the length L shown in FIG. 2 . The material of the sleeve and bearing support is preferably metal, and can be of any number of types of metals.
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A bearing that is used in a motor pump in which a liquid is, not only pumped by means of an impeller driven by the pump, but also is used to lubricate components of the motor pump including the motor pump shaft. The bearing is for supporting the shaft at at least one location of the shaft. The bearing is constructed of a bronze material having added thereto a small amount of graphite, preferably around 2.5%.
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BACKGROUND OF THE INVENTION
This invention relates to a connection for two conduit parts of a vacuum cleaner, such as the air hose and a coupling member which can be connected to the vacuum cleaner housing.
A principal feature of the invention is that a connecting element is securely connected to the hose, and is provided with means for turnable mounting of the hose in relation to the coupling member. In accordance with the teachings of the invention, the connecting element comprises a sleeve securely connectable with the hose, said sleeve at its free end having a plurality of peripheral claws which are intended to engage with a groove in the coupling member in order to facilitate the turning movement of the sleeve, and thereby of the hose in relation to the coupling member.
In order that the invention will be more clearly understood, it will now be disclosed in greater detail with reference to the accompanying drawings, in which:
FIG. 1 shows a perspective, exploded view of the components of the connection; and
FIG. 2 is a longitudinal section of the connection, in an assembled condition.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 2 the reference numeral 10 designates a hose of the type, for example, being intended for household use and the like, and being connected to the apparatus by a coupling member turnably connected with the hose, said coupling member, as a whole, being designated by the reference numeral 11. In the embodiment shown, the coupling member has the form of a valve which is more specifically described hereinafter.
Between the hose and the coupling member is a connecting element that is arranged in the form of a sleeve 12, that may be fabricated of plastic or other flexible material and which has one of its ends threaded on the corrugations of the hose or in another suitable way secured to the hose, for instance by gluing, so that it is firmly connected to the hose 10. In its other end, the sleeve 12 has a number of peripheral claws 13 arranged to engage with a groove 14 adapted in the envelope surface of the coupling member 11, so that the capability of a turnable movement between the sleeve 12 and the coupling member 11 is obtained. The sleeve 12 is at the same time being locked in an axial direction. The claws 13 have the form of bodies with L-shaped cross section and turned towards the center of the sleeve 12, the diametrical distance between their free end surfaces somewhat exceeding the outside diameter of the groove 14.
The groove 14 is mainly U-shaped and has an initial surface 15 slanting in relation to the longitudinal axis of the coupling member 11, said surface being arranged in the free end of the coupling member 11, which end cooperates with the sleeve 12 so that the claws 13 can be more easily inserted in the groove 14.
A sealing sleeve 16 is surrounding the sleeve 12, on one hand to obtain an airtight connection between the hose 10 and the coupling member 11, and on the other hand to join the coupling member and the apparatus. As seen in FIG. 2 the sleeve 12 has two radial elevations 17, 18, which are spaced from each other, and which extend circumferentially around the sleeve 12. The envelope surfaces of the radial elevations are intended to seal with the inner surface of the sleeve 16, and to guide the sleeve 12 inside the sealing sleeve 16. Moreover, in the end of the sleeve 12, which is opposite to the location of the claws 13, there is a tongue 19 which slants in relation of the longitudinal axis of the sleeve 12, and is shaped for additional sealing between the two sleeves 12, 16.
The coupling member 11 is in the form of a valve and comprises a tubular portion 20, which is a projecting portion and is provided with the groove 14. The part of the coupling member remaining in the air channel 22 connected to the vacuum cleaner housing is a scoop-shaped portion 21. It should be evident that the arrangement according to the invention can be used advantageously for vacuum cleaners of the so called "upright" model, which, when the apparatus is moved across the floor, takes in dust-laden air through a suction opening on the underside of the apparatus through an air channel 22, which is only partly shown in FIG. 2.
When using the apparatus for so called off-floor cleaning, i.e. cleaning of furniture or the like, a suction hose can be connected to the apparatus by means of the coupling member 11, which for this purpose, in its free end, has preferably two or three projections 24, for locking of the coupling member and thereby of the hose to the apparatus. An opening, which can be closed by a cover (not shown) is arranged in the housing of the apparatus so that it communicates with the air channel 22 leading to the dust container of the apparatus (not shown).
After the coupling member 11 has been inserted through this opening and has been locked in its position by means of the projections 24 the scoop-shaped portion 21 of the coupling member closes the portion of the air channel leading to the suction opening and a new passage 23 is opened for the air flowing through the hose 10 to the dust container through air channel 22.
Because the hose 10 is turnable relative to the coupling member 11, on one hand, locking of the hose on to the apparatus, and on the other hand the use of the vacuum cleaner are made easier, as the tendency of the hose "to make a knot" is eliminated. The present assembly comprises few details and is very easy to assemble. After connecting the sleeve 12 to the hose, for example by threading, the sealing sleeve 16 is placed on to the sleeve 12 and the tubular portion 20 of the coupling member 11 is inserted in the sleeve 16 until the claws 13 engage with the groove 14 and effectively connect the sleeve 12 with the coupling member 11. The resilient force of the claws 13 is adjusted so that the connection between the two portions can be considered firm, and it cannot be disconnected without destroying the coupling.
Although only one embodiment has been shown and described, it should be evident that several modifications are conceivable within the scope of the invention, as it is described in the following claims.
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A connection for two co-axially arranged conduit parts of a vacuum cleaner. The connection includes a coupling which has means for turnable mounting the vacuum cleaner hose relative to a coupling member on the vacuum cleaner housing. The connection further comprises an outer and inner sleeve, with the latter being provided with said turnable means in the form of claws which are adapted to slidingly fit in a peripheral groove in a tubular portion of the coupling member.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related to U.S. Pat. No. 7,766,006 and U.S. application Ser. Nos. 12/643,880, 12/237,131 and 12/237,136.
FIELD OF THE INVENTION
The present invention relates generally to gas heaters and, more particularly, to unvented gas heaters.
BACKGROUND
Unvented gas heaters are designed to be used indoors without pipes, ducts, or other conduit to vent the heater's exhaust to the exterior atmosphere. Vent free gas heaters typically include one or more gas burners and optionally one or more ceramic containing heating elements in a housing. The gas and air mix in the heater where combustion takes place. These heaters may have a blower to force air flow through the heater providing the release of heated gases or convective heat.
Unvented gas heaters have been designed to be free standing, mounted on a wall, or in a decorative housing such as a vent free fireplace. The housing providing a vent free fireplace is typically substantially the size of a fireplace and has artificial logs above the burners. Some have even been designed with a glass front to provide the appearance of an enclosed fireplace.
The unvented heaters of the prior art are typically designed to use either natural gas or liquid propane gas as a fuel source. It is not permitted for a manufacturer to supply a conversion kit for an unvented gas heater to convert from one fuel source to another. Even if such a conversion kit were permitted, as is the case with vented gas heaters, to change fuel source gas type on a heater in the field, requires the installer to change the regulator, pilot orifice and burner orifice for the alternate gas type.
SUMMARY OF THE DISCLOSURE
A dual fuel gas burner is provided for use in a vent free heater. Embodiments of the dual fuel vent free gas burner can be used in free standing heaters, wall mount heaters, gas fireplaces, or other vent free heaters as is known in the art. A dual fuel vent free gas heater provides convective and/or radiant heat preferably to an indoor environment. The heater may be designed to use natural convective air currents and may optionally have a fan enhancing the natural convective currents within the heater. Alternatively, a fan may be used to force the gases and/or air within the heater at desired flow patterns which may be counter to natural convective forces.
This gas heater can be operated with multiple fuels such as liquid propane or natural gas. In some embodiments, an installer turns a selector valve plumbed in the product gas train. This selection sends the correct gas type to the correct fuel injector and pilot burner. Preferably, all plumbing connections are performed at the factory rather than onsite by the user or installer.
Embodiments of the gas heater can be operated on liquid propane or natural gas by connecting the fuel supply to the correct regulator on the heater. The installer or user then turns a selector valve, in selected embodiments, plumbed in the product gas train. This selection sends the correct gas type to the correct injector and pilot burner for the supply gas. Optionally, an oxygen detection system is incorporated within the heater. Advantageously, the heater is thermostatically controlled.
In one implementation a dual fuel vent free gas heater is provided comprising: a gas burner adapted to receive one of a first type of gas or of a second type of gas, a first pilot burner located adjacent the gas burner and intended to receive the first type of gas, a second pilot burner located adjacent the gas burner intended to receive the second type of gas, a normally closed control valve comprising an actuator and adapted to open upon a predetermined electrical voltage being applied to the actuator, the control valve situated to permit either the first type of gas or the second type of gas to flow through the control valve toward the gas burner when the control valve is in the open position, a first temperature sensor located adjacent the first pilot burner, a second temperature sensor located adjacent the second pilot burner, and a normally closed thermal switch coupled to the first temperature sensor and not couple to the second temperature sensor, the thermal switch located in the electrical flow path between a voltage source and the control valve actuator, the thermal switch configured to open when the temperature detected by the first temperature sensor exceeds a predetermined temperature indicative that the second type of gas is being delivered to the first pilot burner.
In another implementation a dual fuel vent free gas heater is provided comprising: a gas burner adapted to receive one of a first type of gas or of a second type of gas, a first pilot burner located adjacent the gas burner and intended to receive the first type of gas, a second pilot burner located adjacent the gas burner and intended to receive the second type of gas, a first temperature sensor located adjacent the first pilot burner and adapted to generate an electrical voltage deliverable to the control valve upon being heated by a pilot flame emitted by the first pilot burner, a second temperature sensor located adjacent the second pilot burner and adapted to generate an electrical voltage deliverable to the control valve upon being heated by a pilot flame emitted by the second pilot burner, a normally closed control valve comprising an actuator and adapted to open upon a predetermined electrical voltage being applied to the actuator, the control valve situated to permit the first type of gas or the second type of gas to flow through the control valve toward the gas burner when the control valve is in the open position, and a normally closed thermal switch situated between the first temperature sensor and the control valve actuator and not situated between the second temperature sensor and the control valve actuator, the thermal switch configured to open when the temperature detected by the first temperature sensor is indicative that second type of gas is being delivered to the first pilot burner.
In another implementation a dual fuel vent free gas heater is provided comprising: a gas burner adapted to receive one of a liquid propane gas or a natural gas, a first pilot burner located adjacent the gas burner and intended to receive the natural gas, a second pilot burner located adjacent the gas burner and intended to receive the liquid propane gas, a normally closed control valve comprising an actuator and adapted to open upon a predetermined electrical voltage being applied to the actuator, the control valve situated to permit either the natural gas or the liquid propane gas to pass through the control valve towards the gas burner, a first temperature sensor located adjacent the first pilot burner, a second temperature sensor located adjacent the second pilot burner, and a normally closed thermal switch coupled to the first temperature sensor and not coupled to the second temperature sensor, the thermal switch located in the electrical flow path between a voltage source and the control valve actuator, the thermal switch configured to open when the temperature detected by the first temperature sensor is indicative that liquid propane gas is being delivered to the first pilot burner.
In another implementation a dual fuel vent free gas heater is provided comprising: a gas burner adapted to receive one of a liquid propane gas or a natural gas, a first pilot burner located adjacent the gas burner and intended to receive the natural gas, a second pilot burner located adjacent the gas burner and intended to receive the liquid propane gas, a first temperature sensor located adjacent the first pilot burner and adapted to generate an electrical voltage deliverable to the control valve upon being heated by a pilot flame emitted by the first pilot burner; a second temperature sensor located adjacent the second pilot burner and adapted to generate an electrical voltage deliverable to the control valve upon being heated by a pilot flame emitted by the second pilot burner; a normally closed control valve comprising an actuator and adapted to open upon a predetermined electrical voltage being applied to the actuator, the control valve situated to permit the natural gas or the liquid propane gas to flow through the control valve toward the gas burner when the control valve is in the open position, and a normally closed thermal switch situated between the first temperature sensor and the control valve actuator and not the second temperature sensor and the control valve actuator, the thermal switch configured to open when the temperature detected by the first temperature sensor is indicative that liquid propane gas is being delivered to the first pilot burner.
In one implementation the first and second temperature sensors comprise thermocouples.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of an embodiment of a dual fuel vent free showing heater components thereof assembled within a housing;
FIG. 2 is a cut-away view of the dual fuel vent free heater of FIG. 1 showing an oxygen detection system;
FIG. 3 is schematic view of the dual fuel vent free heater of FIG. 1 showing flow connection of component parts;
FIG. 4 is schematic view of a dual fuel vent free heater having a single multiuse injector and a thermal switch;
FIG. 5 is schematic view of a dual fuel vent free heater having a dual burner configuration;
FIG. 6 is schematic view of a dual fuel vent free heater having a dual burner and dual thermostatic control valve configuration;
FIG. 7 is a schematic view of a dual fuel vent free heater having a multi-positional manual control valve, a thermal switch, and a thermostatic control valve;
FIG. 8 is a blow-up view of the multi-positional manual control valve of FIG. 7 ;
FIG. 9A is a schematic view of a dual fuel vent free heater having a multi-positional manual control valve, a thermal switch, a thermostatic control valve, and pilot burners;
FIG. 9B is a schematic view of a dule fuel vent free heater having a multi-positional manual control valve, a thermal switch, a thermostatic control valve, and a pilot burners according to another implementation;
FIG. 10 is schematic view of the dual fuel vent free heater having a first burner, a second burner, and a cross-over burner for use in a vent free fireplace unit; and
FIG. 11 is a schematic view of a dual fuel vent free heater having a multi-positional manual control valve directly controlling the flow of fuel into the heater.
DETAILED DESCRIPTION
The following description describes embodiments of a dual fuel vent free heater. In the following description, numerous specific details and options are set forth in order to provide a more thorough understanding of the present invention. It will be appreciated, however, by one skilled in the art that the invention may be practiced without such specific details or optional components and that such descriptions are merely for convenience and that such are selected solely for the purpose of illustrating the invention. As such, reference to the figures showing embodiments of the present invention is made to describe the invention and not to limit the scope of the disclosure and claims herein.
FIGS. 1 , 2 and 3 show a dual fuel vent free heater 100 . FIG. 1 shows the component parts of dual fuel vent free heater 100 in a housing 180 and FIG. 3 shows the flow diagram of heater 100 . Dual fuel vent free gas heater 100 comprises a gas burner 132 having a plurality of gas outlet ports 155 (shown in FIG. 3 ) in an upper surface thereof. Gas outlet ports 155 are in flow communication with pilot flame burners 120 and 122 . Brackets 139 hold pilot flame burners 120 and 122 , piezometric igniters 157 and 159 , and temperature sensors 152 and 154 proximate burner 132 . Piezometric igniters 157 and 159 are in flow communication with pilot flame burners 122 and 120 respectively. Fuel injectors 126 and 128 are in flow communication with the interior portion of gas burner 132 . Bracket 124 holds fuel injectors 126 and 128 at an injection angle with respect to a longitudinal axis of gas burner 132 other then 0.degree. Non-concentric alignment of injectors 126 and 128 with a burner venturi within burner 132 with hat bracket 124 controls angle of injectors which may be varied depending on the size of burner 132 . Optionally, an oversized venturi may accommodate non-concentric injectors 126 and 128 . Preferably, bracket 124 has threaded apertures for accommodation of injectors having a threaded outer annular surface. Therefore, any size burner 132 may used. Preferably, the injection angel of each injector is of the same magnitude. Fuel supply lines 134 and 136 are in flow communication with fuel injectors 126 and 128 respectively. Fuel supply line 134 and injector 126 have a composition and configuration for transporting a fuel such as natural gas or liquid propane at a desired flow rate and fuel supply line 136 and injector 128 have a composition and configuration for transporting a different fuel such as the other of natural gas or liquid propane at a desired flow rate.
FIG. 2 is a cutaway portion of dual fuel vent free heater 100 showing an oxygen detection system. The oxygen detection system has temperature sensors 152 and 154 in proximity to oxygen detection gas outlet ports 153 in gas burner 132 . Oxygen detection gas outlet ports 153 extend down a cylindrical wall in gas burner 132 from the plurality of gas outlet ports 155 on the upper surface of burner 132 . Oxygen detection control system 131 , shown schematically in FIG. 3 , is in electronic communication with temperature sensors 152 and 154 and thermostatic control 130 wherein thermostatic control 130 has valves controlling the flow of fuels to injectors 126 and 128 and pilot flame burners 120 and 122 . Oxygen detection control system 131 sends an electronic signal to thermostatic control 130 directing thermostatic control 130 to close the valves shutting off the flow of fuel when a temperature sensor 157 or 159 indicates a temperature less than a control temperature.
Dual fuel vent free gas heater 100 comprises two regulators 112 and 114 in flow communication with “T” connector 110 via fuel lines 148 and 150 respectively. Fuel line 146 extends from “T” connector 110 to thermostatic control valve 130 . Pilot line 144 leads from thermostatic control valve 130 to pilot control valve 118 . Injector line 142 leads from thermostatic control valve 130 to injector control valve 116 . Fuel lines 138 and 140 lead from pilot control valve 118 to pilot flame burners 122 and 120 respectively. Fuel lines 136 and 134 lead from injector control valve 116 to injectors 126 and 128 respectively. Control valves 118 and 116 are manually adjusted for the fuel type being connected to regulator 112 or 114 . Typically control valves 118 and 116 each have a setting for natural gas and a setting for liquid propane gas and are adjusted according to the fuel connected to regulator 112 or 114 .
FIG. 4 shows a schematic view of dual fuel vent free heater 400 having a single burner 132 and a thermal switch 458 . Gas burner 132 has a plurality of gas outlet ports in an upper surface thereof, fuel injector 426 is in flow communication with fuel supply line 134 and an interior of gas burner 132 . Fuel injector 426 has a manual control valve therein for controlling the flow of a fuel to burner 132 . Injector 426 has at least two settings for adjustment to alternate between at least two different fuels being fed from regulator 112 or regulator 114 through fuel supply line 134 . Fuel supply line 134 is in flow communication with thermostat control 130 . Fuel line 140 is in flow communication with thermostat control 130 and pilot burner 120 and has regulator 456 inline therewith. Regulators 114 and 112 each have back flow prevention systems or a plug 411 in allowing a single fuel tank to be connected to either regulator leaving the other regulator without a fuel source. Regulators 112 and 114 are each in flow communication with a “T” connector via fuel lines 148 and 150 respectively. Fuel inlet line 146 extends from the “T” connector and feeds into thermostat control valve 130 . Thermal switch 458 is in electronic communication with thermostat control valve 130 and temperature sensor 159 . Temperature sensor 159 is in proximity to pilot burner 120 . Thermal switch 458 sends an electronic signal to thermostat control valve 130 shutting off fuel flow to fuel supply line 134 and pilot burner supply line 140 in the event that an incorrect setting is made with injector 426 with respect to the fuel being fed to regulator 112 or 114 .
FIG. 5 shows dual fuel vent free heater 500 having a dual burner configuration. Two regulators 112 and 114 are in flow communication with a “T” connector via fuel lines 148 and 150 respectively. Fuel line 146 extends from the “T” connector to thermostatic control valve 130 . Pilot burner supply lines 138 and 140 lead from control valve 130 pilot flame burners 122 and 120 respectively. Fuel injector lines 134 and 136 lead from thermostatic control valve 130 to injectors 126 and 128 respectively. Burner 132 a has first pilot flame burner 122 proximate gas outlet apertures therein and injector 126 proximate an axial opening. Burner 132 b has pilot flame burner 120 proximate gas outlet apertures and injector 128 proximate an axial opening therein.
FIG. 6 is schematic view of dual fuel vent free heater 600 having a dual burner and dual thermostatic control valve configuration. Regulator 112 is in flow communication with control valve 130 a via fuel line 148 . Regulator 114 is in flow communication with control valve 130 b via fuel line 150 . Pilot supply line 140 leads from control valve 130 a to pilot flame burner 120 and pilot supply line 138 leads from control valve 130 b to pilot flame burner 122 . Injector supply line 134 leads from control valve 130 a to fuel injector 126 . Injector supply line 136 leads from control valve 130 b fuel injector 128 . Burner 132 a has pilot flame burner 120 proximate gas outlet apertures and fuel injector 126 proximate an axial opening. Burner 132 b has pilot flame burner 122 proximate gas outlet apertures and fuel injector 128 proximate an axial opening therein.
FIG. 7 shows a schematic view of dual fuel vent free heater 700 having a multi-positional manual control valve 800 . Regulators 112 and 114 are in flow communication with a “T” connector via fuel lines 148 and 150 respectively. Fuel line 146 extends from the “T” connector to thermostatic control valve 130 . Pilot line 142 and injector line 144 lead from thermostatic control valve 130 to multi-positional manual control valve 800 . Multi-positional manual control valve 800 directs flow from pilot line 142 and injector line 144 to pilot supply line 140 and injector supply line 136 , or pilot supply line 138 and injector supply line 134 , or blocks the flow from pilot line 142 and injector line 144 . Burner 132 has injectors 126 and 128 held at an axial opening with bracket 124 . Pilot burners 120 and 122 are proximate the outer surface of burner 132 and are in flow communication with pilot supply line 140 and 138 respectively. Thermal switch 158 is in electronic communication with T/C block 756 . T/C block 756 is in electronic communication with a thermocouple proximate each pilot burner 120 and 122 , via T/C lines 154 and 152 , and control valve 130 . In the event an incorrect setting is made with respect to the fuel being fed to the correct injector and pilot burner, thermal switch 158 or control valve 130 shuts off the flow of gas to heater 700 .
FIG. 8 shows a blow-up view of multi-positional manual control valve 800 . Multi-positional manual control valve 800 comprises a control block 804 and a control cylinder 802 . Control block 804 has a cylindrical aperture 850 extending from a front surface to a rear surface. The front surface of control 800 has fuel selection and cut off indicators LP, NG, and OFF. Three fuel injector apertures 820 , 824 and 830 extend from cylindrical aperture 850 at about 90.degree. intervals to a left side, top, and right side of control block 804 . A pilot aperture is axially aligned about cylindrical aperture 850 with each fuel injector aperture, pilot aperture 822 is axial aligned with injector aperture 820 , pilot aperture 826 is axial aligned with injector aperture 824 , and pilot aperture 828 is axial aligned with injector aperture 830 . Control cylinder 802 has an outer circumference proximate the circumference of cylindrical aperture 850 in control block 804 wherein control cylinder 802 is closely received within. Control cylinder 802 has “L” shaped flow through fuel injector aperture 812 and an axially aligned “L” shaped flow through pilot aperture 814 . Control cylinder 802 has a first, second, and third, position within the cylindrical aperture in control block 804 . The front surface of control cylinder 802 has a selection arrow pointing to an appropriate indicator on the front surface of control block 804 . At a first position, fuel injector aperture 820 and pilot aperture 822 are in flow communication with fuel injector aperture 824 and pilot aperture 826 . At a second position, as shown in FIG. 8B , fuel injector aperture 824 and pilot aperture 826 are in flow communication with fuel injector aperture 830 and pilot aperture 828 . At the third position, one end of the “L” shaped flow through fuel injector aperture 812 and axially aligned “L” shaped flow through pilot aperture 814 are blocked by the wall of cylindrical aperture 850 in control block 804 cutting off the flow of fuel.
FIG. 9 shows a schematic view of dual fuel vent free heater 900 . Dual fuel gas heater 900 comprises two regulators 112 and 114 in flow communication with a “T” connector via fuel lines 148 and 150 . Fuel line 146 extends from the “T” connector to thermostatic control valve 130 . A pilot line 142 and an injector line 144 lead from thermostatic control valve 130 to multi-positional manual control valve 800 . Multi-positional manual control valve 800 has a first, second, and third control position as indicated with LP, NG, and OFF. The first control position creates a flow communication between the pilot line 144 and injector line 142 leading from thermostatic control valve 130 with pilot flame burner 120 and injector 128 through pilot feed line 140 and injector feed line 136 respectively. The second control position creates a flow communication between pilot line 144 and injector line 142 leading from thermostatic control valve 130 with pilot flame burner 122 and injector 126 respectively. The third position cuts off fuel flow from pilot line 144 and injector line 142 leading from thermostatic control valve 130 . Thermal switch 935 is in electrical communication with a temperature sensor proximate pilot flame burners 120 and 122 via electrical connectors 154 and 152 respectively. Thermal switch 935 sends a shut off signal to a control valve when a first set temperature is exceeded in pilot flame burner 120 or a second set temperature is exceeded in pilot flame burner 122 cutting off the flow of fuel to heater 900 .
In one implementation the thermal switch 935 is in electrical communication with the temperature sensor proximate pilot flame burner 122 and not with the temperature sensor proximate pilot flame burner 120 . In one implementation, the thermal switch 935 is configured to transition from a closed state to an open state when a temperature at or near the pilot flame burner exceeds a predetermined temperature indicative that an LP gas is being supplied to the NG gas pilot flame burner. In one implementation, upon transitioning from the closed state to the open state, electrical power to a gas supply valve (e.g., thermostatic control valve 130 ) is interrupted resulting in the flow of fuel to heater 900 being terminated.
FIG. 10 shows a schematic view of dual fuel vent free heater 1000 having burner 132 a , 132 b , and cross-over burner 171 . Such a configuration provides a blue flame burner and a yellow flame burner as is often desirable in a vent free fireplace heater. The configuration of heater 1000 is similar to the configuration of heater 900 with the addition of burners 132 b , cross-over burner 171 , two fuel line “T” connectors, and fuel injectors 126 b and 128 b . Crossover burner 171 is in flow communication with burners 132 a and 132 b . Burner 132 b has fuel injectors 126 b and 128 b held by bracket 124 b proximate an axial end and is situated substantially parallel burner 132 a . Fuel supply line 134 b feeds injector 126 b with a “T” connector in flow communication with fuel supply line 134 a . Fuel supply line 136 b feeds injector 128 b with a “T” connector in flow communication with fuel supply line 136 a.
FIG. 11 is a schematic view of dual fuel vent free heater 1100 having a multi-positional manual control valve 800 directly controlling the flow of fuel into heater 1100 . The configuration of heater 1100 is similar to that of heater 900 but does not have thermostatic control 130 . Rather, fuel from either regulator 112 or regulator 114 is fed through fuel line 148 or 150 . Fuel lines 148 and 150 “T” into pilot line 142 and injector line 144 which lead directly to multi-positional manual control valve 800 . Therefore, the amount of heat produced by heater 1100 is manually controlled with multi-positional manual control valve 800 without any thermostatic control.
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A dual fuel vent free gas heater. In one implementation the heater includes a gas burner adapted to receive one of a first type of gas or of a second type of gas with a first pilot burner intended to receive the first type of gas and a second pilot burner intended to receive the second type of gas. A first temperature sensor is located adjacent the first pilot burner and a second temperature sensor is located adjacent the second pilot burner. A normally closed thermal switch is coupled to the first temperature sensor and located in the electrical flow path between a voltage source and a gas control valve actuator, the thermal switch configured to open when the temperature detected by the first temperature sensor exceeds a predetermined temperature indicative that the second type of gas is being delivered to the first pilot burner.
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This application is a divisional, and claims priority, of pending application Ser. No. 11/837,698 filed 13 Aug. 2007.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for cleaning a diesel particulate filter for a motor vehicle.
2. Description of the Prior Art
Diesel engines are efficient, durable and economical. Diesel exhaust, however, can harm both the environment and people. To reduce this harm governments, such as the United States and the European Union, have proposed stricter diesel exhaust emission regulations. These environmental regulations require diesel engines to nearly meet the same pollution emission standards as gasoline engines.
One part of diesel exhaust includes diesel particulate material. Diesel particulate material is mainly carbon particles or soot. One way to remove soot from diesel exhaust is with diesel traps. The most widely used diesel trap is a diesel particulate filter which nearly completely filters the soot without hindering exhaust flow. As a layer of soot collects on the surfaces of the inlet channels of the filter, the lower permeability of the soot layer causes a pressure drop in the filter and a gradual rise in the back pressure of the filter against the engine. This phenomenon causes the engine to work harder, thus decreasing engine operating efficiency. Eventually, the pressure drop in the filter and decreased engine efficiency becomes unacceptable, and the filter must either be replaced or the accumulated diesel soot must be cleaned out.
The filter is cleaned of accumulated diesel soot by burning-off or oxidation of the diesel soot to carbon dioxide which is known as regeneration. Regeneration of an existing filter is superior to filter replacement, because no interruption for service is necessary.
In addition to capturing carbon soot, the filter also traps ash particles, such as metal oxides, that are carried by the exhaust gas. These particles are not combustible and, therefore, are not removed during regeneration. The filter must therefore be cleaned or discarded when the ash particles in the filter build up to high levels.
Cleaning ash from a diesel particulate filter is not easily accomplished with typical maintenance shop equipment. The use of shop air to blow out the ash particles does not lend itself to containment of the ash particles. The use of a wet/dry vacuum tool has limited effectiveness on smaller and deeply embedded particles. The use of water or solvents can be detrimental to the substrate and/or washcoat.
One method exposes the filter to excessive handling which increases the potential for inadvertent damage to this expensive component. This method also suggests precautionary methods such as paint masks, safety goggles, and gloves prior to servicing a filter due to the potential for exposure to the hazardous ash particles.
To avoid this dangerous mess, specialized filter cleaning equipment has been developed. There are two primary types of cleaning machines. The first type is a pulsed air cleaner. The pulsed air cleaner blasts a pressurized charge of air through the filter from the back-side and accumulates the ash in a large filter within the machine. The pulsed air cleaner operates within a 20 minute cycle and is used for most dirty filters. However, in some conditions the truck aftertreatment system does not properly initiate a regeneration cycle to burn the soot burning cycle, and the filters become plugged with sticky soot. It is impossible to blow out the soot plugged filters with the conventional pulsed air cleaner.
The second type of cleaning machine is a thermal regenerator. The soot plugged filter is heated in a thermal regenerator for a period of time to convert the soot to ash. The filter is then removed from the thermal regenerator and subsequently treated with a pulsed air cleaning machine to clean the filter. The thermal regenerator requires from 3 to 7 hours.
This equipment, however, is expensive to purchase for the service shop, which would make the cost of cleaning expensive for the motor vehicle owner. The machines take up a large amount of space in a typical shop. Both types of machines require compressed air sources, 110V electrical sources, and the thermal regenerator requires a 30 A 240V circuit as well.
Therefore, it would be advantageous to develop a method to quickly and easily clean the diesel particulate material from the filter, such as the ash particles and possibly the soot, especially without first baking the filter in a thermal regenerator. It would be further advantageous to clean the filter without using costly equipment or to develop a method using parts that are readily available in a service shop. It would also be advantageous to develop an apparatus that is easy to use and economical.
SUMMARY OF THE INVENTION
According to the invention there is provided an economical way of cleaning the ash and other diesel particulate material from a diesel particulate filter of a motor vehicle, typically using equipment already available in a service shop or economical to order. The method uses an air chamber connected at an open first end to an outlet of the diesel particulate filter. The air chamber has an opposite closed second end where a hanger is located. The air chamber has first and second ports in a sidewall between the first and second ends. A pressure relief valve couples to the first port which can be used to prevent the build up of dangerous pressure within the air chamber.
Air flows from an air supply into an air supply line to pressurize the air chamber. The air pressure can be regulated within the air chamber, such as with an air chamber regulator.
A vibrator coupled to the air chamber vibrates the air chamber. The pressurized air and the vibrations dislodge diesel particulate material from the diesel particulate filter, which can be removed from the filter.
A diesel particulate filter cleaning apparatus of the invention has an air chamber with an open first end, an opposite closed second end and a sidewall therebetween. First and second ports are located in the sidewall. An air chamber hanger is located at the second end. A pressure relief valve coupled to the first port can be used.
A vibrator is coupled to the sidewall of the air chamber to introduce vibrations to the diesel particulate filter cleaning apparatus. An isolator engages the air chamber hanger. An air chamber line couples to the second port of the air chamber and has an air chamber regulator to regulate the air pressure in the air chamber.
Additional effects, features and advantages will be apparent in the written description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself however, as well as a preferred mode of use, further objects and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
The FIGURE is a side view of a diesel particulate filter cleaning apparatus of the invention with the ends of the diesel particulate filter and the air chamber in phantom.
DETAILED DESCRIPTION OF THE INVENTION
Turning to the FIGURE where like reference numerals refer to like structures, the present invention relates to a diesel particulate filter cleaning apparatus 10 and method for cleaning diesel particulate material such as ash and soot from a diesel particulate filter 42 used to treat diesel exhaust gases from a diesel engine in a motor vehicle. The diesel particulate filter cleaning apparatus 10 has a vibrator 14 coupled to an air chamber 12 with a vibrator coupler 56 , such as a U-bolt coupled to a sidewall 32 of the air chamber 12 .
The vibrator 14 is preferably a pneumatic or air actuated vibrator 15 with pressure regulators to increase intensity and frequency of vibration when the pressure increases within the vibrator. Alternatively, the vibrator 14 can be an electric or other type of pulse vibrator. When an pneumatic type vibrator is used, the vibrator 15 is in fluid communication with a vibrator line 34 . The vibrator line 34 can have a vibrator regulator 36 to control the air pressure in the vibrator 15 , and vibrator tubing 35 connecting to the vibrator pressure regulator 36 and the vibrator 15 .
An open first end 22 of the air chamber 12 attaches to the diesel particulate filter 42 with a diesel particulate filter coupler 16 . An opposite, closed second end 23 of the air chamber 12 has an air chamber hanger 24 , such as a loop, handle, hook, clip, and the like. The sidewall 32 located between the first and second ends 22 , 23 defines a chamber of the air chamber 12 and is preferably cylindrical. The air chamber 12 has a first port 60 in the sidewall 32 to which a pressure relief valve 18 attaches. The pressure relief valve 18 vents air from the air chamber 12 when the air pressure reaches a maximum pressure set with the pressure relieve valve 18 . A second port 62 in the sidewall 32 connects to an air chamber line 19 . The air chamber line 19 has an air chamber regulator 20 to regulate the air pressure in the air chamber 12 and air chamber tubing 21 connecting to the second port 62 .
An air supply 26 , such as from a shop air supply or an air tank, is in fluid communication with the air chamber 12 and the vibrator 15 . An air supply line 28 from the air supply 26 connects to a fitting 30 , such as a T-fitting when using the pneumatic vibrator 15 . The fitting 30 connects to the vibrator line 34 , such as at the vibrator regulator 36 and the air chamber line 19 , such as at the air chamber regulator 20 . Alternatively, the air supply line 28 can connect directly to air chamber line 19 or the air chamber regulator 20 when not using a pneumatic vibrator.
An isolator 38 isolates the fitting 30 , the air chamber regulator 20 and vibrator regulator 36 from the vibrations generated by the vibrator 14 . The fitting 30 and/or the pressure regulators can fasten to the isolator 38 with isolator fasteners 57 , such as clips 58 , loops, bands, and the like. The isolator 38 can be a strap made of vibration dampening material, such as a flexible polymer, for example nylon, rubber, and the like. The isolator 38 can be also used to hang the diesel particulate filter cleaning apparatus 10 from an overhead attachment 40 . An isolator hanger 41 , such as a hook, clip, loop, and the like, attaches to the isolator 38 and engages the air chamber hanger 24 .
The diesel particulate filter coupler 16 connects an outlet 44 of the diesel particulate filter 42 to the air chamber 12 . The diesel particulate filter coupler 16 has at least one flange and preferably uses a seal engaging the flange. The diesel particulate filter coupler 16 preferably uses an adaptor flange 48 engaging the air chamber 12 , a diesel particulate filter flange 50 engaging the outlet 44 and a seal 52 , such as a gasket, washer, O-ring, and the like, between the adaptor flange 48 and the diesel particulate filter flange 50 . Diesel particulate filter coupler fasteners 64 fasten the adaptor flange 48 and diesel particulate filter flange 50 together.
The inlet 46 of the diesel particulate filter 42 connects to an ash collector 54 , such as a shop-vac bag or other dust reservoir that allows clean air to vent from the ash collector 54 and the diesel particulate filter cleaning apparatus 10 . The inlet 46 is preferably at least partially enclosed within ash collector 54 to prevent diesel particulate material from escaping into the environment during cleaning.
Once the apparatus is assembled, the air supply 26 is opened and air flows into the air supply line 28 . Air next flows from the air supply line 28 into the air chamber 12 . In one embodiment, the air flows through the fitting 30 and is directed into the air chamber line 19 and the vibrator line 34 . The air chamber 12 and vibrator 15 pressurize. In another embodiment, the air flows only into the air chamber line 19 to pressurize the air chamber 12 .
The air chamber regulator 20 can be set to a desired air chamber pressure to regulate the flow of air into the air chamber 12 . The pressure in the air chamber 12 can range from about 10 psi to about 90 psi for the air chamber 12 , although a maximum pressure is the amount of pressure that can be used without degrading the diesel particulate filter 42 , such as about 120 psi. The pressure relief valve 18 is set to a maximum air chamber pressure in the air chamber 12 , such as greater than about 120 psi. Once the maximum air chamber pressure is reached for the air chamber 12 , the pressure relief valve 18 vents air from the air chamber 12 .
The vibrator regulator 36 can be set to a desired vibrator pressure to regulate the flow of air into the vibrator 15 . The pressure in the vibrator 15 can range from about 10 psi to about 60 psi, although about 90 psi may be the maximum pressure to produce the maximum vibrations without damaging the diesel particulate filter cleaning apparatus 10 and diesel particulate filter 42 .
The vibrator 14 vibrates the air chamber 12 . Vibrations transfer from the air chamber 12 to the diesel particulate filter 42 and air flows from the air chamber 12 through the diesel particulate filter 42 and through the ash collector 54 . The vibrations and air loosen the diesel particulate material from the diesel particulate filter 42 . The flowing air and gravity help remove the diesel particulate material from the diesel particulate filter 42 and into the ash collector 54 . If a shop vacuum is used, it could be turned on to increase the removal of diesel particulate material from the diesel particulate filter apparatus 10 .
Once air flows freely through the diesel particulate filter, the diesel particulate filter can be reinstalled on the vehicle. The vibrator 14 is turned off, such as by closing the air supply 26 . Closing the air supply 26 also stops air from flowing to the air chamber 12 . The diesel particulate filter 42 is disconnected from the ash collector 54 and the air chamber 12 .
While the invention can be readily assembled from parts available in a shop, the invention can also include a kit of parts used to assemble a diesel particulate filter cleaning apparatus. The kit of parts includes the air chamber 12 with the first port 60 adapted to engage a pressure relief valve 18 . A vibrator coupler 56 is adapted to engage a vibrator 14 and the sidewall 32 of the air chamber 12 . At least one flange is adapted to engage the first end 22 of the air chamber 12 or an outlet 44 of the diesel particulate filter 42 . An air chamber regulator 20 is adapted to regulate the air pressure entering the air chamber.
The method and apparatus of the invention have a number of advantages. The pressure within the air chamber of the diesel particulate filter cleaning apparatus is adjustable. The amount of vibration is also adjustable and can be independently adjusted. from the pressure within the air chamber. The pressure relief valve provides a safety measure to prevent dangerous pressure from building up within the diesel particulate filter cleaning apparatus. The diesel particulate filter cleaning apparatus of the invention is a small unit that hangs from an overhead attachment and performs the pulsed air cleaning function in a significantly faster time than the prior cleaning devices for thousands of dollars less. Further, in some instances the diesel particulate filter cleaning apparatus of the invention can open up a clogged diesel particulate filter which would normally require baking, to the extent that the filter can be reinstalled into a functioning aftertreatment system and regenerated by the on-board truck components.
While the invention is shown in only one of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit and scope of the invention.
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A diesel particulate filter of a motor vehicle is cleaned of diesel particulate material like ash and possibly soot, typically using equipment already available in a service shop following the method and diesel particulate filter cleaning apparatus of the invention. The diesel particulate filter cleaning apparatus has an air chamber that is coupled to a vibrator and is attached to the diesel particulate filter. The vibrator vibrates the air chamber and the diesel particulate filter to dislodge the diesel particulate material. Air is introduced into the air chamber and into the diesel particulate filter to further remove the diesel particulate material from the diesel particulate filter.
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RELATION TO PREVIOUS APPLICATIONS
[0001] The present invention is related to and claims priority of PCT Application No. PCT/US/04/03761, filed on Nov. 8, 2004, which is related to and claims priority of U.S. Provisional Patent Application No.60/518,489, filed on Nov. 8, 2003, all of which are hereby incorporated by reference in their entireties.
TECHNICAL FIELD
[0002] The present invention relates to a method for manufacturing fire-retardant materials. The present invention is particularly well suited for providing fire-retardancy to products made from cellulosic or lignin-cellulosic fibers, chips, shavings and/or particles used to produce products including but not limited to fiberboards, wall boards, panels, roofing materials, particle-boards, ceiling tiles, soundproofing boards, and other products.
BACKGROUND ART
[0003] Cellulose-based products made from cellulosic fibers, chips, and shavings make up a significant portion of the building product market because they are cost effective, easy to work with, and environmentally friendly. Cellulose-based products provide structural support, act as roofing substrates, and dampen unwanted noise. Unfortunately, traditional cellulose-based products are also flammable. A number of methods have been developed to reduce the flammability of such materials, but many current methods are inadequate at providing fire-retardancy, are too expensive, or have some other shortcoming.
[0004] For example, U.S. Pat. No.6,518,333 issued to Liu et al., on Feb.11, 2003, teaches a fire-retardant cellulosic product comprising: a cellulosic material, at least one polymeric binder resin, and fire retardant solid particles compressed together to form a panel. While products produced according to Liu have some degree of fire-retardancy, they fail to qualify for the Class A rating for ASTM E-84. Furthermore, products that use polymeric resins can sometimes create toxic off gases when exposed to flames for extended periods time.
[0005] U.S. Pat. No. 5,840,105 issued to Helmsetter et al., on Nov. 24, 1998, discloses a fire-resistant solution for application to the surface of cellulosic materials comprising: water, pure white clay, fine mica and sodium silicate. Surface coatings like that described in Helmsetter '105 provide flame resistance to the surface of cellulosic materials, however, they fail provide full depth fire protection.
[0006] A need exists for a method that provides reliable full-depth fire-retardancy to cellulose-based particle products that is cost effective, and is non-toxic.
DISCLOSURE OF INVENTION
[0007] The present invention imparts fire-retardancy upon cellulosic products utilizing a cost-effective, non-toxic, and reliable process. Unlike previous methods which impart superficial fire-retardant coatings upon finished products, the present process treats the individual particles (i.e. fibers, chips etc.) that make up cellulose-based particle products. Treating the individual particles provides fire-retardancy throughout the entire length and width of the product. This full-depth retardancy provides superior protection, especially in catastrophic fires where the surface coat of product is often compromised.
DETAILED DESCRIPTION OF THE INVENTION
[0008] The present invention imparts full-depth fire-retardancy upon cellulosic particle products utilizing a cost-effective, non-toxic, and reliable process. For the purpose of this disclosure, the term ‘cellulosic particle products’ (“CPPs”) is defined as any product that is made from cellulosic (or lignin-cellulosic) materials like wood fibers, wood chips, sawdust, bagasse, pulp extracts and other cellulosic fibers, particles and waste. CPPs encompass fiberboards, particleboards, medium density fiberboard (MDF), furniture board, fire-resistant panels, and other cellulosic particle products. It is important to note that the process may also be used to impart fire-retardancy to a number of non-cellulosic particulate products as well as cellulosic hard boards.
[0009] The method of one embodiment of the present invention generally comprises the following:
1. Mixing a cellulosic (or lignin-cellulosic) material with an aqueous solution (i.e. water) and a phosphate (i.e. MKP), forming a phosphate-cellulose slurry; 2. Mixing a metal oxide composition with the phosphate-cellulose slurry forming a phosphate-oxide-cellulose slurry, the slurry containing treated cellulosic material; 3. Removing the treated cellulosic material from the aqueous portion of the phosphate-oxide cellulose slurry; 4. (optional) Compressing the cellulose material forming a compressed cellulose material; 5. Drying the compressed cellulose material.
[0015] The preferred order of the steps is shown above, however, some of the steps of the method can be changed.
[0016] For example the cellulosic material can be mixed with an aqueous solution (i.e. water) and a metal oxide to form a metal oxide-cellulose slurry first followed by the addition of a phosphate compound (MKP or MKP plus a silica containing compound) to the aqueous metal oxide-cellulose slurry to form the oxide-phosphate cellulose slurry. The oxide-phosphate-cellulose slurry has similar characterstics as the phosphate-oxide cellulose slurry described herein. Other steps are also similar to what is described below.
[0000] Mixing a Cellulosic (or Lignin-Cellulosic) Material with an Aqueous Solution and a Phosphate, to Form a Phosphate-Cellulose Slurry
[0017] The first step of the present invention involves mixing a cellulose material with an aqueous solution and a phosphate to create a phosphate-cellulose slurry. In a preferred embodiment of the invention the cellulosic material is mixed with the aqueous solution (i.e. water) prior to the addition of the phosphate. Once combined, all three components are mixed. for between about 30 seconds and 20 minutes, or for sufficient time to ensure a relatively homogeneous mixture. Mixing can be achieved using a variety of methods including agitation. The aqueous solution is preferably water. Alternatively, the phosphate and aqueous solution may be combined prior to the addition of the cellulose material.
TABLE 1 Exemplary weight percent for the phosphate-cellulose slurry Aqueous Phosphate Solution Cellulose (i.e. MKP) (ie. water) Material Exemplary ˜0.5-40 wt. % ˜50-99 wt. % ˜0.5-50 wt. % Range Preferred ˜0.5-15 wt. % ˜75-98 wt. % ˜1-15 wt. % Range Commercial ˜0.7-5 wt. % ˜90-97 wt. % ˜2-10 wt. % Range
[0018] Table 1 provides exemplary weight percent ranges for the various components present in the phosphate cellulose slurry. Generally the cellulose materials make up between approximately 0.5-50 weight percent of the phosphate-cellulose slurry. The amount of cellulose present will depend on a variety of factors. When using small cellulosic fibers a preferred weight percent range for the cellulose material is between about 1-15 wt. % of the mixture, more preferably about 2-10 wt. %. The cellulose-based material can be virtually any type of cellulose, however, it is preferably comprised of fibers, shavings, small chips or other fine cellulose particles with high surface-area to weight ratios. The high surface-area to weight ratio allows the materials to absorb the aqueous solution (and the added phosphates and oxides) more rapidly and to a greater degree. It should be also be noted that various non-cellulosic materials can be used in place of cellulose materials. Treating hardboards (or similar large products) may cause the percentages to vary.
[0019] As noted in Table 1 the aqueous solution (i.e. water) is generally present at between about 50-99 wt. percent of the phosphate-cellulose slurry, preferably at a range of between about 75-98 wt. %, and even more preferably between 90-97 wt. %. Increasing the amount of water generally reduces the cost of production and increases the flowability of the slurry. A suitable temperature range for the water (aqueous solution) is between about 40-180° F., more preferably between 60-160° F.
[0020] As described in table 1, the phosphate is present at between about 0.5-40 wt. percent of the phosphate-cellulose mixture, a more cost-effective range being between about 0.5-15 weight percent, a more preferred range being between about 0.7-5 wt. %.
[0021] Suitable phosphates include phosphoric acid or, phosphoric acid salts including but not limited to mono-potassium phosphate (“MKP”), sodium phosphate, ammonium phosphate, aluminum phosphate and combinations thereof. MKP (KH 2 PO 4 ) is the most preferred phosphate. Dry phosphates are generally utilized but other forms can also be envisioned.
[0000] Addition of the Metal Oxide Composition
[0022] A metal oxide mixture is added to, and mixed with the phosphate-cellulose slurry to form a phosphate-oxide-cellulose slurry. The phosphate-oxide-cellulose slurry is mixed for between about 30 seconds and 20 minutes, or until the slurry is well-mixed. Mixing can be achieved by several techniques well known in the art including but not limited to agitation. The metal oxide reacts with the phosphate in the cellulose slurry in an exothermic reaction. Evidence of the reaction can be seen in a raise in the slurry temperature and pH. Dry oxide (or hydroxides) are used but other forms can be employed.
TABLE 1 Exemplary weight percents of the phosphate-oxide cellulose slurry Aqueous Solution Cellulose Metal Oxide Phosphate (i.e. water) Material Mixture Exemplary Range ˜0.5-35 wt. % ˜50-98 wt. % ˜0.5-40 wt. % ˜0.5-30 wt. % Preferred Range ˜0.5-10 wt. % ˜70-98 wt. % ˜2-10 wt. % ˜0.5-10 wt. % Commercial Range ˜1-3 wt. % ˜85-97 ˜2-10 wt. % ˜0.5-2 wt/%
[0023] Table 2 provides exemplary weight percents for the phosphate-oxide cellulose slurry. In general one might assume a higher percentage of phosphate and metal oxide mixture corresponds to higher level of protection. However when the process is being used in large scale commercial production it is cost effective to reduce the amount of phosphate and metal oxide mixture as they are the most expensive reagents.
[0024] Surprisingly it was found that phosphate and metal oxide amounts could be reduced to a few weight percent or less (when the weight percent ratio between the cellulose material and the combination of phosphate and metal oxide (i.e. MKP+MgO) is between approximately 2:1 or less, and possibly as high as 5:1 or 10:1) of the phosphate-oxide slurry while maintaining fire-retardancy. Thus unexpectedly the method can provide fire protection using phosphate and metal oxide even when using less than 3 wt. percent each. The percentages can be varied according to conditions and desired results.
[0000] Metal Oxide Mixture
[0025] As indicated in table 2, the metal oxide mixture is generally present at between 0.5-30 wt. % of the phosphate-oxide cellulose mixture. MgO is the preferred metal oxide. Other metal oxides (and/or hydroxides) may be utilized in place of, or in addition to, MgO, including but not limited to FeO, Al(OH) 3 , aluminum oxides, calcium oxides, Fe 2 O 3 , TiO, ZrO, and Zr(OH) 4 . It is believed that the metal oxide reacts with the phosphate present on the surface of (and possibly inside) the cellulose material. The reaction between the metal oxide and phosphate creates a composition which impart fire-retardancy upon the individual piece of cellulose material.
[0026] It was found that it was beneficial to use MgO that is part light burned (calcined between 700-1000° C.) and part hard burned (calcined at between 1000-1500° C.). The ratio between the hard and light burned generally between (0.5-2):1.
[0027] A salient feature of the present invention is the ratio between the phosphate (i.e. MKP) and the metal oxide/hydroxide (i.e. MgO). A preferred embodiment has a weight percent ratio between MKP and MgO between 5:1 and 1:5, more preferably between approximately 2:1 and 1:1. The weight ratio between MKP and MgO influences reaction rate between the metal oxide and phosphate and thus the ability of each to attach to and coat the cellulosic particles.
[0028] Another important aspect of the invention is the weight percent ratio between the cellulose material and the combination of phosphate and metal oxide (i.e. MKP+MgO). Generally the ratio should be less than 10:1, preferably less than 5:1 and more preferably around 2:1. A proper ratio between phosphate, oxide and cellulose ensures that all the cellulose material is adequately treated.
[0000] Silica-Containing Compound
[0029] A salient feature of at least one embodiment of the invention is the presence of a silica-containing compound in the phosphate-oxide cellulose mixture. The silica-containing compound can be added at any step prior to removal of the cellulose material from the slurry. Generally, the silica containing compound is present at between 0.5 and 20 wt. % of the phosphate-oxide-cellulose mixture, more preferably between about 0.5 and 5 wt. % for commercial uses.
[0030] In one preferred embodiment the silica containing compound is mixed with the metal oxide prior to the addition of the metal oxide composition to the phosphate cellulose slurry. This metal oxide-silica mixture comprises: a metal oxide and a silica containing compound where the weight ratio between the metal oxide and silica containing compound is generally between (0.5-2):1. Suitable silica containing compound(s) include but are not limited to: silica powder, silica fume, crushed rice hulls, small particle fly ash, and combinations thereof. Silica powder is preferred: The silica containing compound is believed to act as a carrier for the MgO (or phosphate), assisting in the reaction between the metal oxide and the phosphate.
[0000] Holding Times/Additional Mixing
[0031] Each mixing step is preferably held for a period of time to ensure adequate absorption/reaction of the mixture components. A series of mixing/holding steps can be employed to ensure proper reactivity and homogeneity. Hold times can vary, however hold times ranging from about 30 seconds to 20 minutes are suitable. Alternatively, the slurry can be allowed to sit for a period following mixture.
[0000] Additives
[0032] Various additives can be added to the phosphate-oxide cellulose mixture. The additives can be added at any step prior to removal of the cellulose material from the phosphate-oxide-cellulose slurry. Suitable additives include but are not limited to: mullite, alumina, sand, clay, volcanic glasses, kyanite, bauxite, aluminum oxide, silicon oxide, chrome oxide, iron oxide, and mixtures thereof. Preferred additives include calcium containing compounds including but note limited to: calcium phosphates, tricalcium phosphates (such as hydroxyapatite), biphasic calcium phosphate, tetracalcium phosphate, CaSiO 3 , and combinations thereof. Tricalcium phosphates such as hyroxyapatite, CaSiO 3 and combinations thereof being the most preferred.
[0000] Separating/Removing Cellulose Material from Dhosphate-Oxide Cellulose Slurry
[0033] After sufficient mixing the cellulose material is removed and separated from the aqueous portion of the phosphate-oxide-cellulose slurry. The cellulose materials can be removed by a number of techniques well known in the art including but not limited to physical removal from the solution, and draining off the aqueous solution. In one embodiment the cellulose materials are physically taken out in clumps and spread out for on a porous support for drying.
[0034] In another embodiment the phosphate-oxide cellulose slurry can be transferred into a moving (or stationary) draining bed in which the aqueous solution is drained away from cellulose material by gravity or other means. Other separation means can also be employed including straining the cellulose material from aqueous portion of the slurry.
[0000] Compression
[0035] After the cellulose materials have been removed and drained from the phosphate-oxide-cellulose slurry the cellulose materials (i.e. fibers, particles) can be compressed using a variety of methods well known in the art including the use of rollers. The cellulose materials can be compressed into variety of shapes, sizes, lengths and widths.
[0000] Drying Cellulose Material
[0036] Drying the cellulose material can be achieved by several techniques known in the art including heating in an oven or a series of ovens. The cellulose material should be heated at temperature and for a time period sufficient to produce cellulose products with a water content of less than 10% by weight, more preferably less than 5% by weight. Exemplary temperatures are between 100-1000° F. Suitable time ranges are between about 5 minutes and about 2 hours.
[0000] Commercial Production
[0037] The present process can be utilized in conjunction with other known methods of manufacturing cellulose particle products like fiberboard, particle board and the like. See, U.S. Pat. Nos. 6,197,414; 4,935,457; 4,597,928; 4,311,555; 4,190,492 which are hereby incorporating by reference in their entirety. The fibers, chips, or other cellulose particles can be treated first using the present process and can then be used known manufacturing process. Alternatively, known processes can incorporate the present process.
[0038] A suitable temperature range for the water being mixed with the phosphate powder is between 40-180° F. The temperature of the water is related to the mixtures reactivity, thus the rate of the reaction can be controlled to some degree by the temperature of the water being added. Warm water tends to speed up the reaction while cool water tends to slow it down. The temperature of such reagents, like that of water can affect the reactivity of the mixtures and can be used to regulate the reaction to a limited degree. Again, warm reagents may speed up the reaction while cool reagents tend it slow them down.
[0039] The treated cellulose material can be coated with other various fire-retardant coatings especially various coatings and compositions invented by present inventor including but not limited to those disclosed in U.S. Pat. Nos. 6,533,821 and 6,787,495.
[0000] Mixing Containers
[0040] The invention can be mixed in a variety of container types. The container is preferably non-reactive with the slurry components and can vary in size and shape according to desired results. An alternate embodiment uses a series of containers. The steps of the invention can be repeated for increase effectiveness.
[0041] The examples below provide exemplary formulations for various embodiments of the present invention.
EXAMPLE I
[0042] Water+Cellulose Material+(MgO/Silica Powder mixture)
[0043] 60,000 lbs of water having a temperature of approximately 140° F. was combined with 3000 lbs of cellulosic fiber forming a cellulosic slurry having a pH between 3.1 and 3.2. 1000 lbs of MKP was added to, and mixed with the cellulosic slurry to form a phosphate cellulose mixture having a pH of between 3.9 and 4.0. The phosphate-cellulose slurry was held for 5 minutes. 1000 lbs of a MgO/Silica composition was added to, and mixed with the phosphate-cellulose slurry creating a phosphate-oxide cellulose slurry having a pH of between 5.8 and 6.0. (hold 5 minutes and then mix again) The MgO/Silica composition was composed of (250 lbs hard burned MgO, 250 lbs light burned MgO and 500 lbs of silica powder (formula). Mixing was achieved by agitation. After mixing the treated cellulose fibers were separated from the aqueous portion of the slurry (by draining the solution), compressed through a series of rollers and dried using a series of ovens.
EXAMPLE II
[0044] MKP+Water+Cellulose Material+(MgO/Silica Powder mixture)
[0045] 3 g of MKP were mixed with 90 g of water to form a well-mixed aqueous phosphate solution. 4 g of cellulose fibers was added to the aqueous phosphate solution and hand mixed for 2 minutes forming a well-mixed phosphate-cellulose slurry. 3 g of MgO/Silica mix was added to the phosphate-cellulose slurry and hand mixed for another 2 minutes forming a phosphate-oxide cellulose slurry. The MgO/Silica slurry was composed of (0.75 g hard burned MgO, 0.75 g of light burned MgO and 1.5 g of silica powder. After mixing was complete, the aqueous portion of the phosphate-oxide-solution was drained and the cellulose fibers were dried in an oven at approximately 500° F.
Alternative Embodiments
[0046] Method for imparting fire-retardancy upon materials comprising:
a. Mixing a cellulose material with a first aqueous solution forming a first cellulose slurry; b. Separating/removing the cellulose material from the first cellulose slurry; c. Mixing the removed cellulose-based material with a second aqueous solution forming a second cellulose slurry, the second slurry containing treated ceullose material. d. Separating/removing the treated cellulose material from the second cellulose slurry.
[0051] The first aqueous can be either an aqueous phosphate solution or an aqueous metal oxide solution. The second aqueous solution can also be either a phosphate or metal oxide solution, however, it should be different than the first slurry. For example if the first slurry contains a phosphate solution than the second should contain a metal oxide and vis versa.
[0052] For further example, the first phosphate solution can be generally between about 0.5-40 wt. percent phosphate and about 60-99 wt. percent water, preferably between about 1-10 percent phosphate and about 90-99 wt. percent water. The second aqueous solution is generally about 1-40 wt. percent metal oxide and about 60-99 wt. percent water, peferably between about 0.5-10 wt. percent metal oxide and about 90-99.5 wt. percent water.
[0053] The cellulose generally comprises about about 0.545 wt. percent of the first and second slurries, preferably between about 0.5-10 wt. percent. The types of phosphate and oxides, ratios and other general features are similar to the embodiment already described.
[0054] Having described the basic concept of the invention, it will be apparent to those skilled in the art that the foregoing detailed disclosure is intended to be presented by way of example only, and is not limiting. Various alterations, improvements, and modifications are intended to be suggested and are within the scope and spirit of the present invention. Additionally, the recited order of the elements or sequences, or the use of numbers, letters or other designations therefor, is not intended to limit the claimed processes to any order except as may be specified in the claims. All ranges disclosed herein also encompass any and all possible sub-ranges and combinations of sub-ranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art all language such as “up to,” “at least,” “greater than,” “less than,” and the like refer to ranges which can be subsequently broken down into sub-ranges as discussed above. Accordingly, the invention is limited only by the following claims and equivalents thereto.
[0055] All publications and patent documents cited in this application are incorporated by reference in their entirety for all purposes to the same extent as if each individual publication or patent document were so individually denoted.
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The present invention imparts fire-retardancy upon cellulosic products utilizing a cost-effective, non-toxic, and reliable process. Unlike previous methods which impart superficial fire-retardant coatings upon finished products, the present process treats the individual cellulosic particles (i.e. fibers, chips etc.) that make up cellulose-based particle products. Treating the individual particles provides fire-retardancy throughout the entire length and width of the product. This full-depth retardancy provides superior protection, especially in catastrophic fires where the surface coat of other products can be compromised.
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CROSS-REFERENCE TO OTHER APPLICATIONS
[0001] This application claims the benefit of provisional patent application No. 60/821,869 filed 9 Aug. 2006, Attorney Docket number PWRL 1045-1. This application is also a continuation in part of U.S. patent application Ser. No. 11/681,972 filed 5 Mar. 2007, Attorney Docket number PWRL 1044-2, which application claims the benefit of provisional patent application No. 60/780,819 filed on 9 Mar. 2006, attorney docket number PWRL 1044-1 and provisional patent application No. 60/821,869 filed on 9 Aug. 2006, attorney docket number PWRL 1045-1, the disclosures of which are incorporated by reference. This application is related to U.S. application patent Ser. No. 11/776,272 filed on the same day as this application, entitled PV Module Mounting and Support Assembly and Installation, attorney docket PWRL 1045-2.
STATE SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was made with State of California support under California Commission Agreement Number 500-04-022. The Energy Commission has certain rights to this invention.
BACKGROUND OF THE INVENTION
[0003] A typical method of securing PV modules to roofs using a wood deck is with a rack system including vertical stanchions and lateral rails. The vertical stanchions are often lag bolted into joists, which are typically on 24″ (61 cm) centers. Conical flashings, similar to the type used for ventilation pipes, are used to waterproof these penetrations. In some cases flashings are not used and “L” brackets or other mounting hardware is lag bolted directly through the roofing material, with the penetration caulked with sealant. Then lateral rails are attached to the stanchions, typically several inches off the roof to allow clearance for the flashings. PV modules are then attached to the rails. Reasons for using the vertical stanchions and a lateral rails approach include: PV modules are not typically designed in convenient widths relative to joist spacing, not all PV modules have geometries amenable to direct-deck mounting, and the racks are designed to accommodate generally any PV module. In most cases framed PV modules are mounted in this manner but methods to mount unframed PV modules to racks do exist.
[0004] In another method for securing PV modules to roofs, the PV modules are typically lag bolted into blocking members installed between rafters in the attic; other mounting hardware can also be used. Relatively large holes must often be pre-drilled through the roofing material to accommodate the mounting hardware. Because of the size of these larger holes and the configuration of the module, it is often difficult to tell if adequate waterproofing has been achieved. If blocking is used, the process of installing blocking involves extensive work in the attic which adds significantly to installation time.
[0005] A further method for securing PV modules to roofs uses a hold down device that can only be used with specially constructed PV modules having complementary hold down structure, such as laterally extending hold down pins.
BRIEF SUMMARY OF THE INVENTION
[0006] An example of a method for mounting first and second PV modules to a support structure, the support structure of the type comprising a deck, is carried out as follows. First and second PV modules are selected. Each PV module has upper and lower sides and edge segments defining a peripheral edge, the peripheral edge having upper and lower peripheral edge surfaces. A layout pattern for the first and second PV modules is selected so that a chosen edge segment of the first PV module will lie adjacent to but spaced apart from a chosen edge segment of the second PV module. A plurality of PV mounting and support assemblies are positioned at selected locations according to the layout pattern. Each PV mounting and support assembly comprises a base, a fastener and PV module mounting hardware. The base comprises a lower base surface and a PV module-support surface, the PV module-support surface located a chosen distance above the lower base surface. The fastener is engageable with the base and penetrable into the deck with the lower base surface facing the deck. The PV module mounting hardware is securable to the base. The PV module mounting hardware comprises a retaining element. Each PV mounting and support assembly is secured to the selected locations using the fasteners to engage the base and to extend into the deck with the lower base surface facing the deck. The first and second PV modules are positioned in the layout pattern and the first and second PV modules are placed on the PV module-support surfaces. Retaining elements are located over the upper peripheral edge surfaces of the first and second PV modules. The retaining elements are secured against the upper peripheral edge surfaces so to secure the first and second PV modules to the deck with the peripheral edges of the PV modules spaced apart from the deck. In some examples the layout pattern is selected without a need for the layout pattern to be aligned with any deck-supporting structure.
[0007] An example of a PV module mounting assembly, for use on a shingled support surface of the type having a deck on which shingles are mounted, comprises flashing, a base, a deck-penetrating fastener and PV module mounting hardware. The base is mountable to the flashing. The deck-penetrating fastener is engageable with the base and securable to the deck so to secure the flashing and the base to the shingled support surface. The PV module mounting hardware is securable to the base. In some examples a sealing layer is used between the upper flashing surface and the base.
[0008] An example of a PV module installation comprises an inclined shingled support surface, flashing, a base, a deck-penetrating fastener, means for sealing holes and PV module mounting hardware. The inclined shingled support surface comprises a deck on which upper and lower rows of shingles are mounted. The flashing has upper and lower flashing edges. The flashing is supported on the lower row of shingles with the upper flashing edge positioned beneath the upper row of shingles. The base is supported on the flashing. The deck-penetrating fastener passes through the flashing and into holes in the deck so to secure the flashing and base plate to the shingled support surface. Means are used to seal the holes in the deck. The PV module mounting hardware is securable to the base.
[0009] An advantage of the invention is that it is suitable for use with a number of different conventionally designed PV modules. The PV modules do not need any special hold down or attachment structures for use with various examples of this invention. In addition, the size of the modules does not depend on the spacing of the joists or other structure supporting the deck. Installation typically does not require access to an attic area for installation of blocking (which is not needed) or inspections. Some examples of the invention significantly reduce part count over conventional mounting systems, for example by eliminating the need for mounting rails, which reduces cost and installation complexity. In addition, some examples help to significantly reduce installation time, which also reduces cost. Additionally, some examples allow very low profile securement of the PV modules to the roof or other support structure. In some examples the PV modules can be mounted nearly flush to the support structure, consistent with proper airflow for cooling, which improves the aesthetics significantly. The region beneath the PV module can typically be fluidly coupled to the region above the module. Wind tunnel tests may be carried out to determine the parameters that would result in, for example, pressure equalization between the upper and lower surfaces, thus providing for reduced loads on the PV modules under different wind conditions. Wind loading on photovoltaic modules is discussed in more detail in U.S. patent application Ser. No. 10/922,117 filed Aug. 19, 2004 and entitled PV Wind Performance Enhancing Methods and Apparatus, US Patent Publication Number US-2005-0126621-A1 published Jun. 16, 2005. In some examples the mounting structure can incorporate both a hold down (mounting) function and an electrical grounding function to substantially eliminate the need for additional grounding structure. Some examples of the PV mounting and support assemblies permit adjacent PV modules to be placed relatively close to one another. This not only improves aesthetics but also increases the energy output for a given area of the roof or other support structure. By positioning deck-penetrating fasteners beneath the PV modules, uplift forces are essentially tension only; this is in contrast with some conventional PV module hold down structures in which the deck-penetrating fasteners are laterally offset from the PV modules resulting in both tension and bending forces on the fasteners.
[0010] Other features, aspects and advantages of the present invention can be seen on review of the figures, the detailed description, and the claims which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an exploded isometric view of a PV mounting and support assembly with only a single deck-penetrating fastener shown for clarity;
[0012] FIG. 2 is an assembled isometric view of the assembly of FIG. 1 ;
[0013] FIG. 3 is an enlarged partial side view of the clip of FIG. 1 ;
[0014] FIG. 4 is an enlarged cross-sectional view of the assembly of FIG. 2 shown securing adjacent PV assemblies to the deck of a support structure;
[0015] FIG. 5 is a simplified overall view of two adjacent PV assemblies secured to one another using the assembly FIGS. 1-4 ;
[0016] FIG. 6 is a view similar to that of FIG. 5 shown using surface-cushioning members engaging frameless PV modules;
[0017] FIG. 7 shows a layout tool used to properly position the assemblies of FIG. 2 on the support structure;
[0018] FIG. 8 illustrates the layout tool of FIG. 7 positioning two of the assemblies of FIG. 2 and one of the internal PV mounting and support assemblies of FIGS. 12-14 ;
[0019] FIG. 9 is a partially exploded isometric view of flashing and the assembly of FIGS. 1 and 2 above a shingled support structure;
[0020] FIG. 10 shows the structure of FIG. 9 with the PV mounting and support assembly secured to the flashing, the flashing supported on a lower row of shingles and extending beneath an upper row shingles;
[0021] FIG. 11 shows the assembly of FIGS. 1 and 2 used at the periphery of a PV array with a spacer;
[0022] FIGS. 12 and 13 are exploded isometric and isometric views of an internal PV mounting and support assembly;
[0023] FIG. 14 is a cross-sectional view showing the assembly of FIG. 13 secured to the internal lip of the frame of a PV assembly;
[0024] FIG. 15 is an isometric view of an example of a PV mounting assembly; and
[0025] FIG. 16 is an exploded isometric view of an example of a peripheral PV mounting assembly using a standoff between the clip and the base body.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The following description will typically be with reference to specific structural embodiments and methods. It is to be understood that there is no intention to limit the invention to the specifically disclosed embodiments and methods but that the invention may be practiced using other features, elements, methods and embodiments. Preferred embodiments are described to illustrate the present invention, not to limit its scope, which is defined by the claims. Those of ordinary skill in the art will recognize a variety of equivalent variations on the description that follows. Like elements in various embodiments are commonly referred to with like reference numerals.
[0027] FIG. 1 is an exploded isometric view of one example of a PV mounting and support assembly 2 made according to the invention. Assembly 2 includes a clip assembly 10 and a base 14 . Clip assembly 10 includes a clip 12 secured to base 14 by a bolt 16 . Base 14 includes a base body 18 , typically of extruded aluminum or some other appropriate material, and a sealant 20 secured to the lower surface 22 of base body 18 . Sealant 20 is typically in the form of a butyl tape about 3 mm thick. Base body 18 has a pair of raised portions 24 defining a gap 26 therebetween. Gap 26 extends down to a central region 28 of base body 18 , central region 28 having a threaded hole 30 formed therein for receipt of bolt 16 Central region 28 may include one or more clearance holes for additional screws 35 . Base body 18 also has a pair of flanges 32 having a number of mounting holes 34 used to secure base 14 to the deck 31 of a support structure 33 , such as a roof, with deck-penetrating fastener 35 . See FIG. 4 . Bolt 16 passes through a central opening 36 in clip 12 , through a hole 38 formed in a spacer 40 , through gap 26 , and into a threaded hole 30 . Other types and configurations for base body 18 , such as a solid block without a gap 26 or flanges 34 , may also be used.
[0028] FIGS. 4 and 5 show clip assemblies 10 securing adjacent PV modules 50 , also called PV assemblies 50 , to base body 18 . Clip assemblies 10 are shown engaging adjacent PV assemblies 50 with screws 16 in the gap 58 between the PV assemblies. Assemblies 2 are commonly referred to as interior assemblies when used between adjacent PV assemblies. PV assemblies 50 include a peripheral frame 52 supporting a PV panel 54 . Frame 52 includes a lower peripheral edge surface 60 which is biased against the PV module support surface 62 of the base body 18 by virtue of clip 12 pressing against the upper peripheral edge surface 64 of frame 52 . The distance 65 between support surface 62 and a lower base surface 67 of base 14 is typically chosen by the desired distance between lower peripheral edge surface 60 and support structure 33 . Support structure 33 typically includes deck 31 covered by a weather barrier layer 66 .
[0029] In one embodiment deck-penetrating fasteners 3 5 are typically self tapping screws 35 between the size of #8 and #14 (M4-M6), and of sufficient length to fully engage with deck 31 and create penetrations or holes 68 therein. Deck 31 is typically 15/32″ (12 mm) thick oriented strand boards (OSB) or ½″ (12 mm) thick plywood or similar materials, on which shingles or other materials to create weather barrier layer 66 are mounted, formed or applied. It is preferably that holes 34 be situated on flange 32 such that the head of each screw 35 does not protrude above the top surface of flanges 32 . In one embodiment weatherproofed screws with sealing washers beneath the head are used in addition to sealant 20 . In some embodiments sealant 20 may be eliminated when other means for sealing the holes in deck 31 are used, such as a liquid sealant. In some embodiments screw 16 is a ¼″-20 (M6) stainless steel screw. A variety of clip or clamp devices, in addition to those described herein, may be used to secure PV assembly 50 to base 14 .
[0030] PV assembly 50 has a structural frame 52 , but may be an unframed PV laminate, or may be framed in a material that provides only protection of the edge of the PV laminate without significant structural function. This material may be nonconductive. An example of a frameless PV module 50 is shown in FIG. 6 . PV mounting and support assembly 2 of FIG. 6 differs from assembly 2 of FIGS. 1-5 primarily by the use of surface-cushioning members 70 between clips 12 and upper peripheral edge surface 64 of PV assembly 50 . Such a surface-cushioning member could be supplemented by or replaced by a force-distributing plate or strip which may be secured to clip 12 or PV assembly 50 or simply located between the two.
[0031] Clip 12 is a generally U-shaped structure having a central portion 42 , through which central opening 36 is formed, and a pair of upstanding arms 44 . Arms 44 and central portion 42 define an access region 45 . Access region 45 is accessible from above to provide clear access to screw 16 thus facilitating the use of clip assembly 10 . Arms 44 include extensions 46 having downwardly extending teeth 48 . As shown in FIG. 3 , clip assembly 10 is used with PV assemblies 50 of the type having electrically conductive frames 52 surrounding PV panels 54 . As can be seen in FIGS. 2 and 3 , the head of screw 16 is located completely within access region 45 and is located below the top surface of frame 52 of PV assembly 50 . In addition, the generally T-shaped configuration of arms 44 with downwardly facing teeth 48 provide for a low profile structure. This low profile structure creates a cleaner, less cluttered appearance and also minimizes shading of PV panel 54 .
[0032] Frames 52 have an upper, circumferentially extending edge 56 which are engaged by teeth 48 of clip 12 . Frame 52 is typically anodized aluminum and thus has a non-conductive outer surface. Frame 52 may also have other types of non-conductive outer surfaces, such as a painted outer surface. To ensure good electrical contact between clip 12 and frame 52 , teeth 48 act as surface-disrupting elements. The serrated teeth or other structure cuts through any nonconductive material on frame 52 thereby creating a positive electrical connection with clip 12 , and via screw 16 , to base 14 . This helps to ensure good grounding between frames 52 of adjacent PV assemblies 50 through clip 12 . Other surface-disrupting methods could also be used, such as causing clip 12 to slide against and score a portion of frame 52 or through the use of other types of surface-disrupting structures or procedures.
[0033] In the example of FIGS. 1-5 , three teeth 48 are used at each extension 46 of arms 44 . The use of a number of points 44 at each extension 46 allows some adjustment in the position of clip 12 relative to frame 52 , thus facilitating installation. Teeth 48 are oriented to be generally parallel to a line connecting extensions 46 of each arm 44 and thus generally perpendicular to the adjacent frame 52 .
[0034] Arms 44 are preferably not perpendicular to central portion 42 . In the disclosed example, arms 44 extend inwardly over central portion 42 to define an included angle 53 , see FIG. 3 . Included angle 53 is an acute angle and typically ranges from 80-88°, and is about 83° in the disclosed example. This helps to strengthen clip 12 because arms 44 will tend to straighten out under load. Another advantage with the angulation of arms 44 is that doing so results in more of a point contact by teeth 48 with frame 52 . This can be for two primary reasons. The first reason is that teeth 48 , for practical purposes, do not narrow down to a true point but rather to a line or edge, the length of which is as long as clip 12 is thick. Therefore, by angling arms 44 , the ends of teeth 48 first engage frame 52 to provide more of a point contact than a line contact. The second reason is based upon the fact that manufacturing constraints limit how sharp of an edge teeth 48 will exhibit. In some examples, teeth 48 will exhibit a rounded edge so that if arms 44 were perpendicular to central portion 42 , teeth 48 would provide a generally cylindrical surface against frame 52 .
[0035] Clip 12 also secures frame 52 to base 14 by capturing the frame between arms 44 of clip 12 and support surface 62 of raised portions 24 of base body 18 . Spacer 40 , as suggested in FIG. 3 , helps to ensure adjacent PV assemblies 50 are located in a proper distance from one another. Spacer 40 is typically made of rubber or some other material including, for example, metal or cardboard, sized to be larger than the width of central portion 42 , illustrated in FIG. 3 . The size of spacer 40 is chosen so that when PV assemblies 50 expand during hot weather, or otherwise, PV assemblies 50 have room to expand before contacting clip 12 . This helps to prevent damage to PV panels 54 , which could occur if PV assemblies 50 were to press directly against clip 12 during such thermal expansion. The use of spacer 40 simplifies installation and by eliminating the need to use a special tool to ensure proper spacing of PV assemblies during installation. Although the primary grounding created by clip 12 is from frame 52 of one PV assembly 50 to frame 52 of an adjacent PV assembly, clip assembly 10 can also be used to provide grounding between PV assembly frames 52 and base 14 . Although not presently preferred because it may require a specially designed frame 52 , in some examples clip 12 may be attached to or an integral portion of frame 52 .
[0036] Assemblies 2 are typically secured to deck 31 of support structure 33 based upon a layout pattern for PV assemblies 50 . After the layout pattern has been chosen, assemblies 2 are located at selected locations according to the layout pattern so that the assemblies are properly positioned to engage the edges of one or more PV assemblies 50 . Although this could be carried out using PV assemblies 50 as a positioning fixture, it is preferably carried out with the aid of a layout tool, such as layout tool 72 shown in FIGS. 7 and 8 . Layout tool 72 has appropriately located openings 74 size to properly position assemblies 2 , see FIG. 8 , at appropriate orientations and spacing. Layout tool 72 helps to accurately position assemblies 2 in two axes. In some examples layout tools may be used to locate guide holes or mounting holes for the proper location of assemblies 2 .
[0037] FIGS. 9 and 10 illustrate mounting PV mounting and support assembly 2 on top of a shingled support structure 76 with flashing 78 between assembly 2 and shingled support structure 76 . Flashing 78 has upper and lower edges 79 , 80 with upper edge 79 extending beneath an upper row 81 of shingles and lower edge 80 extending past the lower edge 83 of a lower row 82 of shingles. Flashing 78 is used to waterproof penetrations 68 into deck 31 . The use of flashing 78 in this manner is advantageous because it provides a smooth and consistent surface for the typically elastomeric sealing material of sealant 20 to seal against. Because flashing 78 covers a relatively large area, 1 square foot (929 cm 2 ) in one example, and is fastened tightly to the support structure 33 , it discourages water infiltration to the area of penetrations 68 , especially by wind-driven rain, and facilitates the shedding of water downwardly. Flashing 78 may be used in conjunction with liquid-applied roofing sealants to further protect penetrations 68 from any water infiltration. Flashing 78 may not be needed when the water shedding layer of support structure 33 is of a type, such as a metal roof, that waterproofing the deck screw penetrations can be made without the use of flashing. For example, with metal roofs sealant 20 may provide sufficient waterproofing. With an asphalt or composition shingle roof, base body 18 may be mounted directly to the shingled weather barrier layer 66 with penetrations 68 sealed using an appropriate sealing composition, alone or in combination with sealant 20 , between the base plate and the shingle surface. In one example flashing 78 is galvanized or Galvalume coated steel. Flashing 78 may be any suitable sheet metal material or fabricated from plastic, composite or elastomeric materials. Flashings 78 may be pre-attached to base 14 rather than field-installed. In some examples shims, not shown, may be used to correct for undulations in support structure 33 so that the PV assemblies 50 remain generally coplanar.
[0038] Clip assembly 10 of FIGS. 1 and 2 can be used at the periphery by using, for example, a spacer 100 located between the otherwise unused extensions 46 of clip 12 , see FIG. 11 , and the base 14 . Spacer 100 is used to ensure that the force exerted by clip 12 is straight down on PV assembly 50 and to keep clip 12 properly engaged with the PV assembly. Spacer 100 has a periphery 102 configured to accommodate frames 52 having different heights. Other types of variable-height of spacers, including threaded, telescoping spacers and spacers consisting of stacks of individual spacer elements, can also be used.
[0039] FIGS. 12-14 illustrate an internal photovoltaic mounting and support assembly 104 including an internal clip assembly 106 designed as a modification of clip assembly 10 of FIGS. 1 and 2 . Clip assembly 106 includes a clip 108 and pieces of electrically insulating adhesive-backed tape 110 , 112 . Tape 110 is secured to raised portions 24 of base body 18 to cover support surface 62 . Tape 112 is adhered to clip 108 as shown in FIGS. 12 and 13 to lie above gap 26 . A gap 113 is formed between clip 108 and support surface 62 . Screw 16 is tightened onto base body 18 and then PV assembly 50 is secured to clip assembly 106 by sliding an internal lip 116 of frame 52 into gap 113 between clip 108 and base body 18 and between insulating tape 110 , 112 . This is possible because of the open region 118 defined by PV panel 54 and peripheral frame 52 . Tape 110 , 112 helps to ensure the snug engagement of lip 116 between clip 108 and base body 18 and also helps to reduce marring of the surface of lip 116 . The size of gap 113 , the thickness of internal lip 116 , and the thickness and physical characteristics of tape 110 , 112 are chosen to permit the internal lip to slide into and out of gap 113 while snugly engaging the internal lip.
[0040] In this example internal PV mounting and support assembly 104 acts to secure PV assembly 50 in place but does not necessarily provide a grounding function. In other examples internal clip assembly 106 could be configured to provide a grounding function as well as a mounting function by, for example, causing a spike to pierce the surface of lip 116 when the lip is inserted between clip 108 and base body 18 . Although tape 110 , 112 is in this example electrically insulating, it need not be.
[0041] Internal PV mounting and support assembly 104 may be used in conjunction with PV mounting and support assembly 2 to secure one edge of PV assembly 50 to support structure 33 in less time than if all edges were secured to the support structure using assemblies 2 . The positioning of two assemblies 2 and one assembly 104 is shown in FIG. 8 .
[0042] FIG. 15 illustrates a PV mounting assembly 120 typically used with the flashing 78 of FIGS. 9 and 10 . Assembly 120 includes a base body 122 that does not have a PV module support surface 62 as do the above-described examples. Rather, separate structure is used to raise PV assemblies 50 above support structure 33 if it is desired to do so. An appropriate sealing mechanism, such as sealant 20 , is used with or as a part of assembly 120 . FIG. 16 illustrates a peripheral PV mounting assembly 124 similar to that of FIG. 15 but including a peripheral mounting clip 126 having arms 44 extending to one side only. In addition, assembly 120 of FIG. 16 uses a standoff 128 between clip 126 and base body 122 to provide stability for assembly 121 when clip 126 is secured against a peripheral edge of a PV assembly 50 .
[0043] The size of PV modules 50 that can be supported using PV support and mounting assemblies 2 , 104 and PV mounting assemblies 120 , 124 is dependent on the expected wind speed and exposure conditions as well as the construction of the underlying support structure. The disclosed examples can typically be used with PV modules 50 having a plan area of up to, for example, about 18 sq ft (1.67 m 2 ) for roofs and other support structures 33 constructed using conventional techniques. PV modules having larger plan areas may be accommodated but in some cases may require an adjustment of conventional construction practices and strengthening of the various mounting components.
[0044] Other contemplated implementations of this invention include the use screws made from other materials, or fasteners other than screws to secure base 14 to support structure 33 . Countersunk fasteners can be used to avoid interference between frame 52 and the fasteners. Instead of a screw 16 engaging threaded hole 30 , a different type of fastening device, such as a threaded stud, friction based connection, bayonet or twist-lock connection, push-on connector, ratchet fastener, or other similar device may be used. Instead of a butyl tape type of sealant 20 , other materials for sealant 20 can be used; examples include an adhered rubber foot, a mechanically fastened rubber foot, foam tape, spray foam, butyl tape, cork, liquid adhesive or sealant, and a gasket. Base body 18 may be made by a variety of methods, including casting, molding, or machining and may be made from any suitable metal, plastic, composite, wood, or elastomeric material. In some examples base 14 may be integrated directly into the PV module 50 so that the bases and modules ship to site and are installed as a unit. In some examples base 14 may be integrated such that PV module frame 52 itself acts as the base and is secured directly to the roof deck. PV modules with bases integrated with the module frame may be constructed such that the frame design promotes airflow beneath the module even with the module fastened directly to the roof.
[0045] During installation mounting screw 16 may be torqued such that the threaded member and the clip are pre-loaded above the maximum code wind load plus an appropriate safety factor. This ensures a secure mechanical and electrical connection in all field conditions and excludes moisture from the ground bond area at teeth 48 by creating a high pressure connection zone around each point.
[0046] The use of threaded connections has been emphasized. However, other types of connections, such as a ratchet-type of connections and connections using spring fingers, may also be used.
[0047] The above descriptions may have used terms such as above, below, top, bottom, over, under, et cetera. These terms are used to aid understanding of the invention are not used in a limiting sense.
[0048] While the present invention is disclosed by reference to the preferred embodiments and examples detailed above, it is to be understood that these examples are intended in an illustrative rather than in a limiting sense. It is contemplated that modifications and combinations will occur to those skilled in the art, which modifications and combinations will be within the spirit of the invention and the scope of the following claims. Any and all patents, patent applications and printed publications referred to above are incorporated by reference.
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A method for mounting PV modules to a deck includes selecting PV module layout pattern so that adjacent PV module edges are spaced apart. PV mounting and support assemblies are secured to the deck according to the layout pattern using fasteners extending into the deck. The PV modules are placed on the PV mounting and support assemblies. Retaining elements are located over and secured against the upper peripheral edge surfaces of the PV modules so to secure them to the deck with the peripheral edges of the PV modules spaced apart from the deck. In some examples a PV module mounting assembly, for use on a shingled deck, comprises flashing, a base mountable on the flashing, a deck-penetrating fastener engageable with the base and securable to the deck so to secure the flashing and the base to the shingled deck, and PV module mounting hardware securable to the base.
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BACKGROUND OF THE INVENTION
The present invention relates to a dry unit of a dry end, in particular, of a paper machine for producing paper webs and including at least one drying cylinder and a dry felt, which is at least partially wrapped around the drying cylinder, with a paper web passing between the dry felt and the drying cylinder.
A dry unit of the above-described type is disclosed in German publication DE 44 16 585. The publication discloses a dry unit for a dry end and including a plurality of heatable drying cylinders and pressure bands (also called dry felts) which press a to-be-dried material web to a drying cylinder.
Generally, single-row and double-row dry units are used. With a single-row dry unit, a material web passes, along a meander-shaped path, alternatively about a drying cylinder and deflection rolls. Thus, when a single-row dry unit is used, only one side of the material web comes into contact with outer surfaces of the drying cylinders, with the other side abutting the pressure band.
With a double-row dry unit, a material web likewise passes along a meander-shaped path, but it is passed, alternatively, from a drying cylinder of one row to a drying cylinder of another row so that one side of the material web comes into contact with the drying cylinder of the one row, and another side of the material web comes into contact with the drying cylinder of the another row.
Usually, each of the two drying cylinders cooperates with a respective pressure band which presses the material web to the outer surface of the drying cylinder.
A dry end of a paper machine often includes a combination of single-row and double-row dry units, whereby the characteristics of a material web, such as shrinkage and strength, can be appropriately influenced.
An increase of the material web strength can be achieved by providing, in an interior of the material web, a temperature of about 100° C. To this end, often gas-fired drying cylinders are used, the temperature of which can reach about 300° C. By additionally using high-stressed, rigid pressure bands, a vapor pressure in the inside of the material web can be attained that would be much higher than the environmental pressure.
However, at that, upon lifting of a pressure band from the material web surface, the vapor pressure established in the material web interior is released abruptly. The sudden release of the vapor pressure results in splinting of the material web in some places or, in worst cases, the sudden release of the vapor pressure leads to rupture of the web.
Accordingly, an object of the invention is to provide a dry unit in which the splinting of the material web and/or web rupture is reliably prevented.
SUMMARY OF THE INVENTION
This and other objects of the present invention, which will become apparent hereinafter, are achieved by providing, according to the present invention, a plurality of pressure bands, further called dry felts, arranged one above another for pressing a material web to the drying cylinder, which pressure bands (dry felts) are lifted off the drying cylinder at different circumferential positions of the dry felts relative to the drying cylinder. Lifting of the dry felts of the drying cylinder at different circumferential position thereof on the drying cylinder permits to provide for a stepwise release of the vapor pressure, whereby the danger of splinting of the material web and/or its rupture is reliably prevented.
Using three or more dry felts, which are lifted off the drying cylinder one after another after certain intervals, permits to stepwise reduce the pressure force acting on the material web which results, in turn, in the stepwise release of the vapor pressure. The stepwise release of the vapor pressure is further improved by using, according to the present invention, separate dry felts, with different permeabilities, i.e., by using dry felts having different vapor perviousness. Thus, the outermost dry felt, when viewed from the cylinder, may have advantageously a zero permeability, with the inside dry felts having an ever increased permeability.
According to a further development of the invention, the outer dry felts wrap smaller circumferential regions of the drying cylinder than the inner dry felts. Advantageously, the wrapping angle of separate dry felts, when viewed from the cylinder, increases from outside inward.
According to a further advantageous embodiment of the present invention, the innermost dry felt is made of a finer and/or thinner material.
Using a fine innermost dry felt, which comes into direct contact with a material web, permits to provide for a very smooth outer surface of the material web. This is because fine dry felts have a reduced felt stress. However, a sufficient pressure force is insured by using more rigid and thicker outer dry felts which, thereby, have an increased felt stress and, thus, apply an increased pressure force.
The present invention is obviously applicable as to single-row dry units so to double-row dry units.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and objects of the present invention will become more apparent, and the invention itself will be best understood from the following detailed description of the preferred embodiments when read with reference to the accompanying drawings, wherein:
FIG. 1 shows a schematic view of a first embodiment of a single-row drying unit according to the present invention;
FIG. 2 shows a schematic view of a second embodiment of a single-row drying unit according to the present invention;
FIG. 3 shows a schematic view of a double-row drying unit according to the present invention;
FIG. 4 shows a schematic view of a dry end including several drying units according to the present invention; and
FIG. 5 shows a schematic view of a still further dry end including drying units according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A drying cylinder 1 and two deflection rolls 3 and 5, which are located adjacent to the drying cylinder 1, form part of a single-row drying unit. Usually, such a single-row drying unit consists of several drying cylinders and associated therewith respective pairs of deflection rolls arranged in a row. The drying cylinders and the deflection rolls are generally so arranged that a paper web passes through the dry unit along a meander-shaped path, with the paper web alternatively passing around drying cylinders and the corresponding deflection rolls.
In the embodiment shown in FIG. 1, a paper web 7 passes around the deflection roll 3, then around the drying cylinder 1 and, finally, around the next deflection roll 5. A wrapping angle a, which is formed by the paper web 7 around the drying cylinder 1, i.e., the wrapping region, depends on the distance between or the arrangement of deflection rolls 3 and 5. The wrapping angle a defines a wrapping region in which heating of the paper web 7 by the outer surface of the drying cylinder 1 takes place. Usually, to this end, the interior of the drying cylinder is supplied with steam. However, if high temperatures, e.g., of about 300° C., are required, then gas firing of the cylinder, i.e., burning of gases in the cylinder interior is used.
In addition to a first continuous dry felt 9, three additional dry felts 11, 13 and 15 are provided. All of the three additional dry felts 11, 13 and 15 are running together with the first dry felt 9 around a common deflection roll 17 at a common point 19. Thus, at this point, all four dry felts 9, 11, 13 and 15 lie on the paper web 7 one after another. The pressing force applied to the paper web 7 consists of four separate force components generated by the dry felts 9, 11, 13 and 15.
The outermost dry felt 15 wraps the drying cylinder 1 about a wrapping angle b and is deflected from the dry cylinder 1 by a deflection roll 21. The dry felt 15 is then returned to the deflection roll 17 by another deflection roll 21a.
In a similar way, the dry felt 13, which wraps the drying cylinder 1 about a wrapping angle c, is guided by deflection rolls 23 and 23a, and the dry felt 11, which wraps the drying cylinder 1 about a wrapping angle d, is guided by deflection rolls 25, 25a and 25b. Only the first dry felt 9 remains in contact with the paper web 7 as it runs about the deflection roll 5.
FIG. 1 clearly shows that the wrapping angle a of the first dry felt is largest while the wrapping angles d, c, b of the following one another dry felts 11, 13 and 15 are stepwise smaller.
With this inventive arrangement of the dry felts, the pressing force acting on the paper web 7 is stepwise reduced, with the biggest force being applied in the wrapping region defined by the wrapping angle b when all four dry felts 9, 11, 13 and 15 lie on the paper web 7, while the pressing force at the end of the wrapping region defined by the wrapping angle a is zero. Thus, four different pressure zones Z1, Z2, Z3 and Z4 are formed in the wrapping region which defines the contact of the paper web 7 with the dry cylinder 1.
When the paper web 7 passes the first pressure region Z1, a very high pressing force is applied thereto, and a very good heat transfer from the drying cylinder 1 to the paper web 7 takes place. As a result, water vapor, which is formed in the interior of the paper web by heating, cannot escape. As a result, a vapor pressure is generated in the paper web interior which is high in comparison with the environmental pressure. In the second pressure zone Z2, the pressing force is somewhat reduced in comparison with the environmental pressure, with the accompanying reduction in the vapor pressure. A further reduction of the pressing force and of the vapor pressure takes place in the pressure zones Z3 and Z4, with the difference between the vapor and environmental pressures in the fourth pressure zone Z4 being relatively small. Thereby, when the paper web 7 is lifted off the dry cylinder 7, due to the reduced vapor pressure, splintering of the paper web does not occur, because the major portion of the vapor pressure has already been diverted in the pressure zones Z2, Z3 and Z4.
An increase in the effect resulting from providing different pressure zones can be achieved by using dry felts 11, 13 and 15 having different permeabilities.
For example, in the first pressure zone Z1 in which the pressing force or vapor pressure is high, the outmost dry felt 15 may have a 0 permeability, i.e., a vapor impermeable dry felt is used. The permeability of the following dry felts 13, 11, and 9 increases from one dry felt to another, so that the vapor permeability increases stepwise from the pressure zone Z2 to the pressure zone Z4. With this, the vapor pressure is stepwise reduced to a magnitude which does not cause splinting of the paper web.
By selecting a very fine first dry felt 9, the formation of felt markings on the upper surface of the paper web, as a result of the contact of the paper web with the dry felt, can be effectively prevented. Fine dry felts have a low felt stress which, however, can be compensated by selecting stronger dry felts 11, 13 and 15.
FIG. 2 shows another embodiment of a dry unit according to the present invention, which is also a single-row dry unit. In comparison with the dry unit shown in FIG. 1, the dry unit shown in FIG. 2 has several dry cylinders 1 and several dry suction rolls 27 arranged in a row.
In the embodiment of FIG. 2 instead of four dry felts, only three dry felts 9, 11, and 13 are provided. Contrary to the embodiment of FIG. 1, in the embodiment of FIG. 2, the separate dry felts 9, 11 and 13 are returned back not after each dry cylinder 1 but only when they reach the end of the dry unit.
However, generally, the basic design of the embodiment shown in FIG. 2 corresponds to that of the embodiment of FIG. 1. Here also, in addition to a dry felt 9, which is displaceable together with the paper web 7, additional dry felts 11 and 13 are provided. The additional dry felts 11 and 13 are displaced together with the dry felt 9 at the start of the dry run of the paper web 7 about the dry cylinder 1 and are wrapped around the dry cylinder 1 with different angles c and d. Between the dry cylinders 1, there are provided deflection rollers 23 and 25 associated, respectively, with the dry felts 11 and 13. By a respective arrangement of the deflection rolls 23 and 25, the respective wrapping angles c and d can be appropriately adjusted. The deflection rolls 23 and 25 fuide the dry felt 11 and 13 about the dry cylinders 1 arranged one after another, as shown in FIG. 1. At the end of the dry unit, the two additional dry felts 11 and 13 are guided about a common deflection roll 23 from the east in the row cylinder 1 to the beginning of the dry unit.
Functionally, the embodiment of a dry unit shown in FIG. 2 correspond to that of FIG. 1, so that describing of its operation is believed to be unnecessary.
However, in the embodiment of FIG. 2, instead of simple deflection rolls 3 and 5, so-called dry suction rolls 27 are used. The dry suction rolls 27 have in their circumferential region a suction zone 29 along which the paper web 7, together with the dry felt 9, are driven. In the suction zones 29, the paper web 7 is drawn to the dry felt 9. Due to elevated friction forces acting between the paper web 7 and the dry felt 9 in the suction zones 29, shrinkage of the paper web is prevented or at least is substantially reduced. In addition, waving of the paper web 7, as it passes around the suction roll 27, is likewise eliminated.
As shown in FIG. 2, the diameter of the dry suction roll 27 substantially correspond to that of the dry cylinder 1. In comparison with the embodiment of FIG. 1, in the embodiment of FIG. 2, the diameter of the dry cylinder 1 is somewhat smaller, and the diameter of the deflection roll, i.e., of the dry suction roll is larger. Such correspondence of the diameters of the dry cylinder and of the deflection roll results in an increase of the wrapping region which leads to a better heat transfer from the dry cylinder to the paper web. On the other side, the dry suction rolls can be made more rigid so that an increase in a longitudinal stress is possible.
Because of a high longitudinal stress of the dry felt and a resulting therefrom pressing force acting on the paper web, the paper web strength can be increased by an additional compression of the material.
FIG. 3 shows an application of the inventive concept to a double-row dry unit. As it has been mentioned previously, the double-row dry unit is generally formed of two rows of dry cylinders 31 and 41, respectively. The paper web 7, in this case, passes through the dry unit along a meander-shaped path from a dry cylinder 31 to a lower dry cylinder 41 and so forth.
Each dry cylinder row is associated with dry felts 32, 33, 34 and 42, 43, 44, respectively, which correspond to the dry felts 11, 13, 15 of FIG. 1.
At the beginning of the double-row dry unit, a dry felt 32 is displaced, together with the paper web 7, about the deflection roll 35. The dry felt 32 wraps the dry cylinder 31 about a wrapping angle a and is deflected by a further deflection roll 35a. The deflection roll 35a serves for joint displacement of the dry felt 32 and the paper web 7 to an adjacent dry cylinder 31 of the upper row of dry cylinders. This process continues until the paper web 7 and the dry felt 32 reach the last dry cylinder 31 of the upper row, where another deflection roll 35c returns the dry felt 32 back to the beginning of the dry unit.
The dry felts 33 and 34 are guided by deflection rolls 36a, 36b and 37a, 37b, respectively, corresponding to deflection rolls 35a, 35b. The guiding of the dry felts 33 and 34 at the beginning of the dry unit and their return at the end of the dry unit is effected with deflection rolls 38 and 38a, respectively.
By a corresponding arrangement of deflection rolls 35a, 36a, 37a and 35b, 36b, 37b different wrapping angles of the dry felts 32, 33, 34 about the dry cylinder 31 can be provided, as it had already been mentioned previously. The wrapping angle c of the outmost dry felt 34 is smallest and the wrapping angle a of the innermost dry felt 32 is largest. The effect of the different wrapping angles has already been described previously, with reference to FIG. 1. Therefore, any further description would be superfluous.
The double-row dry unit shown in FIG. 3 is symmetrically formed, and the dry felts 42, 43, 44 are guided by deflection rolls 45-48 in the same manner as the dry felts 32, 33, 34 of the upper row are guided by the deflection rolls 35-38.
FIG. 4 shows a schematic view of a dry end formed of single-row and double-row dry units 51, 53, 55 and 56 following one another.
A paper web, delivered from a press end, first passes through the double-row dry unit 51 and is heated there. In the following single-row dry unit 53, the paper web is heated to a greater extent, and it is pressed onto a dry cylinder with a greater force by an increased dry felt stress to achieve a better heating and compression of the paper web. With this arrangement, only the two last dry cylinders of the dry unit 53 are provided with a plurality of dry felts, as contemplated by the present invention, whereas in the embodiment of FIG. 2, all of the dry cylinders are associated with a plurality of dry felts.
In the following single-row dry unit 55, with the dry cylinders being located in the lower row, an increased pressing force is applied to the paper web due to the use, as contemplated by the present invention, a plurality of dry felts with the first two dry cylinders in the front region of the dry unit 55. At the end of the dry end, the double-row dry unit is provided.
In the embodiment shown in FIG. 4, the dry cylinders of the dry units 53 and 55, which are associated with a plurality of dry felts, as contemplated by the present invention, are gas fired to achieve a temperature of about 300° C. at which a danger of paper web splinting would have been especially big if the plurality of dry felts according to the present invention had not been provided.
FIG. 5 shows a schematic view of a dry end similar to that of FIG. 4 but with a difference which consists in that in the dry unit 53, two dry felts are associated with each drying cylinder, and in the dry unit 55, three dry felts are associated with each drying cylinder.
Obviously, more dry felts can be associated with a drying cylinder of a dry unit of a dry end. The use of a plurality of dry felts is not limited to single-row units of a dry end shown in FIGS. 4 and 5. The double-row dry unit drying cylinders likewise can be associated with a plurality of dry felts. At that, not only drying cylinders of one row can be associated with several dry felts, but the drying cylinders of both upper and lower rows can cooperate with a plurality of dry felts.
Though the present invention was shown and described with reference to the preferred embodiments, various modifications thereof will be apparent to those skilled in the art and, therefore, it is not intended that the invention be limited to the disclosed embodiments or details thereof, and departure can be made therefrom within the spirit and scope of the appended claims.
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A dry unit of a dry end of a machine for producing a material web and including at least one drying cylinder and a plurality of dry felts parsing around the dry cylinder one above another, with at least two of the dry felts being lifted off the dry cylinder at different circumferential positions of the two dry felts on the dry cylinder.
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BACKGROUND OF THE INVENTION
This invention relates to an apparatus and method for treating a well bore. More particularly, but not by way of limitation, this invention relates to an apparatus and method for heating a treating compound, and thereafter, placing the treating compound within a well bore.
In the exploration and development of hydrocarbon reservoirs, a well is drilled to a subterranean reservoir, and thereafter, a tubing string is placed within said well for the production of hydrocarbon fluids and gas, as is well understood by those of ordinary skill in the art. As the search for additional reserves continues, offshore and remote areas are being explored, drilled and produced with increased frequency. During the production phase, the production tubing may have deposited within the internal diameter such compounds as paraffin, asphaltines, and general scale which are precipitated from the formation fluids and gas during the temperature and pressure drops associated with production.
Further, the subterranean reservoir may become plugged and/or damaged by drilling fluids, migrating clay particles, etc. Once the reservoir becomes damaged, the operator will find it necessary to stimulate the reservoir. One popular method of treatment is to acidize the reservoir.
Both the treatment of tubing string and the reservoir may be accomplished by the injection of specific compounds. The effect of the treating compounds will many times be enhanced by heating the treating compound. Thus, for the treatment of paraffin and asphaltines, the heating of a specific treating compound (e.g. diesel) enhances the removal. Also, in the acidizing of a reservoir, the heating of a specific treating compound (e.g.hydrochloric acid) enhances the treatment efficency.
In order to heat these types of compounds, operators utilize an open or enclosed flame. However, government regulations have either banned or limited the use of open or enclosed flames on offshore locations and some land locations. Thus, there is a need for a thermal fluid unit that will heat a chemical compound without the need for having an open flame. There is also a need for a method of treating well bores with a heated treating compound.
SUMMARY OF THE INVENTION
A method of heating a chemical solution used in a well bore having a tubing string is disclosed. The well bore will intersect a hydrocarbon reservoir. The method will comprise providing a diesel engine that produces heat as a result of its operation. The engine will in turn produce a gas exhaust, a water exhaust, and a hydraulic oil exhaust.
The method would further include channeling the gas exhaust to a gas exhaust heat exchanger, and channeling the water exhaust to a water exhaust heat exchanger. The method further includes injecting a compound into the water exhaust heat exchanger, and heating the compound in the water exhaust heat exchanger. The method may also include producing a hydraulic oil exhaust from the diesel engine and channeling the hydraulic oil exhaust to a hydraulic oil heat exchanger. Next, the compound is directed into the hydraulic oil heat exchanger, and the compound is heated in the hydraulic oil heat exchanger.
The method may further comprise flowing the compound into the gas exhaust heat exchanger and heating the compound in the gas exhaust heat exchanger. The operator may then inject the compound into the well bore for treatment in accordance with the teachings of the present invention.
In one embodiment, the compound comprises a well bore treating chemical compound selected from the group consisting of hydrochloric acid and hydrofluoric acid. The method further comprises injecting the chemical compound into the well bore and treating the hydrocarbon reservoir with the chemical compound.
In another embodiment, the compound comprises a tubing treating chemical compound selected from the group consisting of processed hydrocarbons such as diesel oil which is composed chiefly of unbranched paraffins, and the method further comprises injecting the processed hydrocarbon into the tubing string and treating the tubing string with the processed hydrocarbon.
In another embodiment, during the step of injecting the compound into the well bore, the invention provides for utilizing a coiled tubing unit having a reeled tubing string. The coiled tubing unit and the engine are opertively associated so that said engine also drives the coiled tubing unit so that a single power source drives the thermal fluid sytem and the coiled tubing unit. Thereafter, the reeled coiled tubing is lowered into the tubing string and the heated compound is injected at a specified depth within the tubing and/or well bore.
Also disclosed herein is an apparatus for heating a chemical solution used in a oil and gas well bore. The apparatus comprises a diesel engine that produces a heat source while in operation. The engine has a gas exhaust line, and a water exhaust line. The apparatus further includes a water heat exchanger means, operatively associated with the water exhaust line, for exchanging the heat of the water with a set of water heat exchange coils; and, a gas heat exchanger means, operatively associated with the gas exhaust line, for exchanging the heat of the gas with a set of water heat exchange coils.
Also included will be a chemical supply reservoir, with the chemical supply reservoir comprising a first chemical feed line means for supplying the chemical to the water heat exchanger means, and a second chemical feed line means for supplying the chemical to the gas heat exchanger means so that heat is transferred to the chemical.
The engine will also include a hydraulic oil line, and the apparatus further comprises a hydraulic oil heat exchanger means, operatively associated with the hydraulic oil line, for exchanging the heat of the hydraulic oil with a set of hydraulic oil heat exchange coils. The chemical supply reservoir further comprises a third chemical feed line means for supplying the chemical to the hydraulic oil heat exchanger means so that the chemical is transferred the heat.
In one embodiment, the gas exhaust line has operatively associated therewith a catalytic converter member and the gas heat exchanger means has a gas output line containing a muffler means for muffler of the gas output. The water exhaust line may have operatively associated therewith a water pump means for pumping water from the engine into the water heat exchanger means.
The apparatus may also contain a hydraulic oil line that has operatively associated therewith a hydraulic oil pump means for pumping hydraulic oil from the engine into the hydraulic oil heat exchanger and further associated therewith a hydraulic back pressure control means for controlling the back pressure of the engine.
In one embodiment, the chemical solution in the chemical supply reservoir contains the chemical selected from the group consisting of: hydrochloric or hydrogen fluoride acids. In another embodiment, the operator may select from the group consisting of diesel fuel oil, paraffin inhibitors, HCl and ethylenediaminetetraacetic acid (EDTA).
An advantage of the present invention includes it effectively removes paraffin, asphaltines and general scale deposits through the novel heating process. Another advantage is that fluids are heated in a single pass with continuous flow at temperatures of 180 degrees fahrenheit up to and exceeding 300 degrees fahrenheit without the aid of an open or enclosed flame. Yet another advantage is that the operator is no longer limited to use of heated water and chemicals for cleaning tubing and pipelines i.e. hydrocarbons can be used as the treating compound to be heated.
Another advantage is that hydrocarbons (such as diesel fuel) can be applied through the novel apparatus without the danger of exposure to open or enclosed flames. Yet another advantage is that with the use of heated hydrocarbons, the chemical consumption can be greatly reduced thus providing an economical method for paraffin and asphaltine clean outs. Of course, the novel system can still be used as means for heating chemicals and water for treatment of the tubing, pipeline, or alternatively, stimulating the reservoir.
A feature of the present invention is the system may be used with coiled tubing. Another feature is the engine used herein may be employed as a single power source for the coiled tubing and novel thermal fluid system. Still yet another feature is that the system is self-contained and is readily available for transportation to remote locations with minimal amount of space.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic process diagram of the present invention.
FIG. 2 is a schematic view of one embodiment of the present invention situated on a land location.
FIG. 3 is a schematic view of a second embodiment of the present invention utilizing a coiled tubing unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, a schematic process diagram of the present invention is illustrated. In the preferred embodiment, the novel thermal fluid system 2 includes a diesel engine 4 which is well known in the art. The engine 4 is used as the heat source since during its operation, the engine 4 will provide as an output a gas exhaust, a water exhaust, and a hydraulic oil exhaust. The type of diesel engine used in the preferred embodiment is commercially available.
The engine 4 will have associated therewith the water exhaust line 6 that leads to the water pump member 8. The water pump member 8 will then pump the exhaust water to the engine water jacket heat exchanger 10. As is well known in the art, the water heat exchanger 10 contains therein a tubular coil (not shown) that is wrapped within the water heat exchanger 10. A second coil (not shown) is disposed therein. The second coil is fluidly connected to a reservoir 12. The reservoir 12 will contain the treating compound such as acid, solvents or diesel oil which will be explained in greater detail later in the application. The list of treating compounds is illustrative.
The reservoir 12 will have a feed line 14 that will be connected to the engine water jacket heat exchanger. The feed line 14 will connect to the second coil. Thus, as the heated water is circulated within the heat exchanger 10, the treating compound is transferred the latent heat. In the preferred embodiment, a dual system of heat exchangers is provided as shown in FIG. 1. It should be understood that dual heat exchangers are depicted due to the increased capacity of heating the treating compound; nevertheless, only a single heat exchanger is possible.
As seen in FIG. 1, the heated water will exit the heat exchanger 10 via the feed line 16 and will enter the water jacket heat exchanger 18. The treating compound will exit the heat exchanger 10 via the feed line 20 into the heat exchanger 18, and the treating compound will again be transferred heat. The heated water will then exit the heat exchanger 18 via the feed line 22 and in turn enter the hydraulic heat exchanger 24. The treating compound will exit the heat exchanger 18 and will be steered into the hydraulic heat exchanger 26 via the feed line 28. The treating compound is directed to the hydraulic heat exchanger 26 and not the hydraulic heat exchanger 24.
The water will then be directed to the exit feed line 29A which has associated therewith a thermostatic valve 29B that controls the opening and closing of valve 29B based on water temperature within line 29A. From the thermostatic valve 29B, two branches exit, namely line 29C and 29D. Thus, if the temperature is low enough, the valve 29B directs the water to the engine 4 (thereby bypassing the radiator 30). Alternatively, if the water temperature is still elevated, the valve 29B will direct the water to the radiatior 30 for cooling, and thereafter, to the engine 4.
The engine 4 will have operatively associated therewith the hydraulic pump member 31 as is well understood by those of ordinary skill in the art. The hydraulic pump member 31 will direct the hydraulic oil to the feed line 32 that in turn leads to a hydraulic back pressure pump 34 that will be used for controlling the back pressure. From the hydraulic back pressure pump 34, the feed line 36 leads to the hydraulic heat exchanger 26. The hydraulic oil feed into the hydraulic heat exchanger 26 will exit into the hydraulic heat exchanger 24 via the feed line 38. Thus, the heat exchanger 24 has two heated liquids being circulated therein, namely: water and hydraulic oil. The hydraulic oil will exit the heat exchanger 24 via the feed line 42 and empty into the hydraulic oil tank 44.
The engine, during operation, will also produce an exhaust gas that is derived from the combustion of the hydrocarbon fuel (carbon dioxide). Thus, the engine has attached thereto an exhaust gas line 46 that in the preferred embodiment leads to the catalytic converter member 48. From the catalytic converter 48, the feed line 50 directs the gas to the exhaust heat exchanger 52 which is similar to the other described heat exchangers, namely 10, 18, 24, 26. Thus, the gas will be conducted therethrough.
As depicted in FIG. 1, the treating compound will exit the hydraulic heat exchanger 26 via the feed line 54 and thereafter enter the exhaust heat exchanger 52 for transferring the latent heat of the gas exhaust to the treating compound. In the preferred embodiment, the gas will exit via the feed line 56 with the feed line 56 having contained therein the adjustable back pressure orifice control member 58 for controlling the discharge pressure of the gas into the atmosphere. The back pressure orifice control member 58 is commercially available.
Thereafter, the feed line 56 directs the gas into the muffler and spark arrester 60 for suppressing the noise and any sparks that may be generated from ignition of unspent fuel. The gas may thereafter be discharged into the atmosphere. The outlet line 62 leads from the exhaust heat exchanger 52. In accordance with the teachings of the present invention, the treating compound thus exiting is of sufficient temperature to adequately treat the well bore in the desired manner.
During the well's life, when a well produces formation water, gyp deposits may accumulate on the formation face and on downhole equipment and thereby reduce production. These deposits may also form on the internal diameter of the tubing. The deposits may have low solubility and be difficult to remove. Solutions of HCl and EDTA can often be used to remove such scales. Soluble portions of the scale are dissolved by the HCl while the chelating action of EDTA breaks up and dissolves much of the remaining scale portions. When deposits contain hydrocarbons mixed with acid-soluble scales, a solvent-in-acid blend of aromatic solvents dispersed in HCl can be used to clean the wellbore, downhole equipment, and the first few inches of formation around the wellbore (critical area) through which all fluids must pass to enter the wellbore. These blends are designed as a single stage that provides the benefits of both an organic solvent and an acid solvent that contact the deposits continuously.
With reference to paraffin removal, several good commercial paraffin solvents are on the market. These materials can be circulated past the affected parts of the wellbore or simply dumped into the borehole and allowed to soak opposite the trouble area for a period of time. Soaking, however, is much less effective because the solvent becomes saturated at the point of contact and stagnates.
Hot-oil treatments also are commonly used to remove paraffin. In such a treatment, heated oil is pumped down the tubing and into the formation. The hot oil is pumped down the tubing and into the formation. The hot oil dissolves the paraffin deposits and carries them out of the well bore when the well is produced. When this technique is used, hot-oil treatments are usually performed on a regularly scheduled basis.
Paraffin inhibitors may also be used. These are designed to create a hydrophilic surface on the metal well equipment. This in turn minimizes the adherence of paraffin accumulations to the treated surfaces.
Acid treatments to stimulate and/or treat skin damage to the producing formation is also possible with the teachings of the present invention. Thus, the operator would select the correct type of acid, for instance HCl or HF, and thereafter inject the heated compound into the wellbore, and in particular, to the near formation face area, in accordance with the teachings of the present invention.
The heating of the treating compound will enhance the effectiveness of the treatment. In FIG. 2, a schematic view of one embodiment of the present invention situated on a land location is illustrated. The novel thermal fluid system 2 is shown in a compact, modular form. The system 2 is situated adjacent a well head 70, with the well head containing a series of valves. The well head 70 will be associated with a wellbore 72 that intersects a hydrocarbon reservoir 74.
The wellbore 72 will have disposed therein a tubing string 76 with a packer 78 associated therewith. The production of the hydrocarbons from the reservoir 74 proceeds through the tubing string 76, through the well head 70 and into the production facilities 80 via the pipeline 82.
Thus, in operation of the present invention, if the well bore 72, and in particular, the tubing string 76 becomes coated with scale deposits such as calcium carbonate and/or barium sulfate, the appropriate treating compound may be heated in the novel thermal fluid system 2 as previously described. Thereafter, the heated treating compound may be pumped into the tubing string so as to react with the scale deposit on the internal diameter of the tubing string 76. Generally, the same method is employed for parrafin removal.
If the operator deems it necessary to stimulate the reservoir 74 in accordance with the teachings of the present invention, the operator may heat the treating compound in the system 2 as previously described, and thereafter, inject the heated treating compound down the internal diameter of the tubing string 76 and ultimately into the pores of the reservoir so as to react with any fines, clay, slit, and other material that destroys the permeability and/or porosity of the reservoir 74. Still yet another procedure would be to heat a treating compound in the system 2, as previously described, and thereafter inject into the pipeline 82.
Referring now to FIG. 3, schematic view of a second embodiment of the present invention utilizing a coiled tubing unit 84. This particular embodiment depicts an offshore platform with the coiled tubing unit 84 and novel thermal fluid system 2 thereon. Moreover, the coiled tubing unit 84 and the thermal system 2 may utilize the same power source, which is the engine 4 of the system 2. It should be noted that like numbers appearing in the various figures refer to like components.
The treating compound, which may be a paraffin remover, a scale remover, or acid compound for reservoir stimulation, will be heated in the system 2. Thereafter, the heated treating compound will be injected into the reeled tubing unit 84 and in particular the tubing 86. The tubing 86 may be lowered to a specified depth and the pumping may begin. The tubing 86 will have associated therewith an injector head 88. Alternatively, the pumping may begin, and the injector head 88 may be raised and lowered in order to continuously pump the treating compound over a selective interval.
Changes and modifications in the specifically described embodiments can be carried out without departing from the scope of the invention which is intended to be limited only by the scope of the appended claims.
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A method of heating a chemical solution used in a well bore having a tubing string is disclosed. The well bore will intersect a hydrocarbon reservoir. The method will comprise providing a diesel engine that produces heat as a result of its operation. The engine will in turn produce a gas exhaust, a water exhaust, and a hydraulic oil exhaust. The method would further include channeling the exhaust to a series of heat exchangers. The method may further include flowing a treating compound into the heat exchangers and heating the treating compound in the series of heat exchangers by heat transfer from the exhaust to the treating compound. The operator may then inject the treating compound into the well bore for treatment in accordance with the teachings of the present invention. One such method would be to inject utilizing a coiled tubing unit. The novel thermal fluid heating system is also disclosed.
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RELATIONSHIP TO OTHER APPLICATIONS
[0001] This application claims priority to and the benefit of U.S. provisional application 61/891,455 filed 16 Oct. 2013, titled “A Method for Distance-Vector Routing Using Adaptive Publish-Subscribe Mechanisms”.
STATEMENT OF SUPPORT
[0002] This invention was made with government support under Grant SUB700155/SC20070363 awarded by the US Army Research Office. The government has certain rights in the invention.
FIELD OF THE INVENTION
[0003] The presently disclosed subject matter is directed towards routing in computer networks. More particularly, the present invention relates to integrated routing and discovery services in computer networks using distances and the application of this method in wireless ad hoc networks.
BACKGROUND OF THE INVENTION
[0004] Telecommunications are fundamental to the operation of modern society. The performance and cost advantages of modern telecommunications have lead to the widespread use of computer networks to transmit voice, image, and data around the world. Those computer networks enable billions of people to easily, quickly, and at low cost communicate with one another, share information, and transfer data.
[0005] Computer networks are based on an agreed set of protocols that enable messages to be transmitted from a source, passed along the telecommunication network, and received at a destination. Messages have at least two parts, the actual information that the sender wants to transfer to the destination and the routing information that controls who receives the message. The agreed upon protocols enable a sender to obtain the address of the destination and the various “stations” of the network to handle the message as it passes through the network to the destination.
[0006] A computer network is a collection of nodes (terminals or stations) that are interconnected by links (a connection between two nodes). Each node has a unique network address. Some nodes are directly connected to one another (neighbors) while others are connected through intermediate nodes. The nodes use the message routing information to route the source's message through the links and nodes from the sender node to the destination node. Each transfer of the message from one node to another is a hop.
[0007] As used herein a ‘network’ is an interactive system of computers that often includes peripherals, terminals, and databases that are connected by communications lines. Such communication lines may be wired, fiber optic, wireless, microwave, line of sight, repeaters or other communication paths. The term ‘node’ is used herein expansively. A node is a communication connection point, a communication end point, or a communication distribution point. It is an active entity capable of sending, receiving, or forwarding information over a communications channel. A physical node may be a computer, a terminal or a peripheral. A virtual node may exist as a code construct. While different networks may use different types of nodes the term node should be understood as any entity that receives and transmits messages. By ‘dynamic’ it is meant an interactive network or process is characterized by change and adaptation. A dynamic network adapts to changes and to inputs to and from itself as required to complete its tasks. For example, a new node may join a dynamic network. Required processes such as node addresses are kept and distributed as needed. Nodes can leave, and other networks may be merged. All the while the network still services its clients.
[0008] A small ‘fixed’ computer network with stable members can relatively easily determine the correct or best path for passing messages between any two nodes. But as the network gets larger the number of ‘correct’ paths from one node to the others gets very large. There are numerous methods of selecting ‘correct’ paths. However, no matter the method it is beneficial to reduce the routing information signal handling requirements.
[0009] Greatly complicating the difficultly of choosing a correct path to transfer messages between a source node and a destination node are wireless ad hoc networks. A wireless ad hoc network is a wireless network that sets itself up external of a pre-existing infrastructure. Wireless ad hoc networks are decentralized in the sense that no controlling node manages the entire network. Each wireless ad hoc network node participates in routing by forwarding messages for other nodes dynamically based on network connectivity.
[0010] An ad hoc network should be understood broadly as an improvised, possibly impromptu, dynamically formed network. An ad hoc network forms as needed to service its clients. Then it grows, shrinks, moves, and dissipates as needed.
[0011] Traditional routing protocols for computer networks and wireless ad hoc networks in particular rely on network-wide dissemination of signaling packets that provide proactive updates to the state of links (which nodes are connected by links or the distances to destinations), or on-demand requests for routes to destinations. However, as the number of nodes, dynamic connectivity changes, and new traffic flows increase both approaches tend to incur excessive signaling overhead.
[0012] Making the problem of determining message paths even more difficult are mobile ad hoc networks (MANET). In a MANET a particular node may change its physical location, which changes the nearest nodes it can directly connect to, which changes “best” message paths, which makes keeping track of good message paths even more difficult. The signaling overhead required to track all nodes in a network and to determine how to pass messages from any particular source node to any particular destination node can be prohibitive.
[0013] In a prior art computer network a particular node might be a server having services to offer, a client in need of services, or a router for passing information. To properly use a service a node must be made aware of the availability of that service. For example, to send a message a sender node must be able to find the address of a destination node and a message path. The sender node must use a service that can supply that information, and for that the sender must know how to contact the service. Publishing that information requires service discovery. Considerable work has been performed regarding implementing service discovery in computer networks. Typically service-discovery is performed by operating on top of a routing infrastructure or as an augment of an existing routing protocol.
[0014] Interestingly, prior solutions for making routing more scalable do not integrate destination-based routing with an adaptive publish-subscribe mechanism in a way that reduces the signaling required for both routing and service discovery.
[0015] Prior routing protocols in computer networks and MANETs assumed that the mappings of destination names to either addresses or routes were independent of actual routing. Various routing approaches were used, including hierarchical, limiting the dissemination of control messages, distributed hash tables (DHT), Bloom filters, virtual or geographical coordinates, or sets of dominating nodes to reduce the size of routing tables or the amount of route signaling.
[0016] Hierarchical routing schemes organize nodes into clusters. Some hierarchical routing schemes reduce signaling overhead by limiting the propagation of control messages based on their distance from an originating node. One problem with hierarchical routing schemes in a MANET is that the affiliation of nodes to specific clusters is easily broken when a node moves. Re-establishing affiliations incurs considerable signaling overhead. Unless re-established, incorrect routing can result in signaling decays based on distances to specific links
[0017] Distributed hash tables (DHT)-based schemes are attractive because a distributed hash table grows only logarithmically as the number of destinations grows. However, typical distributed hash table schemes define a virtual topology, which requires substantial signaling overhead to maintain the various links of virtual topologies that are defined in large MANET networks.
[0018] Automatic Incremental Routing (AIR) avoids virtual topologies by using variable-length prefix labels instead of addresses. Another approach is using hashing node identifiers of destinations in Bloom filters, which are then used in routing updates. Unfortunately, such schemes suffer from “false positives” that incur considerable signaling overhead.
[0019] Other routing schemes for MANET rely on geographical coordinates for routing. Unfortunately such protocols require ubiquitous GPS services yet still incur routing signal overhead when discovering the geo-locations of destinations node. Some other routing schemes use virtual coordinates consisting of the distances between nodes and reference nodes. The main limitation of this type of routing scheme is that the virtual coordinates of multiple nodes may be assigned the same virtual coordinates. This is because there is simply no inherent uniqueness to a specific vector of distances to beacons. The result is either possible incorrect routing or the use of additional signaling (typically flooding) to resolve false positives.
[0020] There are also many proposals in the prior art to reduce the number of relays needed to forward signaling messages for a given number of destinations. The best known example uses multipoint relays, for example, P. Jacquet, P. Muhlethaler, T. Clausen, A. Laouiti, A. Qayyum, and L. Viennot, “Optimized Link State Routing Protocol for Ad Hoc Networks,” IEEE INMIC 2001, pages 62-68, 2001. However, such proposals require the establishment and maintenance of “connected dominating sets,” i.e., the nodes selected to forward signaling messages must form a connected sub-graph. This usually requires a large subset of nodes, especially in dynamic topologies.
[0021] There has also been work performed on resource and service discovery in ad hoc networks. Interestingly, such work either assumes that names are mapped to addresses and that routing to those addresses is independent of or augmented by existing routing protocols of service discovery functionality.
[0022] In addition to the classic routing schemes discussed above, ad hoc networks can also simply use flooding for forwarding data. A sender sends a message to its neighbors, which then pass that message on to its other neighbors, and so on. This approach involves very large signaling overhead, especially as the wireless ad hoc network grows.
[0023] In view of the foregoing a new approach to routing in computer networks based on publish-subscribe mechanisms would be beneficial. Even more beneficial would be an adaptive protocol for routing in wireless ad hoc networks. In particular, an adaptive protocol that uses distance vectors for routing in computer networks and that integrates a sub-set of nodes to serve as controllers that maintain routes to nearby destination nodes, maintains routes to all known controllers using distance vectors, and uses publish-subscribe mechanisms in which destinations inform controllers of routes to them and in which sources obtain routes to destinations would be useful.
BRIEF SUMMARY OF THE INVENTION
[0024] The principles of the present invention provide for a novel approach to routing in computer networks, and MANETs in particular. The approach uses publish-subscribe mechanisms in an adaptive distance-vector routing protocol. In particular, the new approach uses distance-vector protocols for routing and integrates a sub-set of nodes to serve as controllers that maintain routes to nearby destination nodes, maintains routes to all known controllers using distance vectors, and uses publish-subscribe mechanisms in which destinations inform controllers of routes to them and in which sources obtain routes to destinations.
[0025] The principles of the present invention are incorporated in a network that implements scalable integrated destination-based routing using adaptive publish-subscribe mechanisms. First a subset of all nodes is selected to act as controllers that maintain routes to nearby destinations. The routes to all known controllers are then maintained using distance vectors. Publish-subscribe mechanisms are then implemented in which destination nodes inform controllers of routes to them and from which sources obtain routes to destinations. Beneficially the adaptive publish-subscribe mechanisms support routing to specific destination nodes as well as copies of content that can be replicated anywhere in the network.
[0026] The principles of the present invention further provide for a method routing that establishes a wireless network comprised of a plurality of nodes, with each node having a unique node identifier (such as an address). Then, dynamically selecting a subset of those nodes to serve as controllers, thereby dividing the nodes into a plurality of controller nodes and a plurality of destination nodes. Furthermore, that method includes maintaining routes to nearby destination nodes of each controller node, thereby forming local controllers, maintaining routes to all controllers in each controller based on distance vectors, and using publish-subscribe mechanisms in which destinations inform local controllers of routes to them and sources obtain routes to local controllers of destination nodes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The advantages and features of the present invention will become better understood with reference to the following detailed description and claims when taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
[0028] FIG. 1 is a topological view of a distributed network having links and a variety of nodes for implementing a method that is in accord with the principles of the present invention;
[0029] FIG. 2 presents pseudo code for adding controllers to the topology shown in FIG. 1 ;
[0030] FIG. 3 presents pseudo code for deleting controllers from the topology shown in FIG. 1 ;
[0031] FIG. 4 presents pseudo code for Update Controller Rules used in the topology shown in FIG. 1 ; and
[0032] FIG. 5 presents pseudo code for the overall functional steps of APDV.
DETAILED DESCRIPTION OF THE INVENTION
[0033] The presently disclosed subject matter now will be described more fully hereinafter with reference to the accompanying figures in which one embodiment is shown. However, it should be understood that this invention may take different forms and thus the invention should not be construed as being limited to the specific embodiment set forth herein.
[0034] All documents and references referred to in this disclosure are hereby incorporated by reference for all purposes. Additionally, in the figures like numbers refer to like elements throughout. The terms “a” and “an” as used herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
[0035] The present invention is described herein with reference to FIGS. 1 to 6 . Specifically, the present invention an Adaptive Publish-Subscribe Distance Vector (APDV) approach to maintaining a communication network that is or that includes a network or sub-network. APDV assumes that each network node is assigned a network-wide unique node identifier. APDV can take advantage of the broadcast nature of radio links by having each network node broadcast control messages to all neighbors once, rather than transmitting a separate control message to each neighboring node.
[0036] In APDV a subset of nodes are dynamically selected to serve as controllers. Once selected a controller acts as a directory server for other nodes by maintaining routes to nearby destinations that are denoted by node identifiers. This dynamic selection is based on a distributed algorithm that selects controllers to ensure that each non-controller destination node is within a maximum distance r from a minimum number k of local controllers. As a side effect a controller node informs each destination node about routes to its one-hop and two-hop neighbors.
[0037] FIG. 1 illustrates a proto-typical computer network with APDV. FIG. 1 is useful for illustrating and explaining the basic operation of APDV. In FIG. 1 each non-controller node has at least one local controller within two hops. The local controllers are nodes a, k, m, x and r. As is described subsequently those nodes are dynamically elected to be the local controllers.
[0038] In APDV all nodes maintain routes to all controllers using a loop-free distance-vector routing algorithm. For simplicity of explanation it will be assumed that a node maintains a single route to each controller. However, in practice APDV can be readily extended to use multiple loop-free paths. Each non-controller node contacts each of its local controllers to publish its presence. That is accomplished by a non-controller node, for example non-controller node d sending a publish message to each of its local controllers with the mapping (d, {l 1 d . . . l k d }), where l l d (1≦i≦k) is a local controller for the non-controller node d. Each local controller l i d of the non-controller node d and each relay node (a node that passes information between other nodes) between the non-controller node d and a local controller that receives the publish request stores a tuple stating the address of the non-controller node d, the next hop to non-controller node d, and the address of the local controllers {l 1 d , . . . l k d }.
[0039] In addition, the non-controller node d uses a common hash function to select an anchor controller a d , which is a selected controller for storing the mapping (d, {l 1 d , . . . l k d }). That mapping is the addresses of all of the local controllers of non-controller node d. That mapping is sent to the anchor controller a d . The anchor controller a d and the relay nodes between d and a d cache the mapping information. In FIG. 1 , node d has published its presence with its local controller (node r) and its anchor controller (node a d ).
[0040] The foregoing produces the important result that each local controller node r has a route to non-controller node d; the relay nodes between each local controller node r and non-controller node d have the path from local controller node r to non-controller node d; the anchor controller a d has a route to each local controller node r; and the relay nodes between the anchor controller a d and each local controller node r have the path between them.
[0041] A source node requiring a route to a non-controller node d uses the same common hash function on the identifier of node d to find the anchor controller for d, a d . Thus any source node can send a subscription request to anchor controller a d by providing d and (s, {l 1 s , . . . l k s }), where l 1 s (1≦i≦k) is a local controller for node s. The controller a d responds with the mapping (d, {l 1 d , . . . l k d }) and sends that response towards the nearest local controller for source s selected from the set {l 1 s , . . . , l k s }. The answer is redirected to source s by either the selected controller l j s or the first relay node along the route from a d to controller k with a route to s.
[0042] Node s can then send data packets to destination d by sending them towards the nearest controller in the set {l 1 d , . . . l k d }. Those packets will be redirected to d after either reaching the selected controller in {l 1 d , . . . , l k d } or a node along the route from s to the selected controller with an active route to d. In FIG. 1 , node s subscribes to node d by contacting anchor a d , which maintains the mapping (d, r) and returns it to node s by sending its response towards node k, which is the local controller of node s. Node a d also caches the mapping (s, k). Node s then sends data packets to d by sending them towards controller r; however, node y is in the route from s to r and also has a route to d, and forwards the data packets directly to d.
[0043] A proper implementation of APDV requires appropriate methods to select controllers, to maintain the routes to the controllers, and then publishing and subscribing to destinations using the controllers. Furthermore, the information maintained at each node must allow that node to select and route to controllers, to route to local destinations, and to learn the local controllers associated with distant destinations on demand.
[0044] To achieve the foregoing a non-controller node i maintains a controller table (CT i ) that states information about all controllers elected in the network (the election process is described subsequently). The non-controller node i also maintains a neighbor controller table (NCT i ) stating information reported by each neighbor of non-controller node i regarding all controllers elected in the network; a neighbor table (NT i ) stating information about all one-hop and two-hop neighbors of non-controller node i; a neighbor local routing table (NLRT i ) stating routing information reported by each neighbor regarding all destinations within two hops and some destinations within r hops; a local routing table (LRT i ) stating routing information about all destinations within two hops and some destinations within r hops; a neighbor routing table (NRT i ) stating information reported by each neighbor regarding distant destinations; and a routing table (RT i ) stating information about distant destinations.
[0045] APDV employs a soft-state to operate efficiently. -A node transmits its HELLOs periodically every 3 seconds. A HELLO includes some or all the updates made to its node tables. A node stores all the information from the HELLOs it receives from its neighbors, and also caches information it receives in subscription or publication requests from neighbors. Entries in RT i and NRT i are populated by the publish-subscribe signaling described subsequently. NT i , CT i , NCT i , LCL i , NLRT i , and LRT i are updated by the exchange of HELLOs among one-hop neighbors. In a network with point-to-point links, a node transmits a HELLO over each of the links it shares with its neighbor nodes. In a network with broadcast links (e.g., a wireless network based on broadcast links) a node transmits a HELLO once and addresses it to all its neighbors.
[0046] For each controller c selected in the network, CT i specifies: the identifier of node c (nid i c ); the distance from i to c (d i c ); the successors (next hops) from i to c (s i c ); and a sequence number (sn i c ) used to avoid routing loops. N CT i stores the controller tables reported by each neighbor of node i. The entry for controller c reported by neighbor j and stored in NCT i is denoted by {nid i cj , d i cj , sn i cj }.
[0047] For each neighbor j of node i, NT i specifies: the identifier of the node (nid i j ); a sequence number (sn i j ) created by j and used to determine that the entry is the most recent from node J; a controller status flag (cs i j ) stating whether or not node j is a controller; the controller counter (k i j ) stating the number of controllers within r hops of node j; and the local controller list (LCL i j ) consisting of the identifiers of all controllers within r hops of node j. An entry for neighbor v in NT j sent in a HELLO to node i is denoted by {nid j v, sn j v, cs j v, k j v, LCL j v}, and the same entry stored in NT i is denoted {nid i vj , sn i vj , cs i vj , k i vj , LCL i vj }.
[0048] An entry for destination j listed in LRT i j ); the identifier of the node (nid i j ); a sequence number (sn i j ) created by j used to avoid routing loops; the distance from i to j (d i j ); the successor in the route to j (si j i ); and the local controller list of node j (LCL i j ), which may be a link to NT i if the node is within two hops. An update made by neighbor j to LRT j communicated in a HELLO is denoted by {nid j v , sn j v , d j v , LCL j v }. The corresponding entry stored at node i in NLRT i is denoted by {nid i vj , sn i vj , d i vj , LCL i vj }. An entry for destination v listed in RT i simply specifies the identifier of the node (nid i v ) and the list of local controllers for node v (LCL i v ), because node i maintains the routes to all controllers in CT i .
[0049] Node i includes its own information in NT i , i.e., it stores an entry corresponding to nid i j , uses the information in its HELLOs. A HELLO from node i contains: nid i i , sn i i , cs i i , k i i , and updates to NT i , CT i and LRT i . An update to NT i regarding neighbor j consists of the tuple {nid i j , sn i j , cs i j , k i j , LCL i j }. An update to CT i regarding controller c consists of the tuple {nid i v , sn i v , d i v , LCL i v }.
[0050] With the foregoing information stored and exchanged within the various nodes a distributed selection of controllers is required. In APDV selecting the controllers amounts to selecting a dominating set C of nodes in the network to serve as controllers. Every node u that is not a member of C (called a simple node) is at a distance smaller than or equal to r hops from at least k nodes in C (called controllers). A node u is said to be (k, r) dominated (or covered) if there are at least k nodes in C within r hops from u. There is a large body of work on dominating sets in graphs. Reference for example T. Haynes, S. Hedetniemi, and P. Slater “Fundamentals of Domination in Graphs,” Marcel Dekker, 1998. Many other distributed algorithms exist to approximate minimum connected dominating sets MCDS with constraints.
[0051] However, the controller selection scheme used in APDV is simply aimed at obtaining a set of controllers that cover all nodes but it need not be a MCDS, and maintaining routes to all selected controllers. The APDV method is based on HELLO messages exchanged among one-hop neighbors. To keep the selection algorithm and signaling simple, only distances to controllers and node identifiers are used as the basis for the selection of controllers.
[0052] In ADPV controllers self-select themselves to become controllers or to stop being controllers. A given node i determines whether to add or delete its own entry in CT i , respectively, according to the Controller Addition Rules (CAR) presented in FIG. 2 and the Controller Deletion Rules (CDR) presented in FIG. 3 .
[0053] Node i is initialized with CT i =φ and NT i =φ, and waits for a few seconds to start receiving HELLOs from nearby nodes. Hence, according to the CAR, node i self selects itself as a controller when it is first initialized, unless node i has received HELLOs from neighbors that prompt it not to include itself as a controller based on the CDR (see below). Node i updates an entry for j≠i ∈ CT i according to the rules shown in FIG. 2 . Those rules ensure that no loops are formed for routes to controllers. Once node i has updated NT i and CT i by processing HELLOs received from neighbors, it computes its local controller list (LCL i ) from CT i , such that v ∈ LCL i if div≦r, and sets k i i |LCL i ≡ 1 .
[0054] The local controller list (LCL) at each node, and each new state per node is determined by the reception of HELLOs from all neighbors, followed by the addition or deletion of controllers in the LCL resulting from applying CAR and CDR, thereby deleting controllers that are farther than 2 hops away, or deleting a controller after the successor to that controller sends an update with a deletion of the controller.
[0055] Following the CAR each new node selects itself as a controller after initialization and sends a HELLO. Nodes do not wait for HELLOs to arrive. After receiving a HELLO from each neighbor, a node may add new controllers reported in the HELLOs. However, it also may delete itself from being a controller based on the CDR.
[0056] For simplicity of explanation it is assumed that each node maintains a single route to each controller selected in the network using the updates to controller tables included in HELLOs.
[0057] APDV uses a distance-vector routing approach to maintaining routes to controllers. To guarantee loop-free routes, APDV uses sequence numbers that restrict the selection of next hops towards a given controller by any node, such that only those neighbors with shorter distances to the controller or with a more recent sequence number reported by the controller can be considered as successors. An important aspect of APDV is that entries for controllers can be deleted on purpose as a result of the CDR, rather than only as rare occurrences due to failures or network partitions. Together with the transmission of periodic HELLOs, the Reset Controller Rule (RCR) and the Update Controller Rule (UCR) discussed below address this functionality.
[0058] The process of routing to controller begins with the set N i ; the set of one-hop neighbors of node i. Node i updates CT i based on HELLOs from neighbor j ∈ N i or the loss of connectivity to neighbor j. If node i loses connectivity to node j, the entries in CT i are deleted. Once node i is selected as a controller, it is the only node that can change the sequence number for its own entry in controller-table updates sent in HELLOs.
[0059] When a given node i decides to delete itself as a controller based on the CDR its entry must be deleted as a controller in the rest of the network. To accomplish this node i uses a Reset Controller Rule (RCR) (provided below) to set its self-entry with an infinite distance and an up-to-date sequence number for a finite period of time T before deleting its self-entry from CT i . This ensures that the rest of the nodes delete i from their controller tables.
[0060] If node i receives a HELLO from j or experiences a link failure that makes it update CT i for entry c≠i: {nid i cj , d i cj , sn i cj }, node i updates its entry for c in CT i according to Update Controller Rules (UCR), see FIG. 4 a , which forces node i to propagate a reset update or to select a successor to controller c that is either closer to c or has reported a more recent sequence number from c.
[0061] The RCR is:
RCR (Reset Controller Rule):
[0062] If node i must delete itself from CT i using CDR then
set d i i =∞; sn i i =sn i i +1; reset-timer i =T
[0063] Nodes learn about routes to controllers and to one- and two-hop neighbors. However, exchanging HELLOs does not provide routes to destinations many hops away. To enable sources to obtain routes to arbitrary destinations without incurring network-wide dissemination of signaling messages, APDV uses a publish-subscribe mechanism for name-to-route resolution.
[0064] The basis of the publish-subscribe mechanism used in APDV is the use of consistent hashing. This is similar to recent proposals for distributed name resolution in MANETs that also use consistent hashing to map the names of destinations to one of several predefined directory sites storing the name-to-address mapping for destinations. Key differences exist however between the APDV approach and the prior art. Those differences include: (a) the directories (i.e., controllers) are selected dynamically; (b) a node publishes its presence with multiple controllers; and (c) name resolution is integrated with the selection of and routing to controllers, rather than running on top of routing. Hence, in APDV, controllers maintain name-to-route mappings rather than storing name-to-address mappings and then using an underlying routing protocol to obtain the routes for known addresses.
[0065] For ease of explanation and understanding the APDV publish-subscribe mechanism described herein assumes that node identifiers constitute the names for which routes must be found. However, the same APDV publish-subscribe mechanism can be used to support information-centric networking, such that nodes publish and subscribe to names of destinations, content or services, rather than just node identifiers.
[0066] Publishing in APDV consists of having a local controller know the route to a given destination or having an anchor controller know the mapping from a node identifier to a list of local controllers. Subscribing in APDV consists of a node requesting a way to reach a named destination through an anchor controller.
[0067] In APDV, node i publishes itself with the k controllers listed in LCL i , and with one or more anchor controllers. The local controllers in LCL i are within r hops of node i and serve as the “landmarks” for other nodes to submit data to node i, given that nodes far away from node i do not have routes to node i. Accordingly, a local controller for node i must maintain a route to node i, and it also maintains the mapping (i, LCL i ), so that it can find alternate ways to reach node i if its route to i fails. The anchor controllers are needed for nodes far away from destinations to obtain the mappings between the identifiers of those destinations and their local controllers.
[0068] For simplicity, the assumption is that a single anchor controller is used for any one node. The anchor controller for node i (denoted by a i ) is obtained by using a network-wide consistent hash function that maps the identifier of node i into the identifier of one of the controllers selected in the network. Controller a i must store the mapping (i, LCL i ), so that it can provide any node v far away from node i the list LCL i , with which node v can send data packets towards the local controller in LCL i that is nearest to node v according to its controller table CT v .
[0069] The forwarding of a publication request from a node to its local controllers is done by the exchange of HELLOs. Given that nodes maintain loop-free routes to all controllers, publication requests directed to local controllers of nodes are forwarded over the reverse loop-free routes already established from local controllers to nodes. The routes maintained by local controllers to nearby nodes are refreshed periodically; each node creates a new publication request by increasing the sequence number included in the LRT self-entry of its own HELLO. If node i receives a HELLO from neighbor j with a publication request originated by node v, which consists of update to LRT j for destination v({nid j v , sn j v , d j v , LCL j v }) then node I forwards the request (i.e., it includes the LRT i entry {nid i v , sn i v , d i v , LDL i x } in its own HELLO) if it is the successor for node j to any of the controllers listed in LCL j v . Once a local controller c receives an entry for destination v and c ∈ LCL v , then c publishes (i.e. stores) the entry {nid c v , sn c v , d c v , s c v , LCL c v }, where s c v is the neighbor from which it received the publication request. Controller c may also forward it if it is the successor to another controller in LCL v for the neighbor from which it received the publication request.
[0070] The submission of a publication request from node i to its anchor controller a i is done by node i using the network-wide consistent hash function on the set of identifiers in CT i to obtain hash(i)=a i , where a j ∈ CT i . After that, node i sends a publication request to its successor towards its anchor controller a i with the tuple {nid i i , sn i i , d i i , LCL i i }. Each node v in the route from node i to controller a i forwards the publication request towards a i and caches the tuple {nid v i sn v i , d v i , s v i , LCL v i }. Once controller a i receives the request, it stores the tuple {nid a i i , sn a i i , d a i i , s a i i , LCL a i i }. Hence, each node processing a publication request learns the route to the node issuing the request, and the anchor controller is able to obtain the mapping needed to redirect nodes sending subscription requests to the local controllers of node i.
[0071] The forwarding of subscription requests is handled in much the same way described above for the case of publication requests. When node o has data for destination j ∉ CT o , it computes hash (j)=a j , where a j ∈ CT o and sends its subscription request towards a j . The subscription request from node o regarding destination j states the identifier of node j, its anchor controller a j , and LCL o . When a j receives o's request, it responds with the tuple {ni a j j , sn a j j LCL a j j } and sends the response to the nearest controller it finds in LCL o .
[0072] Node o stores the tuple {nid o j , sn o j , LCL o j } in RT o upon receiving the reply to its subscription. Data packets from o are then sent towards the controllers in LCL o j that are the closest to node o. A data packet must specify the sender, the destination, and the selected local controller of the destination. This can be done by encapsulating the header of the packet stating the origin and the destination with a header stating the origin and the selected local controller of the destination. Once the packet reaches a relay node y with an active route for the destination, the packet is forwarded directly to the destination itself, as long as the distance from node y to the destination is at most r hops.
[0073] In one embodiment of APDV, the functional steps required for its operation can be organized as illustrated in the pseudo-code listed in FIG. 5 . That pseudo-code can be implemented in a variety of ways as part of a routing protocol designed for wired networks or wireless networks.
[0074] It should also be understood that while the figures and the above description illustrate the present invention, they are exemplary only. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. Others who are skilled in the applicable arts will recognize numerous modifications and adaptations of the illustrated embodiments that remain within the principles of the present invention. Therefore, the present invention is to be limited only by the appended claims.
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A distance-vector based routing protocol that integrates with adaptive publish-subscribe mechanisms by establishing routes to well-known controllers using distance-vector signaling.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
MICROFICHE APPENDIX
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates to the field of energy. More specifically, the invention comprises a method and apparatus for modifying the structure of substances such as hydrocarbon fuels in order to convert low-value fuels into high-value fuels and other useful byproducts. The structural modification may also be employed to convert dangerous or undesirable substances into more desirable substances.
[0006] 2. Description of the Related Art
[0007] The present invention will most often be employed for the production of desirable combustion fuels, and the background will accordingly be discussed with respect to this field of application. Fuels used for energy production are most commonly used as a gas, a liquid, or a finely-particulated solid. Combustion processes for such materials are well-understood and may be well regulated with suitable equipment. Of course, long-chain hydrocarbon fuels are not normally found in this state. The most common fuels include hydrocarbon chains of varying lengths, with coal being a good example.
[0008] Fuels containing long-chain hydrocarbons must be significantly processed before they may be efficiently used. A common application is the processing of coal into a particulated fuel that is suitable for combustion in a large and stationary power plant. Long-chain hydrocarbon-containing solids are an abundant energy source, and it is desirable to use such fuels in areas beyond electric power plants. As an example, it is desirable to make such a fuel source available for motor vehicles. Unfortunately, the transport and handling of a particulated solid is impractical for use in vehicles.
[0009] Coal contains a substantial mass fraction of impurities and a substantial variation in the molecular chain length of the hydrocarbons it contains. These factors require the use of significant “scrubbing” technology (such as required to remove sulfur compounds and carbon dioxide from the exhaust products). The equipment required for scrubbing is complex and heavy, making it undesirable for a vehicle.
[0010] On the other hand, some hydrocarbons can be stored as a gas or liquid. Methane and propane are good examples of hydrocarbons which can be stored as either a gas or a liquid. Both these compounds have been established as suitable fuels for a motor vehicle. It is even possible to use such hydrocarbons as an energy source without combustion (such as via the use of a fuel cell).
[0011] Some shorter chain hydrocarbons may only be practically stored as a liquid (light oils), but even these are useful in the field of transportation. It is therefore desirable to provide an apparatus which can convert the long hydrocarbon chains found in low-value fuels to short hydrocarbon chains such as found in methane, propane, or light oils. Such a conversion has traditionally been performed by a “cracking” process (where the term “cracking” refers to breaking some of the carbon-carbon bonds in a long-chain hydrocarbon to form shorter chains). Traditional cracking requires the addition of a substantial amount of heat and produces many unwanted byproducts. Thus, it is desirable to achieve the end result of a traditional cracking process while reducing the amount of energy required and reducing the production of unwanted byproducts such as carbon dioxide. The present invention proposes such a device.
BRIEF SUMMARY OF THE INVENTION
[0012] The present invention comprises an apparatus and method for the manipulation of selected substances—such as long chain hydrocarbons—to generate more desirable substances having shorter chain lengths. The method also produces heat and electricity as desirable byproducts. Significantly, the chain length reduction is accomplished without an oxidation-reduction reaction such as found in combustion. Thus, no significant amounts of greenhouse gasses are produced.
[0013] A fuel stock with additives is prepared by scrubbing and sizing to produce a suitable particle size distribution and overall viscosity. The prepared fuel stock is then injected into a first stage of an accelerator chamber—where it is subjected to high energy electrical pulses or arc furnace. The preparation, injection, heating, acceleration, and recovery of the products are all performed in the absence of oxygen or other oxidizers (other than those which may be released by the fuel itself).
[0014] The accelerator chamber is operated at high pressure. The fuel injector feeds the fuel into the first stage of the accelerator chamber without allowing any backflow and without allowing oxygen contamination. In the first stage of the accelerator chamber, the fuel is subjected to variable frequency electrical pulses (an arc furnace). The arc furnace converts the fuel into a gaseous form.
[0015] The gaseous fuel leaves the first stage and accelerates through the accelerator chamber. It is next subjected to microwave (or higher frequency) electromagnetic energy. The microwave energy breaks the long chain hydrocarbon bonds, liberating the bond energy. This liberated energy heats and accelerates the gaseous fuel stream to a velocity sufficient to form a plasma.
[0016] The fuel stream then enters a constricting throat area which will further accelerate the stream. At least one stationary target is provided in the throat area. The rapidly flowing plasma reacts with this target. At this point the plasma contains sufficient hydrogen ions and free electrons to be conductive. Just prior to reacting with the target, the fuel stream is aligned or polarized by passing additional microwave energy through the plasma. An electron removal circuit is connected to the target, or possibly to conductive probes in the vicinity of the target. This circuit removes a significant portion of the free electrons found in the flowing plasma.
[0017] Downstream from the target, a magnetohydrodynamic generator (MHG) is preferably employed to harvest more of the remaining free electrons. Prior to the flow entering the MHG, an additional microwave generator may be used to align the plasma with the poles of the MHG.
[0018] The electrons removed from the fast moving plasma may be used to provide power to electrical devices. Waste heat may also be harvested from the accelerator chamber, since the chamber must be cooled to maintain continuous operation. The heat removed may be used to drive a turbine or other waste heat recovery device.
[0019] Exiting the target and the magnetohydrodynamic generator, the contents will be decelerated and cooled (still in the absence of oxygen). The removal of the free electrons while the contents are in the plasma state modifies the reformation of longer hydrocarbon chains upon cooling. Thus, the cooled and decelerated fuel stream will contain modified substances such as shorter hydrocarbon chains than the substance or substances that entered the process. The cooled and decelerated gas preferably undergoes a separation and refining process to extract desired solids, liquids, and gasses.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0020] FIG. 1 is a schematic view, showing the present inventive process.
[0021] FIG. 2 is an elevation view, showing the bending path of a plasma flow into an electron-harvesting target.
[0022] FIG. 3 is an elevation view, showing the accelerator chamber and the components surrounding it.
[0023] FIG. 4 is a detailed elevation view, showing the target.
[0000]
REFERENCE NUMERALS IN THE DRAWINGS
10
chain reduction process
12
fuel stock and additives
14
fuel preparation
16
fuel injector
18
accelerator chamber
20
target system
22
electron removal circuit
24
heat and velocity reduction
26
refinery
28
plasma flow
30
arc furnace
34
microwave generator
36
throat
38
microwave generator
40
MHG
DETAILED DESCRIPTION OF THE INVENTION
[0024] FIG. 1 schematically depicts the inventive process in its entirety (chain reduction process 10 ). Fuel stock and additives 12 are prepared (in step 14 ) by physically manipulating the stock to the correct size (in the case of a solid or viscosity (in the case of a liquid). Additives are preferably blended into the stock to alter the process or the end-products. It is important to reduce the amount of oxidizers in the fuel stock in order to minimize combustion phenomena. Thus, a scrubbing process may be employed to eliminate unwanted constituents (fuel preparation step 14 ).
[0025] Once the fuel is suitably prepared it is fed into fuel injector 16 . The injector must deliver the fuel mixture into accelerator chamber 18 under pressure (generally a pressure greater than that within the accelerator chamber). However, the injector preferably does not allow unwanted oxidizers (typically air) to enter the accelerator chamber, nor does it allow any backflow. In order to accomplish this objective, it may be necessary to employ a suitable gas—such, as argon—as a shield during the injection process.
[0026] Numerous approaches are available to achieve the desired injection. One approach would be to use a mechanical feeding mechanism (such as a screw auger or positive displacement pump) to force the fuel into the pressurized accelerator chamber. Another approach would be to simply load all the required and prepared fuel into a separate pressurized chamber which is then pressurized to a level greater than the accelerator chamber itself in order to produce the desired flow.
[0027] The accelerator chamber 18 includes several stages. FIG. 3 shows accelerator chamber 18 in more detail. Immediately after injection, the fuel mixture is subjected to arc furnace 30 . This rapidly heats the mixture and converts it into a gaseous form. Significantly, the heating and acceleration is done without the use of combustion phenomena. The arc furnace may include a high-energy pulsed input of variable frequency. The frequency or frequencies are preferably selected to match the resonance frequency of the fuel constituents as closely as possible. For complex substances like coal, no single natural frequency will exist. In such a case one or more approximations are used to produce the desired resonance. The resonance process assists in breaking the physical and chemical bonds of the fuel stock. The chemical bond energy is liberated as heat, which causes the mixture to expand and accelerate down the length of the chamber.
[0028] The fuel mixture accelerates to the right in the orientation shown in FIG. 3 . Once the mixture leaves the arc furnace area it is subjected to microwave (or higher frequency) energy for the purpose of further breaking the carbon-carbon bonds within the hydrocarbon chains. One or more microwave generators 34 are used for this purpose. The microwave energy liberates bonding energy and the resulting heat is used to further accelerate the mixture down the accelerator chamber. This process is not to be confused with the process of using microwave energy to break long chain oils into shorter hydrocarbons (such as lighter oils). The inventor is employing the liberation of the bond energy primarily for heating and resulting acceleration down the accelerator chamber.
[0029] Sufficient energy is added (or liberated via bond breaking) to heat and accelerate the fuel mixture until a significant percentage can transition to a plasma state. As the fuel stream accelerates toward the right end of accelerator chamber 18 it is subjected to additional microwave energy to accelerate the fuel stream. Microwave generators 34 provide this energy.
[0030] Throat 36 may be provided to constrict and accelerate the flow further. One or more target systems 20 are provided in a region referred to as the electron removal area. If a constriction is provided—such as throat 36 —the constriction is preferably located just before the flow enters the electron removal area.
[0031] The inventor has discovered that a flowing plasma under certain conditions may be highly conductive and easily oriented in the presence of a microwave source. The invention seeks to take advantage of this phenomenon. Additional microwave generators 38 are provided to polarize the plasma according to the orientation of the target systems.
[0032] Returning to FIG. 1 , the reader will observe that at least one of the target systems 20 is connected to electron removal circuit 22 in the electron removal area. The alignment of the plasma will be “tuned” to maximize the amount of free electrons which may be removed by the electron removal circuit connected to target 20 .
[0033] The target systems are shown in a very simplified depiction. In reality, it is more appropriate to speak of a fast moving plasma as “interacting with” a target rather than striking it. Once the flow exceeds the local speed of sound, normal and oblique shock waves will form ahead of the target. The system for removing free electrons may need to utilize probes placed at suitable locations within the flow (adjacent to the target) rather than electrically connecting the target itself.
[0034] The plasma downstream of the target will have a reduced amount of free electrons. It is also possible to remove even more electrons by encircling this part of the chamber with a MHG (magnetohydrodynamic generator). FIG. 3 shows the placement of MHG 40 just downstream of the two target systems. In this embodiment, a second microwave generator 38 is placed between the target systems 20 and the MHG 40 .
[0035] FIG. 1 shows the continuation of the process downstream of the target area. Leaving the area of free electron removal, the mixture passes into heat and velocity reduction zone 24 . This area may encompass many conventional devices intended to cool and depressurize the mixture—such as a high-ratio expansion nozzle with an encompassing cooling jacket. Other devices include expansion turbines, heat exchangers, and the like.
[0036] When a fuel decelerates and cools from a plasma state it normally reforms most of the original constituents. However, under the inventive process, the removal of a large portion of the available bonding electrons prevents the reformation of the original constituents. As an example, the free hydrogen ions will consume many of the remaining free electrons to reform as diatomic hydrogen gas. Likewise, the relative lack of free electrons will cause the alteration of chain lengths in the hydrocarbon chains. Further, the resulting products can be somewhat “adjusted” by the amount of free electrons removed during the plasma phase. In other words, the system might be operated to remove fewer electrons than the target systems and MHG are capable of removing.
[0037] Heat and velocity reduction 24 reduces the temperature and velocity to a desired state before the mixture enters refinery 26 . The refinery separates the constituents into solids, liquids, and gasses (or in some instances some subset of these three possibilities). The refinery components are conventional and include such things as filters, sedimenters, etc.
[0038] FIG. 2 shows the area of target 20 in greater detail. In FIG. 2(A) plasma flow 28 has been aligned via the addition of the microwave field. In FIG. 2(B) the electron removal circuit has been activated. This causes the streams of plasma flow to bend in toward the target and facilitates the removal of free electrons. Microwave energy in the range of X Band or K Band radar is preferred for this part of the process, but other wavelengths may be used as well.
[0039] FIG. 4 shows the vicinity of the target system or systems 20 . The constriction in the chamber just before the electron removal area may assist in free electron removal. MHG 40 may be added downstream of the target in order to remove additional free electrons. As explained previously, a second microwave generator 38 may be added between the target systems and the MHG.
[0040] The fuel transitions from a plasma state to a non-plasma state (“non-plasma state” meaning one or more of a solid, liquid, or gaseous phase of matter) after passing out of the electron removal area.
[0041] It may be conventional to think of the acceleration chamber, throat, and other structures as being radially symmetric (such as would be the case for a rocket nozzle). However, this need not be the case for every embodiment. A rectangular cross section analogous to the geometry of a wave guide used in microwave antennas may be used. Another analogous geometry is that used for supersonic combustion ramjets. These resemble wave guides, but often allow for a portion of the geometry to be selectively altered. This selective alteration allows the flow characteristics to be changed, which may provide advantages.
[0042] The reader will thereby appreciate that the inventive process alters a hydrocarbon-containing fuel via the use of an intermediate plasma state and the removal of free electrons. Significantly, no combustion process is employed and the production of unwanted greenhouse gasses is thereby eliminated or at least greatly reduced.
[0043] The preceding description contains significant detail regarding the novel aspects of the present invention. It is should not be construed, however, as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. For example, although the use of a constricting throat area has been illustrated, this need not be present in every embodiment of the invention. Thus, the scope of the invention should be fixed by the claims presented, rather than by the examples given.
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An apparatus and method for the manipulation of selected substances—such as long chain hydrocarbons—in order to create resulting substances having shorter chain lengths. The method also produces heat and electricity as byproducts. Significantly, the chain length reduction is accomplished without an oxidation-reduction reaction such as found in combustion. Thus, no significant amount of greenhouse gasses are produced. A hydrocarbon-containing fuel is converted into a plasma within an accelerator chamber. The plasma interacts with one or more target systems which intrude upon the flow. Electron removal devices are used to remove free electrons from the plasma, after which the fuel is decelerated and cooled. The cooled fuel contains altered molecules due to the removal of the free electrons.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to data processing systems. More specifically, the present invention relates to a computer implemented method, computer program product, and a system for computing path oriented statistics and integrating downstream performance and resource usage statistics into load balancing weights.
2. Description of the Related Art
In datacenter environments, many copies of servicing components, such as application servers, http servers, and so forth, are used to handle increasingly large loads. In these cases, incoming service requests typically go to a load balancer to be directed to the appropriate servicing component. Modern advances in technology, like the Server/Application State Protocol (SASP), have allowed load balancers to receive recommendations, in the form of numerical weights, as to the best distribution of the incoming requests. Previous techniques for dynamically calculating these weights involve using application performance and usage statistics from the set of components that are one hop away from the load balancer. Components that are one hop away are the components that the load balancer sends the incoming connections to directly.
Many of today's applications require transactions to go through several components before the transactions may be completed. If complications arise in any of the downstream components, the most important statistical information for the weight computation may be the information from the downstream components where the complication is arising. A downstream component is a component touched by a transaction after the transaction touches the first component. Therefore, it would be advantageous to provide a way of computing applications or system statistics for the entire transaction path. These path-oriented statistics can then be used in any load balancing algorithm that uses application or system statistics for computing load balancing weights.
Patent application number US 2005-0120095 A1 entitled, “Apparatus and Method for Determining Load Balancing Weights Using Application Instance Statistical Information,” published Jun. 2, 2005 addresses a complimentary issue. The US 2005-0120095 A1 application describes a method for generating load balancing weights using application statistics. However, the method described in the US 2005-0120095 A1 application only computes the load balancing weight based on the statistics from a single application, regardless of the number of applications involved in a transaction or of the path the transaction follows. The US 2005-0120095 A1 application does not address the problem of calculating path-oriented statistics. However, path-oriented statistics may be used in a load balancing weight generation algorithm like that described in US 2005-0120095 A1 application.
SUMMARY OF THE INVENTION
Exemplary embodiments describe a computer implemented method, a computer program product and a data processing system for computing path oriented statistics. A transaction path is determined for each transaction in a plurality of transactions to be processed. The transaction paths that start at a same component are combined to form a combined transaction path. A statistic from all components in the combined transaction paths is monitored, wherein the statistic is a statistic that is to be transformed into a plurality of composite statistics. A composite statistic is calculated for each component at each hop. The composite statistics for each component of the combined transaction path is combined to form an overall composite statistic for the combined transaction path.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a pictorial representation of a network of data processing systems in which exemplary aspects may be implemented;
FIG. 2 is a block diagram of a data processing system in which exemplary aspects may be implemented;
FIG. 3 is an exemplary diagram of a non-branching distributed data processing environment in which exemplary aspects may be implemented;
FIG. 4 is an exemplary diagram of a branching distributed data processing environment with statistical values in which exemplary aspects may be implemented;
FIG. 5 is an exemplary diagram of a branching distributed data processing environment with statistical values and timings in which exemplary aspects may be implemented; and
FIG. 6 is a flowchart illustrating the operation of computing path oriented statistics in accordance with exemplary embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1-2 are provided as exemplary diagrams of data processing environments in which embodiments may be implemented. It should be appreciated that FIGS. 1-2 are only exemplary and are not intended to assert or imply any limitation with regard to the environments in which aspects or embodiments may be implemented. Many modifications to the depicted environments may be made without departing from the spirit and scope.
With reference now to the figures, FIG. 1 depicts a pictorial representation of a network of data processing systems in which aspects may be implemented. Network data processing system 100 is a network of computers in which exemplary embodiments may be implemented. Network data processing system 100 contains network 102 , which is the medium used to provide communications links between various devices and computers connected together within network data processing system 100 . Network 102 may include connections, such as wire, wireless communication links, or fiber optic cables.
In the depicted example, server 104 and server 106 connect to network 102 along with storage unit 108 . In addition, clients 110 , 112 , and 114 connect to network 102 . These clients 110 , 112 , and 114 may be, for example, personal computers or network computers. In the depicted example, server 104 provides data, such as boot files, operating system images, and applications to clients 110 , 112 , and 114 . Clients 110 , 112 , and 114 are clients to server 104 in this example. Network data processing system 100 may include additional servers, clients, and other devices not shown.
In the depicted example, network data processing system 100 is the Internet with network 102 representing a worldwide collection of networks and gateways that use the Transmission Control Protocol/Internet Protocol (TCP/IP) suite of protocols to communicate with one another. At the heart of the Internet is a backbone of high-speed data communication lines between major nodes or host computers, consisting of thousands of commercial, government, educational and other computer systems that route data and messages. Of course, network data processing system 100 also may be implemented as a number of different types of networks, such as for example, an intranet, a local area network (LAN), or a wide area network (WAN). FIG. 1 is intended as an example, and not as an architectural limitation for different embodiments.
With reference now to FIG. 2 , a block diagram of a data processing system is shown in which aspects may be implemented. Data processing system 200 is an example of a computer, such as server 104 or client 110 in FIG. 1 , in which computer usable code or instructions implementing the processes for embodiments may be located.
In the depicted example, data processing system 200 employs a hub architecture including north bridge and memory controller hub (NB/MCH) 202 and south bridge and input/output (I/O) controller hub (ICH) 204 . Processing unit 206 , main memory 208 , and graphics processor 210 are connected to north bridge and memory controller hub 202 . Graphics processor 210 may be connected to north bridge and memory controller hub 202 through an accelerated graphics port (AGP).
In the depicted example, local area network (LAN) adapter 212 connects to south bridge and I/O controller hub 204 . Audio adapter 216 , keyboard and mouse adapter 220 , modem 222 , read only memory (ROM) 224 , hard disk drive (HDD) 226 , CD-ROM drive 230 , universal serial bus (USB) ports and other communications ports 232 , and PCI/PCIe devices 234 connect to south bridge and I/O controller hub 204 through bus 238 and bus 240 . PCI/PCIe devices may include, for example, Ethernet adapters, add-in cards and PC cards for notebook computers. PCI uses a card bus controller, while PCIe does not. ROM 224 may be, for example, a flash binary input/output system (BIOS).
Hard disk drive 226 and CD-ROM drive 230 connect to south bridge and I/O controller hub 204 through bus 240 . Hard disk drive 226 and CD-ROM drive 230 may use, for example, an integrated drive electronics (IDE) or serial advanced technology attachment (SATA) interface. Super I/O (SIO) device 236 may be connected to south bridge and I/O controller hub 204 .
An operating system runs on processing unit 206 and coordinates and provides control of various components within data processing system 200 in FIG. 2 . As a client, the operating system may be a commercially available operating system such as Microsoft® Windows® XP (Microsoft and Windows are trademarks of Microsoft Corporation in the United States, other countries, or both). An object-oriented programming system, such as the Java™ programming system, may run in conjunction with the operating system and provides calls to the operating system from Java programs or applications executing on data processing system 200 (Java is a trademark of Sun Microsystems, Inc. in the United States, other countries, or both).
As a server, data processing system 200 may be, for example, an IBM eServer™ pSeries® computer system, running the Advanced Interactive Executive (AIX®) operating system or LINUX operating system (eServer, pSeries and AIX are trademarks of International Business Machines Corporation in the United States, other countries, or both while Linux is a trademark of Linus Torvalds in the United States, other countries, or both). Data processing system 200 may be a symmetric multiprocessor (SMP) system including a plurality of processors in processing unit 206 . Alternatively, a single processor system may be employed.
Instructions for the operating system, the object-oriented programming system, and applications or programs are located on storage devices, such as hard disk drive 226 , and may be loaded into main memory 208 for execution by processing unit 206 . The processes for embodiments are performed by processing unit 206 using computer usable program code, which may be located in a memory such as, for example, main memory 208 , read only memory 224 , or in one or more peripheral devices 226 and 230 .
Those of ordinary skill in the art will appreciate that the hardware in FIGS. 1-2 may vary depending on the implementation. Other internal hardware or peripheral devices, such as flash memory, equivalent non-volatile memory, or optical disk drives and the like, may be used in addition to or in place of the hardware depicted in FIGS. 1-2 . Also, the processes may be applied to a multiprocessor data processing system.
In some illustrative examples, data processing system 200 may be a personal digital assistant (PDA), which is configured with flash memory to provide non-volatile memory for storing operating system files and/or user-generated data.
A bus system may be comprised of one or more buses, such as bus 238 or bus 240 as shown in FIG. 2 . Of course the bus system may be implemented using any type of communications fabric or architecture that provides for a transfer of data between different components or devices attached to the fabric or architecture. A communications unit may include one or more devices used to transmit and receive data, such as modem 222 or network adapter 212 of FIG. 2 . A memory may be, for example, main memory 208 , read only memory 224 , or a cache such as found in north bridge and memory controller hub 202 in FIG. 2 . The depicted examples in FIGS. 1-2 and above-described examples are not meant to imply architectural limitations. For example, data processing system 200 also may be a tablet computer, laptop computer, or telephone device in addition to taking the form of a PDA.
Exemplary aspects provide a method for computing path oriented statistics that enable load balancing algorithms to transparently integrate downstream performance and resource usage statistics into load balancing weights.
In load balancing environments, the load balancer typically only knows about the set of components to which it directly sends the incoming connections. The connection may contain transactions that continue on to additional machines or components. For purposes of the present application, the different components through which transactions may travel before completion are referred to as “hops.” A numerical designation describes how far hops are from the load balancer. For example, hop1 is the first hop from the load balancer, hop2 is the second hop from the load balancer, and so forth. In load balancing environments where dynamic load balancing weights are used, the weights are to provide the load balancer with an indication of how many or what fraction of the incoming connections should be sent to a particular first hop component. When incorporating downstream performance and resource usage statistics into metrics for use in load balancing algorithms, the path transactions take must be examined to make sure the right portion of downstream statistics are attributed to the correct hop1 component. The path the transaction takes is referred to as the “application topology.” This type of path-oriented statistic is referred to as a “composite” statistic.
Application topologies can be provided statically by the administrator. Alternatively, the application topologies can be obtained dynamically using application instrumentation supported with a correlator, such as, for example, Application Response Measurement (ARM). The correlator is a set of bytes sent with the transaction to map the work done on one component to work for the same transaction done on another component. In a straight-forward single-path application topology, the correlation of downstream statistics is direct; all statistical effects seen in downstream components may be wholly attributed to their corresponding first component. For example, FIG. 3 illustrates three separate, isolated application transaction paths, paths 335 , 340 , and 345 . A transaction path is the path of components that the transaction flows through. For the top transaction path, path 335 , the downstream statistics from database 330 and application server 325 are combined with the statistics of the hop1 component, HTTP server 320 , to form the new statistic for hop1.
FIG. 3 is an exemplary diagram of a non-branching distributed data processing environment in which exemplary aspects may be implemented. FIG. 3 may be implemented as a network data processing system, such as network data processing system 100 in FIG. 1 . Incoming requests 310 , which are transactions, originate from request origins 305 and are sent to load balancer 315 . An example of a transaction could be a request for recent stock quotes, product prices, or news stories. Load balancer 315 then sends the requests to one of the transaction paths, path 335 , 340 , or 345 . Path 335 is comprised of components HTTP server 320 , Application server 325 and database 330 . HTTP Server 320 is hop1 for path 335 . Application server 325 is hop2 for path 335 . Database 330 is hop3 for path 335 . Path 340 is comprised of components HTTP server 350 , Application server 355 and database 360 . HTTP Server 350 is hop1 for path 340 . Application server 355 is hop2 for path 340 . Database 360 is hop3 for path 340 . Path 345 is comprised of components HTTP server 365 , Application server 370 and database 375 . HTTP Server 365 is hop1 for path 345 . Application server 370 is hop2 for path 345 . Database 375 is hop3 for path 345 .
If the load balancing environment has branching application topology paths, care must be taken to attribute the correct proportion of downstream statistics to the corresponding hop1 component. These composite statistics are best formed by combining portions of the composite statistics of downstream components that are proportional to the fraction of transactions sent to each of those components. When combining the data from the different hops, some hops may be treated differently to emphasize their importance. For this purpose, a hop weighting coefficient, W hopX , is used. Methods for calculating a correct value for this coefficient is discussed later in the application. An example of the calculation of a general composite statistic A from component x at hop N can be expressed as the following equation:
CompositeStat A ( x ) = W hopN × stat A ( x ) + ∑ y = firstHop ( N + 1 ) Node lastHop ( N + 1 ) Node [ TC x - y TotalTransOut ( x ) × CompositeStat A ( y ) ]
where:
W hopN =the weight given to hop N.
stat A (x)=the non-composite value of statistic A at component x.
Σ firstHop(N+1)Node lastHop(N+1)Node =a summation over the entire set of hop (N+1) components.
TC x−y =number of transactions flowing from component x to component y.
TotalTransOut(x)=total number of transactions flowing from component x.
From the above equation, it can be seen that one may start with the actual value of statistic A at component x, stat A (x), and add fractions of the composite statistic A of the directly connected downstream hops proportionate to the number of transactions component x sends to each particular component which may be expressed as:
∑ y = firstHop ( N + 1 ) Node lastHop ( N + 1 ) Node [ TC x - y TotalTransOut ( x ) × CompositeStat A ( y ) ]
An illustration of such a branching topology is provided in FIG. 4 . A combined transaction path is a set of one or more transaction paths that start at the same hop 1 component. An “overall” composite statistic for a combined transaction path is the sum of the fractional downstream composite statistics of the combined transaction path and may be expressed as the CompositeStat A (x) equation shown above.
FIG. 4 is an exemplary diagram of a branching distributed data processing environment with statistical values in which exemplary aspects may be implemented. The branching distributed data processing environment comprises three hop1 components, HTTP server 405 , HTTP server 410 , and HTTP server 415 ; two hop2 components, application server 440 and application server 445 ; and two hop3 components, database 460 and database 465 . Paths 420 , 425 , 430 , and 435 represent the routes transactions take between specific hop1 and hop2 components. Path 420 represents the path between HTTP server 405 and Application server 440 . Path 425 represents the path between HTTP server 410 and Application server 440 . Both paths 430 and 435 originate from HTTP server 415 , indicating a branching path. Path 430 represents the path between HTTP server 415 and Application server 440 , while path 435 represents the path between HTTP server 415 and Application server 445 . Paths 450 and 455 represent the routes transactions take between specific hop2 and hop3 components. Path 450 represents the path between application server 440 and database 460 . Path 455 represents the path between application server 445 and database 465 .
The calculation of a particular statistic, composite stat A , for the paths starting with HTTP Servers 405 , 410 , and 415 of hop1 would begin with apportioning the composite stat A of hop3 and attributing the composite stat A to the appropriate components of hop2. The process would continue to apportion the resulting hop2 composite stat A calculations and attributing the resulting hop2 composite stat A to the appropriate components of hop1.
The composite statistics for the hop3 components may be calculated using the following equations:
CompositeStat A ( DB 1)= W hop3 ×stat A ( DB 1)
CompositeStat A ( DB 2)= W hop3 ×stat A ( DB 2)
The first equation represents the composite statistics for database 460 , denoted in the equation as DB 1 . The second equation represents the composite statistics for database 465 , denoted in the equation as DB 2 . Notice that the downstream component part of these two equations is evaluated as zero and not shown in the equation. This is because the components database 460 and database 465 are the last in the application path and have no downstream components.
After calculating the composite statistics for databases 460 and 465 the composite stat A for application server 440 and application server 445 is calculated. Application server 440 is denoted in the following equations as AppServer 1 . Application server 445 is denoted in the following equations as AppServer 2 . Database 460 is denoted in the following equations as DB 1 . Database 465 is denoted in the following equations as DB 2 . TC A1−DB1 , denoted by reference number 450 , represents the number of transactions sent from AppServer 1 to DB 1 . TC A2−DB2 , denoted by reference number 455 , represents the number of transactions sent from AppServer 2 to DB 2 . The composite statistics for application servers 440 and 445 may be calculated using the following equations:
CompositeStat
A
(
AppServer
1
)
=
W
hop
2
×
stat
A
(
AppServer
1
)
+
(
TC
A
1
-
DB
1
TC
A
1
-
DB
1
×
CompositeStat
A
(
DB
1
)
)
CompositeStat
A
(
AppServer
2
)
=
W
hop
2
×
stat
A
(
AppServer
2
)
+
(
TC
A
2
-
DB
2
TC
A
2
-
DB
2
×
CompositeStat
A
(
DB
2
)
)
The composite statistics for the hop3 components do not need to be apportioned because each of the hop2 components are connected to only one downstream component, application server 440 is connected only to database 460 and application server 445 is connected only to database 465 . After obtaining composite statistics for each of the hop2 components, the composite statistics for the hop1 components can be computed using the following equations:
CompositeStatA ( HTTP 1 ) = W hop 1 × stat A ( HTTP 1 ) + ( TC H 1 - A 1 TC H 1 - A 1 × CompositeStat A ( AppServer 1 ) ) CompositeStatA ( HTTP 2 ) = W hop 1 × stat A ( HTTP 2 ) + ( TC H 2 - A 1 TC H 2 - A 1 × CompositeStat A ( AppServer 1 ) ) CompositeStat A ( HTTP 3 ) = W hop 1 × stat A ( HTTP 3 ) + ( TC H 3 - A 1 TC H 3 - A 1 + TC H 3 - A 2 × CompositeStat A ( AppServer 1 ) ) + ( TC H 3 - A 2 TC H 3 - A 1 + TC H 3 - A 2 × CompositeStat A ( AppServer 2 ) )
Application server 440 is denoted in the equations as AppServer 1 . Application server 445 is denoted in the equations as AppServer 2 . HTTP server 405 is denoted in the equations as HTTP 1 . HTTP server 410 is denoted in the equations as HTTP 2 . HTTP server 415 is denoted in the equations as HTTP 3 . TC H1−A1 , denoted by reference number 420 , represents the number of transactions sent from HTTP 1 to AppServer 1 . TC H2−A1 , denoted by reference number 425 , represents the number of transactions sent from HTTP 2 to AppServer 1 . TC H3−A1 , denoted by reference number 430 , represents the number of transactions sent from HTTP 3 to AppServer 1 . TC H3−A2 , denoted by reference number 435 , represents the number of transactions sent from HTTP 2 to AppServer 2 . The composite statistics for HTTP 1 and HTTP 2 contain non-branching paths so their downstream component contributions do not need to be apportioned. HTTP 3 does contain a branching path, so the composite statistics for AppServer 1 and AppServer 2 are apportioned to the proportion of transactions that went to each component. This approach is general and can be applied to all application topologies. Path-oriented composite statistics will transparently add depth and focus to applications and algorithms that use them. Path-oriented composite statistics will be particularly useful for resource usage and application result statistics which affect overall performance, such as CPU utilization, memory usage, application failures, and so forth. Statistics that have little meaning in downstream components do not benefit from such an extension. An example of a statistic that has little meaning in downstream components is the overall response time, which only exists in hop1 components.
The previous equations illustrate a way of attributing the data from downstream hops to the appropriate component of the first hop, but did not answer the question of how to weight statistics from each hop. That is, the calculation of appropriate values for W hop1 , W hop2 , and W hop3 was not explained. In order to preserve the meaning of the path oriented statistic, the hop weights, W hop1 , W hop2 , and W hop3 , should be fractional values that add up to one. If this principle is not followed, path oriented statistical calculations could create values that make no sense. For example, consider a path oriented calculation for CPU utilization, a statistic that should range from zero to one. If hop weights that do not add up to one are used when computing this statistic, the resulting path oriented statistic may be out of range.
Consider the following scenario where a path oriented CPU utilization is computed with hop weights W hop1 =2, W hop2 =4, W hop3 =3, stat CPU (hop1component)=0.5, stat CPU (hop2component)=0.5, and stat CPU (hop3component)=0.5: CompositeStat CPU (hop1component)=(2*0.5)+(4*0.5)+(3*0.5)=4.5
As can be seen, the path oriented statistic computation yielded an out of range value of 4.5 for the CPU utilization.
In an exemplary embodiment, each hop is treated equally by making the weight of each hop the same fractional value that must add up to one:
W hop ( i ) = 1 N for every i ,
where N is the total number of hops. In another exemplary embodiment, the most important hop is determined and the weight of that hop is adjusted accordingly. For the purpose of computing load balancing weights, the most important hop is the hop where the transactions are spending the most amount of time. This hop is likely to be the hop where the usage and performance related statistics may make the biggest difference. Therefore, hops are weighted according to the average time spent at the hop. This length of time may be provided by the application through instrumentation or calculated using the difference between component based response times and times in which the component remains blocked while waiting on downstream components. The component time values may be aggregated accordingly to form the weight of the hop.
Current load balancers cannot distinguish between transactions that start at the same hop1 component and then have different transaction paths from hop2 onwards. However, were a load balancer able to distinguish between transactions that start at the same hop1 component but have different paths from hop2 onwards, exemplary embodiments are able to distinguish between these transaction paths and to calculate the downstream statistics for the load balancer. Rather than calculating an overall statistic for each transaction path that starts at the same hop1 component, an overall statistic could be calculated for each set of transaction paths that share the same complete transaction path.
FIG. 5 is an exemplary diagram of a branching distributed data processing environment with statistical values and timings in which exemplary aspects may be implemented. FIG. 5 shows the branching distributed data processing environment of FIG. 4 , but includes time notations for calculating hop weights. In FIG. 5 resp x equals the response time of transactions starting at component x, bt x equals the blocked time at component x, TC x equals the number of transactions processed at component x, and TC x−y equals the number of transactions sent from component x to component y. Blocked time refers to the amount of time component x is waiting for downstream components to process a request.
The branching distributed data processing environment comprises three hop1 components, HTTP server 505 , HTTP server 510 , and HTTP server 515 ; two hop2 components, application server 540 and application server 545 ; and two hop3 components, database 560 and database 565 . Paths 520 , 525 , 530 , and 535 represent the routes transaction take between specific hop1 and hop2 components. Path 520 represents the path between HTTP server 505 and Application server 540 . Path 525 represents the path between HTTP server 510 and Application server 540 . Both paths 530 and 535 originate from HTTP server 515 , indicating a branching path. Path 530 represents the path between HTTP server 515 and Application server 540 , while path 535 represents the path between HTTP server 515 and Application server 545 . Paths 550 and 555 represent the routes transaction take between specific hop2 and hop3 components. Path 550 represents the path between application server 540 and database 560 . Path 555 represents the path between application server 545 and database 565 .
Computing the hop weight of hop1 will begin with determining time spent with each component of hop1. Application server 540 is denoted in the following equations as AppServer 1 . Application server 545 is denoted in the following equations as AppServer 2 . HTTP server 505 is denoted in the following equations as HTTP 1 . HTTP server 510 is denoted in the following equations as HTTP 2 . HTTP server 515 is denoted in the following equations as HTTP 3 . Database 560 is denoted in the following equations as DB 1 . Database 565 is denoted in the following equations as DB 2 . The equation for determining the time spent at a component of hop1 may be expressed as:
HTTP1 time =resp H1 −bt H1
HTTP2 time =resp H2 −bt H2
HTTP3 time =resp H3 −bt H3
The times for these components are summed together to form the total time spent at hop1.
To accurately reflect the amount of time the transactions spend in the hop, one should take into account the number of transactions processed at each component when computing this aggregation. The following equation expresses this consideration:
HOP
1
time
=
(
HTTP
1
time
)
*
TC
H
1
+
(
HTTP
2
time
)
*
TC
H
2
+
(
HTTP
3
time
)
*
TC
H
3
TC
H
1
+
TC
H
2
+
TC
H
3
The weight of the second hop begins by first calculating the time spent at each of the components.
APP1 time =resp A1 −bt A1
APP2 time =resp A2 −bt A2
Next, the total time spent at the hop can be computed.
HOP
2
time
=
(
APP
1
time
)
*
(
TC
A
1
)
+
(
APP
2
time
)
*
(
TC
A
2
)
TC
A
1
+
TC
A
2
The same process is used for the calculating the time spent at hop3:
DB
1
time
=
resp
DB
1
-
bt
DB
1
DB
2
time
=
resp
DB
2
-
bt
DB2
HOP
3
time
=
(
DB
1
time
)
*
TC
DB
1
+
(
DB
1
time
)
*
TC
DB
2
TC
DB
1
+
TC
DB
2
Given the time spent in each hop, the weights for each hop may be computed in the following manner:
W
hop
1
=
HOP
1
time
HOP
1
time
+
HOP
2
time
+
HOP
3
time
W
hop
2
=
HOP
2
time
HOP
1
time
+
HOP
2
time
+
HOP
3
time
W
hop
3
=
HOP
3
time
HOP
1
time
+
HOP
2
time
+
HOP
3
time
Incorporating these hop weights into the equations provided in the earlier composite statistic equations will help focus the resulting load balancing weight computation on the components in the topology that are most important.
FIG. 6 is a flowchart illustrating the operation of computing path oriented statistics in accordance with exemplary embodiments. The operation, which may be implemented by a load balancer, such as load balancer 315 in FIG. 3 , begins by determining the, application topology, or transaction path, of a particular transaction, for each transaction being processed (step 610 ). The statistic to be transformed into composite statistics from each hop is monitored (step 615 ). The weight of each hop is also calculated (step 620 ) and will be used when computing the composite statistics. The hop1 composite calculation can be computed in a recursive manner by first calculating downstream composite statistics. This process begins at the very last hop. The operation sets the current hop to be the last hop, hop N (step 625 ). At each hop, the composite statistic should be calculated taking into account composite statistics previously computed at downstream hops, as shown by steps 630 and 645 . The operation calculates the composite statistic for all the components of the current hop (step 630 ). The operation determines if the current hop is the first hop (step 635 ). If the current hop is not the first hop (a “no” output to step 635 ), the operation sets the current hop, hop N, equal to the current hop minus one, hop N=hop N−1 (step 640 ). The operation uses previous downstream composite statistics to calculate composite statistics of the current hop (step 645 ). The operation then repeats step 635 . If the current hop is the first hop (a “yes” output to step 635 ), the overall composite statistic is complete and the operation ends.
The invention can take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment containing both hardware and software elements. In a preferred embodiment, the invention is implemented in software, which includes but is not limited to firmware, resident software, microcode, etc.
Furthermore, the invention can take the form of a computer program product accessible from a computer-usable or computer-readable medium providing program code for use by or in connection with a computer or any instruction execution system. For the purposes of this description, a computer-usable or computer readable medium can be any tangible apparatus that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device.
The medium can be an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system (or apparatus or device) or a propagation medium. Examples of a computer-readable medium include a semiconductor or solid state memory, magnetic tape, a removable computer diskette, a random access memory (RAM), a read-only memory (ROM), a rigid magnetic disk and an optical disk. Current examples of optical disks include compact disk—read only memory (CD-ROM), compact disk—read/write (CD-R/W) and DVD.
A data processing system suitable for storing and/or executing program code will include at least one processor coupled directly or indirectly to memory elements through a system bus. The memory elements can include local memory employed during actual execution of the program code, bulk storage, and cache memories which provide temporary storage of at least some program code in order to reduce the number of times code must be retrieved from bulk storage during execution.
Input/output or I/O devices (including but not limited to keyboards, displays, pointing devices, etc.) can be coupled to the system either directly or through intervening I/O controllers.
Network adapters may also be coupled to the system to enable the data processing system to become coupled to other data processing systems or remote printers or storage devices through intervening private or public networks. Modems, cable modem and Ethernet cards are just a few of the currently available types of network adapters.
The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
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In datacenter environments, many copies of servicing components (application servers, http servers, etc) are used to handle larger loads. In these cases, incoming service requests typically go to a load balancer to be directed to the appropriate servicing component. Modern advances in technology, like the Server/Application State Protocol, have allowed load balancers to receive recommendations in the form of numerical weights to describe the best distribution for the incoming requests. The present invention provides a method for computing path oriented statistics that enable load balancing algorithms to transparently integrate downstream performance and resource usage statistics into load balancing weights.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119(a) to DK Application No. PA 2008 01690, filed Dec. 1, 2008. This application also claims the benefit of U.S. Provisional Application No. 61/118,754, filed Dec. 1, 2008. Each of these applications is incorporated by reference herein in its entirety.
TECHNICAL FIELD
The present invention generally relates to a method for forming a mono pile foundation in soil for a wind turbine tower, comprising drilling a plurality of holes into the soil and placing the mono pile in an annular cavity. The annular cavity is formed by the plurality of holes alone, and/or by the mono pile breaking up intermediate soil walls between adjacent holes in the plurality of holes while being placed therein. The present invention further relates to a foundation in soil for a wind turbine tower, a wind turbine comprising such a foundation, and use of such a foundation in a wind turbine.
BACKGROUND
A wind turbine tower is generally 30-80 m in height and has a diameter of 2-10 m. Typical modern tower weights are 40 tons for a 50 m tower for a turbine with a 44 m rotor diameter (600 kW), and 80 tons for a 60 m tower for a 72 m rotor diameter. Due to the height and weight of the wind turbine tower, the forces formed by rotational movements of the wind turbine blades, and the very large surface of the tower being exposed to the wind, the tower must be steadily fastened to the ground.
Depending on soil conditions, for example rock, soil or gravel, different kinds of foundations are used for securing the wind turbine tower to the ground. One way of forming a foundation is to form a concrete foundation in a recess, arrange a support structure on the concrete foundation, form a connection to the tower, and arrange anchors into drilled holes in the ground for securing the foundation to the ground.
Another type of foundation for a wind turbine is a mono pile foundation. The mono pile foundation comprises a tubular element, having a length exceeding the diameter, which is forced into the ground by hammering or vibrating. This technique works well as long as the ground does not contain any unexpected objects, like rocks. However, the mono pile is subjected to very large forces when being hammered into the ground. Consequently, the mono pile must be reinforced in order to resist the forces resulting from the hammering. Additionally, vibrating the mono pile into the ground works well in sand but not in clay.
WO 01/66861 discloses a device and a method for anchoring a foundation for a wind turbine tower to a rock bed. This solution represents an embedment foundation, as the anchoring portion is embedded in concrete and may be provided with anchors, and the height of the anchoring portion approximately corresponds to the diameter of the anchoring portion.
SUMMARY
In view of the above, embodiments in accordance with the invention provide an improvement over the above described techniques and prior art.
In particular, one embodiment provides a method for forming a mono pile foundation and a foundation in soil, which does not have to be hammered or vibrated into the ground.
Another embodiment provides a method for forming a mono pile foundation and a foundation in soil, which does not require any anchors in order to obtain the necessary stability of the foundation.
According to a first aspect, a method for forming a mono pile foundation in soil for a wind turbine tower comprises drilling a plurality of holes into the soil, the plurality of holes being arranged along a curve having a contour corresponding to a cross-dimensional shape of the mono pile, placing the mono pile in an annular cavity, the annular cavity being formed by the plurality of holes alone and/or by the mono pile breaking up intermediate soil walls between adjacent holes in the plurality of holes while being placed therein.
An advantage of the inventive method is that forming the mono pile foundation is facilitated, as a cavity, corresponding to the shape of the mono pile, is formed before the mono pile is introduced into the soil and/or as the mono pile is being placed therein. Accordingly, the force required for placing the mono pile in the ground is reduced, compared to hammering or vibrating the mono pile into the ground. If the annular cavity is formed by the mono pile breaking up intermediate soil walls between adjacent holes, the force required for placing the mono pile in the soil only has to exceed the resistance of the intermediate walls between adjacent holes. The force required for placing the mono pile in the soil is still further reduced if the plurality of holes form the annular cavity before placing the mono pile therein.
As the force required for placing the mono pile in the soil is reduced, the mono pile does not have to be hammered or vibrated into the ground as in prior-art mono pile solutions. Consequently, the mono pile does not have to be reinforced in order to resist the forces resulting from the installation process. Thus, the weight of the mono pile is reduced, resulting in material savings and in that transport of the mono pile is facilitated.
A further advantage is that it is possible to divide the mono pile into sections in the vertical direction. Dividing the mono pile into sections facilitates transport of the mono pile to the construction site. Before arranging the mono pile, the mono pile sections are attached to each other. For example, the mono pile sections may be provided with a flange, and be attached to each other in any conventional way. In the prior-art solutions, when hammering or vibrating the mono pile into the soil, the flanges of the attached mono pile sections cause a large resistance, thus hindering using more than one mono pile section. When using the inventive method, forming the cavity reduces the resistance when arranging the mono pile, even if the mono pile comprises multiple sections attached to each other by a flange.
As the foundation is of the mono pile type, the mono pile itself provides the necessary rigidity and stabilization of the foundation. No anchors or concrete foundations are required to stabilize and secure the foundation. Consequently, forming the foundation is facilitated, compared to an embedment foundation comprising a concrete foundation, anchors, anchoring portion etc, as the inventive foundation only includes one major part, i.e., the mono pile.
When drilling the plurality of holes, a first hole may be drilled and filled with a temporary filling material before a subsequent hole adjacent the first hole is drilled. Thus, the first hole does not collapse when drilling the subsequent adjacent hole. Further, filling the first hole with the temporary filling material prevents the first hole from being refilled with soil from the subsequent hole.
The method may further comprise arranging a reinforcement element in at least one of the plurality of holes. The reinforcement element prevents the hole from collapsing before the mono pile is placed in the hole.
The method may further comprise driving the mono pile into the annular cavity. Some force may be required for placing the mono pile in the cavity if the annular cavity is formed by the mono pile breaking up intermediate soil walls between adjacent holes. The force is required to break up the intermediate soil walls between adjacent holes, such that the annular cavity is formed, and depends on the width of the intermediate soil walls.
The method may further comprise filling remaining portions of the holes with soil and/or concrete after placing the mono pile. When the mono pile is placed in the cavity, portions of the holes may remain as a cavity. By filling these portions with soil or concrete, the mono pile foundation is further reinforced and provides additional rigidity and stabilization.
The method may further comprise removing the temporary filling material after placing the mono pile by filling the remaining portions of the holes with concrete from below. The concrete may be fed from additional holes adjacent the holes forming the annular cavity. Because the additional holes extend to the bottom of the annular cavity, the temporary filling material is removed and replaced with the concrete, thus further stabilizing the foundation.
The method may further comprise drilling the plurality of holes such that they are partly overlapping each other. When the holes are partly overlapping, a continuous annular cavity corresponding to the shape of the mono pile is formed, having no intermediate walls between adjacent holes, already before placing the mono pile therein. Thereby, placing the mono pile in the cavity is further facilitated and the force required for placing the mono pile in the cavity is further reduced.
According to a second aspect, embodiments in accordance with the invention include a foundation in soil for a wind turbine tower comprising a mono pile having a tubular shape, and a plurality of holes forming an annular cavity corresponding to a cross-dimensional shape of the mono pile, the mono pile being placed in the annular cavity, the annular cavity being formed by the plurality of holes alone and/or by the mono pile breaking up intermediate soil walls between adjacent holes in the plurality of holes while being placed therein.
An advantage of the inventive foundation is that the mono pile itself provides the necessary rigidity and stabilization of the foundation, as the foundation is of the mono pile type. No anchors or concrete foundations are required to stabilize and secure the foundation. Consequently, the foundation comprises fewer parts and is simplified, compared to an embedment foundation comprising a concrete foundation, anchors, anchoring portion etc, as the inventive foundation only includes one major part, i.e., the mono pile.
A further advantage is that the foundation does not have to be reinforced since the foundation does not have to be hammered or vibrated into the ground. Instead, the foundation is placed in the cavity being preformed and/or formed as the mono pile is placed therein.
Further, as the foundation does not have to be reinforced, the weight of the mono pile is reduced, resulting in material savings and in that transport of the mono pile is facilitated.
Another advantage is that it is possible to divide the mono pile into sections in the vertical direction, thereby facilitating transport of the mono pile to the construction site. Before arranging the mono pile, the mono pile sections are attached to each other, for example, by using a flange provided on the mono pile sections. In the prior-art solutions, when hammering or vibrating the mono pile into the soil, the flanges of attached mono pile sections cause a large resistance, thus hindering using more than one mono pile section. Forming a cavity as in the inventive foundation reduces the resistance when arranging the mono pile, even if the mono pile comprises multiple sections attached to each other by a flange.
An upper portion of the mono pile may be protruding above the soil and a lower portion of the mono pile may be placed in the annular cavity. The first portion may comprise an interface to the tower, for example, a flange corresponding to a mating element arranged on the tower. The second portion being placed in the soil provides the necessary stability of the wind turbine tower.
A ratio between a depth of the lower portion of the mono pile and a diameter of the mono pile may be at least 2:1. For a mono pile foundation, designed as a single pile, the depth of the mono pile being introduced into the soil must be sufficiently large as to provide the required stabilization of the wind turbine tower.
The holes may partly overlap each other. When the holes are partly overlapping, a continuous annular cavity corresponding to the shape of the mono pile is formed, having no intermediate walls between adjacent holes. Thus, placing the mono pile in the cavity is further facilitated and the forces required to introduce the mono pile into the cavity is further reduced.
A distance in a radial direction of the mono pile of an overlapping portion between adjacent holes may exceed a wall thickness of the mono pile. Consequently, the force required for placing the mono pile in the soil is reduced, since a continuous cavity corresponding to the shape of the mono pile is preformed. When the mono pile is arranged into the cavity, parts of the holes remain as a cavity, which may be filled with soil or concrete.
A distance in a radial direction of the mono pile of an overlapping portion between adjacent holes may correspond to a wall thickness of the mono pile. Consequently, the force required for placing the mono pile in the soil is reduced, since a continuous cavity corresponding to the shape of the mono pile is preformed. When the mono pile is arranged into the cavity, parts of the holes remain as a cavity, which may be filled with soil or concrete.
A distance in a radial direction of the mono pile of an overlapping portion between adjacent holes may be smaller than a wall thickness of the mono pile.
Remaining portions of the holes may be filled with soil, concrete, or a temporary filling material. When the mono pile is placed in the cavity, portions of the holes may remain as a cavity. By filling these portions with soil or concrete, the foundation is further reinforced and provides additional rigidity and stabilization.
According to a third aspect, embodiments in accordance with the invention include a wind turbine comprising a foundation according to the second aspect as discussed above. The wind turbine comprising the foundation according to the second aspect incorporates all the advantages of the foundation, which previously have been discussed, whereby the previous discussion is applicable.
According to a fourth aspect, embodiments in accordance with the invention include use of a foundation according to the second aspect. Use of a foundation according to the second aspect incorporates all the advantages of the foundation, which previously have been discussed, whereby the previous discussion is applicable.
Other objectives, features and advantages of embodiments in accordance with the invention will appear from the following detailed disclosure, from the attached claims as well as from the drawings.
Generally, all terms used in the claims are to be interpreted according to their ordinary meaning in the technical field, unless explicitly defined otherwise herein. All references to “a/an/the [element, device, component, means, step, etc]” are to be interpreted openly as referring to at least one instance of said element, device, component, means, step, etc., unless explicitly stated otherwise. The steps of any method disclosed herein do not have to be performed in the exact order disclosed, unless explicitly stated.
BRIEF DESCRIPTION OF THE DRAWINGS
The above, as well as additional objects, features and advantages, will be better understood through the following illustrative and non-limiting detailed description of preferred embodiments of the present invention, with reference to the appended drawings, where the same reference numerals will be used for similar elements, wherein:
FIG. 1 schematically illustrates a cross section of a foundation for a wind turbine.
FIG. 2A schematically illustrates a plurality of partly overlapping holes formed into the soil, forming an annular cavity.
FIG. 2B schematically illustrates the foundation in FIG. 1 as seen from above and placed in the annular cavity.
FIG. 2C schematically illustrates a plurality of holes arranged at a distance from each other.
FIG. 2D schematically illustrates how an overlapping portion of adjacent holes may be varied.
FIG. 3A schematically illustrates how a temporary filling material is arranged in the holes during the drilling process.
FIG. 3B schematically illustrates how reinforcement elements are arranged in the holes.
FIG. 4 schematically illustrates how concrete is introduced into the cavity, thereby removing the temporary filling material.
DETAILED DESCRIPTION
With reference to FIG. 1 , a foundation 1 for a wind turbine tower 20 will be described. The foundation 1 is formed of a mono pile 2 having a tubular shape. The mono pile 2 may be formed of one tubular element 3 , or may be formed of a plurality of segments in the circumferential direction, which together form the tubular element 3 . In the vertical direction, mono pile 2 may be formed of more than one section, which together form the tubular element 3 . The sections may be attached to each other by a flange arranged at an end portion of each section in any conventional way.
A mono pile is a type of foundation for a wind turbine tower, which is not arranged on a concrete foundation, and is not secured to the ground by using anchors. Instead, the length of the mono pile being arranged in the ground provides the stabilization of the wind turbine tower. Compared to an embedment foundation, the depth of the mono pile being introduced into the soil exceeds the diameter of the mono pile.
The mono pile 2 is suitable to be placed in soil 5 , such as for example sand or clay.
The mono pile 2 is placed in a cavity 10 having a shape corresponding to the tubular shape of the mono pile 2 . An upper portion of the mono pile is protruding above the soil, and forms a connection to the wind turbine tower 20 . The upper portion of the mono pile 2 may comprise a flange 4 forming an interface to the tower 20 . The wind turbine tower 20 may comprise a corresponding flange 8 , and the mono pile 2 may be attached to the tower 20 by passing a bolt 6 through a hole 7 arranged in the flanges 4 , 8 . The wind turbine tower 20 may be formed of a plurality of tower segments in the circumferential direction, each forming a portion of the tower 20 . A lower portion of the mono pile 2 is placed in the cavity 10 in the soil 5 .
The ratio between the depth of the lower portion of the mono pile being introduced into the soil and the diameter of the mono pile 2 is at least 2:1. The depth of the lower portion of the mono pile 2 being placed in the soil 5 must be sufficiently large such that a stable support is formed for the wind turbine tower 20 . The depth of the lower portion depends on tower height, soil conditions, expected loads etc.
Portions of the cavity 10 may remain as a cavity even after the mono pile 2 has been placed in the cavity 10 . These remaining portions may be filled with concrete. By filling any remaining cavities with concrete, the foundation 1 is further reinforced. The concrete filling also forms an anchoring to the soil.
FIGS. 2A and 2B illustrate the cavity 10 as seen from above, in FIG. 2A before the mono pile 2 is placed in the cavity 10 , and in FIG. 2B when the mono pile 2 is placed in the cavity 10 . The cavity 10 has an annular shape, essentially corresponding to the annular shape of the mono pile 2 .
When forming the inventive foundation 1 , a plurality of holes 11 are drilled into the soil 5 . The holes 11 are arranged along a contour corresponding to the cross-dimensional shape of the mono pile 2 . If the holes 11 are partly overlapping, as shown in FIG. 2A , the plurality of holes 11 forms the annular cavity 10 . The mono pile 2 is then placed in the annular cavity 10 . If intermediate soil walls 13 remain between adjacent holes when the holes are drilled, as shown in FIG. 2C , the plurality of holes 11 prepares for an annular cavity 10 to be formed. When placing the mono pile 2 in the holes 11 , the mono pile 2 breaks the intermediate soil walls 13 such that they collapse. Thereby, the annular cavity 10 is formed while placing the mono pile 2 .
The annular cavity 10 may also be formed as a combination of the above described situations. For example, in a first portion, the holes 11 may be partly overlapping, thereby forming a cavity already before the mono pile 2 being placed in the cavity 10 . In another portion, the holes 11 may be arranged adjacent each other, being separated by an intermediate wall 13 . In this portion, the annular cavity 10 is formed when the mono pile 2 is being placed in the cavity 10 . Additionally, the diameter of the holes 11 may be smaller than the wall thickness of the mono pile 2 . In this case, a cavity 10 corresponding to the shape and wall thickness of the mono pile 2 is formed when the mono pile 2 is being placed in the cavity.
When drilling the holes 11 for forming or preparing for the cavity 10 , a first hole 11 a is drilled into the soil 5 . A second hole 11 b is then drilled adjacent the first hole 11 a . A third hole 11 c is then drilled adjacent the second hole 11 b . This procedure continues until a plurality of holes 11 arranged along a curve having a contour corresponding to the cross-dimensional shape of the mono pile 2 is formed, as shown in FIG. 2A .
If the holes 11 are partly overlapping, the distance d 1 , d 2 and d 3 in the radial direction of the mono pile of an overlapping portion may either exceed, correspond or be smaller than the wall thickness D of the mono pile 2 , which is shown in FIG. 2D . If the distance d 1 of the overlapping portion is smaller than the wall thickness D of the mono pile 2 , some force is required to place the mono pile 2 in the cavity in order to widen the cavity 10 .
Further, the diameter of the holes 11 may either exceed, be smaller than or equal the wall thickness of the mono pile 2 . If the wall thickness D of the mono pile 2 exceeds the diameter of the holes 11 , no cavity remains when the mono pile is placed in the annular cavity 10 .
With reference to FIG. 3A , drilling the holes 11 will be described in more detail. A first hole 11 a is drilled into the soil 5 , as previously described. Before drilling a second hole 11 b , the first hole 11 a is filled with a temporary filling material 12 . The temporary filling material 12 may be bentonite, or any other suitable temporary filling material. The temporary filling material 12 prevents the first hole 11 a from collapsing when drilling the adjacent hole.
When the first hole 11 a is filled with the temporary filling material 12 , the second hole 11 b is drilled. The second hole 11 b is then filled with the temporary filling material 12 before drilling a third hole 11 c . This process is continued until a plurality of holes 11 arranged along a curve having a contour corresponding to the cross-dimensional shape of the mono pile 2 is formed.
Before arranging the mono pile 2 in the formed or prepared annular cavity 10 , the temporary filling material 12 arranged in the holes 11 is dissolved using a suitable chemical or water if needed. If using bentonite as a temporary filling material, it is not necessary to dissolve the bentonite before arranging the mono pile 2 due to the material properties of bentonite.
Alternatively, the holes 11 do not have to be drilled in a sequence, one after another. After drilling the first hole 11 a and filling the first hole 11 a with the temporary filling material 12 , a second hole (e.g., hole 11 c or 11 d ) may be drilled at a distance from the first hole 11 a along the contour of the curve corresponding to the cross-dimensional shape of the mono pile 2 and not adjacent the first hole 11 a . After a while, after having drilled holes at a distance from the first hole 11 a , the hole 11 b adjacent the first hole is drilled. Thereby, the temporary filling material 12 has had time to harden, and the risk that the first hole collapses when drilling the adjacent hole 11 b is further reduced.
After dissolving the temporary filling material 12 , if necessary, the mono pile 2 is arranged in the cavity 10 in the soil 5 . If the diameter of the holes 11 exceeds the wall thickness of the mono pile 2 , a portion of the holes 11 will remain as a cavity, which is shown in FIGS. 2C and 2D .
In order to fill any remaining portions of the holes 11 , and to further stabilize the foundation 1 , concrete 16 is introduced into the cavity 10 from below, as shown in FIG. 4 . The concrete 16 is introduced into an additional hole 15 being arranged adjacent the cavity 10 and extending along the cavity 10 . The concrete 16 flows into a lower portion of the cavity 10 , thus pressing any remaining temporary filling material 12 upwards. The cavity 10 is thereby filled with concrete 16 from below.
Even if the temporary filling material 12 is dissolved by using a chemical, some of the temporary filling material 12 may remain in the cavity 10 . Thereby, the cavity 10 may be filled with a mixture of concrete, soil and temporary filling material. However, for obtaining the best stabilization of the foundation 1 , all temporary filling material 12 should, if possible, be replaced with concrete. The temporary filling material 12 used to temporarily fill the holes 11 during drilling does not possess enough bearing capacity for stabilizing the foundation 1 .
As an alternative to filling the holes 11 with a temporary filling material 12 , a reinforcement element 14 may be arranged in the holes 11 for temporarily reinforcing the holes 11 , which is shown in FIG. 3B . One reinforcement element 14 is adapted to be placed in one of the plurality of holes 11 . The reinforcement element 14 may be a tubular element, for example made of plastic. Alternatively, the reinforcement element 14 may be a reinforcing structure, or a wiring. The reinforcement element 14 is adapted to withstand the forces directed from the surrounding soil in order to prevent the hole 11 from collapsing, but is adapted to break when the mono pile 2 is placed in the cavity 10 . For example, the material in the reinforcement element 14 may be weakened by perforations in the material, or having weaker portions. When the mono pile 2 is placed in the cavity 10 , the reinforcement element 14 breaks, or partly breaks, such that the reinforcement element 14 does not hinder the mono pile 2 from being placed in the cavity 10 .
It is contemplated that the mono pile may have any other shape, and that the corresponding cavity may have any other shape. Further, even if circular holes are shown, the holes may have any other shape. It is also contemplated that the interface to the wind turbine tower may have another design.
The invention has mainly been described above with reference to a few embodiments. However, as is readily appreciated by a person skilled in the art, other embodiments than the ones disclosed above are equally possible within the scope of the invention, as defined by the appended patent claims.
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This invention relates to a method for forming a mono pile foundation in soil for a wind turbine tower including drilling a plurality of holes into the soil, the plurality of holes being arranged along a curve having a contour corresponding to a cross-dimensional shape of the mono pile, and placing the mono pile in an annular cavity, the annular cavity being formed by the plurality of holes alone and/or by the mono pile breaking up intermediate soil walls between adjacent holes in the plurality of holes while being placed therein. A foundation in soil for a wind turbine tower, a wind turbine comprising such a foundation, and use of such a foundation in a wind turbine is also disclosed.
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BACKGROUND OF THE INVENTION
[0001] The user of public transportation must deal with a variety of constraints: his or her hands are full with objects to be carried, briefcase, school bags, errand items, etc. Public transportation is cramped and overcrowded; the sidewalk is busy, the stairs are narrow and steep, the public thoroughfare is governed by strict rules. After arriving at his or her destination, he or she must deal with social constraints whether at work or at school, and it can be difficult to change shoes and clothes. In addition, he or she must be able to use the aid in his or her usual attire.
[0002] It is also impossible to travel on the subway or train every day with a bicycle. It is difficult to go down stairs in roller skates; electric skateboarding are prohibited on public thoroughfares, such as a scooter; and even a vehicle such as the Segway®, designed for short-range city trips, turns out to be cumbersome on the sidewalk and not transportable on the subway and bus.
[0003] The state of the art comprises the Segway®, a platform aid comprising two wheels, rechargeable batteries, a central inertial stabilization device, and a handlebar integrated with the platform. This platform is not sufficiently compact to move along without difficulty on the sidewalk. It is too slow to move along on the road and, finally, its weight, in the order of 30 kg, prevents it from access to public transportation.
[0004] Document DE 100 27 466 describes a unicycle onto which the pedestrian climbs on two footrests, rests his or her hands on a handle that transmits the longitudinal inclination to the frame of the unicycle. An electronic device reads the longitudinal inclination of the unicycle by means of an electronic inclinometer and monitors the position of the wheel to maintain the balance of the user's means his center of gravity over the stand in order to prevent him or her from falling in accordance with an inverse tilt effect. The device moves forward as soon as the user inclines the handle forward. The wheel exhibits a square section so that the user is stable laterally. Because of this, path is guided within the longitudinal axis. The means for turning is not described, it is understood that it is necessary to briefly stand on the ground in order to convey lateral torque. Of course, turning the handle cannot ensure rotation because the footrests and the shaft are integrated via the fork.
[0005] Document DE 100 27 466 thus does not meet the criteria of the invention to the extent that it requires the user to hold the handle with at least one hand, and what is more it does not permit agile and harmonious steering to the extent that only longitudinal travel is provided for. Finally, the electronic device controlling the motor is served by an inclinometer, which is a different solution than that adopted by the invention.
[0006] U.S. Pat. No. 6,302,230, of Kamen represents several embodiments of balance unicycles, not optimized in order to be easily carried which imposes compact and lightness and it not described how to climb on it since the wheel is exposed and turning and its side may in consequence not transmit any lateral torque on the user's legs.
[0007] U.S. Pat. No. 8,616,313 Simeray of December 2013 under priority of November 2005 describes an:
[0008] ‘Autonomous electric mobile aid intended to transport a city dweller comprising: a single wheel, an electric motor, a battery, a fork, and two footrests characterized in that the ergonomics and driving of it are intuitive and do not require the use of the hands by means of:
two combined supports secured to the fork on either side of the wheel that are each configured to operate as a lever to convey stress and torque of the wheel response to a leg of the user; the motor being of the type that keeps the wheel directly under the center of gravity of the average city dweller; a driving electronics of the motor controlled linearly by a balance sensor on the fork;
[0012] wherein lateral steering is agile by means of the single wheel having a tread that is approximately round in shape in a plane parallel to an axis of rotation of the single wheel; and wherein it is compact when carried by the city dweller by means of the two footrests being foldable.’
[0013] This USA patent also describes and protects:
Any balanced wheel with combined supports configured so as to tightly holding the leg and the calf or with combined support configured so as not tightly holding the leg and the calf, according to the preference of the dweller to unfold or fold down the combined supports or guides during use. Any balanced wheel having at least one footrest longer than the lateral supports in a direction perpendicular to the plan of the wheel, even if the support is an unfolded guide in the FIG. 6 disclosing a footrest around 30% longer than the guide. This is illustrated by the dashed lines added FIG. 20 of the present document on the copy of the original publication. Any balanced wheel operating legs supports configured as not to substantially encircle the leg of the user as it is represented in FIG. 1 , FIG. 2 , and also represented in FIG. 6 and reported FIG. 20 of the present document because:
Tightly holding the leg and the calf does not mean ‘significantly encircling the leg’. Lateral supports are not described as ‘significantly encircling the legs’ of the user The legs supports are not configured to encircle the leg in FIGS. 1 and 2 but are in a U shape allowing the user to escape easily and are represented in the folded and unfolded positions.
[0020] There is no leg represented in FIG. 6 , and in consequence there is no representation of a leg substantially encircled by a leg guide.
[0021] If the guide represented in FIG. 6 encircled the leg, it would be technically and anatomically impossible to insert a leg due to the narrow opening represented.
[0022] The man skilled in the art would then have immediately understood that inserting a leg in a guide like the one represented in FIG. 6 is impossible because even handcuffs need a large opening for imprisoning hands.
[0023] He would have also understood that FIG. 6 illustrates the concept of a guide transmitting torque and stress and is not a tridimensional drawing for a servile execution.
[0024] He would have built a guide or a lateral support in the essence of the invention and in accordance with the general specifications of a balanced wheel such to consider the comfort, security, and the level of torque and stress to transfer according to the power and speed of the wheel and its version, sport or commuter, without the need of an inventive step.
[0025] He would have adapted its size, shape, material, friction, softness, and elasticity. Connection with the footrest by a rod would have been optional. All said specifications are therefore respected without any inventive step.
[0026] It is therefore believable that the man skilled in the art would have reduced the guides to a low profile shape of U for a low power and low speed wheel transmitting low torque and low stress to the user's legs and increased such branches of the U for the guides for a wheel dedicated to competition and/or acrobatic figures generating high torque and high stress to the user's legs.
[0027] Inventist and its owner Shane Chen concluded with the present applicant Simeray in March 2011 a license of Simeray's 2005 invention with an option of exclusivity worldwide and in consideration of royalties and operated under the Trade Mark®Solowheel the Simeray invention since 2012.
[0028] Inventist has distributed a wheel manufactured in China, exhibiting a very low top speed and a low power generating almost no stress and no torque on the user's leg, except when the user climbs on it and generates with his leg and foot in a significant lateral torque and stress.
[0029] As license operator having an average skill in his art, Shane Chen has adapted the size and the shape of the guide to the very low level of longitudinal torque and of stress to convey to the user's leg, and designed guides with a U shape in soft material having very short branches, not foldable.
[0030] During the negotiation of the license, and without disclosing it to Simeray, Shane Chen has filed the utility patent application US 20110220427 of March 2011 claiming;
[0031] ‘A powered unicycle device, comprising: a single wheel rotatably coupled to a frame; a motor which drives said wheel; an electronic fore-and-aft balance control system which controls said motor; a foot platform or platforms coupled to said frame; and leg contact surfaces on said frame, made of a yielding material and protruding outward from the main body of said frame’.
[0032] This application rejected 6 times in consideration of Simeray's prior art and lack of inventiveness finally became a patent in august 2014 U.S. Pat. No. 8,807,250 allowing:
[0033] A powered unicycle device, comprising:
a single wheel having an axis of rotation and defining a central vertical plane in the line of direction of travel that is rotatably coupled to a seat-less frame; a motor which drives the wheel; an electronic fore-and-aft balance control system which controls said motor; first and second foot platforms coupled to the frame and each having a standing surface that is below the axis of rotation of the wheel; a first leg contact surface that in its entirety extends substantially longitudinally in the line of travel of the device and is configured to be readily contactable by the side of a user's leg, at or below the knee, when that user is standing on the first foot platform; and a second leg contact surface that in its entirety extends substantially longitudinally in the line of travel of the device and is configured to be readily contactable by the side of a user's leg, at or below the knee, when that user is standing on the second foot platform;
[0040] wherein the first and second foot platforms extend in a direction perpendicular to the central vertical plane of the wheel further than the contact surfaces extend perpendicular to the central vertical plane, and further wherein the leg contact surfaces are configured so as to not substantially encircle a user's leg.
[0041] The present applicant Simeray doesn't understand this new previous art and especially:
Why and how Mr Shane Chen operator of a license with option of exclusivity, beneficiary of the transfer of know how necessary for operating the invention, exhibiting no inventive step by adapting the Simeray's invention to a slow balanced wheel, has been granted a utility patent for demonstrating skill as operator of a license. Why the exclusive right to operate his invention in USA granted by the USPTO in December 2013 to Simeray has been almost equally granted to his licensee Shane Chen of 6 months later for a utility patent application filed 6 years after Simeray's priority. Why Simeray's right to operate his invention without damageable interference is now restricted to the combination of handcuff like leg clips with 2 very short footrests that any skilled man wouldn't have considered knowing of the reasonable configuration of appropriately sized footrests and leg clips as show in FIG. 2 of Simeray's patent. Why the concept of leg clips that ‘encircle’ the legs has been associated with Simeray's patent when there is no mention of it in the description or claims. Why Shane Chen's patent application was rejected 6 times for obvious lack of inventiveness and on which new argument it has been finally granted.
[0047] Inventist concluded a license with an option of exclusivity worldwide of Simeray's patent and taken a design called Solowheel to market for 3 years in consideration of paying royalty when Simeray's patent is granted.
[0048] When the Simeray patent was granted in December 2013, Inventist breached the license agreement with by not paying the royalties due. The license of Inventist has been terminated in March 2014 by Simeray because of the breach.
[0049] The applicant not only unable to understand the prior art, its chronology and its meaning, respectfully apologizes for being also unable to identify who owns said previous art.
[0050] The present invention discloses the several improvements all necessary for the dissemination of the balanced wheel in the mass market.
[0051] Those improvements fix:
[0052] The weight, its width, its static and dynamical balance, the learning curve, the cost, the liability.
[0053] The present invention solves simultaneously these issues by inventive steps in a configuration remaining outside of the scope of the claims granted seemingly consecutively to Simeray and to Shane Chen in order that Simeray may have the privilege to operate his invention freely.
[0054] The current electric unicycles on the market fall inside the original Simeray patent and are designed with most of the weight above their center.
[0055] The power required to balance the user increases with the level of the center of gravity of the unicycle.
[0056] When the user steps down from the wheel, it needs lateral stabilization either from one leg on the side of the wheel (requiring torque against the wheel) with its foot on the pedal and one foot on the ground or held up by hand to keep if from falling down and becoming dirty.
[0057] With the electric unicycles on the market, there is a significant learning curve due to a lateral instability caused by a large wheel and no freedom of motion for the user's legs. This loss of freedom of motion is due to the size of the electric unicycle and how far apart it spreads the user's legs. This problem can be solved by having a design narrow enough that allows the users legs to move freely (as shown in the 2005 Simeray patent when the leg guides are in the folded position). This freedom of motion would allow the user to tilt the wheel laterally and in effect shift the contact point laterally allowing for better control.
[0058] However the user still needs to transmit a lateral torque and stress on the wheels side with his leg when he climbs on it.
[0059] A safety issue relates to a lack of headlights, tail lights, and running lights. The headlight is especially necessary to prevent the user from being surprised by surface irregularities. This is even more critical than for a bicycle, having a natural longitudinal stability. By highlighting through illumination obstacles and surface irregularities, the user may anticipate and react in a way to avoid falling.
[0060] Another safety issue is how a pedestrian may be surprised by the silent or fast electric unicycle rider. A sound warning could be used to prevent collisions.
[0061] Another safety issue is noted when the user steps down in an emergency or unpredictable situation and the sudden longitudinal misbalance causes the device to drive the wheel at full power spinning the frame into the user's leg.
[0062] A detection of the lateral misbalance should cause the motor to brake.
[0063] Another safety issue is related to the ground clearance necessary when the turns and leans. If the footrest bumps the floor during a high speed turn then the user twists and falls painfully. The balanced wheel must be able to lean around 30° before a footrest touches the ground.
[0064] Another security issue is related to the liability.
[0065] Regulations limit up the speed on the sidewalks and limits down the speed on the street. The dweller must adapt his driving to the existing regulation and assume the responsibility of any accident happening in breach of the regulation. The public information related to the current speed of the electric transportation device could contribute to attribute the responsibilities.
SUMMARY OF THE INVENTION
[0066] The invention is designed as a motorized electric aid that helps the city dweller in his or her pedestrian trips and that ideally remains compatible with all of the constraints listed above.
[0067] In a preferred embodiment, the invention abides by the following criteria: the aided pedestrian has the size of a normal pedestrian; moves along on the sidewalk at a pedestrian speed up to approximately 7 km/h and moves along on the road at a speed less than 30 km/h. The pedestrian has the agility of a normal pedestrian or skater and moves along without effort with the use of both hands and is able to wear his or her usual clothing and shoes.
[0068] The aid is compact, portable, and light, in for example a backpack, it weighs less than 5 kg has a volume less than 40 cm in diameter by less than 6 cm in thickness and can be recharged via a household electric socket or by another equivalent means. It offers a range of approximately one hour or 15 km.
[0069] The present invention by inventive step solves the dilemma of how to keep sufficient ground clearance under the pedals, a tight profile of the wheel in and after use, and how to increase its static, dynamic, lateral, and longitudinal stability by placing the heavy components under the wheels center. The wheels on the market are too large especially at the ankle level and there would be no improvement by lowering the batteries at the ankle level and enlarging the profile even more.
[0070] The inventive step include a complete reconstruction of the balanced wheel in which most of the weight is located in the foot rest, the wheel is a tight light and flexible hub-less wheel and the unique foot rest or the combined foot rests crosses the wheel's main plan, what is totally new and operable.
[0071] This present invention further describes:
The static longitudinal and lateral stability of the motorized wheel standing up by itself before use and in use
Due to a Center of Gravity (CG) significantly lower than its axe. Due to a center a curvature of the tire over the center of gravity. Due to its tight profile of the wheels casing, its large footrest allowing enough room between the legs in order to lean it between the legs and to move the contact point on the floor laterally even at no speed.
The dynamic stability of the motorized wheel:
[0077] The longitudinal stability is improved through
a lighter wheel, its empty center, (around 600 g, effectively ten time less than the current wheels on the market) allowing efficient short response time longitudinal adjustments. a high power to weight ratio of the motorization system allowing short response time of the stabilization. a Gravity Center significantly lower than its axe and near the floor reducing the power needed for a short time reaction almost independent from the weight of the user, but directly proportional to the powered unicycle's weight relative to the center of gravity and relative to the floor.
[0081] The lateral stability improved through
the comparatively high inertial momentum of the rim and tire compared to the weight of the rest of the device. This gyroscopic effect combined with the freedom of motion between the device and the user's legs allows for a greater lateral stability. at least 2 mechanical connections and 2 electrical connections to a combined or removable gyroscope composed of a housing embedding a flywheel powered by an electrical motor, turning around an axe parallel to the wheel's axes in the same or the opposite direction according to the balanced wheel's speed for increasing the precession of the tire at low speed and reducing it effect at high speed. An airless tire made of a rubber like material exposing to the floor a circular contact surface generating almost no friction torque when the user orients the wheel at no or low speed for keeping balanced, thanks to a curvature center significantly over the center of gravity CG. Its weight and encumbrance is reduced when it is carried by the user, thanks to
a compact light powerful and efficient brushless motor, connected to a speed reducer in order to operate the motor at its efficient speed. an hub-less wheel, a tight profile, an empty space in the center of the wheel casing being the placement of the footrest when the device is not is use. a light battery solution combining high power density battery and high energy density battery. A footrest or combined foot-rests being the container of the main heavy and cumbersome components. a photoelectric charger of the battery covering its surface.
The friendly learning and the ergonomics, the lateral torque transmitted to the legs when climbing on suppressed or dramatically reduced due to:
The said tighter profile reducing the lever of the foot on the foot-rest. A lateral support on the ground, retractable in option, ensuring with the wheel a natural lateral stability and suppressing any lever on the leg for stepping up and down like if the wheel were a stable step.
The large platform and tire curvature allow for a higher stability in use and before and after use. The dynamic stability resulting from
the optimized gyroscopic momentum of the wheel in combination with the freedom of motion to tilt the wheel laterally.
the combination of an electrically powered removable gyroscope and with the freedom of motion to tilt the wheel laterally. The comfort of the user improved due to:
The rolling vibrations damped thanks to the suspension of the footrest, rolling inside the rim of a flexible wheel, having a tire or rim composed of an elastic material. A mechanical transmission compatible with such flexibility of the rim. Enough room for the ankles due to the empty space in the center of the wheel. A foldable seat supporting the user when tired and converting the said self balanced wheel into a electric self balanced unicycle with a reasonably comfortable seat, becoming fully a stable seat due to the lateral supports unfolded when the wheel is static and or the power switched off.
The security of the user and the conformity to the regulations due to
An illumination of the path in front of the wheel by a white light and a warning behind by a red light, whenever the wheel has no identified front or back side. An automatic switch off of the motors due to a lateral balance sensor turning the motor driver off when it falls on its side. A source of sound warning, for example a music player with a volume substantially proportional to the speed in order to alert the pedestrians. A source of sound warnings for low battery and for when the user leans beyond the wheels maximum power output. A vibration generated by a motor under the users feet warning the user for the same purposes.
The balanced wheel's low center of gravity achieved through
A foot rest being a container containing either the batteries, motor, electronic balance system, or any combination of said components. This footrest could also be structured in a way to be part to the wheel casing. This footrest could also be secured to the to the wheel casing. This footrest could also be an independent part of the wheel casing.
The liability and the safety of the user is improved due to a color pattern and a color code light informing the public about the current speed range of the wheel, in combination with a way to change the color of the balanced wheel or the color of its illumination in accordance with the current speed so that the witness in the case of an accident may report the speed range of the user by only reporting the electric vehicle's color and in consequence contribute to identify who is responsible. A design with removable battery packs allowing the user to optimize its wheel's weight according to the autonomy desired. A charger for recharging the batteries connectable to the domestic power having the shape of a battery pack for embedding in the wheel's platform despite of a battery pack. A photoelectric charger of the battery covering at least one foot-rest connected to a step up voltage elevator for a permanent charge of the battery when expose to the sun. One Unique footrest in order
to allow the user to ride frontward, backward, and laterally in a surf position
BRIEF DESCRIPTION OF THE DRAWINGS
[0121] Preferred and alternative examples of the present invention are described in detail below with reference to the following drawings:
[0122] FIG. 1 illustrates a nonexclusive embodiment of the present invention;
[0123] FIG. 2 illustrates a nonexclusive embodiment of the motor fixation of the footrests and transmission
[0124] FIG. 3 illustrates a nonexclusive embodiment of the footrests including the batteries
[0125] FIG. 4 illustrates a nonexclusive embodiment of the bumpers for suspending the footrests.
[0126] FIG. 5 illustrates a nonexclusive embodiment of one unique footrest inserted inside the wheel for carrying.
[0127] FIG. 6 illustrates a nonexclusive embodiment of the unique footrest inserted on the frame of the wheel for riding.
[0128] FIG. 7 illustrates a non exclusive embodiment of the motors batteries electronic and transmission included in the said unique footrest.
[0129] FIG. 8 illustrates a non exclusive embodiment of the deformation of the hub-less flexible wheel and its guide submitted to the user's weight.
[0130] FIG. 9 illustrates a non exclusive embodiment of the circuitry of the lighting.
[0131] FIG. 10 illustrates a non exclusive embodiment of 2 additional stands ensuring the lateral stability of the user at no or low speed thanks to an actuator unfolding them.
[0132] FIG. 11 illustrates optional parts on the guide.
[0133] FIG. 12 illustrates those parts assembled into a seat when unfolded.
[0134] FIG. 13 illustrates the 3 main interactions of the dweller with the balanced wheel.
[0135] FIG. 14 illustrates the respective position of the gravity center of the wheel in use.
[0136] FIG. 15 illustrates the removable battery packs, the removable charger, the motor for warning by vibration under the user's foot, the colored light for displaying the speed range.
[0137] FIG. 16 illustrates the mechanical and electrical connection of a removable housing embedding a fly wheel and a motor.
[0138] FIG. 17 illustrates the difference of shape of the interface between the floor and a air tire and the floor and the airless tire.
[0139] FIG. 18 illustrates an electrically balanced wheel without wheel's casing transmitting directly the lateral stress and torque of the wheel to a combined protection secured on the user's leg.
[0140] FIG. 19 illustrates an airless tire and rim which main deformation contributing actively to the longitudinal stability of the user.
[0141] FIG. 20 is a reproduction of Simeray's original patent with dashed annotations.
DRAWINGS LISTING TO THE REFERENCES
[0142]
[0000]
2 Footrests
14
Brushless motor
16
Electronic Motor driver
17
Tires
12
Flexible rim
13
Guiding - ring
15
Tube axe
21
Motor's axe
23
90° Gear reducer
24
Rollers
25
Rechargeable batteries
36
Batteries compartment cover
32
Walls for structure
35
Foot-rest tubular connection
33
Bumpers
34
Casing for electronic
26
Axis of the guide support
43
Soft and frictional surface
45
Guide support
42
Unique footrest
55
Handle
54
Direct reducer and gear
53
Electronic System
71
Roller's shaft
72
High Energy density battery
73
High power density battery
74
Illumination led
80
Warning led
81
Lateral balance leg
110
Lateral balance wheel
112
Actuator
113
Loudspeaker & music player
75
Speed detector and driver
76
2 axis balance sensor
77
Opening in guide
78
Foldable part of guide
121
Foldable part of guide
122
Removable handle and seat
123
Hinge
124
Surf position
A
Frontward backward riding
B
Carrying position
C
Gravity center
CG
Lateral curvature center
CC1
Longitudinal curvature center
CC2
Removable battery pack
151
Removable domestic charger
152
Speed range color display LED
153
Gyro Locking holes & connectors
154
Warning vibration motor
155
Removable Gyroscope
161
Flywheel of the Gyroscope
162
Casing of the Gyroscope
163
Electric motor of the Gyroscope
164
Bearing of the gyroscope
165
Mechanical & electrical connection
166
Normal Air tire
171
Interface of airless tire
S1
Interface of air tire
S2
Leg protection
181
Roller
182
Rim with gear
183
Airless rim with spiral spokes
191
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0143] FIG. 1 represents the wheel when the footrests 14 and the guides 42 are unfolded in the right side and folded down in the left side.
[0144] The wheel includes a brushless motor, in a central casing 16 having the same level as the unfolded footrests, controlled by an electronic driver 17 .
[0145] The inflated or plain tires 12 , on the flexible ring 13 is guided by another ring 15 connected to the central casing of the motor 16 and to the guides 42 also used as a handle.
[0146] Preferably, the guide-handle 42 is surrounded by a soft and high friction material, avoiding the hand to glide for carrying.
[0147] FIG. 2 illustrates the tubes 21 , common axes of the 2 footrests 14 , the brushless motor 16 , controlled by its electronic controller 17 in its casing 26 , and its axes 23 terminated by a 90° gear 24 turning one of the 4 rollers 25 guiding the wheel, and the Gravity Center under the lever of the center of the wheel.
[0148] FIG. 3 illustrates the footrest 31 filled by rechargeable batteries 36 enclosed in a compartment sealed by covers 32 and separated by walls 35 for structural robustness, its tubular connection 33 with the tube 21 and the bumper 34 ensuring suspension and damping of the high frequency vibration by pressure on the casing 26 .
[0149] FIG. 4 illustrates again the action of the bumper 41 compressed by the footrests 14 , the axis 43 of the guide 42 and its soft and frictional surface 45 .
[0150] The heavy parts of the motorized wheel batteries, motors and structure are located under the feet during use, and contribute to the low position of the Gravity Center.
[0151] A bumper ensures some suspension of the footrests and damps the vibrations.
[0152] The ring wheel connected by roller to the structure may absorb vibrations thanks to its soft tire and by effect of an elastic deformation.
[0153] The encumbrance and the weight are minimized when folded because the thickness of the folded wheel is similar to the thickness of the tire and the thickness of the stack of 2 batteries and their casing.
[0154] The foldable guides are optional and the user may use the motorized unicycle with the guide 42 folded or with the guide unfolded.
[0155] The FIG. 5 represents another embodiment of the invention having one only footrest 55 inserted in the center of the flexible wheel 13 and guide 15 for carrying.
[0156] According to a preferred embodiment of the invention this only footrest's 55 surface is made of a photoelectric material for a permanent recharge of the battery when exposed to the sun connected to battery via a step up voltage elevator according to the state of the art.
[0157] This guiding ring 15 has as first option, the shape of a tube enclosing the wheel for water protection need, and as another option the shape of a simple ring, both with guiding roller 25 . It is catch as a handle 54 by the user and is surrounded by a soft material in option for a better grip of the hand not represented.
[0158] FIG. 6 represents the same footrest 55 inserted into the wheel 13 and guide 15 displaying a large stand, enough room for the ankles, a profile of the guide 15 tight enough so the user may keep the feet very close over the contact point on the floor, minimizing for each leg the lateral torque that the guide 15 could oppose when the user balances laterally. It represents also the gravity center CG lower than the wheel's axis and represents the lights 80 and the warnings 81 . Such lights are preferably electroluminescent diodes. In such position the said footrest 55 covered by a photoelectric material in combination with a step up voltage elevator persists to charge the battery during use.
[0159] FIG. 7 represents the footrest 55 open beside the guide 15 open and displays several rollers 25 , at least three for guiding the flexible wheel 13 inside the guide 15 , and two embedded in the footrest rolling on the wheel's rim, when the footrest is inserted. The roller crosses a opening 78 open in the guide 15 .
[0160] This footrest and the user are supported by the two rollers 25 rolling on the rim of the wheel 13 , when the user stands on the footrest 55 .
[0161] The guide 15 achieves also the function of a handle 54 when the footrest is horizontal, for carrying it unfolded or folded down, and it may be surrounded by a soft material for comfortable handling.
[0162] The footrest includes a transmission 53 , a direct reducer by gear, able to transmit the motor's torque and speed to the rollers 25 when it is inserted. Optionally this transmission may be ensured by a belt.
[0163] According to the invention, it is provided a reduction of the motor's speed almost without lost with only 2 gears, when the brushless motor running at 8000 rpm, propels the wheel at a relatively low speed of 200 rpm corresponding at 14 km pro hour.
[0164] This high reduction ratio of 40 is the consequence of the roller rolling directly on the rim of the wheel 13 having an empty center.
[0165] This high reduction ratio allows operating a much faster motor than the torque motor currently used for electric scooter. Such high speed out runner brushless motor delivers a density of power 40 times higher, having as consequence that a motor of only 400 g delivers more power to the wheel 13 than a scooter's wheel of 8 kg powered by a torque motor directly connected between the rim and the fork.
[0166] The speed is controlled by an electronic system 71 managing also the unique or combined battery charge and discharge. The balance is controlled thanks to an internal longitudinal balance sensor serving the said electronic system 71 and optionally by a 2 axis longitudinal and lateral balance sensor 77 . In this last option the lateral misbalance once detected by 71 cuts off the motor's power for the security reasons exposed earlier.
[0167] The combined batteries are for a non exclusive example a lithium ion polymer battery 74 able to a very high discharge rate, but an average energy storage, associated in parallel with a Lithium Nickel Manganese Cobalt battery 73 of the same voltage able to a very high energy storage at a reasonable cost but a low discharge rate.
[0168] The 75 loudspeaker and music player's volume is preferably controlled thanks to a speed controller 76 substantially in proportion to the speed.
[0169] The actuator 113 is driven by the said speed controller 76 and activated at a predetermined speed.
[0170] FIG. 8 represents the elastic deformation of the empty center wheel 13 made in a high flexibility material for example in polyamide.
[0171] According to the invention the rollers 25 guide the wheel 13 inside or around the guide 15 , even when the said flexible wheel compressed. Those rollers 25 are made of a strong and resilient material for transferring the strength of the wheel to the guide's structure and for ensuring no direct friction between those 2 parts.
[0172] FIG. 9 describes an embodiment of the circuitry for lighting for example white 80 frontward and red 81 backward, when the user does not select a preferred side A or B of the wheel. The light sources are for example LEDs driven by the speed detector
[0173] According to the direction driven, the speed signal changes the polarity of the voltage, and induces a commutation of the diode's power and a commutation of the lighting color.
[0174] FIG. 10 is a back side view of the 2 lateral and retractable supports made of a lever 110 supporting a wheel 112 connected to a roller shaft 72 . Optionally those supports are automatically unfolded at low speed of the unicycle under the control of the actuator 113 served by the speed controller 76 .
[0175] FIG. 11 represents movable parts 121 , 122 , 123 , of the guide 15 folded down around the said guide.
[0176] FIG. 12 represents the same parts deployed such to realize a seat in which as a non limitative example 121 and 122 are connected to said guide 15 by hinges 124 , and are realized in a robust and flexible material. 123 is an handle cover is a soft material clip on the guide 15 , now used as a flexible seat when parts 121 and 122 are deployed and it is realized for example in a flexible silicon or polyurethane over wrapping a strong nylon tissue. 123 is clip on the extremities of 121 and 122 when it realizes the function of seat, and also clips on the guide 15 when it realizes the function of a soft handle.
[0177] FIG. 12 also represents at smaller scale this unicycle with foldable seat in static position, the lateral balance legs being unfolded down as lateral support ensuring a triangle of stability. This combination transforms automatically the said unstable unicycle rolling, into a stable seat when the speed decreases, allowing the user to step on and down in security and comfort.
[0178] Any rotation translation and assemblage of parts of an electric self balanced wheel may be operated for unfolding and strap a seat on it, the example exposed is not limitative of the preferred designs and realizes the invention becoming an electric self balanced unicycle.
[0179] FIG. 13 illustrates the 3 main postures of the user, surfing A, riding frontward or backward B, carrying the wheel by hand C. Carrying the wheel in a bag is also recommended.
[0180] FIG. 14 illustrates lateral curvature center CC 1 and the longitudinal curvature CC 2 of the tire 12 , and the gravity center CG. According to the invention le lateral curvature CC 1 is located substantially over the gravity center CG and preferably under the longitudinal center of curvature CC 2 .
[0181] FIG. 15 illustrates several non limitative and non exclusives embodiments of the invention, with removable battery packs 151 , a removable and optional domestic battery charger with a connection cable 152 , for example a led strip lighting outside and inside the wheel's casing being translucent a combination of the 3 main colors RGB in order to display by an identified color the current range of speed of the balanced wheel; a mechanical and electrical connection 154 made of several connectors for powering and securing several optional devices, an internal vibration motor for warning the user.
[0182] FIG. 16 illustrates a non exclusive embodiment of the combination of a removable Gyroscope 161 with the balanced wheel for regulating the precession level according to the wheels speed, by rotating the flywheel 162 in the same direction as the balanced wheel when slow, and opposite direction when the balanced wheel is fast, thanks to a motor 164 , torque transfer bearings 165 , a robust casing 163 , and robust connections 166 . According to the invention a direct current source embedded inside in the unique footrest 55 powers the said motor 164 with a polarity according to the wheel's speed.
[0183] FIG. 17 illustrates the difference between an inflated tire having necessarily a short lateral curvature radius, and a long interface with the floor with the compact circular interface of the airless lire having a long lateral curvature radius. This illustration exposes that a circular interface with the floor oppose less frictional torque than a long interface of an inflated tire to the orientation of the wheel and facilitates the small adjustments requested by the balance at low speed.
[0184] FIG. 18 exposes a balanced wheel without wheel's casing, a rim with gear 183 and its tire 12 is supported by a leg protection 181 when the user climbs on it and transfers to the wheel a lateral torque and stress, this leg protection secured like a sock according to the state of the art is manufactured either in a very low friction material for example like PTFE, or includes a roller 182 of substantially vertical axis.
[0185] FIG. 19 exposes a rim dedicated to a competition version of the balanced wheel able to absorb high impacts and overpass significant obstacles thanks to spiral oriented spokes 191 acting like suspension, damper and pole vaulting levers if the wheel is traveling from left to right and passes over obstacles.
[0186] The invention has been described as a
[0187] Seat-less electric self-balanced wheel having
at least one rechargeable battery pack, at least one electric motor, at least one electronic balance control system, at least one lateral support of one user's leg, at least one wheel's casing
[0193] wherein it includes:
only one wheel, said wheel is hub-less, at least one power transmission between said motor and the said wheel, At least one foot-rest where the footrest or combined footrests size are up to the diameter of the wheel casing said footrest is a container said foot-rest is configured to support one or two feet of the user standing with both legs on the same side of the wheel or with one leg on either side of the wheel when it is located bellow the center of the wheel a placement of the center of gravity substantially below the center of said hub-less wheel due to the placement of its heavy components such to include inside the said footrest container the batteries and-or motor and-or transmission and-or balance system
[0200] in respect with the ground clearance and with optimized static, dynamic, longitudinal, and lateral stability with safety and ergonomic design.
[0201] wherein said foot-rest may be located in the empty center of the wheel during transportation and storage.
[0202] wherein said foot-rest and said wheel may be separated parts.
[0203] wherein the said wheel may include a flexible rim.
[0204] wherein the said wheel may be guided by at least 3 rollers rolling on said rim with their axis connected to said wheel's casing.
[0205] wherein said transmission may include a rotational speed reducer transmitting the motor's power to the rim.
[0206] wherein at least 2 rollers connected to at least one foot rest may roll on said rim.
[0207] wherein at least one roller may be driven by the said motor.
[0208] wherein the said rim may include leaning spokes.
[0209] wherein a high density power battery may cooperate with a high density energy battery.
[0210] wherein a soft material may cover the wheel's casing.
[0211] wherein it may stand on the floor before and after use thanks to a lateral center of curvature of the tire located significantly higher than its center of gravity.
[0212] wherein its foot-rest surface may be a photoelectric charger of battery.
[0213] wherein one light may illuminate the way frontward thanks to said balance sensor detecting the direction combined with at least 2 light sources driven by the electronic balance sensor.
[0214] wherein 2 additional supports on the ground may be located backward on both sides being retractable by a rotation around one axis automatically deployed or retracted by an actuator driven by a speed sensor.
[0215] wherein foldable and un-foldable parts of the structure may support and become a seat when unfolded.
[0216] wherein it may be dynamically stable laterally in combination with a flywheel, an electric motor, removable mechanical and electric connections between the said electric balanced wheel and said motor and housing, said flywheel turning in the same direction as the wheel when slow, and in an opposite direction when the balanced wheel is fast.
[0217] wherein it may include no wheel's casing in combination with at least one lateral leg supports and protection.
[0218] wherein it may include a vibration generator motor mechanically secured to one foot-rest or vibration generated with the primary drive motor.
[0219] wherein it may include at least two similar removable battery packs and at least two similar placements for those batteries pack.
[0220] an electric vehicle wherein it may include at least 2 similar placements for battery packs, one battery pack inserted in one placement and one charger with a connection to the domestic power network inserted in the second placement.
[0221] an electric vehicle wherein its current speed range may be displayed thanks to a color of illumination or a color of its casing resulting from the combination of a speed detector and comparator included in the electronic balance system, at multiple colored light sources connected to said electronic, and with several transparent or translucent parts of its casing.
[0222] While the preferred embodiment of the invention have been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment and any combination of the ensegnements of the description enters into it scope.
[0223] Instead, the invention should be determined entirely by reference to the following claims:
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Self balanced electric wheel optimized for dynamic stability suspension and damping functions in use, compactness and low weight when carried short learning step, low cost and liability.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Related subject matter is disclosed in a U.S. patent application of Cha-Mei Tang entitled “A Method and Apparatus for Making Large Area Two-Dimensional Grids”, Ser. No. 08/879,258, filed on Jun. 19, 1997, issued as U.S. Pat. No. 5,949,850 on Sep. 7, 1999, the entire contents of which is expressly incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus employing detector pixels for obtaining an image having a resolution which is not directly related to the sizes of the detector pixels. More particularly, the present invention relates to a method and apparatus which obtains a series of spatially filtered high-resolution digital x-ray or gamma ray images of portions of an object or objects while minimizing image degradation due to conversion blurring and radiation scattering, and which arranges the spatially modulated images into a larger complete image of the object or objects.
2. Description of the Related Art
Various techniques currently exist and many are under development for obtaining digital x-ray and gamma ray images of an object for purposes such as x-ray diagnostics, medical radiology, non-destructive testing, and so on. Known devices include line digital detectors, which obtain images along essentially one direction, and therefore must be scanned across an object to obtain sectional images of the object which can be arranged into an image of the entire object. Also known are two-dimensional digital detectors which can obtain an image of the entire object at one time, and thus can operate faster than an apparatus which includes a line detector.
A digital x-ray imager creates a digital image by converting received x-rays, which are used to form the image, into electrical charges, and displaying the charge as a function of position. Digital x-ray detectors typically have the potential of high sensitivity and large dynamic range. Therefore, when used in medical applications, a digital x-ray detector will generally be capable of obtaining a suitable image of the patient without requiring the patient to receive a large dose of x-ray radiation.
Digital image data is also much easier to store, retrieve and transmit over communication networks, and is better suited for computer-aided diagnostics, than conventional film x-rays. Digital x-ray images can also be displayed more easily than conventional film x-rays, and provide greater image enhancement capabilities, a faster data acquisition rate, and simplified data archival over conventional film x-rays. These advantages make digital x-ray imaging apparatus more desirable than film x-ray apparatus for use in many diagnostic radiology applications, such as mammography.
The general construction and operation of digital x-ray detectors will now be described. As discussed briefly above, digital x-ray detectors collect electrical charges produced by x-rays as a function of position, where the amount of charge is directly proportional to the x-ray intensity. Two general approaches for x-ray conversion are currently under investigation for flat-panel digital x-ray detectors. These approaches are generally referred to as the indirect method and the direct method.
In the indirect method, x-rays are converted to low-energy photons by a scintillator, and the low-energy photons are then converted to electrical charges by solid-state detectors. This method is described in a publication by L. E. Antonuk et al., “Signal, Noise, and Readout Considerations in the Development of Amorphous Silicon Photodiode Arrays for Radiotheraphy and Diagnostic Imaging” Proc. SPIE 1443:108 (1991), the entire contents of which is incorporated by reference herein.
In the direct method, x-rays are converted to electron-hole pairs by photoconductors. An electric field applied to the photoconductor separates the electrons from the holes. This method is described in a publication by J. A. Rowlands et al. entitled “Flat Panel Detector for Digital Radiology Using Active Matrix Readout of Amorphous Selenium,” Physics of Medical Imaging SPIE 3032: 97-108(1997), and in an article by R. Street, K. Shah, S. Ready, R. Apte, P. Bennett, M. Klugerman and Y. Dmitriyev, entitled “Large Area X-Ray Image Sensing Using a PbI hd 2 Photoconductor,” Proc. SPIE 3336: 24-32 (1998). The entire contents of both of these papers are incorporated by reference herein. Many types of photoconductors are under development by medical imaging community.
A type of flat-panel, two-dimensional, digital x-ray, imager comprises a plurality of charge-coupled devices (CCDs) on a silicon substrate. The CCDs can be easily made on the silicon substrate to have a pixel pitch smaller than 10 μm×10 μm. However, because the maximum size of silicon substrates is limited, to achieve the dimensions needed for a large-area flat-panel x-ray detector, multiple wafers have to be patched together. Some of the CCD x-ray detectors are described in the following publications: F. Takasashi, et al., “Development of a High Definition Real-Time Digital Radiography System Using a 4 Million Pixels CCD Camera”, Physics of Medical Imaging SPIE 3032: 364-375 (1997); J. M. Henry, Martin J. Yaffe and T. O. Tumer, “Noise in Hybrid Photodiode Array—CCD X-ray Image Detectors for Digital Mammography,” Proc. SPIE 2708: 106 (1996); and M. P. Andre, B. A. Spivey, J. Tran, P. J. Martin and C. M. Kimme-Smith, “Small-Field Image-Stitching Approach to Full-View Digital Mammography,” Radiology 193, Suppl. Nov.-Dec., 253-253 (1994), the entire contents of each being incorporated by reference herein.
Alternatively, a flat-panel imager can include active matrix arrays of thin film transistors (TFTs) on a glass substrate. Because glass substrates can be large, the digital x-ray imager can, in principle, be made of a single substrate. However, it is very difficult to make a digital detector with a pixel pitch much smaller than 100 μm using substrates other than silicon wafers, as described in the following publications: L. E. Antonuk et al., “Development of Thin-Film, Flat-Panel Arrays for Diagnostic and Radiotherapy Imaging”, Proc. SPIE 1651: 94 (1992); L. E. Antonuk et al., “Large Area, Flat-Panel, Amorphous Silicon Imagers”, Proc SPIE 2432: 216 (1995); and L. E. Antonuk et al., “A Large-Area, 97 μm Pitch, Indirect-Detection, Active Matrix Flat-Panel Imager (AMFPI)”, SPIE Medical Imaging 1998 Technical Abstracts, San Diego, 83 (1998), the entire contents of each being incorporated by reference herein.
As discussed above, digital x-ray imaging techniques represent a vast improvement over conventional film x-ray apparatus. However, digital x-ray imaging systems experience certain drawbacks with regard to image resolution.
It has been a common belief that the resolution of the digital image can be no better than the pixel pitch (pixel periodicity) of the imaging apparatus, and is rather often much worse due to various types of blurring phenomena which occur during image acquisition. However, as can be appreciated from the description of the operation of digital x-ray detectors set forth below, pixel pitch is only one of the many factors that influence the resolution of a digital image obtainable by a digital imaging apparatus.
Detectors for digital radiography are composed of discrete pixels which generally have a uniform size, shape and spacing. The “fill factor” is defined as the active portion of each detector pixel that is used for charge collection relative to pixel pitch or, in other words, the fraction of the pixel area occupied by the sensor for x-ray detection. A flat-panel imager having thin-film transistors (TFTs), for example, has a fill factor which decreases dramatically as the pixel pitch decreases. The TFTs are large compared to transistors on silicon substrates, and the various electrode lines occupy much surface area of the glass substrate. Hence, the fill factor decreases greatly as the pixel pitch decreases.
For example, the fill factor is 57% for a 127 μm pixel pitch array, and is 45% for a 97 μm pixel pitch array which performs indirect x-ray conversion and has been aggressively designed, as described in the article entitled “A Large-Area, 97 μm Pitch, Indirect-Detection, Active Matrix Flat-Panel Imager (AMFPI)” cited above.
The fill factor approaches zero as the pixel pitch decreases toward 50 μm in a detector employing indirect converters. When the fill factor is small, the sensitivity of the detector suffers greatly. Fortunately, however, the fill factor can be improved using direct x-ray converters and a vertical stacking architecture. However, such device becomes increasingly difficult to fabricate as pixel pitch decreases. Thus, development costs for such a device are very high, and it is unclear what the smallest achievable pixel pitch could be with this technique.
In addition, connecting the data and control lines from the detectors to the gate driver chips and readout amplifiers of the pixel array presents severe packaging problems. Currently, bonding of large array of leads from substrate to cable is limited to a device having no less than about an 80-100 μm pixel pitch. By increasing the pixel resolution, multiplexed contacts or new bonding techniques must be developed to create input and output terminals for the device.
The modulation transfer function (MTF), which is a function of spatial frequency f versus location on the detector, is useful for analyzing spatial resolution. Larger MTF values mean better resolution. For existing flat-panel detectors, MTFs are important in analyzing two steps of the image acquisition sequence: the detector pixel pitch, and the blurring produced during the conversion of x-rays to charges. (See, e.g., an article by J. M. Henry, Martin J. Yaffe and T. O. Tumer, “Noise in Hybrid Photodiode Array—CCD X-ray Image Detectors for Digital Mammography,” Proc. SPIE 2708:106(1996), the entire contents of which is incorporated by reference herein).
The charges generated by x-ray conversion can become blurred spatially. The source of blurring for indirect conversion using phosphor is different from that for direct conversion. For most detectors, the measured MTF is dominated primarily by the blurring of the converter when the pixel pitch is 100 μm or smaller.
In addition, settled phosphor scatters light generated by the x-rays. The lateral spreading of the light is approximately equal to the thickness of the layer. For settled phosphor, spatial resolution becomes finer, but the quantum efficiency decreases as the thickness of the phosphor decreases. Optimized thin photoconductors are expected to produce smaller spread. Although the light spread may be less of a problem for thick collimated CsI phosphor, the boundaries of the CsI grains are not perfect.
Furthermore, spatial resolution can be degraded due to x-rays striking the detector at an oblique angle. This problem exists for both direct and indirect x-ray converters. The extent of the charge spread collected by the detector is a function of the incidence angle. Since the x-ray incidence angle is a function of location on the detector relative to the x-ray point source, the modulation transfer function (MTF) of conversion blurring and oblique x-ray incidence blurring MTF conversion is also a function of the location on the detector. The MTF conversion of for Lanex Regular is much worse than Lanex Thin. The MTF of for Lanex Thin is 0.2, at 5 cycles/mm, as described in the article entitled “A Large-Area, 97 μm Pitch, Indirect-Detection, Active Matrix Flat-Panel Imager (AMFPI)”, cited above.
The final system MTF is the product of the MTF associated with various components of the system, including the detector array MTF introduced by the detector pixel pitch and the MTF of conversion blurring. For these reasons, the reduction of pixel pitch alone is not as good the combination of reduction of pixel pitch and reduction of conversion blurring. The resolution of the detector is also effected by a variety of other factors that will not be discussed in detail here such as signal statistical noise, charge conversion noise and electronic noise.
Gamma rays are radiation generated by nuclear process. The energy of gamma rays are typically higher than that of the x-rays, but low energy range of the gamma rays can overlap the high energy end of the x-rays. These detector concepts can also be applied to the detection of gamma rays and megavolt radiation. A thick scintillator or a metal plate/phosphor screen combination is used. This is described in a publication by L. E. Antonuk, et al., “Demonstration of Megavoltage and Diagnostic X-ray Imaging with Hydrogenated Amorphous Silicon Arrays,” Med. Phys. 19: 1455 (1992), the entire contents of which is incorporated by reference herein.
In summary, the major problems expected with small pixel detector development are complicated circuit architecture, increased number of leads to be bonded, the small pitch of the leads necessary for bonding, and resolution being increasingly dominated by scintillator blurring and the oblique x-ray incidence effect. These drawbacks result in decreased manufacturing yield, high risk and expensive development.
Accordingly, a continuing need exists for an apparatus capable of obtaining high-resolution digital x-ray or gamma ray images without the drawbacks discussed above.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method and apparatus for obtaining high-resolution digital x-ray or gamma ray images of an object or objects emitting x-rays or gamma rays, or of an object or objects irradiated with radiation having a wavelength within the x-ray or gamma ray spectrum.
Another object of the present invention is to obtain digital x-ray or gamma ray images at a resolution better than the pixel pitch of the detectors used to obtain the digital images.
Another object of the present invention is to reduce scattered x-rays or gamma rays detected by the digital detector while also improving image resolution.
A further object of the present invention is to minimize blurring of the digital x-ray or gamma ray images which can occur when the x-rays or gamma rays are directly converted into electron-hole pairs in a photoconductor and collected by the active area of the digital detectors.
A still further object of the present invention is to minimize blurring of the digital x-ray or gamma ray image which occurs when the x-rays or gamma rays are indirectly converted into electric charges first by converting x-rays or gamma rays to a longer wavelength radiation, for example, optical radiation, and then collecting and converting these radiation and converting them to electrical charge.
These and other objects of the present invention are substantially achieved by providing an apparatus and method for obtaining a digital image of an object or objects generating x-rays or gamma rays, or of object or objects irradiated with radiation having a wavelength in the x-ray or gamma ray spectrum generated by a radiation source. The apparatus comprises a detector matrix and a radiation mask. The detector matrix comprises a plurality of two-dimensional array of detector pixels, each of which comprises a detection surface having a respective active surface area and being adapted to generate an electrical signal in response to a radiation stimulus applied thereto. The radiation mask has an opaque portion and a plurality of apertures therein. The mask is positioned between the detector matrix and the radiation source. The radiation can pass through the mask to the detector only through the apertures of the mask. The image resolution is related to the aperture size and system configuration. Many modes of operation of this detector system are described below.
In the first mode of operation, the detector images object or objects that give radiation. The mask is placed between the object and the active detector pixels. The mask allows radiation from selected portions of the objects to be imaged by the detector for a single imaging frame.
In the second mode of operation, the object or objects are placed between a radiation source and the mask. Again, the mask allows a selected portion of the object or objects to be imaged by the detector for a single image frame.
In the third mode of operation, the object or objects are placed between the mask and the detector array, such that the opaque portion of the mask prevents portions of the radiation from passing therethrough, and each of the apertures permits a portion of the radiation which has passed through a respective portion of the object or objects to pass therethrough and propagate onto an active area of the detection surface of a respective one of the detector pixels. The detector pixels therefore each output a respective signal of the respective portion of the object.
The imaging apparatus further includes a conveying device which moves the detector matrix and radiation mask in unison in relation to the object to enable the areas of the detection surfaces of the detector pixels to receive portions of the radiation propagating through other portions of the object, and to output signals representative of those other portions. In particular, the detector matrix and radiation mask are moved along a pattern of movement in increments which are a fraction of the pixel pitch of the detector pixels. After each exposure of the detector to the radiation source, the charges collected by the detector array are read out to a computer and the detector array is reinitialized and the detector and mask are moved to the next appropriate position. This process is repeated so those portions of the object or objects which would not normally be imaged by this detector in the stationary mode can be imaged. These steps of moving the detector pixels and mask, and irradiating the object, are repeated until digital images of all portions of the object or objects have been obtained. The digital data are then arranged into an image representative of the entire object or objects.
BRIEF DESCRIPTION OF THE DRAWINGS
The various objects, advantages and novel features of the present invention will be more readily appreciated from the following detailed description when read in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic side view illustration of a high-resolution x-ray or gamma ray imaging apparatus according to an embodiment of the present invention;
FIG. 2 is a schematic illustration of the high-resolution imaging apparatus shown in FIG. 1 in relation to an object being imaged and a point x-ray or gamma ray source;
FIGS. 3 a and 3 b are schematic illustrations showing the scattering of light generated in phosphor screens by incident x-ray energy in relation to the thickness of the phosphor screens which can be employed to perform x-ray conversion in the imaging apparatus shown in FIGS. 1 and 2;
FIG. 4 is a schematic illustration showing charge smear generated in a photoconductor, which can be employed to perform x-ray conversion in the imaging apparatus shown in FIGS. 1 and 2, in relation to various angles of incidence of x-ray energy striking the photoconductor;
FIG. 5 is a schematic illustration of a top plan view of a mask which can be employed in the imaging apparatus shown in FIGS. 1 and 2;
FIG. 6 is a schematic top plan view of an example of a detector pixel array which can be employed in the imaging apparatus shown in FIGS. 1 and 2;
FIG. 7 a is a schematic illustration showing the pattern of electromagnetic radiation which passes through the mask shown in FIG. 5 and strikes the scintillator adjacent the active area of the detector pixels of the detector pixel array shown in FIG. 6;
FIG. 7 b is a diagram illustrating an exemplary sequence of movements of the detector pixel array shown in FIG. 6 and the mask shown in FIG. 5 of the imaging apparatus shown in FIGS. 1 and 2 with respect to the object being imaged according to an embodiment of the present invention;
FIG. 8 is a schematic top plan view of another example of a mask which can be employed in the imaging system shown in FIGS. 1 and 2;
FIG. 9 a is a schematic illustration showing the pattern of electromagnetic radiation which passes through the mask shown in FIG. 8 and strikes the scintillator adjacent the active area of the detector pixels of the detector pixel array shown in FIG. 6;
FIG. 9 b is a diagram illustrating an exemplary sequence of movements of the detector pixel array shown in FIG. 6 and the mask shown in FIG. 8 of the imaging apparatus shown in FIGS. 1 and 2 with respect to the object being imaged according to an embodiment of the present invention;
FIG. 10 is another diagram illustrating an exemplary sequence of movements of the detector pixel array shown in FIG. 6 and the mask shown in FIG. 5 of the imaging apparatus shown in FIGS. 1 and 2 with respect to the object being imaged according to an embodiment of the present invention;
FIG. 11 is a schematic top plan view illustration of another example of a mask which can be employed in the imaging system shown in FIGS. 1 and 2;
FIG. 12 a is a schematic showing the pattern of electromagnetic radiation which passes through the mask shown in FIG. 11 and strikes the scintillator adjacent the active area of the detector pixels of the detector pixel array shown in FIG. 6;
FIG. 12 b is a diagram illustrating an exemplary sequence of movements of the detector pixel array shown in FIG. 6 and the mask shown in FIG. 11 of the imaging apparatus shown in FIGS. 1 and 2 with respect to the object being imaged according to an embodiment of the present invention;
FIG. 13 is a schematic top plan view of another example of a detector pixel array which can be employed in the imaging apparatus shown in FIGS. 1 and 2;
FIG. 14 is a schematic top plan view of another example of a mask which can be employed in the imaging system shown in FIGS. 1 and 2;
FIG. 15 a is a schematic illustration showing the pattern of electromagnetic radiation which passes through the mask shown in FIG. 14 and strikes the scintillator adjacent the active area of the detector pixels of the detector pixel array shown in FIG. 13;
FIG. 15 b is a diagram illustrating an exemplary sequence of movements of the detector pixel array shown in FIG. 13 and the mask shown in FIG. 14 of the imaging apparatus shown in FIGS. 1 and 2 with respect to the object being imaged according to an embodiment of the present invention;
FIG. 16 is a schematic top plan view of another example of a detector pixel array which can be employed in the imaging apparatus shown in FIGS. 1 and 2;
FIG. 17 is a schematic top plan view of another example of a mask which can be employed in the imaging system shown in FIGS. 1 and 2;
FIG. 18 a is a schematic illustration showing the pattern of electromagnetic radiation which passes through the mask shown in FIG. 17 and strikes the scintillator adjacent the active area of the detector pixels of the detector pixel array shown in FIG. 16;
FIG. 18 b is a diagram illustrating an exemplary sequence of movements of the detector pixel array shown in FIG. 16 and the mask shown in FIG. 17 of the imaging apparatus shown in FIGS. 1 and 2 with respect to the object being imaged according to an embodiment of the present invention;
FIG. 19 is a schematic top plan view of another example of a detector pixel array which can be employed in the imaging apparatus shown in FIGS. 1 and 2;
FIG. 20 is a schematic top plan view of another example of a mask which can be employed in the imaging system shown in FIGS. 1 and 2;
FIG. 21 a is a schematic illustration showing the pattern of electromagnetic radiation which passes through the mask shown in FIG. 20 and strikes the scintillator adjacent the active area of the detector pixels of the detector pixel array shown in FIG. 19;
FIG. 21 b is a diagram illustrating an exemplary sequence of movements of the detector pixel array shown in FIG. 19 and the mask shown in FIG. 20 of the imaging apparatus shown in FIGS. 1 and 2 with respect to the object being imaged according to an embodiment of the present invention;
FIG. 22 is a schematic illustration of a high-resolution x-ray or gamma ray imaging apparatus according to another embodiment of the present invention in relation to an object being imaged and a point x-ray or gamma ray source;
FIG. 23 a is a schematic top plan view of an example of a mask which can be employed in the imaging system shown in FIG. 22;
FIG. 23 b is a diagram illustrating an exemplary sequence of movements of the mask shown in FIG. 23 a of the imaging apparatus shown in FIG. 22 with respect to the object being imaged according to an embodiment of the present invention;
FIG. 24 a is a schematic illustration of a high-resolution x-ray or gamma ray imaging apparatus according to another embodiment of the present invention in relation to an object being imaged and a point x-ray or gamma ray source;
FIG. 24 b is a diagram illustrating an exemplary pattern of movement of the x-ray source of the apparatus shown in FIG. 24 a with respect to the object being imaged according to an embodiment of the present invention;
FIGS. 25 a, 25 b and 25 c are schematic cross-sectional views of examples of masks which can be employed in an imaging apparatus as shown in FIGS. 1, 2 , 22 , 24 a, 26 , 27 or 28 , when the imaging apparatus is used with a point x-ray source;
FIGS. 25 d and 25 e are schematic cross-sectional views of examples of masks which can be employed in an imaging apparatus as shown in FIGS. 1, 22 , 27 or 28 , when the imaging apparatus is used with a parallel beam x-ray source;
FIG. 26 is a schematic illustration of a high-resolution x-ray or gamma ray imaging apparatus according to another embodiment of the present invention in relation to an object being imaged and a point x-ray or gamma ray source;
FIG. 27 is a schematic illustration of a high-resolution x-ray or gamma ray imaging apparatus according to a further embodiment of the present invention in relation to an object being imaged and a point x-ray or gamma ray source;
FIG. 28 is a schematic illustration of a high-resolution x-ray or gamma ray imaging apparatus according to still another embodiment of the present invention in relation to an object being imaged and a point x-ray or gamma ray source;
FIG. 29 is a schematic illustration of a detector array such as a charge coupled device (CCD); and
FIG. 30 is a schematic illustration showing the pattern of electromagnetic radiation which passes through the mask and strikes the scintillator adjacent the active area of the detector pixels of the detector pixel array shown in FIG. 29 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of a high-resolution x-ray or gamma ray imaging apparatus 100 is exemplified in FIGS. 1-7 b. In particular, FIG. 1 is a schematic diagram illustrating a view of a side of the imaging apparatus 100 lying in the x-z plane. The imaging apparatus 100 includes a substrate 102 , which can be a silicon or glass substrate or any other appropriate material as described in the Background section above, a detector pixel array 103 with detector pixels 104 which are disposed on the substrate 102 , and a scintillator 106 . The active area of the detector pixels 104 can be any type of pixel as described in the Background section above.
In this embodiment, the scintillator 106 converts x-rays or gamma rays to electron-hole pairs or visible photons. The electron hole pairs or visible photons are converted to electrical charge, current or voltage collected on the active radiation detector area of the pixel 104 . In the typical digital x-ray or gamma ray detectors and visible imagers, the active area of the detector pixels 104 each measure the amount of charge collected per pixel. In general, the active area of the detector pixel 104 measures the change of electrical properties, material properties, physical properties, and so on, produced by the variation of the electromagnetic radiation intensity on the active area of the detector pixel 104 .
A mask or mask/antiscatter grid 108 (hereinafter “mask 108 ”) having aperture openings 110 therein is disposed on the upper surface of the scintillator 106 . Each aperture opening 110 is aligned with a corresponding active area of the detector pixel 104 as shown. For many applications, the mask 108 can be rigidly attached to the scintillator 106 , or can be directly attached to the active area of the detector pixels 104 . The mask 108 must be opaque enough to substantially block the penetration of the electromagnetic radiation except through the aperture openings 110 .
The active area of each detector pixel 104 is larger than its respective aperture opening 110 , and detects the electromagnetic radiation (x-rays or gamma rays) passing through its respective aperture opening 110 . As discussed below, the size of the aperture openings 110 and the number of images taken, not the detector pixel pitch, determines the image resolution.
The detector shown in FIG. 1 can be used to image objects that radiate x-rays or gamma rays. For example, the detector can be used for x-ray astronomy.
FIG. 2 is a schematic drawing illustrating a side view of the embodiment of the imaging apparatus 100 shown in FIG. 1 being used in an x-ray radiography application to image the interior of an object 112 , which can be, for example, a human body (or a portion thereof) or any other object. An x-ray source 114 is also illustrated schematically. Also, the source 114 could be a gamma ray source, or any energy source.
As shown, the object 112 to be imaged is positioned between the x-ray source 114 and the x-ray mask 108 of the imaging apparatus 100 . After the x-ray source 114 emits a pulse of x-rays and the x-rays penetrate the object 112 , the x-rays reach the mask 108 . The mask 108 blocks all the x-rays from hitting the scintillator 106 except at the mask openings 110 .
The scintillator 106 can be a phosphor screen, which converts the x-rays to optical radiation, and the photodiodes on each detector 104 covert the optical radiation to electrical charge. Alternatively, the scintillator 106 can be of the type that converts the x-rays directly to charge, such as a photoconductor, photocathode, or the like. The geometry and dimensions of the active area of the detector pixels 104 and x-ray mask openings 110 are such that the x-rays passing through a single mask or mask/antiscatter grid opening 110 will strike preferably only a single detector pixel 104 . Preferably, the active detector area of one pixel 104 captures the charges created by one x-ray beamlet. The charge collected per pixel is then output via data lines (see FIG. 6 ), and processed in a manner known in the art.
The arrangement of the imaging apparatus 100 will improve the detector system MTF and increase the Nyquist frequency of even the existing best known detector pixels arrays to obtain a resolution much higher than that obtained by the same detector without a mask and without motion. The detector system MTF is the product of MTF associated with various component of the detector. Two MTF will be discussed: MTF associated with detector geometry and MTF associated with x-ray conversion.
As will now be explained, the operation of the imaging apparatus 100 will improve MTF associated with the detector system geometry for detectors which perform either direct or indirect conversion of the x-rays or gamma rays as discussed above.
FIGS. 3 a and 3 b are schematic diagrams illustrating the manner in which phosphor screens scatter the light generated by the x-rays during indirect x-ray conversion. As shown, the light scatter is proportional to the thickness of the phosphor screen. A thicker phosphor screen will provide a greater light scatter.
FIG. 4 is a schematic diagrams illustrating that for direct conversion of x-rays, charge smear is minimal when the x-ray incidence angle is zero degrees, and increases as the x-ray incidence angle increases. For both of these situations, an active pixel detector area much larger than the x-ray mask aperture will reduce conversion blurring and improve conversion MTF.
The active area of the detector pixels 104 and mask 108 can have a wide range of pattern or layout. For example, FIG. 5 is a schematic diagram of mask 108 of the imaging apparatus, with apertures 110 viewed in the x-y plane in FIG. 1 . The apertures 110 are square or essentially square, and each have a length and width equal to d 1 . The area of each aperture is d 1 ×d 1 , and the pitch of the aperture is equal to the pixel pitch D 1 in both directions. The arrangement of the apertures 110 forms a uniform grid of openings in the mask 108 . As discussed above, the electromagnetic radiation to be detected has to be completely blocked by the mask 108 except at apertures 110 in the mask 108 . The apertures 110 are used to control the area and position at which the electromagnetic radiation hits the detector pixels.
In this embodiment, the pixel pitch D 1 is an integer multiple of d 1 . To enable the object to be 112 imaged without missing any areas and without double-exposing any areas, the imaging apparatus 100 is configured and operated so that the beamlets will each “fit” into a respective active area of the detector pixel 104 an exact number of times. In other words, D 1 =nd 1 , and n is an integer equal to or greater than 2. FIG. 5 shown an aperture arrangement where D 1 =2d 1 .
FIG. 6 is a generalized schematic illustration of a top view of a possible layout of the detector pixel array 103 and the active area of the detector pixels 104 for the imaging apparatus 100 as shown in FIGS. 1 and 2. The active radiation detector areas of the pixels 104 are shown shaded with hatched lines. It is noted that the dimensions of the active area of the detector pixels 104 vary greatly from one manufacturer to another, and that the shapes of the active radiation detector areas of the pixels 104 can vary widely and are represented as squares only for illustration purposes. Row control (selection) lines 116 , which are disposed on the substrate 102 (see FIGS. 1 and 2 ), are spaced uniformly from each other at the distance D 1 as shown. Column data lines 118 , which are also disposed on substrate 102 , are also spaced uniformly from each other at the distance D 1 . Typically, data is read out one row at a time (but could be more than one row at a time) through the column data lines 118 to a processing device, such as a computer 119 or the like, as controlled by the row control lines 116 .
FIG. 7 a is a schematic representation of the radiation beamlets 120 that pass through the apertures 110 of the mask 108 which has been superimposed over the active area of the detector pixels 104 . Specifically, the electromagnetic radiation beamlets 120 are illustrated as white squares on the pixels 104 , with each white square having a dimension d 1 ×d 1 , which is equal to or essentially equal to the dimension of the aperture 110 through which the beamlet 120 has passed. In summary, as shown in FIG. 7 a, the radiation beamlets 120 hit the scintillator above the active area of the detector pixels 104 with dimension d 1 ×d 1 . The distance between the centers of adjacent apertures 110 is equal to D 1 , which is the pitch of the active area of the detector pixels 104 . The relationship between the dimensions of each active area of the detector pixel and the dimensions of the radiation beamlets when they hit the detector pixel is D 1 =nd 1 , where n=2 in this example. Also, the x-rays are only allowed to impact the detector during the x-ray exposure time, but not during the data read out time or while the mask or detector is being moved.
To assure that the entire object 112 (FIG. 2) is imaged, a conveying device 124 (see FIG. 1 ), such as a stepper motor, servo motor, motorized table, or any other suitable device, is configured to move the imaging apparatus 100 in a controlled manner. The imaging apparatus 100 is moved with respect to the object 112 in increments equal to d 1 along the pattern shown in FIG. 7 b. That is, after one exposure of the object 112 to the x-rays, a x-ray image of a respective portion of the object 112 is obtained by each pixel 104 . The data produced by the pixels 104 is output through the column data lines 118 . The imaging apparatus 100 is then moved in the x-y plane by a distance d 1 along an arrow in FIG. 7 b.
This process is repeated n 2 times with the imaging apparatus 100 (i.e., the detector pixels grid 103 , scintillator 106 and mask 108 ) moved systematically in the x-y plane, for example, in the directions along arrows 126 , 128 , 130 and 132 for each exposure and reading, so that every part of the object 112 is imaged. After all four x-ray image patterns (n 2 =4 in this example) have been obtained and stored, they are reconstructed by a processing device, such as the computer 119 or the like into a complete image representative of the entire object 112 . The reconstructed image has higher resolution than any single x-ray image pattern obtained with or without the mask 106 .
The principle of improvement of image resolution is explained first assuming no x-ray conversion blurring and then expanded to include x-ray conversion blurring.
For the fill factor of the active area of the detector is 100%,
MTF geometry =sin(π fD )/(π fD ),
Where MTF geometry is the MTF associated with the geometry of the detector system in one direction, D is the dimension of the pixel pitch, and f is the spatial frequency. The Nyquist frequency is 1/2D.
When the linear dimension of the active area of the detector pixel is reduced to d 1 , for D=2d 1 ,
MTF geometry =sin(π f ( d 1 ))/(π f ( d 1 )),
and the Nyquist frequency is still 1/2D.
When the linear dimension of the active area of the detector is d 1 and D=2(d 1 ), and the detector is moved as shown in FIG. 7 b and D=2(d 1 ), then
MTF geometry =sin(π f ( d 1 ))/ (π f ( d 1 )),
and the Nyquist frequency is increased to 1/4D. This technique is used to reduce aliasing and improve image resolution for infrared cameras. The technique is called microscanning, dithering and microdithering, as described in the following publications: J. C. Gillette, T. M. Stadtmiller and R. C. Hardie, “Aliasing reduction in staring infrared imagers utilizing subpixel techniques,” Optical Engineering 34, 3130-3137 (1995); R. C. Hardie, K. J. Barnard, J. G. Bognar, E. E. Armstrong and E. A. Watson, “High-resolution image reconstruction from a sequence of rotated and translated frames and its application to an infrared imaging system,” Optical Engineering 37, 247-260 (1998), the entire contents of each being incorporated by reference herein.
For x-ray and gamma ray imaging, there is conversion blurring. Conversion blurring can eliminate the benefits of microscan without mask and significantly reduce the signal. For example, for a TFT digital x-ray detector having an active area of the pixel with a dimension d 1 ×d 1 , if If N number of x-rays impinges on this active area of the pixel and M number of electrons are created per x-ray, then the total number of electrons created per pixel would be MN. When there is no conversion blurring, the total number of charge collected by this pixel would be MN. Due to conversion blurring, the percentage of charge collected by this pixel decreases as the pixel dimension decreases, and the remaining charges are spread to the neighboring pixels.
In the detector system of the present invention as shown, for example, in FIGS. 1-2, the aperture size of the mask determines the Nyquist frequency and the MTF associated with the pixel, while the active area of the pixel is kept large to increase the percentage of charge collected as the aperture of the mask decreases.
The small aperature of the mask and large detector pixel size also improves the MTF associated with the conversion blurring, MTF conversion . The detector system MTF, MTF system , is the product of the MTF associated with the various aspects of the system,
MTF system =MTF geometry *MTF conversion *MTF others ,
Where MTF others is the MTF associated with other component of the detector system.
The detector system described in FIGS. 1-2 and 5 - 7 b with a mask and motion has a higher Nyquist frequency, larger values for the MTF within the Nyquist frequency and improve signal as compared to imaging without the mask and motion. As explained above, the detector pixel array 103 and mask 108 arrangement can have a wide variation of patterns and dimensions. For example, FIG. 8 is a schematic of a top view of a mask 134 which can be used in the imaging apparatus 100 shown in FIGS. 1 and 2 instead of mask 108 . Mask 134 includes apertures 136 which are square or essentially square and have a dimension d 2 ×d 2 , such that the pixel pitch D 1 of detector pixels 104 is equal to 3(d 2 ), (D 1 =3(d 2 )) in both directions.
FIG. 9 a is a schematic view showing the electromagnetic radiation that has passed through the mask 134 and has impacted on the scintillator above detector pixels 104 . That is, the x-ray beamlets 138 pass through respective apertures 136 in the mask 134 and strike the center of the active radiation detection area of the respective pixel 104 .
To obtain an entire x-ray image of the object 112 with an imaging apparatus 100 including mask 134 , the imaging apparatus 100 is moved along a pattern as shown, for example, in FIG. 9 b. That is, as discussed above with regard to FIGS. 7 a and 7 b, after each exposure of the object 112 to x-rays and, generation of an x-ray image sub-pattern by the pixels 104 , and read-out of the pixel data through column data lines 118 , the imaging apparatus 100 is moved to a new location. The imaging apparatus 100 is moved sequentially each time an x-ray image is taken, and is moved in a possible pattern shown in FIG. 9 b with each arrow representing one successive movement(d 2 =D/3). This process is repeated n 2 =9 times with the detector 103 , scintillator 106 and mask 134 moved in unison so that every part of the object 112 will be imaged. After all of the x-ray image sub-patterns have been obtained and stored, they are combined by a processor such as a computer or the like to provide an x-ray image representative of the entire object 112 .
In addition, aliasing can be further minimized and MTF improved by oversampling and applying appropriate mathematical algorithms. That is, returning to the example discussed with regard to FIGS. 7 a and 7 b, instead of moving the imaging apparatus 100 including detector 108 by a distance d 1 between successive x-ray or gamma ray exposures, the imaging apparatus 100 is moved by a distance of (d 1 )/2=(D 1 )/2n, so the total number of sub-frames required is (2n) 2 . The value (d 1 )/2=(D 1 )/2n. The arrows shown in the diagram of FIG. 10 suggest a possible sequence of movements for imaging apparatus 100 including detector pixels array 103 , scintillator 106 and mask 108 for a detector motion of (d 1 )/2 between exposures, with the distance d 1 being equal to one-half the pixel pitch D 1 (i.e., D 1 /d 1 =2).
An example of sampling variation by increasing the size of the apertures in the mask without changing the detector size or the distance between exposures is exemplified in FIGS. 11, 12 a and 12 b. FIG. 11 shows a mask 140 with apertures 142 each having a dimension d 3 ×d 3 , where D 1 /(n−1)>d 3 >D 1 /n. In this example, n=2. FIG. 12 a shows the spot size of the radiation beamlets 144 formed by mask 140 on the scintillator above the detector pixels 104 . After each x-ray exposure and data readout operation is performed in the manner discussed above, the detector is moved a distance D 1 /n along the arrows shown in FIG. 12 b. This process is repeated n 2 times with the detector 103 , scintillator 106 and mask 140 moving in unison so that every part of the object 112 is imaged. The suggested motion is similar to that of the example showing FIG. 10 to reduce aliasing. The aliasing reduction is dependent on the amount of overlapping image.
It is noted that the periodicity of the detector pixel pitch need not be square. For example, as shown in FIG. 13 shows a detector pixel array 146 having the active area of the detector pixels 148 within the D 1 ×0.75(D 1 ) pixel pitch. For some applications, a rectangular area of the detector pixel layout is more effective than a layout of square detector pixels.
FIG. 14 is a schematic illustration of a mask 150 having apertures 152 appropriate for the detector pixels 148 shown in FIG. 13 . In this example, n=D 1 /d 4 =3.
FIG. 15 a is a schematic diagram illustrating the location of the radiation beamlets 154 passing through the apertures 152 of the mask 150 onto the scintillator above the detector pixels 148 . Preferably, the x-ray beams that pass through each aperture 152 in the mask 150 are centered on the active radiation detection area of a respective pixel 148 . After each x-ray exposure to the object 112 and data readout is performed in the manner discussed above, the imaging apparatus 100 including detector pixel array 146 and mask 150 is moved a distance (D 1 )/4 along the arrows shown in FIG. 15 b. This process is repeated 6 times with the detector grid 146 and mask 150 moved systematically so that every part of the object 112 will be imaged.
FIG. 16 is a schematic of a top view of a variation in the layout of the detector pixels for the imaging apparatus 100 shown in FIGS. 1 and 2. In the pixel array 156 , the active areas for radiation detection of the pixels 158 are shown shaded with hatched lines. The shape of each pixel 158 is shown as a square for schematic purpose only. In general, the pixel shape can vary from one product to another and from one manufacturer to another.
As shown, the detector pixels 158 are staggered in formation. The periodicity of the pixel is 2D 1 in the horizontal direction and D 1 in the vertical direction. The arrangement further includes column data lines 160 , which are similar to the column data lines 118 discussed above and are spaced uniformly a distance D 1 apart. Each data line will be connected to all the pixels 158 in a respective column of pixels. Control lines 162 run in a staggered zigzag pattern from left to right in this embodiment, and are spaced uniformly a distance D 1 apart.
FIG. 17 is a schematic illustration of the aperture layout of the mask 164 employed in the imaging apparatus 100 shown in FIGS. 1 and 2 having a detector pixel layout as shown in FIG. 16 . The apertures 166 are arranged in a staggered fashion as shown, and D 1 /(d 5 )=2.
FIG. 18 a is a schematic illustration showing the locations at which the radiation beamlets 168 pass thought the apertures 166 overlaying the detector pixel array 156 . FIG. 18 b is a diagram showing an example of movement of the mask 164 and detector pixel array 156 for four x-ray exposures and returning to its original position and image readings which occur in the manner discussed above. As shown, the mask 164 and detector pixel array 156 move along the arrows by a distance d 5 between each exposure and image reading. The minimum number of exposures is n 2 , and n=2 in this example.
In general, there are many variations in direction and distance in which the detector pixel array 156 and mask 164 can be moved. For instance, D 1 /(d 5 ) can be any number greater than or equal to 2, and various image data sampling algorithms can be implemented. Also, the pixel pitch does not have to be square.
For example, FIG. 19 is another schematic illustration of a top view of a detector pixel array 170 which can be employed in imaging apparatus 100 shown in FIGS. 1 and 2 in place of detector pixel array 103 . This figure is similar to FIG. 16, except the periodicity of the pixel detectors 172 is 3(D 1 ) in the x direction.
FIG. 20 is a schematic illustration of a mask 174 which can be employed in an imaging apparatus 100 which includes detector pixel array 170 shown in FIG. 19 . The apertures 176 of the mask 174 are arranged in a staggered fashion along the x direction, and D 1 =3(d 6 ).
FIG. 21 a is a schematic illustration of the positions at which the radiation beamlets 178 which pass through the aperture of the x-ray mask 174 overlaying the detector pixel array 170 strike the detector pixels 172 of the grid 170 . FIG. 21 b is a diagram of an example of the manner in which the detector pixel array 170 and mask 174 are moved for nine exposures by a distance d 6 between exposures and returning to its original position. As can be appreciated from FIG. 21 b, the staggered formation of the detector pixels grid 170 and mask 174 enable the entire object to be imaged by moving the grid 170 and mask 174 in one direction (i.e., the x direction), as opposed to in the x and y directions as from a non-staggered grid discussed above.
Another mask variation is that the apertures are not squares. For some applications, other x-ray aperature shapes might be more appropriate.
Although only several examples of masks and detector pixel array arrangements are described above, various types of mask having various apertures patterns can be used in the imaging system 100 to provide a wide variety of possible image system configurations. Also, as discussed below, the masks need not be attached to the scintillator, but rather, could be positioned at any appropriate location between the x-ray or gamma ray source and the detector pixel array.
For example, FIG. 22 is a schematic illustrating an embodiment of an imaging apparatus 180 which includes a substrate 182 , a detector pixel array 184 including detector pixels 186 , a scintillator 188 , and a mask 190 having apertures 191 therein similar to those described above. The imaging apparatus 180 can also include an antiscatter grid 192 which is disposed over the scintillator as shown. An example of an antiscatter grid is disclosed in related copending U.S. patent application Ser. No. 08/879,258, cited above. An x-ray source 194 and object 196 being imaged are also illustrated in relation to the apparatus 180 .
Unlike imaging apparatus 100 , in this embodiment the object to be imaged 196 is positioned between x-ray mask 190 and the detector pixel array 184 . As shown, the x-ray energy propagates out of a point x-ray source in a cone shape.
FIG. 23 a shows the mask 190 as viewed in the x-y plane. The apertures 191 are shown as having a square shape, but could have any suitable shape as discussed above for the other masks configurations. Primarily, the size and arrangement of the apertures 191 on the mask 190 should be such that they permit uniform sized and equally spaced beamlets to form on the detector pixels 186 .
The periodicity of the square digital detector pixels is defined to be D 1 ×D 1 . The dimension of each x-ray beamlet as it hits the detector pixel (the “x-ray spot size”) is equal to d 7 ×d 7 , where d 7 <D. Using Euclidean geometry, if the x-ray source 194 is considered to be a vertex of a triangle, the x-ray beamlet on the detector pixels 186 is the base of the triangle, and the distance between the x-ray source 194 and the detector pixel is L (distance measured orthogonally), then if the x-ray mask 190 is placed a distance αL from the x-ray source where α is a fraction less than 1, the dimensions of the apertures 191 in the x-ray mask 190 must be equal to α(d 7 )×α(d 7 ). Also, as with the variations discussed above, the apertures of the mask and the detector pixels can vary in size and shape depending on the need.
The operation of the imaging apparatus 180 will now be described. When the x-ray source 194 emits a pulse of x-ray energy which strikes the x-ray mask 190 , the mask blocks all of the x-rays from striking the object except at the mask apertures 191 . The x-ray beamlets which pass through the apertures of the mask penetrate the object 196 and propagate toward the antiscatter grid 192 . The antiscatter grid 192 eliminates the scattered radiation, so that only the primary radiation impacts the scintillator 188 . As in the imaging apparatus 100 shown in FIGS. 1 and 2, the scintillator 188 can be a phosphor screen, which converts the x-rays to optical radiation. A photodiode on each detector pixel coverts the optical radiation to electrical charge. Alternatively, the scintillator 188 can be of the type that converts the x-rays directly to electrical charge, such as photoconductor, photocathodes, and so on.
The geometry and dimensions of the detector pixels 186 and x-ray mask openings 191 are such that each x-ray beamlet passing through a respective aperture in the mask and a respective aperture in the antiscatter grid 192 will strike within a single detector pixel 186 . Preferably, the active detector area of one pixel 186 captures the charges created by the impacting x-ray beamlet. After each exposure, the x-ray source is turned off or x-ray shutter is closed. The charges collected by the pixels 186 are then output via data lines in a manner similar to that described above for imaging apparatus 100 .
For this example, n=D 1 /d 7 =2. After one exposure and data read out, the detector grid 184 (and hence the substrate 182 , scintillator 188 and antiscatter grid 192 ) is moved a distance D 1 /2 for n=2 in a sequence as shown in FIG. 12 b and the x-ray mask 190 is moved by a distance αd 7 in the same sequence as shown in FIG. 23 b while the object 196 (patient) remains stationary, to expose a different portion of the object 196 . This process is repeated n 2 times with the detector and mask moved in unison so that every part of the object will be imaged. After all the necessary sub-images have been output and stored, the data is processed to produce one image in a manner similar to that described above. Even though n 2 exposures are taken, the tissue is exposed to the same dose of x-ray as in one exposure without the mask, because each exposure is 1/n 2 the area of an exposure without the mask. The data is then reconstructed digitally to produce the high-resolution image.
Variations of the embodiments for the mask and the detector grid layout are the same as those exemplified in FIGS. 8 through 21, except that each aperture of the mask is reduced in size by the factor a and the motion of the mask is reduced by the same factor.
FIG. 24 a is a schematic diagram illustrating that the image filtering concept can be obtained by moving the location of the x-ray source 194 without moving the mask 190 . For the detector shown in FIG. 6 and D 1 /d 7 =n=2, the detector motion is shown in FIG. 12 b, the corresponding x-ray source displacement is shown in FIG. 24 b, where the distance between displacement is d 8 and d 8 ≈(D 1 /n)(α/(1−α)). The direction of motion for the source, shown in FIG. 24 b, is opposite to the direction of motion for the detector, shown in FIG. 12 b. The range for α is between 0 and 1, and the optimal values for a are near 0 . 5 . The positions for the x-ray source 194 are such that every part of the object will be imaged. Variations of the embodiments for the mask and the detector grid layout are the same as those exemplified in FIGS. 8 through 21, except that each aperture is reduced in size by the factor α.
Another variation of FIG. 24 a is to move the location of the x-ray source 194 and the x-ray mask 190 , but not move the detector 184 , the scintillator 188 or the antiscatter grid 192 .
As discussed above, the x-ray mask 190 should be made of high atomic number materials 191 on x-ray transparent substrate 192 , so that the x-rays can be substantially completely blocked with even a thin mask. The desirable thickness will dependent on the allowable transmitted x-rays and the x-ray energy. Gold is most commonly used as x-ray lithography masks. The attenuation factor of gold over the density, μ/ρ, varies with x-ray energy. For example, at x-ray energy of 22.16 keV, μ/ρ=59.7 cm 2 /g and at x-ray energy of 30 keV, μ/ρ=25.55 cm 2 /g, where ρ=19.3 g/cm3 is the density of gold. The amount of x-ray that penetrates the mask is equal to exp(−μL), where L is the thickness of the mask. Typically gold masks of can produce apertures with dimensions of 75 μm to 100 μm and vertical walls are routinely used to block x-rays in the 5-20 keV range. The mask needs to be thicker as the x-ray energy increases. The aperture walls of the mask should ideally be slanted along the direction at which the x-rays are received. If the x-ray source is from a point, then the mask should have the configuration shown schematically in FIGS. 25 a, 25 b or 25 c, in which the slant angles increase with distance from the center of the mask. The top layer of the mask in FIG. 25 c does not have to have the same thickness as the bottom layer.
On the other hand, if the x-ray source is a parallel beam, the mask should have a configuration like that shown schematically in FIG. 25 d, in which the aperture walls are all substantially vertical. The photoresist used in making the x-ray mask 193 does not have to be removed if it is x-ray transparent material, as shown in FIG. 25 e. This is also true for a mask focused to a point x-ray source.
In an imaging apparatus 100 as shown in FIGS. 1 and 2, x-ray scatter can be reduced if the mask is thick and configured as an antiscatter grid. However, in the imaging apparatus 180 as shown in FIG. 22, x-ray scatter can be reduced even without the use of an antiscatter grid.
That is, when the x-ray sensitive area ε of the detector pixels is small compared to the area associated with the detector pitch E, the scatter is reduced by approximately the ratio ε/E. Alternatively, a thin mask 200 with aperture d 9 ×d 9 can be used in the imaging apparatus 180 in place of the antiscatter grid 192 , as shown schematically in FIG. 26, to reduce x-ray scatter by the ratio of (d 9 /D 1 ) 2 .
FIG. 27 is a schematic illustration of another embodiment of an imaging apparatus according to the present invention. Imaging apparatus 202 includes a substrate 204 , a digital detector pixel array 206 comprising detector pixels 208 , a scintillator 210 , and an x-ray mask 212 having apertures d 10 ×d 10 . However, in this embodiment, the mask is placed a distance λ 1 above the scintillator, and the object (not shown) to be imaged is placed above the x-ray mask 212 . The mask wall thickness and the distance x can act as an antiscatter grid. Alternatively, a properly aligned double mask 214 , having apertures d 11 ×d 11 and individual mask portions separated by an appropriate distance λ 2 , can be used to reduce scatter as shown schematically in FIG. 28 .
The invention as described with regard to FIGS. 1-28 employs a detector having a detector pixel pitch that is larger than the x-ray mask opening. The following embodiment of the invention employs detectors that have small pixels to obtain high-resolution images. A schematic of a CCD is shown in FIG. 29 . The pixel sizes of the CCD can have dimensions d 12 ×d 12 , with d 12 being less than 10 μm. However the resolution of the conventional x-ray image is degraded by the phosphor so that the small pixels of the CCD still cannot produce high-resolution images.
The concept described above is also applicable to the CCD detector. A group of the CCD can be configured together to collect data for one x-ray image pixel, where d 12 is the pixel pitch of the CCD. The CCD arrays can be used in configurations shown in FIGS. 1, 2 , 22 , 24 , 26 , 27 and 28 .
FIG. 30 is a schematic illustration showing the pattern of x-rays which passes through the mask overlaying the active area of the detector pixels of the detector pixel array shown in FIG. 29 . The example shown in FIG. 30 utilizes 3×3 CCD pixels to collect the information relating to x-ray intensity for one x-ray image pixel, i.e., 3(d 12 )=D 2 , and d 13 is the x-ray spot size overlapping the CCD.
The signal collected by each group of CCD pixels with dimension D 2 ×D 2 under an x-ray beamlet will be grouped together to form the signal for the x-ray beamlet. Each D 2 ×D 2 group of pixels is effectively a macro pixel analogous to a single pixel of D 1 ×D 1 as shown, for example, in FIG. 6 . For illustration purposes, nine CCD pixels form a macro pixel in FIG. 30 .
If the CCD pixels are much smaller than D 2 , then slight misalignment of the CCD array with respect to the mask can be tolerated by redistributing the signal of the CCD pixel to different macro pixels using software algorithms. The amount of misalignment may be on the order d 11 over a distance of tens of D 2 .
When CCD detectors are used and d 13 /d 12 is greater than or equal to one, only the mask, and not the detector, needs to move for configurations shown in FIGS. 1, 2 , 22 , 27 and 28 . Neither the mask nor the detector are required to move for the configuration shown in FIG. 24 a.
The high-resolution x-ray imaging apparatus discussed above according to the present invention has many applications. In addition to medical applications (e.g., mammography), such imaging apparatus can be used in scientific research, defense and security environments, biotechnology, x-ray microscopy, x-ray astronomy, three-dimensional x-ray tomography and various industrial applications such as those in which non-destructive testing is required.
For example, radiographic testing is used in industry in process control to detect manufacturing flaws and is increasingly integrated as a crucial component on the manufacturing floor. The trend of non-destructive testing is moving toward the use of real-time, non-film radioscopic systems over traditional film-based systems. Digital non-destructive evaluation offers all the traditional benefits of detecting microscopic flaws and providing permanent inspection records. It enables new capabilities such as computer-based inspection methods and cost reduction. The electronics and automotive industries have moved fastest to adopt radioscopy; many other industries are following this trend.
The spatial filtering which is performed by the present invention to obtain high-resolution digital x-ray or gamma ray images provides several advantages. The imaging apparatus can use either direct or indirect x-ray or gamma ray conversion to generate signals representative of the image. The invention provides an improvement of the MTF beyond the limitation of the pixel pitch of the detector pixel array. Image degradation by conversion blurring caused by phosphor screens can be minimized, and image degradation by oblique x-ray incidence can be minimized, thus providing improved image resolution as well as more spatially uniform image resolution. In medical applications, the method and apparatus of the present invention also allow for x-ray detection efficiency beyond the limitation of the fill factor of the imager, without the need for increasing the x-ray or gamma ray dosage to a patient.
In addition, a wide range of image resolutions can be achieved using the present invention, with digital x-ray or gamma ray images having a resolution as small as 1 μm. This concept of using mask to select the resolution is independent of the dimensions. Typically, the pixel size of gamma cameras are large while the pixel size of the CCDs are typically small. The pixel size depends on the energy of the radiation to be detected, the application and availability of detectors. Similarly, the mask thickness and the aperature size depends on the application's needs, the x-ray energy and the ability to fabricate the aperture size with the appropriate mask thickness.
Although only a limited number of exemplary embodiments of the invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of the invention as defined in the following claims.
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An apparatus and method for obtaining a high-resolution digital image of an object or objects irradiated with radiation having a wavelength in the x-ray or gamma ray spectrum generated by a radiation source, or of an object or objects emitting radiation within the x-ray or gamma ray spectrum. The apparatus comprises a detector matrix and a radiation mask. The detector matrix comprises a plurality of detector pixels, each comprising a detection surface having a respective surface area which generates a signal in response to an energy stimulus. The radiation mask has an opaque portion, and a plurality of apertures. The aperture size and position relative to the detector array determines the image resolution not the size of the detector pixels. The mask is positioned between the detector matrix and the radiation source, such that the opaque portion prevents portions of the radiation from passing through the mask, and each of the apertures permits a portion of the radiation which has passed through or has been emitted from a respective portion of the object to propagate onto an area of the detection surface, less than the surface area, of a respective one of the detector pixels. The signal from a large detector pixel or from a group of small detector pixels represent an image of the respective portion of the object. The detector matrix and radiation mask are moved in synchronism in relation to the object to enable the areas of the detection surfaces of the detector pixels to receive portions of the radiation propagating through or emitted from other portions of the object, and to output signals representative of those other portions. These steps of moving the detector pixels and mask and irradiating the object are repeated until digital images of all portions of the object have been obtained. Alternatively, the x-ray source can be moved to image all portions of the object. The images are then arranged into an image representative of the entire object.
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FIELD OF THE INVENTION
The present invention relates to monitoring the cut-off function of individual cylinders or cylinder groups in internal combustion engines having multiple cylinders.
BACKGROUND INFORMATION
In multi-cylinder internal combustion engines, individual cylinders or cylinder groups are conventionally cut off during partial engine operation, in other words, switched between full engine operation using all cylinders, and partial engine operation using only a part of the cylinders, such as only one cylinder group of a V-engine. As a result of the cut-off, the remaining cylinders which are still operating in partial engine operation are operated with increased cylinder charge when compared to full engine operation, and thus at improved efficiency, resulting in better fuel consumption.
The cut-off may be implemented, for instance, by deactivating the gas exchange valves, e.g., those valves controlling the change of the cylinder charge. For example, the intake valve as well as the exhaust valve of the particular cylinder are closed for the duration of the deactivation to effect the cut-off.
In this context, a particular problem may arise that in those cases where full engine operation is desired, the gas exchange valves of one or more cylinders are incorrectly deactivated. Likewise, the opposite error may occur; the gas exchange valves of one or more of the cylinders to be cut off are not properly deactivated when partial engine operation is desired.
SUMMARY
An example embodiment of the present invention makes it possible to monitor whether the valves of the cylinders capable of being shut off are properly activated during full engine operation, and whether, in partial engine operation, the valves of the cylinders to be shut off are properly deactivated.
This allows, for instance, in the case of undesirably deactivated gas exchange valves, to additionally cut off the fuel injection of the respective cylinders, so that an over-enrichment of the fuel/air mixture for the remaining cylinders may be prevented.
If no counter-measures were taken when the gas exchange valves are undesirably activated, the fuel injection of the cylinders to be cut off would be properly switched off. The undesirably active gas exchange valves cause an undesired rate of airflow through the cylinders to be cut off, which is effectively missing in the properly functioning cylinders. Since the control device calculates the fuel quantity for the properly functioning cylinders as if they were to process the entire air quantity, these cylinders are metered too much fuel, which results in deterioration in the emission behavior and in the performance of the internal combustion engine. Here, too, the amount of fuel metered to the properly working cylinders may be corrected as a counter measure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the technical field of the present invention.
FIG. 2 shows a flow chart as an exemplary embodiment of the method of the present invention.
DETAILED DESCRIPTION
In FIG. 1, “ 1 ” represents an internal combustion engine having a combustion chamber 2 , fuel injector 3 , intake valve 4 , intake valve actuator 5 , exhaust valve 6 , exhaust valve actuator 7 , intake manifold 8 , throttle valve 9 , sensor 10 for throttle valve angle alpha, air mass flow meter 11 , intake manifold pressure sensor 12 , engine temperature sensor 13 , speed sensor 14 and lambda sensor 15 in exhaust pipe 16 , as well as an electronic control device 17 .
The electronic control device processes the signals shown concerning intake-air mass ML, throttle valve opening angle α, intake manifold pressure p, engine temperature tmot, rotational speed n and fuel/air mixture composition lambda, to form control signals for the internal combustion engine, for instance, to form fuel injection pulse widths ti, ignition signals etc. In FIG. 1, the control device also generates signals EVS and AVS, which determine the activation and deactivation of gas exchange valves 4 and 6 , and thereby the cylinder cut-off. The specific implementation of the valve actuation, whether hydraulic, mechanical, or controllable either individually or as a group, is not decisive. In any case, however, the control device can activate and deactivate the intake and exhaust valves.
FIG. 2 shows an exemplary embodiment of the method of the present invention. After the diagnostic program is launched, in step 3 . 1 , a first signal NLS for the air mass flowing into the internal combustion engine is formed from throttle opening angle a and signals EVS, AVS about the activation of the gas exchange valves.
In step 3 . 2 , a second signal HLS for the air mass flowing into the internal combustion engine is formed from intake-air mass ML. The sequence for forming of NLS and HLS may also be reversed. In step 3 . 3 , the amount of the difference is calculated from the first and second air mass signals and its absolute value is compared with a threshold value S. If, for example, the difference amount is smaller than the threshold value, the cylinder cut-off function is deemed operative (step 3 . 4 ). If the amount is greater than the threshold value, an error message is generated in step 3 . 5 .
Instead of using the difference, it is also possible to compare a quotient, derived from signals HLS and NLS, to a predefined reference value. If the quotient is approximately 1, the cylinder cut-off function is operative.
A significant deviation from value 1 signals a malfunction in the activation or deactivation of the cylinders. The extent of the deviation, which allows differentiation between an operative and a malfunctioning cylinder cut-off function, can be determined by bench testing and stored in electronic control device 17 for later use during the operation of the internal combustion engine.
The generation of the first air mass signal is based on the assumption that the cylinder cut-off function is operative. If the cylinder cut-off function is indeed operative, the first air mass signal derived from throttle opening angle alpha and control signals EVS, AVS, will then also correctly reflect the actual cylinder charge. It is also possible to take intake-manifold pressure p into consideration in forming the first air mass signal, either alternatively or in addition to throttle valve angle alpha. Engine speed n may also be considered in forming the first air mass signal, but only additionally, not alternatively. The actual cylinder charge is also reflected in second air mass signal HLS, irrespective of which control signals EVS, AVS are used in the electronic control device. In other words: optimally, if the valve control is operative, the first and second air mass signals do not differ, which, via step 3 . 3 , leads to the result of step 3 . 4 .
According to the present embodiment of the present invention, for monitoring purposes, two signals which supply a measure of the air mass flowing into the internal combustion engine are thus compared.
The second signal is provided by an air mass flow sensor, such as a hot-wire or hot-film air mass flow sensor. This signal represents the air actually flowing into the internal combustion engine, be it during full engine operation or during partial engine operation.
The first signal, for instance, is formed by taking into account the intake manifold pressure, the rotational speed and the number of the desirably active cylinders. At a given speed and pressure, for example, the air mass flowing into the engine will be greater during full engine operation than in partial engine operation.
In the above-described fault situations, a disproportion exists between the air mass signal calculated from the signal of the air mass meter and the air mass signal calculated from the intake-manifold pressure. To detect the disproportion, the quotient of both signals is low-pass filtered in each engine operating mode and compared with a threshold. The respective fault is set if this threshold is exceeded or undershot. For instance, if the air mass calculated from the intake-manifold pressure constitutes the numerator and the measured air mass the denominator, and if some cylinders are undesirably deactivated, the quotient will be greater than expected. In contrast, if some of the cylinders to be cut off are undesirably active, the quotient will be smaller than expected.
In one exemplary embodiment of the present invention, a fault might be inferred if, during desired full engine operation, the quotient is greater than expected, the fault being verified through an analysis of the irregular running of the internal combustion engine. The analysis of the irregular running can be carried out by evaluating the fluctuations in the angular velocity of the crankshaft, and may also be additionally used to identify the affected cylinder. The undesired deactivation of the gas exchange valves of the affected cylinder during desired full engine operation causes a loss of the torque contribution of this cylinder, which occurs periodically and which periodically brakes, or fails to accelerate, the crankshaft. The position of the missing acceleration relative to a reference angle of the crankshaft, such as the dead center of the piston of the first cylinder during the power stroke, makes it possible to identify the affected cylinder and thus allows a controlled cut-off of the fuel supply to this cylinder. In modern motor vehicles, an evaluation of the irregular running is already being carried in order to comply with legal requirements relating to on-board diagnosis of faults relevant to the exhaust gas system, such as combustion misses in the operation of the internal combustion engines used as automotive propulsion.
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A method is described for monitoring the temporary cut-off function of the gas exchange valves of individual cylinders or cylinder groups in internal combustion engines, in which the gas exchange valves of the cylinders to be temporarily cut off are deactivated in the closed state for the duration of the cutoff. Two signals, which supply a measure for the air mass flowing into the internal combustion engine, are compared for monitoring purposes. A disproportion between both signals is interpreted as a fault in the described chain of action.
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FIELD OF INVENTION
This invention relates to marking fluid such as ink dyes and pigments for imprint on textiles and other porous materials.
DESCRIPTION OF INVENTION
The present invention relates a mixture to which dyes, pigments, inks and other materials may be added, referred to herein as the basic mixture; a mixture which has been colored with dyes, pigments, ink and the like and to which other materials may be added and which provides a fluid for imprinting fabric and other porous materials permanently with ink, dye, or pigment, or other materials without using acceptors in the fabric and without using heat to set the imprint in the fabric, herein referred to as the ink mixture. The basic mixture is extremely slow to evaporate in a substrate allowing inks, pigments and dyes and the like to remain in a conveyable form in a substrate over an extended period of time.
The invention, may be used to mark fabric, paper, vinyl, wood, leather and other porous materials. For the purposes of this description, ink mixture will be used to describe a mixture to which ink, dye, pigments or other materials have been added and the basic mixture will refer to a mixture to which ink, dyes, pigments or other materials may be added to achieve the desired result. The invention is not limited to a mixture to which either pigments, dyes or ink have been added.
The present invention has particular use, but is not limited to, to marking cloth by conveying a colored liquid by a rubber, or like, hand stamp usually with letters or numbers to identify clothing and personal items.
OBJECTS AND ADVANTAGES
Accordingly, several objects and advantages of the invention include but are not limited to the following: Other existing permanent ink formulas dry quickly in a stamp pad and require ink to be supplied with the ink pad to replenish it. In this invention permanent ink, dyes, pigments and the like can be impregnated into a pad and remain wet and in conveyable form over an extended period of time. This invention is safer than existing products because it is not necessary to supply liquid ink in a bottle with the stamp pad to the consumer.
The invention was originally designed to identify children's clothing and sports equipment. Liquid ink, could be ingested by children. In an example herein, it is shown that is possible to have less than 2 ml of ink mixture impregnated into a pad which reaches the consumer. Remarkably this small amount effectively achieves the desired result. Even if the whole pad was ingested by a child, consultation with poison control experts indicate that this would not harm the child. Because the product was designed for households with children, the mixture needed to be non-toxic upon ingestion of small amounts. It is also desirable for the invention to be non toxic to the environment. This invention meets, but is not limited to these criteria.
The elimination of liquid ink for the use of permanent marking of fabric is particularly useful to the military where military personnel must permanently identify their clothing, uniforms, and other belongings. The use of existing inventions where bottles of ink must be poured on the stamp pad is messy, wasteful and time consuming. The handling of bottles of ink by military stores is costly and often results in messy breakages. This invention, while not limited to these criteria, solves these problems. Further objects and advantages of my invention will become apparent from a consideration of the ensuing description, herein.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,702,742 Iwata et al (1987), discloses a mixture to keep the ink from drying in a jet ink printing machine. The cloth to be imprinted requires pre-treatment with an acceptor before applying the ink. The mixture disclosed contains some substantial differences to the present invention in components and methods of preparation. For example, the compound is subjected to extensive mixing. The PH balance is adjusted by adding sodium hydroxide. In several examples the mixture was heated, changing the molecular structure of the compound.
U.S. Pat. No. 4,455,168 Togata et al (1984) discloses an ink mixture which is heated, changing the molecular structure of the mixture.
U.S. Pat. No. 5,419,8243, Tanaka (1978) discloses a mixture to mark occlusion in dentistry. The mixture used and the application are substantially different from the present invention.
The present invention is distinguished from all examples of the prior art because it combines a unique combination of ingredients without heating, to provide a mixture which will permanently imprint cloth without the necessity of pre-treatment acceptors in the cloth and will remain permanent in the cloth without heat setting and will remain wet and in conveyable form in the substrate over an extended period of time and yet dry quickly in a porous material to which it is applied. The invention also describes a procedure to impregnate a substrate which will contain the ink mixture in a conveyable form over an extended period of time.
Permanent imprinting of cloth conventionally requires that the cloth be pre-treated by an acceptor such as water soluble or hydrophilic natural or synthetic polymers, to enable the dye or ink or pigments to adhere to the cloth and be permanently imprinted and be able to withstand washing without the dye, pigments or ink being removed from the cloth. Additionally, permanent imprinting of cloth usually requires that the fabric be heat treated after imprinting for the purpose of setting the dye, ink or pigments in the fabric permanently.
Ink pads are known in which the ink does not dry out immediately in the ink pad, but the ink in these ink pads will wash out of cloth.
Permanent ink is known which, when poured on a stamp pad, can be used to imprint fabric and other porous surface and remains permanent on these surfaces. However, such ink dries quickly on the ink pad and additional ink must be supplied to replenish the ink pad.
At present there is no device, method, or chemical mixture for maintaining or containing permanent ink, dyes, pigments or the like in a conveyable form over an extended period of time to imprint textiles and other porous surfaces except for the above described liquid ink contained in bottles with its attendant disadvantages, or inks, dyes, pigments or the like which require treatment acceptors and heat setting which is costly and cumbersome.
In contrast this invention provides a product in which permanent ink, dyes, pigments or the like remain in a wet and conveyable in the substrate over an extended period of time. There is a need for this invention anywhere that clothing and personal items require identification. Such places include but are not limited to children's camps, the military, hospitals, prisons, nursing homes, little league baseball, school uniforms and like institutions.
For purposes of the present invention, permanently imprinted refers to the ability of the cloth to withstand 12 washings of detergents commonly used in households and the imprint of letters or numbers remains readable after the 12th washing.
SUMMARY OF THE INVENTION
To overcome these disadvantages, it is an object of the present invention to provide a mixture and a procedure which would result in permanent ink in a long lasting conveyable form which can be used to imprint fabric and other porous materials without the ink hardening and drying in the pad and without requiring a pre-treatment acceptor in the fabric or other porous materials, and without requiring heat setting of the ink dye or pigments in the materials. The basic mixture meets this objective. Furthermore, other materials, such as dyes, inks, pigments, and the like and thickeners, gelling, congealing and viscous agents and the like may be added to the basic mixture to achieve the objective. The addition of these materials forms the ink mixture which further achieves the objectives.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The mixture of the present invention is preferably diethylene glycol mono butyl ether from 662/3% to 85% by volume; glycerine from 331/3% to 15% by volume; traces of ethylene glycol; 0.045% by volume; and monoethanolamine 0.0075% by volume are added to enhance flow. Various inks, dyes and pigments may be added to this mixture to form an ink mixture. A preferred ink mixture is ink which is permanent on fabric and porous surfaces and is preferably a glycol based permanent ink. From 33% to 41% may be added to diethylene glycol mono butyl ether from 37% to 51% by volume and glycerine from 20% to 24% by volume to form the ink mixture; traces of ethylene glycol; 0.045% by volume and monoethanolamine 0.0075% by volume may be added to enhance flow.
For the purposes of this invention it is necessary to distinguish between a basic mixture to which the ink, dyes and pigments are added and will herein be called "basic mixture" and a mixture which includes the ink, dyes and pigments and will herein be called an "ink mixture".
EXAMPLE 1
A commercial embodiment for the basic mixture is: 8 ml Diethylene glycol mono butyl ether; 4 ml glycerine; and traces of 1 drop of monoethanolamine and 3 drops of ethylene glycol may be added to enhance flow. This is the basic mixture.
EXAMPLE 2
A commercial embodiment for a black permanent ink mixture is: To the basic mixture is added 7 ml permanent black or india ink to form an ink mixture.
The butyl ether, glycerine, monoethanolamine and ethylene glycol are combined in a bottle at room temperature. Ink is added to the mixture and the bottle is shaken vigorously for 2 minutes.
EXAMPLE 3
1,080.7 ml of diethylene glycol mono butyl ether, 506.88 ml of glycerine, 887.1 ml permanent ink, 128.38 ml ethylene glycol and 20.27 ml monoethanolamine were mixed by shaking the mixture in a 3 liter bottle at room temperature. The bottle was shaken for 2 minutes.
EXAMPLE 4
84.75 tablespoons Polyvinyl Pyrrolidone (DVP) was added to the mixture cited in example 3 above. Said ink mixture was put in blender and said PVP was added slowly during the blending process. This additional ingredient thickens the ink mixture, keeps it from leaking out of a foam ink pad and adds additional darkness and clarity to the imprint of the ink on fabric to which it is applied.
EXAMPLE b 5
To the mixture cited in example 3 above the following were added: 42.38 tablespoons guar gum, 53 tablespoons fumed silica and 0.01 ml dimethyl benzyl ammonium chloride to prevent mould growth.
The ink mixture was placed in a blender on high at room temperature. The guar gum and fumed silica were added slowly while blending. The mixture was further blended for 3 minutes. The addition of these chemicals thickened the ink causing a darker and clearer impression while preventing the ink from leaking out of a foam pad. These chemicals are somewhat more economical than PVP.
Mixed with some dyes pigments, and glycol based permanent inks, the ink mixture is permanent on the cloth and other porous surfaces. The basic mixture causes the ink, dye or pigments to remain wet and in conveyable form in the substrate for extended periods of time however when applied to cloth, the mixture is absorbed immediately leaving a clear long lasting impression on the cloth.
For example: A felt pad so treated was left open to dry in the air. No signs of drying appeared for six weeks. The ink mixture was still in conveyable form. The pad was then usable for an additional two weeks although the print was no longer solid.
In another example a pad was kept closed and opened for ordinary use from time to time. This pad showed no signs of drying for one year. The ink remained in conveyable form and provided solid printing for one year.
TESTING
Mixed with a glycol based permanent ink, and using a felt pad and rubber hand stamp to imprint the fabric, this mixture was tested by washing fabric so imprinted 12 times with common household detergents.
The following fabrics were used for testing purposes:
1. 100% cotton denim
2. Spandex
3. Polyester blend 65% polyester, 35% cotton
4. 100% cotton
5. Polyester Pile
6.100% polyester
7. Cotton sweat shirt
8. Polyester knit
9. Nylon
10. Polyester blend "Duck"
The results were superior on cotton, spandex and most of the polyester blends, and the imprinting on all fabrics was readable after 12 washes.
SUMMARY, RAMIFICATION AND SCOPE OF INVENTION
While the above description contains many specificities these should not be construed as limitations on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof. Many other variations are possible. For example: Future uses of this ink mixture may include jet ink printing of fabric which will not require pre-treatment with fabric acceptors. Various dyes, pigments and inks may be added to the original mixture for variations in colors and properties. For example, the addition to the basic mixture of titanium dioxide, a binder and thickener should provide a white ink with the same above described properties. Addition of a blue pigment, dye or ink would provide a blue ink with the same above described properties, etc.
Thus, the scope of the invention should be determined not by the embodiments described herein, but by their appended claims and their legal equivalents.
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A mixture to which ink, dye or pigments may be added producing an ink mixture which is extremely slow in evaporating from a substrate but which can be used to imprint a permanent, identifiable mark on various types of fabric and requires no acceptor on the fabric, will dry quickly on the fabric and requires no heat setting. An ink mixture which uses the above described mixture and adds to the above mixture dyes, inks, pigments and/or other materials.
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FIELD OF THE INVENTION
The present invention relates to a commercial printing system that provides scheduling so as to meet service level agreement requirements.
BACKGROUND OF THE INVENTION
Popular web sites now enable customers to create and order a variety of personalized print products, including inter alia calendars, greetings cards, notepads, and photo books. Customers insert their own text and photos within templates provided on the web sites and in retail stores, and fulfillers print the resulting photo products. Such web sites include www.snapfish.com operated by Hewlett-Packard Company of Palo Alto, Calif., www.shutterfly.com operated by Shutterfly, Inc. of Redwood City, Calif. and www.blurb.com operated by Blurb, Inc. of San Francisco, Calif. Such retailers include Walmart and Walgreens.
Orders for personalized print products typically involve low quantities. Often customers order only a single copy of a book or calendar. As such, a fulfiller must be able to print and manage a very large number of very small jobs. Moreover, the jobs themselves often include a variety of component parts. For example, a book generally includes a dust cover, a spine and the pages themselves.
Managing and monitoring orders for large numbers of personalized print products as they proceed through a print workflow moving from prepress to press to postpress is very complex. Such complexity stems from many factors, including job ingest, job scheduling, coordination of physical component print parts on the shop floor, product dispatch, inventory control, machine maintenance, failover protection, product defects, customer returns, irregular seasonal volume, and much more.
Conventional short run printing systems enable printing of small quantities of a document. Conventional variable data printing systems enable changes in text on a per document basis. For example, multiple copies of a letter can be printed, and a name can be changed for each copy.
However, conventional printing systems are not optimized for the complexity of the massive volume and diversity of small individual print jobs characterized by online printing systems that cater to consumers and small businesses. There is thus a need for a method and system to efficiently manage and monitor the fulfillment printing workflow, in order to guarantee that an order consisting of a plurality of print products is printed, bound and shipped within a prescribed deadline.
SUMMARY OF THE DESCRIPTION
The present invention concerns a system and method for monitoring and controlling an end-to-end printing workflow for printing a wide diversity of variable length short run personalized print products. The end-to-end printing workflow includes (i) prepress stages that ingest customer print orders for books, greetings cards, playing cards, notepads, stationary, stickers, calendars, magnets, and other such merchandise, and generate a series of print jobs therefrom; (ii) raster image processing and print stages that rasterize the print jobs and print them on appropriate printers; and (iii) postpress stages that gather and bind various product parts, package them, and prepare them for shipping to customers.
In accordance with an embodiment of the present invention, customer orders are transmitted to a printing system via partners, such as web sites and retail stores. The printing system has an agreement with each partner, referred to as a service level agreement (SLA), which stipulates the terms and conditions of the service provided by the printing system to the partner. Terms of the SLA include legal terms such as indemnifications, and pricing terms. In addition, the SLA includes a maximum time delay from the time a customer order is entered into the printing system until the order is finished and ready for shipping.
In accordance with an embodiment of the present invention, the end-to-end printing workflow is represented as a plurality of processing states through which a print order advances as it moves through the printing system. An order serializer decomposes printer orders into a plurality of work items. A work scheduler assigns priorities to each work item waiting in queue at a processing state, and the work item with the highest priority is processed first. The work scheduler assigns priorities in such a way that each print job is finished within the deadline prescribed by the SLA with the partner that transmitted the print job. Furthermore, the work scheduler assigns priorities in such a way as to maximize efficiency and profitability. Some print jobs include multiple parts, such as a book that includes a cover, a spine and book pages, and the work scheduler assigns priorities to parts in an intelligent way so that all parts of a print product are ready for postpress processing in time to be finished within the deadline.
In accordance with an embodiment of the present invention, work items are lotted; i.e., combined in a single lot for printing together. Additionally, work items are imposed so that multiple surfaces are printed on a single large sheet of paper. In a business environment typified by many diverse small print orders, imposition and lotting achieve efficiency in avoiding wastage of paper, efficiency in use of printers and other resources, and efficiency in timely completion of print orders.
The present invention also concerns binning of parts of print orders, such as book covers and book pages, so that parts corresponding to the same print order can easily be gathered together, and so that the locations of parts can be tracked on the shop floor.
The present invention also includes the ability to outsource processing at various stages of the overall workflow, and the ability to coordinate multiple printing systems housed in different locations.
It will thus be appreciated by those skilled in the art that the present invention provides for comprehensive and optimized management and monitoring of an end-to-end printing workflow for complex business environments with large numbers of diverse small run print orders. The present invention also provides for control of work priorities at various stages of the workflow in order to meet contractual deadlines for finishing orders.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject invention will be more fully understood and appreciated from the following detailed description, taken in conjunction with the drawings in which:
FIG. 1 is a depiction of a greeting card with four surfaces, in accordance with an embodiment of the subject invention;
FIG. 2 is a simplified block diagram of a printing system, in accordance with an embodiment of the subject invention;
FIG. 3 is an exemplary web user interface used by a retail customer to create a calendar, in accordance with an embodiment of the subject invention;
FIG. 4 is a schematic description of a simplified order of a photo book, in accordance with an embodiment of the subject invention;
FIG. 5 is a simplified flowchart of an overall method for a printing system, in accordance with an embodiment of the present invention;
FIG. 6 is a flow diagram describing the processing steps performed by a work scheduler to calculate the priorities of work items, in accordance with an embodiment of the subject invention.
FIG. 7A is a flow diagram describing the processing steps performed by a work scheduler to compute the Shop_Priority attribute for a work item, in accordance with an embodiment of the subject invention.
FIG. 7B is a flow diagram describing the processing steps performed by a work scheduler to calculate the Late_Priority attribute for a work item, in accordance with an embodiment of the subject invention.
FIG. 8 is a simplified block diagram of a prepress system, in accordance with an embodiment of the subject invention.
FIG. 9A is a flow diagram illustrating the initial processing steps performed by a prepress server, in accordance with an embodiment of the subject invention;
FIG. 9B is a flow diagram illustrating the final processing steps performed by a prepress server, in accordance with an embodiment of the subject invention;
FIG. 10 is a flow diagram that illustrates the processing steps performed by a prepress server to select material parts for a print lot, in accordance with an embodiment of the subject invention.
FIG. 11 is a simplified block diagram of a RIP and print system, in accordance with an embodiment of the subject invention;
FIG. 12 is an illustrative screen capture from a printer console, in accordance with an embodiment of the subject invention;
FIG. 13 is a simplified block diagram of a finishing system, in accordance with an embodiment of the subject invention;
FIG. 14 is a simplified flow diagram that illustrates the steps performed in material sorting, in accordance with an embodiment of the subject invention;
FIG. 15 is an illustrative screen capture from a shop floor console, in accordance with an embodiment of the subject invention; and
FIG. 16 is a simplified block diagram of a multi-site printing system, in accordance with an embodiment of the subject invention.
DETAILED DESCRIPTION
The present invention concerns a printing system that accepts orders from business partners and manages a print workflow to enable the printing system to meet service level agreements (SLAs). The printing system is operated by a printing system provider. Print orders flow into the system from one or more partners, where a partner is a company or organization that operates a system, referred to as a “partner system,” that receives print orders from retail customers. The partner system can be inter alia a web-based system or a retail store. For each partner there is a service level agreement (“SLA”) between the printing system provider and the partner that defines inter alia the products that the printing system can accept and print, and the maximum delay to be incurred in printing each product. The present invention relates to the ability of the printing system to meet the SLA-defined maximum delay requirements.
For purposes of clarity, a print order, or simply an “order,” includes one or more copies of one or more print products. An order is equivalent to a shopping cart in an ecommerce system. The order can have multiple line items where each line item designates a unique product to be printed. In addition, an order may include one or more embellishments. An embellishment is an item, such as a coupon, that may not be explicitly ordered by a retail customer but which is added to one or more of the packages shipped to the recipient of the order. Embellishments may include inter alia a coupon, a free sample, or promotional literature. A maximum allowed delay incurred in printing a product, referred to as “Max_Delay,” is defined as an upper limit on the amount of time spent from the moment that a print order for a printed product is accepted into the print system until the moment the printed product is picked up by a shipping service. The Max_Delay includes the time to perform various prepress steps, then to raster image process (“RIP”) and print the document, and then to finish the document. The finishing process includes binding, packaging and printing a packing slip and a mailing label.
A line item, also known as a stock keeping unit (SKU) or a part, refers to a single product. Example line items include photo books, notepads, and greeting cards. A line item has attributes including inter alia a quantity and a number of pages. A line item with quantity greater than one, i.e., multiple copies of the same product, can be shipped to multiple recipients. For example, if four copies of a calendar are printed, three may be shipped to one recipient and one to a different recipient. A line item is composed of one or more “material parts.” For example, a photo book consists of a cover, a spine and book pages, referred to as “book block”. Each of the components (e.g. cover, spine, book block) of a line item or product is referred to as a “material part.” Some material parts are printed items, e.g. greetings cards and calendars; other material parts are non-printed items such as a velum separator page or a red cover.
Reference is now made to FIG. 1 which is a depiction of a greeting card with four surfaces, in accordance with an embodiment of the subject invention. Generally, each product to be printed consists of one or more “surfaces” where a surface is defined as a printed side of a page. For example, a page in a photo book has two surfaces, front and back, while a greeting card has four surfaces. Thus the greeting card illustrated in FIG. 1 has four surfaces; namely, front, inside top, inside bottom, and back.
In one embodiment, one digital image, referred to as a “composite image” or “composite,” is stored by the partner for each surface. The composite image exactly represents the surface to be printed. The use of composite images between the partner and the printing system allows the printing system to provide WYSIWG (what you see is what you get) printing. In other words, the document that the customer sees on their display appears identical to the printed product that they receive in the mail. In order to achieve WYSIWG printing, the composite is typically an image that covers the entire surface and that is reproduced as precisely as possible by the subject invention.
Reference is now made to FIG. 2 , a simplified block diagram of a printing system 200 , in accordance with an embodiment of the subject invention. Retail customers 210 place orders with partner system 215 . An order may be placed inter alia using a web interface or may be made in a retail store. An order may include multiple products, or “line items,” and multiple copies of each line item. Line items are printed items such as calendars, notepads, and books that typically include content supplied by a retail customer. For example, a calendar may include one photo for each month of the year provided by the retail customer; and a notepad may include the name of the retail customer. An example of a web user interface for creating a calendar is illustrated in FIG. 3 .
An order is typically stored in a computer file. An order can be represented inter alia as a text file, as a coded binary file, as an HTML formatted file, or as an XML formatted file. In one embodiment, an order is represented by a single XML file with a schema defined by the print system. This schema is referred to as the “native XML format” of the print service. In one embodiment, a single XML file can contain multiple orders.
In one embodiment, partner system 215 represents orders using a proprietary file format. In this case, printing system 200 transforms the proprietary format into its native XML format.
Reference is now made to FIG. 3 , an exemplary web user interface used by a retail customer to create a calendar, in accordance with an embodiment of the subject invention. FIG. 3 is displayed after a customer selects calendar as the product type he/she wishes to create. The customer selects the month he/she wishes to create 310 . The customer can change the default page layout 320 . The customer can add text and/or photos to individual dates 330 . The customer selects photos from a gallery of photos that is displayed at the bottom of the screen 340 . The exemplary user interface depicted in FIG. 3 shows two surfaces that would be visible for the month of August 2007: on the left of the screen is a single, large, user-supplied photo; and the right side of the screen shows a graphical layout for the month of August, which includes two small user-supplied photos and several textual comments.
Reference is now made to FIG. 4 , a schematic description of a simplified order of a photo book, in accordance with an embodiment of the subject invention. An order 400 includes CustomerAddress information 405 , BillTo information 410 , ShipTo information 415 , one or more CartItems 420 and optionally or more Embellishments 425 . It is noted that a CartItem is also referred to as a line item. Order 400 includes a single 8×10 inch photo book, referred to as PhotoBook — 8by10 430 . Photo book 430 includes a PhotoBookCover 435 , a PhotoBookBookBlock 440 , and a NonPrintableMaterial 465 . Typically, NonPrintableMaterial 465 is a velum separator page between the cover and the first page of book block. PhotoBookCover 435 includes a single PhotoBookPage 445 , which may contain one or more photo 450 elements. PhotoBookBookBlock 440 includes one or more PhotoBookPage 455 elements. Each PhotoBookPage 455 includes one or more photo 460 elements.
In one embodiment, the format of each printed element, such as cover page and book block pages, is defined by a template that is commonly agreed to between the partner and the printing system provider. Thus, in FIG. 4 the photo book cover template is specified by a TemplateName attribute within PhotoBookPage 445 . Similarly, the template of each book block page is specified by the TemplateName attribute within PhotoBookPage 455 . Use of said commonly agreed to templates ensures that each line item can be processed by the printing system. Also, when using said commonly agreed to templates only information not defined by the template need be included in the order. For example, a calendar page template might define the position of textual, graphical and user-supplied photos for a cover and for each month of the year. Since this formatting information is defined in the template and stored by the printing system it doesn't have to be included in the order.
In one embodiment, PhotoBookPage 445 contains multiple photos, indicated by Photo # 1 450 , and Photo #N 450 . The number of photos and size and location of each photo are specified by the template referred to by the TemplateName attribute within PhotoBookPage 455 . Each photo can be inter alia supplied by the customer, selected by the customer from a list of photos presented by the partner, or supplied by the partner with no input from the customer.
In one embodiment, each surface is provided by the partner as a composite image that includes all required information to print one surface. In this embodiment, each PhotoBookPage 445 element includes a single photo 450 element whose filename attribute references a single composite image.
The XML code for a simplified, exemplary, order for a photo book that follows the schema depicted in FIG. 4 is provided in LISTING 1 at the end of this specification. The order includes a single line item, an 8by10 photo book. The 8by10 photo book includes a cover, 2 book block pages and a velum separator page. Due to the use of templates, formatting information is not required in the XML order.
Referring back to FIG. 2 , in one embodiment, partner system 215 receives an order from retail customer 210 and transforms it into the native XML of printing system 200 before providing it via the Internet 220 to printing system 200 . In another embodiment, partner system 215 provides the order to printing system 200 in the proprietary format of partner system 215 , and printing system 200 transcodes the order into its native XML.
A prepress server 225 downloads orders from partner system 215 . Prepress server 225 “serializes” each order. When an order is serialized, each line item in the order is decomposed into one or more material parts. Each printed material part is assigned a unique serial number. For example, in a photo book the cover and the book block would be assigned two different serial numbers. Each serialized item can be individually managed and tracked. Further, line items with quantity greater than one are individually serialized. Non-printed material parts are not assigned serial numbers since they are not customized; only a part number is necessary to uniquely denote a non-printed material part. Each serialized material part is processed in a series of steps, first by prepress server 225 , then by a RIP and print system 250 and finally by a finishing system 260 .
It is pointed out that in some cases a processing step is performed on an order, in some cases on a single material part and in some cases on multiple material parts. For purposes of clarity, the term “work item” is used to refer to a data structure that defines the atomic or most granular level of processing performed at a particular processing step in the printing workflow, regardless of whether it is performed on an order or on one or more material parts.
Each work item has a state associated therewith. TABLE 1 lists the states that a work item can be in, in accordance with an embodiment of the present invention. Upon completion of certain processing steps, the state associated with the work item is changed to a new state. This is referred to as updating the work item's state. A work item's state determines what processing step will next be performed on it.
TABLE 1
Processing States
Where
ID
State Name
Occurs
Short Description
1
Hold
Prepress
The work item is on hold for a non system failure, such
as missing images or corrupt images, also duplicate
orders from the partners will be parked in hold for
manual release.
2
Error
Prepress
The work item has failed to process because of a system
failure - the printing system will automatically re-
process the work item
3
Pending-
Prepress
Order has been received from a partner and is available
Order-Import
for processing and import into data storage.
4
Pre-Order_Import-
Prepress
An error occurred while processing an order. The order
Error
cannot be imported into data storage.
5
Pre-Batch
Prepress
The order has been successfully accepted into the
system
6
Reprint
Prepress
A temporary place for work items that were mishandled
and need reprinting
7
Downloaded
Prepress
All composite images within the order have been
downloaded or moved to data storage
8
Imaged
Prepress
All composite images within the order have been
verified.
9
Processed
Prepress
The order has been serialized into work items or serial
items and is ready for lotting.
10
Lotted
Prepress
The serial item has been grouped into a lot. The lot is
ready for raster image processing.
11
Imported
RIP &
The lot has been accepted by the rater image processor
Print
(RIP).
12
Ready-to-Print
RIP &
The lot has been ripped and is ready for press
Print
13
Moved-to-
RIP &
The lot has been moved to a press for printing
Press
Print
14
Imported-to-
RIP &
The printing press has accepted the lot for printing
Press
Print
15
Printed
RIP &
The lot has been printed
Print
16
Bindery
Finishing
The serial item is in the bindery
17
Bound
Finishing
The serial item is bound and ready for sorting and
fulfillment
18
Ready-to-Ship
Finishing
The serial item is sorted and ready to be packaged
19
Packaged
Finishing
The serial item has been placed into a package for
shipping
20
Shipped
Finishing
The serial item has been shipped
21
Voided
Finishing
The serial item has been voided
A management server 230 performs tasks that are common to multiple processing steps including work schedule management performed by a work scheduler 245 , communication of status to partner 215 , performed by a status updater 240 , and data storage and management performed by a data storage 235 . It will be appreciated by those skilled in the art that management server 230 may be a separate computer system, or it may be configured as hardware or software running inside of prepress server 225 , print server 1110 (described with reference to FIG. 11 ), or finishing server 1305 (described with reference to FIG. 13 ). It will be further appreciated that management server 230 may be several computer systems, each configured to run one or more processes. For example, one management server 230 may run work scheduler 245 and status updater 240 , while another management server runs data storage 235 .
Data storage 235 includes a relational database management system (RDBMS) and physical storage. In addition, database management system may include network attached storage (NAS), which is data storage that can be connected directly to a computer network to provide centralized data access and storage for other network devices. For example, NAS would enable prepress server 225 , a print server 1110 , or a finishing server 1305 to directly store and share data.
Work scheduler 245 runs periodically as a background process on management server 230 . For each state listed in TABLE 1, work scheduler 245 maintains a prioritized queue of all work items awaiting processing for each state. The prioritized queue for each state is stored in data storage 235 . When a work item changes state, work scheduler 245 moves the work item to the appropriate prioritized queue. For example, a work item that is being printed is in the prioritized queue for the “Imported-to-Press” state (with reference to TABLE 1). When the work item prints successfully, print server 1130 changes the state of said work item to “Printed.” When work scheduler 245 determines that said work item has changed state it moves the work item into the prioritized queue for the “Printed” state. It then recalculates the priorities for all work items in the prioritized queue for the “Printed” state.
In one embodiment, processing steps that correspond to the states Pre-batch, Imaged, Processed, operate at the order level. In one embodiment, the prioritized queue for each of these states lists the orders in first-in-first-out sequence.
Orders whose state is “Processed” state have been serialized into serial items, or material parts, each having a unique serial number. At this point, each Work item in the prioritized queue for the “Processed” state corresponds to a material part. Each work item includes inter alia the attributes listed in TABLE 2 below:
TABLE 2
Work Item Attributes
Attribute Name
Description
Order_ID
The order that this work item pertains to.
Material_Part_ID
Material part identifier
Tote_ID
Identifier for the physical container that printed material parts
are to be placed into
Late_Priority
BOOLEAN (TRUE, FALSE). The current estimate of
whether the order to which the material part belongs will
exceed SLA delay if any further delay is incurred in
processing this material part. Described in greater detail
relative to FIG. 6.
Shop_Priority
Date. The current estimate of the date at which the
order to which the material part belongs, will complete
processing. Described in greater detail relative to FIG. 6.
Destination
Shipping destination of the part to which this material
part belongs.
Single_Part
BOOLEAN (TRUE, FALSE). Does this part comprise
multiple material parts?
Destination_Part_Quantity
Quantity of parts being shipped to same destination.
Order_Priority
Date. Priority of the order, computed when the order is
first accepted by the system.
N-up Priority
Check the waste percentage and determine if this print
lot is able to be created. If it fails the test the print lot
will not be created and all parts will be put back into the
pool. (Applies to variable length parts only.)
State
State of the work item: completed, pending, error.
It is to be noted that not all of the work item attributes are necessary or available at each processing step. For example, the Tote_ID attribute isn't assigned until a work item reaches the “Lotted” state.
Work scheduler 245 sorts the queue of work items using the attributes listed in TABLE 2 as sort keys to produce a prioritized queue. The order of the sort keys and the sorting algorithm itself may vary at each processing step.
Periodically, work scheduler 245 recalculates the late priority and shop priority attributes of each work item. It then sorts the prioritized queue to both maximize efficiency and minimize the risk that the time to process any of the orders dependent on work items in the prioritized queue will exceed the SLA-defined Max_Delay period. The order of work items allows the processing module associated with each state to simply select the first work item in the prioritized queue and begin processing. Methods employed by work scheduler 245 to prioritize work items are further described with reference to FIG. 6 .
Using a network data transfer protocol, a prepress server 225 downloads an order and any composite files included in the order from partner system 215 and then performs a series of processing steps to prepare the orders for printing. The output from prepress server 225 is one print-ready file and one or more job control files, which are stored in data storage 235 . Prepress server 225 , said print-ready file, and said job control files are described in greater detail relative to FIG. 8 and FIG. 9 .
Status updater 240 runs as a background process on management server 230 . When status updater 240 detects that a work item has changed status, it updates the status of the corresponding order. In one embodiment, status information for an order is defined as the lowest status of each of the material parts that comprise the order where lowest status is defined by the Table 1 ID value. In one embodiment, status updater 240 notifies partner system 215 of status changes in the form of an email acknowledgement message. In one embodiment, when status updater 240 detects that a n order has changed status, it stores status information in an acknowledgement file on data storage 235 . Then, partner system 215 can download the acknowledgement file at its convenience. In one embodiment, the acknowledgement file is in XML format. In another embodiment, status information for each order is provided using a SOAP web service. In this embodiment, partner system 215 requests information for a specific order using a SOAP request message and status updater 240 provides the current status of the order by sending a SOAP response message. The SOAP protocol is maintained by the World Wide Web Consortium (W3C) and the specification can be found at http://www.w3.org/TR/soap/.
When a work item reaches a state of “Lotted” (TABLE 1) it is assigned to RIP and print system 250 . The output from RIP and print system 250 is one or more printed material parts that serve as input to finishing system 260 . RIP and print system 250 is described in greater detail with reference to FIG. 11 .
Printed material parts are then processed by a finishing system 260 . Most steps performed by finishing system 260 are performed by human operators. Finishing system 260 first binds printed parts into complete printed products. Finishing system 260 then prints a packing slip, packages the printed products with the packaging slip and affixes a mailing label onto the package. At this point, finishing system 260 assigns the final state of “Shipped” to the work item. When all work items that comprise an order have shipped the order is deemed to be complete. Finishing system 260 is described in greater detail with reference to FIG. 13 .
Reference is now made to FIG. 5 , which is a simplified flowchart of an overall method for a printing system, in accordance with an embodiment of the present invention. At Step 505 printing system 200 enters into a service level agreement (SLA) with a partner system 215 . Each SLA defines inter alia a maximum service delay, termed “Max_Delay”, for each print product that can be accepted by printing system 200 . At Step 510 once the SLA between the partner system and printing system is effective, printing system 200 commences to receive customer print orders from partner system 200 . At Step 515 printing system 200 imports an order into its native XML and stores it in data storage 235 .
The work performed by printing system 200 to process a print order is divided into a plurality of tasks which are referred to as work items. When the processing of a work item completes, a new state is associated with it. At Step 580 work scheduler 245 maintains a prioritized queue of work items for each state. Work scheduler 580 is depicted independently from the other steps in FIG. 5 because is executes on a scheduled basis independent of the other steps. Work scheduler 245 updates the prioritized queue for each state by calculating the priority of each work item within each prioritized queue. It then orders each prioritized queue using an algorithm that takes into account the updated priorities.
At Step 520 prepress server 225 downloads from partner system 215 one composite image for each image referenced in a print order. At Step 525 prepress server 225 serializes an order into a plurality of work items, also referred to as serial items, where each work item has a unique serial number. At Step 530 one or more work items are lotted to create a print job. At Step 535 prepress server 225 creates one or more print-ready files and one or more job control files that will control the printing process and print the print job. At Step 540 RIP and print system 250 raster image processes a print job and the resulting raster image file(s) is stored in data storage 235 . At Step 545 RIP and print system 250 prints a print job. RIP and print system 250 is further described with reference to FIG. 11 .
At Step 550 , finishing system 260 assigns each work items, which references a single material part, to a tote and a shop floor operator places the material part inside the designated tote. When a tote is full shop floor operator moves the tote near to a designated material bin unit. At Step 555 shop floor operator material sorts the material parts from a tote into designated material bins. Material sorting is further described with reference to FIG. 14 . At Step 560 the material parts are bound. At Step 565 finishing system 260 assigns the bound material parts to totes and a shop floor operator moves the totes near to a shipping bin unit. At Step 570 the bound material parts, also referred to as serial items, are ship sorted into designated shipping bins. At Step 575 the bound serial items are withdrawn from the shipping bins, packaged and moved to the shipping area. Finishing system 260 is further described with reference to FIG. 13 .
Reference is now made to FIG. 6 , which is a flow diagram describing the processing steps performed by work scheduler 245 ( FIG. 2 ) to calculate the priorities of work items, in accordance with an embodiment of the subject invention. Work scheduler 245 executes periodically on management server 230 . Work scheduler 245 maintains and periodically updates the order of a prioritized queue of work items for each state. Once an order reaches the “lotted” state, it has been serialized into material parts and the prioritized queue consists of an ordered list of material parts and attributes associated with each material part.
FIG. 6 describes one example method for ordering the prioritized queue of work items for a processing state. It will be appreciated by one skilled in the art that various methods may be used to prioritize the list of work items and that a different method may be used at each state.
At Step 610 the Shop_Priority is calculated for all work items in the prioritized queue. The calculation of Shop_Priority is described relative to FIG. 7A . At Step 620 the Late_Priority attribute is calculated for all work items in the prioritized queue. The calculation of Late_Priority is described relative to FIG. 7B .
At Step 630 the prioritized queue is sorted on the attribute Late_Priority such that all material parts whose Late_Priority attribute is set to TRUE are moved to the top of the queue. Material parts whose Late_Priority attribute is set to TRUE must be processed immediately in order to avoid having their corresponding print product exceed the contractual delay requirement defined in a SLA for the print product, referred to as Max_Delay. Note that if the time spent within printing system 200 exceeds Max_Delay for any product in an order then the entire order is deemed to exceed the Max_Delay requirement.
At Step 640 the prioritized queue is sorted on the Material_Part_ID. At Step 650 the prioritized queue is sorted on the Tote_ID attribute. Totes are described relative to FIG. 13 . At Step 660 the prioritized queue is sorted on the Destination attribute. Destination is described relative to FIG. 13 . At Step 670 the prioritized queue is sorted on the Order_Priority attribute. Order_Priority is described relative to FIG. 7B .
Reference is now made to FIG. 7A , which is a flow diagram describing the processing steps performed by a work scheduler to compute the SLA-based priority attribute for a work item, in accordance with an embodiment of the subject invention. FIG. 7A describes one algorithm for calculating Shop_Priority, which is a date/time that represents the best estimate of the time when a work item will complete all processing and be picked up by a shipper. This algorithm uses the Order_Priority attribute. Order_Priority defines the latest time that a product can be completed and not exceed the Max_Delay requirement. Order_Priority is defined as:
Order_Priority=Order_Accepted_Time+Max_Delay,
where Order_Accepted_Time is the time when the order was accepted into the system, i.e. when the order status was changed to “imaged” by prepress server 225 . For purposes of clarity, Order_Priority is a date that represents the priority or urgency of a work item relative to other work items in a prioritized queue. The earlier the date, the faster the corresponding work item needs to be processed.
Referring to FIG. 7A , at Step 705 , using the Material_Part_ID and the current status of the work item as indices, work scheduler 245 looks up the Expected_Delay from a list of expected delays named Expected_Delay_List 710 . In one embodiment, Expected_Delay_List 710 has a format as illustrated below in TABLE 3.
TABLE 3
Expected_Delay_List (in minutes)
Line Item
001-123
002-432
003-456
004-789
Current State
(Photo Book)
(Sticker)
(Notecard)
(Calendar)
Imaged
420
340
310
410
Processed
402
322
192
392
Lotted
370
307
277
360
Imported
328
301
271
315
Ready_To_Print
315
285
255
301
Moved_To_Press
245
265
235
235
Press_Imported
210
213
215
201
Printed
130
124
132
122
Bindery
110
112
104
99
Bound
102
100
82
87
Ready_To_Ship
73
65
53
62
Packaged
42
34
40
34
Shipped
—
—
—
—
In one embodiment, an Expected_Delay value from the Expected_Delay_List is the empirically determined average number of minutes for a work item to complete processing, i.e. move from a given state to the final state (State=Shipped). For example, using TABLE 3, a photo book whose state is “Lotted” will require 370 minutes on average to reach the “Shipped” state, i.e. to complete processing.
At Step 715 , work scheduler 245 consults Modifier_TABLE 720 to determine if there are any “modifiers” that must be taken into account when determining job priority. Modifiers are values that are subtracted or added to the priority in order to respectively increase or decrease priority. Modifiers can be inter alia per customer, per partner, per part, or per order. For example, for a two week period all orders coming from a specific partner can be increased in priority by 1 hour. As another example, if an order had been delayed for a particular customer, then future orders for that customer can be accorded higher priority for a period of time using modifiers.
At Step 725 Priority_Now is calculated by adding together the current time, the Expected_Delay determined at Step 705 and any modifiers determined at Step 715 . In one embodiment, times are represented as the number of minutes since a reference time, which is taken to be Jan. 1, 1900. In another embodiment, times are represented as days and fractions of days since a reference time.
At Step 730 , the work item's Shop_Priority attribute is set to the smaller of Order_Priority and Priority_Now.
Reference is now made to FIG. 7B , which is a flow diagram describing the processing steps performed by a work scheduler to calculate the Late_Priority attribute for a work item, in accordance with an embodiment of the subject invention. At Step 750 a determination is made as to whether Shop_Priority is greater than or equal to Order_Priority. If this is the case, then the order corresponding to the work item is in danger of being late; accordingly, at Step 755 the Late_Priority attribute is set to TRUE. If Shop_Priority is less than Order_Priority then there is some slack time and at Step 760 Late_Priority is set to FALSE.
As an example of the way that priorities come into play, the book block and cover of a photo book each comprise different work items, are assigned different serial numbers, and are processed separately by the prepress system and the RIP and print system. Typically, book block and covers will be printed in different print runs on different printers. While both the book block and cover of a photo book will each have the same Order_Priority, work scheduler 235 will calculate different Shop_Priorities for each work item at each state to reflect the different delays that each component will experience. This step-by-step approach to scheduling guarantees that the entire order is printed on time, per the Max_Delay requirement.
Reference is now made to FIG. 8 , which is a simplified block diagram of a prepress system, in accordance with an embodiment of the subject invention. Relative to FIG. 2 , this block diagram introduces additional detail concerning prepress server 225 .
An order puller 810 downloads orders from partner system 215 ( FIG. 2 ), using an appropriate file transfer method. File transfer methods performed by order puller 810 include File Transfer Protocol (FTP), User Datagram Protocol (UDP), Hypertext Transfer Protocol (HTTP), and Simple Object Access Protocol (SOAP).
An order importer 820 transforms the order into the native XML format of the printing system and stores it in data storage 235 ( FIG. 2 ). The XML attributes of the order are stored in a relational database within data storage 235 according to a pre-defined schema; this provides efficient access to the order data during subsequent processing steps. Order importer 820 also “serializes” the order into material parts that are separately processed. For example, the serialization of a line item consisting of five copies of a single calendar will result in the creation of five work items or serial items, one for each calendar, each with a unique serial number. Serialization enables the printing system to efficiently manage reprints. Thus if one copy of a calendar is damaged, then only that copy need be reprinted.
In one embodiment, partner system 215 provides orders in a proprietary file format; in this case, order importer 820 transforms the non-standard format into the native XML format of the printing service.
In one embodiment, partner system 215 provides orders in a XML format that uses a proprietary schema; in this case, order importer 820 uses XSLT to transform the XML into the native XML format of the printing system. XSLT is a language for transforming XML documents conforming to a first schema into XML documents conforming to a second schema. The XSLT standard is defined and maintained by the worldwide web committee (W3C—see http://www.w3.org/TR/xslt).
An image puller 830 downloads one composite image for each surface referenced in a line item, and stores the composites in storage system 235 . For example, if the line item consists of a greetings card, then prepress server 225 downloads four composite image files corresponding to the four surfaces shown in FIG. 1 . In one embodiment, a composite image can be in inter alia JPEG, PDF, EPS, BMP or TIFF format. In one embodiment, image puller 830 retrieves composites using standard file transfer methods including FTP, UDP and HTTP. Although a line item may call for a quantity greater than one to be printed, the composite images associated with the line item are only downloaded once.
A pre-flighter 840 “validates” or tests each composite image. Pre-flighter 840 analyzes each image to ensure that the image is formatted correctly and contains meaningful information. In the printing industry, such validation is commonly referred to as “pre-flight.” A variety of tests can be performed to ensure that the image data is meaningful. In one embodiment, thumbnails are generated and an operator views the thumbnails to ensure that they are visually meaningful. It is also possible to perform automated tests; for example, correlation tests can identify if the images contain noise or meaningful data. Additionally, if multiple composite images are included in a single file, pre-flighter 840 extracts each composite image to a separate file. Additionally, if the composite image is in the PDF file format then the PDF file will be checked to determine if there are mistakes in the PDF file that would cause the composite image to be rejected or printed incorrectly. Examples of mistakes that can be identified include inter alia wrong document size, missing fonts, incorrect image resolution, use of layers, and PDF/X print compliancy.
An order serializer 850 takes an order as input and serializes the order into one or more new work items each of which consists of a single material part. Printed material parts are rasterized and printed by RIP and print system 250 . Printed and non-printed material parts are then bound together and packaged by finishing system 260 to form one or more completed, ready-to-ship, products.
A print-ready maker 860 creates one print-ready file for each surface and one or more job control files for the print job. A print ready file describes the formatting and content of a document in a manner suitable for printing. The print-ready file can be in any standard or non-standard page document description format including inter alia PostScript, PDF, Microsoft Word, HTML, and rich text format (RTF). In one embodiment, the print ready file uses the portable data format (PDF). PDF is defined and maintained by Adobe Systems, Inc. More information about PDF can be found at http://www.adobe.com/products/acrobat/adobepdf.html.
Each print-ready file references one or more composite images, which remain in data storage 235 . Reference to a composite image is made using comments that are embedded in the print-ready files. The comments follow the open prepress interface (OPI) specification. OPI is defined and maintained by Adobe Systems, Inc. More information about OPI can be found at partners.adobe.com/public/developer/en/ps/5660_OPI — 2 — 0.pdf. The comments specify all information necessary for RIP and print system 250 to substitute the composite image data into the print-ready file during the printing process.
A job control file specifies how PDF files are to be combined and provides information about crop marks, score marks and barcode. The job control file provides information that is specific to the printing workflow but which is not contained in the print-ready file. For example, a job control file specifies inter alia where to place crop marks, and whether to print a bar code and if so where to place it. In one embodiment, the job control file uses job definition format (JDF) standard. JDF is defined and maintained by CIP4. More information about JDF can be found at http://www.cip4.org/.
A lotter 870 combines print jobs together, a process commonly referred to as “lotting.” Lotting offers two main advantages: (1) it improves efficiency by increasing the number of material parts printed per print job and thus decreasing the amount of time spent transitioning from one print job to the next, and (2) it minimizes paper wastage for variable length products such as photo books. The lotting process intelligently selects parts that can be combined together into a lot and produces a job control file that provides the necessary information for combining the parts to the printer. In one embodiment, lotting always combines parts of the same type; for example, notepads are only lotted with notepads, calendars are only lotted with calendars. In one embodiment, parts of different types can be combined; for example, notepads and calendars can be printed together as part of a single print run.
Lotting takes into account two cases: (1) the case of fixed length material parts, and (2) the case of variable length material parts. In the case of fixed length material parts, e.g. calendars and notecards, a preset number of material parts are lotted together. For example, in one embodiment, a lot size of 10 calendars is used where possible. Thus if 10 copies of the same calendar have been ordered they can be lotted together to form one print run. Alternatively, if two orders, one for 8 calendars and one for 2 calendars, are waiting in the prioritized queue then they can be lotted together. In the case of variable length material parts, e.g. photo books, lotting attempts to minimize the percentage of wasted paper in a print run. One method for lotting is described below with reference to FIG. 10 . It will be appreciated by those skilled in the art that in order to perform efficient lotting, prepress server 225 must take into account print run efficiency, variable length material parts such as photo book book block, wastage requirements that are established for each material part, and Max_Delay requirements defined per partner for each line item.
Lotter 870 takes into account the imposition requirement for the type of material part that is being lotted. Imposition is the process of intelligently arranging surfaces on a sheet of paper. Imposition is desirable because printing presses typically print multiple pages on a single large sheet of paper to make the most efficient use of the paper and to shorten the time required for printing. Imposition ensures that after the sheets of paper are printed, folded and trimmed, the resulting pages will be in the proper order. For example, in one embodiment greeting cards are printed “4-up.” This means that four greeting card surfaces are printed on a single sheet of paper by the printer.
A print-ready generator 880 takes as input all the print-ready files (one per surface) for a lot and the job control files for the lot, and produces as output a single print-ready file and one or more job control files. If the raster image processor (RIP) that will subsequently be used to process this print job is capable of interpreting and processing embedded OPI commands then print-ready generator 880 continues to embed OPI comments. However, not all RIPs are capable of processing embedded OPI comments; if that is the case, then print-ready generator 880 incorporates the composite images stored in data storage 235 into the print-ready file. Raster image processing is discussed in greater detail with reference to FIG. 11 .
TABLE 4, below, summarizes the processing required for one lot of ten calendars
TABLE 4
Example of processing required for one lot of ten calendars
Process
Print-ready file processing
Job control file processing
Print-
Creates 1 print-ready file per
Creates 1 job control file per
ready
calendar surface. There are 12
calendar; thus creates 10 job
maker
double sided pages (one for
control files.
each month) + 1 double sided
cover page in a calendar.
Hence, 13 double sided
pages × 2 files
per page = 26 print-ready files
per calendar.
Lotter
Lots 10 calendars together.,
Combines 2 calendars per page
Creates 26 × 10 = 260 print-
to take into account 2 UP
ready files per lot.
imposition; thus creates 5 new
job control files.
Print-
Creates a single print ready
Combines the 5 job control files
ready
file (from the 260).
into a single job control file for
genera-
the entire print job.
tor
Also, creates two additional job
control files: (1) describes the
imposition of two calendars onto
a single page, and (2) provides
additional details such as what
color management profile to use
and whether the print run is
simplex or duplex.
Reference is now made to FIG. 9A , which is a flow diagram illustrating the initial processing steps performed by a prepress server, in accordance with an embodiment of the subject invention. At Step 902 , order puller 810 downloads an order from partner system 215 ( FIG. 2 ). The order is initially assigned a state of “Pending-Order-Import” which signifies that the order has been downloaded but has not yet been processed. At Step 904 , order importer 820 performs two tasks: (1) it transforms the order into the native XML format of the printing system and stores it in data storage 235 ; and (2) it stores the XML attributes of the order in a relational database within data storage 235 according to a pre-defined schema.
At Step 906 a determination is made as to whether the order was successfully imported. If no errors are detected, then the order is determined to have been successfully imported and at Step 910 the order state is set to “Pre-batch.” The Pre-batch state signifies that the order has been successfully imported and stored.
If at Step 906 an error was detected, then at Step 908 the state of the order is set to “Pre-Order-Import-Error” which signifies that the order will not be processed any further. Partner system 215 can resubmit the order at its option.
At Step 912 , the order enters the prioritized queue for the “Pre-batch” state. At Step 914 image puller 830 selects the first work item in the prioritized queue to process. The Image puller 830 downloads one or more composite images for each surface in each line item in the order and stores them in storage system 235 . At Step 916 a determination is made as to whether the prepress server has successfully downloaded all composites for each line item in the order. If so, then processing continues to Step 918 where the state is set to “Downloaded.” If at Step 916 it is determined that one or more composite images was not successfully downloaded then processing continues at Step 920 .
At Step 920 , a determination is made as to whether the error is due to a system error. System errors include inter alia power failure, disc failure, processor failure, and disc full. Generally, system errors result from hardware or software failures in printing system 200 ( FIG. 2 ). Generally, system errors are quickly detected and corrected by operations staff. Non-system errors generally result from corrupted, incorrect or missing image data. If at Step 920 a system error is detected then at Step 922 the state is set to Reprint and the order is then returned to the prioritized queue at Step 912 and subsequently, another attempt will be made to process the order. If at Step 920 a non-system error is detected then the order cannot be successfully processed and control moves to Step 908 where, as previously described, the order is voided.
Reference is now made to FIG. 9B , which is a flow diagram illustrating the final processing steps performed by a prepress server, in accordance with an embodiment of the subject invention. At Step 950 the order now enters the prioritized queue for the “Downloaded” state. At Step 952 pre-flighter 840 validates all composite images for one line item. Additionally, if multiple composite images are included in a single file, pre-flighter 840 extracts each image to a separate file.
At Step 954 , if all the downloaded composite images in the order are determined to be valid, then at Step 956 the state is set to “Imaged.” Once the order has been imaged, all parts of the order including its XML specification and image content have been verified and stored in data storage 235 . At this point the “contractual clock” starts relative to the Max_Delay requirement. If, at Step 954 , it is determined that any of the composite image are not valid then processing continues at Step 920 .
At Step 958 , the order enters the prioritized queue for the “Imaged” state. At Step 960 order serializer 850 selects the first work item in the prioritized queue to process. Order serializer 850 serializes the order into one or more new serial items each of which consists of a single material part.
At Step 962 a determination is made as to whether the order was successfully serialized. If it is determined that the order was not successfully serialized then processing continues at Step 920 .
At Step 964 , for each material part in the order, print-ready maker 860 takes the composite image(s) that corresponds to the material part as input and produces a print-ready file and a job control files as output. The print-ready file and the job control file(s) are used subsequently by the RIP and printing service.
At Step 966 the state of the order is set to “Processed.” For purposes of clarity is should be noted that at the “Processed” state each work item references one serial item or material part. Then, at Step 968 the order enters the prioritized queue for the “Processed” state. At Step 970 , lotter 870 attempts to lot the material part with other material parts waiting in the prioritized queue in order to efficiently use printer resources as previously described. Finally, print-ready generator 880 takes as input the print-ready files (one per surface) and the job control file and produces as output a single print-ready file and one or more job control files.
If, at Step 972 , the print-ready file and the job control files are determined to have been created successfully, then, at Step 974 the prepress server 225 sets the state to “Lotted.” If an error occurs during creation of either the print ready file or the job control file, then control is transferred to Step 920 .
Now reference is made to FIG. 10 , which is a flow diagram that illustrates the processing steps performed by lotter 870 to select material parts for a print lot, in accordance with an embodiment of the subject invention. The exemplary method described in FIG. 10 attempts to lot together one or more material parts to create one print lot. At Step 1010 , lotter 870 selects the first work item from the prioritized queue for the “Processed” state. At Step 1020 , lotter 870 determines if the work item to be processed is a fixed length material part. It should be noted that a fixed length material part has a fixed number of pages such as a greeting card or calendar. If the material part is fixed length, then at Step 1030 lotter 870 searches the prioritized queue in priority order and attempts to select up to Preferred_Lot_Quantity −1 additional material parts of the same type where Preferred_Lot_Quantity is the preferred number of material parts of this type to be included in a single lot. Lotter 870 will attempt to select up to Preferred_Lot_Quantity of the same material parts but will accept less. As an example, if Preferred_Lot_Quantity is ten (10) in the case of calendars and lotter 870 has selected a first calendar to lot, then it attempts to include 9 additional calendars in the lot. If only 5 additional calendars are included as work items to be processed in the prioritized queue for the “processed” state then those five calendars together with the first will be lotted together for further processing and then printing. In other words, in the case of lotting fixed length material parts lotter 870 simply lots whatever material parts are currently available in the prioritized queue and doesn't wait for additional material parts to arrive.
If at Step 1020 it is determined that the material part to be processed is not fixed length, i.e. it is variable length, then at Step 1040 lotter 870 searches the prioritized queue in priority order and attempts to select up to N_UP-1 additional material parts of the same type such that taken together the N_UP-1 material parts enable the print lot to meet a Waste Threshold requirement. The term “N_UP” refers to the number of pages that are imposed on a single sheet during printing. For example, the book block of a photo book is a variable length material part that is printed 2 Up. In this case N_UP-1 is one (1); thus at Step 1040 lotter 870 searches the prioritized queue for another photo book book block material part which if selected would enable the two photo book book block material parts to meet said Waste Threshold requirement. A “Waste Threshold” requirement is a pre-established value and is defined as the percentage of pages wasted due to inefficient lotting. Table 5, below, presents an example of how the Waste_Threshold requirement is applied to variable length products. In the example, there are five photo book book block material parts awaiting lotting. The algorithm first selects the #1 position material part and then attempts to find a second material part that would enable the two material parts to meet meets the Waste_Threshold requirement. If the Waste_Threshold requirement is set to 10%, meaning that the target is to waste less than 10 percent of the pages, then material part in the eighth position would be selected to fill the lot as 21 sheets of paper will be required to print the two photo book book block material parts and each of the sheets of paper except for the last include two surfaces. The last sheet will include only one surface. Thus the page wastage is only 0.5* 1/21=2.4%. However, if the Waste_Threshold requirement is set to 15% then the material part in the fifth position, that is 16 pages long would be selected, because of the 20 paper sheets required for printing 5 would have a single surface and the paper wastage would be 0.5* 5/20=12.5%.
TABLE 5
Example Of Variable Length Lotting
Position in
Prioritized
Queue
Number of Book Block Pages
1
20
3
10
5
15
8
21
12
8
At Step 1050 a determination is made as to whether N_UP-1 material parts were selected for lotting that meet the Waste_Threshold. If so then lotting has been successful and processing continues at Step 1090 . If not, then at Step 1060 a determination is made as to whether the first work item's Late_Priority attribute is set to True. If Late_Priority is set to TRUE then no further delay can be tolerated and processing continues at Step 1070 . At Step 1070 any additional material parts of similar type are included in the lot up to a total lot size of N_UP even if the additional subparts will cause the lot to exceed the Waste_Threshold. After completing the lot processing continues at Step 1090 .
If at Step 1060 the Late_Priority attribute for the work item is not TRUE, i.e. it is FALSE, then the lot has not been completed and processing proceeds at Step 1080 . At Step 1080 the next work item in the prioritized queue is selected and processing returns to Step 1020 . If the last work item in the prioritized queue is reached then processing begins again with the first item. At Step 1090 the state of the work item is set to “Lotted.”
Now reference is made to FIG. 11 which is a simplified block diagram of a RIP and print system 1100 , in accordance with an embodiment of the subject invention. Two printer clusters are illustrated, a printer cluster # 1 1110 and a printer cluster # 2 1120 . Each printer cluster includes a print server 1130 , a raster image processor (RIP) 1140 , a printer console 1150 and a printer 1160 . In a RIP and printing system there is typically one such cluster for each type of printer and there are typically a plurality of different types of printers. Further a printer cluster may include a plurality of printers 1160 of the same type. Vendors of commercial quality printers include HP, XEROX, and Kodak. Typically, a commercial quality printer requires a RIP 1140 designed specifically for said commercial quality printer. It will be appreciated by those skilled in the art that print server 1130 may be a separate computer system, a card running inside a server computer, or it may be configured as software or hardware inside of prepress server 225 , management server 230 , or a finishing server 1305 ( FIG. 12 ). Similarly, it will be appreciated by those skilled in the art that RIP 1140 may be a separate computer system, a card running inside a server computer, or it may be configured as software or hardware inside of prepress server 225 , management server 230 , or a finishing server 1305 .
Print server 1130 periodically reviews the prioritized queue of work items for the “Lotted” state provided by work scheduler 245 ( FIG. 2 ). Print server 1130 selects the highest priority work item that needs to be raster image processed (commonly referred to as “ripped”) and transfers the print-ready file and job control file for the work item to RIP 1140 . Print server 1130 then changes the work item state to “Imported.”
RIP # 1 1120 receives a print-ready file and a job control file as input. If the print-ready file embeds OPI comments to reference high resolution composite images, then RIP 1140 replaces the OPI comments with the composite images stored in data storage 235 ( FIG. 2 ) during raster image processing. When RIP 1140 completes raster image processing the print job, print server 1130 updates the work item state to “Ready-to-print.” RIP 1140 stores the ripped print data in data storage 235 .
Print server 1130 displays the prioritized queue for the “Ready-to-Print” state produced by work scheduler 245 on printer console 1150 . The prioritized queue includes work items whose state may be: Lotted, Imported, Ready-to-Print, Imported-to-Press, or Printed.
A human printer operator 1170 uses printer console 1150 to perform a plurality of functions including selecting and initiating the next work item (commonly referred to as a “print job” while it is being processed by RIP and print system 1100 ) on printer 1160 . Prior to starting the next work item, printer operator 1170 may have to inter alia load additional paper, load a new type of paper, or add ink. Once printer operator 1170 selects and initiates a work item, print server 1130 moves the ripped print data from data storage 235 to printer 1160 . Print server 1130 then updates the work item state to “Imported to Press.” Once the print job successfully prints, print server 1130 updates the job status to “Printed.”
In one embodiment, printer operator 1170 can select a print job to be printed by an external printer 1180 . For purposes of clarity, the term external printer refers to a printing press or printing service that operates at a physically remote location. The printing press or printing service may be managed by the same organization that manages printing service 200 or it may be managed by a distinct organization or entity. The operator selects a work item whose status is Ready-to-Print and selects an external printer to perform the printing. The ripped data file(s) for the work item is transferred either across a network or are written onto removable storage media and then transferred to external printer 1160 . Removable storage media includes inter alia USB drive, DVD-RW, DVD-ROM, CD-RW, CD-ROM and external hard drive. The work item is printed off-site by external printer 1160 and the printed materials are then transported back to printing system 200 . When a work item is printed by an external printer 1160 the printed work item itself is scan-verified using a hand-held scanner 1330 to signal that the work item has completed and to change the job status to “Printed.” Scan-verification is described with reference to FIG. 13 ) The print job can be scan-verified by the external printer, in which case a message is generated and sent electronically to print server 1130 or it can be scan-verified by a shop floor operator 1350 after the print job is received. Shop floor operator 1350 is described with reference to FIG. 13 . Once the print job successfully and has been scanned, print server 1130 updates the job status to “Printed.”
Reference is now made to FIG. 12 , which is an illustrative screen capture from a printer console, in accordance with an embodiment of the subject invention. A printer console screen 1200 enables printer operator 1170 to interactively control the flow of print jobs to one or more printers 1160 . There is a unique printer console 1150 for each type of printer. Typically, thus one printer console 1150 may control the flow of print jobs to several printers 1160 of the same type. On the left side of printer console screen 1200 , an “awaiting print” window 1210 displays each work item which has “Ready-to-Print” status and is thus ready to be printed. The work items, or print jobs as they are commonly referred to, are lotted material parts that have been ripped by RIP 1140 and which are stored on data storage 235 . Awaiting print window 1210 displays a part number for each type of material part awaiting printing and the number of waiting print jobs for each said type of material part. It should be noted that the label “Part” that appears in awaiting print window 1210 is an abbreviation for the previously defined term “material part”. When a Part is expanded, as shown in 1220 , the material part serial number, shop priority date and size are listed for each work item in the list.
A “hot folder” window 1230 , entitled “iGen-1”, displays each print job that has moved by printer operator 1170 from awaiting print window 1210 to hot folder window 1230 . Print jobs in hot folder window 1230 will be printed on the currently selected printer. In this example, the currently selected printer is iGen-1 as indicated by an enabled printer button 1240 . In this example, the DocuSP Console controls four printers of the same type: iGen-1, iGen-2, iGen-3, and iGen-4. Printer operator 1170 can drag or more print jobs from awaiting print window 1210 into hot folder window 1230 to initiate printing of print jobs. Alternatively, printer operator 1170 can select one or more print jobs listed in awaiting print window 1210 and then click an “Add Selected to Hot Folder” button 1250 to initiate printing of print jobs. Printer operator 1170 can select print jobs listed in hot folder window 1230 and click on “Remove Selected from Hot Folder” button 1260 to remove print jobs from the hot folder window 120 and place them back in the awaiting print window 1210 .
Reference is now made to FIG. 13 , which is a simplified block diagram of a finishing system 1300 , in accordance with an embodiment of the subject invention. Finishing system 1300 takes printed parts from the RIP and print system 250 ( FIG. 2 ) and binds them into completed products, packages them and ships them to recipients to fulfill orders received from partner system 215 ( FIG. 2 ). Two types of human staff or workers are employed in finishing system 1300 . A shop floor manager 1340 utilizes a management console 1335 to manage the flow of tasks and a shop floor operator 1350 performs sorting, binding, and packaging tasks. A finishing server 1305 exchanges status information with management server 230 and interacts with shop floor manager 1340 via a management console 1335 , and with shop floor operator 1350 via a shop floor console 1325 and via a hand-held scanner 1330 . Hand-held scanner 1330 can be wirelessly connected to finishing server 1305 , or it can be connected by a hard-wired communications line.
Finishing server 1305 three processing modules. A bin manager 1310 manages the sorting of printed parts into and out of material bin 1362 by shop floor operator 1350 . A console manager 1315 manages the flow of messages to and from shop floor console 1325 , hand held scanner 1330 and management console 1335 . A shipping manager 1320 generates a packing slip and a mailing label for each package.
It will be appreciated by those skilled in the art that finishing server 1305 may be a separate computer system; or alternatively finishing server software modules, bin manager 1310 , console manager 1315 and shipping manager may be configured to run inside of management server 230 , prepress server 225 or print server 1110 . It will be further appreciated that finishing server 1305 may be several computer systems, each configured to run one or more processes or handle a certain number of jobs. For example, one finishing server 1305 may run bin manager 1310 and shipping manager 1320 , while another finishing server 1305 runs console manager 1315 .
Once material parts have been printed by RIP and printing system 250 ( FIG. 2 ), they are transported by shop floor operator 1350 using a tote 1355 near to a material bin unit 1360 on the shop floor. For purposes of simplicity, the term “tote” refers to a container of known size used to transport physical items such as material parts, bound products, and packaged products from one location within finishing system 1300 physical premise to another. Typically, one or more totes are placed onto a cart which has wheels and which can be conveniently pushed across finishing system 1300 physical premise. For purposes of clarity, the finishing system 1300 physical premise is referred to as the “shop floor.”
A material bin unit 1360 is a temporary storage unit that is constructed from inter alia wood, metal or plastic that is divided into a plurality of material bins 1362 , each having a designated height, width and depth. In addition, each material bin 1362 displays a unique bin number, both in numeric format and in bar code format so that it can be conveniently scanned using hand-held scanner 1330 . In one embodiment material bins 1362 are of different sizes, e.g. 1 inch, two inches, and three inches wide.
Shop floor operator 1350 performs material sorting, which is also known as collating. Before starting to sort materials into material bins 1360 , shop floor operator 1350 signs in to finishing server 1305 . To sign in, shop floor operator 1350 uses either hand-held scanner 1330 or shop floor console 1325 to provide his operator id, and to identify his location on the shop floor. After signing in, shop floor operator 1350 may perform material sorting.
Now reference is made to FIG. 14 , a simplified flow diagram that illustrates the steps performed in material sorting, in accordance with an embodiment of the subject invention. At Step 1410 shop floor operator 1350 selects a material part from tote 1355 and scans it using hand-held scanner 1330 . Hand-held scanner 1330 scans the bar code printed on the material part and transmits this information to console manager 1315 . At Step 1420 a determination is made as to whether a co-material part has already been scanned. A “co-material part” refers to one of the material parts that makes up a serial item. For a serial item to be complete and ready for binding, all of its co-material parts must be placed by shop floor operator 1350 into the same material bin 1362 . For example, if a photo book cover is in a material bin 1362 , there is a corresponding book block co-material part because a photo book cover and its corresponding book block are required for the complete photo book serial item to be bound. If a co-material part has already been scanned, then, at Step 1430 , bin manager 1310 obtains the bin number that the first co-material part was placed into by shop floor operator 1350 .
If no co-material part has yet been received, then, at Step 1440 , a new material bin 1362 is assigned by bin manager 1310 . Bin manager 1310 takes into account the size requirement of the serial item material parts when assigning a material bin. In one embodiment, there are a plurality of bin sizes, e.g. 1 inch, 2 inches, and 3 inches; and bin manager 1310 takes into account the sizes of all available bins in selecting the bin size that will afford the tightest fit. For variable size material parts, such as the book block of a photo book, bin manager 1310 computes the size of the part by taking into account the page count. In one embodiment, if there are multiple bins of the correct size available, bin manager 1310 selects a bin where the adjacent bins are not currently storing parts in order to reduce the possibility of accidental mistakes by shop floor operator 1350 such as placing a material part into the wrong material bin 1362 .
At Step 1450 , bin manager 1310 provides console manager 1315 the number of the material bin assigned to the serial item and console manager 1315 displays said material bin number on hand-held scanner 1330 . At Step 1460 , shop floor operator 1350 places the part into the material bin 1362 that corresponds to said material bin number.
At Step 1470 , shop floor operator 1350 uses hand-held scanner 1330 to scan-verify the bar code for said material bin 1362 to indicate that the material part was successfully placed into the correct material bin 1362 . The action of scanning a bin's barcode into which the operator just placed, or withdrew an item is referred to as “scan-verifying.” At Step 1480 , after receiving the scanned bin number via console manager 1315 , bin manager 1310 determines whether material sorting of the serial item is complete, i.e. whether all of its component material parts have been placed into material bin 1362 . If material sorting is determined to be complete then, at Step 1490 , bin manager 1310 updates the job status to “Bindery.” At this point, the serial item has been successfully sorted and is ready to be processed in a bindery 1365 . If not all co-material parts have been placed into material bin 1362 , then additional parts will have to arrive and be material sorted in order to complete material sorting of the serial item and send it to bindery 1365 .
In one embodiment, after shop floor operator 1350 places the last co-material part into material bin 1362 hand-held scanner 1330 beeps to indicate that all co-material parts have been placed into material bin 1362 .
Referring back to FIG. 13 , once a serial item has been material sorted then the serial item can enter bindery 1365 . Bindery 1365 is a location, including staff and equipment, on the shop floor where binding is performed. The term “binding”, refers to actions that are performed on material parts of a serial item to create a finished product. Said actions include inter alia gluing, stapling, folding, cutting and sewing. For example, if the material parts consist of a cover and book block, then these will have to be glued, stapled or otherwise attached in the bindery. Note that some serial items, including greeting cards and calendars, have only one material part. In such cases, bindery actions such as folding may still be necessary. In some cases, for example with certain types of greeting cards, no bindery actions at all are required. In such cases material sorting is not required and the tote carrying the printed material part will bypass the bindery and be moved to the area on the shop floor where the material part will be ship sorted into a shipping bin 1372 .
In bindery 1365 , shop floor operator clicks a “Find Next” button on hand-held scanner 1330 and bin manager 1310 retrieves the first work item from the appropriate prioritized queue. Hand-held scanner 1330 displays the number of the material bin 1362 that holds the material parts to bind. Shop floor operator takes the material parts out of the indicated material bin 1360 and scan-verifies each material part by scanning the bar code that has been printed and is visible on the material part. After the last material part has been scan verified, bin manager 1310 releases the material bin for subsequent use. Hand-held scanner 1330 then indicates any non-printed material parts, e.g. a velum separator sheet or a non-printed book cover, to be bound together with the printed material parts. Shop floor operator retrieves any such non-printed material parts which are typically stored within bindery 1365 . Shop floor operator 1350 then performs the appropriate binding task on the material parts. Next, shop floor operator 1350 scans the bound serial item and places it into tote 1355 . At this point, bin manager 1210 updates the job status to “Bound.” When said tote 1355 is full, shop floor operator 1350 moves said tote 1355 near to a shipping bin unit 1370 so that the bound serial items can be “ship sorted.”
A shipping bin unit 1370 is a temporary storage unit that is constructed from inter alia wood, metal or plastic that is divided into a plurality of shipping bins 1372 , each having a designated height, width and depth. In addition, each shipping bin 1372 displays a unique bin number, both in numeric format and in bar code format so that it can be conveniently scanned using hand-held scanner 1330 . In one embodiment shipping bins 1372 are of different sizes, e.g. 1 inch, two inches, and three inches wide.
Shop floor operator 1350 performs ship sorting which is the process of taking individual bound serial items out of tote 1355 and placing them in designated shipping bins 1372 . Before starting to ship sort, shop floor operator 1350 signs in to finishing server 1305 . To sign in, shop floor operator 1350 uses either hand-held scanner 1330 or shop floor console 1325 to provide his operator id, and to identify his location on the shop floor. After signing in, shop floor operator 1350 may perform ship sorting.
The process of ship sorting is analogous to the process of material sorting. However, in the case of ship sorting, bound serial items are taken from tote 1355 and placed into designated shipping bins 1372 by shop floor operator 1350 . A shipping bin holds all serial items that will be packaged together. Ship sorting employs a similar algorithm to that used for material sorting, described with reference to FIG. 14 , with three exceptions: (1) rather than placing co-material parts into material bins 1362 , shop floor operator 1350 places bound serial items into shipping bins 1372 ; (2) rather than wait for all co-material parts for the bin to be considered full, the algorithm waits for all serial items that will later be packaged together; and (3) rather than updating the job status to “Bound”, bin manager 1310 updates the job status to “Ready-To-Ship.” As with material sorting, shop floor operator 1350 withdraws a serial item and scans it. Then, bin manager 1310 uses console manager 1315 to display the shipping bin number into which to place the line item. Next, shop floor operator 1350 places the serial item into the shipping bin 1372 that corresponds to said shipping bin number and scan-verifies the shipping bin. When assigning a shipping bin 1372 , bin manager 1310 takes into account the size of all serial items that must fit into the shipping bin.
Once all serial items that will be included in a package have been ship sorted into shipping bins 1372 , they are ready to be packaged at a packaging station 1375 . Packaging station 1375 is a physical location on the shop floor where packaging is performed.
At packaging station 1375 shop floor operator 1330 clicks a “Find Next” button on shop floor console 1325 and bin manager 1310 retrieves the first work item from the appropriate prioritized queue and displays the number of the shipping bin 1372 that contains the serial items to package. Shop floor operator 1350 takes the serial items out of the indicated shipping bin 1372 . Shop floor operator 1250 then scan-verifies said shipping bin 1372 to indicate that the serial items have been taken out and that said shipping bin 1372 is now empty and can be reused. Then bin manager 1310 changes the status of the work item to “Packaged” and (1) selects the appropriate box from a plurality of different types and sizes of boxes, taking into account the size and weight requirements for each serial item to be included in the box, and (2) prints a packaging slip. If the package is to be picked up by a shipping service then a shipping label including postage is also printed. If the package is to be set aside for pickup by a “lab” then a lab label is printed. A lab is a photo lab service or other company for whom packages are batched and shipped together.
Shop floor operator 1350 then uses shop floor console 1325 to determine if any embellishments need to be added to the package. Shop floor operator 1350 retrieves any such needed embellishments which are typically stored near to packaging station 1375 .
Shop floor operator 1350 completes the packaging task by (1) pulling the appropriate box as indicated by the packaging screen displayed by shop floor console 1325 , (2) placing the serial items, the packaging slip, and packaging material in the box, (3) sealing the box and (4) affixing the shipping label or lab label to the box. Shop floor operator 1350 then places the package into tote 1355 which will be moved to a designated pick up area on the shop floor. At this point, bin manager 1310 updates the work item status to “Shipped.”
If an error occurs during packaging an error label is printed and the order remains in the “Packaged” state. In this case, the package and the error label are set aside for shop floor manager 1340 . Once shop floor manager 1340 resolves the error he scans the package again to obtain a shipping label, then affixes the label and places the package into the designated tote 1355 . Bin manager 1310 then updates the work item status to “Shipped.”
In one embodiment, if the package is intended for a lab then a lab label is affixed and the package is placed in a designated tote, referred to as a “lab bin.” Periodically, shop floor operator 1350 uses shop floor console 1325 to scan-verify packages from the lab bin and place the packages into a box. When the box is full shop floor operator 1350 uses shop floor console 1325 to indicate to bin manager 1310 that the package is full. Shipping manger 1320 then prints a packing slip and a shipping label. Shop floor operator 1350 places the packing label inside the box, seals the box, and places the shipping label on the box. Shop floor operator 1350 then moves the box to a designated location on the shop floor. Bin manager 1310 then updates status for each of the work items that were placed in the box to “Shipped.”
Now reference is made to FIG. 15 . which is an illustrative screen capture from a shop floor console, in accordance with an embodiment of the subject invention. In this example, shop floor operator 1350 selects the operation “Scan to Reprint” and the user interface screen depicted in FIG. 15 appears. Next, shop floor operator 1350 scans the barcode that appears on a serial item to be reprinted. The serial item number appears in a barcode field 1510 . Shop floor operator 1350 may use a checkbox 1520 to indicate whether the entire lot, a single serial item or an entire lot with scan verification should be assigned to reprint. Shop floor operator 1350 can check a box 1530 and enter a reason code that indicates the reason why the serial item is to be reprinted. Window 1540 displays a list of previous serial items that were scanned to reprint.
Now reference is made to FIG. 16 , which is a simplified block diagram of a multi-site printing system, in accordance with an embodiment of the subject invention. A “multi-site printing system” enables a plurality of printing systems, each at a different location, to work together cooperatively to share and distribute the printing workload. Multi-site printing offers several advantages including increased redundancy in case of equipment or system failure, increased capacity for peak workload and decreasing shipping times by having printing systems geographically close to the recipient. The following discussion (with reference to FIG. 16 ) describes only the enhanced capabilities of the “multi-site printing system” embodiment. The multi-site printing system embodiment incorporates all the features and functions of printing system 200 as described with reference to FIG. 2 .
FIG. 16 includes two printing systems, a printing system # 1 1610 and a printing system # 2 1640 . Printing system # 1 1610 receives orders from partner system 215 ( FIG. 2 ). To accomplish this, prepress server 225 ( FIG. 2 ) downloads, imports, and stores each order in a data storage # 1 1620 using the method described with reference to FIG. 8 . A site assigner 1630 then assigns the order a print site identifier (referred to as a “site ID”) that identifies the site that will rasterize, print, bind, package, and ship the order. Site, in this case, refers to either printing system # 1 1610 or printing system # 2 1640 .
In one embodiment, site assigner 1630 automatically assigns the site ID based on the addresses of the recipients of the printed products included in the order. For example, if the majority of recipients are located in the eastern United States then the order may be assigned to printing system # 1 whereas if the majority of recipients are located in the western and midwestern United States the order may be assigned to printing system # 2 .
In a second embodiment, site assigner 1630 automatically assigns the site ID based on the type of printer. For example, orders that contain posters may be printed by printing system # 1 1610 whereas orders containing photo books may be assigned to printing system # 2 . 1640 .
Data storage # 1 1620 and data storage # 2 1650 each include relational databases. Said two relational databases are synchronized using transaction replication. Transactional replication is an industry standard type of replication, provided by most commercial relational database management systems, that allows data modifications to be propagated incrementally between databases in a distributed environment.
Once a site ID is assigned to an order and the order has been imported, the rest of the workflow is identical to that described previously with reference to FIG. 2 with the exception that printing system # 1 1610 only processes orders that are assigned to it, and printing system # 2 1640 only processes orders that are assigned to it. For example, if printing system # 2 1640 processes an order then the prepress server included in printing system # 2 will download the composite images required to print the order and store them in data storage # 2 1650 .
The multi-site printing system offers protection in case of a component failure in one of the printing systems. In one embodiment, if there is a component failure in one printing system, for example, in printing system # 2 , then any order assigned to printing system # 2 1640 are reassigned to printing system # 1 1610 for processing. Orders that are being processed by printing system # 2 at the time of the component failure can be halted and reprinted by printing system # 1 1640 . Halting and reprinting an order that is in process can be perfomed as follows: (1) a printer operator such as printer operator 1170 reassigns the order's site ID to printing system # 1 ; (2) any data associated with the order in data storage # 2 1650 is replicated to data storage # 1 1620 ; and (3) the job status is set to Reprint which puts the system into the prioritized queue of printing system # 1 1610 . One method for replicating data from data storage # 2 1650 to data storage # 1 1620 is to use a folder replication feature that is commonly available with network addressable storage (NAS) systems such as those typically used by data storage # 1 1620 .
It will be appreciated by those skilled in the art that site assigner 1630 may run in any server within printing system 1610 including management server 230 , prepress server 225 , print server 1110 , or finishing server 1205 . Additionally, it will be appreciated by those skilled in the art that the previously described approach to multi-site printing can be used to share print order processing among more than two printing systems.
LISTING 1
<?xml version=“1.0” encoding=“ISO-8859-1”?>
<Order xmlns=“http://www.ipads.com/xml/iPads_Order”
xmlns:xsi=“http://www.w3.org/2001/XMLSchema-instance”
CustomerID=“Partner_Brand” EnvelopeID=“33809” OrderID=“33809”
orderDate=“2007-02-12”
xsi:schemaLocation=“http://www.ipads.com/xml/iPads_Order
iPads_Order.xsd”>
<Address AddressID=“1”>
<firstname>Mark</firstname>
<lastname>Gustafson</lastname>
<address1>100 EastLake Ave N</address1>
<address2></address2>
<address3></address3>
<city>Seattle</city>
<state>WA</state>
<postalcode>98101</postalcode>
<country>US</country>
<phone></phone>
<email>mark@rpiprint.com</email>
</Address>
<Contact ContactID=“1” AddressID=“1” />
<BillTo BillingID=“1” AddressID=“1”> <Invoice /> </BillTo>
<ShipTo AddressID=“1”>
<ShipMethod>GROUND</ShipMethod>
<PackingSlip include=“true” />
</ShipTo>
<CartItem ContactID=“1” description=“scenes” quantity=“7”>
<PhotoBook_8by10wrap>
<PhotoBookAttributes/>
<PhotoBookCover>
<PhotoBookCoverAttributes>
<JobName Value=“CoverPortrait”/>
<JobStock
Value=“Black_Small_Wrap_Cover_Port_PartnerBrand”/>
</PhotoBookCoverAttributes>
<PhotoBookPage PartOrder=“1”>
<PhotoBookPageAttributes>
<TemplateName Value=“StandardWrapPortraitCover”/>
</PhotoBookPageAttributes>
<Photo>
<PhotoAttributes>
<Filename Value=“cover_P24786_0002.pdf”/>
<ImageType Value=“pdf”/>
<ElementName Value=“Photo1”/>
<CropStyle Value=“StretchFit”/>
</PhotoAttributes>
</Photo>
</PhotoBookPage>
</PhotoBookCover>
<PhotoBookBookBlock>
<PhotoBookBookBlockAttributes>
<JobName Value=“DuplexPortrait”/>
</PhotoBookBookBlockAttributes>
<PhotoBookPage PartOrder=“1”>
<PhotoBookPageAttributes>
<TemplateName Value=“StandardPortrait”/>
</PhotoBookPageAttributes>
<Photo>
<PhotoAttributes>
<Filename Value=“page_P24786_0001.pdf”/>
<ImageType Value=“pdf”/>
<ElementName Value=“Photo1”/>
<CropStyle Value=“StretchFit”/>
</PhotoAttributes>
</Photo>
</PhotoBookPage>
<PhotoBookPage PartOrder=“2”>
<PhotoBookPageAttributes>
<TemplateName Value=“StandardPortrait”/>
</PhotoBookPageAttributes>
<Photo>
<PhotoAttributes>
<Filename Value=“page_P24786_0002.pdf”/>
<ImageType Value=“pdf”/>
<ElementName Value=“Photo1”/>
<CropStyle Value=“StretchFit”/>
</PhotoAttributes>
</Photo>
</PhotoBookPage>
</PhotoBookBookBlock>
<NonPrintableMaterial>
<NonPrintableMaterialAttributes>
<Description Value=“VelumSeparator012”/>
<Quantity Value=“1”/>
</NonPrintableMaterialAttributes>
</NonPrintableMaterial>
</PhotoBook_8by10wrap>
</CartItem>
</Order>
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A method for end-to-end printing, including entering into service level agreements with each of a plurality of partner systems that enable customers to order personalized print products, wherein a service level agreement designates maximum delays for finishing customer print orders, receiving customer print orders forwarded from the plurality of partner systems, each print order specifying at least one personalized print product, serializing the print orders into a plurality of work items, each work item corresponding to a part of a personalized print product that is to be printed on printable material, dynamically assigning priorities to the work items, dynamically advancing the work items through a plurality of print processing states, wherein each processing state processes work items in order of their priorities.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to water-immersible seats for use at the edges of swimming pools, on the sides of boats, and over the rims of hydrotherapy equipment.
(2) Description of the Prior Art
In order to be used in conjunction with a water environment, chairs and seats have been subjected to modification and adaptation to fit particular situational requirements. For example, chairs and seats have been adapted for use in bathtubs for persons required to take sitting baths in the treatment of medical and physical disorders. Seats have been adapted for weight-trimming use on sailboats by providing means for allowing a sailor to place his weight outboard of the sailboat.
BRIEF SUMMARY OF THE INVENTION
This invention provides such a means and device whereby an occupant of a water-immersible seat of the invention can be immersed in water to the extent desired. Quite frequently water in swimming pools of hydrotherapy equipment is heated to such an extent that a significant temperature differential exists between that of the heated water and the ambient. For effective hydrotherapeutic bathing, patients are positioned in such manner as to permit circulation of water in direct contact with afflicted areas. In order to promote maximum comfort for the patient, the unaffected areas of the body are permitted to remain out of the water. Likewise swimmers, because of ambient/water temperature differential, may desire to slowly withdraw from the warmer temperature of the water to the cooler temperature of the ambient, or sunbathers may desire to have only the lower part of their bodies immersed in water, or people who are afraid of water can immerse themselves to the extent desired.
It is an object of this invention to provide a water-immersible seat adapted particularly to support a seat occupant with maximum comfort and safety while such occupant is immersed in water to a desired amount.
Another object of this invention is to provide a water-immersible seat which may be easily installed to and removed from a supporting member and yet is completely stable.
A further object of this invention is to provide a water-immersible seat of simplified construction for economical manufacture that can be easily assembled or disassembled.
The foregoing and other objects and advantages of this invention will appear from the following detailed description taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a water-immersible seat embodying the features of the present invention.
FIG. 2 is an enlarged isometric view of a deck base plate.
FIG. 3 is an enlarged isometric view of a height-adjustment lock.
FIG. 4 is an enlarged isometric view of the connection of a front horizontal member with a vertical member.
FIG. 5 is a plan view of a water-immersible seat as is shown in FIG. 1.
Preferred features of construction have been illustrated and will be specifically described, with the understanding, however, that variations may be made within the scope of the invention as claimed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 5, the framework of a water-immersible seat is formed by inserting a right and left vertical hooked rods 1, the upper ends of which are bent laterally and downwardly in the form of hooks, into two other right and left vertical curved rods 4, which may be tubular or which may be solid with the upper portion of such rods 4 hollowed out to permit the insertion of the longer legs of right and left vertical hooked rods 1. Such right and left vertical curved rods are bent backwardly, then downwardly, then laterally, and finally upwardly, as shown in FIG. 5, to which a front horizontal curved tube 7, that is smoothly curved at both ends at an angle of 90 degrees and whose internal diameter is slightly larger than the external diameter of right and left vertical curved rods 4, fits snugly onto right and left vertical curved rods 4, as is shown in FIG. 4. Right and left vertical curved rods 4 are curved backwardly to such an extent necessary so as to permit the waterimmersible seat, when in contact, for example, with the side of a swimming pool, to maintain a vertical position.
A horizontally positioned cross bar 5, both ends of which are threaded to shoulders, connects right vertical hooked rod 1 and right vertical curved rod 4 to left vertical hooked rod 1 and left vertical curved rod 4. This is accomplished by providing a passageway through right and left vertical curved rods 4 and a series of evenly spaced passageways in right and left vertical hooked rods 1. The purpose of the several evenly spaced passageways in right and left vertical hooked rods 1 is to provide means whereby the height of the water-immersible seat can be adjusted.
The shoulder of horizontal cross bar 5 can be provided by having a retaining ring or a nut screwed onto horizontal cross bar 5 or alternatively the unthreaded portion of horizontal cross bar 5 can be larger in diameter than is the diameter of the passageways of right and left vertical hooked rods 1 and right and left vertical curved rods 4.
Referring to FIG. 3, horizontal cross bar 5, after one of its threaded ends pass through the passageways of right vertical curved rod 4 and right vertical hooked rod 1 and the other of its threaded ends pass through the passageways of left vertical curved rod 4 and left vertical hooked rod 1, secures such rods into position by means of wing-tip nuts 6.
The foregoing describes the assembly of the framework of a water-immersible seat and for purposes of clarity the attachment of a back and seat bottom 8 to the framework was omitted.
A back and seat bottom 8 is made of fabric, synthetic or natural, wherein pieces of fabric are stitched or stapled in the form of tubes whereby four such tubes are rectangularly positioned in such a manner as is shown in FIG. 8, open at all ends to permit the passage of tubes or rods, and held together by means of a cross-hatching of synthetic or natural fibers so as to form what is commonly known as a fish-net.
The longer tubes of a back and seat bottom 8 slip over right and left vertical curved rods 4, while one of the shorter tubes of back and seat bottom 8 slips over horizontal curved tube 7 and the other of the shorter tubes slips over horizontal cross bar 5. Because of the design and size of back and seat bottom 8, horizontal curved tube 7 is held firmly attached to right and left vertical curve rods 4 so that along with the snug fit of horizontal curved tube 7 onto right and left vertical curved rods 4, as shown in FIG. 4, no other means for securing this connection are necessary.
The assembled water-immersible seat can be secured to deck of a pool or boat, as is shown in FIG. 2, by means of a base plate 2 having some three holes drilled into such base plate 2 to permit screws to attach such base plate 2 to a deck. As an integral part of base plate 2, a cylindrical rod fits snugly into right and left vertical hooked rods 1, hollowed out to permit the insertion of such cylindrical rod. Toward the ends of the shorter legs of the right and left vertical hooked rods 1 and in the cylindrical rods of base plate 2 passageways are provided for pull-ring pins 3 to secure the water-immersible seat to the deck.
Although the teachings of this invention have herein been discussed with reference to specific embodiments, it is understood that these are by way of illustration only and that others may wish to utilize this invention in different designs or applications.
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A water-immersible seat for use at the edges of swimming pools, on the sides of boats, and over the rims of hydrotherapy equipment is disclosed wherein the amount of immersion of an occupant of the seat can be varied.
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BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for evening the sliver produced by a card, wherein conventionally a determined output rate and a determined draft is set; the actual sliver weight for a given sliver length is determined by weighing and in case of a deviation from a desired sliver weight, the draft (tension) is varied to correspond to a predetermined desired sliver thickness.
According to a known process, in case of predetermined output rate and draft, the sliver number is determined by monitoring weight measurements while sliver regulation is deactivated. By virtue of a subsequent alteration of the draft the difference between the determined (actual) sliver number and the desired sliver number may be reduced. The thus resulting change in the sliver number is verified by renewed weighing. This process is repeated as often as necessary to achieve a sufficient agreement between the desired sliver number and the measured sliver number. Subsequently, the desired sliver thickness value is determined by potentiometer balancing.
In the sliver manufacture it is an objective to produce a sliver having a determined sliver number which should remain substantially constant. According to the known process at the beginning of the manufacture a determined output rate (m/min) and a determined draft (for example, 80-fold) are set. Subsequently, a determined sliver length is sampled and weighed (first monitoring weighing) from which the actual sliver weight (g/m) and thus the actual sliver number (m/g) is obtained. In case of a deviation from the desired sliver number the draft is changed by altering the feed roller speed whereby the quantity of the fiber material supplied to the carding machine is changed. Thereafter a second monitoring weighing is performed. In case the actual sliver weight then corresponds to the desired sliver weight (that is, the actual sliver number is identical to the desired sliver number), the desired sliver thickness may be determined which is utilized as a desired value for setting a sliver regulating device. Since there is a relationship between the sliver thickness and the sliver number dependent upon the fiber material, the desired sliver thickness corresponding to the desired sliver number may be derived from such relationship. The above-described prior art method is disadvantageously complex.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved method and apparatus of the above-outlined type from which the discussed disadvantages are eliminated and with which particularly the desired sliver thickness values may be determined in a simple manner.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, during a predetermined time period the actual sliver thickness is measured at the card output; the measured values are converted into an electric signal and combined into an average value for the actual sliver thickness, stored and applied to a computer. Further, a signal representing the actual sliver weight is applied to the computer which determines--from the relationship between the actual sliver weight and the actual sliver thickness--a desired sliver thickness corresponding to a desired sliver weight.
By virtue of the invention, a desired sliver thickness value may be determined in a simple manner. The method merely requires the determination of the output rate and the inputting of the desired sliver number and the actual sliver number determined from the monitoring weighing.
Preferably, the method according to the invention is used in a card sliver regulating system wherein at the output of the card the actual sliver thickness is measured, the measured value is transformed into an electric signal by a transducer and applied to a regulating device which in case of a deviation from a predetermined desired sliver thickness changes the rpm of the drive motor of a setting member, for example, the feed roller or doffer of the carding machine. In order to achieve an automatic setting of the desired sliver thickness value at the regulating device, the latter sets the rpm of the drive motor to a temporary desired value for the sliver thickness. Thereafter, there is determined a desired sliver thickness corresponding to the desired sliver weight and corrected based on the actual sliver weight and the actual sliver thickness and the desired value setter of the regulating device is set according to the corrected desired sliver thickness.
The given magnitudes are the desired output rate and a desired sliver number which are inputted in a computer. Initially, the draft is arbitrary. Starting from a functional relationship between the sliver number and sliver thickness the apparatus determines the corresponding desired sliver thickness value. By virtue of a comparison of the measured sliver thickness value and the desired value, by means of a regulating device (or manually) at constant output rate the actual sliver thickness value may be adapted to the desired sliver thickness value. A possible setting magnitude is the rpm of the feed roller of the card. The resulting actual sliver number is verified by a monitoring weighing. If the weighing shows a difference between the desired and actual sliver numbers, the actual sliver number is inputted in the computer. This input is used to correct the desired sliver thickness value such that the sliver supplied by the carding machine has tee desired sliver number.
Preferably, the computer determines--from a stored, fiber material-related function between sliver weight and sliver thickness--the temporary desired value for the sliver thickness, corresponding to the desired sliver weight.
The apparatus according to the invention for performing the above-outlined method comprises a measuring member which is arranged at the card output, and which may be a sliver trumpet, for determining the actual sliver thickness. A transducer which receives thickness signals from the trumpet is connected with the drive motor of a roller, such as a feed roller or a doffer with the intermediary of a regulating device having a desired value setter. The apparatus is characterized n that the computer is connected to the measuring member for the actual sliver thickness by means of an integrating device and a memory and to an inputting device for the actual sliver weight. Preferably, the computer is connected with the desired value setter of the regulating device. The integrating device is preferably an R.C. member; and the memory is preferably a buffered memory. According to an advantageous feature of the invention, the inputting device receives signals from a weighing device connected to the inputting device. According to another advantageous feature of the invention, the computer combines the electric signals of the transducer corresponding to the actual sliver thickness and the combined signals are stored. From the actual sliver thickness and the actual sliver weight a desired sliver thickness is determined which serves for setting the desired value of the regulating device.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic side elevational view, with block diagram, of a preferred embodiment of the invention for regulating the feed roller speed.
FIG. 2 is a schematic side elevational view, with block diagram, of another preferred embodiment of the invention for regulating the doffer speed.
FIG. 3 is a diagram illustrating the sliver weight (or sliver number) as a function of the sliver thickness, determined while the sliver regulating device is idle.
FIG. 4 is a diagram illustrating the voltage of a plunger coil of a measuring element as a function of the sliver thickness, at the measuring location.
FIG. 5 is a diagram illustrating the sliver weight (or sliver number) as a function of the sliver thickness, determined while the sliver regulating device is operational.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning to FIG. 1, there is illustrated therein a carding machine which may be an "EXACTACARD DK 3" model, manufactured by Tr/u/ tzschler GmbH & Co. KG, M/o/ nchengladbach, Federal Republic of Germany. The carding machine has a feed roller 1, a licker-in 2, a main carding cylinder 3, a doffer 4, a stripper roller 5, two crushing rollers 6 and 7, a web guiding element 8, a sliver trumpet 9 and two calender rollers 10, 11. The feed roller 1 is coupled with a drive motor which is associated with a motor regulator comprising an electronic tachogenerator 11a, an electronic motor regulator 12 (such as a "SIMOREG" model, manufactured by Siemens AG, Federal Republic of Germany) and a variable-speed motor 13 driving the feed roller 1. A desired value setter for the feed roller 1, for example, a potentiometer, is connected with the electronic motor regulator 12. The electronic tachogenerator 11a and the electronic motor regulator 12 are connected by means of a sliver regulating device 14 (which may be a "CORRECTACARD CCM" model, manufactured by Tr/u/ tzschler GmbH & Co. KG) with the elements for regulating the sliver gathered by the sliver trumpet 9. A measuring element, for example, the sliver trumpet 9 equipped with a mechanical sensor senses the fluctuations of the sliver thickness. A sliver trumpet with mechanical thickness sensor element is described, for example, in German Offenlegungsschrift (non-examined published application) 2,358,941. The thickness fluctuations of the sliver are converted in a transducer 15 into electric signals applied to the sliver regulating apparatus 14. In this manner the desired rpm of the feed roller 1 is continuously varied as a function of the thickness fluctuation of the sliver. By virtue of a corresponding alteration of the rpm of the feed roller 1, the quantity of fiber material supplied to the card is varied, resulting in a corresponding variation of the weight of the sliver.
The measuring member for the actual sliver thickness, that is, the sliver trumpet 9 is connected with a microcomputer 18 by means of an integrating device 16, such as an R.C. member and a memory 17. The computer 18 is coupled to an inputting device 19 for manual inputting of, for example, the actual sliver weight. Further, the computer 18 is connected with the regulating device 14 by means of a desired value setter 20.
In operation, the desired sliver number is manually inputted in the computer 18 (which is a microcomputer controlling the operation of the carding machine). At a given desired value, in conjunction with a fiber-specific characterizing value there may be determined, by means of the inputted calibrating values or a formula, the clearance width of the measuring trumpet 9 at which the zero balancing for the regulating system 14 is to be effected for the desired sliver number. The zero balancing for determining the desired sliver value is automatically performed under the control of the microcomputer 18. A time-wise limited test phase is started during which the actual sliver thickness is measured, integrated and stored. The sliver produced during the test phase is manually removed and weighed. From the result of the weighing and a length determination the actual sliver number may be established. This sliver number or the length and weight values of the sliver specimen are applied to the computer 18. If the desired sliver number deviates from the measured actual sliver number, the computer 18 calculates the correction for the zero balancing (desired value) and performs thereafter automatically a new zero balancing at the previously calculated point. Thereafter, the regulating device is activated. In this manner, a self-setting carding machine is obtained in which the setting of the desired sliver thickness is carried out in the above-described manner in order to obtain the desired sliver number.
Turning to FIG. 2, with the doffer 4 a motor regulating system is associated which includes an electronic tachogenerator 21, an electronic motor regulator 22 (such as a "SIMOREG" model manufactured by Siemens AG) and a motor 23 which drives the doffer 4 or components associated therewith (including, for example, a sliver coiler). The electronic motor regulator 22 comprises an rpm regulator with a subordinated current regulator. The load part is formed as a semi-controlled one-phase bridge. A desired value setter (such as a potentiometer) for the output rate which corresponds, for example, to the rpm of the doffer 4, is connected with the electronic motor regulator 22. German Offenlegungsschrift No. 2,944,428 describes the regulation of the feed roller 1 and the doffer 4 by means of an electronic motor regulating device 12 and 22, respectively.
The sliver trumpet 9 (sliver thickness measuring device) is connected by means of a transducer 15 with the card sliver regulating system 14 which in turn is connected with the motor regulator 22. Further, the sliver regulating system 14 is connected by means of a desired value setter 24 with a process control apparatus 25 such as a "TMS" model manufactured by Tr/u/ tzschler GmbH & Co. KG, with a microprocessor which may be a Rockwell model 6502. The process control apparatus 25 includes a microcomputer as well as an integrating device and a memory, which are shown in FIG. 1 at 18, 16 and 17, respectively. With the process control apparatus 25 there is connected an inputting and retrieving device 19. For an automatic operation, the inputting device 19 may be coupled with a weighing device 26 which determines automatically the actual sliver weight for a predetermined sliver length (testing phase) and applied the data to the process control apparatus 25.
Turning now to FIG. 3, there is graphically illustrated the determination of the desired sliver thickness according to the invention. Such determination is effected in the following steps:
(a) The regulating device 14 is switched off.
(b) At the beginning of the operation there is set with the potentiometer an output rate for the doffer 4, for example 200 m/min and an arbitrary draft, for example, an 80-fold draft at the potentiometer of the feed roller 1, whereby an arbitrary sliver thickness is set. The setting of the output rate and the draft are procedures known by themselves.
(c) The curve A of FIG. 3 is inputted in the memory of the computer 18. The curve A shows the relationship between sliver weight (or sliver number) and sliver thickness at the measuring location of the sliver trumpet 9. The curve A is fiber material-specific and had been determined empirically.
(d) The function between the voltage U of a plunger coil which is connected in the CORRECTACARD device with the sensor lever of the measuring trumpet 9 and the sliver thickness (clearance width) at the measuring location in the sliver trumpet 9 according to FIG. 4 is applied to the computer 18. This relationship serves for calibrating (zero balancing) the regulating device 14.
(e) The desired sliver number is applied to the computer 18 via the inputting device 19. Such sliver number may be, for example, N m =0.20 m/g (desired value).
(f) According to curve A to the desired sliver number N m =0.20 m/g there corresponds a provisional desired sliver thickness of d=2.5 mm. This thickness is determined by the computer 18.
(g) First zero balancing of the regulating device. To the provisional desired sliver thickness d=2.5 mm there corresponds according to FIG. 3 a voltage U=10V at the plunger coil of the transducer 15. Based on that voltage there is automatically set the sensor lever and thus the clearance d=2.5 mm in the sliver trumpet 9 by means of the plunger coil. In this manner there is automatically set, by means of the desired value setter 20 of the regulating device 14, the provisional desired sliver thickness d=2.5 mm determined by the computer 18 in the measuring trumpet 9. By virtue of the provisional desired sliver thickness there is first obtained an approximate value for the desired sliver number of 0.20
(h) Weighing check. The actual sliver number is determined by weighing; for example, N m =0.16 m/g (actual sliver number). This result indicates that the sliver is too heavy.
(i) Determination of the actual sliver thickness. For a predetermined sliver length (or a predetermined time period) the electric signals for the actual sliver thickness values are integrated at the measuring location in the sliver trumpet 9 and are thereafter stored and applied to the computer 18. The result is, for example, d=3.5 mm (actual sliver thickness).
(j) Computer. From the actual sliver number N m =0.16 m/g and the actual sliver thickness of d=3.5 mm the computer 18 generates a new curve B.
(k) From the curve B there is obtained for the desired sliver number a value N m =0.20 m/g, a corrected desired sliver thickness d corr =4.4 mm.
(1) Second zero balancing. The corrected desired sliver thickness d corr =4.4 mm is set in the regulating device 14 by means of the desired value setter 20. In this manner, the corrected desired sliver thickness is automatically set by the computer 18 at the sliver measuring trumpet 9.
(m) Thereafter, the regulating device 14 is switched on. At the desired sliver thickness d corr =4.4 mm the discharged sliver has the desired sliver number N m =0.20 m/g.
In the above-discussed method of the invention first the regulating device 14 has been disconnected as the operating person manually assumes the task of the regulating device 14.
The method according to the invention may be also performed while the regulating device 14 remains operational. The steps of the method in such a case are as follows:
(a) The regulating device is switched on.
(b) Initially there is set an output rate of, for example, 200 m/min at the potentiometer of the doffer 4 and an arbitrary draft, for example, an 80-fold draft at the potentiometer of the feed roller 1, whereby an arbitrary sliver thickness is obtained. The setting of the output rate and the draft by means of the potentiometer are procedures known by themselves.
(c) In a memory of the computer 18 the curve A of FIG. 5 is inputted. Curve A represents the relationship between the sliver weight (or sliver number) and the sliver thickness at the measuring location of the sliver trumpet 9. The curve is fiber material-specific and had been previously determined empirically.
(d) The function between the voltage U at the plunger coil which is connected in the CORRECTACARD device with the sensor lever of the measuring trumpet 9 and the sliver thickness (clearance width) at the measuring location in the sliver trumpet 9 is inputted in the computer 18 according to FIG. 4. This relationship serves for calibrating (zero balancing) the regulating device 14.
(e) The desired sliver number is applied to the computer 18 via the inputting device 19. Such sliver number may be, for example, N m =0.20 m/g (desired value).
(f) To the desired sliver number N m =0.20 m/g there corresponds according to curve A provisional desired sliver thickness of d=5 mm. This thickness is determined by the computer 18.
(g) First zero balancing of the regulating device. To the provisional desired sliver thickness d=5 mm there corresponds according to FIG. 5 a voltage U=10V at the plunger coil. Based on that voltage there is set automatically the rpm of the feed roller 1 by means of the regulating device. This automatically sets in the measuring trumpet 9, by means of the desired value setter 20 of the regulating device 14 the provisional desired sliver thickness d=5 mm determined by the computer 18. By virtue of setting the provisional desired sliver thickness there is obtained first an approximate value for the desired sliver number of 0.20.
(h) Weighing check. By weighing, the actual sliver number is determined which was found to be N m =0.15 m/g (actual sliver number). This value indicates that the sliver is too heavy.
(i) Computer. From the actual sliver number N m =0115 m/g and the actual sliver thickness d=5 mm the computer 18 generates a new curve B.
(j) From the curve B there is obtained for the desired sliver number N m =0.20 m/g a corrected desired sliver thickness d corr =4.0 mm.
(k) Second zero balancing. The corrected desired sliver thickness d corr =4.0 mm is set with the desired value setter 20 of the regulating device 14. In this manner there is automatically set the corrected desired sliver thickness (determined by the computer) in the regulating device 14.
The invention was described by way of an example for determining the actual sliver thickness in a sliver trumpet 9 with a mechanical thickness sensing. The invention may find application for all equivalent measuring values corresponding to the actual sliver thickness, for example, determination of the actual sliver mass, for example, by means of light irradiation, pneumatic measuring processes, weighing processes or scintillation counters.
The present disclosure relates to subject matter contained in Federal Republic of Germany Patent Application Nos. P 36 17 528.5 (filed May 24th, 1986) and P 37 03 450.2 (filed Feb. 5th, 1987) which are incorporated herein by reference.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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A method of evening a sliver produced by a carding machine in which a predetermined output rate and draft are set. The method includes the steps of determining the actual weight of a predetermined sliver length by weighing; determining the difference between the actual sliver weight and a desired sliver weight; as a function of the difference altering the draft corresponding to a predetermined sliver thickness; measuring momentary actual thicknesses of the running sliver at a card output for a determined time period or sliver length and generating mechanical signals representing the momentary actual sliver thicknesses; converting the mechanical signals to first electric signals; combining the first electric signals into a second electric signal constituting an average of the first electric signals and representing the actual sliver thickness of the measured sliver; storing the second electric signal; applying the second electric signal to a computer; applying to the computer a third electric signal representing the actual sliver weight; and determining, with the computer and from a function between the actual sliver weight and the actual sliver thickness, a desired sliver thickness corresponding to a desired sliver weight.
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FIELD OF THE INVENTION
[0001] The present invention relates to a field of pharmaceutical chemistry, more specifically, the present invention relates to a garcinia derivative, its preparing method, and medicinal use. The derivative of the present invention is a structurally simplified analogue of the gambogic acid compound which possesses anti-cancer characteristics and could be used for the preparation of anti-tumor drugs.
BACKGROUND OF THE INVENTION
[0002] It has been recently discovered that the natural product gambogic acid that is extracted from the gambogic resin of the Garcinia plant, is an effective ingredient in terms of anti-tumor characteristics. Research has shown that gambogic acid could selectively kill the various tumor cells without influencing the human hematopoietic or immune system. The gambogic acid could also combine with various proteins which are related to tumor formation and invasion, and thus induce apoptosis of the tumor cells. Therefore the gambogic acid could be used as an effective apoptosis inducer for various tumor systems. The formula of gambogic acid is shown below:
[0000]
[0003] Due to the fact that the molecular weight of gambogic acid is relatively high, the presence of a corresponding group in modified structure might lead to undesired druggability, furthermore, the gambogic acid is obtained from natural products via extraction and separation, which does not facilitate industrial production. A structurally simplified analogue of the gambogic acid has been reported (Compound (II)), however, the anti-pharmaceutical test of the structurally simplified analogue of the gambogic acid (Compound (II)) showed that its anti-tumor activity is significantly reduced compared to the gambogic acid, thereby leading to poor medicinal properties. (Bioorganic & Medicinal Chemistry 16 (2008) pgs. 4233-4241).
SUMMARY OF THE INVENTION
[0004] In the present invention, the structurally simplified analogue which is based on the gambogic acid caged scaffold structure, is prepared for the first time by using a tactic of precursor compound structural simplification. The compound of the present invention possesses similar anti-tumor activity when compared with that of gambogic acid, and it could be used for the preparation of anti-tumor drugs.
[0005] The compound structure of the present invention is shown in Formula (I):
[0000]
[0006] Wherein R 1 is a single substituted group or a multi substituted group; when it is the single substituted group, R 1 is a hydroxyl group; and when it is the multi substituted group, one of the substituted groups is a hydroxyl group, the rest of substituted groups are selected from an amino group, a hydroxyl group, a nitro group, cyano group, an alkyl group containing C 1 -C 6 carbons, or an alkenyl group containing C 2 -C 6 carbons. More specifically, R 1 is at least one hydroxyl group, which can be only substituted by a hydroxyl group, or can be substituted by a hydroxyl group while the other substituted group is selected from one or several said substituted groups. Experiments show that the series compound of Formula (I), wherein R 1 is at least one hydroxyl group, has higher compound activity compared to Compound (II).
[0007] R 2 is hydrogen, halogen, a hydroxyl group, an alkoxy group containing C 1 -C 4 carbons, an amide group containing C 1 -C 4 carbons, a carboxyl group, or an aldehyde group.
[0008] The preferred R 1 is a single substituted group, and the preferred substituent is a hydroxyl group.
[0009] The preferred R 1 is a double substituted group, wherein one preferred substituent is a hydroxyl group and another preferred substituent is an isopentene group.
[0010] The preferred R 2 is hydrogen, a hydroxyl group, an aldehyde group, a carboxyl group, or an amide group.
[0011] The compound of the present invention is prepared via the following methods, wherein the reaction formula is:
[0000]
[0012] Wherein the included reagents and conditions are as follows: a. K 2 CO 3 , KI, chloro-methyl-butyne, CuI and acetone; b. 10% Pd/BaSO 4 , ethyl acetate; and c. DMF (N,N-dimethyl formamide).
[0013] Take the compound wherein R 1 is a hydroxyl group and R 2 is a hydrogen as an example, the said compound could be used as reference for the other substituent, the more detailed and preferred preparing method is shown as below:
[0000]
[0014] The compound 3 is obtained from compound 1 and compound 2 via a two-step reaction. The compound 1 and compound 2 react for 12-18 hours at room temperature. The preferred solvent is ethylether and AlCl 3 is added to the reaction solution. After the reaction, the obtained product without any treatment is directly heated to reflux and is then reacted for 20-30 hours in the strong alkali. As a result, the compound 3 is obtained. The preferred solvents are water and methanol; the ratio between said water and methanol is 1:1 to 4:1; and inorganic alkali, for instance, NaOH, KOH, and the like is then added to the reaction solution.
[0000]
[0015] The compound 3 is heated and refluxed for 6 hours in a mixed solution containing 40% HBr and glacial acetic acid, as a result, the compound 4 is obtained. The solvent ratio between glacial acetic acid: 40% HBr is 1:1 to 4:1.
[0000]
[0016] When R 1 is hydroxyl group, the compound 6 is obtained via reaction between the compound 5 and diphenyl dichloromethane, wherein the preferred solvent is xylene or diphenylether and the preferred reaction temperature is 160° C.-180° C.
[0000]
[0017] The compound 6 reacts with chloromethyl methyl ether at room temperature, and as a result, the compound 7 is obtained. The solvent is selected from acetonitrile, N,N-dimethyl formamide (DMF), acetone, dichloromethane, and the like; the reaction time is 6-10 hours; and the inorganic alkali or organic alkali, for instance, NaOH, KOH, K 2 CO 3 , triethylamine, and the like could be added during the reaction.
[0000]
[0018] The compound 8 is obtained via hydrogenation of the compound 7 at normal pressure, wherein the reaction temperature is 20° C.-50° C.; the solvent is selected from THF, acetonitrile, DMF, methanol, trichloromethane, and the like; and a hydrogenation catalyst should also be added, for instance. 5% Pd/C. 10% Pd/C, and the like.
[0000]
[0019] When R 1 is the other substituent or chloromethyl methyl, except said hydroxyl group, the compound 9 is obtained via reaction between the compound 4 and chloro-methy I-butyne, wherein the reaction temperature is 60° C.-90° C., and the solvent is selected from DMF, acetone, acetonitrile, dichloromethane, trichloromethane, and the like. The inorganic alkali or organic alkali, for instance, NaOH, KOH, K 2 CO 3 , triethylamine, and the like should also be added to the reaction, furthermore, the catalyst CuCl, CuI, or KI should also be added.
[0000]
[0020] The compound 10 is formed via hydrogenation of the compound 9 at normal pressure, wherein the reaction temperature is 20° C.-50° C.; the solvent is selected from ethyl acetate, THF, acetonitrile, ethanol, and the like; a hydrogenation catalyst, for instance, 5% Pd/C, 10% Pd/C, 5% Pd—BaSO 4 , 10% Pd—BaSO 4 , and the like, should also be added.
[0000]
[0021] The compound 10 is heated to be rearranged, and as a result, the compound 11 is obtained, wherein the reaction temperature is 120° C.-180° C., and the solvent is selected from toluene, DMF, diphenyl ether, and the like.
[0000]
[0022] The compound 12 is obtained via oxidation of the compound 11, wherein the reaction temperature is 25° C.-40° C., and the preferred oxidants are SnO 2 and t-butyl hydroperoxide, lead tetraacetate, and the like. The solvent is selected from toluene, dichloromethane, trichloromethane, DMF, and the like.
[0000]
[0023] When R 1 is double substituted by a hydroxyl group and an isopentene group, the compound 5 reacts with chloro-methyl-butyne, and as a result, the compound 13 is obtained, wherein the reaction temperature is 60° C.-90° C., and the solvent is selected from DMF, acetone, acetonitrile, dichloromethane, trichloromethane, and the like. An inorganic alkali or organic alkali, for instance, NaOH, KOH, K 2 CO 3 , or triethylamine should be added to the reaction, and CuCl, CuI, or KI should also be added as catalyst.
[0000]
[0024] The compound 14 is obtained via hydrogenation of the compound 13 at normal pressure, wherein the reaction temperature is 20° C.-50° C.; the solvent is selected from ethyl acetate, THF, acetonitrile, ethanol, and the like; and a hydrogenation catalyst, for instance, 5% Pd/C, 10% Pd/C, 5% Pd—BaSO 4 , 10% Pd—BaSO 4 , and the like should also be added.
[0000]
[0025] The compound 14 is heated to be rearranged, as a result, the compound 15 is obtained, wherein the reaction temperature is 120° C.-180° C., and the solvent is selected from toluene, DMF, diphenyl ether, and the like.
[0026] The compound of Formula (I) is purified by a common separation method, for instance, recrystallization, column chromatography, and the like.
[0027] The present invention also includes a hydrate, a stereomer, and/or a solvate of compound of Formula (I).
[0028] A pharmaceutically acceptable carrier, for instance, a tablet, a capsule, a powder, a syrup, a liquid, a suspension, or an injection could be a carrier for the compound of the present invention so as to form normal pharmaceutical preparations, and furthermore, the normal pharmaceutic adjuvants, for instance, a flavor, a sweetening agent, a liquid or solid filler, or a thinner, could also be included in the carrier for the compound of the present invention.
[0029] The compound of the present invention could be served as an oral or injection manner in the clinical administration.
[0030] The clinical dosage of the compound of present invention is 0.01 mg/day to 1000 mg/day, furthermore, according to the health conditions and dosage types, the clinical dosage which may deviate from said range could also be accepted.
[0031] The results obtained from the pharmaceutical test show that the compound of the present invention has relatively strong anti-proliferative activity with the tumor cells, which is comparable with that of natural gambogic acid. Therefore, the compound of the present invention might be an attractive ingredient for use in the development of anti-tumor drugs.
[0032] The results obtained from the pharmaceutical test by using partial compounds of the present invention are as shown below:
[0000] Test method: The cells of log phase are cultivated in the culture plate with 96 pores, and each pore contains 100 μL of solution (including 1000-1200 tumor cells). The next day, different concentrations of the present compound are added to the treatment groups, each compound contains 4 to 5 dosage groups, and each dosage group contains at least 3 parallel pores. The solvent with an equivalent volume of the said compound is added to the control groups. The said culture plate is then placed in a 5% CO 2 incubator, cultured at 37° C., and the culture solution is discharged 4 days later. Next, 200 μL of the 0.2% MTT solution (RPMI1640 preparation) is added to each pore and incubated at 37° C. for 4 hours; the obtained supernatant is discharged; and 150 μL of DMSO is added to each pore so as to dissolve formazane particles. After slightly shaking the mixture, the optical density (OD) is measured by the ELIASA in the conditions of a resulting reference wavelength 450 nm and a detection wavelength 570 nm. The tumor cells treated with solvent are used as control groups, and the inhibition rate of the drugs against the tumor cells and IC50 are calculated according to the following equation. The obtained results are shown in Table 1 which displays the antiproliferative activity of the tumor cells IC 50 of the compound. The MCF-7 cells are human breast cancer cells and the BGC-823 cells are human gastric carcinoma cells.
[0000]
Inhibition
rate
=
Average
OD
of
comparison
group
-
Average
OD
of
treatment
group
Average
OD
of
comparison
group
×
100
%
[0000]
TABLE 1
Antiproliferative activity of the tumor cells IC 50 of the compound.
Corresponding
MCF-7 cell
BGC-823 cell
Compound No.
Examples
IC 50 (μM)
IC 50 (μM)
CPUY I-1
Example 1
9.16
3.59
CPUY I-2
Example 4
12.40
17.60
CPUY I-5
Example 10
5.79
15.00
CPUY I-6
Example 11
11.90
21.70
CPUY I-7
Example 12
10.90
18.20
CPUY I-8
Example 13
9.06
11.30
II
13.90
20.30
Gambogic acid
2.19
2.35
[0033] The present invention possesses the following advantages: the natural product of gambogic acid is not necessary to be used as raw material, instead the structurally simplified analogue of the gambogic acid (Formula (1)) can be directly prepared; the obtained structure is simple in comparison with that of the gambogic acid; the anti-tumor activity is the same as that of gambogic acid; and the obtained anti-tumor activity that resulted from the hydroxyl substitution is higher than that of the reported Compound (II).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Example 1
[0034] The following formula represents a 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-8-hydroxyl-1,5-dimethylene-1 H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound (CPUY I-1).
[0000]
(1) Preparation of 1,5,6-trimethoxy-9H-xanthenone
[0035] In preparation of 1,5,6-trimethoxy-9H-xanthenone, 9.6 g (52.8 mmol) of 2,6-dimethoxy benzoic acid is dissolved in 140 mL of dried benzene, 24 mL of oxalyl chloride is added and mixed at room temperature for 24 hours. Subsequently, the solvent and remaining oxalyl chloride are removed via vacuum distillation; 160 mL of dried ethyl ether is added to dissolve the remains; 8.8 g (52.4 mmol) of 1,2,3-trimethoxybenzene is added; the mixture is stirred for 30 minutes in an ice-bath; 20 g (152 mmol) of anhydrate AlCl 3 is added and reacted at room temperature for 20 hours; the over amount of AlCl 3 is quenched with the diluted HCl solution (15%) and then extracted with ethyl acetate (2×100 mL); the organic phase is dried with anhydrous sodium sulfate and condensed; and as a result, 16 g of yellow solid is obtained. The obtained solid is directly dispersed in 240 mL of mixed solution containing methanol and water (methanol: water=5:3) without purification; 23.2 g (58.36 mmol) of NaOH is added; the mixture is stirred and refluxed at 110° C. for 36 hours; 6 mol/L of HCl is added until the pH value is adjusted to 6-8; and as a result, a large amount of solid is precipitated. The said precipitation is filtered, and the resulting filter cake is purified with the aid of column chromatography, wherein the eluent is the mixed solution containing petroleum ether and ethyl acetate (petroleum ether:ethyl acetate=4:1), and as a result, 12.8 g white solid is obtained, and the productivity is 85%; m.p. is 144.6° C.-145.7° C.; 1 H-NMR (300 MHz, CD3COCD3): 3.95 (m, 6H), 4.01 (s, 3H), 6.97 (d, 1H, J1=8.4 Hz, J2=0.6 Hz), 7.14 (d, 1H, J1=8.4 Hz, J2=0.6 Hz), 7.15 (d, 1H, J=9.0 Hz), 7.69 (t, 1H, J=8.4 Hz), 7.89 (d, 1H, J=9 Hz); EI-MS (m/z): 286 (M+).
(2) Preparation of 1,5,6-trihydroxy-9H-xanthenone
[0036] In preparation of 1,5,6-trihydroxy-9H-xanthenone, 15 g (52.5 mmol) of 1,5,6-trimethoxy-9H-xanthenone is dissolved in 500 mL of mixed solution (HBr:acetic acid=1:2), the said mixture is heated to 120° C., and refluxed for 12 hours. Next, 10% NaOH solution is added until the pH value is adjusted to 3-4, and as a result, a large amount of gray solid is precipitated. The said precipitation is filtered, and as a result, 9 g of grey solid is obtained, and the productivity is 70%; m.p. is 300° C.-301° C.; 1 H-NMR (300 MHz, DMSO-d6): 6.77 (dd, 1H, J1=8.3 Hz, J2=0.87 Hz,), 6.97 (d, 1H, J=8.8 Hz), 67.05 (dd, 1H, J1=8.3 Hz, J2=0.87 Hz), 7.57 (d, 1H, J=8.8 Hz), 7.68 (t, 1H, J=8.3 Hz), 9.53 (s, 1H), 10.68 (s, 1H), 12.91 (s, 1H); ESI-MS (m/z): 243 ([M−H]−).
(3) Preparation of 7-hydroxy-2,2-diphenyl-6H-[1,3]dioxolo[4,5-c]-6-xanthenone
[0037] In preparation of 7-hydroxy-2,2-diphenyl-6H-[1,3]dioxolo[4,5-c]-6-xanthenone, 5 g (22.3 mmol) of 1,5,6-trihydroxy-9H-xanthenone is added to 40 mL of diphenyl ether, subsequently, 7 mL (35 mmol) of diphenyl dichloromethane is added, and the mixture reacts at 175° C. for 4 hours. After the reaction solution is cooled, 800 mL petroleum ether is added, and as a result, a large amount of gray solid is precipitated. The said precipitation is filtered and purified with the aid of column chromatography, wherein the eluent is the mixed solution containing petroleum ether and ethyl acetate (petroleum ether:ethyl acetate=8:1), and as a result, 6.1 g of light yellow solid is obtained, and the yield is 79%; m.p. is 203° C.-205° C.; 1H-NMR (300 MHz, CDCl3): 6.72 (d, J=8.4 Hz, 1H), 6.90 (d, J=9.3 Hz, 1H), 6.93 (d, J=9.3 Hz, 1H), 7.34 (m, 6H), 7.49 (t, J=9.3 Hz, 1H), 7.57 (m, 4H), 7.82 (d, J=8.4 Hz, 1H), 12.70 (s, 1H); EI-MS (m/z): 408.
(4) Preparation of 7-methoxy methylenedioxy-2,2-diphenyl-6H-[1,3]dioxolo[4,5-c]xanthenone
[0038] In preparation of 7-methoxy methylenedioxy-2,2-diphenyl-6H-[1,3]-dioxolo[4,5-c]xanthenone, 6.1 g (14.85 mmol) of 7-hydroxy-2,2-diphenyl-6-[1,3]dioxolo[4,5-c]-6-xanthenone is dissolved in 200 mL of acetone, 1.2 g (29.7 mmol) of NaH is added, the mixture is mixed at 0° C. for 0.5 hours, 2.43 mL (29.7 mmol) chloromethyl methyl ether is added, and at the end of addition, the mixture reacts at room temperature for 8 hours. The reaction solution is then poured into 800 mL of ice water, and as a result, a large amount of white solid is precipitated. The said precipitation is filtered and dried, and as a result, 6 g of white solid is obtained, and the yield is 90%; m.p. is 138° C.-140° C.; 1H-NMR (300 MHz, CDCl3): 3.56 (s, 3H), 5.36 (s, 2H), 6.94 (d, J=8.4 Hz, 1H), 7.04 (dd, 1H, J1=8.2 Hz, J2=0.6 Hz, 1H), 7.17 (dd, J=8.2 Hz, J2=0.6 Hz, 1H), 7.40 (m, 6H), 7.55 (dd, J=8.2H, J2=0.6 Hz), 7.64 (m, 4H), 7.89 (d, J=8.4 Hz, 1H); EI-MS (m/z): 452 (M+).
(5) Preparation of 3,4-dihydroxy-7-methoxy methylenedioxy-9H-xanthenone
[0039] In preparation of 3,4-dihydroxy-7-methoxy methylenedioxy-9H-xanthenone, 6 g (13.2 mmol) of 7-methoxy methylenedioxy-2,2-diphenyl-6H-[1,3]-dioxolo[4,5-c]xanthenone is dissolved in 420 ml of mixed solution containing methanol: THF=1:1, 700 mg of 10% Pd/C is added, and the mixture undergoes hydrogenation at normal pressure for 24 hours. The reaction solution is filtered, the filtrate is condensed, the residue is purified with the aid of column chromatography (petroleum ether/ethyl acetate=1:1), and as a result, 3 g of dark green solid is obtained, and the yield is 78.5%; m.p. is greater than 300° C.; 1H NMR (300 MHz, DMSO): 3.46 (s, 3H), 5.31 (s, 2H), 6.90 (d, 1H, J=8.25 Hz), 7.02 (dd, 1H, J1=8.8 Hz, J2=2.2 Hz), 7.14 (dd, J1=8.8 Hz, J2=2.2 Hz), 7.84 (dd, 1H, J1=8.8 Hz, J2=2.2 Hz), 8.25 (d, 1H, J=8.25 Hz); EI-MS (m/z) 288 (M+), 288, 256, 244.
(6) Preparation of 1-hydroxy-5,6-dimethyl butynyloxy-9H-xanthenone
[0040] In preparation of 1-hydroxy-5,6-dimethyl butynyloxy-9H-xanthenone, 3 g (10.2 mmol) of 3,4-dihydroxy-7-methoxy methylenedioxy-9H-xanthenone is dissolved in 200 mL of acetonitrile, and subsequently, KI (1.73 g, 10.2 mmol), 1,8-diazabicyclo-dicyclo(5,4,0)-7-undecene (7.2 mL, 57.12 mmol), and CuI (300 mg, 1.6 mmol) are added, respectively. The said mixture is stirred at room temperature for 10 minutes; is placed in an ice-bath; chloro-methyl-butyne (8.4 ml, 81.6 mmol) is added; and the said mixture then reacts at room temperature for 48 hours.
[0041] It is then vacuum distilled to condense acetonitrile; 800 mL of water and 200 mL of ethyl ether are added; and 2 mol/L of HCl are added until the pH value is adjusted to 3. The mixture is stirred at room temperature for 4 hours; the water phase is extracted with 800 mL of ethyl acetate four times; the extracted ethyl acetate is dried with anhydrous sodium sulfate; the organic phase is condensed; the resulting residue is purified with the aid of column chromatography, wherein the eluent is the mixed solution containing petroleum ether and ethyl acetate (petroleum ether:ethyl acetate=8:1); and as a result, 2 g of brown crystals are obtained, and the productivity is 49%; m.p. is 138° C.-140° C.; 1H-NMR (300 MHz, CDCl3): 1.79 (s, 6H), 1.83 (s, 6H), 2.28 (s, 1H), 2.66 (s, 1H), 6.79 (dd, J1=8.1 Hz, J2=0.6 Hz, 1H), 6.95 (dd, J1=8.1 Hz, J2=0.6 Hz, 1H), 7.56 (t, J=8.1 Hz, 1H), 7.66 (d, J=9 Hz, 1H), 7.98 (d, J=9 Hz, 1H), 12.71 (s, 1H); EI-MS (m/z): 376, 310, 244.
(7) Preparation of 1-hydroxy-5,6-dimethyl butenyl-9H-xanthenone
[0042] In preparation of 1-hydroxy-5,6-dimethyl butenyl-9H-xanthenone, 1-hydroxy-5,6-dimethyoxy butynyloxy-9H-xanthenone (2 g, 5.3 mmol) is dissolved in 18 mL of ethanol, 50 mg of 10% Pd/BaSO 4 is added, and the mixture undergoes hydrogenation at normal pressure for 12 hours. The obtained is filtered, the reaction solution is condensed, and the obtained gray solid is washed with petroleum ether and is used directly in the following step.
(8) Preparation of the 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-8-hydroxy-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound
[0043] In preparation of the 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-8-hydroxy-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound, 1.8 g of 1-hydroxy-5,6-dimethyl butenyl-9H-xanthenone is dissolved in 15 mL of DMF and the said mixture reacts at 125° C. for 6 hours. The solvent is evaporated, the resulting residue is purified with the aid of column chromatography (petroleum ether/ethyl acetate=6:1), and as a result, 1.2 g brown solid is obtained, and the yield is 66%. The obtained solid is further crystallized in the mixed solution containing acetone and petroleum ether (acetone:petroleum ether=1:20), and the brown crystal is obtained, and the m.p. is 130° C.-132° C.; 1H-NMR (300 MHz, CDCl3): 0.95 (s, 3H), 1.18-1.25 (m, 4H), 1.30 (s, 3H), 1.61 (s, 3H), 2.26 (dd, J1=13.5 Hz, J2=4.5 Hz, 1H), 2.37 (d, J=9.6, 1H), 2.54 (d, J=7.8 Hz, 2H), 3.44 (dd, J1=6.9 Hz, J2=4.5 Hz, 1H), 4.34 (m, 1H), 6.43 (dd, J1=8.1 Hz, J2=0.9 Hz, 1H), 6.45 (dd, J1=8.1 Hz, J2=0.9 Hz, 1H), 7.32 (t, J=8.1 Hz, 1H), 7.41 (d, J=9.6 Hz, 1H), 12.00 (s, 1H).
Example 2
[0044] The following formula represents a 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-8-hydroxyl-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound (CPUY I-1).
[0000]
(1) Preparation of 5,6-dihydroxyl-1-acetoxy xanthenone
[0045] In preparation of 5,6-dihydroxyl-1-acetoxy xanthenone, 5 g (20.5 mmol) of 1,5,6-trihydroxy-9H-xanthenone is dissolved in 35 mL of DMF; subsequently, 5 g of K 2 CO 3 , 500 mg of KI, and 7 mL (61 mmol) of benzyl chloride are added; the said mixture reacts at 65° C. for 2 hours; the reaction solution is cooled and transferred to 2 mol/L of HCl; and as a result, a large amount of solid is precipitated. The said precipitation is vacuum filtered and dried, and as a result, 8 g of light yellow solid 5,6-dibenzyl-1-hydroxyl-xanthenone is obtained. The said obtained solid is directly dissolved in 80 mL of dichloromethane, subsequently, 5 g of DMAP and 6 mL of acetic anhydride are added in turn, and the said mixture reacts at a constant temperature of 25° C. for 2 hours. The obtained reaction solution is washed twice with saturated NH 4 Cl solution (80 mL×2) and twice with water (80 mL×2); the obtained organic phase is dried with anhydrous sodium sulfate; and 8 g of white solid 5,6-dibenzyl-1-acetyl xanthenone is obtained via vacuum condensation. The said obtained solid is dissolved in 400 mL of mixed solution containing THF and methanol (THF:methanol=1:1), and hydrogenation takes place under normal pressure with the aid of 10% Pd/C. The said mixture reacts at a constant temperature of 40° C. for 2 hours; the obtained substance is filtered; the filtrate is condensed; 200 mL of petroleum ether is added to wash the resulting residue; 4.5 g of grey solid is obtained via vacuum filtration; and the obtained solid is directly used in the following step without purification.
(2) Preparation of 5,6-dimethyl butynyl-1-acetoxy xanthenone
[0046] In preparation of 5,6-dimethyl butynyl-1-acetoxy xanthenone, 5,6-dihydroxy-1-acetoxy xanthenone (5 g, 17.5 mmol) is dissolved in 80 mL of acetone, and 5 g of K 2 CO 3 , 5 g of KI, 1 g of CuI, and 7 mL of chloro-methyl-butyne are added in turn. The said mixture is heated and refluxed for 5 hours. At the end of the reaction, 300 mL of water and 80 mL of ethyl acetate are added and mixed; and the organic phase is separated and dried with anhydrous sodium sulfate. The obtained is separated with the aid of column chromatography (petroleum ether: ethyl acetate=8:1) and 3 g of yellow solid is obtained, and the yield is 41%; 1H-NMR (300 MHz, CDCl 3 ): 1.76 (s, 3H), 1.82 (s, 3H), 2.31 (s, 1H), 2.50 (s, 3H), 2.65 (s, 1H), 6.97 (d, J=7.5 Hz, 1H), 7.42 (d, J=8.4 Hz, 1H), 7.59-7.69 (m, 2H), 7.95 (s, J=9 Hz, 1H).
(3) Preparation of 5,6-dimethyl butenyl-1-acetoxy xanthenone
[0047] In preparation of 5,6-dimethyl butenyl-1-acetoxy xanthenone, 5,6-bis(dimethyl butynyl-1-acetoxy xanthenone (3 g, 12.3 mmol) is dissolved in 70 mL of mixed solution containing ethyl acetate and ethanol (ethyl acetate:ethanol=1:3), and undergoes hydrogenation at normal pressure with the aid of 300 mg 10% Pd—BaSO 4 . The obtained reacts at room temperature for 16 hours; the reaction solution is filtered; and the solvent is condensed and dried in reduced pressure, and is used directly in the following step.
(4) 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-8-acetoxy-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound
[0048] In preparation of the above compound, 1-hydroxyl-5,6-dimethyl butenyl-9H-xanthenone (1.8 g, 7.3 mmol) is dissolved in 15 mL of DMF and the said mixture reacts at 125° C. for 6 hours and the solvent is evaporated. The resulting residue is separated with the aid of column chromatography (petroleum ether: ethyl acetate=6:1), and as a result, 1 g of yellow solid is obtained, and the yield is 55.6%; 1H-NMR (300 MHz, CDCl3): 0.99 (s, 3H), 1.18-1.25 (m, 4H), 1.30 (s, 3H), 1.61 (s, 3H), 2.26 (dd, J1=13.5 Hz, J2=4.5 Hz, 1H), 2.28 (s, 3H), 2.37 (d, J=9.6, 1H), 2.54 (d, J=7.8 Hz, 2H), 3.44 (dd, J1=6.9 Hz, J2=4.5 Hz, 1H), 4.34 (m, 1H), 6.43 (dd, J1=8.1 Hz, J2=0.9 Hz, 1H), 6.45 (dd, J1=8.1 Hz, J2=0.9 Hz, 1H), 7.32 (t, J=8.1 Hz, 1H), 7.41 (d, J=9.6 Hz, 1H).
(5) 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-8-hydroxyl-1,5-dimethylene1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound:
[0049] In preparation of the above compound, 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-8-acetoxy-1,5-dimethylene-1 H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound (1 g, 4 mmol) is dissolved in 10 mL of mixed solution containing THF and methanol (THF:methanol=1:1), subsequently, 4 mL (4 mol/L) of HCl is added and the mixture is mixed at room temperature for 6 hours, 10 mL ethyl acetate and 10 mL 10% NaHCO 3 are added, and the obtained organic phase is separated and dried with anhydrous sodium sulfate. The obtained is separated with the aid of column chromatography (petroleum ether: ethyl acetate=4:1), and as a result, 810 mg of yellow solid is obtained, and the productivity is 90%; m.p. is 130° C.-132° C.; 1H-NMR (300 MHz, CDCl3): 0.95 (s, 3H), 1.18-1.25 (m, 4H), 1.30 (s, 3H), 1.61 (s, 3H), 2.26 (dd, J1=13.5 Hz, J2=4.5 Hz, 1H), 2.37 (d, J=9.6, 1H), 2.54 (d, J=7.8 Hz, 2H), 3.42 (dd, J1=6.9 Hz, J2=4.5 Hz, 1H), 4.33 (m, 1H), 6.43 (dd, J1=8.1 Hz, J2=0.9 Hz, 1H), 6.45 (dd, J1=8.1 Hz, J2=0.9 Hz, 1H), 7.32 (t, J=8.1 Hz, 1H), 7.41 (d, J=9.6 Hz, 1H), 12.00 (s, 1H).
Example 3
[0050] The following formula represents a (E)-3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-hydroxymethyl-2-butenyl)-8-hydroxy-1,5-dim ethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound:
[0000]
[0000] (1) The synthetic method in preparation of 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-8-hydroxy-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound is same as those described in Example 1 and Example 2.
(2) In preparation of (E)-3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-hydroxymethyl-2-butenyl)-8-hydroxyl-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound,
[0051] 800 mg of 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-8-hydroxy-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound is dissolved in 5 mL of dichloromethane, 80 mg of SnO 2 and 1 ml of t-butyl hydroperoxide are added, and the said mixture is stirred at room temperature for 24 hours. After the reaction, the obtained is washed with water three times, the organic phase is separated, and is then separated again with the aid of column chromatography (petroleum ether: ethyl acetate=2:1), and as a result, 780 mg of yellow solid is obtained, and the yield is 94%.
Example 4
[0052] The following formula represents a 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-10-hydroxyl-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound (CPUY I-2).
[0000]
(1) Preparation of 3-hydroxyl-4,6-dimethoxy-9H-xanthenone
[0053] In preparation of 3-hydroxyl-4,6-dimethoxy-9H-xanthenone, 2.4 g (13.14 mmol) of 2,4-dimethoxy benzoic acid is dissolved in 60 mL of dried dichloromethane, 5 mL of oxalyl chloride is added, and the said mixture is stirred at room temperature for 24 hours. Once the solvent is evaporated, 80 mL of ethyl ether is added to dissolve resulting residue; 2.19 g (13.03 mmol) of 1,2,3-trimethoxy benzene is added; the said mixture is cooled in an ice-bath for 30 min, 5.0 g of anhydrate AlCl 3 (37.5 mmol) is added; the said mixture reacts at room temperature for 12 hours; and the over amount of AlCl 3 is quenched with the aid of diluted HCl solution (15%). The obtained is then extracted with ethyl acetate (80 mL×2) and dried with anhydrous sodium sulfate. The resulting residue is condensed in reduced pressure and is directly dissolved in the mixed solution containing methanol (20 mL) and 30% NaOH (40 mL). The said mixture is heated and refluxed for 14 hours, the pH value of the obtained solution is adjusted with the aid of 6 mol/L HCl until the pH value reaches 6, the said mixture is vacuum filtered and dried, and as a result, 3 g of crude product is obtained, and the yield is 81%; m.p. is 120.2° C.-121.2° C.; 1H-NMR (300 MHz, CD3COCD3): 3.98-4.03 (m, 9H), 7.00 (dd, 1H, J1=8.9 Hz, J2=2.4 Hz), 7.09 (d, 1H, J=2.4 Hz), 7.19 (d, 1H, J=9.0 Hz), 7.95 (d, 1H, J=9.0 Hz), 8.13 (d, 1H, J=8.9 Hz); EI-MS (m/z): 286 [M+], 271, 256, 241.
(2) Preparation of 3,4,6-trihydroxyl-9H-xanthenone
[0054] In preparation of 3,4,6-trihydroxyl-9H-xanthenone, 8 g (2.79 mmol) of 3-hydroxyl-4,6-dimethoxy-9H-xanthenone is dissolved in 160 mL of mixed solution containing HBr and acetic acid (HBr:acetic acid=1:2) (V: V), the said mixture is heated to 120° C. and refluxed for 12 hours, the pH value of the obtained mixture is adjusted with the aid of 10% NaOH solution until the pH value reaches 3-4, and as a result, a large amount of grey solid is precipitated. It is then vacuum filtered and purified with the aid of silica gel column chromatography (petroleum ether/ethyl acetate=1:1), and as a result, 5.8 g of grey solid is obtained, and the yield is 85%; m.p. is greater than 300° C. (reported m.p. is 340° C.-341° C.); 1H-NMR (300 MHz, DMSO-d6): 6.83-6.93 (m, 3H,), 7.50 (d, 1H, J=8.8 Hz), 8.00 (d, 1H, J=8.8 Hz), 9.28 (s, 1H), 10.31 (s, 1H), 10.77 (s, 1H), ESI-MS (m/z): 243 ([M−H]−).
(3) Preparation of 9-hydroxyl-2,2-diphenyl-6H-[1,3]dioxolo[4,5-c]xanthenone
[0055] In preparation of 9-hydroxyl-2,2-diphenyl-6H-[1,3]dioxolo[4,5-c]xanthenone, 5 g (21 mmol) of 3,4,6-trihydroxyl-9H-xanthenone is added to 30 mL of diphenyl ether, 7 mL (36 mmol) of diphenyl dichloromethane is added, and then the said mixture reacts at 175° C. for 2 hours. The obtained is cooled, 100 mL of petroleum ether is added, and as a result, a large amount of yellow solid is precipitated. The obtained solid is vacuum filtered and purified with the aid of filter cake column chromatography, the eluent (petroleum ether/ethyl acetate=4:1) is used, and as a result, 5.1 g of yellow solid is obtained, and the yield is 61%; m.p. is 231° C.-232° C.; 1H-NMR (300 MHz, CD3COCD3): 6.94-6.98 (m, 2H), 7.1 (d, 2H, J=8.7 Hz), 7.47˜7.50 (m, 6H), 7.66-7.69 (m, 4H), 7.85 (d, J=8.7 Hz, 1H), 8.10 (q, J=9 Hz, 1H); EI-MS (m/z) 408 [M+], 331, 303, 165.
(4) Synthesis of 9-methoxy methyleneoxy-2,2-diphenyl-6H-[1,3]dioxolo[4,5-c]xanthenone
[0056] In preparation of 9-methoxy methyleneoxy-2,2-diphenyl-6H-[1,3]dioxolo[4,5-c]xanthenone, 5 g (2.45 mmol) of 9-hydroxyl-2,2-diphenyl-6H-[1,3]dioxolo[4,5-c]xanthenone is dissolved in 70 mL of DM, 515 mg (4.29 mmol) of sodium hydride is added, and the said mixture is mixed for 10 min. Subsequently, 1.8 mL (23 mmol) of chloromethyl methyl ether is added; the said mixture reacts at room temperature for 8 hours; 200 mL water is added to the said reaction solution; the said solution is extracted with 200 mL of ethyl acetate four times; and the organic phase is condensed. The resulting residue is separated and purified with the aid of column chromatography (petroleum ether/ethyl acetate=4:1), and as a result, 5 g of white solid is obtained, and the yield is 99%; m.p. is 179° C.-181° C.; 1H NMR (300 MHz, CDCl3): 3.44 (s, 3H), 5.21 (s, 2H), 6.91-6.96 (m, 2H), 7.10 (s, J1=2.4 Hz, 1H), 7.32-7.36 (m, 6H), 7.54-7.59 (m, 4H), 7.82 (d, 1H, J=5.1 Hz), 8.17 (d, 1H, J=5.3 Hz); EI-MS (m/z) 452 (M+), 375, 331, 165, 105.
(5) Preparation of 3,4-dihydroxyl-6-methoxy methyleneoxy-9H-xanthenone
[0057] In preparation of 3,4-dihydroxyl-6-methoxy methyleneoxy-9H-xanthenone, 5 g (2.2 mmol) of 9-methoxy methyleneoxy-2,2-diphenyl-6H-[1,3]dioxolo[4,5-c]xanthenone is added to 90 ml of mixed solution containing ethanol and THF (ethanol: THF=1:1), 500 mg of 10% Pd/C is added, and the said mixture undergoes hydrogenation at normal pressure for 24 hours. The obtained reaction solution is vacuum filtered and the filtrate is condensed. The resulting residue is separated and purified with the aid of column chromatography (petroleum ether: ethyl acetate=2:1), and as a result, 5 g of light yellow solid is obtained, and the yield is 90%; m.p. is greater than 300° C.; 1H NMR (300 MHz, DMSO-d6): 3.52 (s, 3H), 5.30 (s, 2H), 6.97 (d, J=8.8 Hz, 1H), 7.04-7.07 (q, J1=2.2 Hz, J2=8.8 Hz, 1H), 7.14 (d, J=2.2 Hz, 1H), 7.84 (d, J=8.8 Hz, 1H), 8.25 (d, J=8.8 Hz, 1H); EI-MS (m/z) 288 (M+), 258, 215, 187, 167.
(6) Preparation of 3,4-dimethyl butynyl-6-methoxy methyleneoxy-9H-xanthenone
[0058] In preparation of 3,4-dimethyl butynyl-6-methoxy methyleneoxy-9H-xanthenone, 5 g (16.5 mmol) of xanthenone is dissolved in 80 mL of acetonitrile, and subsequently, 2.5 g (20 mmol) of KI, 9.5 mL of DBU, and 250 mg (0.028 mmol) of CuI are added in turn. Then 0.42 ml (3.3 mmol) of chloro-methyl butyne is added; the said mixture reacts at room temperature for 24 hours; 800 mL water is added; the said mixture is stirred at room temperature for 15 min; the obtained water phase is extracted with 200 mL ethyl acetate four times; and the obtained organic phase is condensed. The resulting residue is separated and purified with the aid of column chromatography, the eluent (petroleum ether/ethyl acetate=8:1) is used, and as a result, 3.5 g of orange powder is obtained, and the yield is 45%; m.p. is 128° C.-130° C.; 1H-NMR (300 MHz, CDCl3): 1.69 (s, 6H), 1.75 (s, 6H), 2.26 (s, 1H), 2.58 (s, 1H), 3.45 (s, 3H), 5.22 (s, 1H), 6.96 (d, J1=8.7 Hz, J2=2.1 Hz, 1H), 7.04 (d, J=2.1 Hz, 1H), 7.54 (d, J=9 Hz, 1H), 7.97 (s, J=9 Hz, 1H), 8.18 (d, J=8.7 Hz, 1H); EI-MS (m/z): 420, 405, 377, 354, 339, 324, 309, 295, 288, 244.
(7) Preparation of 2-methoxy methyleneoxy-5,6-dimethyl butenyl-9H-xanthenone
[0059] In preparation of 2-methoxy methyleneoxy-5,6-dimethyl butenyl-9H-xanthenone, 3.5 g of xanthenone is dissolved in 80 mL of ethanol, 350 mg of 10% Pd—BaSO 4 is added, and the said mixture undergoes hydrogenation at room temperature for 2 hours. The obtained reaction solution is vacuum filtered and the obtained filtrate is condensed. The resulting residue is separated and purified with the aid of column chromatography, the eluent (petroleum ether/ethyl acetate=8:1) is used, and as a result, 3 g of colorless oil is obtained, the yield is 89%, and the said obtained is used directly in the following reaction step.
(8) Preparation of 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-10-methoxy methyleneoxy-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone
[0060] In preparation of 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-10-methoxy methyleneoxy-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone, 3 g of 2-methoxy methyleneoxy-5,6-methyl butenyl-9H-xanthenone is dissolved in 30 mL of DMF, the said mixture reacts at 125° C. for 6 hours, and the solvent is evaporated. The obtained residue is separated and purified with the aid of column chromatography, and as a result, 1.4 g of white solid is obtained, and the yield is 45%; m.p. is 168° C.-169° C.; 1H-NMR (300 MHz, CDCl3): 0.92 (s, 3H), 1.17-1.29 (m, 7H), 1.63 (s, 3H), 2.24 (dd, J1=13.5 Hz, J2=4.5 Hz, 1H), 2.37 (d, J=9.6, 1H), 2.51 (d, J=9.3 Hz, 2H), 3.36-3.44 (m, 4H), 4.36 (m, 1H), 5.15 (s, 2H), 6.57 (d, J=2.1 Hz, 1H), 6.64 (dd, J1=8.7 Hz, J2=2.1 Hz, 1H), 7.31 (d, J=6.9 Hz, 1H), 7.80 (d, J=8.7 Hz, 1H); IR (KBr): 2974.4, 2909.6, 1737.2, 1647.4, 1611.2, 1499.2, 1438.5, 1290.5, 1150.5, 1079.2, 1009.2, 982.4; EI-MS (m/z): 424, 396, 381, 368, 353, 327, 299, 285, 257; Anal. Calcd for C25H28O6(%): C, 70.74; H, 6.65. Found: C, 70.64; H, 6.95.
(9) Preparation of 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-10-hydroxy-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone
[0061] In preparation of 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-10-hydroxy-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone, 1.4 g of 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-10-methoxy methyleneoxy-1,5-dimethylene-1H,7H-furan[3,4-d]xanthenoid-7,13-diketone is dissolved in 18 mL of mixed solution containing dichloromethane and ethyl ether (dichloromethane: ethyl ether=1:1), the said mixture is cooled in an ice-bath, 10 mL of concentrated HCl is added, and the said mixture reacts at room temperature for 1 hour. After the reaction, the said reaction solution is extracted with ethyl acetate, and washed with saturated NaCl solution. The ethyl ester phase is dried and condensed, and then separated and purified with the aid of column chromatography, the eluent (petroleum ether/ethyl acetate=4:1) is used, and as a result, 686 mg of yellow solid is obtained, and the yield is 50%; m.p. is 197° C.-199° C.; 1H-NMR (300 MHz, DMSO): 1.02 (s, 3H), 1.22-1.33 (m, 7H), 1.68 (s, 3H), 2.31 (dd, J1=13.5 Hz, J2=3.9 Hz, 1H), 2.42-2.57 (m, 3H), 3.49 (d, J=6.6 Hz, 1H), 4.4 (m, 1H), 6.46 (s, 1H), 6.63 (d, J=9 Hz, 1H), 7.37 (d, J=6.9 Hz, 1H), 7.46 (d, J=9, 1H); IR (KBr): 3376, 3275.5, 2970.6, 2927.1, 1738, 1650, 1607, 1584, 1493, 1332, 1278, 1233.5, 1146, 958, 866, 745; EI-MS (m/z): 379 ([M−H]+); Anal. Calcd for C 23 H 24 O 5 (%): C, 72.61%; H, 6.36%. Found: C, 72.29%; H, 6.54%.
Example 5
[0062] The following formula represents a 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-hydroxymethyl-2-butenyl)-10-hydroxyl-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound:
[0000]
[0000] The 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-10-hydroxyl-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone compound is used as a starting material, the operating procedures are the same as those described in Example 3, and as a result, 746 mg of yellow solid is obtained, and the total yield is 4%.
Example 6
[0063] The following formula represents a 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-9-hydroxyl-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound (CPUY I-3).
[0000]
[0064] Similar to Example 4, except that the compound 2,5-dimethyoxy benzoicacid is used instead of 2,4-dimethoxy benzoicacid, and as a result, 690 mg of yellow solid is obtained, and the yield is 3.3%; m.p. is 158° C.-159° C.; 1H-NMR (300 MHz, CDCl 3 ): 0.91 (s, 3H), 1.18-1.31 (m, 7H), 1.65 (s, 3H), 2.27 (dd, J1=13.5 Hz, J2=4.5 Hz, 1H), 2.46 (d, J=9.6, 1H), 2.62 (d, J=9.3, 2H), 3.52 (t, J=4.5 Hz, 1H), 4.34 (m, 1H), 6.04 (s, 1H), 6.91 (d, J=9 Hz, 1H), 7.06 (dd, J1=9 Hz, J2=3 Hz, 1H), 7.35 (d, J=6.9 Hz, 1H), 7.41 (d, J=3 Hz, 1H), EI-MS (m/z): 380 [M+], 352, 337, 283, 255, 213; Anal. Calcd for C 23 H 24 O 5 (%): C, 72.61%; H, 6.36%. Found: C, 72.33% ; H, 6.50%.
Example 7
[0065] The following formula represents a 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-hydroxymethoxy-2-butenyl)-9-hydroxyl-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound.
[0000]
[0066] The 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-9-hydroxyl-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound is used as starting material, the rest of the procedures are the same as those described in Example 3, and as a result, 753 mg of yellow solid is obtained, and the total yield is 4%.
Example 8
[0067] The following formula represents a 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-11-hydroxyl-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound (CPUY I-4).
[0000]
[0068] Similar to Example 4, except that the compound 2,3-dimethoxy benzoic acid is used as a starting material instead of 2,4-dimethoxy benzoic acid, and as a result, 820 mg of yellow solid is obtained, and the yield is 5%; m.p. is 203° C.-205° C.; 1H NMR (300 MHz, DMSO): 0.82 (s, 3H), 1.19-1.34 (m, 7H), 1.64 (s, 3H), 2.27 (dd, J1=13.5 Hz, J2=4.5 Hz, 1H), 2.46-2.56 (m, 3H), 3.45 (m, 1H), 4.45 (m, 1H), 5.38 (s, 1H), 6.90 (t, J=8.1 Hz, 1H), 7.11 (dd, J1=7.8 Hz, J1=1.2 Hz, 1H), 7.43 (d, 1H), 7.46 (d, J=9 Hz, 1H); IR (KBr): 3425, 2966.2, 2925.1, 1738.22, 1650, 1607, 1583, 1493, 1377, 1279, 1233.9, 1152, 748.9; EI-MS (m/z): 380, 352, 337, 309, 283, 255, 241, 213; Anal. Calcd for C23H24O5(%): C, 72.61%; H, 6.36%. Found: C, 72.60%; H, 6.70%.
Example 9
[0069] The following formula represents a 3,3a,4,5-tetrahydro-3,3-dimethyl-1-(3-hydroxymethoxy-2-butenyl)-11-hydroxyl-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound.
[0000]
[0070] The 3,3a,4,
[0071] 5-tetrahydro-3,3-dimethyl-1-(3-methyl-2-butenyl)-11-hydroxyl-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound is used as a starting material, the rest of procedures are same as those described in Example 3, and as a result, 755 mg of yellow solid is obtained, and the yield is 4%.
Example 10
[0072] The following formula represents a 3,3a,4,5-tetrahydro-3,3-dimethyl-1,11-bis(3-methyl-2-butenyl)-10-hydroxyl-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound (CPUY I-5).
[0000]
(Step 1) Preparation of 3,4,6-trimethyl butynyl-9H-xanthenone
[0073] In preparation of 3,4,6-trimethyl butynyl-9H-xanthenone, 2.7 g (11.07 mmol) of 3,4,6-trimethyl-9H-xanthenone is dissolved in 100 mL of acetone; subsequently, 7.34 g (44.18 mmol, 4 equiv) of KI, 6.1 g (44.28 mmol, 4 equiv) of K 2 CO 3 and 0.21 g (0.8 mmol, 0.1 equiv) of CuI are added in turn; the said mixture is stirred at room temperature for 15 min; 7.29 ml (66.42 mmol, 6 equiv) chloro-methyl butyne is added; and the said mixture reacts at 50° C. for 6 hours. The reaction solution is vacuum filtered and the filtrate is condensed. The resulting residue is separated and purified with the aid of column chromatography, the eluent (petroleum ether/ethyl acetate=8:1) is used, and as a result, 2.4 g of orange solid is obtained, and the yield is 49%; m.p. is 117° C.-119° C., 1 H NMR (300 MHz, CDCl 3 ): δ 1.76 (s, 12H), 1.82 (s, 6H), 2.33 (s, 1H), 2.65 (s, 1H), 2.69 (s, 1H), 7.16 (dd, J1=8.7 Hz, J1=2.1 Hz, 1H), 7.40 (d, J=2.1 Hz, 1H), 7.62 (d, J=9.0 Hz, 1H), 8.04 (d, J=9.0 Hz, 1H), 8.22 (d, J=8.7 Hz, 1H), EI-MS (m/z): 442, 427, 376, 361, 324, 310, 281, 244.
(Step 2) Preparation of 3,4,6-trimethyl butenyl-9H-xanthenone
[0074] In preparation of 3,4,6-trimethyl butenyl-9H-xanthenone, 200 mg of 2,5,6-trimethyl butynyl-9H-xanthenone (22) and (0.45 mmol) of xanthenone are dissolved in 30 mL of ethanol, 20 mg of 10% Pd/BaSO 4 is added, and the said mixture reacts at room temperature for 4 hours. The obtained reaction solution is vacuum filtered and the filtrate is condensed. The resulting residue is separated and purified with the aid of column chromatography, the eluent (petroleum ether/ethyl acetate=8:1) is used, and as a result, 170 mg of light green oil is obtained, and the yield is 85%; 1H NMR (300 MHz, CDCl 3 ): 1.56 (s, 12H), 1.60 (s, 6H), 5.16˜5.28 (m, 6H), 6.11˜6.34 (m, 3H), 6.95 (dd, J1=9 Hz, J2=2.1 Hz, 1H), 7.05˜7.10 (m, 2H), 7.89 (d, J=9 Hz, 1H), 8.14 (d, J=9.0 Hz, 1H), EI-MS (m/z): 448, 436, 420, 405, 380, 365, 325, 312, 256, 244.
(3) Preparation of 3,3a,4,5-tetrahydro-3,3-dimethyl-1,11-bis(3-methyl-2-butenyl)-10-hydroxyl-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone
[0075] In preparation of 3,3a,4,5-tetrahydro-3,3-dimethyl-1,11-bis(3-methyl-2-butenyl)-10-hydroxyl-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone, 120 mg of 2,5,6-trimethyl butenyl-9H-xanthenone (23) is dissolved in 120 ml of DMF, the said mixture reacts at 125° C. for 4 hours, and subsequently, the DMF is heated and vacuum evaporated. the resulting residue is separated and purified with the aid of column chromatography, the eluent (petroleum ether/ethyl acetate=4:1) is used, and as a result, 65 mg of yellow solid is obtained, and the yield is 53%. The obtained is crystallized with 95% ethanol, and as a result, the orange fine crystal is obtained, and the m.p. is 158° C.-160° C.; 1H NMR (300 MHz, CDCl 3 ): 0.93 (s, 3H), 1.29-1.33 (m, 7H), 1.71 (s, 3H), 1.77 (s, 3H), 1.83 (s, 3H), 2.33 (dd, J1=13.5 Hz, J2=4.5 Hz, 1H), 2.50 (d, J=9.3, 1H), 2.57 (d, J=8.7 Hz, 2H), 3.46-3.55 (m, 3H), 4.40-4.45 (m, 1H), 5.28 (t, J=6.6 Hz, 1H), 6.30 (s, 1H), 6.58 (d, J=8.7 Hz, 1H), 7.43 (d, J=6.9 Hz, 1H), 7.80 (d, J=8.7 Hz, 1H), IR (KBr): 3438.7, 2964.3, 2922.1, 2849.9, 1738.9, 1649.6, 1605.3, 1433.0, 12984.6, 1262.8, 1079.6, 1046.7, 802, EI-MS (m/z): 448, 420, 405, 377, 351, Anal. calcd for C 28 H 32 O 5 .H 2 O(%): C, 72.08; H, 7.35. Found: C, 72.33; H, 7.36.
Example 11
[0076] The following formula represents a 3,3a,4,5-tetrahydro-3,3-dimethyl-1,8-bis(3-methyl-2-butenyl)-9-hydroxyl-1,5-dimethylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound (CPUY I-6).
[0000]
[0077] Similar to the procedures described in Example 10, except that the compound 2,5,6-hydroxyl-9H-xanthenone is used as a starting material instead of 3,4,6-trimethyl-9H-xanthenone, and as a result, 80 mg of orange solid is obtained, and the yield is 40%; m.p. is 138° C.-139° C.; 1H NMR (300 MHz, CDCl 3 ): δ 1.03 (s, 3H), 1.16-1.23 (m, 4H), 1.32 (s, 3H), 1.63 (s, 3H), 1.67 (s, 3H), 1.77 (s, 3H), 2.22 (dd, J1=13.5 Hz, J2=4.5 Hz, 1H), 2.29 (d, J=9.6, 1H), 2.56 (d, J=8.7 Hz, 2H), 3.38 (dd, J1=6.9 Hz, J2=4.5 Hz, 1H), 3.88 (d, J=6.6, 2H), 4.38 (t, J=8.7 Hz, 1H), 5.13 (t, J=6.6, 1H), 5.39 (s, 1H), 6.81 (d, J=9 Hz, 1H), 7.00 (d, J=9 Hz, 1H), 7.18 (d, J=6.9 Hz, 1H), IR (KBr): 3506.1, 3171.6, 2967.4, 2918.6, 1737.0, 1659.6, 1606.3, 1486.0, 1443.5, 1376.5, 1298.6, 1221.8, 1145.25, 1042.6, 822.7, 790.5, EI-MS (m/z): 448, 420, 378, Anal. calcd for C 28 H 32 O 5 .H 2 O(%): C, 72.08; H, 7.35. Found: C, 72.10; H, 7.30.
Example 12
[0078] The following formula represents a 1,3a,4,11a-tetrahydro-3,3-dimethyl-1,7-bis(3-methyl-2-butenyl)-8-hydroxyl-3H-1,4-a-dimethylene-10H-furan[3,4-b]xanthene-10,12-diketone endocyclic compound (CPUY 1-7).
[0000]
[0079] Similar to the procedure described in Example 10, except that the compound 2,5,6-hydroxyl-9H-xanthenone is used as a starting material instead of 3,4,6-trimethyl-9H-xanthenone, and as a result, 40 mg of orange crystals are obtained, and the yield is 20%; m.p. is 148° C.-150° C.; 1H NMR (300 MHz, CDCl 3 ): 1.30 (s, 3H), 1.33 (s, 3H), 1.52 (s, 3H), 1.64 (s, 3H), 1.67 (s, 3H), 1.76 (s, 4H), 2.01 (dd, J1=8.4 Hz, J2=14.7 Hz, 1H), 2.10 (dd, J1=4.5, J1=9.9, 1H), 2.56 (d, J=8.7 Hz, 2H), 3.65 (dd, J1=6.9 Hz, J2=4.5 Hz, 1H), 3.82 (d, J=6.6, 2H), 4.95 (t, J1=6.9 Hz, J2=8.1 Hz, 1H), 5.11 (m, 2H), 6.96 (s, 2H), 7.00 (d, J=6.9 Hz, 1H), IR (KBr): 3506.1, 3171.6, 2967.4, 2918.6, 1737.0, 1659.6, 1606.3, 1486.0, 1443.5, 1376.5, 1298.6, 1221.8, 1145.25, 1042.6, 822.7, 790.5, ESI-MS (m/z): 447 ([M+H] + ), Anal. calcd for C 28 H 32 O 5 .H 2 O(%): C, 72.08; H, 7.35. Found: C, 72.11; H, 7.40.
Example 13
[0080] The following formula represents a 3,3a,4,5-tetrahydro-3,3-dimethyl-1,10-bis(3-methyl-2-butenyl)-11-hydroxyl-1,5-dimeth ylene-1H,7H-furan[3,4-d]xanthene-7,13-diketone endocyclic compound (CPUY I-8).
[0000]
[0081] Similar to the procedure described in Example 10, except that the compound 3,4,5-trihydroxyl-9H-xanthenone is used as starting a material instead of 3,4,6-trimethyl-9H-xanthenone, and as a result, 60 mg of yellow solid is obtained, and the yield is 40%; m.p. is 157° C.-158° C.; 1H NMR (300 MHz, CDCl 3 ): 0.81 (s, 3H), 1.24-1.29 (m, 7H), 1.64 (s, 3H), 1.67 (s, 3H), 1.68 (s, 3H), 2.27 (dd, J1=13.5 Hz, J2=4.8 Hz, 1H), 2.45-2.49 (m, 3H), 3.33 (d, J=7.2 Hz, 2H), 3.43 (dd, J1=6.6 Hz, J2=4.8 Hz, 1H), 4.47 (t, J=6.6 Hz, 1H), 5.20 (dd, J1=7.2 Hz, J2=1.2 Hz, 1H), 5.41 (s, 1H), 6.79 (d, J=8.1 Hz, 1H), 7.37 (d, J=8.1 Hz, 1H), 7.41 (d, J=6.6 Hz, 1H), IR (KBr): 3416.4, 2969.4, 2909.6, 1739.5, 1654.8, 1607.8, 1448, 1313.7, 1249.2, 1213.7, 1037.7, EI-MS (m/z): 448, 436, 420, 405, 377, 351, 323, 281, Anal. calcd for C28H32O5.CH3OH(%): C, 72.08; H, 7.35. Found: C, 72.02; H, 7.30.
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The present invention relates to a field of pharmaceutical chemistry, more specifically, the present invention relates to a garcinia derivative Formula (I), its preparing method, and medicinal use. Wherein the definitions of R 1 and R 2 are disclosed in the specification of the present invention, and the derivative of the present invention is a structurally simplified analogue of the gambogic acid compound; wherein the gambogic acid compound possesses anti-cancer characteristics, and could be used for preparation of anti-tumor drugs.
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FIELD OF INVENTION
[0001] The present invention relates to the culturing of cells. More particularly, the invention includes a matrix to support the functional longevity and differentiation of cultured cells.
BACKGROUND OF THE INVENTION
[0002] The culture of cells is a basic protocol that laboratory experiments and studies often require and employ on a daily basis. Maintaining cells in vitro provides a simple and safe way to test cell response in a variety of situations without requiring live subjects. Morphology and metabolic activity of cultured cells are affected by the composition of the substrate on which they are maintained and are believed to function best (e.g., perform their natural in vivo functions and/or proliferate) when cultured on substrates that closely mimic their natural environment. Currently, in vitro studies of cellular function are limited by the availability of cell growth substrates that effectively and affordably present an optimal physiologic environment for cultured cells.
[0003] The interaction of cells with their extracellular matrix in both in vivo and in vitro environments plays an important role in the function of cells from all organs. Continuous communication between cells and the surrounding matrix environment directs necessary processes such as the acquisition and maintenance of differentiated phenotypes during embryogenesis, the development of form, angiogenesis, wound healing, and even tumor metastasis. Both biochemical and biophysical signals from the extracellular matrix regulate fundamental cellular activities including adhesion, migration, proliferation, differential gene expression, and programmed cell death. Conversely, the cell can modify its extracellular matrix environment by modulating synthesis and degradation of specific matrix components.
[0004] The ability of complex substrates to support cell viability, functions and growth in vitro has been previously reported, and matrix products supporting cells in vitro are commercially available. Such complex substrates represent combinations of extracellular matrix components in a natural or processed form. For example, Human Extracellular Matrix and MATRIGEL Basement Membrane Matrix are both available from BD Biosciences Discovery Labware (Bedford, Mass.). Human Extracellular Matrix is a chromatographically partially purified matrix extract derived from human placenta and includes laminin, collagen IV and heparin sulfate proteoglycan. MATRIGEL is a soluble basement membrane extract of the Engelbreth-Holm-Swarm (EHS) tumor, gelled to form a reconstituted basement membrane. Both of these matrix products require costly biochemical isolation, purification, and synthesis techniques. Consequently, production costs are high.
[0005] Other, more recently developed matrices speak to improving the maintenance of cell cultures in vitro, but they are derived from decellularized tissue. This requires the costly steps of digestion or chemical breakdown of the organ used to produce the matrix. Therefore, there is a need in the art for a more comprehensive biological support, capable of enhancing cell proliferation and maintaining functional longevity, which is more affordable and easily produced than other currently available products.
SUMMARY OF THE INVENTION
[0006] The invention pertains to an improved matrix and methods of making the matrix. The matrix reflects the natural interstitial environment of cells. It maintains cell viability and supports both functional longevity and differentiation. More specifically, the matrix is derived from a whole organ, a whole tissue or a portion thereof, and is believed to be a superior support matrix for cells that would normally constitute at least a portion of that organ or tissue in vivo. Moreover, the additional steps of enzymatic digestion or chemical breakdown of tissue may not be required in preparing a matrix in accordance with various embodiments of the present invention.
[0007] Furthermore, the matrix is illustratively demonstrated herein to achieve functional longevity and increased proliferation with hepatocytes. The liver has many functions, playing roles in detoxification, metabolism, and protein synthesis. However, regulation of hepatocyte DNA synthesis, cell growth and cell function are still unclear, making hepatocytes difficult cells to culture. That the matrix of the present invention can support hepatocyte viability, functional longevity and growth thus underscores its remarkable performance abilities.
[0008] An additional aspect of the invention relates to expanding the current knowledge and possibilities for artificial organs and organ parts. Current shortages with organ donors and problems with transplantations and grafts in injured organs create a great need for other therapeutic alternatives. The present invention may further research and enhance progress in this area, providing greater possibility that making and using artificial organs and organ parts will be likely in the future.
BRIEF DESCRIPTION OF THE FIGURES
[0009] The file of this patent contains at least one drawing executed in color. Copies of this patent with color drawing(s) will be provided by the patent and Trademark Office upon request and payment of the necessary fee.
[0010] FIG. 1 is executed in color and illustrates the reduction of a harvested liver into a powder form, in accordance with an embodiment of the present invention. FIG. 1A depicts a harvested liver after it was sliced into 1-3 mm thickness, frozen in liquid nitrogen (N 2 ) and dried in a low pressure tank. FIG. 1B depicts the same freeze-dried liver in powder form, following grinding with a mortar and pestle.
[0011] FIG. 2 is executed in color and illustrates a morphological difference among hepatocytes cultured with a freeze-dried liver powder (“FDLP”) and those cultured on collagen, in accordance with an embodiment of the present invention. FIGS. 2A, 2C and 2 E depict the morphology of hepatocytes cultured on a collagen-coated dish, at twenty-four hours, six days and fourteen days after plating, respectively. FIGS. 2B, 2D and 2 F depict the morphology of hepatocytes cultured with FDLP, at twenty-four hours, six days and fourteen days after plating, respectively.
[0012] FIG. 3 illustrates albumin secretion at established time points after plating (Day 2, Day 4, Day 6, Day 10, Day 14) of hepatocytes cultured with FDLP and a control, in accordance with an embodiment of the present invention.
[0013] FIG. 4 illustrates urea synthesis at established time points after plating (Day 2, Day 4, Day 6, Day 10, Day 14) of hepatocytes cultured with FDLP and control collagen-coated dishes, in accordance with an embodiment of the present invention.
[0014] FIG. 5 is executed in color and illustrates the formation of a “hepatocyte sheet” four days after culturing cells with a matrix derived from a whole organ, in accordance with an embodiment of the present invention. FIG. 5A depicts the organization of hepatocytes into a three-dimensional structure and the formation of secondary structures in spite of weak cell attachment to the bottom of the culture plate. FIG. 5B depicts the ease with which hepatocytes of the present invention can be lifted off a culture plate as a sheet-like form with gentle pipetting after four days in culture.
[0015] FIG. 6 illustrates the small diameter of a microcarrier (around 3 μm) made of FDLP that is believed to be suitable to culture hepatocytes in order to yield a high density of cells, in accordance with an embodiment of the present invention. The measurement of the diameter is based on the following mathematical relationship: r=(⅔ 1/2 -1)R.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The invention is based on the inventors' discovery that a matrix derived from a whole organ, a whole tissue or a portion thereof demonstrates enhanced cell viability and differentiation, even in cell types that are difficult to culture. The discovery indicates that the commonly-used technique of decellularization in making commercially available matrices may not only be unnecessary, but perhaps even counterproductive.
[0017] In one embodiment of the present invention, cells are contacted, in vitro, with a matrix derived from an organ, under conditions conducive to cell growth and differentiation. The term “contacting,” as used herein with reference to cell culture, shall be understood as including direct and indirect contact between the cultured cells and the matrix, as in in vivo fluid communication. The term “conditions conducive to cell growth,” as used herein, refers to environmental conditions, such as sterile technique, temperature, nutrient supply or other conditions that will be readily apparent to those of skill in the art as being relevant to cell growth. Although the conditions used for culturing cells may depend on the particular cell type, cell growth conditions are generally well known in the art.
[0018] The invention provides a process by which to create a matrix (substratum) that supports viability and growth of isolated cells from various organs. “Supporting cell viability and growth,” as used herein, includes inducing cell viability and growth, maintaining cell viability and growth, cultivating cell viability and growth, or any other means of increasing or maintaining cell viability and count, as will be readily recognized by those of skill in the art. The described methods generate a product that achieves both functional longevity and greater cell differentiation.
[0019] The terms “isolated organ” and “isolated tissue” as used herein refer to an organ or tissue, respectively, which has been removed from a mammal. Any organ, tissue or portion thereof that is obtained from a mammal may be suitable for use in accordance with various embodiments of the present invention. By way of example, organs may include a liver, lung, kidney, pancreas, spleen, testis, intestinal wall, adrenal gland, thyroid gland, parathyroid gland, ovary or brain, while exemplary tissues might include skin, muscle, blood vessel wall or bone marrow. The aforementioned list of organs and tissues is by no means exhaustive; rather it is used to illustrate the broad array of organ and tissue types that may be used in connection with various embodiments of the present invention.
[0020] Correspondingly, a wide array of cell types may be cultured with a matrix of the present invention. It is believed that cells exhibit optimal growth and differentiation when cultured in a matrix derived from the same organ with which the cells being cultured are associated. Examples of cells that may be cultured with various matrices of the present invention may include, but are in no way limited to, hepatocytes, lung cells (e.g., lung alveolar cells), kidney cells (e.g., renal tubule cells), enterocytes, pancreatic islet cells (e.g., alpha, beta), splenocytes, neural cells and others.
[0021] The term “whole,” when used with reference to the organs and tissues included in various embodiments of the present invention, denotes the fact that these biological materials are not decellularized or otherwise digested prior to being processed into support matrices. Instead, such organs and tissues are processed in an undigested form. Moreover, use of the term “whole” is not intended to imply that a full and intact organ is necessarily processed; indeed, in many embodiments of the present invention only a portion of an organ is used to produce a matrix. By way of example, a segment of an intestine or a piece of skin may be utilized, just as a full, intact liver might be used. However, in each embodiment, the “whole” organ, tissue or portion thereof is processed in undigested form, whether the organ is a full and intact organ or tissue, or only a portion thereof.
[0022] Accordingly, the invention includes methods for reducing a whole isolated organ, tissue or portion thereof, through lyophilization, grinding and sonication (or other techniques), into a tissue powder. This powder constitutes the base component for the support matrix. The present invention takes advantage of a whole organ or tissue (or portion thereof) to provide a more comprehensive biological support for cell culture. While not wishing to be bound by any particular theory, it is believed that this ensures that many or all of the essential elements, which cells contact and interact with in vivo within specific organs, are present in the matrix. This results in a matrix that is able to support cell proliferation and maintain cell functional longevity to a greater extent than other methods currently available on the market. Furthermore, by using the whole organ or tissue (or portion thereof) to derive the tissue powder, the need to decellularize the organ by enzymatic digestion or chemical breakdown is obviated. Consequently, the invention offers an easier and more affordable way to obtain a matrix that is also more conducive to inducing cell proliferation and differentiation than other commercially available products.
Isolation of Natural Organs of Interest and Process to Obtain Freeze-Dried Tissue Powder
[0023] The base component of the present invention is a tissue powder. This powder may be derived from a variety of organs or tissues. Depending on the cells to be cultured, an appropriate organ, tissue or portion thereof may be isolated after a preservation approach such as in situ perfusion using physiological saline, phosphate buffer solution, Hank's Balanced Salt Solution (“BSS”) or commercially available organ preservation media (e.g., University of Wisconsin solution); although other techniques may be employed to preserve cells for use with the matrix of the present invention, as will be readily understood by those of skill in the art.
[0024] After harvesting, blood may be removed from the organ, tissue or portion thereof, and the selected organ or tissue may be cleaned. The organ or tissue may be frozen in liquid nitrogen, and subsequently dried (e.g., in a low pressure tank). In alternate embodiments of the present invention, other conventional techniques may be used to freeze the selected organ or tissue. For example, the organ, tissue or portion thereof may be frozen using a helium-based technique. Additionally, the organ, tissue or portion thereof may be sliced or otherwise reduced into smaller pieces prior to freezing.
[0025] The resulting freeze-dried organ, tissue or portion thereof (whether reduced to smaller pieces or not) is next converted into powder. This may be achieved, for example, by grinding with a mortar and pestle. The powder may then be soaked in a culture medium and sonicated using a sonic dismembranator to further reduce the powder into finer particles. Other methods known in the art and comparable to those described may be used in the alternative. Due to the lypholization (freeze-drying) undergone by the powder in one embodiment of the present invention, it may be stored for future use without losing its potency.
Preparing Support Matrix and Cell Culture
[0026] Cells to be cultured with the matrix of the present invention may be obtained by a variety of techniques, including in situ perfusion with collagenase, ethylenediaminetetraacetate (EDTA) or other solution causing cell separation. Enrichment of cells increases viability prior to suspension in a suitable medium, such as Dulbecco's Modified Eagle Medium (DMEM). An appropriate media may be selected based on a variety of factors, including, for example, the type of cell being cultured. Other examples of media that may be suitable for use with the cells and matrix of the present invention may include, but are in no way limited to, Williams E medium, Minimum essential medium (MEM) (Eagle), Ham's F10 medium, Ham's F12K medium and RPMI-1640 medium. Moreover, it will be readily apparent to those of skill in the art that any number of conventional cell growth media may be used in accordance with alternate embodiments of the present invention. Many cell growth media are commercially available and are used routinely to culture cells. Alternatively, one may easily create one's own cell growth medium and use the same in connection with various embodiments of the present invention.
[0027] Suspended cells are mixed with tissue powder that has been preferably soaked in the same culture medium as the cells, although soaking in an identical medium, indeed soaking in any medium at all, is not required for the tissue powder of the present invention to function properly. The mixture may be seeded on tissue culture plates and placed under conditions conducive to cell growth. About six hours after plating, various nutrients and/or antibiotics may be added to the culture medium. Subsequently, the medium may be periodically replaced (e.g., every 24 hours). The duration of time before additional components (e.g., nutrients, antibiotics, growth factors, etc.) are added, as well as the frequency with which the medium is replaced may vary with the type of cells being cultured, as well as other relevant factors that will be readily recognized by those of skill in the art.
EXAMPLES
[0028] The liver was used as a model system to conduct proof-of-concept studies. The studies demonstrate that the instant invention provides a coating matrix as well as a micro-skeletal structure to support the cells. These are believed to be important features in culturing hepatocytes, which are anchorage-dependent and function through cell-to-cell contact. Primary studies show that even cell types that are considered difficult to culture (e.g., hepatocytes) successfully proliferate and maintain functional longevity with the methods of the present invention.
EXAMPLE 1
[0029] Isolation of Liver and Preparation of Freeze-Dried Liver Powder (FDLP)
[0030] Adult male Sprague-Dawley rats ( 200 - 250 g ) were obtained from Harlan Sprague-Dawley Inc. (Indianapolis, Ind.). Animals were housed in a climate-controlled (21° C.) room under a 12-hours light-dark cycle and were given tap water and standard laboratory rat chow (Rodent Chow 5001, Ralston Purina; St. Louis, Mo.) ad libitum. Cell harvesting was performed between 9:00 a.m. and noon under general anesthesia (isoflurane) using sterile surgical technique. This study was performed in compliance with institutional and National Research Council guidelines for the care and use of experimental animals.
[0031] The rat liver was harvested after in situ perfusion with cold physiological saline (0.9% NaCl). The harvested liver was sliced into 1-3 mm thickness and frozen in liquid nitrogen. After freezing, the liver was dried in a low pressure tank ( FIG. 1 a ). The freeze-dried liver was subsequently broken into powder using a mortar and pestle ( FIG. 1 b ). Finally, the powder was soaked in a culture medium (DMEM) and sonicated using a sonic dismembranator (available from Fisher Scientific; Pittsburgh, Pa.) to further reduce particle size.
EXAMPLE 2
Hepatocyte Isolation
[0032] Hepatocytes were harvested by the Seglen in situ two-step liver perfusion method with some modifications (P.O. Seglen, “Preparation of Isolated Rat Liver Cells,” Methods Cell Biol . (Prescott, D. M., ed.) 13:29-83, Academic Press, New York (1976)). After enrichment through a PERCOLL density gradient (Pharmacia; Piscataway, N.J.), viability of the cells was always greater than 90%, as judged by trypan blue exclusion. The cells were next suspended in DMEM (Omega Scientific; Tarzana, Calif.) with 10% fetal bovine serum (FBS) (Sigma Chemical Co.; Saint Louis, Mo.).
EXAMPLE 3
Use of FDLP Matrix as Hepatocyte Cell Culture Substrate
[0033] Rat hepatocytes suspended in DMEM with 10% FBS were mixed with FDLP soaked in the same culture medium (1.5 mg/ml) and seeded on 60-mm non-coated tissue culture plates at densities of 4.5×10 5 cells/ml and placed in a humidified, 5% CO 2 ; 95% air incubator at 37° C. Six hours after plating, the medium was replaced with DMEM enriched with 10% FBS, 20 mM HEPES, 10 mM nicotinamide, 1 mM ascorbic acid 2-phosphate, 10-7 M dexamethasone, 1 mg/ml galactose, 30 μg/ml proline, ITS mixture, 10 ng/ml epidermal growth factor (EGF) and antibiotics. The medium was replaced every 24 hours. In addition to the basal medium, 1% dimethyl sulfoxide (DMSO) was used from day four onward. Control dishes contained no FDLP and hepatocytes were cultured on 60-mm dishes coated with type I rat tail collagen (obtained from Collaborative Biomedical Products; Bedford, Mass.). Additionally, as a background, a culture plate containing only FDLP (1.5 mg/ml) was cultured with the same conditions. Five dishes from each culture group were used for a urea formation and albumin secretion study, and each cell culture experiment was repeated three times, using freshly isolated rat hepatocytes.
EXAMPLE 4
Measurements of Cell Growth through Urea Formation and Albumin Secretion
[0034] The culture medium was collected at 2, 4, 6, 10, and 14 days after plating and analyzed for albumin concentration using an ELISA kit (Nephrat II, Exocell Inc.; Philadelphia, Pa.). The antibodies in this kit were not cross-reactive with bovine albumin. The amount of albumin secreted into the culture medium during the last 24 hours was calculated.
[0035] 20 mM ammonium chloride was spiked at 2, 4, 6, 10 and 14 days after plating. After 6 hours of incubation, samples were collected and ammonia and urea concentrations were measured, using an enzymatic test kit (Boehringer Mannheim GmbH; Biochemica, Germany) with 340 nm spectrometer (BECKMAN model DU 530 , Beckman Instruments, Inc.; Fullerton, Calif.).
[0036] Data were analyzed using Student's t test (P values equal to or less than 0.05 were considered significant). Resulting values are presented as means±SD ( FIGS. 3-4 ).
EXAMPLE 5
Comparison of Urea Formation and Albumin Secretion
[0037] At 2 days after plating, there was no significant difference between hepatocytes cultured with FDLP and the control (FDLP group, 57.9±14.7 μg/24 h/plate; control group, 62.7±17.0 μg/24 h/plate). Hepatocytes cultured with FDLP secreted maximum amounts of albumin at 4 days after plating and kept the level until 14 days after plating (Day 4, 120.8±23.3 μg/24 h/plate; Day 6, 115.8±30.6 μg/24 h/plate; Day 10, 82.8±33.6 μg/24 h/plate; Day 14, 94.2±31.1 μg/24 h/plate). In the control culture, the amount of secreted albumin decreased rapidly and reached almost zero at 14 days after plating (Day 4, 41/1±8.5 μg/24 h/plate; Day 6, 23.7±4.8 μg/24 h/plate; Day 10, 9.7±3.7 μg/24 h/plate; Day 14, 3.9±3.2 μg/24 h/plate) ( FIG. 3 ). The background, culturing FDLP with no cells, was zero at every time point.
[0038] When the hepatocytes with FDLP and the control culture were given 2.0 mM of ammonium chloride, the amount of urea synthesized in 6 hours decreased according to the age in both cultures. However, the decrease rate was much slower in the FDLP group (FDLP group, Day 2, 312.3±9.5 μg/6 hours; Day 4, 300.7±13.4 μg/6 hours; Day 6, 240.0±25.9 μg/6 hours; Day 10, 184.4±38.9 μg/6 hours; Day 14, 123.3±22.3 μg/6 hours; control group, Day 2, 287.3±22.6 μg/6 hours; Day 4, 264.9±15.0 μg/6 hours; Day 6, 121.0±31.3 μg/6 hours; Day 10, 39.0±17.8 μg/6 hours; Day 14, 17.8±14.6 μg/6 hours) ( FIG. 4 ). 14 days after plating, the hepatocytes cultured with FDLP maintained the same level of metabolic function as the hepatocytes on collagen, 6 days after plating. The background, culturing FDLP with no cells, was zero at every time point.
EXAMPLE 6
Morphological Appearance of Cells
[0039] Morphology of the hepatocytes cultured with FDLP was significantly different from that of the hepatocytes cultured on collagen. At 24 hours after plating, in contrast to hepatocytes cultured on collagen, those cultured with FDLP showed minimal spreading and formed aggregates ( FIG. 2 b ). At Day 6, the hepatocytes attached to the bottom of the dish and made islet-like structures. The cells tended to pile up into three-dimensional spheroids ( FIG. 2 d ). These spheroids were maintained until 14 days after the plating ( FIG. 2 f ).
EXAMPLE 7
Tissue-Like Cell Formation
[0040] Results from studies show greater growth in cells cultured in the instant matrix than in those cultured in the traditional matrix or the control. More promising, the cells cultured through the invention organized into three-dimensional structure with tight junctions (within 6-7 days) and formed secondary structures such as ducts and bile canaliculi. The result was the formation of a “hepatocyte sheet” after only 4 days of plating ( FIG. 5 ).
EXAMPLE 8
Applications in Bioengineering
[0041] Microcarrier-attached hepatocytes are unique culture systems, and the ideal diameter of a microcarrier needed to achieve the highest density of hepatocytes is very small (approx. 3 μm) ( FIG. 6 ). It is difficult to make such a small artificial particle which contains a matrix, even with the technology we have available today. In this regard, FDLP is thought to have significant potential advantages in its size and use as a matrix.
[0042] One interesting aspect of this culture system, using FDLP as a microcarrier, is that hepatocytes can make spheroids despite the fact that cell attachment to the bottom of the culture plate is weak. The inventors used non-coated plastic culture plate for hepatocyte culture using FDLP. Four days after plating, hepatocytes may be readily lifted off from the plate as a sheet-like form with gentle pipetting ( FIG. 5 ). This “hepatocyte sheet” is thought to have many benefits that may allow wide use in research and in different applications in the field of tissue engineering. For example, cells cultured in this fashion may be used to fabricate artificial organs or components thereof for transplantation.
[0043] While the description above refers to particular embodiments of the present invention, it should be readily apparent to people of ordinary skill in the art that a number of 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 spirit and scope of the invention. The presently disclosed embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than the foregoing description. All changes that come within the meaning of and range of equivalency of the claims are intended to be embraced therein.
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Described herein is a novel biological support for cells, derived from a mammalian whole organ, tissue or portion thereof. In various embodiments, a support matrix is prepared by isolating a whole organ, tissue or portion thereof, and thereafter converting it into a tissue powder. Various washing and freeze-drying techniques are employed, as well as mechanical reduction, sonication and further processes to convert the whole organ, tissue or portion thereof into a matrix suitable for supporting functional longevity and proliferation of cultured cells. It is believed that by culturing a particular type of cell in a matrix derived from the whole organ, tissue or portion thereof with which that cell is normally associated, one may achieve optimal cell support and differentiation. The whole organs, tissues and portions thereof used in connection with aspects of the present invention need not be decellularized or otherwise digested prior to processing into the matrix.
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BACKGROUND OF THE INVENTION
The present invention relates to a method of producing cartons of cigarettes.
Cartons of cigarettes are known to be produced using flat, precut blanks, each of which is folded along yield lines to define a box housing a respective group of packets of cigarettes constituting the content of the carton.
According to one known method, each blank is folded in a U about a respective group of packets, so as to cover three of the surfaces of the group and leave a further three surfaces exposed, from each of which exposed surfaces the blank presents at least two outwardly-projecting tabs, which are subsequently folded to cover the respective exposed surface.
For folding the tabs projecting from each exposed surface, Italian Patent Application N. 3422A/90 utilizes, for at least one of the surfaces, a folding head past which the U-folded blank and the respective group of packets are fed so as to gradually fold part of the tabs squarely. Subsequently, the folding head is moved in a direction substantially perpendicular to the traveling direction of the blanks, so as to complete square-folding of the respective tabs.
Though employed successfully on cartoning machines, the above known method presents several drawbacks, mainly due to both the blank with the respective group of packets and the folding head necessarily being moved during the tab folding process, thus resulting in obvious mechanical complications and the possibility of the blank being moved incorrectly in relation to the stationary folding head.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method of producing cartons of cigarettes, designed to overcome the aforementioned drawbacks.
According to the present invention, there is provided a method of producing cartons of cigarettes, said method comprising a stage wherein a blank is folded in a U about a respective group of packets of cigarettes, in such a manner that the blank leaves three surfaces of the group exposed, and presents at least two tabs projecting outwards of and substantially perpendicular to each said exposed surface; characterized by the fact that it comprises a further stage wherein, for at least one of said surfaces, said blank is finish-folded about the respective said group by maintaining the blank and respective group of packets stationary at a folding station, and by squarely folding all the tabs projecting from said surface using a single folding head to which is imparted a single linear movement in a direction parallel to the tabs for folding and to the respective exposed surface.
BRIEF DESCRIPTION OF THE DRAWINGS
A non-limiting embodiment of the present invention will be described by way of example with reference to the accompanying drawings, in which:
FIG. 1 shows a view in perspective, with parts removed for clarity, of a cartoning machine implementing the method according to the present invention;
FIG. 2 shows a side view of a first detail in FIG. 1;
FIG. 3 shows a side view of a second detail in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Number 1 in FIG. 1 indicates a cartoning machine for producing cartons of cigarettes 2, each comprising a number of packets of cigarettes 3 arranged side by side in layers so as to form a group 4 in the form of a parallelepipedon, and housed inside a single box 5 defined by a known blank 6 of precut sheet material.
Group 4 presents a longitudinal axis 7, and is defined by two large longitudinal lateral surfaces 8 and 9, two small longitudinal lateral surfaces 10 and 11, and two end surfaces 12.
Machine 1 comprises a known loading station (not shown) where each group 4 is assigned a respective blank 6, which is folded in a U about and contacting group 4 so that surfaces 8 and 9 are covered by respective lateral panels 13 and 14; surface 10 is covered by intermediate panel 15; two longitudinal tabs 16 and 17 respectively integral with panels 13 and 14 project outwards of surface 11; and two tabs 18 and 19 respectively integral with respective longitudinal ends of panels 13 and 14, and a tab 20 integral with a respective end of panel 15, project from each end surface 12.
As shown in FIG. 1, tab 17 is substantially the same size as surface 11 and substantially twice as wide as tab 16, while each tab 18 is substantially the same size as respective surface 12 and substantially twice as wide as respective tab 19.
Once blank 6 is folded in a U about group 4 in known manner as described above, assembly 4, 6 is fed by known pushers (not shown) in direction 21 perpendicular to panel 15 and longitudinal axis 7, and, by means of a clamping device 22a, is clamped in a fixed position on a plate 22 and inside a folding station 23 forming part of machine 1. For each surface 12 of group 4 clamped in position in station 23, station 23 comprises a folding head 24 for folding respective tabs 18, 19 and 20 of blank 6 on to surface 12, with tab 18 on top of tabs 19 and 20. Folding station 23 also comprises a third folding head 25 for surface 11 of group 4 clamped in position in station 23, and which provides for folding respective tabs 16 and 17 of blank 6 on to surface 11, with tab 17 on top of tab 16.
Each head 24 is connected to the output rod 26 of a respective known linear actuator indicated as a whole by 27, and which provides for imparting to respective head 24 a linear work movement in direction 28 parallel to direction 21 and to respective surface 12, and a linear return movement between two limit positions (only one of which is shown in FIG. 1) on either side of surface 12.
As shown in FIG. 1, each head 24 comprises a U-shaped bracket 29 having its concavity facing respective surface 12 of group 4 clamped inside station 23, and defined by a central wall 30 parallel to respective surface 12 and from the top and bottom ends of which project two rectangular walls 31 and 32 substantially parallel to plate 22.
As shown in FIG. 1 and, in particular, FIG. 2, each head 24 also comprises a first and second helical folding device 33 and 34 substantially coplanar with respective surface 12 of group 4 in station 23, and extending towards each other so as to define a channel 35 of variable width engaged by respective tabs 18 and 19 during the work stroke of respective head 24. More specifically, folding device 34 is defined by a plate substantially in the form of a rectangular trapezium, having its longer edge connected to a free end portion of wall 32, and extending towards wall 31, parallel to wall 30. Folding device 34 is partially defined at the free end by a curved edge 36 having its concavity facing wall 31, and sloping towards inlet 37 of channel 35, which, as of inlet 37, tapers from a width greater than to a width smaller than the distance between surfaces 8 and 9 of group 4.
Similarly, folding device 33 is defined by a plate substantially in the form of a rectangular trapezium, having its longer edge connected integral with a free end portion of wall 31, and extending towards wall 32, parallel to wall 30. On the side facing folding device 34, folding device 33 is defined, at least partially, by a curved edge 38 having its concavity facing wall 32, and sloping towards inlet 37 of channel 35.
As shown in FIGS. 1 and 2, each head 24 also comprises a further folding device 39 perpendicular to direction 28 and projecting from the lateral edge of wall 30 facing inlet 37 of channel 35 and located frontwards during the work movement of head 24 in direction 28. Folding device 39 is defined at the free end by a straight edge 40 substantially coplanar with surface 12 of group 4 in station 23.
With reference to FIGS. 1 and 3, head 25 is connected to the output rod 41 of a known linear actuator indicated as a whole by 42, and which provides for imparting to head 25 a reciprocating linear movement in direction 43 perpendicular to direction 21 and parallel to surface 11, and between two limit positions (only one of which is shown in FIG. 1) on either side of surface 11 in relation to direction 43.
Head 25 (FIG. 1) comprises a U-shaped bracket 44 having its concavity facing surface 11 of group 4 clamped on to plate 22, and in turn comprising a central wall 45 parallel to surface 11 and from the top and bottom ends of which project rectangular walls 46 and 47 substantially parallel to plate 22. As shown also in FIG.3, head 25 also comprises a pair of first helical folding devices 48, and a pair of second helical folding devices 49. First folding devices 48 are geometrically similar to devices 34, each present the longer side connected integral with wall 46, and are coplanar with each other and substantially with surface 11 of group 4 clamped in station 23. Second folding devices 49 are geometrically similar to devices 33, each present the longer side connected integral with wall 47, and are also coplanar with each other and substantially with surface 11 of group 4 clamped in station 23. Each folding device 49 is located facing a respective device 48, so as to define the opposite edges of a respective channel 50 of variable width and geometrically similar to channels 35. More specifically, channels 50 are positioned specularly in relation to each other and along the center line of head 25 in direction 43, and present respective inlets 51 at either end of head 25 in relation to direction 43. Channels 50 communicate with each other and, like channels 35, taper as of respective inlet 51 from a width greater than to a width smaller than the distance between surfaces 8 and 9 of group 4.
In actual use, when assembly 4, 6 is fed into station 23 and clamped on to plate 22 by clamping device 22a, with surfaces 12 parallel to directions 28 and substantially coplanar with respective folding devices 33 and 34, and with surface 11 parallel to direction 43 and substantially coplanar with folding devices 48 and 49, head 25 is set to one of its two limit positions, clear of the path of assembly 4, 6 towards station 23, e.g. to the right of assembly 4, 6, as shown in FIG. 1, while each of heads 24 is set to the idle position shown in FIG. 1, downstream from station 23 in relation to direction 21.
At this point, actuators 27 are operated so as to move respective heads 24 in direction 28 and from said idle position into a limit position upstream from station 23 in relation to direction 21. As each head 24 is so moved, folding device 39 engages respective tab 20 and folds it squarely on to respective surface 12; folding device 34 then engages respective tab 19 and folds it squarely in known manner on to respective surface 12; and folding device 33 then engages respective tab 18 and folds it squarely in known manner towards respective surface 12 and on to tabs 19 and 20.
Heads 24 are then restored to the idle position so as not to interfere with head 25, which, upon heads 24 clearing station 23, is moved by actuator 42 in direction 43 and from the FIG. 1 limit position to a further limit position (not shown) to the left of assembly 4, 6 as shown in FIG. 1. As head 25 is so moved, the leading folding devices 48 and 49 provide in known manner for squarely folding tab 16 on to surface 11, and tab 17 on to tab 16, thus completing box 5.
Head 25 is arrested in this position, and is moved back to the FIG. 1 limit position during the next folding cycle.
According to a variation not shown, at least one of heads 24 and 25 may obviously be replaced in known manner by a number of known movable folding devices, each designed to squarely fold a respective tab.
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A method of producing cartons of packets of cigarettes, whereby a blank, folded in a U about a respective group of packets so as to leave three exposed surfaces from each of which at least two tabs of the blank project outwards, is finish-folded, over at least one of the exposed surfaces, by a respective single folding head having a folding device for each tab, and which provides for folding the tabs in the course of one linear movement in a direction parallel to the tabs for folding and to the respective exposed surface, and with the blank maintained stationary, together with the respective group of packets, in a folding station.
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BACKGROUND OF THE INVENTION
The present invention relates generally to the making of elongate sections of fence and the like, and more specifically, to an apparatus and method for making elongate flexible sections of a movable decorative fence which may be placed wherever desirable for landscaping purposes.
At the present time, it has become popular to landscape an area using a small fence consisting of multiple boards or pickets to delineate the boundaries of areas of landscaping. The individual pickets used are typically approximately six inches in length by three inches in width, having a thickness of nominally 3/4 of an inch, and have a substantially rectangular shape with the corners at the top end cut off and are commonly called dog-eared pickets.
While the landscaper may purchase raw wood and make his own pickets, this would involve hand cutting each picket, which would be quite time consuming, and, furthermore, the landscaper would be purchasing the wood in such small quantities that the cost of wood would become excessive. Additionally, if each individual picket was placed to form the desired fence, each picket would need to be placed into the ground at a specific depth and at a specific spacing to provide the aesthetically pleasing view of a regularly spaced fence.
This placement of the individual pickets would also be quite time consuming, and owing to the variations of the soil where the pickets are placed. For example, soft soil would be ineffective to retain the picket in the chosen upright position.
In response to the market demands, several vendors have begun to produce precut lengths of decorative picket fence for sale. A typical precut length of picket consists of the multiple pickets constructed of wood, plastic or other suitable material, disposed along the length of one or more rigid stringers. While the use of such lengths of decorative fencing allows the landscaper to purchase the precut lengths which are readily installed in the selected locations, the use of the rigid stringers limits the use of these precut lengths to straight runs of fencing, and requires the stringers to be cut or broken to produce a corner in the fence.
We have found that it is not necessary to use a rigid stringer to provide the necessary rigidity along the length of a run of decorative fence, but that sufficient rigidity can be provided using a flexible stringer. The use of a flexible stringer allows the fence to be coiled for storage and shipment, thereby enhancing the ease of handling while allowing the fence to be economically packed.
Previously, when such flexible stringer fence was made, it was made manually by spacing the pickets along a work table and manually fastening the wire stringer transversely therealong to form the fence lengths. While this method does produce the fence lengths as desired, it is a very labor intensive method and therefore an expensive method of producing the fence, which negates most of the cost savings in materials that would have accrued owing to the scale of commercial manufacturers. Additionally, manually making fence is a very repetitive, boring, and low skilled work. It is difficult, therefore, for the workers to perform the repetitive task and maintain a sufficient quality standard.
The prior art discloses several devices and methods for attaching a plurality of transverse members along longitudinal stringers. Most of these devices are drawn toward the attachment of transverse members to rigid stringers.
Such devices are exemplified in U.S. Pat. No. 3,763,547, issued Oct. 9, 1973, to Blakeslee for an automatic fastening machine. The Blakeslee apparatus provides a plurality of longitudinal magazines holding a supply of stringers and a transverse magazine holding a supply of transverse members, and a multiple chain drive mechanism for synchronizing the movement of the longitudinal stringers and the transverse members from the magazines to fastening stations where the collection of stringers and transverse members is stopped while the fasteners are inserted. This process is then repeated a fixed number of times, until the longitudinal stringers receive their last transverse member, thus completing the construction of one frame.
U.S. Pat. No. 3,945,549 issued March 23, 1976, to Colson, discloses a somewhat complex apparatus for producing pallets and the like by feeding the transverse members onto the moving longitudinal stringers which are advanced to a nailing station where the movement is stopped, and at least one nail is inserted therein at the juncture of each stringer and transverse member.
U.S. Pat. No. 4,467,951 issued Aug. 28, 1984, to Pagano for Apparatus for Nailing Pickets on Stringers discloses another variant of an apparatus for fastening transverse members to longitudinal stringers. Similarly, Pagano places transverse members on advancing rigid stringers at a predetermined spacing and advances this array to a nailing station. Pagano advances the prior art by movably mounting his nailing guns so that the nailing point of the gun traces an elliptical path allowing the nailing gun to be fired upon contact with the transverse member while moving synchronously therewith, simplifying the timing requirements of the apparatus.
Another variation is disclosed in U.S. Pat. No. 2,016,623, issued to Brooks on Oct. 8, 1935. Brooks discloses a machine for attaching for a multiplicity of transverse members along the length of metal strips while forming the fasteners integral with the metal strips. The Brooks apparatus is a heavy duty unitary device which cuts and forms fastener ears along the length of metal strip and thereafter presses these fastening ears into the plurality of transverse members synchronously carried along a conveyor system. The Brooks machine requires synchronizing the movement of the metal strip to the movement of the plurality of transverse members, and, once set up, appears to be limited to a fixed spacing of transverse members having a fixed width along the length of the metal strip stringer.
SUMMARY OF THE INVENTION
The invention involves an apparatus for feeding individual pickets from a hopper for placement along an elongate flexible stringer and attachment thereto and thence cutting the lengths of fence formed into convenient lengths for packaging and shipment.
The invention disclosed herein is an apparatus for continuous-flow making of lengths of decorative fence. The invention consists of a moving belt endless conveyor for receiving the individual pickets, and transporting the pickets through the apparatus. The pickets are first placed in a storage hopper, located overlying the moving conveyor belt. From the storage hopper, the pickets are individually dispensed in a spaced relationship onto the moving conveyor and carried therefrom to a fastening station. Concurrent with the movement of the pickets, the flexible stringer is dispensed and located along the pickets for attachment thereto. As the pickets pass through the fastening station, their presence is sensed, and used to trigger the insertion of a fastener attaching the flexible stringer to each picket.
As the pickets pass to the bottom of the hopper, the bottom two pickets are segregated from the remaining stack, using two retainers. The one separator further segregates the bottom-most picket, allowing it to fall onto the conveyor belt and be urged forward thereby.
From the fastening station, the fence sections are advanced by the conveyor belt through a guillotine station which is periodically triggered responsive to the movement of the conveyor belt, cutting the fence sections into predetermined lengths. The fence sections are now completed and may be rolled for storage and packaging and shipment.
It is an object of the present invention to provide an apparatus for quickly and accurately producing lengths of landscaping fence.
It is another object of the invention to provide an apparatus wherein the attachment of the stringers to the pickets and the cutting the fence into lengths is synchronous and responsive to movement of the conveyor belt therethrough.
It is another object of the invention to provide an apparatus for making landscaping fence which minimizes the amount of manual labor required.
It is a further object of the invention to provide an apparatus that can reliably feed a single picket onto a moving conveyor belt.
The foregoing and other objects of the invention will become apparent upon reading the following specification, with reference to appended claims and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall side view of the invention in operation.
FIG. 2 is an overhead view of the invention.
FIG. 3 is an enlarged perspective view of the picket feeding hopper portion of the invention.
FIG. 4 is a cross-sectional view of the picket segregating mechanism taken approximately along 4--4 of FIG. 3.
FIG. 5 is a partially exploded perspective view of the stapling station of the invention.
FIG. 6 is a perspective view of the guillotine station of the present invention.
FIG. 7 is an overhead plan view of one picket of the type contemplated for use in the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, where the invention, generally 10, consisting of the hopper station 11, the fastening station 12 and the guillotine station 13 disposed along the length of an endless belt conveyor.
The belt conveyor 14 consists of an endless belt 15 composed of a rubber or elastomeric material of conventional design running from the tail roller 16 over a stabilizing work table 17 past the hopper station 11 and the fastening station 12 to the head roller 18, and returning therefrom to the tail roller 16. The belt is driven by any conventional means, and is preferably driven by an electric motor 19 through a suitable reduction gearing box 20 to drive the tail roller 16, thereby urging the belt 15 into motion. Although the belt 15 may be driven through the head roller 18, it is preferred that the belt 15 be driven through the tail roller 16 to provide a clutching effect should the belt 15 become jammed in operation. Thus, the tail roller drive prophylactically abrogates the need for a separate slip clutch between the electric motor 19 and the belt 15.
A plurality of drive bars 22 are attached to the outer surface of the belt 15 perpendicular to the direction of belt movement and extending slightly less than the full width of the belt 15. The drive bars 22 may be formed of any suitable rigid non-wearing material and thus far have been made of iron. The height of the drive bars 22, as measured from the surface of the belt 15 may be of any height sufficient to carry the pickets 21 along the belt 15 without interfering with the operation of the hopper station 11. It is preferred, however, that the height of the drive bars 22 be slightly less than the height of each picket 21. The width of each drive bar 22 is used to define the spacing between the adjacent pickets 21 and may be varied, depending on the size of the individual picket 21 in use and other aesthetic considerations.
The spacing between the adjacent drive bars 22 is determined based on the width of the pickets 21 being used. Thus, the spacing along the belt 15 of the drive bars 22 will be slightly greater than the width of a picket 21. In practice, it is been found that, as the spacing between the drive bars 22 approaches the width of the picket 21, the pickets 21 will not reliably fall into the designated space, causing missing pickets 21 in the fence or jamming the operation of the machine 10. Additionally, as the spacing between the adjacent drive bars 12 is increased in excess of the width of the pickets 21, the placement of the pickets 21 along the drive belt 15 becomes unreliable and the fence thus produced will have unevenly spaced pickets 21. In practice, it has been found that the preferred spacing between adjacent drive bars 22 is such as to allow the insertion of one picket 21 and an additional space of approximately 11/88 of an inch. Thus, the spacing between two adjacent drive bars 22 is dependent upon the width of the picket 21 being used. When pickets of a different width are selected, it is therefore advantageous to change not only the drive bars 22 but to replace the entire conveyor belt assembly 14 with one adapted for the particular picket width in use.
In addition to the drive bars 22 located along the belt 15, there is also an end bar 23 and a guillotine bar 24. The end bar 23 is effectively a drive bar 22 having a greater width to define the end of one section of fence. The end bar 23 may be formed of any suitable material having a suitable width. It is found to be preferred to form the end bar by using a pair of regular drive bars 22 to form a first and second end bar 23.1, 23.2.
While the two closely spaced bars 23.1 and 23.2 will function to define an end bar and operate reasonably well, there is some interference to hopper station 11 by the pickets 21 attempting to fit the too small a space between the respective end bars 23.1 and 23.2. It is therefore preferable to include a flexible spacer 25 between the two end bars 23.1 and 23.2 to prevent the ingress of a picket therebetween. The flexible spacer 25 may be made from any suitable material and is conveniently constructed of a short length of roller chain having a sufficient height to prevent a picket 21 from entering the space between the end bars 23.1 and 23.2.
The guillotine bar 24 precedes the end bar 23 and is formed identical to any one of the drive bars 22, excepting having a greater length so as the guillotine bar 24 extends beyond the edge of the belt 15, so as its passage actuates the guillotine section 13 using the guillotine actuator 26 located adjacent the bottom or return portion of the belt 15.
The hopper station 11 consists of a "C" shaped hopper 30 extending vertically above the belt 15, having a length and width to fit loosely about the individual pickets 21. The hopper 30 is a sufficient height so as to store a large number of pickets 21 when stacked one upon another. Thus, multiple pickets 21 may be placed within hopper 30 and the pickets 21 are urged downwardly toward the belt 15 through gravitational force.
The "C" shape of the hopper 30 provides an opening slot 31 where the operator can visually determine the amount of pickets 21 remaining in the hopper 30, and add pickets 21 when necessary. At the lower edge of the hopper 30, and adjacent the belt 15, the first picket segregating stop 32 is attached overlying and extending past the end of the hopper and proximate the moving drive bars 22. The first picket stop 32 consists of a settable plate 33 attached to the hopper 30 in a manner allowing upward or downward movement of the settable plate 33. The settable plate 33 may be attached to the hopper conveniently using attachment bolts 34 affixed to the hopper 30, passing through elongate adjustment slots 35 formed in the settable plate 33.
The second part of the first picket stop 32 is a door 35 which is hingedly attached along the lower edge of the settable plate 34 using a hinge 36 extending the length thereof. The door 35 is biased to a vertical position using the spring 37 operating through the door arm 38.
A second picket separator 40 fits abutting the settable plate 33 and within the open slot 31 of the hopper 30 and is mounted attached to the settable plate 33 on the second separator mount 41 affixed to the settable plate 33. The second separator 40 extends downwardly therefrom and angularly inwardly into the hopper 30, having its terminal end 42 spaced approximately one and one-half picket heights above the belt 15.
After placement of the one picket 21 between the respective drive bars 22, moving belt 15 carries the picket past the first hold down 43, which urges the picket 21 downwardly and in an abutting relationship with the belt 15. Thereafter, the one picket 21 is carried to the fastening station 12.
Additionally delivered to the fastening station 12 is the flexible stringer. The flexible stringer may be of any suitable material providing the requisite combination of rigidity and flexibility between the adjacent pickets 21. It has been found in some instances that an elongate sheet of a plastic material such as polyethylene having a suitable thickness provides these necessary characteristics, and thus, may be inserted therein.
In most applications, however, it is preferred to use two elongate wires to form the flexible stringer between the adjacent pickets 21. The stringer wire 44 may be any suitable material and is preferably 19 gauge soft iron wire. FIG. 2 shows the wire spools 45 being located in an offset manner past the tail roller 16 of the apparatus 10. It is understood, however, that the location of the wire spools 45 is unimportant to the invention and they may be located in any convenient location, and are preferably located somewhere near the tail roller 16 so that the path of the stringer wire therefrom can be guided into a reasonably straight path to the fastening station 12. This location allows the passage of the stringer wire 44 through respective first wire guides 46 around the respective ends of the hopper 30 and thence to the fastening station 12.
The fastening station 12, as more clearly shown in FIG. 5, has a second picket hold-down 47 for guiding the pickets 21 downwardly to abut the belt 15, where the stringer wire 44 is attached to each picket 21. While the stringer wire 44 may be attached to each picket 21 using any suitable fastener, it is preferable that staples 48 be used. The staples may be attached using any suitable stapling gun 49, and it is preferred to use a stapling gun 49 such as the Duofast Model BN 1832, which is an air operated stapling gun 49 operated in the open trigger mode. Such stapler guns are available from Duofast Corporation of Franklin Park, Illinois. The stapler 49 is mounted on stapler mount 50, such as Martin-Lewis magazine, also available through Duofast Corporation, which has adapted by addition of a height adjustment screw 51 passing therethrough.
The staples 48 used may be of any suitable size and are preferably quarter inch staples, having a length sufficient to attach the stringer wires 44 without passing entirely through the individual pickets 21. Suitable staples are available from Duofast, and numerous other vendors.
While only one stapler 49 is shown in FIG. 5, it is understood that it is preferred to use two staplers 49, as is shown in FIG. 2.
Each stapler 49 and its respective stapler mount 50 has a mounting bar 52 attached to its respective stapler mount 50. The mounting frame 53 is fixed to the apparatus 10 and extends over the belt 15. The mounting bar 52 is pivotally attached to mounting frame 53, using the removable pin 54, which places the stapler 49 over the belt 15 and the individual pickets 21. The height adjustment screw 51 of the stapler mount 50 extends downwardly therefrom, resting on the second hold down 47. The height adjustment screw 51 is adjustable and used to set the height of the stapler anvil 55 above the picket 21. It has been found necessary to include the height adjustment screw 51 since, owing to variations in the thickness of the pickets 21, the stapler anvil 55 must float above the surface of the picket.
When the anvil 55 is set at too low a height, it will drag upon the surface of the picket 21 and jam the apparatus 10. Conversely, when the anvil 55 is set at too great a height above the surface of the picket 21, the individual staples 48 will not be driven fully into the pickets 21, and will therefore not properly attach the stringer wire 44 thereto.
While it is not necessary, it is preferred to attach each stringer wire 44 to each picket 21 at two locations, using the staples 48. In order to locate the staples 48 properly with respect to each picket 21, the actuation of the stapler 49 must be coordinated with the position of the individual pickets 21. The actuation of each stapler 49 may be readily effected responsive to the passage of each picket 21 using a pair of actuator skis 56, locating riding along the upper surface of the belt 15, such that the position of a picket 21 thereby will urge each actuator ski 56 away from the belt 15, as indicated by arrow (A) in FIG. 5. Thus, as each picket 21 passes the first actuator ski 56.1, the ski 56.1 is urged upwardly away from the belt 15, triggering the stapler 49 to insert a staple 48 at the selected location. As the picket 21 advances, it next trips the second actuator ski 56.2 thereby again triggering the stapler 49 and causing the insertion of a second staple 48 in the picket 21.
The actuation mechanism whereby each ski 56 actuates each stapler 49 involves using micro switches to trigger relays controlling the flow of air to each stapler 49. Such actuating systems are well known in the art and may be readily constructed from commonly available micro switches and relays and are therefore not shown or described in detail.
The thus-constructed fence sections are then carried along with belt 15 past the head roller 18 and into the guillotine section 13. The guillotine section 13 consists of a guillotine frame 60 having a central opening through which the individual pickets 21 forming the fence section pass. After the fence section passes therethrough, the pickets 21 slide along the output table 61 where they are removed for packaging and shipment.
Guillotine frame 60 is a rigid frame containing an anvil 62 and movable cutter blades 63. The cutter blades 63 are attached to the cutter frame 64 which is held in its open position, as shown in FIG. 6, by spring tension using springs, not shown. When actuated, the cutter blades 63 descend to abut the anvil 62, thereby cutting the stringer wire 44 passing therebetween. The guillotine section 13 is actuated responsive to the guillotine bar 24, actuating the guillotine actuator 26, thereby causing the guillotine cylinder 65 to urge the cutter frame and the attached cutter blades 63 downwardly, so as the cutter blade 63 abuts the anvil 62.
The guillotine actuating mechanism 26 includes a micro switch actuated by the passage of the guillotine bar 24, triggering a relay, not shown, to actuate the guillotine cylinder 65. These uses of micro switches and relays are well known in the art, and use readily available micro switches and relays, and the conventional technology thereof, and will not be described in detail.
Thus, each passage of the guillotine bar 24 past the guillotine actuator 26 causes the movement of the guillotine cutter blades, cutting through the stringer wire 44, between the two adjacent pickets 21 formed over the end bar 23 located upon the belt 15, cutting free one section of the fence thus produced.
Should it be desired to produce sections of fence using pickets 21 having a different width, it is necessary thence to only make the adjustments to hopper 30 so as to accept the different width pickets 21 and replace the belt conveyor 14 with a different belt conveyor 14 adapted by having the appropriate spacing between its respective drive bars 22 to accept these pickets 21. The actuation of the staplers 49 will remain responsive to the passage of each picket 21 past each ski 56 and will therefore adjust automatically to pickets of varying widths.
In its operation, the operator fills the hopper 30 using a suitable number of pickets 21, that have been previously cut to size. The stringer wires 44 are then threaded through the first wire guide 46 around the hopper 30 and through the second wire guide 70. A suitable supply of air is then provided for operation of the staplers 49, and the guillotine cylinder 65. The drive motor 19 is then actuated, causing rotation of the tail roller 16 through the reduction gearing 20 and movement of the belt 15 of the belt conveyor 14.
As the belt 15 moves beneath the hopper station 11, the pickets 21 are urged downwardly by gravity to abut the belt. However, the picket can only fall onto the belt between two adjacent drive bars 22. FIG. 4 illustrates the separation and dispensing of one picket onto the belt. For the purpose of explaining the operation of the hopper section 11, the pickets 21 are further identified with the bottom-most picket as 21.1, the second picket is 21.2, the third picket is 21.3, etc. It being understood that the references to the individual pickets is in relationship to the picket position within the hopper 30 stack, and that as one picket 21 is removed by conveyor 14, the pickets move down.
As the belt 15 with its attached drive bars 22 is moved responsive to the motor 19 in the direction shown by arrow (C) on FIG. 4, the bottom-most picket 21.1 first rests upon the upper surface of a drive bar, as indicated at 22.1. As the belt further moves forward, the friction between the drive bar 22.1 and the bottom-most picket 21.1 urges the picket in the direction of the belt, and against the second picket separator 40. As the leading drive bar 22.1 passes the first picket 21.1, the space between the leading drive bar 22.1 and the trailing drive bar 22.2 becomes available to accept the downward motion of the first picket 21.1 and the first picket drops past the terminal end 42 of the second picket separator 40 and into the space between the two drive bars.
The picket thence may be drawn forward by the belt toward the next, or fastening station, 12. In most instances, the bottom-most picket 21.1 will assume a position abutting the belt 15 surface and will therefore pass beneath the door 35 of the first picket separator 32 and on. However, in some instances the picket may not completely fall during the time allowed and the leading edge of the picket 21.1 will be slightly above the surface of the belt 15, which is shown in FIG. 4. Thence, the belt will draw the picket 21 forward, driven by the trailing drive bar 22.2 against the door 35 of the first picket separator 32, urging the door 35 to an open position in phantom. As the door 35 further opens, its bottom edge 39 will rise with relationship to the belt 15 owing to the arcuate movement of the door bottom edge 39, allowing additional space for the first picket 21.1 to pass thereunder. The movement of the door 35 will increase the tension upon the door spring 37 and thus, as the door bottom edge 39 opens to allow passage of the first picket 21.1 thereunder, the door spring 37 will be urging the door 35 toward a closed position and therefore pushing the first picket 21.1 downwardly while closing the door 35.
During this process, the second picket 21.2 is drawn in the same direction as the first picket 21.1 by friction therebetween and will abut against the second picket separator 40, thereby allowing the freer movement of the first picket 21.1, and further segregating the first picket 21.1 from the second picket 21.2 and segregating the second picket 21.2 from the remaining pickets 21 in the hopper 30. This effectively segregates the mass of the stack of pickets 21, 21.3 and upwardly therefrom from the two lower pickets 21.1 and 21.2, allowing the smooth dispensing of the bottom-most picket 21.1 onto the belt 15 without interference from the mass of the numerous pickets 21 stacked thereon.
As each picket 21 is carried along belt 15 from the hopper station 11, it passes first under the first hold down 43 which urges the picket downwardly against the belt 15 surface, preventing the upward movement of the picket 21 from warpage or other non-uniformity of the picket 21 or responsive to the picket 21's interaction with the bottom edge 39 of the door 35.
The pickets 21 thus arrayed are thus carried forward to the fastening station 12 where the wire stringer 44 is attached thereat using staples 48. The belt 15 carries the pickets 21 first under a second hold down 47 where the stringer wire 44 is fed through the second wire guide 70, aligning the stringer wire 44 with the stapler anvil 45, for attachment using the staple 48. The second hold down 47 is hingedly attached to a mount and rides upon the upper surface of each picket 21. Each stapler 49 is likewise pivotally attached through a mount pin 54, and partially overlies the second hold down 47. The height relationship of the stapler 49 and its anvil 55 is controlled by adjusting the height adjustment screw 51, and thus, the stapler 49 and its respective mount 50 ride upon the second hold down 47 and float a fixed distance above the surface of the picket 21. As the picket 21 is advanced, as indicated by the arrow (C), its leading edge first contacts the first ski 56.1 and displaces the ski 56.1 in an upward direction, as indicated by arrow (A). Responsive thereto, the staplers 49 are actuated, driving the respective anvils 55 in a downward direction and inserting staples 48, overlying the respective wire stringers 44 and attaching a stringer wire 44 to the picket 21.
As the belt 15 continues to advance the picket 21, it next contacts the second ski 56.2, which is similarly urged in an upwards direction away from the surface of the belt 15, as indicated by arrow (A), thereby again actuating the staplers 49, causing the placement of a second staple 48 and attaching the respective stringer wires 44 to the picket 21. The cycle as thus described is thence repeated, with the next picket.
As the pickets 21, now a fence section, have been fastened and are carried past the fastening station 12, they are carried thereafter along the length of the work table 17 and past the head roller 18, into the guillotine section 13, and finally to the output table 61.
The pickets normally pass through the opening in the guillotine frame 61 uninterrupted and uneffected, excepting when the end point of a fence section is periodically sensed. The end point of the fence section, which is the space between two adjacent pickets defined by the end bars 23, passes under the guillotine cutters 63, the end bar 23 is disposed to actuate the guillotine actuator 26, thereby causing the cutter blades 63 to descend to the anvil 62, thereby cutting the stringer wires 44 and defining the end of one length of fence. After the guillotine cutters 63 have been actuated and moved downwardly to cut the stringer wires 44, the cutters are returned to their upward, or open, position, and the fence composed of the pickets 21 continues to flow through the opening in the guillotine frame 60, until another length of fence has been measured by the passage of the end bar 23 upon the belt 15, thereby again actuating the guillotine cutters 63.
The fence sections thus produced may be thus rolled or packaged in any other way for shipment from the location.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than the foregoing description to indicate the scope of invention.
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An apparatus and process for making flexible sections of fence having an endless moving belt moving the individual fence pickets therethrough, and hopper stations individually dispensing the pickets onto the moving belt for transport to a fastening station where the fixedly spaced pickets are attached to continuous stringers and transported therefrom where the fence section thus formed is cut in the selected lengths.
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CROSS REFERENCE TO RELATED APPLICATION
This application is based on a provisional application No. 60/483,029, filed Jun. 27, 2003, entitled Through Hub Oil Fill And Vent For Fluid Dynamic Motors, and assigned to the Assignee of this application and incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates generally to spindle motors, and more particularly to filling and venting a fluid dynamic bearing for use with disc drive data storage systems.
BACKGROUND OF THE INVENTION
The recent new environments for usage of disc drive memory systems have intensified design and performance needs including needs for heightened robustness. Besides traditional computing environments, disc drive memory systems are used more recently by devices including digital cameras, digital video recorders, laser printers, photo copiers, jukeboxes, video games and personal music players. Disc drive memory systems store digital information that is recorded on concentric tracks of a magnetic disc medium. Several discs are rotatably mounted on a spindle, and the information, which can be stored in the form of magnetic transitions within the discs, is accessed using read/write heads or transducers. A drive controller is conventionally used for controlling the disc drive system based on commands received from a host system. The drive controller controls the disc drive to store and retrieve information from the magnetic discs. The read/write heads are located on a pivoting arm that moves radially over the surface of the disc. The discs are rotated at high speeds during operation using an electric motor located inside a hub or below the discs. Magnets on the hub interact with a stator to cause rotation of the hub relative to the stator. One type of motor is known as an in-hub or in-spindle motor, which typically has a spindle mounted by means of a bearing system to a motor shaft disposed in the center of the hub. The bearings permit rotational movement between the shaft and the sleeve, while maintaining alignment of the spindle to the shaft. The read/write heads must be accurately aligned with the storage tracks on the disc to ensure the proper reading and writing of information.
Spindle motors have in the past used conventional ball bearings between the sleeve and the shaft. However, the demand for increased storage capacity and smaller disc drives has led to the design of higher recording area density such that the read/write heads are placed increasingly closer to the disc surface. A slight wobble or run-out in disc rotation can cause the disc to strike the read/write head, possibly damaging the disc drive and resulting in loss of data. Conventional ball bearings exhibit shortcomings in regard to these concerns. Imperfections in the raceways and ball bearing spheres result in vibrations. Also, resistance to mechanical shock and vibration is poor in the case of ball bearings, because of low damping. Vibrations and mechanical shock can result in misalignment between data tracks and the read/write transducer. These shortcomings limit the data track density and overall performance of the disc drive system. Because this rotational accuracy cannot be achieved using ball bearings, disc drives currently utilize a spindle motor having fluid dynamic bearings between a shaft and sleeve to support a hub and the disc for rotation. One alternative bearing design is a hydrodynamic bearing.
In a hydrodynamic bearing, a lubricating fluid such as gas or liquid or air provides a bearing surface between a fixed member and a rotating member of the disc drive. Hydrodynamic bearings eliminate mechanical contact vibration problems experienced by ball bearing systems. Further, hydrodynamic bearings can be scaled to smaller sizes whereas ball bearings have smallness limitations. However, hydrodynamic bearings suffer from sensitivity to external loads or mechanical shock events. Fluid can in some cases be jarred out of the bearing by vibration or shock events. Further, bearing fluid is susceptible to evaporation over time. Bearing fluids can give off vaporous components that could diffuse into a disc chamber. This vapor can transport particles such as material abraded from bearings or other components. These particles can deposit on the read/write heads and the surfaces of the discs, causing damage to the discs and the read/write heads as they pass over the discs. It is critical to avoid outgassing of contaminants into the sealed area of the head/disc housing.
Proper sealing is critical in the case of hydrodynamic bearings, and efforts have been made to address these problems. A capillary seal is typically employed to ensure fluid is maintained within a bearing. Here, a fluid meniscus is formed between two walls and capillary attraction retains the fluid. However, tests show that recent radial capillary seal designs fail at about 500 Gs of shock, and fluid leaks through fill holes at about 500 Gs of shock. Additionally, mobile applications require higher resilience to shock events than desktop or enterprise products. Laptop or portable computers can be subjected to large magnitudes of mechanical shock as a result of handling. It has become essential in the industry to require disc drives to be capable of withstanding substantial mechanical shock.
Fluid must be accurately filled into the journal gap and bearing. If excessive fluid is loaded into the bearing, the fluid will escape into the surrounding atmosphere landing on the surface of the disc and degrade the performance of the disc drive. If insufficient fluid is loaded into the bearing, then the physical bearing surfaces could contact, leading to increased wear and eventual failure of the bearing system.
Further, current oil fill and air evacuation methods for fluid dynamic bearings are relatively complex and costly due to the often awkward filling angles and tight clearances. It can be difficult to consistently accurately load fluid into the sharp corners of a shield hole. Further, current oil filling methods can leave a considerable amount of excess oil on the surfaces of the sleeve, which must be subsequently removed through an arduous post-cleaning process. The cleaning process can amount to ten percent of the total assembly cost of the motor.
SUMMARY OF THE INVENTION
A through hub oil fill and air vent is provided for spindle motors. Oil leakage and evaporation from a motor is reduced, potentially extending motor life. In an embodiment, the present invention provides for oil retention under conditions of a shock event of at least 1000 G. The present invention may be used with top cover attach motors, additionally providing a more robust motor.
The process of filling oil into a spindle motor is made easier from a motor set up and tooling perspective. In conventional designs, the hub typically is removed or oil fill is performed prior to installation of the hub. Additionally, in an embodiment, bottom shield motor designs can be filled in a normal orientation, rather than filled at an angle or filled in an inverted orientation. Further, the through hub oil fill design allows for use with a relatively large diameter oil jet fill dispenser head, and further allows for subambient fill methods, ambient fill methods, injection fill methods or micro dispenser fill methods. A measured and controlled amount of oil or hydrofluid can therefore be dispensed into the motor, reducing any variability in the motor filling process.
Features of the invention are achieved in part by forming an oil fill and air vent passageway through a hub. As compared to previous designs, a longer oil diffusion path from within the motor is provided. In previous designs, oil is filled through a shield having a fill hole that extends a shorter length than a hub fill hole. The present invention eliminates the shield as a potential oil leakage source by utilizing a shield without a fill or vent hole.
Moreover, as compared to conventional designs, the present invention positions the oil fill passageway a greater distance from the motor oil reservoir, further reducing oil loss. In an embodiment, the hub oil channel and vent hole have a varying diameter and geometry, and can be angled, utilizing centrifugal forces, further reducing oil leakage. In an embodiment, an additional cavity is employed within the hub, substantially opposite the hub oil fill channel, for maintaining rotor rotational balance.
Other features and advantages of this invention will be apparent to a person of skill in the art who studies the invention disclosure. Therefore, the scope of the invention will be better understood by reference to an example of an embodiment, given with respect to the following figures.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a top plan view of a disc drive data storage system in which the present invention is useful, in an embodiment of the present invention;
FIG. 2 is a sectional side view of a hydrodynamic bearing spindle motor with a rotating hub and an attached shield, in which the present invention is useful;
FIG. 3 is another sectional side view of the hydrodynamic bearing spindle motor of FIG. 2 , illustrating a previously employed fluid filling method through a shield;
FIG. 4 is a further sectional side view of the hydrodynamic bearing spindle motor of FIG. 2 , with an enlarged view of the hub and shield illustrating a fluid fill hole through the hub, in an embodiment of the present invention;
FIG. 5 is a hydrodynamic bearing spindle motor with a shield attached to a thrust plate, in which the present invention is additionally useful; and
FIG. 6 illustrate various diameters and geometries that can be utilized for a fluid fill hole and a balancing hole, in an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Exemplary embodiments are described with reference to specific configurations. Those of ordinary skill in the art will appreciate that various changes and modifications can be made while remaining within the scope of the appended claims. Additionally, well-known elements, devices, components, methods, process steps and the like may not be set forth in detail in order to avoid obscuring the invention.
An apparatus and method is described herein for filling and venting a fluid dynamic bearing motor and other spindle motors. By employing a hub having a fill hole and vent hole, oil leakage and oil evaporation is reduced, and the oil filling process is simplified. The present invention is especially useful with motor designs where a shield is employed adjacent to a sleeve having a fluid reservoir therebetween.
It will be apparent that features of the discussion and claims may be utilized with disc drives, low profile disc drive memory systems (including one-inch disc drive designs), spindle motors, various fluid dynamic bearing designs including hydrodynamic and hydrostatic bearings, and other motors employing a stationary and a rotatable component. Further, embodiments of the present invention may be employed with a fixed shaft and a rotating shaft.
As used herein, the terms “axially” or “axial direction” refers to a direction along a centerline axis length of the shaft (i.e., along axis 440 shown in FIG. 4 ), and “radially” or “radial direction” refers to a direction perpendicular to the centerline length of the shaft.
Referring to the drawings wherein identical reference numerals denote the same elements throughout the various views, FIG. 1 illustrates a typical disc drive data storage device 110 in which the present invention is useful. Clearly, features of the discussion and claims are not limited to this particular design, which is shown only for purposes of the example. Disc drive 110 includes housing base 112 that is combined with cover 114 forming a sealed environment to protect the internal components from contamination by elements outside the sealed environment. Disc drive 110 further includes disc pack 116 , which is mounted for rotation on a spindle motor (described in FIG. 2 ) by disc clamp 118 . Disc pack 116 includes a plurality of individual discs, which are mounted for co-rotation about a central axis. Each disc surface has an associated head 120 (read head and write head), which is mounted to disc drive 110 for communicating with the disc surface. In the example shown in FIG. 1 , heads 120 are supported by flexures 122 , which are in turn attached to head mounting arms 124 of actuator body 126 . The actuator shown in FIG. 1 is a rotary moving coil actuator and includes a voice coil motor, shown generally at 128 . Voice coil motor 128 rotates actuator body 126 with its attached heads 120 about pivot shaft 130 to position heads 120 over a desired data track along arc path 132 . This allows heads 120 to read and write magnetically encoded information on the surfaces of discs 116 at selected locations.
A flex assembly provides the requisite electrical connection paths for the actuator assembly while allowing pivotal movement of the actuator body 126 during operation. The flex assembly (not shown) terminates at a flex bracket for communication to a printed circuit board mounted to the bottom side of disc drive 110 to which head wires are connected; the head wires being routed along the actuator arms 124 and the flexures 122 to the heads 120 . The printed circuit board typically includes circuitry for controlling the write currents applied to the heads 120 during a write operation and a preamplifier for amplifying read signals generated by the heads 120 during a read operation.
FIG. 2 is a sectional side view of a hydrodynamic bearing spindle motor 255 used in disc drives 110 in which the present invention is useful. Again, the present invention is not limited to use with a hydrodynamic spindle motor design of a disc drive, which is shown only for purposes of example. Typically, spindle motor 255 includes a stationary component and a relatively rotatable component, defining a journal gap there between. The stationary component includes shaft 275 that is fixed and attached to base 210 . In an embodiment, shaft 275 is attached to top cover 256 , providing stability to shaft 275 and improving dynamic performance. Thus, in a fixed shaft motor, both upper and lower ends of shaft 275 can be fastened to base 210 and to top cover 256 of the housing, so that the stiffness of the motor and its resistance to shock as well as its alignment to the rest of the system is enhanced.
The rotatable components include sleeve 280 and hub 260 having one or more magnets 265 attached to a periphery thereof. The magnets 265 interact with a stator winding 270 attached to the base 210 to cause the hub 260 to rotate. Magnet 265 can be formed as a unitary, annular ring or can be formed of a plurality of individual magnets that are spaced about the periphery of hub 260 . Magnet 265 is magnetized to form one or more magnetic poles.
The hub 260 is supported on a shaft 275 having a thrust plate 283 on one end. Thrust plate 283 can be an integral part of the shaft 275 , or it can be a separate piece that is attached to the shaft, for example, by a press fit. Thrust plate 283 engages with base 210 at interface 290 . Hub 260 includes a disc carrier member 214 , which supports disc pack 116 (shown in FIG. 1 ) for rotation about shaft 275 . Disc pack 116 is held on disc carrier member 214 by disc clamp 118 . Hub 260 , positioned for rotation about shaft 275 , is situated adjacent to shaft 275 across journal bearing 262 . A fluid, such as lubricating oil or a ferromagnetic fluid fills interfacial regions between shaft 275 and sleeve 280 , thrust plate 283 and sleeve 280 , thrust plate 283 and shield 282 , and between shield 282 and sleeve 280 . While the present figure is described herein with a lubricating fluid, those skilled in the art will appreciate that useable fluids include a lubricating liquid and gas.
Typically, one of shaft 275 and sleeve 280 includes sections of pressure generating grooves, including asymmetric grooves 242 , and symmetric grooves 246 . Asymmetric grooves 242 and symmetric grooves 246 having a pattern including one of a herringbone pattern and a sinusoidal pattern induces fluid flow in the interfacial region and generates a localized region of dynamic high pressure and radial stiffness. As sleeve 280 rotates, pressure is built up in each of its grooved regions and shaft 275 supports hub 260 for constant high speed rotation.
A Shield 282 is radially self-aligned into sleeve 280 . On one end (adjacent to thrust plate 283 ) sleeve 280 locates shield 282 radially, and on another end shield 282 is attached to hub 260 (i.e., laser welded). A constant gap of about 20 to 30 microns is formed between thrust plate 283 and shield 282 . A fluid reservoir 284 is formed between shield 282 and sleeve 280 . Embodiments of the present invention can be utilized with motor designs wherein shield 282 is attached to hub 260 , or alternatively wherein shield 282 is attached to thrust plate 283 , as shown in FIG. 5 . A fluid recirculation path (sleeve passageway 286 ) is formed through sleeve 280 to pass and recirculate fluid through journal bearing 262 . Sleeve passageway 286 is positioned such that one end is placed generally adjacent to a midpoint along shaft 275 and a second end joins recirculation plenum 432 (shown in FIG. 4 ) such that, in one situation, fluid and air may travel along channels on shield 282 toward and along fluid reservoir 284 .
FIG. 3 shows a fluid fill hole previously employed with a fluid dynamic bearing motor design. As illustrated, fluid fill hole 302 is formed through shield 282 . The length of fluid fill hole 302 is determined by the distance across shield 282 . In some cases, a shorter length fill hole is more vulnerable to leakage and evaporation, as well as to a shock event. As shown in FIG. 4 , the present invention provides a longer fluid fill hole 450 than previous designs. Further, fluid fill hole 302 is positioned closer to fluid and a fluid meniscus 316 situated in fluid reservoir 284 , as compared to fluid fill hole 450 of the present invention as shown in FIG. 4 . Therefore, fluid fill hole 302 presents an added opportunity, by reason of closer proximity to a fluid situated in fluid reservoir 284 , for loss of fluid out the fill hole.
Fluid fill and air evacuation processes for fluid dynamic bearings can be relatively complex and costly due in part to the often awkward filling angles and tight clearances. Further, positioning of a spindle motor for fluid filling can be complicated by gravitational effects, thus requiring abnormal or restrictive filling orientations. As shown on the right half of FIG. 3 , components including base 210 are absent in order to position a filling apparatus 310 and filler extension 312 within fluid fill hole 302 . Base 210 and additional components must be removed or the components installed subsequent to filling fluid into spindle motor 255 . A tight filling angle exists and is apparent from the illustrated angle of filling apparatus 310 in FIG. 3 , even with a number of components removed.
Referring to FIG. 4 , another sectional side view of the hydrodynamic bearing spindle motor of FIG. 2 is shown, with an enlarged view of components for focusing on components near fill hole 450 and fluid reservoir 284 . Due to a lower flow resistance and lower pressure in fluid reservoir 284 , compared with other fluid containing areas, fluid is received and retained within fluid reservoir 284 during operating or non-operating shock events. When the motor is spinning and forcing fluid by centrifugal force from reservoir 284 , pumping grooves 424 on thrust plate 283 generate pumping pressure and drive fluid recirculation through the motor. However, when the motor is not spinning and centrifugal force subsides, or during shock events, reservoir 284 can receive fluid from areas including the outer diameter gap 446 of thrust plate 283 and from the journal between shaft 275 and sleeve 280 .
Grooved pumping is employed along the inside diameter (ID) and the outside diameter (OD) of thrust plate 283 . In the case of the ID, spiral pumping grooves 424 generate pumping pressure to drive fluid recirculation and to pump fluid from thrust plate bearing passageway (adjacent to the thrust plate ID) toward shaft 275 , into the journal bearing 262 , when shaft 275 and sleeve 280 are in relative rotational motion. In an embodiment, when the motor is spinning, the fluid flow direction is inward from the bearing of the thrust plate ID 430 , along the journal bearing 262 to journal plenum 412 , through sleeve passageway 286 , to recirculation plenum 432 and then returning to the bearing of the thrust plate ID 430 . Recirculation plenum 432 is defined by a junction joining fluid reservoir 284 , sleeve passageway 286 , thrust plate ID 430 and thrust plate OD gap 346 . The fluid flow direction, in an example, is illustrated by solid lines shown in FIG. 3 . A grooved pumping seal (GPS) 418 is employed in outer diameter gap 446 defined between shield 282 and an OD of thrust plate 283 . GPS 418 pumps fluid from outer diameter gap 446 serving to prevent fluid leakage from the motor. Further, a centrifugal capillary seal (CCS) 316 is employed between sleeve 280 and shield 282 . In an embodiment, the adjacent surfaces of shield 282 and sleeve 280 have relatively tapered surfaces that converge toward recirculation plenum 432 . A meniscus 316 is formed between the tapered surfaces, and fluid within reservoir 284 is forced toward recirculation plenum 432 by centrifugal force when shaft 275 and sleeve 280 are in relative rotational motion.
An embodiment of the present invention is illustrated by fill hole 450 and balancing hole 452 . Fill hole 450 , being extended, withstands a shock event and prevents any fluid from leaking, evaporating or wicking from the motor. That is, fill hole 450 being formed through hub 260 has a longer length than previous fill hole designs through shield 282 , hub 260 having a greater length than shield 282 for forming a fill hole. As spindle motor 255 proceeds through operational cycles, fluid is better retained with an extended fluid fill hole 450 , especially during an air purge cycle. Fill hole 450 provides a longer oil diffusion path from within the motor, extending motor life through improved fluid retainment. In an embodiment, the extended fill hole 450 provides for oil retention under conditions of a shock event of at least 1000 G.
Further, fluid fill hole 450 is positioned a greater distance from fluid and a fluid meniscus situated in fluid reservoir 284 , as compared to fluid fill hole 302 of previous designs as shown in FIG. 3 . Therefore, fluid fill hole 450 further reduces a chance for fluid loss out a fill hole by reason of greater distance from fluid situated in fluid reservoir 284 .
Shield 282 , forming a sealed location, is attached to sleeve 280 at attachment location 402 , in an embodiment of the invention. Fill hole 450 is positioned adjacent to attachment location 402 . Fill hole 450 is positioned without making an angle with a surface of hub 260 . In another embodiment, fill hole 450 is positioned to make a 30 degree angle or an alternative angle with a surface of hub 260 . An angled fill hole opposes escape of fluid during shock since the fluid follows a path of least resistance and an angled fill hole presents greater resistance in comparison to capillary force gradients. In an embodiment, fill hole 450 is angled through hub 260 toward shaft 275 such that when the motor is spinning, centrifugal force aids to retain fluid. Further, the thickness of hub 260 supports various angles and geometries for fill hole 450 . In an embodiment, fill hole 450 is positioned between channels formed on shield 282 (not shown).
Fill hole 450 (also an air vent hole) provides a means to fill a fluid dynamic bearing with fluid by injecting a predetermined amount of fluid into fill hole 450 above capillary seal 316 . In an embodiment, fill hole 450 supports both ambient fluid fill and subambient fluid fill processes for dispensing fluid to spindle motor 255 . In an ambient fill process, fluid is dispensed through, for example, a high precision, neumatically controlled syringe. In a subambient fill process, the fluid dynamic bearing is under vacuum and the fluid is dispensed. Fluid volume is controllable through these fill processes, which is critical for issues including performance and motor life in the case of hydrodynamic bearing spindle motor 255 .
Fluid fill hole 450 allows fluid filling the motor with hub 260 , base 210 and other components in place. Further, fluid fill hole 450 allows spindle motors, including bottom shield motors to be fluid filled in a normal orientation, rather than an angled fluid fill process with an inverted spindle motor orientation as in previous designs such as that shown in FIG. 3 . Further, added space for positioning a fluid dispenser head is provided with the fluid fill hole 450 as compared to previous designs shown in FIG. 3 . As shown, in an embodiment of the present invention, filling apparatus 456 is positioned over the top of the spindle motor, the spindle motor being in a normal orientation, and spindle motor components including the base being previously installed and present during the fill process. Further, filling apparatus 456 is positioned in a non-angled orientation over the spindle motor and filling extension 454 is inserted into fluid fill hole 450 .
FIG. 5 shows a further embodiment of the invention wherein spindle motor 500 employs a shield 520 attached to thrust plate 552 , attached at shield attachment 522 . Hub 554 and sleeve 556 rotate relative to stationary shield 520 , stationary shaft 575 and base 550 . As in previously discussed spindle motor designs, a fluid recirculation path, including sleeve passageway 526 , is formed through sleeve 556 to pass and recirculate fluid through the journal bearing. Also, a fluid reservoir 524 is formed between shield 520 and sleeve 556 .
Fill hole 510 (or air vent hole) provides a means to fill the fluid dynamic bearing motor with fluid. Similar advantages as discussed above are provided by the positioning of fill hole 510 through hub 554 , including an extended fill hole, reduced oil leakage and evaporation from the motor, as well as a simplified oil filling process.
In an embodiment, fill hole 510 further supports a micro dispenser system including a MicroDrop™ fluid fill process, which fills a predetermined volume of fluid with a tightly controlled volume tolerance for spindle motor designs. The MicroDrop™ fill process utilizes a nozzle 530 with a frequency controlled electric element for controlling fluid drop volume (i.e., droplets of 30 μm to 100 μm). Fluid 532 is dispensed from the MicroDrop™ process on an individual droplet sequence and drops are expelled and fly at a velocity of 1.5 to 3 meters per second or more. Thus, fluid from the MicroDrop™ process may be dispensed from a distance, rather than requiring embedding a syringe into the fluid reservoir of the spindle motor. The MicroDrop™ process offers a further advantage by expelling fluid from a non-contact nozzle, rather than from a syringe. With a syringe having a fluid adhering surface, a fluid drop can be undesirably removed from a spindle motor and contaminate areas outside a fluid reservoir.
Referring to FIG. 6 , various diameters and geometries may be utilized for fluid fill hole 450 and balancing hole 452 . Additionally, in an embodiment, two fill holes are employed through hub 260 , and it is to be appreciated that additional numbers of fill hole 450 and balancing hole 452 can be utilized. The through passageway as described herein is one of a fluid fill-hole and an air vent. The various geometries or shapes for fluid fill hole 450 include a rounded end, a rectangular end, and a triangular end, with a smaller diameter passageway extended through hub 260 to the opposite end. It is to be appreciated that the diameter of both fluid fill hole 450 and balancing hole 452 can be varied through the length of hub 260 or can remain a constant diameter. In an embodiment, balancing hole 452 is similarly shaped as fluid fill hole 450 . Balancing hole 452 can either form an opening completely through hub 260 or be formed some length into hub 260 without making an opening completely through hub 260 . In an embodiment, balancing hole 452 is employed for rotor rotational balance.
Further, in an embodiment, fluid fill hole 450 is shaped such that a narrow passageway is positioned distant to the fluid reservoir 284 , and a geometry such as a rounded end is positioned adjacent to the fluid reservoir 284 . This allows any air bubble to burst into the rounded end to retain residual fluid, rather than burst externally from the motor.
Other features and advantages of this invention will be apparent to a person of skill in the art who studies this disclosure. For example, those skilled in the art will appreciate that features of the present invention allows various fluid filling processes including the MicroDrop™ fluid dispenser process. Further, fill hole 450 and balancing hole 452 , having an extended length and allowing various diameters and geometries, may be utilized to provide rotational balance where rotational balance difficulties arise with a spindle motor. Thus, exemplary embodiments, modifications and variations may be made to the disclosed embodiments while remaining within the spirit and scope of the invention as defined by the appended claims.
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A through hub fill hole and air vent having an enlarged fluid diffusion path is provided for spindle motors. Oil leakage and evaporation from a motor is reduced. In an aspect, oil is retained under conditions of at least a 1000 G shock event. In an aspect, the hub fill hole has a varying diameter and geometry, and is angled, further reducing oil leakage. In an aspect, an additional cavity is employed within the hub, for maintaining rotor rotational balance. The process of filling oil into a spindle motor is made easier from a motor set up and tooling perspective. Removal of the hub and other motor components is not necessary for filling a motor. Large diameter oil fill dispenser heads, subambient and ambient fill processes, and micro dispenser fill processes may be utilized. A measured and controlled amount of oil can be dispensed, reducing variability in the motor filling process.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to a hydraulic accumulator device constructed as a diaphragm accumulator, having a diaphragm which separates a pneumatic volume from a hydraulic volume.
SUMMARY OF THE INVENTION
[0002] It is an object of the invention to improve a hydraulic accumulator device constructed as a diaphragm accumulator, having a diaphragm which separates a pneumatic volume from a hydraulic volume, with regard to its efficiency and/or its production costs.
[0003] The object is achieved, in the case of a hydraulic accumulator device constructed as a diaphragm accumulator, having a diaphragm which separates a pneumatic volume from a hydraulic volume, in that the diaphragm is clamped between two holding bodies which have in each case a plurality of depressions and between which the diaphragm is clamped in order to form a plurality of hydropneumatic diaphragm accumulators. The holding bodies are preferably of plate-like form. One of the holding bodies delimits a plurality of pneumatic volumes. The other holding body delimits a plurality of hydraulic volumes. By means of the hydraulic accumulator device according to the invention, it is possible in a simple manner for a hydraulic accumulator field having a multiplicity of hydropneumatic diaphragm accumulators to be realized. In the hydraulic accumulator device according to the invention, it is also possible in a simple manner for a plurality of hydraulic accumulator fields to be combined with one another. The shape and the size of the hydraulic accumulator fields can be adapted in a simple manner to a given installation space.
[0004] A preferred exemplary embodiment of the hydraulic accumulator device is characterized in that the depressions of the holding bodies face toward one another in pairs in order to form in each case one hydropneumatic diaphragm accumulator. The depressions of one holding body delimit a multiplicity of hydraulic volumes. The depressions of the other holding body delimit a multiplicity of pneumatic volumes. The hydraulic volumes and pneumatic volumes are assigned to one another in pairs and are separated from one another by the diaphragm. This yields, with few components, a multiplicity of diaphragm accumulators.
[0005] A further preferred exemplary embodiment of the hydraulic accumulator device is characterized in that the holding bodies are connected to one another between the depressions. The holding bodies preferably bear areally against one another between the depressions. In said areal regions, the holding bodies are connected to one another at least in punctiform fashion for example by means of fastening elements.
[0006] A further preferred exemplary embodiment of the hydraulic accumulator device is characterized in that the depressions have the shape of spherical segments or combs. The spherical segments or combs are outwardly bulged. The combs have for example a hexagonal cross section in the manner of honeycombs.
[0007] A further preferred exemplary embodiment of the hydraulic accumulator device is characterized in that the holding bodies have in each case at least one connector, and/or in that the depressions assigned to in each case one of the holding bodies are fluidically connected to one another. The connector may comprise for example a pneumatic connector duct or a hydraulic connector duct. The individual depressions may be hydraulically or pneumatically connected to one another. The connector ducts may be formed for example by sickle-shaped deformations of the holding bodies.
[0008] A further preferred exemplary embodiment of the hydraulic accumulator device is characterized in that, in the holding bodies, there are formed connecting ducts by means of which depressions assigned to in each case one of the holding bodies are fluidically connected to one another. The connecting ducts may, in a simple manner, be formed by sickle-shaped deformations of the holding bodies.
[0009] A further preferred exemplary embodiment of the hydraulic accumulator device is characterized in that the diaphragm is pre-shaped, reinforced and/or supported in the region of the connecting ducts and/or of the depressions. The diaphragm may for example be supported by supporting rings. On the supporting rings there may be formed supporting collars, the shape of which is adapted to the shape of the depressions.
[0010] A further preferred exemplary embodiment of the hydraulic accumulator device is characterized in that a plurality of hydraulic accumulator fields which comprise in each case two holding bodies and one diaphragm are mechanically and/or fluidically coupled to one another. The mechanical coupling of the hydraulic accumulator fields may be realized for example by means of tie rods. The fluidic coupling of the hydraulic accumulator fields may be realized for example by means of correspondingly designed coupling elements and/or lines.
[0011] A further preferred exemplary embodiment of the hydraulic accumulator device is characterized in that the holding bodies are provided as plate-like main bodies with the depressions. The holding bodies with the plate-like main bodies may be formed from a deep-drawn or stamped sheet-metal material. The holding bodies with the plate-like main bodies may also be formed from a laminated fiber-composite plastics material. The holding bodies may for example be formed as CFRP plates. The abbreviation CFRP stands for a Carbon Fiber Reinforced Plastic composite, that is to say a plastics material reinforced with carbon fibers.
[0012] A further preferred exemplary embodiment of the hydraulic accumulator device is characterized in that suitable support rings are inlaid in the region of the depressions, and/or in that the hydropneumatic diaphragm accumulators are clamped by means of tie rods between two supporting plates.
[0013] A further preferred exemplary embodiment of the hydraulic accumulator device is characterized in that, instead of one continuous diaphragm, a plurality of individual diaphragms are used.
[0014] A further preferred exemplary embodiment of the hydraulic accumulator device is characterized in that support rings are formed into the diaphragm.
[0015] A further preferred exemplary embodiment of the hydraulic accumulator device is characterized in that the diaphragm simultaneously performs the function of a seal between the holding bodies.
[0016] The invention also relates to the use of an above-described hydraulic accumulator device as a load-bearing structural component.
[0017] The invention also relates to a diaphragm and/or a holding body for a hydraulic accumulator device as described above.
[0018] The hydraulic accumulator device according to the invention is particularly suitable for mobile hydraulic applications, in particular for motor vehicles with a hydraulic traction drive and for hydraulic hybrid vehicles. By means of the design according to the invention of the hydraulic accumulator device, the integration thereof into a motor vehicle is simplified. The hydraulic accumulator device may be used as a load-bearing component, for example as a floor plate. The vehicle structure can be stiffened in this way.
[0019] The design according to the invention of the hydraulic accumulator device provides inter alia the advantage that a plurality of individual accumulators can be produced in a simple manner in only one manufacturing step. As a result of the special design and arrangement of the holding bodies and of the diaphragm, it is possible for a hydraulic accumulator device having a plurality of hydropneumatic diaphragm accumulators to be produced from only three simple components. The holding bodies and the diaphragm can be produced in a simple and inexpensive manner. By storing a plurality of storage fields one above the other or adjacent to one another, the hydraulic accumulator device according to the invention can be adapted in a simple manner to a predefined installation space. The depressions in the holding bodies are formed preferably by domed formations with relatively small radii. This provides the advantage that relatively thin-walled materials can be used to produce the holding bodies, which has a positive effect on the weight and the material costs of the hydraulic accumulator device.
[0020] Further advantages, features and details of the invention will emerge from the following description, in which various exemplary embodiments are described in detail with reference to the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In the drawing:
[0022] FIG. 1 is a simplified illustration of a hydraulic accumulator device according to the invention in section;
[0023] FIG. 2 shows a corner of the hydraulic accumulator device from FIG. 1 , in a plan view;
[0024] FIG. 3 shows a similar hydraulic accumulator device to that in FIG. 2 with connecting ducts, in a plan view;
[0025] FIG. 4 shows a detail from FIG. 3 in section ( FIG. 4 a ) and in a plan view ( FIG. 4 b );
[0026] FIG. 5 shows a detail from FIG. 1 in section ( FIG. 5 a ) and in a plan view ( FIG. 5 b ), with a connecting duct formed as a bead;
[0027] FIG. 6 shows a detail from FIG. 1 with a supporting ring;
[0028] FIG. 7 shows the detail from FIG. 6 in a plan view;
[0029] FIG. 8 shows a similar illustration to FIG. 6 , with a modified supporting ring;
[0030] FIG. 9 shows the detail from FIG. 8 in a plan view;
[0031] FIG. 10 shows a similar illustration to FIG. 8 , with a pre-shaped diaphragm;
[0032] FIG. 10 a shows a similar illustration to FIG. 8 , as per a further exemplary embodiment;
[0033] FIG. 11 shows a detail of a hydraulic accumulator device having two hydraulic accumulator fields coupled to one another, in a plan view;
[0034] FIG. 12 shows a hydraulic accumulator field from FIG. 11 with a connected line;
[0035] FIG. 13 shows a detail of a hydraulic accumulator device with three hydraulic accumulator fields coupled to one another, in section;
[0036] FIG. 14 shows an arrangement, optimized with regard to installation space and forces, of two hydraulic accumulator fields one above the other; and
[0037] FIG. 15 shows a hydraulic accumulator device having a plurality of hydraulic accumulator fields which are connected to one another by means of tie rods.
DETAILED DESCRIPTION
[0038] FIGS. 1 and 2 illustrate a detail of a hydraulic accumulator device 1 according to the invention in different views. The hydraulic accumulator device 1 comprises two holding bodies 4 , 5 which are formed in each case from a substantially plate-like main body 8 , 9 . The two plate-like main bodies 8 , 9 are equipped with hemispherical depressions 11 , 12 ; 13 , 14 , in a manner similar to a baking tray for cakes, in particular muffins. The holding bodies 4 , 5 are formed for example from a sheet-metal material. The plate-like main bodies 8 , 9 are outwardly bulged in the region of the depressions 11 , 12 ; 13 , 14 such that the depressions 11 , 12 and 13 , 14 of the two holding bodies 4 , 5 face toward one another.
[0039] Each holding body 4 , 5 is equipped with a multiplicity of depressions 11 , 12 ; 13 , 14 . It can be seen in FIG. 2 that the depressions 11 , 12 are distributed uniformly over the plate-like main body 8 . It can be seen in FIG. 1 that in each case two mutually opposite depressions 11 , 13 and 12 , 14 delimit in each case one substantially spherical volume.
[0040] A diaphragm 16 is clamped between the holding bodies 4 , 5 such that the volumes enclosed by the depressions 11 , 12 and 13 , 14 are divided in each case into a pneumatic volume 21 and a hydraulic volume 22 . The pneumatic volume 21 , like the hydraulic volume 22 , has substantially the shape of a hemisphere owing to the shape of the depressions 11 and 13 .
[0041] The two holding bodies 4 , 5 are fastened to one another, with the interposition of the diaphragm 16 , by means of fastening elements 24 , 25 . The fastening elements 24 , 25 extend through the plate-like main bodies 8 , 9 and the diaphragm 16 perpendicular to the components 8 , 9 and 16 . Here, the fastening elements 24 , 25 are arranged not in the region of the depressions 11 to 14 but rather between these.
[0042] The fastening elements 24 , 25 may for example comprise rivet connection elements or screw connection elements. Alternatively or in addition, the holding bodies 4 , 5 may be connected to one another in punctiform fashion in a cohesive manner, for example by adhesive bonding or welding. The diaphragm 16 is interrupted, or provided with a through hole, in the region of the connection between the holding bodies 4 , 5 .
[0043] The pneumatic volumes 21 of the hydraulic accumulator device 1 are filled with a pneumatic medium, such as gas, during operation. The hydraulic volumes 22 of the hydraulic accumulate device 1 are filled with a hydraulic medium, such as oil, during operation. To be filled, the individual pneumatic volumes 21 and hydraulic volumes 22 at the oil and gas sides must be connected to one another and, via connectors, to the outside.
[0044] FIGS. 3 and 4 illustrate, on the basis of the example of a holding body 34 , that the depressions 11 , 12 or the pneumatic volumes enclosed by the depressions 11 , 12 and the diaphragm are fluidically, that is to say pneumatically, connected to one another by a connecting duct 36 . The pneumatic volume delimited by the depression 11 is connected to a pneumatic volume delimited by a depression 38 by a further connecting duct 37 .
[0045] It can be seen in FIG. 3 that the connecting ducts 36 , 37 are arranged in a uniformly distributed manner between the pneumatic volumes. The holding body 5 which serves for delimiting the hydraulic volumes is preferably of the same design as the holding body 34 with the pneumatic volumes. According to a further aspect of the invention, connecting ducts of the hydraulic volumes may be arranged offset with respect to connecting ducts of the pneumatic volumes so as not to impair the stability of the holding bodies.
[0046] It is indicated in FIG. 5 that the inflow and outflow into and out of the pneumatic volume of the depression 11 can be optimized by virtue of the connecting duct 36 being continued in a bead 40 .
[0047] In FIG. 5 , the diaphragm 16 is illustrated in a state in which it bears at the inside against the depression 11 . In the region of the connecting duct 36 or of the bead 40 , the diaphragm 16 may be clamped in a non-optimum manner between the holding bodies.
[0048] FIGS. 6 to 9 show how the clamping of the diaphragm 16 between the holding bodies 34 and 5 can be improved through the use of supporting rings 41 , 42 ; 45 , 46 .
[0049] In the exemplary embodiment illustrated in FIGS. 6 and 7 , the supporting rings 41 , 42 are designed as simple rings, the diameter of which corresponds to the diameter of the depressions 11 , 12 . The supporting rings 41 , 42 prevent the diaphragm 16 from deforming into the connecting duct 36 .
[0050] In the exemplary embodiment illustrated in FIGS. 8 and 9 , the supporting rings 45 , 46 are additionally provided with a supporting collar 47 , 48 which extends into the depression 11 , 12 . The design of the collars 47 , 48 is adapted to the design of the associated depression 11 , 12 . The supporting collar 47 , 48 prevents the diaphragm 16 from deforming into a bead, as denoted by 40 in FIG. 5 .
[0051] It is indicated in FIG. 10 that the diaphragm need not imperatively have a planar form. In FIG. 10 , there is clamped between the holding bodies 4 , 5 a diaphragm 56 which comprises pre-shaped regions 61 , 62 in the region of the depressions 11 , 12 . The pre-shaped regions 61 , 62 have the shape of a hemisphere which is adapted to the shape of the depression 11 , 12 . Further forms such as for example that shown in FIG. 10 a are also possible.
[0052] FIG. 11 shows that, in a hydraulic accumulator device 71 according to the invention, two or more hydraulic accumulator fields 72 , 73 can be combined with one another in a simple manner. Each hydraulic accumulator field 72 ; 73 comprises a multiplicity of hydropneumatic diaphragm accumulators 74 , 75 ; 76 , 77 . The two hydraulic accumulator fields 72 , 73 are fluidically coupled to one another by means of a coupling element 80 . The coupling element 80 connects two connector ducts 78 , 79 to one another. The connector duct 78 extends from a pneumatic volume or a hydraulic volume of the hydropneumatic diaphragm accumulator 75 . The connector duct 79 extends from a pneumatic volume or hydraulic volume of the hydropneumatic diaphragm accumulator 76 .
[0053] It is shown in FIG. 12 that a line 85 may also be connected to the connector duct 78 of the hydraulic accumulator field 72 by means of a coupling element 84 . The line 85 may be in the form of a hydraulic line or pneumatic line.
[0054] It is indicated in FIG. 13 that, in a hydraulic accumulator device according to the invention, two or more hydropneumatic accumulator fields 91 , 92 , 93 may also be arranged one above the other. In this arrangement of the accumulator fields 91 to 93 one above the other, it is possible for the otherwise unutilized volumes between the individual accumulators to advantageously be utilized as a low-pressure volume. The low-pressure volume may for example be filled with a hydraulic medium which is at low pressure.
[0055] In FIG. 13 , the accumulator field 92 comprises two holding bodies 95 , 96 , between which a diaphragm 98 is clamped. The accumulator field 93 comprises two holding bodies 100 , 101 , between which a diaphragm 103 is clamped. In the region of a depression 105 of the holding body 101 , a line 108 is connected to the illustrated hydraulic accumulator device by means of a coupling element 106 . According to a further aspect of the invention, the diaphragm 103 is provided with a through hole 110 which connects the volume in the depression 105 to the volume in a depression 111 of the holding body 100 . The volume enclosed by the depression 111 is connected via a further coupling element 112 to a volume 114 of the holding body 96 . The volume 114 is in turn connected via a through hole 118 to a volume 115 of the holding body 95 .
[0056] It is shown in FIG. 14 that, in the case of an arrangement of two accumulator fields 121 , 122 one above the other, an existing installation space can be optimally utilized by virtue of the accumulator fields 121 , 122 being arranged offset relative to one another. In the case of the offset arrangement, the hemispheres, formed by the depressions, of the holding bodies can be supported on one another in punctiform fashion. As a result of the stabilization associated with this, the wall thickness of the holding bodies can be reduced. In connection with the offset arrangement of the accumulator fields 121 , 122 , a comb-shaped form of the depressions has proven to be particularly advantageous.
[0057] FIG. 15 illustrates how three accumulator fields 131 to 133 arranged one above the other can be mechanically coupled to one another in a particularly stable manner by means of tie rods 141 to 144 . The tie rods 141 and 142 extend between the holding bodies of the accumulator fields 131 and 133 . The tie rods 143 , 144 extend between two supporting plates 151 , 152 between which the three accumulator fields 131 to 133 are clamped.
[0058] The combinations, illustrated in FIGS. 13 to 15 , of a plurality of accumulator fields in a hydraulic accumulator device according to the invention permit a considerably higher rigidity than a flat plate of the same material. This effect can be even further intensified under pressure. In this way, it is possible for the hydraulic accumulator device according to the invention to be utilized as a load-bearing structure, for example in a motor vehicle. The hydraulic accumulator device may be used as a vehicle floor or as some other structural component in a motor vehicle.
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The invention relates to a hydraulic accumulator device in the form of a membrane accumulator, comprising a membrane ( 16 ) which separates a pneumatic volume from a hydraulic volume. In order to improve said hydraulic accumulator device with respect to the degree of efficiency and/or manufacturing costs, the membrane ( 16 ) is tensioned between two holding bodies ( 4,5 ) which respectively comprise several recesses ( 11 - 14 ) and between which the membrane ( 16 ) is tensioned in order to produce several hydropneumatic membrane accumulators.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the priority of provisional patent application serial No. 60/308,365 filed Jul. 27, 2001.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to methods and devices for providing a stress-relieving joint between a riser and the keel of a floating platform.
2. Description of the Related Art
Deep water floating platforms use risers to communicate production fluid from the sea floor to the floating production platform. Floating platforms have a portion that lies below the surface of the sea. For stability of the platform, it is desired that there be a very deep draft. The spar, for example, is a popular style of floating platform that has an elongated, cylindrical hull portion which, when deployed, extends downwardly a significant distance into the sea. The lowest portion of the submerged hull is referred to as the keel. Currents in the sea tend to move the floating platform laterally across the sea surface. Despite the presence of anchorages, the platform imparts bending stresses to the riser during lateral movement. Localized, or point, stresses are particularly problematic for risers.
One known joint arrangement for use with risers and floating vessels is described in U.S. Pat. No. 5,683,205 issued to Halkyard. Halkyard describes an arrangement wherein a joint means is positioned within a keel opening in the floating vessel to reduce the amount of stress upon a pipe passing through the keel opening. The joint means consists of a radially enlarged sleeve member with an elastomeric annulus at either end that is in contact with both the sleeve member and the pipe. Halkyard's intent is to reduce stress upon the pipe that is imposed by lateral movement of the floating vessel upon the sea. In order to reduce stress, Halkyard contacts the pipe at two points with an elastomeric annulus, which is described as providing a resilient, somewhat yieldable connection. Unfortunately, Halkyard's arrangement is problematic since it permits almost no angular movement of the pipe within the sleeve member. While point stresses upon the pipe are reduced, they are still significant. Further, the pipe is required to bend within the confines of the sleeve. This bending, together with the induced point stresses at either end of the sleeve, place significant strain on the pipe.
The present invention addresses the problems in the prior art.
SUMMARY OF THE INVENTION
Keel joint assemblies are described that permit a degree of rotational movement of a riser within the keel of a floating vessel. The assemblies of the present invention greatly reduce the amount of stress and strain that is placed upon the riser, as well. The present invention describes keel joint assemblies that provide a limiting joint between the riser and the keel opening that permits some angular rotation of the riser with respect to the floating vessel. Additionally, the limiting joint permits the riser to move upwardly and downwardly within the keel opening, but centralizes the riser with respect to the keel opening so that the riser cannot move horizontally with respect to the keel opening.
In described embodiments, the limiting joint is provided by a single annular joint that allows that riser to move angularly with respect to the can. In some embodiments, the keel joint assembly incorporates a cylindrical stiffening can that radially surrounds a portion of the riser and is disposed within the keel opening. In these embodiments, a flexible joint is provided between the can and the riser. Supports or guides may be used to retain the can within the keel opening.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an exemplary riser extending upwardly from the sea floor and through a spar-type floating platform.
FIG. 2 is a schematic side, cross-sectional view of a first exemplary keel joint assembly constructed in accordance with the present invention.
FIG. 3 is a schematic side, cross-sectional view of a second exemplary keel joint assembly constructed in accordance with the present invention.
FIG. 4 is a schematic side, cross-sectional view of a third exemplary keel joint assembly constructed in accordance with the present invention.
FIG. 5 is a schematic side, cross-sectional view of a fourth exemplary keel joint constructed in accordance with the present invention.
FIG. 6 is a schematic side, cross-sectional view of a fifth exemplary keel joint assembly constructed in accordance with the present invention.
FIG. 7 is a schematic side, cross-sectional view of a sixth exemplary keel joint assembly constructed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 generally illustrates a subsea wellhead 10 that has been installed into the sea floor 12 . A riser 14 is connected to the wellhead 10 and extends upwardly through the waterline 16 to a floating platform 18 . The riser 14 is used to transmit production fluids or as a drilling conduit from the wellhead 10 to production facilities (not shown) on the floating platform 18 . The riser 14 is used to provide a closed conduit from the wellhead 10 to the floating platform 18 . The floating platform 18 shown is a spar-type floating vessel that carries production equipment (not shown) on an upper deck 20 . The hull 22 of the platform 18 is a cylinder having flotation chambers within and a central, vertically-oriented passage 24 through which the riser 14 is disposed. It is noted that the configuration for a passage used in floating platforms varies from platform to platform. Sometimes the passage is lined by a cylindrical wall that extends substantially the entire length of the hull. In other platforms, the passage is partially lined by such a wall, and in still other platforms, there is essentially no lining for the passage. The keel 26 is located at the lower end of the hull 22 . A keel joint, indicated generally at 28 , is used to permit axial upward and downward motion as well as angular deflection of the riser 14 with respect to the keel 26 . It is desired that the keel joint 28 be constructed to preclude localized bending stresses in the riser 14 that could damage it, resulting in structural failure of the riser 14 .
Referring to FIG. 2, there is shown a first, and currently most preferred, exemplary keel joint arrangement 30 that can be used as the keel joint 28 to support the riser 14 . The keel joint arrangement 30 includes a stiff cylindrical can 32 that radially surrounds a portion of the riser 14 . The can 32 is retained within and disposed away from the walls of the keel opening or passage 24 by supports or guides 34 that are securely affixed with the hull 22 . While there are only two upper and two lower supports 34 shown in FIG. 2, it should be understood that there are actually more such supports 34 , perhaps four or more upper and four or more lower supports 34 and that the supports are located to surround the circumference of the riser 14 . The supports 34 have rounded, non-puncturing ends 36 to contact the outer wall of the can 32 . It is noted that the supports 34 are not affixed to the can 32 , thereby permitting the can 32 to move upwardly and downwardly within the passage 24 . The keel joint arrangement 30 maybe thought of an “open can” arrangement since the can 32 is affixed to the riser 14 by a stress joint (straight or tapered) 38 proximate the lower end of the can 32 while the upper end 40 of the can 32 is not secured to or maintained in contact with the riser 14 . The exemplary stress joint 38 illustrated consists of a pair of radially enlarged collars 42 that surround the riser 14 and are affixed to the inner radial surface of the can 32 . The collars 42 are shown to be fashioned of metal. However, the collars 42 may also be fashioned of a suitable elastomeric material. The collars 42 may be substantially rigid so as to permit a small amount of angular movement of the riser 14 with respect to the can 32 . Alternatively, the collars 42 may be relatively flexible to permit additional angular movement.
In operation, the riser 14 can move angularly to a degree within the can 32 under bending stresses. Illustrative directions of such relative angular movement are shown in FIG. 2 by arrows 33 about rotation point 35 . During such angular movement, the outer walls of the riser 14 are moved closer to or further away from the inner walls of the keel opening 24 . The stress joint 38 forms a fulcrum. The can 32 is stiff enough that it transfers stresses directly from the stress joint 38 to the supports 34 , thereby preventing any significant stresses from being seen by the upper portion of the riser 14 . Generally, this arrangement allows the upper portion of the riser 14 to have a smaller cross section than the stress joint 38 .
FIG. 3 illustrates an alternative embodiment for a keel joint arrangement 50 that is useful as a keel joint 28 . In the keel joint arrangement 50 , a heavy walled wear sleeve 52 radially surrounds a portion of the riser 14 . The wear sleeve 52 may or may not be secured to the riser 14 in a fixed relation, such as by the use of welding or retaining rings such as are known in the art. A central portion of the wear sleeve 52 has an external annular ring 54 that extends radially outwardly and forms the portion of the sleeve 52 having the largest exterior diameter. The ring 54 presents an outer radial surface that is vertically curved in a convex manner. The outer radial surface of the ring 54 may also be frustoconical in shape. Below the annular ring 54 is a lower inwardly tapered portion 56 . Above the ring 54 is an upper inwardly tapered portion 58 . A partially-lined passage, designated as 24 ′, in the hull 22 of the floating vessel 18 has an open upper end 60 that is outwardly flared for installation purposes. The flare of the upper end assists in guiding the sleeve 52 and ring 54 into place when lowering the riser 14 through the hull 22 . The lower end of the passage 24 has an annular recess 62 that is sized and shaped for the annular ring 54 to reside within. The recess 62 presents an inner surface that is vertically curved in a concave manner so that the outer convex surface of the annular ring 54 can be matingly engaged. If the outer radial surface of the ring 54 is frustoconical in shape, however, the inner surface of the recess 62 will be made complimentary to that frustoconical shape.
In operation, the keel joint arrangement 50 helps to prevent damage to the riser 14 from bending stresses. The wear sleeve 52 is located at the keel 26 where the primary bending stresses are imparted to the riser 14 and, therefore, is designed to absorb most of those stresses and prevent them from being imparted directly to the riser 14 . The interface of the ring 54 and the recess 62 provides a fulcrum wherein the riser 14 can move angularly with respect to the hull 22 . In addition, the elongated upper tapered portion 58 will tend to bear against the length of the passage 24 ′, thereby reducing or eliminating localized, or point, stresses.
Referring now to FIG. 4, there is shown a keel joint arrangement 70 , which is a second alternative embodiment that is useful as the keel joint 28 . The keel joint arrangement 70 employs centralizer assemblies 72 that are secured within the passage 24 of the hull 22 . Preferably, the centralizer assemblies 72 are spaced angularly about the circumference of the passage 24 . In a preferred embodiment, the centralizers 72 comprise hydraulically actuated piston-type assemblies, the piston arrangement being illustrated schematically by two 72 a , 72 b . In practice, the two arms 72 a , 72 b would be nested one within the other in a piston fashion and would be selectively moveably with respect to one another. In an alternative embodiment, the centralizer assemblies 72 comprise hinged assemblies wherein the two arms 72 a , 72 b are hingedly affixed to one another at hinge point 72 c . Actuation of the centralizer assembly in this case would move the arm 72 a angularly with respect to the arm 72 b about the hinge point 72 c , thereby permitting the arm 72 a to be selectively moved into and out of engagement with the riser 14 . The centralizers 72 are energized via hydraulic lines (not shown) to urge the riser toward the radial center of the passage 24 to resist contact between the riser 14 and the passage 24 . The centralizers 72 have rounded, non-puncturing tips 74 that bear upon the riser 14 . Preferably, the non-puncturing tips comprise either wear pads or rollers for engagement of the riser 14 . It is noted that the piston-type centralizer assemblies 72 may be actuated mechanically rather than hydraulically. Also, the centralizer assemblies' attachments to the passage 24 may be softened, such as through use of springs or rubber, in such a way as to decrease bending stresses by yielding to riser deflection. In a further alternative embodiment, the centralizers 72 will comprise members that have a hinged attachment to the passage 24 .
FIG. 5 depicts a third alternative embodiment for the keel joint 28 . Keel joint assembly 90 includes a riser collar 92 that surrounds a portion of the riser 14 proximate the keel 26 . The collar 92 is not affixed to the riser 14 but instead permits sliding movement of the riser 14 upwardly and downwardly through the collar 92 . The collar 92 is generally cylindrical but includes a bulbous central portion 94 and two tapered end portions 96 , 98 . A guide sleeve 100 radially surrounds the collar 92 and features an interior rounded profile 102 that is shaped and sized to receive the bulbous portion 94 of the collar 92 . An exterior landing profile 104 is located at the lower end of the guide sleeve and is shaped and sized to form a complementary fit with a landing profile 106 formed into the keel 26 . The passage 24 ′ is constructed identically to the passage 24 ′ described earlier in that it has an open upper end with an outward flare.
To assemble the keel joint arrangement 90 , the collar 92 and guide sleeve 100 are assembled onto the riser 14 . Then the riser 14 is run through the passage 24 ′ and the landing profile 104 of the guide sleeve 100 is seated into the matching profile 106 in the keel 26 . In operation, the riser 14 can slide upwardly and downwardly within the collar 92 as necessary to compensate for movement of the floating platform 18 . Rotation of the platform 18 with respect to the riser 14 is permitted between the riser 14 and the collar 92 as well as between the collar 92 and the guide sleeve 100 . Angular movement of the riser 14 with respect to the platform 18 is accommodated by rotation of the bulbous portion 94 within the rounded profile 102 of the guide sleeve 100 . Alternatively, a rubberized flex joint of a type known in the art (not shown) might be used to accommodate angular rotation.
A fourth alternative exemplary embodiment for the keel joint 28 is shown in FIG. 6 . Keel joint assembly 110 incorporates a flexible cage assembly to permit relative movement between the riser 14 and the floating vessel 18 . A flexible cage assembly 112 is formed of an inner riser sleeve 114 and an outer keel sleeve 116 . A central cage 118 adjoins the two sleeves 114 , 116 . The cage 118 includes an upper ring 120 , a central ring 122 , and a lower ring 124 . There are a series of upper spokes 126 that radiate upwardly and outwardly from the central ring 122 to the upper ring 124 . There are also a series of lower spokes 128 that radiate outwardly and downwardly from the central ring 122 to the lower ring 124 . The upper and lower spokes 126 , 128 are each arranged in a spaced relation from one another about the circumference of the central ring 122 . The spokes 126 , 128 are fashioned from a material that is somewhat flexible yet has good strength under both tension and compression. It is currently preferred that the spokes 126 , 128 are fashioned of a steel alloy, although other suitable materials may be used. The spokes 126 , 128 are elastically deformable as necessary to allow the riser 14 to move angularly within the passage 24 ′. Angular deflection of the riser 14 results in non-uniform deflection of upper spokes 126 and lower spokes 128 . The upper ring 120 affixes the upper spokes 126 to the outer keel sleeve 116 . The lower ring 124 is not affixed to the outer keel sleeve 116 .
The outer keel sleeve 116 is seated within the passage 24 ′ by means of a landing profile 130 that is shaped and sized to be seated within a complimentary seating profile 132 at the lower end of the passage 24 ′. Locking flanges 134 are secured onto the lower side of the keel 26 to secure the outer keel sleeve 116 in place. In a manner known in the art, the locking flanges 134 may be selectively disengaged, or unlocked, and subsequently retrieved by upward movement of the riser 14 with respect to the passage 24 ′, i.e., by pulling upwardly on the riser string.
During operation, the cage 118 holds the riser 14 in a semi-rigid manner that permits some flexibility. The riser 14 can move angularly with respect to the hull 22 due to the flexibility of the spokes 126 and 128 of the cage 118 . Loading from movement of the riser 14 is transferred by the upper spokes 126 to the keel sleeve 116 which, in turn transfers the loading to the hull 22 . Because the keel sleeve 116 engages the passage 24 ′ of the hull 22 along substantially its entire length, point loading is avoided.
FIG. 7 depicts a fifth alternative embodiment for use as the keel joint 28 . Keel joint arrangement 130 includes an open top can structure, which is shown incorporated into the riser 14 as a sub 132 at is affixed at either end to other riser sections 134 , 136 . The can sub 132 includes a pair of concentric tubular members. The inner tubular member 138 has the same interior and exterior diameters as a standard riser section. The outer tubular member, or can, 140 is coaxial with the inner tubular member 138 and is affixed to the inner tubular member 138 by a flange adapter, or stress joint, 142 that joins the two pieces together proximate the lower end of the sub 132 . While FIG. 7 shows the flange adapter 142 to be an annular metallic collar that is integrally formed into both the inner and outer tubular members 138 , 140 , it might also comprise a separate collar or elastomeric member as well as a flexible casing.
A cylindrical guide sleeve 144 radially surrounds the open top can sub 132 . The guide sleeve 144 is securely affixed to the outer tubular member 140 by, for example, welding. Supports 146 are used to secure the guide sleeve 144 within the passage 24 of the hull 22 . The supports 146 maintain the guide sleeve 144 a distance away from the wall of the passage 24 so that the guide sleeve 144 is substantially radially centered within the passage 24 . The supports 146 are preferably formed of structural beams. The supports 146 are arranged in two tiers, an upper tier and a lower tier, and each tier surrounds the circumference of the passage 24 . The outer tubular member 140 is stiff enough that it transfers stresses directly from the flange adapter 142 to the guide sleeve 144 . Because the guide sleeve 144 and the outer tubular member 140 are affixed along substantially their entire length, point stresses are avoided. In addition, the supports transmit loads or stresses from the guide sleeve 144 to the passage 24 walls. The length of contact between the outer tubular member 140 and the guide sleeve 144 allows for a longer vertical riser stroke than arrangements wherein there is less contact area, such as the arrangement 30 shown in FIG. 2 .
While described in terms of preferred embodiments, those of skill in the art will understand that many modifications and changes may be made while remaining within the scope of the invention.
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Keel joint assemblies are described that permit a degree of rotational movement of a riser within the keel of a floating vessel and greatly reduce the amount of stress and strain that is placed upon the riser, as well. Keel joint assemblies described provide a limiting joint between the riser and the keel opening that permits some angular rotation of the riser with respect to the floating vessel. Additionally, the limiting joint permits the riser to move upwardly and downwardly within the keel opening, but centralizes the riser with respect to the keel opening so that the riser cannot move horizontally with respect to the keel opening. In described embodiments, the limiting joint is provided by a single annular joint that allows that riser to move angularly with respect to the can. In some embodiments, the keel joint assembly incorporates a cylindrical stiffening can that radially surrounds a portion of the riser and is disposed within the keel opening. In these embodiments, a flexible joint is provided between the can and the riser. Supports or guides may be used to retain the can within the keel opening.
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FIELD OF THE INVENTION
[0001] The present invention relates to oxime ether acetate compounds, and in particular, to oxime ether acetate compounds containing phenylpyridine moieties, preparation method therefor and use thereof as an active ingredient in controlling weeds in crops.
BACKGROUND TECHNOLOGY
[0002] Strobilurin fungicides, as a type of highly effective, broad-spectrum, low-toxicity fungicides, have been well developed and applied widely. Oxime ether acetate compounds are a very important type of strobilurins. But till now, the herbicidal activity of oxime ether acetate compounds has been rarely reported.
SUMMARY OF THE INVENTION
[0003] An object of the present invention is to provide oxime ether acetate compounds containing a phenylpyridine moieties that can be used to effectively control noxious weeds at a low dose, preparation method thereof and use thereof in weeding.
[0004] To achieve the above object, the present invention adopts the following technical solutions:
[0005] An oxime ether acetate compound containing a phenylpyridine moiety, having formula (I):
[0000]
[0000] wherein, X is O, S, COO or NH;
R and n represent a substituent on the pyridine ring and the number of substituents respectively, wherein 0≦n≦4, preferably, 0≦n≦3, and n is a natural number, when n=0, it means that the pyridine ring does not contain R, when 0<n≦4, each of the substituents on the pyridine ring (i.e. R) is selected from the group consisting of CH 3 , OCH 3 , Br, Cl, F, CN, CF 3 , NO 2 and OH, and the substituents (i.e. R) on the pyridine ring are same or different;
R′ and n′ represent a substituent on the benzene ring and the number of substituents, wherein 0≦n′≦4, preferably, 0≦n′≦3, and n′ is a natural number, when n′=0, it means that the benzene ring does not contain R′, when 0<n′≦4, each of the substituents on the pyridine ring (i.e. R′) independent from each other is selected from the group consisting of CH 3 , OCH 3 , Br, Cl, F, CN, CF 3 , NO 2 and OH, and the substituents (i.e. R′) on the benzene ring are same or different;
relative to the benzene ring, pyridinyl is positioned at ortho-, meta- or para-position of X on the benzene ring, and relative to the pyridine ring, the substituted phenyl is positioned at ortho-, meta- or para-position of N on the pyridine ring.
[0006] In formula (I), the pyridine ring and the benzene ring can be linked in 9 ways, which is shown as formula (I-1)-formula (I-9).
[0000]
[0000] Wherein, in formula (I-1)˜formula (I-3), relative to the phenyl ring, the pyridinyl group is positioned at ortho-, meta-, para-position of X on the benzene ring respectively; and relative to the pyridine ring, the substituted phenyl group is positioned at ortho-position of N on the pyridine ring;
in formula (I-4)˜formula (I-6), relative to the phenyl ring, the pyridinyl group is positioned at ortho-, meta-, para-position of X on the benzene ring respectively; and relative to the pyridine ring, the substituted phenyl group is positioned at meta-position of N on the pyridine ring;
In formula (I-7)˜formula (I-9), relative to the phenyl ring, the pyridinyl group is positioned at ortho-, meta-, para-position of X on the benzene ring respectively; and relative to the pyridine ring, the substituted phenyl group is positioned at para-position of N on the pyridine ring.
[0007] Preferably, the oxime ether acetate compound in the present invention has formula (I) wherein X is O.
[0008] More preferably, the oxime ether acetate compound in the present invention has formula (I) wherein X is O,
[0000] R is selected from the group consisting of Br, Cl, F, CN, CF 3 and NO 2 ; when 0<n≦4, the substituents (R) on the pyridine ring are same,
R′ on the benzene ring is selected from the group consisting of Br, Cl, F, CN, CF 3 and NO 2 , when 0<n′≦4, the substituents (R′) on the benzene ring are same,
relative to the pyridine ring, the substituted phenyl group is positioned at ortho-, meta- or para-position of N on the pyridine ring, and relative to the benzene ring, the pyridinyl group is positioned at meta-position of X on the benzene ring.
[0009] Furthermore, preferably, the oxime ether acetate compound in the present invention has formula (I) wherein X is O,
[0000] R is selected from Br, Cl, F, CN, CF 3 or NO 2 ; when 0<n≦4, the substituents (R) on the pyridine ring are same,
R′ on the benzene ring is selected from Br, Cl, F, CN, CF 3 or NO 2 , when 0<n′≦4, the substituents (R′) on the benzene ring is same, and
relative to the pyridine ring, the substituted phenyl group is positioned at ortho-position of N on the pyridine ring, and relative to the benzene ring, pyridinyl is positioned at meta-position of X on the benzene ring.
[0000]
TABLE 1
List of synthesized compounds
linking position
X (linking
No. of
of substituted
position of
Com-
phenyl and
X and
pound
pyridine ring
benzene ring)
Rn
R‘n’
1
2
O(2-)
2
3
O(2-)
3
4
O(2-)
4
2
O(3-)
5
3
O(3-)
6
4
O(3-)
7
2
O(4-)
8
3
O(4-)
9
4
O(4-)
10
2
O(2-)
5-Cl
11
2
O(2-)
5-F
12
2
O(2-)
5-Br
13
2
O(2-)
5-CN
14
2
O(2-)
5-NO 2
15
2
O(2-)
5-CF 3
16
2
O(2-)
5-CH 3
17
2
O(2-)
5-OCH 3
18
2
O(2-)
3-OH
19
2
O(3-)
5-C1
20
2
O(3-)
5-F
21
2
O(3-)
5-Br
22
2
O(3-)
5-CN
23
2
O(3-)
5-NO 2
24
2
O(3-)
5-CF 3
25
2
O(3-)
5-CH 3
26
2
O(3-)
5-OCH 3
27
2
O(4-)
5-Cl
28
2
O(4-)
5-F
29
2
O(4-)
5-Br
30
2
O(4-)
5-CN
31
2
O(4-)
5-NO 2
32
2
O(4-)
5-CF 3
33
2
O(4-)
5-CH 3
34
2
O(4-)
5-OCH 3
35
3
O(2-)
5-Cl
36
3
O(2-)
5-F
37
3
O(2-)
5-Br
38
3
O(2-)
5-CN
39
3
O(2-)
5-NO 2
40
3
O(2-)
5-CF 3
41
3
O(2-)
5-CH 3
42
3
O(2-)
5-OCH 3
43
3
O(3-)
5-Cl
44
3
O(3-)
5-F
45
3
O(3-)
5-Br
46
3
O(3-)
5-CN
47
3
O(3-)
5-NO 2
48
3
O(3-)
5-CF 3
49
3
O(3-)
5-CH 3
50
3
O(3-)
5-OCH 3
51
3
O(4-)
5-Cl
52
3
O(4-)
5-F
53
3
O(4-)
5-Br
54
3
O(4-)
5-CN
55
3
O(4-)
5-NO 2
56
3
O(4-)
5-CF 3
57
3
O(4-)
5-CH 3
58
3
O(4-)
5-OCH 3
59
4
O(2-)
2-Cl
60
4
O(2-)
2-F
61
4
O(2-)
2-Br
62
4
O(2-)
2-CN
63
4
O(2-)
2-NO 2
64
4
O(2-)
2-CF 3
65
4
O(2-)
2-CH 3
66
4
O(2-)
2-OCH 3
67
4
O(3-)
2-Cl
68
4
O(3-)
2-F
69
4
O(3-)
2-Br
70
4
O(3-)
2-CN
71
4
O(3-)
2-NO 2
72
4
O(3-)
2-CF 3
73
4
O(3-)
2-CH 3
74
4
O(3-)
2-OCH 3
75
4
O(4-)
2-Cl
76
4
O(4-)
2-F
77
4
O(4-)
2-Br
78
4
O(4-)
2-CN
79
4
O(4-)
2-NO 2
80
4
O(4-)
2-CF 3
81
4
O(4-)
2-CH 3
82
4
O(4-)
2-OCH 3
83
2
O(3-)
3-CH 3
84
2
O(3-)
4-CH 3
85
2
O(3-)
6-CH 3
86
2
O(3-)
3-CF 3
87
2
O(3-)
4-CF 3
88
2
O(3-)
6-CF 3
89
2
O(3-)
3-NO 2
90
2
O(3-)
4-NO 2
91
2
O(3-)
6-NO 2
92
2
O(3-)
3-Cl
93
2
O(3-)
4-Cl
94
2
O(3-)
6-Cl
95
2
O(3-)
3-CN
96
2
O(3-)
4-CN
97
2
O(3-)
6-CN
98
2
O(3-)
3,5-Cl,Cl
99
2
O(3-)
3,5,6-Cl,Cl,Cl
100
2
O(3-)
5,6-Cl,Cl
101
2
O(3-)
3-Cl, 5-CF 3
102
2
O(3-)
3-Cl, 5-NO 2
103
2
O(3-)
3-NO 2 , 5-Cl
104
2
O(3-)
3-NO 2 , 5-Br
105
2
O(3-)
3-NO 2 , 6-Cl
106
2
O(3-)
3-NO 2 , 6-Br
107
2
O(3-)
3-CN, 4-CH 3 , 6-Cl
108
2
O(3-)
6-COOEt
109
3
O(3-)
2-Cl, 5-NO 2
110
4
O(3-)
3,5-Cl,Cl
111
2
O(3-)
4-Cl
112
2
O(3-)
4-CF 3
113
2
O(3-)
4-NO 2
114
2
O(3-)
4-CN
115
2
O(3-)
4-CH 3
116
2
O(3-)
2,6-F,F
117
2
NH(3-)
118
2
O(4-)
3-CH 3
119
2
O(4-)
4-CH 3
120
2
O(4-)
6-CH 3
121
2
O(4-)
3-CF 3
122
2
O(4-)
4-CF 3
123
2
O(4-)
6-CF 3
124
2
O(4-)
3-NO 2
125
2
O(4-)
4-NO 2
126
2
O(4-)
6-NO 2
127
2
O(4-)
3-Cl
128
2
O(4-)
4-Cl
129
2
O(4-)
6-Cl
130
2
O(4-)
3-CN
131
2
O(4-)
4-CN
132
2
O(4-)
6-CN
133
2
O(4-)
3,5-Cl,Cl
134
2
O(4-)
3,5,6-Cl,Cl,Cl
135
2
O(4-)
5,6-Cl,Cl
136
2
O(4-)
3-Cl, 5-CF 3
137
2
O(4-)
3-Cl, 5-NO 2
138
2
O(4-)
3-NO 2 , 5-Cl
139
2
O(4-)
3-NO 2 , 5-Br
140
2
O(4-)
3-NO 2 , 6-Cl
141
2
O(4-)
3-NO 2 , 6-Br
142
2
O(4-)
3-CN, 4-CH 3 , 6-Cl
143
2
O(4-)
6-COOEt
144
2
O(4-)
2-Cl, 5-NO 2
145
2
O(4-)
3,5-Cl,Cl
146
2
O(4-)
4-Cl
147
2
O(4-)
4-CF 3
148
2
O(4-)
4-NO 2
149
2
O(4-)
4-CN
150
2
O(4-)
4-CH 3
151
2
O(4-)
2,6-F,F
152
2
NH(4-)
153
2
O(2-)
3-CH 3
154
2
O(2-)
4-CH 3
155
2
O(2-)
6-CH 3
156
2
O(2-)
3-CF 3
157
2
O(2-)
4-CF 3
158
2
O(2-)
6-CF 3
159
2
O(2-)
3-NO 2
160
2
O(2-)
4-NO 2
161
2
O(2-)
6-NO 2
162
2
O(2-)
3-Cl
163
2
O(2-)
4-Cl
164
2
O(2-)
6-Cl
165
2
O(2-)
3-CN
166
2
O(2-)
4-CN
167
2
O(2-)
6-CN
168
2
O(2-)
3,5-Cl,Cl
169
2
O(2-)
3,5,6-Cl,Cl,Cl
170
2
O(2-)
5,6-Cl,Cl
171
2
O(2-)
3-Cl, 5-CF 3
172
2
O(2-)
3-Cl, 5-NO 2
173
2
O(2-)
3-NO 2 , 5-Cl
174
2
O(2-)
3-NO 2 , 5-Br
175
2
O(2-)
3-NO 2 , 6-Cl
176
2
O(2-)
3-NO 2 , 6-Br
177
2
O(2-)
3-CN, 4-CH 3 , 6-Cl
178
2
O(2-)
6-COOEt
179
2
O(2-)
2-Cl, 5-NO 2
180
2
O(2-)
3,5-Cl,Cl
181
2
O(2-)
4-Cl
182
2
O(2-)
4-CF 3
183
2
O(2-)
4-NO 2
184
2
O(2-)
4-CN
185
2
O(2-)
4-CH 3
186
2
O(2-)
2,6-F,F
187
2
NH(2-)
Note:
In Table 1, the numbering rules of benzene ring and pyridine ring are as follows: on the pyridine ring, the position of N is numbered as No. 1 position, and number the other positions according to the sequence which makes the position of substituted phenyl have the smallest number; and on the benzene ring, the position of pyridinyl is numbered as No. 1 position, then number the other positions according to the sequence which makes the position of X have the smallest number.
[0010] The present invention also provides a method for preparing the oxime ether acetate compound containing a phenylpyridine moiety, which comprises the following steps:
[0011] (1) Preparation of a compound of formula (II) (as shown in scheme 2: Mixing a compound of formula (IV), a compound of formula (V), an alkaline substance A, a palladium catalyst and a solvent A; subjecting the mixture to a reaction at the temperature ranging from −10° C. to the reflux temperature for 0.5-20 hours to obtain a reaction solution A; post-treating the solution A to obtain a compound of formula (II); in which the alkaline substance A is selected from the group consisting of potassium carbonate, potassium phosphate, potassium hydroxide, potassium t-butoxide and cesium fluoride; the palladium catalyst is selected from the group consisting of palladium chloride, palladium acetate, tetrakis (triphenyl phosphine) palladium, palladium triphenylphosphine acetate and [1,1′-bis (diphenylphosphino) ferrocene] dichloropalladium; the solvent A is selected from the group consisting of isopropyl alcohol, ethylene glycol, glycerol, ethanol, water, tetrahydrofuran, dioxane, toluene, xylene, PEG2000, and any combination thereof;
[0012] (2) Preparation of the compound of formula (I) (as shown in scheme 1): Mixing the obtained compound of formula (II), an alkaline substance B, a phase transfer catalyst and a solvent B; subjecting the mixture to a reaction at the temperature ranging from −10° C. to the reflux temperature for 0.1-2 hours; then adding a compound of formula (III), continuing to react at the temperature ranging from −10° C. to the reflux temperature for 0.5-20 hours to obtain a reaction solution B; and post-treating the solution B to obtain the compound of formula (I); in which, the alkaline substance B is selected from the group consisting of sodium hydride, sodium methoxide, tert-butyllithium, sodium hydroxide, potassium hydroxide, potassium carbonate and sodium carbonate; the phase transfer catalyst is selected from the group consisting of n-butyl ammonium bromide and 18-crown-6; and the solvent B is selected from the group consisting of N,N-dimethylformamide; N,N-dimethylacetamide; tetrahydrofuran, acetonitrile, acetone, methylene chloride, dimethyl sulfoxide, and any combination thereof.
[0013] In preparation step (1) of the present invention, it is recommended that, the mole ratio of the compound of formula (IV) to the compound of formula (V) ranges from 1:1 to 1:2, the mole ratio of the compound of formula (IV) to the alkaline substance A ranges from 1:2 to 1:3, the mole ratio of the compound of formula (IV) to the palladium catalyst ranges from 1:0.01 to 1:0.2; and the ration of the solvent A to the compound of formula (IV) ranges from 20 mL/g to 70 mL/g.
[0014] The reaction solution A is post-treated as follows: after completion of the reaction, the solvent is removed from the solution A by distillation under reduced pressure, then water is added to the residue, the mixture is extracted with ethyl acetate, the organic phase is dried with anhydrous magnesium sulfate, then filtered, and the filtrate is concentrated and dried to obtain the compound of formula (II).
[0015] In preparation step (2) of the present invention, it is recommended that, the mole ratio of the compound of formula (II) to the compound of formula (III) ranges from 1:1 to 1:2, the mole ratio of the compound of formula (II) to the alkaline substance B ranges from 1:1 to 1:3, the mole ratio of the compound of formula (II) to the phase transfer catalyst ranges from 1:0.01 to 1:0.2; and the ratio of the solvent B to the compound of formula (II) ranges from 20 mL/g to 30 mL/g.
[0016] The reaction solution B is post-treated as follows: after completion of the reaction, water and ethyl acetate are added into the reaction B for extraction, the combined ethyl acetate phase is reversely extracted by saturated brine, then the aqueous phase is discarded, the organic phase is dried, filtered and desolventized; then the resultant concentrate is subjected to silica gel column chromatography; use the petroleum ether/acetone mixed solvent with a volume ratio ranging from 1:1 to 30:1 as the eluent, the eluate containing the target compound is collected, concentrated and dried to obtain the compound of formula (I).
[0000]
[0000]
[0017] In the formula (III), L represents a leaving group and is Cl or Br. The compound of formula (III) can be prepared according to the method in prior art (refer to DE10017724, CN1793115A, CN101941921A, CN100357263C). In the formula (II), (IV) or (V), R and n represent a substituent on the pyridine ring and the number of substituents respectively, wherein 0≦n≦4, preferably, 0≦n≦3, and n is a natural number, when n=0, it means that the pyridine ring does not contain R, when 0<n≦4, each of the substituents on the pyridine ring independent from each other is selected from CH 3 . OCH 3 , Br, Cl, F, CN, CF 3 , NO 2 or OH, and the substituents on the pyridine ring are same or different; R′ and n′ represent a substituent on the benzene ring and the number of substituents, wherein 0≦n′≦4, preferably, 0≦n′≦3, and n′ is a natural number, when n′=0, it means that the benzene ring does not contain R′, when 0<n′≦4, each of the substituents on the pyridine ring independent from each other is selected from CH 3 , OCH 3 , Br, Cl, F, CN, CF 3 , NO 2 or OH, and the substituents on the benzene ring are same or different. In the formula (II) or (V), X is O, S, COO or NH. In the formula (II), relative to the benzene ring, pyridinyl is positioned at ortho-, meta- or para-position of XH on the benzene ring, and relative to the pyridine ring, the substituted phenyl is positioned at ortho-, meta- or para-position of N on the pyridine ring.
[0018] The letter A in the alkaline substance A, solvent A, and reaction solution A, and the letter B in the alkaline substance B, solvent B, and reaction solution B have no particular meanings, which are only used to mark or distinguish the alkaline substance, solvent or reaction solution in different reaction steps, to avoid confusion.
[0019] The oxime ether acetate compound containing a phenylpyridine moiety in the present invention can be used for weeding in crops, the use is as follows: the oxime ether acetate compound containing a phenylpyridine moiety, as the active ingredient of a herbicide, is used for controlling and killing broadleaf weeds and grass weeds. The oxime ether acetate compound containing a phenylpyridine moiety in the present invention can be further prepared to preparations such as wettable powders, suspensions, creams, or water-dispersible granules, and the herbicidal activity of such compounds can be evaluated using the plate count method or potted plants live body test method. Results show that, the oxime ether acetate compound containing a phenylpyridine moiety is particularly suitable for the fields of crops such as corn and wheat, etc., and especially for inhibiting the growth of the weeds in the farmland such as mustard, Beckmannia syzigachne, chickweed, bluegrass, small quinoa, Polypogon grass, Abutilon, crabgrass, Amaranthus retroflexus, barnyard grass, Eclipta, dog point, etc.
[0020] Herbicidal activity assay results of the present invention show that: Compared with the clear water control, 30 days after postemergence spraying with compounds 19, 27, 83, 85, 98, 99, 101, 112, 120, 133 at a dose of 150 g a.i./ha, they exhibit inhibitory activity on the growth of broadleaf weeds such as mustard, small quinoa, Abutilon, Amaranthus retroflexus and Eclipta prostrate, but they almost have no activity on grass weeds such as crabgrass, dog point, etc.; in which compounds 101 and 103 exhibit inhibition rate up to 100% on the growth of broadleaf weeds such as mustard, small quinoa, Abutilon, Amaranthus retroflexus and Eclipta prostrate.
[0021] The results of screening tests for the herbicidal activity of compounds 101 and 133 show that, postemergence herbicide treatment is carried out at a dose of 150, 75, 37.5 g a.i./ha, and compounds 101 and 103 show an efficiency of 97.5˜100% on the amaranthus retroflexus and Eclipta prostrate, and compound 133 shows an efficiency of 100% on the Abutilon, but showed not good activity or no activity on crabgrass, barnyard grass, dog point; when the pre-emergence soil treatment is carried out at a dose of 150 g a.i./ha, compounds 101 and 133 have good activity on broad-leaved weeds, but not good activity on grass weeds; when the dose is lowered, they showed significantly decreased activity or no activity on 6 kinds of weed targets.
[0022] Safety studies show that, it is safer for corns and barleys when compounds 101 and 133 are used in post-emergence spray treatment.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0023] Representative embodiments are detailed below, but they should not be understood as limiting the scope of the present invention.
[0024] The content of products below is measured by HPLC. The detection conditions are as follows:
[0025] Instruments: Shimadzu® LC-10AT; chromatographic column: Hypersil BDS C 18 , 4.6 mm×150 mm, 5 μm; mobile phase: methanol/water=60:40; flow rate: 0.8 ml/min; detection wavelength: 254 nm; injection volume: 2 μL.
Example 1
Preparation of Compound 4 in Table 1
[0026]
Synthesis of 3-(2-pyridinyl) phenol (4-C)
[0027] 3-hydroxyphenylboronic acid (formula 4-A, 20 mmol, 2.77 g), 2-bromopyridine (formula 4-B, 10 mmol, 1.58 g), potassium phosphate (30 mmol, 6.39 g), palladium acetate (0.2 mmol, 45 mg), isopropanol (50 ml) and water (50 ml) were added to a 250 ml, three-necked reaction flask successively, heated to 80° C. to react for 6 hours. When the reaction was finished, isopropanol was removed by rotary evaporation and ethyl acetate (40 ml×3) was added for extraction, then the obtained organic phase was dried, filtered, desolventized, crystallized and dried to obtain 1.32 g of pale yellow solid, i.e. compound 4-C, with the content of 98.6% (HPLC) and the yield of 76.1%.
Synthesis of Compound (4)
[0028] 3-(2-pyridyl) phenol (formula 4-C, 2 mmol, 342 mg), NaH (60 wt %, 2 mmol, 80 mg), tetra-n-butylammonium bromide (0.02 mmol, 6.4 mg) and acetonitrile (10 ml) were added to a 100 ml three-necked reaction flask, heated to 64° C. to stir for half an hour, and then (E)-2-(2′-chloro-methylphenyl)-2-carbonyl methyl acetate-O-methyl oxime (2.4 mmol, 580 mg) was added, heated to reflux temperature to react for 3-6 hours. When the reaction was finished, acetonitrile was removed by rotary evaporation, and ethyl acetate (30 ml×3) and water (30 ml) were added for extraction, the obtained organic phase was dried with anhydrous magnesium sulfate for 2 hours, then suction filtered and desolventized to obtain a crude product. The crude product was subjected to Silica gel column chromatography using the mixture of petroleum ether and acetone (V/V=10:1) as the mobile phase, and the eluent containing the target compound was collected, concentrated and dried to obtain 0.40 g of pale yellow oily liquid, i.e. the target compound 4, with the content of 96.5% (HPLC) and the yield of 51.7%.
[0029] 1 H NMR (500 MHz, CDCl 3 ) δ 8.70 (m, 1H), 7.76 (td, J=7.7, 1.8 Hz, 1H), 7.71 (d, J=8.0 Hz, 1H), 7.61-7.57 (m, 3H), 7.49-7.34 (m, 3H), 7.26-7.23 (m, 2H), 6.96 (ddd, J=8.2, 2.6, 0.8 Hz, 1H), 5.06 (s, 2H), 4.04 (s, 3H); IR (KBr): v max (cm −1 ) 2943, 1729, 1586, 1456, 1300, 1212, 1069, 1018, 956, 771, 740, 693; MS (ESI): m/z (%)=377.20 [M+1].
Example 2
Preparation of Compound 47 in Table 1
[0030]
Synthesis of 3-(2-nitro-5-pyridinyl) phenol (47-C)
[0031] 3-hydroxyphenyl boronic acid (formula 47-A, 15 mmol, 2.08 g), 3-bromo-5-nitropyridine (formula 47-B, 10 mmol, 2.03 g), potassium phosphate (25 mmol, 5.33 g), palladium acetate (0.2 mmol, 45 mg), ethylene glycol (50 ml) and water (50 ml) were successively added to a 250 ml, three-necked reaction flask to react for 6 hours under the temperature of −10° C. When the reaction was finished, the solution was extracted with ethyl acetate (40 ml×3), then reversely extracted with saturated brine (40 ml×3), the organic phase was dried, filtered, desolventized, crystallized and dried to obtain 1.67 g of pale yellow solid, i.e. compound 47-C, with the content of 96.5% (HPLC) and the yield of 74.6%.
Synthesis of Compound (47)
[0032] 3-(2-nitro-5-pyridinyl) phenol (formula 47-C, 2 mmol, 432 mg), NaH (60 wt %, 2.4 mmol, 96 mg), 18-crown-6 (0.1 mmol, 27 mg) and 10 ml DMF (10 ml) were added to a 100 ml three-necked reaction flask, stirred at −10° C. for half an hour, and then (E)-2-(2′-chloro-methylphenyl)-2-carbonyl methyl acetate-O-methyl oxime (2.4 mmol, 580 mg) was added to continue to react for 3-6 hours. When the reaction was finished, the solution was extracted with ethyl acetate (30 ml×3) and water (30 ml), and the combined organic phase was reversely extracted with saturated brine (30 ml×3), the organic phase was dried, suction filtered, and desolventized to obtain a crude product. The crude product was subjected to Silica gel column chromatography using the mixture of petroleum ether and acetone (V/V=15:1) as the mobile phase, and the eluent containing the target compound was collected, concentrated and dried to obtain 0.52 g of pale yellow solid, i.e. the target compound 47, with the content of 99.2% (HPLC) and the yield of 61.2%.
[0033] 1 H NMR (500 MHz, CDCl 3 ) δ 8.38-8.34 (m, 2H), 7.59-7.54 (m, 2H), 7.50-7.49 (m, 1H), 7.39 (d, J=1.7 Hz, 1H), 7.33 (td, J=8.1, 2.4 Hz, 2H), 7.22 (s, 1H), 7.14-7.11 (m, 1H), 6.89 (ddd, J=8.2, 2.5, 0.9 Hz, 1H), 5.01 (s, 2H), 4.02 (s, 3H), 3.83 (s, 3H); MS (ESI): m/z (%)=421.96 [M+1].
Example 3
Preparation of Compound 48 in Table 1
[0034]
Synthesis of 3-(2-trifluoromethyl-5-pyridyl) phenol (Formula 48-C)
[0035] 3-hydroxyphenyl boronic acid (formula 48-A, 12 mmol, 1.66 g), 2-bromo-5-trifluoromethyl-pyridine (formula 48-B, 10 mmol, 2.26 g), potassium phosphate (25 mmol, 5.33 g), palladium acetate (0.1 mmol, 23 mg), THF (50 ml) and water (50 ml) were successively added to a 250 ml, three-necked reaction flask, heated to reflux temperature to react for 6 hours. When the reaction was finished, THF was removed by rotary evaporation and ethyl acetate (40 ml×3) was added for extraction, dried, filtered, desolventized, crystallized and dried to obtain 2.10 g of pale yellow solid, i.e. compound of formula 48-C, with the content of 98.2% (HPLC) and the yield of 86.6%.
Synthesis of Compound (Formula 48)
[0036] 3-(2-trifluoromethyl-5-pyridyl) phenol (formula 48-C, 2 mmol, 478 mg), NaOH (3 mmol, 120 mg), 18-crown-6 (0.2 mmol, 53 mg) and acetone (10 ml) were added to a 100 ml, three-necked reaction flask, heated to reflux temperature to react for half an hour, then (E)-2-(2′-chloro-methylphenyl)-2-carbonyl methyl acetate-O-methyl oxime (2.4 mmol, 580 mg) was added, cooled down to 60° C. to react for 3-6 hours. When the reaction was finished, acetonitrile was removed by rotary evaporation and ethyl acetate (30 ml×3) and water (30 ml) were added for extraction, the organic phase was dried, suction filtered, and desolventized to obtain a crude product. The crude product was subjected to Silica gel column chromatography using the mixture of petroleum ether and acetone (V/V=18:1) as the mobile phase, and the eluent containing the target compound was collected, concentrated and dried to obtain 0.58 g of pale yellow solid, i.e. the target compound 48, with the content of 98.8% (HPLC) and the yield of 64.5%.
[0037] 1 H NMR (500 MHz, CDCl 3 ) δ 8.91 (s, 1H), 8.01 (d, J=8.0 Hz, 1H), 7.76 (d, J=8.1 Hz, 1H), 7.57 (d, J=7.4 Hz, 1H), 7.47 (td, J=7.5, 1.4 Hz, 1H), 7.43 (ddd, J=13.8, 9.1, 4.6 Hz, 2H), 7.24 (dd, J=7.5, 1.3 Hz, 1H), 7.19 (d, J=7.6 Hz, 1H), 7.11 (s, 1H), 7.00 (dd, J=8.3, 2.1 Hz, 1H), 5.05 (s, 2H), 4.03 (s, 3H), 3.84 (s, 3H); MS (ESI): m/z (%)=445.11 [M+1].
Example 4
Preparation of Compound 86 in Table 1
[0038]
Synthesis of 3-(2-trifluoromethyl-5-pyridyl) phenol (Formula 86-C)
[0039] 3-hydroxyphenyl boronic acid (formula 86-A, 12 mmol, 1.66 g), 2-bromo-5-trifluoromethyl-pyridine (formula 86-B, 10 mmol, 2.26 g), potassium carbonate (25 mmol, 3.45 g), palladium acetate (0.5 mmol, 110 mg), dioxane (50 ml) and water (50 ml) were successively added to a 250 ml, three-necked reaction flask, heated for reflux temperature to react for 6 hours. When the reaction was finished, dioxane was removed by rotary evaporation and ethyl acetate (40 ml×3) was added for extraction, the organic phase was dried, filtered, desolventized, crystallized and dried to obtain 1.94 g of pale yellow solid, i.e. compound of formula 86-C, with the content of 99.1% (HPLC) and the yield of 80.6%.
Synthesis of Compound (Formula 86)
[0040] 3-(2-trifluoromethyl-5-pyridyl) phenol (formula 86-C, 2 mmol, 478 mg), K 2 CO 3 (4 mmol, 552 mg), 18-crown-6 (0.2 mmol, 53 mg) and THF (10 ml) were added to a 100 ml, three-necked reaction flask, heated to reflux temperature to react for half an hour, and then (E)-2-(2′-chloro-methylphenyl)-2-carbonyl methyl acetate-O-methyl oxime (2.4 mmol, 580 mg) was added to continue the reaction at reflux temperature for 3-6 hours. When the reaction was finished, THF was removed by rotary evaporation and ethyl acetate (30 ml×3) and water (30 ml) were added for extraction, the organic phase was dried, suction filtered, desolventized to obtain a crude product. The crude product was subjected to Silica gel column chromatography using the mixture of petroleum ether and acetone (V/V=18:1) as the mobile phase, and the eluent containing the target compound was collected, concentrated and dried to obtain 0.48 g of pale yellow solid, i.e. the target compound 86, with the content of 99.1% (HPLC) and the yield of 53.7%.
[0041] 1 H NMR (500 MHz, CDCl 3 ) δ 7.57 (s, 1H), 7.46 (d, J=1.3 Hz, 1H), 7.41 (d, J=1.1 Hz, 1H), 7.31 (s, 1H), 7.26-7.24 (m, 1H), 7.16 (s, 1H), 7.13 (s, 1H), 7.05 (s, 1H), 7.00 (d, J=1.9 Hz, 1H), 6.89 (dd, J=8.3, 2.3 Hz, 1H), 6.81 (dd, J=8.0, 2.4 Hz, 1H), 5.03 (s, 2H), 4.03 (s, 3H), 3.84 (s, 3H); MS (ESI): m/z (%)=445.17 [M+1].
Example 5
Preparation of Compound 87 in Table 1
[0042]
Synthesis of 3-(2-trifluoromethyl-5-pyridyl) phenol (Formula 87-C)
[0043] 3-hydroxyphenyl boronic acid (formula 87-A, 12 mmol, 1.66 g), 2-bromo-5-trifluoromethyl-pyridine (formula 87-B, 10 mmol, 2.26 g), cesium fluoride (25 mmol, 3.80 g), palladium acetate (0.2 mmol, 45 mg), toluene (50 ml) were successively added to a 25 ml, three-necked reaction flask to react at room temperature (25° C.) for 6 hours. When the reaction was finished, the solution was extracted with ethyl acetate (40 ml×3) and water (40 ml), the organic phase was dried, filtered, desolventized, crystallized and dried to obtain 2.09 g of pale yellow solid, i.e. compound of formula 87-C, with the content of 97.8% (HPLC) and the yield of 85.5%.
Synthesis of Compound (87)
[0044] 3-(2-trifluoromethyl-5-pyridyl) phenol (formula 87-C, 2 mmol, 478 mg), NaH (60 wt %, 3 mmol, 120 mg), 18-crown-6 (0.05 mmol, 13 mg) and N′N-dimethylacetamide (10 ml) were added to a 100 ml, three-necked reaction flask, stirred to react at −10° C. for half an hour, and then (E)-2-(2′-chloro-methylphenyl)-2-carbonyl methyl acetate-O-methyl oxime (2.4 mmol, 580 mg) was added to continue the reaction for 3-6 hours at −10° C. When the reaction was finished, the solution was extracted with ethyl acetate (30 ml×3) and water (30 ml), and the combined organic phase was reversely extracted by saturated brine (30 ml×3), dried, suction filtered, and desolventized to obtain a crude product. The crude product was subjected to Silica gel column chromatography using the mixture of petroleum ether and acetone (V/V=18:1) as the mobile phase, and the eluent containing the target compound was collected, concentrated and dried to obtain 0.64 g of pale yellow solid, i.e. the target compound 87, with the content of 99.5% (HPLC) and the yield of 71.2%.
[0045] 1 H NMR (500 MHz, CDCl 3 ) δ 8.92 (d, J=5.2 Hz, 1H), 7.97 (s, 1H), 7.69-7.53 (m, 4H), 7.48-7.39 (m, 3H), 7.23 (dd, J=7.5, 1.3 Hz, 1H), 7.07-6.99 (m, 1H), 5.10 (s, 2H), 4.04 (s, 3H), 3.86 (s, 3H); MS (ESI): m/z (%)=445.12 [M+1].
Example 6
Preparation of Compound 101 in Table 1
[0046]
Synthesis of 3-(2-trifluoromethyl-5-pyridyl) phenol (Formula 101-C)
[0047] 3-hydroxyphenyl boronic acid (formula 101-A, 10 mmol, 1.38 g), 2-bromo-5-trifluoromethylpyridine (formula 101-B, 10 mmol, 2.26 g), cesium fluoride (20 mmol, 3.04 g), palladium acetate (0.2 mmol, 45 mg), xylene (50 ml) were successively added to a 250 ml, three-necked reaction flask to react at room temperature (25° C.) for 6 hours. When the reaction was finished, the solution was extracted with ethyl acetate (40 ml×3) and water (40 ml), dried, filtered, desolventized, crystallized and dried to obtain 2.09 g of pale yellow solid, i.e. compound of formula 101-C, with the content of 97.8% (HPLC) and the yield of 85.5%.
Synthesis of Compound (101)
[0048] 3-(2-trifluoromethyl-5-pyridyl) phenol (formula 101-C, 2 mmol, 478 mg), NaH (60 wt %, 3 mmol, 120 mg), 18-crown-6 (0.2 mmol, 53 mg) and CH 2 Cl 2 (10 ml) were added to a 100 ml, three-necked reaction flask, stirred to react at −10° C. for half an hour, and then (E)-2-(2′-chloro-methylphenyl)-2-carbonyl methyl acetate-O-methyl oxime (2.4 mmol, 580 mg) was added to continue to react for 3-6 hours at −10° C. When the reaction was finished, the solution was extracted with ethyl acetate (30 ml×3) and water (30 ml), and the combined organic phase was reversely extracted with saturated brine (30 ml×3), dried, suction filtered, and desolventized to obtain a crude product. The crude product was subjected to Silica gel column chromatography using the mixture of petroleum ether and acetone (V/V=18:1) as the mobile phase, and the eluent containing the target compound was collected, concentrated and dried to obtain 0.64 g of pale yellow solid, i.e. the target compound 101, with the content of 99.5% (HPLC) and the yield of 71.2%.
[0049] 1 H NMR (500 MHz, CDCl 3 ) δ 8.85 (d, J=1.1 Hz, 2H), 8.05 (d, J=1.5 Hz, 2H), 7.58 (d, J=7.5 Hz, 2H), 7.46 (dd, J=7.6, 1.4 Hz, 2H), 7.44-7.37 (m, 4H), 7.36 (dd, J=5.1, 3.9 Hz, 2H), 7.31-7.28 (m, 3H), 7.23 (dd, J=7.5, 1.2 Hz, 2H), 7.03 (ddd, J=8.2, 2.6, 1.0 Hz, 2H), 5.03 (s, 4H), 4.02 (s, 6H), 3.84 (s, 6H); MS (ESI): m/z (%)=478.87 [M+1].
Example 7
Preparation of Compound 133 in Table 1
[0050]
Synthesis of 3-(2-trifluoromethyl-5-pyridyl) phenol (133-C)
[0051] 3-hydroxyphenyl boronic acid (133-A, 12 mmol, 1.66 g), 2-bromo-5-trifluoromethylpyridine (133-B, 10 mmol, 2.26 g), cesium fluoride (25 mmol, 3.80 g), palladium acetate (0.2 mmol, 45 mg), PEG2000 (50 ml) were successively added to a 250 ml, three-necked reaction flask to react at room temperature (25° C.) for 6 hours. When the reaction was finished, the solution was extracted with ethyl acetate (40 ml×3) and water (40 ml), the organic phase was dried, filtered, desolventized, crystallized and dried to obtain 2.09 g of pale yellow solid, i.e. compound 133-C, with the content of 97.8% (HPLC) and the yield of 85.5%.
Synthesis of Compound (133)
[0052] 3-(2-trifluoromethyl-5-pyridyl) phenol (133-C, 2 mmol, 478 mg), NaH (60 wt %, 3 mmol, 120 mg), 18-crown-6 (0.2 mmol, 53 mg) and DMSO (10 ml) were added to a 100 ml, three-necked reaction flask, stirred to react at −10° C. for half an hour, and then (E)-2-(2′-chloro-methylphenyl)-2-carbonyl methyl acetate-O-methyl oxime (2.4 mmol, 580 mg) was added to continue to react for 3-6 hours at −10° C. When the reaction was finished, the solution was extracted with ethyl acetate (30 ml×3) and water (30 ml), and the combined organic phase was reversely extracted with saturated brine (30 ml×3), dried, suction filtered, and desolventized to obtain a crude product. The crude product was subjected to Silica gel column chromatography using the mixture of petroleum ether and acetone (V/V=18:1) as the mobile phase, and the eluent containing the target compound was collected, concentrated and dried to obtain 0.64 g of pale yellow solid, i.e. the target compound 133, with the content of 99.5% (HPLC) and the yield of 71.2%.
[0053] 1 H NMR (500 MHz, CDCl 3 ) δ 8.54 (d, J=2.2 Hz, 1H), 7.83 (d, J=2.2 Hz, 1H), 7.72-7.66 (m, 2H), 7.61-7.53 (m, 1H), 7.47-7.39 (m, 2H), 7.24 (dd, J=7.5, 1.3 Hz, 1H), 7.02-6.97 (m, 2H), 5.03 (s, 2H), 4.05 (s, 3H), 3.86 (s, 3H); MS (ESI): m/z (%)=444.88 [M+1].
[0054] Examples 8-10 are examples of Preparations
[0055] The following content of ingredients are calculated by mass percentages. All active ingredients are selected from compounds in Table 1.
Example 8
60% Wettable Powder
[0056]
[0000]
TABLE 2
List of ingredients of 60% wettable powder
Ingredient
Content
Compound 48
60%
SDBS
1%
sodium lignosulphonate
6%
Diffusant NNO
5%
Diatomite
28%
[0057] All ingredients were mixed uniformly and smashed in a pulverizer until the fineness reaches the standard (≦44 μm), to obtain a wettable powder containing an active ingredient (i.e. compound 48), whose content was 60%.
Example 9
35% Emulsifiable Concentrate (EC)
[0058]
[0000]
TABLE 3
List of ingredients of 35% EC
Ingredient
Content
Compound 48
35%
Cyclohexanone
20%
Emulsifier OP-10 (emulsifier A)
7%
SDBS (emulsifier B)
5%
Solvent oil
33%
[0059] Compound 48 was dissolved in cyclohexanone and solvent oil and then emulsifier A and emulsifier B were added to mix uniformly to obtain a transparent homogeneous solution, i.e. 35% emulsifiable concentrate containing an active ingredient (i.e. Compound 48).
Example 10
50% Water Dispersible Granules
[0060]
[0000]
TABLE 4
50% water dispersible granules
Ingredient
Content
Compound 48
50%
Sorbitan sulfate
1%
Polyvinylpyrrolidone
3%
sodium lignosulfonate
10%
Diatomite
36%
[0061] The above ingredients were mixed uniformly and ground, then a small amount of water was added, kneaded, granulated and dried, to obtain 50% water dispersible granules containing active ingredient (Compound 48).
Example 11
Determination of Herbicidal Activity
Preparation
[0062] The raw drug which was selected from the compounds in table 1 was weighed using an analytical balance (0.0001 g), and dissolved in DMF containing 1 wt % Tween-80 emulsifier to prepare a mother liquor of raw drug with a mass concentration of 1.0˜5.0%, and then diluted with distilled water, to prepare preparations at desired concentrations according to the ratio of ingredients in Examples 8, 9 and 10.
Test Method
[0063] Culture dish method (general screening): The test targets were radish, cucumber, rape, wheat, sorghum and barnyard grass; the seeds of wheat, sorghum and radish were germinated in advance, and the uniform emerge-germinating seeds were used in the test. The above targets were placed in culture dishes with a diameter of 9 cm paved with double filter paper respectively, and added 9 mL of a solution of a new compound at concentration of 100 mg/L to each culture dish; after uniformly immersed, they were numbered and labeled, cultured in an artificial climate chamber, wherein the temperature was set at 28° C., the illumination light intensity was set at 3000 Lux, the photoperiod was 16 h light/8 h dark, and RH was 75%; 7 days later, the growth inhibition rate (%) of roots and stems of the targets were observed and calculated.
Potted Plants Live Body Test Method (Determination of High-Activity Compounds):
[0064] The test targets were mustard, small quinoa, Abutilon, amaranthus retroflexus, Eclipta prostrata, crabgrass, dog point. A pot with a diameter of 7.5 cm was used, filled with composite soil (garden soil:nursery matrix, 1:2, v/v) to ¾ of the pot, then the above six kinds of weeds targets were directly seeded (germination rate ≧85%), covered with soil at a thickness of 0.2 cm. When the weeds grew to 3-leaf stage, pre-emergence soil treatment for weeds planting, and then spraying was performed. After administration of all compounds in the automatic spray tower (Model: 3WPSH-700E) at the dose of 150, 75, 37.5 g a.i./ha, they were cultured in greenhouse culture when the foliage liquid was dried, 30 days later, the comprehensive inhibition rate on the weeds was observed and calculated (%).
Test Results
[0065]
[0000]
TABLE 8
Test results of culture dish test for herbicidal activity of some compounds
(inhibition rate/%, 100 mg/L)
Chinese
Compound
Wheat
sorghum
Barnyardgrass
Cucumber
Rape
Radish
No.
Root
Stem
Root
Stem
Root
Stem
Root
Stem
Root
Stem
Root
Stem
4
0
0
0
0
30
30
30
0
30
0
50
30
7
20
0
0
0
50
20
30
0
60
30
20
0
19
30
0
80
30
70
30
90
70
100
100
80
80
27
50
0
50
0
60
30
60
0
50
50
50
20
32
0
0
0
0
0
0
0
0
80
80
80
50
67
30
0
50
50
50
0
50
0
50
30
50
50
75
0
0
0
0
30
30
30
0
0
0
0
0
83
60
20
80
30
80
0
80
30
80
50
50
50
84
0
0
0
0
80
0
30
0
50
0
0
0
85
60
20
80
30
80
0
80
30
80
50
50
50
98
20
0
50
30
60
20
50
80
50
80
50
80
99
30
0
50
50
50
0
70
0
60
30
60
50
101
50
20
100
100
100
95
95
100
100
100
100
100
104
0
0
0
0
0
0
20
0
50
0
0
0
110
0
0
0
0
0
0
20
0
20
0
0
0
112
0
0
0
0
0
0
50
80
50
80
50
80
120
20
0
50
30
60
20
70
30
60
0
50
0
133
50
0
100
100
100
100
100
100
100
100
100
100
Pyribambenz
95
95
100
90
100
95
95
90
100
100
100
90
isopropyl
[0066] The results of dish test for herbicidal activity showed (table 8) that, compounds 19, 27, 83, 85, 98, 99, 101, 112, 120, 133 exhibited strong growth inhibition on the roots/stems of 3 or more test targets (≧60%) at a dose of 100 mg/L, and then potted plants live body test method was carried out for the above 10 compounds to further identify their herbicidal activity.
[0000]
TABLE 9
General screening test results of herbicidal activity for some compounds
(efficiency/%, 150 g a.i./ha)
amaranthus
Compound No.
Mustard
Small quinoa
Abutilon
retroflexus
Eclipta prostrata
Crabgrass
Dog point
Postemergence spraying
19
50
60
40
50
50
0
0
27
80
60
60
80
80
0
0
83
0
50
30
20
0
0
0
85
30
0
50
0
50
0
0
98
100
75
80
80
80
0
0
99
60
50
20
40
25
0
0
101
100
100
100
100
100
0
0
112
100
75
50
80
60
0
0
120
40
60
50
20
30
0
0
133
100
100
100
100
100
0
0
Clear water
0
0
0
0
0
0
0
Pre-emergence soil treatment
19
0
25
0
30
0
0
0
27
30
25
0
50
0
0
0
83
0
30
0
20
0
0
0
85
20
0
20
0
0
0
0
98
50
45
60
50
50
0
0
99
0
30
0
0
0
0
0
101
100
100
100
100
85
80
50
112
50
45
0
50
0
0
0
120
20
50
0
0
0
0
0
133
100
100
100
100
100
50
50
Clear water
0
0
0
0
0
0
0
[0067] Potted plants live body test results (Table 9) showed that, compared with the clear water control, 30 days after administration at the dose of 150 g a.i./ha, compounds 19, 27, 83, 85, 98, 99, 101, 112, 120, 133 exhibited herbicidal activity on broadleaf weeds targets such as mustard, small quinoa, Abutilon, amaranthus retroflexus and Eclipta prostrate, but poor activity for the grass targets such as crabgrass and dog point. Generally, the activity of the compounds used in postemergence spray treatment is superior to that of the compounds used in pre-emergence soil treatment. Compounds 101 and 133 exhibited 100% inhibition rate on the growths of broadleaf weeds such as mustard, small quinoa, Abutilon, Amaranthus retroflexus and Eclipta prostrate at the dose of 150 g a.i./ha. Therefore, further screening of herbicidal activity of the two compounds was performed.
[0000]
TABLE 10
Results of screening of herbicidal activity of compounds 101 and 133
(efficiency/%)
Dose
amaranthus
Eclipta
Dog
Compound No.
g a.i./ha
Abutilon
crabgrass
retroflexus
Barnyardgrass
prostrate
point
postemergence spraying
101
150
100
0
100
0
100
0
75
60
0
100
0
100
0
37.5
30
0
100
0
97.5
0
133
150
100
0
100
0
100
0
75
100
0
100
0
100
0
37.5
100
0
100
0
97.5
0
Pyribambenz
150
0
50
70
50
0
80
isopropyl
Pre-emergence soil treatment
101
150
100
80
100
0
85
50
75
0
0
15
0
0
0
37.5
0
0
0
0
0
0
133
150
100
50
100
0
100
50
75
0
0
30
0
0
0
37.5
0
0
20
0
0
0
pre-emergence soil
150
100
97.5
95
97.5
75
97.5
treatment
[0068] The results of preliminary screening tests for herbicidal activity of compounds 101 and 133 showed that (table 10), compounds 101 and 103 were used in postemergence herbicidal treatment at a dose of 150, 75, 37.5 g a.i./ha and showed an efficiency of 97.5˜100% on the amaranthus retroflexus and Eclipta prostrate, and compound 133 showed an efficiency of 100% on the Abutilon, but showed not good activity or no activity on crabgrass, barnyard grass, dog point; when they were used in pre-emergence soil treatment at a dose of 150 g a.i./ha, compounds 101 and 133 had better activity on broad-leaved weeds, but not good activity on the grass weeds; when the dose was lowered, they showed significantly decreased activity or no activity on 6 kinds of weed targets.
[0000]
TABLE 11
Crop inhibition rate of compounds 101 and 133 (%)
Dose
Compound
g a.i./
No.
ha
Corn
Soybean
Cotton
Rice
Rape
Barley
101
150
0
40
50
30
50
0
133
150
0
40
50
30
100
0
[0069] The safety test showed (table 11) that, it was safer for corns and barleys when compounds 101 and 133 were used in post-emergence spray treatment.
|
The present invention discloses an oxime ether acetate compound containing a phenylpyridine moiety of formula (I), whose preparation method is as follows: (1) mixing a compound of formula (IV), a compound of formula (V), an alkaline substance A, a palladium catalyst and a solvent A; subjecting the mixture to a reaction at the temperature ranging from −10° C. to the reflux temperature for 0.5-20 hours to obtain a reaction solution A; post-treating the solution A to obtain a compound of formula (II); (2) mixing the compound of formula (II), an alkaline substance B, a phase transfer catalyst and a solvent B; subjecting the mixture to a reaction at the temperature ranging from −10° C. to the reflux temperature for 0.1-2 hours; then adding a compound of formula (III), continuing to react at the temperature ranging from −10° C. to the reflux temperature for 0.5-20 hours to obtain a reaction solution B; and post-treating the solution B to obtain the compound of formula (I). The oxime ether acetate compound containing a phenylpyridine moiety of formula (I) can be used for weeding in crops.
| 2
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BACKGROUND OF THE INVENTION
The finishing of textile substrates, e.g. of synthetic leather based fleeces, with binders is frequently carried out in the known art with a thermosensitized binder liquor. In such a liquor, the binder used is a plastic dispersion which has been adjusted to be heat sensitive. After its introduction into the fleece, the material is heated, so that the binder is completely coagulated and thus fixed in the fleece without leaving a residue and localized. This may be followed by a squeezing off process to remove excess water, and the material is then dried and subsequently cross-linked or vulcanized.
For economic reasons, the materials which are strengthened in this way are in practice mainly comparatively thick fleeces which are split into individual layers after they have been treated with the binder. These stiff layers are then buffed to produce a smooth surface.
The synthetic leathers known in the art, which are manufactured by the process described above or by similar processes, have excellent mechanical properties but they generally do not have the water vapor absorption capacity of natural leather, which is very important for the comfort in wear of articles manufactured from such synthetic leather materials, particularly shoes.
There have therefore been many attempts to remedy this defect by subsequently impregnating the finished synthetic leather fleeces or combining the binders with hydrophilic additives.
It has not hitherto been possible to find a finish which not only increases the water vapor absorption capacity of synthetic leather but also has a combination of the following properties which are very important in practice:
(a) The finishing should not require an additional operating step, i.e. subsequent or previous impregnation and possibly drying and cross-linking of the finished fleeces is undesirable.
(b) In order that the finish may be carried out in a single bath, the hydrophilising agent must be compatible with the binder and auxiliary agents.
(c) The hydrophilising agent must not alter the coagulation point of the thermosensitive binder liquor for a period of several days nor may it deleteriously affect the running stability during impregnation, in order not to cause premature coating of the foulard rollers with coagulate produced by shearing forces during the finishing process.
(d) The hydrophilising agent should be available in a liquid form so that it can easily be mixed with the other components. It must have a sufficiently low viscosity not to interfere with the impregnating process but must be sufficiently highly concentrated so that sufficient quantities thereof can be incorporated in a single process step.
(e) The hydrophilising agent contained in the finishing liquor should be uniformly deposited in the fleece together with the binder in order to ensure homogeneous distribution. During the drying process, it should not migrate with the water which is removed by drying. The external surfaces of the article should not contain more hydrophilising agent than the core of the fleece so that the layers obtained by splitting do not differ from each other in their water storage capacity.
(f) The hydrophilising agent applied to the fleece should be capable of being cross-linked and thereby rendered insoluble in water and should not be capable of being removed by dissolving when subsequently exposed to moisture. The cross-linking process should be completed under the conditions employed for cross-linking or vulcanizing the binder.
(g) It is particularly important that the introduction of sufficient quantities of hydrophilising agent should not deleteriously affect the handle of the finished fleece and in particular it should not harden the fleece.
(h) The processes of splitting and buffing which follow the finishing process should not be rendered more difficult, for example by the premature addition of buffing paper because the hydrophilising agent has thermoplastic properties.
None of the hydrophilising agents hitherto proposed meet all the requirements mentioned above; at most, they satisfy only some of them, so that the problem of finding a suitable hydrophilising agent remained.
SUMMARY OF THE INVENTION
The present invention relates to a process for improving the water vapor absorption capacity of textile substrates, in particular of synthetic leather based fleeces, by treating them with a hydrophilising agent, characterized in the the hydrophilising agent used is a polymeric organic compound which is cross-linked and/or capable of being cross-linked and which is water-soluble in the uncross-linked state, and which, when in the form of a 25% by weight aqueous solution, has a turbidity point of between 25° and 95° C. Preferred are those water-soluble polymeric organic compounds which, in the cross-linked state, are insoluble in water and yet capable of swelling, and which, in the uncross-linked state, have turbidity points of between 30° and 60° C. in 25% by weight aqueous solution.
It has been found that the process according to the invention produces excellent results, particularly in accordance with the requirements listed above, if the hydrophilising agents used are copolymers of ethylene oxide and at least one other epoxide component, in particular propylene oxide, which carries cross-linkable end groups, particularly compounds of the type of methylol compounds.
The copolyether of ethylene oxide and at least one other epoxide component such as, preferably, propylene oxide but possible also, for example, butene oxide, cyclohexene oxide, epichlorohydrin or styrene oxide can easily be prepared according to the known art as mixed block polyethers or block mixed polyethers or statistically mixed polymers by reaction of the epoxides with a starter alcohol, usually under alkaline catalysts and continuing polymerization, the functionality of the resulting mixed polyether depending on the functionality of the starter alcohol, whether it is, for example a monohydric alcohol such as methanol or butanol, a diol such as glycol or propylene glycol or a polyol such as glycerol, trimethylol propane, pentaerythritol, sugar or sorbitol, etc.
DETAILED DESCRIPTION OF THE INVENTION
Mixed polyethers which are particularly suitable for the purpose of the invention are preferably trifunctional but difunctional or tetra or polyfunctional mixed polyethers may also be used. A certain proportion, up to 50% by weight, of monofunctional polyethers may also be included.
The mixed polyethers have molecular weight of between about 500 and 8500, preferably between about 2000 and 7000. As used herein the term molecular weight refers to number average molecular weight.
Particularly preferred hydrophilising agents are those mixed polyethers in which from about 35 to 80% by weight, preferably from about 40 to 75% by weight of ethylene oxide is incorporated, propylene oxide being preferably also incorporated as another essential component apart from the starter alcohol.
The hydrophilising agents to be used according to the invention are preferably mixed polyethers of the type mentioned above which have cross-linkable end groups, i.e. groups which after application during the finishing process allow the applied mixed polyethers to be fixed on the substrate or the binder or which allow them to be fixed by a reaction with each other or with a cross-linking reagent to form an insoluble cross-linking product or by a combination of one or more of these possibilities.
Since the finishing process in most cases takes place in an aqueous medium and is followed by drying and cross-linking at temperatures which may reach 150° C., the cross-linking reaction should not be severely disturbed by moisture or by access of air but cross-linking temperature of up to about 150° C. are quite acceptable and commonly employed.
Suitable groups which can be cross-linked, apart from the hydroxyl group which is in any case present as a result of the method of preparation employed, which hydroxyl group can be cross-linked with, for example, aldehydes to form acetals or formals or with N-methylol compounds such as methylolureas or melamine-N-methylol methyl ethers, also include, for example, carboxyl groups which have been formed by semiester formation with acids such as phthalic acid, maleic acid, succinic acid or adipic acid and which may also be cross-linked with methylol compounds. Unsaturated groups may also be cross-linked, e.g. the groups obtainable by esterification of the hydroxyl end groups with (meth)-acrylic or maleic or fumaric acid; also allyl ether groups, which incidentally are capable of radical cross-linking on their own or with the binder, to which an additional cross-linker such as triallylcyanurate, acrylamide methylol ether or divinylbenzene may be added.
Particularly interesting is the conversion of the hydroxyl end groups of the mixed polyether into N-methylolalkyl ether-urethane groups, which can easily be carried out e.g. by reaction of the mixed polyethers with methoxymethyl isocyanate. This type of cross-linkable group can easily be cross-linked with itself or with hydroxyl carboxylic acid or amide groups by the action of heat, optionally in the presence of acid catalyst.
Mixed polyethers with cross-linkable end groups represented by the following general formula I:
Mixed polyether chain
--O--CO--NH--R(--NH--CO--NH.sub.2).sub.m (I)
or their reaction products with formaldehyde are particularly preferred because they are highly reactive when treated with the usual reagents and can be prepared by simple processes and give rise to very satisfactory properties within the meaning of the requirements according to this invention.
In the above formula (I), R represents an aliphatic, cycloaliphatic, araliphatic or aromatic group derived from a (1+m) functional isocyanate, where m is an integer of from 1 to 3, but preferably 1, i.e. R is preferably derived from a bifunctional isocyanate.
These mixed polyethers with cross-linkable end groups which are preferred as hydrophilising agents according to the invention are prepared by conventional methods in which the mixed polyether which carries the hydroxyl end groups or mixtures of such mixed polyethers are first reacted with a preferably bifunctional isocyanate to be converted into a so-called isocyanate prepolymer or polyether isocyanate in which the majority of the hydroxyl groups of the polyether have reacted half sidedly with the bifunctional isocyanate so that the original polyether, for example a triol, has given rise predominantly to a triisocyanate. This generally requires the use of a certain stoichiometric excess of isocyanate, and the resulting prepolymer therefore contains a small amount of free diisocyanate, but this does not interfere with subsequent processing. The prepolymer prepared in this way, which may also be regarded as a polyfunctional polyether isocyanate in which the polyether portion is strongly hydrophilic on account of the given composition, is then reacted with aqueous ammonia. In this reaction, the urea structure shown in the general formula is formed very easily and an aqueous solution of the hydrophilising agent required for the process is obtained. To this solution is now preferably added a sufficient quantity of formaldehyde to produce a slight odor of formaldehyde, and the solution can then be used for the purpose of the invention, if indicated after several hours' stirring at 15° to 60° C., followed by cooling.
Any known aliphatic, cycloaliphatic, araliphatic or aromatic di-, tri- or polyisocyanates may be used for preparing the isocyanate prepolymer or polyether isocyanate. It is preferred to use diisocyanates such as hexamethylene diisocyanate, isophorone diisocyanate, 2,4- and/or 2,6-tolylene diisocyanate or 4,4'- and/or 2,4'-diphenylmethane diisocyanate.
Commercially available mixtures of tolylene diisocyanate isomers are particularly preferred on account of their suitable reactivity and ready availability although aliphatic isocyanates such as isophorone diisocyanate or hexamethylene diisocyanate have advantages with regard to their resistance to ageing by the action of light.
The reaction of the resulting polyether isocyanate with ammonia is preferably, but not necessarily, carried out with aqueous ammonia using any quantity of water but preferably a quantity which allows the polyether urea to be obtained directly as a 5 to 60% solution. The quantity of ammonia used should be at least equivalent to the number of free isocyanate groups present but should preferably be 2 to 3 times this quantity. The quantity of formaldehyde subsequently added to the polyether urea should be equivalent to the quantity of ammonia used but is preferably about 1.5 to 2 times this quantity.
Other known cross-linking agents may, of course, also be used instead of formaldehyde, e.g. resoles or N-methylol compounds of urea, of melamine or urethanes, biurets or allophanates or their ethers, for example tris-methylol urea or hexamethylolmelamine or their methyl ethers.
Cross-linking of the hydrophilising agents according to the invention is suitably carried out by a method similar to the cross-linking of other methylol compounds aided by catalysis with acid reagents such as oxalic acid, maleic acid, ammonium chloride, phosphoric acid or the like. These catalysts are used in quantities of up to about 3% by weight, preferably up to about 1.5% by weight, based on the hydrophilising agent. Cross-linking is also achieved without these additives but in that case requires higher temperatures or longer times. It is normally carried out at temperatures between about 80° and 180° C., preferably at about 110° to 150° C.
According to the invention, the thermosensitive, cross-linkable and binder compatible hydrophilising agent used in the impregnating bath are preferably urea mixed polyethers of the general formula I or their formaldehyde reaction products, in which m is preferably 1, R is preferably a tolyl group and the mixed polyether component is preferably derived from a trifunctional ethylene oxidepropylene oxide mixed polyether containing from about 40 to 65% by weight of ethylene oxide built into it and having a molecular weight of from 2000 to 7000.
The hydrophilising agents are preferably applied from the aqueous phase in quantities such that the amount of solid substance applied is from 5 to 50% by weight, preferably 10 to 35% by weight, based on the weight of the substrate.
According to a particular embodiment of the process, the hydrophilising agent is applied to a hydrophilic carrier substance, e.g. an inorganic asbestos, kaolin, chalk, talcum, powdered rock or wood meal or particularly to finely divided silicate, for example of the type K 322 supplied by Degussa, Frankfurt, and is subjected to a preliminary process of cross-linking by heating the suspension of hydrophilising agent and silicate, which also contains an acid such as oxalic or maleic acid as cross-linking catalyst, to a temperature above the turbidity point of the hydrophilising agent, which lies at temperatures of from about 30° to 60° C., so that the hydrophilising agent is adsorbed on the silicate. After drying and cross-linking at temperatures of between about 100° to 160° C., preferably at about 130° to 150° C., the reaction product is ground to dust (silicate portion about 25 to 80% by weight, preferably about 40 to 70% by weight). The powder thus obtained is then mixed with water to form a suspension in the form of a fine paste which is capable of being impregnated, the suspension having a solids content of preferably about 25 to 40% by weight. This paste is compatible with the binder normally used, for example a thermosensitive butadiene/acrylonitrile copolymer latex. The impregnating mixture also contains other auxiliary agents such as sulphur, vulcanizing agents, accelerators or dyes.
The material obtained after impregnating, drying and vulcanizing is a flexible synthetic leather which has a soft handle and, after it has been split, all of the layers have a uniform water vapor storage capacity.
The following Examples serve to illustrate the process without limiting it. The parts and percentages given are parts by weight and percentages by weight unless otherwise indicated.
The turbidity point is determined by slowly heating a 25% aqueous solution of the hydrophilising agent in a test tube inside a water bath and occasionally stirring it with a thermometer. The temperature at which cloudiness becomes irreversible is recorded.
The capacity to be cross-linked is determined by applying a 25% aqueous solution of the hydrophilising agent to a glass plate, optionally after addition of the cross-linking agent, and then heating it in a drying cupboard at 120° C. for 30 minutes. When subsequently treated in a water bath at 15° to 25° C., the cross-linked material may swell but must not dissolve.
The softness of the cross-linked product gives some indication of the handle which the material may be expected to have after application of the finish. It is assessed subjectively or measured in terms of the Shore A hardness.
The following are examples of mixed polyethers used as bases for the preparation of the hydrophilising agents:
Type A:
Glycerol is used as starter, on which are polymerized
60% of ethylene oxide and
40% of propylene oxide.
Molecular weight approx. 6500,
hydroxyl number approx. 26.
Type B:
Similar to Type A but
Molecular weight approx. 3000,
hydroxyl number approx. 56.
Type C:
Glycerol is used as starter on which are polymerized
45% of ethylene oxide and
55% of propylene oxide.
Molecular weight approx. 6000,
hydroxyl number approx. 28.
Type D:
Trimethylolpropane is used as starter on which are polymerized
45% of ethylene oxide and
55% of propylene oxide.
Molecular weight approx. 3000,
hydroxyl number approx. 56.
Preparation of the hydrophilising agent
Type I:
Thermosensitive hydrophilising agent having carboxyl end groups as groups which are to be cross-linked.
100 Parts of Type D polyether and 10 parts of succinic acid anhydride are stirred together for 10 hours at 80° C. Semi-ester formation takes place. The 25% aqueous solution of the reaction product has a turbidity point at 52° C. 10 Parts of a 40% solution of hexamethylolmelamine methyl ether and 0.5 parts of ammonium chloride are added to 100 parts of the 40% aqueous solution of the reaction product and the mixture is vigorously stirred. A film cast from this solution and cross-linked gives rise to a cross-linked product which only undergoes swelling in the presence of water and is not dissolved by it. Shore A hardness: 18.
Type II:
Thermosensitive hydrophilising agent which can be cross-linked through its unsaturated end groups: This substance is prepared by a similar method to that used for Type I but using maleic acid anhydride instead of succinic acid anhydride. The reaction product has a turbidity point of 53° C.
Acrylamide methylol methyl ether is used as cross-linking agent because it can take part in the cross-linking reaction through both the double bond and by way of the methylol group. 100 parts of the 30% aqueous solution of the hydrophilising agent, 8 parts of acrylamidomethylolmethyl ether and 1 part of ammonium persulphate are vigorously mixed with stirring. A film cast from this solution undergoes cross-linking at 120° C. to form a cross-linked product which is no longer soluble in water but only capable of swelling in it. Shore A hardness: 23.
Type III:
Thermosensitive hydrophilising agent having cross-linkable N-methylol methyl ether-urethane end groups.
100 parts of polyether Type B and 10 parts of methoxy methyl isocyanate are stirred together for 8 hours at 50° C.
The reaction product has a turbidity point at 56° C. 1.0 Part of ammonium chlorides is dissolved in 100 parts of an approximately 50% solution of the hydrophilising agent in water. A film cast from this solution undergoes cross-linking to form a product which is still capable of swelling in water but no longer soluble. Shore A hardness 22.
Type IV:
Thermosensitive hydrophilising agent having cross-linkable end groups according to the general formula I on page 7 (polyether-urea):
1250 Parts of the mixed polyether Type A and 205 parts of a commercially pure mixture of 80% 2,4-tolylene diisocyanate and 20% 2,6-tolylene diisocyanate are stirred together with the exclusion of moisture for 3.5 hours at 80° C. At the end of this time, the reaction product has an isocyanate content of 4.2%.
525 Parts of the polyether isocyanate prepared as described above are then stirred at room temperature into a mixture of 690 parts of water and 79 parts of an approximately 24% aqueous ammonia. An aqueous solution which still smells faintly of ammonia is obtained. 75 Parts of an approximately 37% aqueous formalin solution are added after about 30 minutes. After 24 hours' stirring at approximately 30° C. and cooling to room temperature, the resulting solution of the product has a viscosity at room temperature of 40 seconds, measured in a Ford cup, nozzle 4, and a solids content of approximately 40%. The turbidity point of the hydrophilising agent prepared in this way is approximately 50° C. 1 Part of oxalic acid is added to 100 parts of the solution of hydrophilising agent and the solution is cast to form a film. The film cross-links at 120° C. to form a highly elastic film which swells strongly in water but does not dissolve in it. Shore A hardness 19.
Type V:
Thermosensitive hydrophilising agent with cross-linkable end groups analogous to Type IV:
1293 Parts of the mixed polyether Type C and 208 parts of a commercially pure mixture of 80% of 2,4- and 20% of 2,6-tolylene diisocyanate are stirred together for 3.5 hours at 80° C. with exclusion of moisture. The reaction product obtained at the end of this time has an isocyanate content of 5.2%.
525 parts of this polyether isocyanate are then vigorously mixed with a mixture of 1144 parts of water and 79 parts of an approximately 20% aqueous ammonia at room temperature and the resulting solution is then stirred for a further 30 minutes. 79 parts of an approximately 37% formalin solution are then added and the mixture is stirred at room temperature for approximately 20 hours.
The resulting approximately 30% solution of hydrophilising agent has a throughflow time of 14 seconds measured at approximately 20° C. in a Ford cup nozzle 4. The turbidity point is 37° C. After the addition of 0.5% of maleic acid, based on the solid content, a film prepared from the solution crosslinks at 120° C. to form a highly elastic film which swells in water but does not dissolve in it. Shore A hardness: 26.
Type VI:
Thermosensitive hydrophilising agent analogous to Types IV and V:
262 Parts of the polyether isocyanate prepared by the method given for Type IV and 262 parts by weight of the polyether isocyanate prepared by the method given for Type V are mixed vigorously. The mixture obtained is then mixed vigorously at room temperature with a mixture of 414 parts of water and 79 parts of an approximately 22% aqueous ammonia solution. The resulting mixture is then stirred for a further 30 minutes and 79 parts of an approximately 37% formalin solution are added. After vigorous mixing, the mixture is left to stand for about 24 hours at 25° C. The approximately 50% hydrophilising agent prepared as described above has a throughflow time of approximately 160 seconds measured at 20° C. in a Ford cup, nozzle 4. The turbidity point lies at 41 to 42° C.
After the addition of 0.5 parts of ammonium chloride, a film prepared from this solution cross-links at 80° to 120° C. to form a highly elastic film which undergoes considerable swelling in water but is not water-soluble. Shore A hardness: 24.
The hydrophilising agents of Types IV to VI make it possible to prepare hydrophilic films which have exceptionally good mechanical properties. Since they have excellent compatibility with the usual binders used for synthetic leather fleeces and their turbidity points lie in the very interesting low temperature range, these hydrophilising agents will be used as examples to illustrate the method according to the invention of manufacturing synthetic leather fleeces.
Fleece materials suitable for the process according to the invention are preferably produced from staple fibers although fleeces made of endless filament fibers, for example fibers obtained by the fleece spinning process, may also be used. The fibers used may be either synthetic fibers such as polyamide, polyester, polyolefine or polyacrylonitrile fibers or regenerated fibers such as rayon staple fibers or natural fibers such as wool or cotton fibers, or mixtures of these fibers. Apart from the usual staple fibers, shrinkable fibers may also be used in which the shrinkage is subsequently removed by a heat treatment, e.g. fibers of this kind based on polyesters or polyacrylonitrile.
Manufacture of the fleeces is carried out by the known dry laying or wet laying process and may comprise, for example, the following steps:
(a) Crimping, cross-laying, stitching and optionally shrinking if shrinkable fibers are used, or dispersion of the fibers, formation of sheets and dewatering by suction.
The fleeces are then after-treated and finished by the following steps:
(b) Impregnation, coagulation, drying, vulcanizing;
(c) Splitting and buffing.
EXAMPLES
EXAMPLE 1
A synthetic fiber fleece composed of 60% of polyamide fibers 1.6 dtex/40 mm and 40% of polyester fibers 1.3 dtex/3.8 mm (shrinkable) is produced by crimping followed by repeated stitching. The fleece obtained after shrinkage in hot air has a weight per square meter of 825 g, a thickness of 4.1 mm and a density of 0.2 g/cm 3 . The fleece is then impregnated with a mixture of a 50% butadiene/acrylonitrile copolymer latex which has been carboxylated by the incorporation of methacrylic acid and the 40% hydrophilising agent type IV according to the invention, used in proportions of approximately 1:1. The following components were added to the mixture to vulcanize the butadiene/acrylonitrile polymer:
__________________________________________________________________________Colloidal sulphur 1.5 parts dispersed in 11 parts ofZinc-N-diethyldithiocarbamate 0.8 parts methylene-bis- naphthaleneActive zinc oxide 2.5 parts sulphate acid sodium in 5% aque-for pigmentation: ous solutionTitanium dioxide (rutile) 2.0 partsVulcanosol orange (manufac-turers BASF AG, Ludwigshafen) 0.2 partsfor stabilizing:Benzyl-p-oxydiphenyl polyglycol etherin 20% aqueous solution 10.0 partsto adjust the products to beheat sensitive:Organopolysiloxane compoundaccording to U.S. Pat. No.3,255,140 (coagulant WS of 0.5 parts.Bayer AG)__________________________________________________________________________
The parts given above are based in each case on 100 parts of dry rubber substance.
The pH of the finishing liquor was 8, the coagulation point 40° C. and the viscosity 200 mPas.
After impregnation and squeezing off, the fleece was passed through an infra-red path acting from both sides with a power of 10 kilowatt from each side. The fleece travelled through this path at a rate of 0.2 m/min. This treatment coagulated the binder. The fleece was then dried and vulcanized (20 minutes at 110° C.). Quantity of solid substance incorporated: 90%, based on the weight of the substrate. The fleece was then split into four layers each approximately 1.0 mm in thickness.
The values for the water vapor absorption capacity are shown in Table I and the most important mechanical properties in Table II.
EXAMPLE 2
The same fleece as in Example 1 was used. Hydrophilising agent Type IV was used for finishing in combination with very finely divided silicate (Type K 322, manufacturers Degussa, Frankfurt) mixed with the binder used in Example 1.
The combination of silicic acid/hydrophilising agent was prepared as follows: A mixture of 1 part of silicate to 5 parts of solution IV with the addition of 0.2% of maleic acid was dried and then after heated at 150° C. for 30 minutes. The product obtained was then milled and 1 part of the milled substance was mixed to a paste with 1.5 parts of water. The suspension thus obtained was mixed in proportions of 1:1 with the binder used in Example 1. The additives described in Example 1 were then added in the quantities indicated there. The mixture was diluted with water to a total solid concentration of 31%. The coagulation point of the diluted mixture was 44° C.
The fleece was impregnated with this mixture and then finished as described in Example 1. Quantity incorporated: 95%, based on the weight of fibers. The values for the water vapor absorption capacity are shown in Table I, the most important mechanical properties in Table II.
EXAMPLE 3 (Comparison example)
The fleece described in Example 1 was impregnated with the same butadiene/acrylonitrile copolymer latex as described in Example 1. No hydrophilising agent was added but the additives given in Example 1 were added in the same quantities as indicated there. The properties of the fleece finally obtained are shown in Tables I and II. Quantity of incorporated binder: 100%, based on the weight of the fibers. Explanations to Table I: measurement of hydrophilic character:
Samples measuring 2×5 cm were removed from the individual layers obtained by splitting the fleeces, and the samples were dried to constant weight. They were then introduced into an air conditioned chamber which was at a relative humidity of 45%, and left therein for 24 hours. The absorption of water vapor was determined quantitatively in relation to time. The water vapor absorption in an air conditioned chamber at 86% relative humidity was then measured over a period of 24 hours. To measure the amount of moisture given off, the samples were again introduced into a chamber at 45% relative humidity and weighed at intervals.
The data shown in the Table represent the changes in weight of the samples due to absorption and release of water vapor of the individual layers. Columns 1 and 4 refer to the outermost layers and columns 2 and 3 to the internal layers.
The data clearly show that the tendency to migration of the hydrophilic finish applied in Example 1 is very slight but still detectable at 85% relative humidity from the low values obtained for the water absorption of the inner layers. In Example 2, this tendency to migration is completely eliminated. The inner layers of the fleece according to Example 3 have virtually no water vapor storage capacity. The higher values of the outer layers compared with those of the inner layers are due to the fact that the emulsifier formed from the latex which was used to bind the fleece migrated to the surface in the course of the drying process, i.e. to what subsequently forms the outer layers. The water vapor storage capacity of the fleece manufactured according to Example 2 is substantially higher in the inner layers than that of the fleece manufactured according to Example 3.
Explanations to Table 2--mechanical values:
The comparison shows that compared to a fleece manufactured according to Example 3, i.e. in accordance with the known art, the addition of hydrophilising agent has no deleterious effect on the mechanical properties of the fleeces.
TABLE I__________________________________________________________________________Water vapor absorption and releaseFleece Permeabilityaccording Increase and decrease in weight in % after storage to waterto Example Layer 45% r.H. 86% r.H. 45% r.H. vapor inNo. No. 4 h 8 h 24 h 4 h 8 h 24 h 4 h 8 h 24 h mg/h/cm.sup.2__________________________________________________________________________1 1 1.05 1.05 1.05 2.60 2.85 4.65 1.60 1.40 1.25 21.3 2 0.70 0.95 0.95 2.40 2.60 3.90 1.60 1.30 1.20 3 0.85 1.00 1.05 2.25 2.40 3.10 1.45 1.30 1.20 4 0.90 1.10 1.15 2.85 3.40 5.10 2.00 1.50 1.352 1 1.05 1.05 1.05 3.65 3.70 4.10 1.30 1.25 1.15 22.7 2 1.10 1.10 1.10 3.40 3.40 4.05 1.25 1.20 1.20 3 1.10 1.10 1.10 3.50 3.55 3.95 1.25 1.25 1.25 4 1.15 1.20 1.20 3.80 3.80 4.10 1.35 1.30 1.203 1 0.20 0.20 0.20 2.50 2.50 2.90 0.20 0.20 0.20 23.1 2 0.10 0.10 0.10 1.40 1.40 1.60 0.10 0.10 0.10 3 0.10 0.10 0.10 1.20 1.40 1.60 0.10 0.10 0.10 4 0.20 0.20 0.20 1.60 1.70 1.90 0.20 0.20 0.20__________________________________________________________________________
TABLE II__________________________________________________________________________ Resistance toTensile tearing bystrength Elongation needle punc- Tear propagationMPa at break ture resistanceLongitud- % N/mm N/mm Stretching in Bally tensometerinal Traverse Long. Trans. Long. Trans. Linear Permanent Pressuredirection direction dir. dir. dir. dir. V % V % bar__________________________________________________________________________Example1 4.9/110 12.1/86 52.0 76.0 29.0 39 25 10.0 3.2Example2 6.8/88 10.1/116 71.0 67.0 51.0 31 25 13.2 2.8Example3 6.6/109 9.3/118 71.8 57.3 41.5 31 25 6.5 2.3__________________________________________________________________________
Although the invention has been described in detail 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 present invention is concerned with a method for improving the water storage capacity of textile substrates, particularly fleece based artificial leathers by treatment with a hydrophilizing agent. This agent, once applied to the substrate is insoluble in but swellable in water. The agent in an uncross-linked state is water soluble and has a turbidity point of between about 25° and 95° C. in a 25% aqueous solution. The agent may be applied to the substrate from aqueous solution and then cross-linked or it may be applied to an inert carrier such as kaolin, cross-linked and applied to the substrate from an aqueous suspension. A particularly suitable agent is a polyether with a molecular weight of between 500 and 8500, an ethylene oxide content of about 35 to 80 wt. % and cross-linkable end groups. The end groups may be self cross-linking such as vinyl groups or they may be cross-linkable via a cross-linking promoter such as hexamethylol melamine. These end groups include the hydroxyl groups normally present in polyethers produced from polyalkylene oxides.
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[0001] This application claims benefit, under U.S.C. §119 or §365 of French Application Number 02/11992, filed Sep. 27, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates to a coextrusion tie which adheres to polyester layers and which comprises a blend of metallocene polyethylene, abbreviated to mPE in the continuation of the text, of non-metallocene LLDPE, both cografted, and of ungrafted metallocene polyethylene. The invention also relates to the multilayer structure comprising this tie and to the objects comprising such a structure.
BACKGROUND OF THE INVENTION
[0003] To date, the adhesives for binding layers or films made of PE or made of polyester were based on ethylene/alkyl (meth)acrylate and/or ethylene/vinyl acetate copolymers. However, these adhesives have the disadvantages of giving off a strong smell, which presents operating problems. Moreover, their adhesiveness is not in particular very effective and, in any case, not in duration. These adhesives also have the disadvantages of not allowing the adhesion of polyester or polyolefin layers to EVOH (barrier material) layers.
[0004] The document FR 2 806 734 of the Applicant Company discloses a composition comprising metallocene PE and non-metallocene LLDPE which are cografted with unsaturated carboxylic acid or its derivative, said composition being diluted in PE or an elastomer. The PE being able [sic], in this application, to be a PE homopolymer or copolymer with, in this case, an α-olefin for comonomer and it can be a PE of HDPE (high density PE), LDPE (low density PE), LLDPE (linear low density PE) for VLDPE (very low density PE) type or a metallocene PE. No information or examples are given with regard to the diluent when the latter proves to be metallocene PE.
[0005] The Applicant Company has now found a tie which no longer presents olfactory problems like the ties of the former generation and which exhibits a significant adhesiveness from its application which increases until a plateau is reached. Furthermore, this adhesive adheres to EVOH (barrier material) layers, contrary to the adhesives of ethylene/alkyl (meth)acrylate or ethylene/vinyl acetate type.
[0006] This tie exhibits adhesion characteristics which are not described in the other documents of the prior art. These characteristics are described later in the present document.
[0007] The tie is recovered in the form of granules at the outlet of an extruder or of any other equivalent device; the Applicant Company has found that this granulation was much easier than for the ties of ethylene/vinyl acetate type which are grafted.
[0008] This tie thus makes possible the preparation of varied structures comprising, inter alia, a polyethylene layer, a polyester layer and/or a barrier material layer. A person skilled in the art will adapt the choice of the polyester according to the conversion method chosen.
[0009] These structures are of use in the manufacture of flexible or rigid packagings, such as bags, bottles, containers, pipes, coextruded hoses, or multilayer gas tanks for vehicles.
SUMMARY OF THE INVENTION
[0010] A subject matter of the invention is a coextrusion tie, which comprises:
5 to 35% by weight of a polymer (A) itself composed of a blend of 80 to 20% by weight of a metallocene polyethylene (A1) with a density of between 0.863 and 0.915 and of 20 to 80% by weight of a non-metallocene LLDPE polyethylene (A2) with a density of between 0.900 and 0.950, the blend of polymers (A1) and (A2) being cografted by a grafting monomer chosen from unsaturated carboxylic acids and their derivatives, the content of the grafting monomer in said blend being between 30 and 100 000 ppm, preferably between 600 and 5 000 ppm; 95 to 65% by weight of metallocene polyethylene (B) homo- or copolymer, the comonomer of which comprises 3 to 20 carbon atoms, preferably 4 to 8 carbon atoms, the density of which is between 0.863 and 0.915 and the MFI, melt flow index, of which, measured under 2.16 kg at 190° C. according to Standard ASTMD 1238, is between 0.5 and 30, preferably between 3 and 15, g/10 min; the total forming 100%, the blend of (A) and (B) being such that its MFI is between 0.1 and 15, preferably between 1 and 13, g/10 min.
[0014] According to one embodiment, the adhesive strength of the tie is increased by 5 to 50% between the time t=0 corresponding to its application immediately after its extrusion and the time t=8 days.
[0015] According to one embodiment, the grafting monomer for the tie is maleic anhydride.
[0016] According to one embodiment, the tie additionally comprises an ethylene/alkyl (meth)acrylate copolymer (C).
[0017] According to one embodiment, the MFI of (A) for the tie is between 0.1 and 5 g/10 min (ASTMD 1238 at 190° C. under 2.16 kg).
[0018] Another subject matter of the invention is a multilayer structure, which comprises a layer (L) comprising the tie described above and a layer (E) directly attached to one of the two faces of said layer (L), said layer (E) being a polyolefin or polyester layer.
[0019] According to one embodiment, in the multilayer structure, a layer (F) is directly attached to the second face of the layer (L), the layer (L) being sandwiched between the layers (E) and (F), said layer (F) being either a polymer layer, the polymer being chosen from the group of the polyamides, saponified copolymers of ethylene and of vinyl acetate (EVOH), polyolefins and polyesters, or a metal layer.
[0020] The invention additionally relates to an object comprising a structure described above and to the use of the structure in manufacturing films or sheets.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The invention will now be described in detail.
[0022] As regards (A1), the term “metallocene polyethylene” denotes the polymers obtained by copolymerization of ethylene and of an α-olefin having from 3 to 30 carbon atoms, preferably from 3 to 8 carbon atoms, such as, for example, propylene, butene, pentene, hexene or octene, in the presence of a single-site catalyst.
[0023] Examples of α-olefins having 3 to 30 carbon atoms as possible comonomers comprise propylene, 1-butene, 1-pentene, 3-methyl-1-butene, 1-hexene, 4-methyl-1-pentene, 3-methyl-1-pentene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-icocene [sic], 1-dococene [sic], 1-tetracocene [sic], 1-hexacocene [sic], 1-octacocene [sic] and 1-triacontene. These α-olefins can be used alone or as a mixture of two or of more than two.
[0024] A single-site catalyst is generally composed of an atom of a metal which can be, for example, zirconium or titanium and of two cyclic alkyl molecules bonded to the metal. More specifically, the metallocene catalysts are usually composed of two cyclopentadiene rings bonded to the metal. These catalysts are frequently used with aluminoxanes as cocatalysts or activators, preferably methylaluminoxane (MAO). Hafnium can also be used as metal to which the cyclopentadiene is attached. Other metallocenes can include transition metals from Groups IVA, VA and VIA. Metals from the lanthanide series can also be used.
[0025] These metallocene polyethylenes can also be distinguished by their {overscore (Mw)}/{overscore (Mn)} ratio <3 and preferably <2, in which {overscore (Mw)} and {overscore (Mn)} respectively denote the weight-average molar mass and the number-average molar mass. The term “metallocene polyethylene” also denotes those having an MFR (Melt Flow Ratio) of less than 6.53 and an {overscore (Mw)}/{overscore (Mn)} ratio of greater than MFR minus 4.63. MFR denotes the ratio of the MFI 10 (MFI under a load of 10 kg) to the MFI 2 (MFI under a load of 2.16 kg). Other metallocene polyethylenes are defined by an MFR equal to or greater than 6.13 and an {overscore (Mw)}/{overscore (Mn)} ratio of less than or equal to MFR minus 4.63.
[0026] Advantageously, the density of (A1) is between 0.863 and 0.915. The MFI of the mPE (A1) is between 0.5 and 30 g/10 min (according to Standard ASTM D1238 at 190° C. under 2.16 kg).
[0027] As regards (A2), the polymer (A2) is a copolymer of ethylene and of an α-olefin of LLDPE (linear low density polyethylene) type and is not of metallocene type. The α-olefins advantageously have from 3 to 30 carbon atoms. The list of these α-olefins has already been given above. They are preferably α-olefins having from 3 to 8 carbon atoms.
[0028] The density of (A2) is advantageously between 0.900 and 0.950.
[0029] The MFI or melt flow index of (A2) is between 0.1 and 8 g/10 min (according to Standard ASTM D1238 at 190° C. under 2.16 kg).
[0030] The blend of the polymers (A1) and (A2) is grafted with a grafting monomer, that is to say that the polymers (A1) and (A2) are cografted. The grafting monomer is chosen from unsaturated carboxylic acids or their functional derivatives.
[0031] Examples of unsaturated carboxylic acids are those having 2 to 20 carbon atoms, such as acrylic, methacrylic, maleic, fumaric and itaconic acids. The functional derivatives of these unsaturated carboxylic acids comprise the anhydrides, the ester derivatives, the amide derivatives, the imide derivatives and the metal salts (such as the alkali metal salts) of these unsaturated carboxylic acids.
[0032] Unsaturated dicarboxylic acids having 4 to 10 carbon atoms and their functional derivatives, particularly their anhydrides, are particularly preferred grafting monomers.
[0033] These grafting monomers comprise, for example, maleic, fumaric, itaconic, citraconic, allylsuccinic, cyclohex-4-ene-1,2-dicarboxylic, 4-methylcyclohex-4-ene-1,2-dicarboxylic, bicyclo[2.2.1]hept-5-ene-2,3-dicarboxylic and x-methylbicyclo[2.2.1]hept-5-ene-2,3-dicarboxylic acids and their functional derivatives and maleic, itaconic, citraconic, allylsuccinic, cyclohex-4-ene-1,2-dicarboxylic, 4-methylenecyclohex-4-ene-1,2-dicarboxylic [sic], bicyclo[2.2.1]hept-5-ene-2,3-dicarboxylic and x-methylbicyclo[2.2.1]hept-5-ene-2,2-dicarboxylic [sic] anhydrides.
[0034] Examples of other grafting monomers comprise C 1 -C 8 alkyl esters or glycidyl ester derivatives of unsaturated carboxylic acids, such as methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, butyl acrylate, butyl methacrylate, glycidyl acrylate, glycidyl methacrylate, monoethyl maleate, diethyl maleate, monomethyl fumarate, dimethyl fumarate, monomethyl itaconate and diethyl itaconate; amide derivatives of unsaturated carboxylic acids, such as acrylamide, methacrylamide, maleic acid monoamide, maleic acid diamide, maleic acid N-monoethylamide, maleic acid N,N-diethylamide, maleic acid N-monobutylamide, maleic acid N,N-dibutylamide, fumaric acid monoamide, fumaric acid diamide, fumaric acid N-monoethylamide, fumaric acid N,N-diethylamide, fumaric acid N-monobutylamide and fumaric acid N,N-dibutylamide; amide derivatives of unsaturated carboxylic acids, such as maleimide, N-butylmaleimide and N-phenylmaleimide; and metal salts of unsaturated carboxylic acids, such as sodium acrylate, sodium methacrylate, potassium acrylate and potassium methacrylate. Maleic anhydride is preferred.
[0035] Various known processes can be used to graft a grafting monomer to the blend of polymers (A1) and (A2). The blend can comprise the additives generally used during the processing of polyolefins at contents of between 10 ppm and 50 000 ppm, such as antioxidants based on substituted phenolic molecules, UV stabilizers, processing aids, such as fatty amides, stearic acid and its salts, fluoropolymers known as agents for preventing extrusion defects, amine-based antifogging agents, antiblocking agents, such as silica or talc, masterbatches with dyes, and nucleating agents, inter alia.
[0036] For example, the grafting can be carried out by heating the polymers (A1) and (A2) at high temperature, approximately 150° C. to approximately 300° C., in the presence or in the absence of a solvent and with or without radical initiator. Appropriate solvents which can be used in this reaction are benzene, toluene, xylene, chlorobenzene or cumene, inter alia. Appropriate radical initiators which can be used comprise t-butyl hydroperoxide, cumene hydroperoxide, diisopropylbenzene hydroperoxide, di(t-butyl) peroxide, t-butyl cumyl peroxide, dicumyl peroxide, 1,3-bis(t-butylperoxyisopropyl)benzene, acetyl peroxide, benzoyl peroxide, isobutyryl peroxide, bis(3,5,5-trimethylhexanoyl) peroxide and methyl ethyl ketone peroxide.
[0037] In the blend of polymers (A1) and (A2) modified by grafting obtained in the abovementioned way, the amount of the grafting monomer can be appropriately chosen but it is preferably from 0.01 to 10% by weight, that is to say preferably from 600 ppm to 5 000 ppm, with respect to the weight of cografted (A1) and (A2).
[0038] The amount of the monomer grafted is determined by quantitative determination of the succinic functional group by FTIR spectroscopy. The MFI or melt flow index of (A), that is to say of the blend of (A1) and (A2) which have been cografted, is between 0.1 and 15 g/10 min (ASTM D 1238, 190° C., 2.16 kg), advantageously between 0.1 and 5 g/10 min, preferably between 0.1 and 3 g/10 min.
[0039] As regards the polyethylene (B), it is a metallocene polyethylene homopolymer or copolymer with, in this case, a comonomer chosen from α-olefins having from 3 to 20 carbon atoms, preferably from 4 to 8 carbon atoms.
[0040] Examples of α-olefins having from 3 to 20 carbon atoms comprise propylene, 1-butene, 1-pentene, 3-methyl-1-butene, 1-hexene, 4-methyl-1-pentene, 3-methyl-1-pentene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene or 1-icocene [sic]. These α-olefins can be used alone or as a mixture of two or of more than two.
[0041] The metallocene polyethylene (B) has a density of between 0.863 and 0.915 and an MFI (measured according to Standard ASTM D 1238 at 190° C. under 2.16 kg) of between 0.5 and 30 g/10 min, preferably between 3 and 15 g/10 min.
[0042] The MFI of the coextrusion tie is between 0.1 and 15 g/10 min, preferably between 1 and 13 g/10 min (ASTMD 1238, 190° C., 2.16 kg).
[0043] The ties of the invention are of use for multilayer structures, such as, for example, films, sheets, pipes and hollow bodies.
[0044] The multilayer structure of the present invention comprises a layer (L) comprising the tie described above and a layer (E) directly attached to a first face of said layer (L). The layer (E) is a layer of polymers chosen from polyolefins and polyesters.
[0045] A layer (F) can also be directly attached to the second face of the layer (L), the layer (L) being sandwiched between the layers (E) and (F), said layer (F) being either a polymer layer, the polymer being chosen from the group of the polyamides and saponified copolymers of ethylene and of vinyl acetate (EVOH), or a metal layer.
[0046] However, the multilayer structure can also comprise a layer (L) comprising the tie sandwiched between two layers (F).
[0047] The following structures can be listed by way of example: PA denoting polyamide, L the tie, PE polyethylene, PET poly(ethylene terephthalate) and EVOH the saponified copolymer of ethylene and of vinyl acetate:
structures of type layer (E)/layer (L)/layer (F): PE/L/EVOH/L/PET, PE/L/PA or PE/L/PA/L/PE, and; structures of type [lacuna] (E)/layer (L)/layer (E) and layer (F)/layer (L)/layer (F): PET/L/PE, PE/L/PE, PET/L/PET or PA/L/PA, mixed structures: PE/L/EVOH/L/PA.
[0051] More specifically, the polyamides are long-chain synthetic polyamides having structural units of the amide group in the main chain, such as PA-6, PA-6,6, PA-6,10, PA-11, PA-6/6,6 and PA-12.
[0052] The saponified copolymers of ethylene and of vinyl acetate have a degree of saponification of approximately 90 to 100 mol % and are obtained by saponifying an ethylene/vinyl acetate copolymer having an ethylene content of approximately 15 to approximately 60 mol %.
[0053] The polyesters are homo- or copolymers. The homopolyesters can be taken from the group of poly(ethylene terephthalate), poly(butylene terephthalate) and poly(ethylene naphthenate) or aromatic polyesters, such as polymeric liquid crystals.
[0054] Appropriate copolyesters of use in the invention can be formed from aromatic dicarboxylic acids, from dicarboxylic acid esters, from dicarboxylic ester [sic] anhydrides, from glycols or from their mixtures. Partially aromatic copolyesters formed from repeat units comprising terephthalic acid, dimethyl terephthalate, isophthalic acid, dimethyl isophthalate, dimethyl 2,6-naphthalenedicarboxylate, 2,6-naphthalenedicarboxylic acid, 1,2-, 1,3- and 1,4-phenylenedioxydiacetic acids, ethylene glycol, diethylene glycol, 1,4-cyclohexanedimethanol, 1,4-butanediol or their mixtures are also appropriate.
[0055] Preferably, the structure of the polyesters comprises repeat units comprising terephthalic acid, dimethyl terephthalate, isophthalic acid, dimethyl isophthalate and/or dimethyl 2,6-naphthalenedicarboxylate. The dicarboxylic acid of the polyester can be modified with one or more different dicarboxylic acids (preferably up to approximately 20 mol %). Such dicarboxylic acids comprise aromatic dicarboxylic acids preferably having 8 to 14 carbon atoms, aliphatic dicarboxylic acids preferably having 4 to 12 carbon atoms or cycloaliphatic dicarboxylic acids preferably having 8 to 12 carbon atoms. The examples of dicarboxylic acids are: terephthalic acid, phthalic acid, isophthalic acid, naphthalene-2,6-dicarboxylic acid, cyclohexanedicarboxylic acid, cyclohexanediacetic acid, diphenyl-4,4′-dicarboxylic acid, succinic acid, glutaric acid, adipic acid, azelaic acid, sebacic acid or their mixtures.
[0056] Furthermore, the glycol can be modified with one or more different diols other than ethylene glycol (preferably up to approximately 20 mol %). Such diols comprise: cycloaliphatic diols preferably having 6 to 20 carbon atoms or aliphatic diols preferably having 25 [sic] to 20 carbon atoms. The examples of such diols comprise: diethylene glycol, triethylene glycol, 1,4-cyclohexanedimethanol, propane-1,3-diol, butane-1,4-diol, pentane-1,5-diol, hexane-1,6-diol, 3-methylpentane-2,4-diol, 2-methylpentane-1,4-diol, 2,2,4-trimethylpentane-1,3-diol, 2-ethylhexane-1,3-diol, 2,2-diethylpropane-1,3-diol, hexane-1,3-diol, 1,4-di(hydroxyethoxy)benzene, 2,2-bis(4-hydroxycyclohexyl)propane, 2,4-dihydroxy-1,1,3,3-tetramethylcyclobutane, 2,2-bis(3-hydroxyethoxyphenyl)propane, 2-bis(4-hydroxypropoxyphenyl)propane [sic], (hydroxyethyl)resorcinol or their mixtures. The polyesters can be prepared with two or more than two of the above diols.
[0057] The metal layer can be, for example, a film or a sheet of a metal, such as aluminum, iron, copper, tin and nickel, or an alloy comprising at least one of these metals as main constituent. The thickness of the film or of the sheet can be suitably chosen and it is, for example, from approximately 0.01 to approximately 0.2 mm. It is common practice to degrease the surface of the metal layer before rolling the tie of the invention onto it.
[0058] The compositions forming the various layers of the structures of the invention can comprise additives, such as fillers, stabilizers, slip agents, antistatic agents or flame retardants.
[0059] The structures of the invention can be manufactured by coextrusion, extrusion-blow molding, thermoforming, film coating or rolling processes known in the field of thermoplastics.
EXAMPLES
[0060] The tie compositions according to the invention (Ex. 1-4) and the comparative compositions (Comp. 1-7) are combined in Table 1 below.
[0061] The peel strength F in N/15 mm at t0 (time=0, when the tie has just been extruded and applied to the test specimen) and at t8 (corresponding to time=8 days) are combined in Table 2 below. The films used for these tests are coextruded films composed of 3 layers for case 1: PET layer/tie layer (L)/PE layer, with respective thicknesses of 150/30/350 in μm, and films composed of 5 layers for cases 2 and 3: PET layer/tie layer (L)/EVOH layer/tie layer (L)/PE layer, with respective thicknesses of 150/30/20/30/300 in μm.
[0062] The peel tests were carried out at a temperature T of 25° C. and at a peel rate of 200 mm/min. VORIDIAN 9921W PET from Eastman, LACQTENE LD0304 LDPE from Atofina and SOARNOL EVOH, comprising 38% of ethylene, from Nippon Gohsei were used to prepare these films. The symbol σ corresponds to the standard deviation.
TABLE 1 Ex. 1 Ex. 2 Ex. 3 Ex. 4 Characteristics of Type of PE mPE LLDPE mPE LLDPE mPE LLDPE mPE LLDPE the cografted Density (g/cm 3 ) 0.87 0.92 0.87 0.92 0.87 0.92 0.87 0.92 polymer (A) Comonomer 1-octene 1-butene 1-octene 1-butene 1-octene 1-butene 1-octene 1-butene Composition 50% 50% 50% 50% 50% 50% 50% 50% Degree of grafting 0.9% 0.9% 0.9% 0.9% Grafting monomer MAH MAH MAH MAH MFI (g/10 min) 0.7 0.7 0.7 0.7 190° C., 2.16 kg Proportion of (A) 15% 25% 15% 25% Characteristics of Type of mPE E/1-octene E/1-octene E/1-octene E/1-octene the polymer (B) Density (g/cm 3 ) 0.870 0.870 0.902 0.902 MFI (g/10 min) 5 5 10 10 190° C., 2.16 kg Proportion of (B) 85% 75% 85% 75% MFI of the blend (A) and (B) 3 2.5 5.5 4.5 Comp. 1 Comp. 2 Comp. 3 Comp. 4 Characteristics of Type of PE mPE LLDPE mPE LLDPE mPE LLDPE mPE LLDPE the cografted Density (g/cm 3 ) 0.87 0.92 0.87 0.92 0.87 0.92 0.87 0.92 polymer (A) Comonomer 1-octene 1-butene 1-octene 1-butene 1-octene 1-butene 1-octene 1-butene Composition 50% 50% 50% 50% 50% 50% 50% 50% Degree of grafting 0.9% 0.9% 0.9% 0.9% Grafting monomer MAH MAH MAH MAH MFI (g/10 min) 0.7 0.7 0.7 0.7 190° C., 2.16 kg Proportion of (A) 25% 25% 15% 25% Characteristics of Type of mPE E/Me acrylate E/vinyl acetate E/Me acrylate VLDPE and (E/1-octene) mPE** the polymer (B) Density (g/cm 3 ) 0.943 0.950* 0.943 and 0.902** 0.911 MFI (g/10 min) 8 20 and 3* 8 and 10** 6.6 190° C., 2.16 kg Proportion of (B) 75% 75% 85%** 75% MFI of the blend (A) and (B) Comp. 5 Comp. 6 Comp. 7 Characteristics of Type of PE mPE LLDPE mPE LLDPE mPE LLDPE the cografted Density (g/cm 3 ) 0.87 0.92 0.87 0.92 0.87 0.92 polymer (A) Comonomer 1-octene 1-butene 1-octene 1-butene 1-octene 1-butene Composition 50% 50% 50% 50% 50% 50% Degree of grafting 0.9% 0.9% 0.9% Grafting monomer MAH MAH MAH MFI (g/10 min) 0.7 0.7 0.7 190° C., 2.16 kg Proportion of (A) 25% 25% 25% Characteristics of Type of mPE LLDPE LDPE HDPE (E/1-octene) the polymer (B) Density (g/cm 3 ) 0.919 0.924 0.955 MFI (g/10 min) 4.4 2 4 190° C., 2.16 kg Proportion of (B) 75% 75% 75% MFI of the blend (A) and (B) *37.5% of E/vinyl acetate copolymer with MFI = 20 and d = 0.950, and 37.5% of E/vinyl acetate copolymer with MFI = 3 and d = 0.950; **42.5% of E/methyl acrylate copolymer with MFI = 8 and d = 0.943, and 42.5% of mPE with 1-octene as comonomer and MFI = 10 and d = 0.902
[0063]
TABLE 2
CASE 1
CASE 2
CASE 3
F at t0
F at t8
F at t0
F at t8
F at t0
F at t8
in
in
in
in
in
in
N/15 mm
σ
N/15 mm
σ
N/15 mm
σ
N/15 mm
σ
N/15 mm
σ
N/15 mm
σ
Ex. 1
13.4
0.5
16.7
0.7
8.2
0.2
10.7
0.1
—
—
—
—
Ex. 2
14.2
0.5
17.8
0.4
10.6
0.3
12.8
0.4
—
—
—
—
Ex. 3
11.6
0.6
15.1
3.4
8.5
0.1
10.1
0.2
—
—
—
—
Ex. 4
12.5
0.8
20.1
1.8
10.4
0.2
12.1
0.3
—
—
—
—
Comp. 1
6
0.5
5.6
0.4
—
—
—
—
5.8
0.5
5.2
0.4
Comp. 2
6.1
0.5
6.6
0.9
—
—
—
—
5.7
0.2
5.8
0.4
Comp. 3
6.5
0.9
6.8
0.8
—
—
—
—
6.2
0.9
6.1
0.8
Comp. 4
4.4
2.1
1.3
0.2
—
—
—
—
4.1
1
2.1
0.2
Comp. 5
3.2
0.3
1.2
0.2
—
—
—
—
3.2
0.1
1.4
0.2
Comp. 6
2.6
0.2
1
0.1
—
—
—
—
2.7
0.2
1.2
0.1
Comp. 7
1.2
0.1
0.5
0.1
—
—
—
—
1
0.1
0.6
0.1
Case 1: Failure between the PET layer and the tie layer (L)
Case 2: Failure between the EVOH layer and the tie layer (L)
Case 3: Failure between the PET layer and the tie layer (L)
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A subject matter of the invention is a coextrusion tie, which comprises: 5 to 35% by weight of a polymer (A) itself composed of a blend of 80 to 20% by weight of a metallocene polyethylene (A1) with a density of between 0.863 and 0.915 and of 20 to 80% by weight of a non-metallocene LLDPE polyethylene (A2) with a density of between 0.900 and 0.950, the blend of polymers (A1) and (A2) being cografted; 95 to 65% by weight of metallocene polyethylene (B) homo- or copolymer, the comonomer of which comprises 3 to 20 carbon atoms, preferably 4 to 8 carbon atoms, the density of which is between 0.863 and 0.915 and the MFI of which is between 0.5 and 30, preferably between 3 and 15, g/10 min; the total forming 100%, the blend of (A) and (B) being such that its MFI is between 0.1 and 15, preferably between 1 and 13, g/10 min.
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TECHNICAL FIELD
This invention relates to vision improvement devices, and more specifically, to devices for maintaining clear visibility through viewing windows.
BACKGROUND OF THE INVENTION
The need for maintaining clear visibility through viewing windows has long been recognized, particularly in the automobile industry, the shipping industry, the tooling and machining industry, and in many other areas where clear visibility through a window is required.
Visibility through a viewing window is commonly impeded when, for example, water and other debris impacts the window. In the automotive and shipping industry, reciprocating wipers have been used to remove water and debris from windshields. Windshield wipers cannot, however, overcome the problem of water collecting on the windshield in between swipes of the wiper, regardless of the speed at which the wiper reciprocates.
In the machining and tooling industry, there is a need to maintain the window through which the work piece is viewed clear of coolant used in machining and scraps of metal and debris resulting from the machining process. Wire screens have been used to protect the window from flying pieces of debris. However, use of a screen tends to impede, rather than improve, visibility through the window.
In all of the above-mentioned applications, a need exists not only to maintain the viewing window free of water and other debris, but also to keep intact as much of the structural integrity of the viewing window as possible. Preferably, there should be no reduction in such structural integrity for safety reasons.
Rotating windows have been used to overcome some of the above-noted problems in the shipping and machining industry. A rotating window places a centrifugal force on any object that comes into contact with the window and slings the object immediately off the rotating window.
Prior known rotating windows suffer, however, from several drawbacks. First, traditional mounting techniques for windows have required that some type of a mounting hole be cut through the viewing window. This, of course, weakens the strength of the viewing window and creates safety concerns. Further, the bigger the rotating window, the bigger the hole must be and the weaker the viewing window becomes. Stress cracks commonly originate from the edges of such a mounting hole which further weaken the strength of the window.
Another problem with respect to known prior rotating windows is that they must typically be installed on an existing enclosure that has a stationary or viewing window. Such installation requires cutting a hole in the viewing window and mechanically securing the rotating window to the stationary window, which is labor intensive and therefore expensive. Further, holes cannot generally be cut into windows made of certain materials, such as glass that has already been tempered, and laminated safety glass.
Another problem associated with prior rotating windows is that they have a tendency to fog up. These prior rotating windows have one sheet of transparent material facing the area to be viewed that rotates and a second sheet of transparent material closest to the person looking through the rotating window. This second sheet is stationary and overlies the opening which has been cut in the larger viewing window. If moisture, such as from water or lubricants, enters into the area in between the two sheets of material, the transparent materials will fog up. The problem of moisture entering in between the sheets of material commonly arises when the rotating window has been deactuated.
A further problem created by prior rotating windows is that because they are mounted through holes, they create a tunnel-vision effect, from the length of cylindrical window housing, that restricts the angle of vision of the operator through the rotating window.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a rotating window for maintaining a viewing window free from water and other debris.
Another object of the invention is to provide a rotating window that can be directly secured to a stationary window without the need of cutting a hole in the stationary window for installation.
Another object of the invention is to provide a rotating window that includes a means for creating a positive pressure to force air through an internal area between the rotating window and the stationary window to remove any moisture inside the internal area and prevent the windows from fogging up.
Still another object of the invention is to provide a rotating window that prevents water and moisture from entering in between the rotating window and the stationary window to prevent either window from fogging up.
Another object of the invention is to increase the viewing angle through the rotating window so that more of the work being performed within the enclosure can be viewed by the operator.
Another object of the present invention is to provide a unique seal in between the rotating window and the stationary window to prevent moisture and water from entering into an area in between the windows.
Yet another object of the invention is to provide a rotating window that is easy to install.
Another object of the invention is to provide a rotating window that can be manufactured relatively inexpensively.
These objects, as well as other objects that will become apparent from the detailed description of the invention that follows, are achieved by a rotating window mounted directly to one side of a stationary, viewing window without the need to cut a hole in the stationary window. The rotating window faces toward the working or weather-exposed area and slings off any water or other debris that contacts the rotating window to maintain clear visibility through the stationary window. The rotating window further comprises a means for drawing air through the area in between the rotating window and the viewing window so that moisture does not collect on and fog up either window.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective, environmental view of a rotating window.
FIG. 2 is a front elevational view of the rotating window.
FIG. 3 is a sectional side elevational view, taken along line 3--3 of FIG. 2, of the rotating window.
FIG. 4 is a enlarged, partial side elevational view of the rotating window as shown in FIG. 3.
FIG. 5 is an alternative embodiment of a safety means for securing the rotating window to the stationary window.
FIG. 6 is a side elevational view of a prior art window.
FIG. 7 is a side elevational view of the rotating window showing.. the angle of view through the rotating window.
DETAILED DESCRIPTION OF THE INVENTION
The present invention comprises generally, as shown in FIGS. 1-4, a rotating window 10 rotatably coupled to a base member 12, which in turn is directly attached to one side of a viewing or stationary window 14. The stationary window is the type through which a person must ordinarily look through to view a work being performed. The rotating window 10 is rotatably driven by an electric motor means 16 which causes the window 10 to rotate at a high rate of speed and sling off objects that contact the window 10 due to the resulting centrifugal force. The main object of the rotating window 10 is to maintain clear visibility through a portion of the stationary window 14.
With reference to FIG. 1, one environment in which the present invention is intended to be used is the machining and tooling industry. FIG. 1 shows a person looking through the rotating window 10 while operating a control panel for controlling machining or tooling that is taking place inside an enclosure having a viewing window 12. Clear vision through such a viewing window has traditionally been difficult, if not impossible, because the inside of the viewing window quickly becomes covered by oils, coolants, metal fragments, and other debris from the machining process.
Although FIG. 1 shows an operator looking through the rotating window 10 at the machining process taking place inside an enclosure, the present invention is also intended to be used on windshields for all types of vehicles, particularly ships and other aquatic vessels, to maintain clear vision through a viewing window or windshield. Additionally, the rotating window may be used to create a viewing port through a solid, nontransparent material such as sheet metal. In such an application, the rotating window would be secured to the sheet metal over a hole that is smaller than the rotating window. Further, the rotating window can be used on the outside of a transparent box through which a camera or person monitors any type of outdoor activity where exposure to adverse weather conditions, such as rain or snow, is possible.
With reference to FIGS. 2-3, the rotating window 10 is rotatably coupled to a base member 12 at a central hub 18. The base member 22 is generally circular except for a pre-shaped section that extends upwardly from the lower portion of base member 12 (as shown in FIG. 2) terminates in a central circular portion that corresponds to the hub 18. A housing member 50 covers the major portion of the sector, as shown in FIGS. 2 and 3. Thus, the operator is able to see through the rotating window except for the areas corresponding to the base member 12, which includes portions behind housing member 50 and central hub 18.
The rotating window 10 comprises an annular frame member 20 having an interior annular shelf 22, and a transparent material 24, such as a polycarbonate material or piece of glass, which is inserted over the hub 18 and seats inside the shelf 22 of the frame member 20. The transparent material or glass 24 is secured to the hub 18 by a clamp ring 26. Although FIG. 3 shows the clamp ring 26 being threaded over the hub, it is understood that any conventional means may hold the clamp ring on the hub. Installation and removal of the rotating window 10 from the base 12 is accomplished by a plurality of mounting screws 60 (preferably three to six, although only one is shown in FIG. 4) which are inserted through the central hub 18 and threadedly received by the rotor hub 36. The glass 24 can be removed by removing the screws 36 to access the interior of the rotating window 10 so that, for example, the stationary window 14 can be cleaned. Since the hub 18 detaches from the rotor hub 36, the balance between the motor means 16 and the shaft 30 is not affected when the glass 24 is removed.
Referring now to FIGS. 3 and 4, the base member 12 is secured to the stationary window 14 by means of an adhesive material shown as a ring 28 and a center pad 27. Although the adhesive ring 28 and adhesive center pad 27 could be any suitable type of adhesive, one embodiment of the invention utilizes a double-sided, adhesive-backed tape comprising an acrylic, high-adhesion bonding material. A primary advantage of this securing method is that there is no need to cut a hole in the stationary window 14 in order to mount the rotating window 10. Thus, the structural integrity of the stationary window 14 remains unchanged. This is particularly important in tooling and machining applications where, for example, milling machines inside the enclosure constantly throw projectiles, such as coolant, oil, and chips and fragments of metal, toward the stationary, viewing window 14 of the enclosure. An O-ring seal 29 is placed around the outermost periphery of the base member 12 to prevent any fluids from contacting the adhesive ring 28 and possibly destroying its adhesion properties.
The rotating window 10 is coupled to the base member 12 by means of a shaft 30. A pair of ball bearings 32, 43 provide a means for allowing the rotating window 10 to rotate about the shaft 30. The ball bearing 43 is secured to the shaft 30 in-between the rotor hub 36 and the combination spacer 49 and snap ring 42. The ball bearing 32 is secured, in turn, to the shaft 30 in-between the rotor hub 36 and a safety washer 45, which is held in place by a screw 47 threadedly received by the shaft 30. The present mounting arrangement securely couples the rotating window 10 to the base member 12 without creating any gyro effects that would otherwise cause the rotating window to pivot relative to the stationary window if, for example, the rotating window were mounted to a hinged door being opened or closed during actuation of the rotating window.
With reference to FIG. 5, an alternative embodiment of the invention includes a safety means for preventing the rotating window 10 from being thrown from the base member 12 if, for some reason, the means for securing the rotating window 14 to the shaft 30 (FIG. 4) fails. This alternative embodiment comprises a plurality of safety posts 53 (only one is shown in FIG. 5) threadedly engaging the periphery of base member 12. The annular frame member 20 defines a peripheral groove 55 which corresponds in shape to the top of the safety post 53. During normal operation, the annular frame 20 will rotate unimpededly inside of the safety posts 53. If, however, the rotating window 10 becomes separated from the shaft 30, the heads of the safety posts 53 will engage the peripheral groove 55 and prevent the rotating window from being thrown away from the base member 12.
The safety posts 53 may also act as jack screws to lift and separate the base member 12 from the stationary window 14. As mentioned above, the sole means for securing the base member 12 to the window 14 is by the adhesive 28. The high-adhesion properties of this material make it extremely difficult to remove the base member 12 from the window 14 without damaging one or the other. Thus the safety posts 53, being located around the periphery of the base member 12, can be sequentially turned to completely pass through the base member 12 and engage the window 14 and gradually separate the base member 12 from the window 14.
The rotating window 10 can be actuated by any conventional means, such as by a conventional alternating current or direct current motor. The speeds at which the window 10 rotates depend primarily upon the diameter of the window, but the speeds commonly range from 2,000 RPM to 8,000 RPM. Typical diameters for the rotating window 10 are nine inches to twelve inches for tooling and machining applications, and from six inches to eighteen inches for marine applications.
In one embodiment, the rotating window is driven by an electric motor means 16 having multiple magnets 44 secured to the periphery of a rotor hub 36 opposite a stack 46. When power is supplied to the motor, the hub 36 and magnets 44 rotate relative to the stack 46.
The electronics (not shown) which actuate the power to the motor means 16 can be housed in space 48 defined by the base member 12 and a housing member 50. It is understood, however, that the electronics could also be located separate from the rotating window 10 without departing from the scope of the present invention. It is also understood that any suitable, conventional electronics could be utilized in the present invention. Lead wires (not shown) pass into the space 48 via a conduit 51 coupled directly to the housing member 50.
With reference to FIG. 3, the annular frame member 20 of the rotating window 10 includes an annular channel 52. The shape of the channel 52 corresponds to the shape of a labyrinth 54 which extends perpendicularly outwardly of the annular frame member 20 to create a seal between the rotating window and the base member 12. The labyrinth 54 includes a plurality of annular flanges 56a, 56b, 56c which extend radially outwardly of the labyrinth.
The purpose of the labyrinth 54 is to reduce the likelihood that liquid, such as water or coolant, will enter into an area 58 in between the rotating window 10 and the stationary window 14 which could cause the windows to fog up. For water to enter into area 58, it would have to pass sequentially over the flanges 56a, 56b, and 56c, respectively, and the channels therebetween before entering into area 58. The labyrinth 54 prevents water or coolant for passing into the internal area 58 whether or not the rotating window 10 is revolving. If, for some reason, liquid enters into the area 58, a drain hole 57 is provided in the base member 12 to allow the liquid to drain by gravity to the outside of the rotating window 10.
Referring now to FIG. 4, another function of the conduit 51, other than to house the lead wires, is to provide a means for ambient air to pass through the rotating window so that moisture can be removed to prevent the stationary window and the rotating window from fogging up. Ambient air enters into the conduit 51 and passes into space 48, between the magnet 44 and the stack 46, between the housing member 50 and the hub 18, between the transparent material 24 and the stationary window 14, and finally exit by passing between the labyrinth 54 and an the annular frame member 20. The above-described direction of air flow is shown by the arrows in FIG. 4. A positive pressure is created when the rotating window rotates which draws air into the conduit 51. It is also understood that air could be forced through the conduit 51 to remedy a severe fogging problem.
Referring now to FIGS. 6 and 7, another feature of the present invention is that is provides an increased angle of view through the rotating window. FIG. 7 shows the present invention wherein the rotating window 10 is secured directly to one side of the stationary window 14 without the need to cut a hole in the window. The total thickness a of the rotating window (i.e., the cross-sectional dimension of the rotating window from the outer surface of the glass 24 to the side of the base member 12 adjacent of the stationary window 14 as shown in FIG. 5) is approximately one inch. The combination of the minimal thickness and the mounting of the rotating window 10 to one side only of the stationary window results in an increased viewing angle α. This, of course, allows the operator to view more of the work being performed within the enclosure.
FIG. 6 shows a prior art rotating window mounted through a hole in a stationary window. This mounting arrangement requires that a width b of the rotating window be located on one side of the window and a second width located on the opposite side of the stationary window. The combination of widths a, b (approximately four inches total) create a tunnel through which the operator must look to see the work being performed. The result is a restricted angle of view β as compared to the present invention.
From the foregoing, it will be appreciated that, although specific embodiments of the invention have been shown and described herein for purposes of illustration, various modifications may be made without departing from the spirit and scope of the invention. Therefore, the invention is not to be limited to specific embodiments shown in the drawings.
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A rotating window mounted directly to one side of a stationary, viewing window or panel without the need to cut a hole in the stationary window. The rotating window faces toward the working or weather-exposed area and slings off any water or other debris that contacts the rotating window to maintain clear visibility through the stationary window. The rotating window further comprises a means for drawing air through the area in between the rotating window and the viewing window so that moisture does not collect on and fog up either window.
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BACKGROUND OF THE DISCLOSURE
Methylchloroform is particularly susceptible to decomposition in the presence of metals, especially when aluminum and iron are present. Stabilizers are known which are effective in stabilizing methylchloroform against decomposition induced by contact with iron and aluminum even at elevated temperatures, such as are encountered in vapor degreasing and processes involving purification by distillation.
It is also known, however, that while pure uninhibited methylchloroform at elevated temperatures is relatively inert to the presence of zinc, methylchloroform which is stabilized against decomposition due to contact with other metals, particularly iron and aluminum, tends to decompose badly in the presence of zinc and cause substantial corrosive attack on the zinc metal. Decomposition of the solvent and corrosion of the zinc occur only when the zinc is exposed to the hot vapors of methylchloroform stabilized against iron and aluminum induced decomposition. Zinc below the surface of the boiling solvent will remain virtually unaffected. This is due to the fact that these inhibitors, which stabilize methylchloroform against iron and aluminum, catalyze the attack of methylchloroform on zinc in the boiling vapors of the solvent. This undesirable property causes a restriction of the utility of methylchloroform particularly as a solvent in the vapor degreasing field as galvanized equipment is common and many of the articles to be degreased are zinc or zinc alloy, such as brass or galvanized iron.
An additional need for a stabilizer system to render the hot vapors of methylchloroform inert to zinc surfaces is found in the recovery of used solvent. Methylchloroform may be used in the cold degreasing of metals until it becomes saturated with dirt, grease and other impurities from the metal being cleaned. Spent solvent without the stabilizer system hereinafter proposed cannot be recovered by distillation in the zinc-lined stills commonly used in the industry without damage to the lining thereof.
Methylchloroform where used as a vapor degreasing solvent contains minor amounts of certain additives or stabilizers to prevent decomposition of the solvent induced by its contact with metals such as aluminum and iron. Inhibitors such as 1,4-dioxane alone or in combination with nitromethane, secondary butyl alcohol, or monohydric acetylenic alcohols are commonly employed. Such stabilizers are quite effective in rendering the solvent inert to attack of the metal by the degradation products, but greatly increase the ability of zinc, in the boiling solvent vapors, to cause degradation of the solvent and concomitantly increased attack of the metal. This undesirable property of the solvent may be eliminated, however, by the addition thereto of a vicinal monoepoxide in the amount of from about 0.01 to 5.0 percent by weight of the solvent mixture.
Numerous formulations which contain the epoxide are known to the literature. Thus, for example in U.S. Pat. No. 3,099,694 an epoxide, together with dioxolane and a monoolefin, is employed as stabilizer for methylchloroform. In U.S. Pat. No. 3,265,747 methylchloroform is stabilized with the combination of a lower dialkyl ketone and an epoxide. More recently U.S. Pat. No. 3,974,230 employs methyl butynol, t-amyl alcohol, a nitroalkane and an epoxide in a formulation for stabilizing methylchloroform used in degreasing operations.
It has now been found unexpectedly that the epoxide can be substituted with an alicyclic compound which contains a cyclopropane ring, particularly those tricyclic and quadricyclic compounds having a fused cyclopropane ring in their structure.
A cyclopropane ring compound in which the ring is not fused into a larger cyclic structure is disclosed in our copending application Ser. No. 212,649, filed Dec. 3, 1980. In that disclosure the compound employed is cyclopropyl methyl carbinol.
SUMMARY OF THE INVENTION
Alicyclic compounds which contain a cyclopropane ring fused into a larger cyclic structure have been found useful as a substitute for the epoxide in formulations of stabilizers employed to protect methylchloroform in the presence of metals. Such formulations have been found effective in vapor degreasing applications, especially when metals such as aluminum, zinc, copper, and iron are present. Concentration of the alicyclic compound preferably is at approximately the same level as that of the alkylene oxide it replaces. Thus, the preferred amount is from about 0.5 to about 1 volume percent in the stabilized methylchloroform solvent, but as little as 0.2% and as much as 2% is operable in the composition of the invention.
DETAILED DESCRIPTION OF THE INVENTION
As representative of formulations useful in stabilizing methylchloroform employed in degreasing operations is one in U.S. Pat. No. 3,974,230. Experiments were performed which show that the cyclopropane ring compounds can be effectively substituted for the epoxide in that formulation.
Formulations according to U.S. Pat. No. 3,974,230 may contain by volume from 1.75 to 3.5% 2-methyl-3-butyn-2-ol, 0 to 4.25% of t-amyl alcohol, 0.5 to 2% nitroalkane and 0.5 to 1% of an alkylene oxide. The nitroalkane may be nitromethane or a mixture thereof with nitroethane.
EXAMPLE 1
A formulation in accordance with the above mentioned patent was tested by refluxing the stabilized material and its top and bottom distilled fractions, i.e. fractions of the composition which would correspond to that found in the vapor section and sump section, respectively, of a vapor degreaser. The formulations containing the epoxide and the same formulations in which the cyclopropane ring compounds had been substituted for the epoxide were tested against certain metals. Approximately 430 g of each formulation was partitioned by distillation into 1:1 fractions. Ten milliliter aliquots of both fractions and the non-fractionated solution were refluxed for seven days in the presence of Al-2024, Zn, Cu, brass, steel, and iron and the solvent stability was rated. A formulation according to the '230 patent containing the epoxide was tested as above and compared with the same formulation in which the epoxide had been replaced with one of the cyclopropane ring-containing compounds. The formulation according to the '230 patent contained 2.0 vol. % 2-methyl-3-butyn-2-ol, 2.0 vol. % t-amyl alcohol, 0.4 vol. % nitromethane, 0.5 vol. % butylene oxide or the test compound. The results are shown in Table I.
TABLE I__________________________________________________________________________ Ratings** 2024 Mossy Zn Aluminum Zinc + Steel IronFormulations* Coupon Chips Coupon Mossy Al Chips Copper Brass Wool Filings__________________________________________________________________________A. Butylene oxide (Comparative) a 0 0 0 0 0 1 1 1 0 b 0 0 0 0 0 1 2 1 0 c 0 0 0 0 0 1 1 0 0B. Nortricyclyl formate*** a 0 0 0 0 0 -- 0 -- --C. Quadricyclane a 0 0 0 0 0 0 1 2 1 b 0 0 0 0 0 1 0 0 0 c 0 0 0 0 1 0 0 1 0__________________________________________________________________________ *a unfractionated solution b top fraction c bottom fraction **The ratings are on a scale of 0-5, zero being substantially no corrosio and clear solvent, while 5 indicates heavy corrosion and discolored, decomposed solvent. ***Contained 0.6% volume nitroethane (in addition to the nitromethane)
EXAMPLE 2
In another test in which the same formulation was prepared, but containing norcarane and norbornylene each in place of the butylene oxide in separate formulations, the unfractionated stabilizer was tested by refluxing in the presence of zinc coupons and mossy zinc for seven days. The results are shown in Table II.
TABLE II______________________________________ Zn Coupons Mossy ZnEpoxide Substitute 0.5% 1.0% 0.5% 1.0%______________________________________Norcarane 0 0 1 2Norbornylene 0 0 0 5(comparative)______________________________________
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A stabilized methylchloroform solvent useful in degreasing operations in which the alkylene oxide stabilizer component normally employed is replaced by a tricyclic or quadricyclic compound containing a fused cyclopropane ring.
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FIELD OF THE INVENTION
The present invention relates to the field of computer hardware and, more specifically, to a method and apparatus for latent fault memory scrub in memory intensive computer hardware.
BACKGROUND OF THE INVENTION
In many applications it is important that a proper command is generated in response to command inputs. Therefore, various ways to check that a given command was generated correctly in response to command inputs have been developed. One way to help ensure proper commands are generated is to use hardware command monitors that can be used to check the output of a logic device that generates the commands. These self-checking architectures can be implemented in several ways. In one embodiment, two processing lanes are provided. Each processing lane includes a command generating logic device and a comparison logic device. The command generating device in each processing lane receives the same command requests and generates a command from those requests. The command generated by each command logic device is sent to the comparison logic device in the opposite processing lane, to verify the generated command is correct. If the output of both processing lanes is verified as correct, the commands can be used. If the commands do not match, the commands are discarded.
Command monitoring is implemented in many fields, including the avionics field. For example, a pilot may wish to bank the plane a certain amount and control the yoke of the aircraft a certain amount. The commands generated by the pilot's maneuvering of the yoke can be sent to a flight control system that will monitor the process to ensure the commands generated are correct. In some cases, such as in fly-by-wire systems, the commands may be generated by the flight control system. Therefore, it is desirable to verify the command generation process.
As command generating systems become more sophisticated, they may require memory, such as random access memory (RAM), to store data to and retrieve data from while generating commands. The self-checking hardware thus becomes dependent on the proper functioning of the RAM. It then becomes necessary to ensure the RAM is operating properly. One potential failure mode for RAM particularly troubling in self-checking architectures is a latent failure whereby specific bits in the memory cannot assume a specific state when required. The redundant nature of self-checking architectures makes it highly probable that faults are detected when they occur. However a latent failure can occur in RAM that usually receives the same data, such as a RAM where certain bits always take on the value of “0”, except upon the occurrence of a rare operational condition or mode when the value needs to be a “1”. If a failure has occurred in the memory such that the bit can't change from a “0”, the fault may go unnoticed until that condition occurs. Thus, the latent memory failure renders the command generating system unavailable, potentially at a time most critical.
One way to detect latent RAM failure is through the use of built in testing (BIT) for memory. These tests typically read and write specific patterns to the memory to ensure each memory bit is operating properly. However, to develop BIT for memory in hardware based comparison systems that do not contain microprocessors can be complex.
Accordingly, it is desired to provide a method and apparatus for latent fault memory scrub in memory intensive computer hardware. Furthermore, the desirable features and characteristics of the present invention will be apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background.
BRIEF SUMMARY OF THE INVENTION
In one embodiment of the present invention a method for operating a memory checker in a command monitoring architecture comprising at least two processing lanes comprises a first step of receiving a command to activate a first test mode. The first test mode comprises an initial step of inverting data read from a memory and inverting data written to the memory. Next, it is determined if there is a match between data associated with a first processing lane and retrieved by a second checker logic associated with a second processing lane and with data associated with a second processing lane and retrieved by a first checker logic associated with a first processing lane. A failure in the memory is determined if there is no match.
In another embodiment, a logic device for use in a command monitoring situation comprises a command generating section configured to receive a common input and output a command. The logic device further comprises an inverting interface section coupled to the command generating section. The inverting interface section comprising a plurality of write inverters for inverting data prior to writing data to a memory, a plurality of read inverters for inverting data retrieved from the memory; and a control line for activating the write inverters and the read inverters.
In another embodiment, a command generating system utilizing command monitoring comprises a first processing lane. The first processing lane comprises a first command generating logic, a first memory coupled to the first command generating logic; and a first checker logic coupled to the first memory. The system also includes a second processing lane comprising a second command generating logic, a second memory coupled to the second command generating logic and a second checker logic coupled to the second memory. The system further includes a shared memory coupling the first checker logic and the second checker logic. In the system the first command generating logic is configured to invert data written to and read from the first memory, the second command generating logic is configured to invert data written to and read from the second memory, the first checker logic is configured to invert data written to and read from the first memory and the shared memory, and the second checker logic is configured to invert data written to and read from the second memory and the shared memory.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and:
FIG. 1 illustrates an exemplary embodiment of a command generating device in accordance with the teachings of the present invention;
FIG. 2 is a block diagram of an exemplary embodiment of a command generating logic in accordance with the teachings of the present invention; and
FIG. 3 is a block diagram of an alternative embodiment of a command generating logic in accordance with the teachings of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The following detailed description of the invention is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background of the invention or the following detailed description of the invention.
FIG. 1 illustrates an exemplary embodiment of a command generating device 100 utilizing hardware comparison architecture in accordance with the teachings of the present invention. Device 100 comprises a first processing lane 102 and a second processing lane 104 . First processing lane 102 comprises a first command generating logic 108 coupled to a first random access memory (RAM) 112 , which is coupled to a first checker logic 116 . Second processing lane 104 comprises a second command generating logic 110 coupled to a second RAM 114 , which is coupled to a second checker logic 120 . A common input 106 is coupled to the first command generating logic 108 and the second command generating logic 110 . An invert command line 122 is coupled to the first command generating logic 108 , the second command generating logic 110 , the first checker logic 116 , and the second checker logic 120 .
First command generating logic 108 and second command generating logic 110 receive inputs and produce outputs based on the received inputs. For example, in one exemplary embodiment, first command generating logic 108 and second command generating logic 110 receive inputs from common input 106 to generate commands. In an avionics embodiment, the inputs can be inputs generated by a pilot and the commands can be flight control commands such as commands to move one or more flight control surfaces, such as an aircraft aileron or rudder. First command generating logic 108 and second command generating logic 110 can be any one of numerous hardware logic devices such as application specific integrated circuits (ASICs), programmable logic devices (PLDs), field programmable gate arrays (FPGAs), state machines, and the like.
First command generating logic 108 and second command generating logic 110 also read and write data to first RAM 112 and second RAM 114 , respectively, in the process of generating commands. In the present invention, additional structure can be added to first command generating logic 108 and second command generating logic 110 . Turning to FIG. 2 , a block diagram of first command generating logic 108 in accordance with the teachings of the present invention is depicted. First command generating logic 108 includes a logic device section 202 coupled to an inverter interface 204 . First RAM 112 couples to the inverter interface 204 .
Logic device section 202 , in one exemplary embodiment, generates commands from common inputs 106 . Additionally, logic device section 202 can act as a comparison logic device to compare generated commands or data.
Inverter interface 204 provides an interface between the logic device section 202 and first RAM 112 . Inverter interface 204 includes a plurality of read/write data lines 203 coupled to logic writer inverters 206 , logic writer drivers 207 and logic read inverters 208 . Inverter interface 204 receives initial activation signals from invert command line 122 to activate the logic writer inverters 206 and logic read inverters 208 . When activated, data to be written to first RAM 112 via read/write lines 203 is first inverted (typically by taking the ones complement) before being stored to RAM 112 using the logic writer drivers 207 . This forces all cells in the first RAM 112 to take an opposite value as to what was being held in a previous state. If RAM 112 has a latent fault, such as the inability to hold a certain value, this inversion of the bit values can expose such an error to the architectures' checker logic.
When receiving the data from first RAM 112 via read/write lines 203 in the inverted mode, the value from the first RAM 112 is inverted prior to being sent to the logic device section 202 . In the present invention, the logic device section 202 of first command generating logic 108 always uses non-inverted data and when the inverting process is activated, the logic device section 202 operates normally using non-inverted data.
While FIG. 2 has been described as an exemplary embodiment of first command generating logic 108 , the same or similar situation can be used for second command generating logic 110 , first checker logic 116 and second checker logic 120 .
FIG. 3 illustrates an alternative embodiment of first command generating logic 108 . In this embodiment, first command generating logic 108 comprises a logic device section 302 and an inverter interface section 304 .
Logic device section 302 , in one exemplary embodiment, generates commands from common inputs 106 . Additionally, logic device section 302 can act as a comparison logic device to compare generated commands or data.
The inverter interface 304 in this exemplary embodiment comprises a plurality of read/write data lines 303 that couple to an external memory and a first set of write inverters 306 , a second set of write inverters 308 , a first set of read inverters 310 and a second set of read inverters 312 coupled to the plurality of read/write data lines 303 . First set of write inverters 306 and first set of read inverters 310 are coupled to a first logic control line 314 . The second set of write inverters 308 and the second set of read inverters 312 are coupled to a second logic control line 316 .
In this embodiment, instead of completely inverting all of the data sent to first RAM 112 , only data for a particular set of bits is inverted. A purpose of this embodiment is to test for pattern dependent memory faults such as “bridge-faults” (wherein physically adjacent memory cells or control sense logic couples or bridges in behavior in another cell). For example, if the first set of write inverters 306 and the first set of read inverters 310 are coupled to only odd bits of first RAM 112 , when the first logic control line 314 is activated, only the odd bits of first RAM 112 are inverted. When only the second logic control line 316 is activated, the second set of write inverters 308 and the second set of read inverters 312 are activated, which will invert the even bits written to and read from first RAM 112 . When both the first logic control line 314 and the second logic control line 316 are activated, both the odd and even bits can be inverted. While FIG. 3 illustrates individual inversion of odd or even bits, additional control lines can be added to further divide which bits of first RAM 112 are inverted.
While FIG. 3 has been described as an exemplary embodiment of first command generating logic 108 , the same or similar situation can be used for second command generating logic 110 , first checker logic 116 and second checker logic 120 .
Turning back to FIG. 1 , first RAM 112 and second RAM 114 store data for use by the first command generating logic 108 and the second command generating logic 110 . First RAM 112 and second RAM 114 can be any type of RAM as is well known in the art. In one exemplary embodiment, first RAM 112 and second RAM 114 can be integrated with first command generating logic 108 and second command generating logic 110 , respectively.
First checker logic 116 and second checker logic 120 check, by comparison, the output of first command generating logic 108 and second command generating logic 110 , respectively. In this embodiment, the first command generating logic 108 and second command generating logic 110 are coupled to the First checker logic 116 and second checker logic 120 (not pictured in FIG. 1 ). In one embodiment, the first checker logic 116 independently generates commands from common input 106 . The first checker logic 116 then receives the output from the second command generating logic 110 . First checker logic 116 then determines if the commands generated by the first checker logic 116 and the second command generating logic 110 match. Second checker logic 120 operates in a similar manner. If both the first checker logic 116 and the second checker logic 120 determine a match, the output can then be used. If not, the generated commands are discarded. First checker logic 116 and second checker logic 120 can be any one of numerous hardware logic devices such as an ASIC, FPGA, PLD, and the like, as is known in the art.
In the present invention, the first checker logic 116 and the second checker logic 120 can also be used to check first RAM 112 and second RAM 114 for latent errors. As discussed previously, when the first checker logic 116 and the second checker logic 120 receive an invert command from invert command line 122 , the first checker logic 116 and second checker logic 120 will invert data before writing to first RAM 112 and second RAM 114 and will invert any data that is read from first RAM 112 and second RAM 114 . In one exemplary embodiment, first checker logic 116 can read from first RAM 112 and write and read to shared memory 118 and second checker logic 120 can read from second RAM 114 and read and write to shared memory 118 . As will be discussed in detail below, first checker logic 116 and second checker logic 120 can determine if there is a fault in first RAM 112 and second RAM 114 .
Shared memory 118 is shared between first checker logic 116 and second checker logic 120 . In one exemplary embodiment, shared memory 118 has a first portion 119 and a second portion 121 . First checker logic 116 writes to one portion of shared memory 118 and the second checker logic 120 reads from that section and vice versa. The first portion 119 and the second portion 121 need not be physical memory portions, but rather denote the ability of a checker logic to read a value written by another checker logic. As before, shared memory 118 can be any type of RAM as is known in the art. Shared memory 118 may also be a shared register, buffer or other similar device.
In normal operation, command inputs are supplied via common input 106 to the first command generating logic 108 and the second command generating logic 110 . The first command generating logic 108 and the second command generating logic 110 generate commands which can be checked by first checker logic 116 and second checker logic 120 . During the command generating process, first command generating logic 108 and second command generating logic 110 can read or write to first RAM 112 and second RAM 114 , respectively. For example, in one exemplary embodiment, during normal operation first command generating logic 108 and second command generating logic 110 will write and read a binary number, such as “1010”, to first RAM 112 and second RAM 114 .
Additionally, first checker logic 116 can read the contents of first RAM 112 and write that value to shared memory 118 . Second checker logic 120 can read the contents of second RAM 114 and write that value to shared memory 118 . First checker logic 116 can then read the data written by second checker logic 120 , while second checker logic 120 will read the data written by first checker logic 116 . Then, first checker logic 116 and second checker logic 120 can determine what data read from shared memory 118 matches the data read from first RAM 112 and second RAM 114 . Therefore, for normal operation:
Data as
Data as
read by
Data
Data read
Data generated by
written to
first and
written
by checker
first and second
first and
second
to
logic across
command
second
checker
shared
shared
generating logic
RAM
logic
memory
memory
Lane A
1010
1010
1010
1010
1010
Lane B
1010
1010
1010
1010
1010
To check for errors, such as latent errors in RAM, an invert command is given, via invert command line 122 . This causes the first command generating logic 108 , the second command generating logic 110 , the first checker logic 116 , and the second checker logic 120 to invert the data prior to writing the data to the first RAM 112 , the second RAM 114 and the shared memory 118 and to invert the data read from the first RAM 112 , the second RAM 114 and the shared memory 118 . Again, assuming that a “1010” is to be written to memory, when there is no error in either first RAM 112 or second RAM 114 , the following table illustrates an example result:
Data generated
Data as
by first and
written
Data
second
to
Data as read
written
Data read by
command
first and
by first and
to
checker logic
generating
second
second
shared
across shared
logic
RAM
checker logic
memory
memory
Invert A
1010
0101
1010
0101
1010
Invert B
1010
0101
1010
0101
1010
Since the same value is sent by both first checker logic 116 and second checker logic 120 there is no error in the first RAM 112 and second RAM 114 .
In the next example, it is assumed that there is a fault in the second RAM 114 such that the least significant bit is stuck at “0”. Therefore, when the second command generating logic 110 attempts to write the inverted data to second RAM 114 , a “ 0100 ” is written to second RAM 114 instead of “0101”. The following table illustrates the detection of such an error:
Data
generated by
Data as
first and
written
Data read
second
to
Data as read
Data
by checker
command
first and
by first and
written
logic across
generating
second
second
to shared
shared
logic
RAM
checker logic
memory
memory
Invert A
1010
0101
1010
0101
1011
Invert B
1010
0100
1011
0100
1010
Note, that since the first checker logic 116 reads the data written to the portion of the shared memory by second checker logic 120 , the data read by the first checker logic 116 in this case is the “0100”, which is inverted to “1011” before reaching the first checker logic 116 . Since there was a mismatch at the first checker logic 116 and the second checker logic 120 , an error exists in either first RAM 112 or second RAM 114 .
In an exemplary embodiment, in order to check that the memory testing system is working properly, a single lane can be inverted to see if an error can be generated.
Data
generated by
Data as
Data as
first and
written
read by
second
to
first and
Data
Data read by
command
first and
second
written to
checker logic
generating
second
checker
shared
across shared
logic
RAM
logic
memory
memory
Invert A
1010
0101
1010
0101
0101
Non-invert B
1010
1010
1010
1010
1010
Note, that when inversion is active for lane A, the first checker logic 116 reads the contents of the shared memory 118 as inverted data. This data was originally written by second checker logic 120 , which was originally not inverted. Since the contents of the first checker logic 116 and the second checker logic 120 do not match, an error is detected. In this example, an error was expected since only one lane was inverted. Thus, the integrity of the memory checking system is verified.
While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims.
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A method for operating a memory checker in a command monitoring architecture comprising at least two processing lanes comprises a first step of receiving a command to activate a first test mode. The first test mode comprises an initial step of inverting data read from a memory and inverting data written to the memory. Next, it is determined if there is a match between data associated with a first processing lane and retrieved by a second checker logic associated with a second processing lane and with data associated with a second processing lane and retrieved by a first checker logic associated with the first processing lane. A failure in the memory is determined if there is no match.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of the filing date of U.S. Provisional Patent Application Ser. No. 60/574,792, filed May 27, 2004 (May 27, 2004).
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
TECHNICAL FIELD
[0004] The present invention relates generally to seismic anchoring systems, and more particularly to seismic restraints for small articles, and still more particularly to a method and apparatus for securing wine bottles in a wine rack.
BACKGROUND INFORMATION AND DISCUSSION OF RELATED ART
[0005] It is well known to protect articles and equipment from earthquake damage by using seismic anchoring devices, tie-downs, hold-downs, mooring apparatus, displacement limiting devices, and the like. In fact, the prior art is so replete with seismic protection devices that it would require volumes simply to catalogue them all. Many are directed to reinforcing and securing structures and providing increased structural support for expensive material, equipment, and furnishings, or to prevent structural damage from structural mechanical damage (seismic straps for securing water heaters, for example). A few prior art devices are illustrative of art in field analogous to that of the present invention. Among them:
[0006] U.S. Pat. No. 6,349,906 to Anderson, discloses an earthquake-proof beverage bottle support and storage structure adapted to be fastened to a building wall, or other support structure, for securing a bottled beverage container holder and dispenser above a floor, including a shelf for supporting a bottled beverage container holder and dispenser, at least three legs secured to the shelf extending above and below the shelf for supporting the shelf above a floor, and straps with interlocking buckles for securing the beverage bottle to the support system to restrict horizontal movement between the shelf and the beverage bottle. The entire structure can be secured to a wall, or other support structure, by fasteners, or additional straps. Additional shelves and straps can be added to provide storage for additional bottles, whether full or empty.
[0007] U.S. Pat. No. 6,050,538 to Marrow et al., teaches a restraint system and method for protecting at wine barrels in a barrel stack against earthquake damage. The stack includes a plurality of modules and each of the modules has a top rack, at least one intermediate rack and a bottom rack and at least one barrel on each of the racks. The barrel restraint system comprises a restraining mechanism operably engaged to at least the top barrels in the module at the top of the barrel stack for restraining the top barrels within the top module. Typically each module contains at least two barrels and the restraining means restrains all of the top barrels, because by restraining all of the top barrels and only the top barrels within the top module, the top barrels will be protected from being ejected from the top rack. All of the remaining barrels in the intermediate and bottom racks may be protected without the use of the restraining means due to the overburden weight of the barrels stacked above.
[0008] The foregoing patents reflect the current state of the art of which the present inventor is aware. Reference to, and discussion of, these patents is intended to aid in discharging Applicant's acknowledged duty of candor in disclosing information that may be relevant to the examination of claims to the present invention. However, it is respectfully submitted that none of the above-indicated patents disclose, teach, suggest, show, or otherwise render obvious, either singly or when considered in combination, the invention described and claimed herein.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention is an anchoring system directed to preventing wine bottle breakage during earthquakes. In its most essential aspect, the system can be understood as a seismic anchoring system, a tie down apparatus, a hold down bracket, a seismic isolation device, a displacement control device, and/or a mooring apparatus. It comprises a partially resilient leash which has a ring on a free end and which is connected at its other end to or proximate to a holding bin. To accomplish its purpose, the ring is disposed over the neck of a bottle in a bottle bin, generally in a wine rack. When used in this manner the leash restricts movement of the wine bottle and prohibits excursion of the bottle from the bin. The leash also provides a convenient means to display bottle identifying placards or tags so that a long-cellared bottle need not be disturbed when determining its contents.
[0010] It is therefore an object of the present invention to provide a new and improved wine bottle seismic anchoring system.
[0011] Another object of the present invention is to provide an economical system for anchoring wine bottles, in which individual restraints are inexpensive to provide and to replace and
[0012] A further object or feature of the present invention is a new and improved wine bottle anchoring system that facilitates bottle identification.
[0013] An even further object of the present invention is to provide an aesthetically appealing wine bottle seismic anchoring apparatus that easily incorporates elegant design features complementary to fine wines.
[0014] Other novel features which are characteristic of the invention, as to organization and method of operation, together with further objects and advantages thereof will be better understood from the following description considered in connection with the accompanying drawings, in which preferred embodiments of the invention are illustrated by way of example. It is to be expressly understood, however, that the drawings are for illustration and description only and are not intended as a definition of the limits of the invention. The various features of novelty that characterize the invention are pointed out with particularity in the claims annexed to and forming part of this disclosure. The invention does not reside in any one of these features taken alone, but rather in the particular combination of all of its structures for the functions specified.
[0015] There has thus been broadly outlined the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form additional subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception upon which this disclosure is based readily may be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
[0016] Further, the purpose of the Abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The Abstract is neither intended to define the invention of this application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
[0017] Certain terminology and derivations thereof may be used in the following description for convenience in reference only, and will not be limiting. For example, words such as “upward,” “downward,” “left,” and “right” would refer to directions in the drawings to which reference is made unless otherwise stated. Similarly, words such as “inward” and “outward” would refer to directions toward and away from, respectively, the geometric center of a device or area and designated parts thereof. References in the singular tense include the plural, and vice versa, unless otherwise noted.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0018] The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
[0019] FIG. 1 is a perspective view of the bottle rack retainer leash of the present invention; and
[0020] FIG. 2 is a perspective view showing several of the inventive apparatus installed on a wine bottle rack, all but one of which are shown restricting wine bottles from removal or displacement from a holding bin in the rack.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Referring to FIGS. 1 and 2 , wherein like reference numerals refer to like components in the various views, there is illustrated therein a new and improved bottle rack retainer leash, generally denominated 100 herein.
[0022] FIG. 1 and illustrate a preferred embodiment of the inventive apparatus, showing that the bottle rack retainer leash of the present invention comprises a bottle retention ring 110 to which a cord or leash 120 is connected. The ring is sized with a sufficient diameter to fit easily over the neck of standard wine bottles. The leash is preferably extensible and retractable and/or includes at least a resilient portion which is preferably fabricated from helically wound plastic line, elastic cord, elastic shock cord, braided elastic, rubber band, metal spring and/or the like. At its first end 130 the leash is connected to the bottle retention ring. A leash connection ring 140 , such as a key ring, plastic hook, or another slidable connection means, and having a diameter substantially smaller than that of the bottle retention ring, may be interposed between the first end and the bottle retention ring 110 to facilitate movement of the leash along the circumference of the bottle retention ring. Additionally, the first end itself may comprise attachment means in the form of an integral ring or a terminal expansion having a through hole.
[0023] At a second end 150 the leash terminates in attachment means 160 , such as a tab having a through hole, for fixing the second end to a structural element in a bottle holding bin, such as a frame member 170 as found in a conventional bottle rack.
[0024] When used for restraining and protecting wine bottles 180 , or other bottles for which long term storage may be called for (and thus where it is undesirable to disturb the bottle during storage), yet where easy bottle identification may be important, it may be desirable to provide a hang tag 190 , preferably attached to the bottle retention ring through a tag connection ring 200 , also having a diameter substantially smaller than that of the bottle retention ring. When employed to identify wine bottles, such a tag might include, for example, information concerning the vintage, the winery or estate, the varietal, or tasting notes.
[0025] FIG. 2 shows how the inventive apparatus may be installed on a conventional wooden wine bottle rack 300 . This view shows how when not in use the inventive bottle rack retainer leash 100 hangs freely within a holding bin. However, when employed to restrain a bottle, it will be seen that the bottle retention ring 110 is placed over the neck of a wine bottle 180 and generally rests upon the shoulder of the bottle, and the resilient leash gently urges the bottle inwardly, or toward the interior portion of the bin. The leash thus restricts the bottle from moving out of the bin when the rack is jarred, for instance during a seismic event or inadvertent jostling. Additionally, it provides a small amount of lateral restraint, so that excessive side-to-side movement is also reduced.
[0026] Preferably the leash is resilient enough only to allow the neck 185 of the bottle to be inserted through the bottle retention ring and then to be properly seated between the vertical rack supports 310 so that the cork or foil portion 187 of the bottle neck extends outwardly from the vertical supports. However, any further outward movement of the bottle is prevented until the ring is removed.
[0027] As will be immediately appreciated by those with skill in the art, the inventive apparatus also provides a novel method of preventing damage to wine bottles during seismic event, the method comprising the steps of: (a) providing a bottle rack retainer leash which includes a leash with a first end and a second end, the first end terminating in a bottle retention ring and the second end having connection means for connecting the second end to a surface on a bottle holding bin, and a resilient portion of cord interposed between the first and second ends; (b) providing a wine rack with one or more holding bins with a front opening and a bottom surface for placing wine bottles in a substantially horizontal disposition such that the neck of the wine bottle is directed toward the opening of the holding bin; (c) connecting the second end of the bottle rack retainer leash to a surface on or proximate the holding bin; and (d) placing the bottle retention ring over the neck of the wine bottle.
[0028] The above disclosure is sufficient to enable one of ordinary skill in the art to practice the invention, and provides the best mode of practicing the invention presently contemplated by the inventor. While there is provided herein a full and complete disclosure of the preferred embodiments of this invention, it is not desired to limit the invention to the exact construction, dimensional relationships, and operation shown and described. Various modifications, alternative constructions, changes and equivalents will readily occur to those skilled in the art and may be employed, as suitable, without departing from the true spirit and scope of the invention. Such changes might involve alternative materials, components, structural arrangements, sizes, shapes, forms, functions, operational features or the like.
[0029] Therefore, the above description and illustrations should not be construed as limiting the scope of the invention, which is defined by the appended claims.
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A seismic anchoring system to prevent damage to wine bottles during earthquakes, including a resilient leash having a ring on a free end and connected at its other end to or proximate to a holding bin. In use, the ring is disposed over the neck of a bottle in a bottle holding bin and thus prevents excursion of the bottle from the bin. The leash further provides means for displaying bottle content information.
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[0001] “This application claims priority from copending provisional application, application No. 60/434,004 filed Dec. 17, 2002 the entire disclosure of which is hereby incorporated by reference”
FIELD OF THE INVENTION
[0002] The invention relates to new antibiotics designated Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D, and Cyan-416 E, to production by fermentation, to methods for recovery and concentration from the crude solutions, to process for purification of Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D and Cyan-416 E and to the synthesis of the esters of Cyan-416 B.
BACKGROUND OF THE INVENTION
[0003] New improved antibiotics are continually in demand, for the treatment of diseases in man. Antibiotic resistant organisms are continually a problem, with Vancomycin the last defense, particularly in hospitals. Especially in hospitals, isolates, which are vancomycin resistant, are becoming more common. A recent survey found 7.9% of Enterococci in United States hospitals are now vancomycin resistant. “Nosocomial Enterococci Resistant to Vancomycin” Morbidity and Mortality Weekly Report 42(30):597-598(1993). Further resistance of Vancomycin and other antibiotics to Enterococcus faecium is reported, Handwergers. et al., Clin. Infect. Dis. 1993(16),750-755. Resistance organisms are also a problem for other important antibiotics, which includes methicillin.
[0004] Clearly, antibiotic resistance is a growing public health problem and having new antibiotics available could provide additional options for physicians in treatment regimens.
[0005] The medical community recognizes that there is an ongoing need for additional antibiotics. The search for new antibiotics which exhibit antibacterial activity against vancomycin-resistant isolates and having structures which are not derivatives of vancomycin are particularly appealing.
[0006] Antibiotics described in the literature include: Xanthoquinodins, Tabata, Noriko; Suzumura, Yasuko; Tomoda, Hiroshi; Masuma, Rokuro; Haneda, Katsuji; Kishi, Masanori; Iwai, Yuzuru; Omura, Satoshi. Xanthoquinodins, new anticoccidial agents produced by Humicola sp.: production, isolation, and physico-chemical and biological properties. J. Antibiot . (1993), 46(5), 749-55. Tabata, Noriko; Tomoda, Hiroshi; Matsuzaki, Keiichi; Omura, Satoshi. Structure and biosynthesis of xanthoquinodins, anticoccidial antibiotics. J. Am. Chem. Soc . (1993), 115(19), 8558-64. Omura, Satoshi; Koda, Hiroshi; Masuma, Rokuro; Haneda, Katsuji; Iwai, Yuzuru. Anticoccidial agents manufactured with Humicola . (1994), 25 pp., JP 06116281 A2 19940426. Tabata, Noriko; Tomoda, Hiroshi; Iwai, Yuzuru; Omura, Satoshi. Xanthoquinodin B3, a new anticoccidial agent produced by Humicola sp. FO-888 . J. Antibiot . (1996), 49(3), 267-71 and Pinselic acid, related to Cyan-416 D is reported by Law, Kai-Kwong; Chan, Tze-Lock; Tam, Shang Wai; Shatin, N. T. Synthesis of pinselic acid and pinselin. J. Org. Chem . (1979), 44(24), 4452-3.
[0007] However, all of the above-disclosed antibiotics are distinct from the present invention.
BRIEF SUMMARY OF THE INVENTION
[0000] The present invention relates to the following antibiotic compounds:
[0008] Antibiotic Cyan-416 A having the structure:
Antibiotic Cyan-416 B having the structure:
Antibiotic Cyan-416 C having the structure:
Antibiotic Cyan-416 D having the structure:
Antibiotic Cyan-416 E having the structure:
and
further relates to esters of Cyan-416 B of Formula I and a process for the preparation thereof
where R is straight or branched alkyl of 1 to 10 carbon atoms, alkenyl of 2 to 10 carbon atoms, cycloalkyl of 3 to 10 carbon atoms and cycloalkenyl of 3 to 10 carbon atoms.
[0009] The present invention includes within its scope the agents in dilute form, as a crude concentrate, and in pure form. The present invention also relates to the use of the compounds according to the invention in antimicrobial compositions and as an antiseptic, or disinfectant.
[0000] It is an object of this invention to provide compounds of the invention, which are shown to possess antibacterial activity, especially against vancomycin resistant bacterial isolates and in particular having a chemical structure unlike vancomycin.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 . shows ultraviolet absorption spectrum of Cyan-416 A.
[0011] FIG. 2 . shows ultraviolet absorption spectrum of Cyan-416 B.
[0012] FIG. 3 . shows ultraviolet absorption spectrum of Cyan-416 C.
[0013] FIG. 4 . shows ultraviolet absorption spectrum of Cyan-416 D.
[0014] FIG. 5 . shows ultraviolet absorption spectrum of Cyan-416 E.
[0015] FIG. 6 . shows proton nuclear magnetic resonance spectrum of Cyan-416 A in DMSO-d 6 at 400 MHz.
[0016] FIG. 7 . shows proton nuclear magnetic resonance spectrum of Cyan-416 B in DMSO-d 6 at 400 MHz.
[0017] FIG. 8 . shows proton nuclear magnetic resonance spectrum of Cyan-416 C in DMSO-d 6 at 400 MHz.
[0018] FIG. 9 . shows proton nuclear magnetic resonance spectrum of Cyan-416 D in DMSO-d 6 at 400 MHz.
[0019] FIG. 10 . shows proton nuclear magnetic resonance spectrum of Cyan-416 E in DMSO-d 6 at 400 MHz.
[0020] FIG. 11 . shows carbon-13 nuclear magnetic resonance spectrum of Cyan-416 A in DMSO-d 6 at 100 MHz.
[0021] FIG. 12 . shows carbon-13 nuclear magnetic resonance spectrum of Cyan-416 B in DMSO-d 6 at 100 MHz.
[0022] FIG. 13 . shows carbon-13 nuclear magnetic resonance spectrum of Cyan-416 C in DMSO-d 6 at 100 MHz.
[0023] FIG. 14 . shows carbon-13 nuclear magnetic resonance spectrum of Cyan-416 D in DMSO-d 6 at 100 MHz.
[0024] FIG. 15 . shows carbon-13 nuclear magnetic resonance spectrum of Cyan-416 E in DMSO-d 6 at 100 MHz.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] The invention relates to new antibiotics Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D and Cyan-416 E, to the production of the antibiotics by fermentation, to methods for the recovery and concentration of the antibiotics from crude solutions, and to processes for the purification of the antibiotics. The invention includes within its scope the new antibiotics in diluted form, as crude concentrate and in pure form. The novel antibiotics are useful as antibacterial agents.
[0000] As used herein the term alkyl means a branched or straight chain radical having from 1 to 10 carbon atoms.
[0026] As used herein the term alkenyl as used herein means an unsaturated branched or straight chain radical having from 2 to 10 carbon atoms. Alkenyl, may be used synonymously with the term olefin and includes alkylidenes. Exemplary alkenyl groups include but are not limited to ethylene, propylene and isobutylene.
[0000] As used herein the term cycloalkyl means a saturated monocyclic ring having from 3 to 10 carbon atoms. Exemplary cycloalkyl rings include but are not limited to cyclopropyl, cyclobutyl, cyclopentyl, and cyclohexyl,
[0000] As used herein the term cycloalkenyl means a non-aromatic monocyclic ring system containing a carbon-carbon double bond and having about 3 to about 10 atoms. Preferred monocyclic cycloalkenyl rings include cyclopentenyl and cyclohexenyl.
[0000] The new antibiotics designated Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D and Cyan-416 E are formed during the fermentation of Acremonium sp. NRRL30631.
[0027] The structure of the new antibiotic Cyan-416 A is:
[0028] The physico-chemical characteristics of Cyan-416 A are as follows:
[0029] 1. Molecular weight: 614 (ESIMS);
[0030] 2. Apparent molecular formula: C 33 H 26 O 12 ;
[0031] 3. High-resolution Fourier transform ion cyclotron resonance mass spectrum (positive): m/z 615.14913 (MH + , C 33 H 27 O 12 requires 615.14970);
[0032] 4. Ultraviolet absorption spectrum as shown in FIG. 1 ;
[0033] 5. Proton nuclear magnetic resonance signals as shown in FIG. 6 (400 MHz, DMSO-d 6 );
[0034] 6. Carbon-13 nuclear magnetic resonance signals as shown in FIG. 11 (100 MHz, DMSO-d 6 ), with significant signals listed below:
199.88 187.56 183.39 169.69 167.70 160.45 159.55 158.48 151.00 147.22 145.61 145.50 136.70 132.37 131.68 131.09 123.18 122.04 118.88 117.66 113.08 112.44 112.06 109.48 108.69 105.45 72.46 52.01 41.08 37.62 33.93 21.52 20.78
[0035] The structure of the new antibiotic Cyan-416 B is:
[0036] The physico-chemical characteristics of Cyan-416 B are as follows:
1. Molecular weight: 572 (ESIMS); 2. Apparent molecular formula: C 31 H 24 O 11 ; 3. High-resolution Fourier transform ion cyclotron resonance mass spectrum (positive): m/z 573.13900 (MH + , C 31 H 25 O 11 requires 573.13968); 4. Ultraviolet absorption spectrum as shown in FIG. 2 ; 5. Proton nuclear magnetic resonance signals as shown in FIG. 7 (400 MHz, DMSO-d 6 );
[0042] 6. Carbon-13 nuclear magnetic resonance signals as shown in FIG. 12 (100 MHz, DMSO-d 6 ), with significant signals listed below:
199.86 187.03 184.84 167.76 160.51 159.50 158.39 151.04 147.07 146.31 145.53 142.73 134.69 131.16 130.18 122.22 122.08 117.64 117.36 113.77 112.45 111.63 109.45 108.64 106.16 71.39 52.02 42.37 37.41 34.44 21.56
[0043] The structure of the new antibiotic Cyan-416 C is:
[0044] The physico-chemical characteristics of Cyan-416 C are as follows:
1. Molecular weight: 630 (ESIMS); 2. Apparent molecular formula: C 33 H 26 O 13 ; 3. High-resolution Fourier transform ion cyclotron resonance mass spectrum (positive): m/z 631.14490 (MH + , C 33 H 27 O 13 requires 631.14462); 4. Ultraviolet absorption spectrum as shown in FIG. 3 ; 5. Proton nuclear magnetic resonance signals as shown in FIG. 8 (400 MHz, DMSO-d 6 );
[0050] 6. Carbon-13 nuclear magnetic resonance signals as shown in FIG. 13 (100 MHz, DMSO-d 6 ), with significant signals listed below:
202.78 199.83 195.54 171.03 167.72 162.68 158.96 158.55 151.09 149.44 145.55 145.00 139.53 134.60 131.00 128.72 122.14 118.24 117.69 117.38 114.67 112.33 109.90 108.85 108.60 81.51 70.12 51.95 46.74 43.40 31.51 21.84 20.86
[0051] The structure of the new antibiotic Cyan-416 D is:
[0052] The physico-chemical characteristics of Cyan-416 D are as follows:
[0053] 1. Molecular weight: 318 (ESIMS);
[0054] 2. Apparent molecular formula: C 16 H 14 O 7 ;
[0055] 3. High-resolution Fourier transform ion cyclotron resonance mass spectrum (positive): m/z 319.08104 (MH + , C 16 H 15 O 7 requires 319.08177);
[0056] 4. Ultraviolet absorption spectrum as shown in FIG. 4 ;
[0057] 5. Proton nuclear magnetic resonance signals as shown in FIG. 9 (400 MHz, DMSO-d 6 );
[0058] 6. Carbon-13 nuclear magnetic resonance signals as shown in FIG. 14 (100 MHz, DMSO-d 6 ), with significant signals listed below:
199.35 168.06 161.57 151.23 147.56 145.65 131.24 122.21 117.52 112.36 108.96 107.53 51.94 21.65
The structure of the new antibiotic Cyan-416 E is:
The physico-chemical characteristics of Cyan-416 E are as follows:
1. Molecular weight: 648 (ESIMS); 2. Apparent molecular formula: C 33 H 28 O 14 ; 3. High-resolution Fourier transform ion cyclotron resonance mass spectrum (negative): m/z 647.14154 (M−H, C 33 H 27 O 14 requires 647.14016); 4. Ultraviolet absorption spectrum as shown in FIG. 5 ; 5. Proton nuclear magnetic resonance signals as shown in FIG. 10 (400 MHz, DMSO-d 6 );
[0064] 6. Carbon-13 nuclear magnetic resonance signals as shown in FIG. 15 (100 MHz, DMSO-d 6 ), with significant signals listed below:
199.56 168.06 160.99 157.67 151.28 146.97 145.48 131.44 122.23 117.24 116.67 111.98 108.50 108.08 51.76 21.44 20.16
[0065] A further preferred embodiment within the scope of this invention relates to the novel esters of Cyan-416 B and the process for the production of these compounds (Formula I):
where R is straight or branched alkyl of 1 to 10 carbon atoms, alkenyl of 2 to 10 carbon atoms, cycloalkyl of 3 to 10 carbon atoms and cycloalkenyl of 3 to 10 carbon atoms.
Preferably R is —CH 2 CH 2 CH 3 , —CH(CH 3 ) 2 , —CH 2 CH 2 CH 2 CH 3 , or —CH 2 CH 2 CH 2 CH 2 CH 3 .
[0066] The new antibacterial agents Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D and Cyan-416 E are formed during the cultivation under controlled conditions of a fungus, LL-Cyan-416, which is a strain of Acremonium sp. NRRL30631.
[0067] This microorganism is maintained in the cultural collection of Wyeth Research, Pearl River, N.Y. 10965, as culture LL-Cyan-416.
[0000] Description of LL-Cyan-416
[0068] Culture LL-Cyan426 is that of a fungus, Acremonium sp., isolated from a sample collected from a mixed Douglas Fir-Hardwood forest, Crane Island Preserve, San Juan County, Washington State, in 1993. The culture has been deposited with Agricultural Research Services Culture Collection (NRRL), National Center for Agricultural Utilization Research, Agricultural Research Service, U.S. Department of Agriculture at 1815 North University Street, Peoria, Ill. 61604 as NNRL 30631.
[0069] The culture LL-Cyan416, identified as Acremonium sp., exhibits the following morphological features:
[0070] On oatmeal agar (Difco Laboratories), colony attaining a diameter of 37 mm after 21 days at 25° C. Colony mat white to Yellowish White (4A2), floccose; reverse Ivory (4B3); very light brown pigment present and exudate absent.
[0071] On potato-dextrose agar (Difco) colony attaining a diameter of 39.5 mm after 21 days at 25° C. Colony mat white, sulcate; reverse Pompeian Yellow (5C6) to Golden Brown (5D7), to margin Champagne (4B4); pigment and exudate absent.
[0072] On corn meal agar (Difco) colony attaining a diameter of 24.7 mm after 21 days at 25° C. Colony mat Yellowish White (3A2), floccose; reverse Yellowish White (3A2); pigment and exudate absent.
[0073] On YpSs agar (0.4% yeast extract, 1% soluble starch, 1.5% agar (all Difco), 0.05% K 2 HPO 4 (Sigma), pH 7.2) colony attaining 39 mm after 21 days at 25C. Colony mat white, sulcate; reverse Light Yellow (4A4) to margin Yellowish White (3A2) to Pale Yellow (3A3); pigment and exudate absent.
[0074] The characteristics of colony described were based on Methuen Handbook of colour (Komerup, A. and Wanscher, J. H. 3 rd ed., 252p., Eyre Methuen, London. 1978.
[0075] Mycelium micronematous; conidophores simple to sometimes branched, phialides usually arising from aerial hyphae, erect, collarette not visible, 15.5-30 um height, widest portion 1.5 um and gradually taper to 0.5 um; conidia in slim heads, asymmetrical, elongate ellipsoidal to fusoid, 3-6×1.5 um, hyaline, smooth walled; chlamydospores absent.
[0076] For the production of the new antibiotics, of the present invention are not limited to this particular organism or to organisms fully answering the above characteristics, which are given for illustration purpose only. It is desired and intended to include the use of mutants produced from this organism by various means such as exposures to X-radiation, ultraviolet radiation, N′-methyl-N′-nitro-N-nitrosoguanidine, phages, and like.
Acylation Method for the Preparation of Compounds of Formula I
[0077] The selective acylation of Cyan-416 B1 with an anhydride of the formula (R—C(O)—) 2 O where R is straight and branched alkyl of 1 to 10 carbon atoms, alkenyl of 2 to 10 carbon atoms, cycloalkyl of 3 to 10 carbon atoms and cycloalkenyl of 3 to 10 carbon atoms in the presence of boron trifluoride diethyl etherate (BF 3 -Et 2 O) affords an ester derivative of Cyan-416 B 2 as shown in Scheme 1.
where R is straight or branched alkyl of 1 to 10 carbon atoms, alkenyl of 2 to 10 carbon atoms, cycloalkyl of 3 to 10 carbon atoms and cycloalkenyl of 3 to 10 carbon atoms.
Preferably, R is —CH 2 CH 2 CH 3 , —CH(CH 3 ) 2 , —CH 2 CH 2 CH 2 CH 3 , or —CH 2 CH 2 CH 2 CH 2 CH 3 . As further shown in Scheme 2, hydrolysis with acid of Cyan 416 A 3 affords Cyan 416 B 1.
Biological Activity
Standard Pharmacological Test Procedures
[0078] The minimum inhibitory concentration (MIC), the lowest concentration of the antibiotic which inhibits growth of the test organism, is determined by the broth dilution method using Muller-Hinton II agar (Baltimore Biological Laboratories) following the recommendations of the National Committee for Clinical Laboratory Standards [Methods for dilution antimicrobial susceptibility tests for bacteria that grow aerobically. Approved standard M7-A2. National Committee for Clinical Laboratory Standards, Villanova, Pa].
[0079] An inoculum level of 5×10 5 CFU/ml, and a range of antibiotic concentrations (64-0.06 μg/ml) is used. The MIC is determined after the microtiter plates are incubated for 18 hours at 35° C. in an ambient air incubator. The test organisms comprise a spectrum of the Gram-positive bacteria Staphylococcus aureus, Streptococcus pneumoniae , and Enterococcus sp., the Gram-negative bacteria Escherichia coli , and the yeast Candida albicans . These organisms include recent clinical isolates that are resistant to methicillin and vancomycin. MIC data of Cyan-416 A-E are listed in Table 1 and MIC data of ester derivatives of Cyan-416 B (Formula I) are listed in Table 2.
TABLE 1 Antimicrobial Activity of Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D, and Cyan-416 E. MIC (μg/ml) Cyan 416 A Cyan 416 B Cyan 416 C Cyan 416 D Cyan 416 E Test organism Example 3a Example 3b Example 3c Example 4a Example 4b Staphylococcus aureus GC 4536 8 32 32 64 64 Staphylococcus aureus GC 1131 8 32 32 64 64 Staphylococcus aureus GC 2216 8 32 32 64 64 Enterococcus faecalis GC 842 16 64 32 64 64 Enterococcus faecalis GC 2242 16 32 32 32 64 Enterococcus faecalis GC 4555 16 64 64 64 64 Pseudomonas aeruginosa GC 2214 >64 >64 >64 >64 64 Escherichia coli GC 2203 >64 >64 >64 >64 >64 Escherichia coli GC 4560 (imp) 32 64 >64 64 64 Candida albicans GC 3066 >64 >64 >64 >64 64
[0080]
TABLE 2
Antimicrobial Activity of Esters of Cyan-416 B (Formula I).
MIC (μg/ml)
Formula I,
R = CH 3
(Cyan416-A)
(CH 2 ) 2 CH 3
CH(CH 3 ) 2
(CH 2 ) 3 CH 3
(CH 2 ) 4 CH 3
Test organism
Example 3a
Example 6
Example 7
Example 8
Example 9
Staphylococcus aureus GC 1131
8
8
4
4
4
Staphylococcus aureus GC 4541
16
8
2
4
4
Staphylococcus aureus GC 4543
8
8
4
4
4
Staphylococcus aureus GC 2216
8
8
4
4
4
Staphylococcus haemolyticus GC 4547
16
16
4
4
4
Enterococcus faecalis GC 6189
16
16
4
4
4
Enterococcus faecalis GC 4555
16
16
4
4
4
Enterococcus faecalis GC 2242
16
8
4
4
4
Enterococcus faecium GC 4556
16
8
4
4
4
Enterococcus faecium GC 2243
8
16
8
4
4
Enterococcus faecium 4558
8
8
2
2
2
Streptococcus pneumoniae GC 1894
8
16
8
8
8
Streptococcus pneumoniae GC 6242
8
32
16
8
8
Escherichia coli coli GC 2203
>128
>128
>128
>128
>128
Escherichia coli GC 4560 (imp)
32
16
8
8
8
Candida albicans GC 3066
>128
>128
>128
>128
>128
[0081] The in vitro antimicrobial results show that the products according to the invention have significant activity against Gram-positive bacteria tested.
[0082] Antibiotic Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D, Cyan-416 E and esters of Cyan-416B derive their utility from antibacterial activity. For example, Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D, and Cyan-416 E may be used in the suppression of bacterial infections, as topical antibacterial agents or as a general disinfectant. Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D, and Cyan-416 E and esters of Cyan-416B are not limited to the uses listed. In therapeutic use, the compound of this invention may be administered in the form of conventional pharmaceutical compositions appropriate for the intended use. Such compositions may be formulated as to be suitable for oral, parenteral or topical administration. The active ingredient may be combined in admixture with a nontoxic pharmaceutical carrier that may take a variety of forms depending on the form of preparation desired for administration, i.e. oral, parenteral, or topical.
[0083] When the compounds of the invention are employed as antibacterials, they can be combined with one or more pharmaceutically acceptable carriers, for example, solvents, diluents and the like, and may be administered orally in such forms as tablets, capsules, dispersible powders, granules, or suspensions containing, for example, from about 0.05 to 5% of suspending agent, syrups containing, for example, from about 10 to 50% of sugar, and elixirs containing for example, from about 20 to 50% ethanol and the like, or parenterally in the form of sterile injectable solutions or suspensions containing from about 0.05 to 5% suspending agent in an isotonic medium. Such pharmaceutical preparations may contain, for example, from about 25 to about 90% of the active ingredient in combination with the carrier, more usually between about 5% and 60% by weight. An effective amount of compound from 0.01 mg/kg of body weight to 100.0 mg/kg of body weight should be administered one to five times per day via any typical route of administration including but not limited to oral, parenteral (including subcutaneous, intravenous, intramuscular, intrasternal injection or infusion techniques), topical or rectal, in dosage unit formulations containing conventional non-toxic pharmaceutically acceptable carriers, adjuvants and vehicles. It will be understood, however, that the specific dose level and frequency of dosage for any particular patient may be varied and will depend upon a variety of factors including the activity of the specific compound employed, the metabolic stability and length of action of that compound, the age, body weight, general health, sex, diet, mode and time of administration, rate of excretion, drug combination, the severity of the particular condition of the host undergoing therapy.
[0084] Additionally, the antibacterially effective amount of the antibiotic of the invention may be administered at a dosage and frequency without inducing side effects commonly experienced with conventional antibiotic therapy which could include hypersensitivity, neuromuscular blockade, vertigo, photosensitivity, discoloration of teeth, hematologic changes, gastrointestinal disturbances, ototoxicity, and renal, hepatic, or cardiac impairment. Further the frequency and duration of dosage may be monitored to substantially limit harmful effects to normal tissues caused by administration at or above the antibacterially effective amount of the antibiotic of the invention.
[0085] The active compound of the invention may be administered orally as well as by intravenous, intramuscular, or subcutaneous routes. Solid carriers include starch, lactose, dicalcium phosphate, microcrystalline cellulose, sucrose and kaolin, while liquid carriers include sterile water, polyethylene glycols, non-ionic surfactants and edible oils such as corn, peanut and sesame oils, as are appropriate to the nature of the active ingredient and the particular form of administration desired. Adjuvants customarily employed in the preparation of pharmaceutical compositions may be advantageously included, such as flavoring agents, coloring agents, preserving agents, and antioxidants, for example, vitamin E, ascorbic acid, BHT and BHA. The active compound may also be administered parenterally or intraperitoneally. Solutions or suspensions of the active compound as a free base or pharmacologically acceptable salt can be prepared in glycerol, liquid, polyethylene glycols and mixtures thereof in oils. Under ordinary conditions of storage and use, these preparations contain a preservative. The pharmaceutical forms suitable for injectable use include sterile aqueous solutions or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions or dispersions. In all cases, the form must be sterile and must be fluid to the extent that easy syringability exists. It must be stable under the conditions of manufacture and storage and must be preserved against the contaminating action of microorganisms such as bacterial and fungi. The carrier can be a solvent or dispersion medium containing, for example, water, ethanol, polyol (e.g., glycerol, propylene glycol and liquid polyethylene glycol), suitable mixtures thereof, and vegetable oil.
[0086] The invention accordingly provides a pharmaceutical composition, which comprises a compound of this invention in combination or association with a pharmaceutically acceptable carrier. In particular, the present invention provides a pharmaceutical composition, which comprises an antibacterially effective amount of a compound of this invention and a pharmaceutically acceptable carrier.
[0087] The present invention further provides a method of treating bacterial infections in warm-blooded animals including man, which comprises administering to the afflicted warm-blooded animals an antibacterially effective amount of a compound or a pharmaceutical composition of a compound of the invention. The invention will be more fully described in conjunction with the following specific examples, which are not to be construed as limiting the scope of the invention.
[0088] As used herein an effective amount refers to the quantity of a compound of the invention which is sufficient to yield a desired therapeutic response without undue adverse side effects (such as toxicity) commensurate with a reasonable benefit/risk ratio when used in the method of this invention.
[0089] The Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D, Cyan-416 E and esters of Cyan-416B according to the invention, have good antimicrobial activity may be used in antimicrobial compositions, especially as an antiseptic by local and general application, and as a disinfectant.
[0090] As antiseptics for human or veterinary use, the concentration of active product can vary from about 0.01% to 5% by weight according to the use and the chosen formulation. Thus, it is possible to prepare foaming detergent solutions to be used by surgeons and nursing staff for washing their hands or to be used for cleansing dermatological lesions such as impetigo, pityriasis and leg ulcers. Foaming detergent solutions are also used as shampoos (for example antidandruff shampoos) or for the preparation of shower gels, shaving creams and foaming lotions. Foaming solutions containing Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D, Cyan-416 E and esters of Cyan-416B according to the invention are obtained using amphoteric, anionic, cationic or non-ionic surfactants at a concentration of about 0.3 to 30%, humectants such as glycols or polyethylene glycols, at a concentration of 0 to 20% ethylene oxide and polypropylene copolymers at a concentration of 0 to 20%, and an alcohol (ethanol, isopropanol, benzyl alcohol) or a polyol, such as glycerol, at a concentration of 0 to 15%, as well as agents for complexing Ca++, Mg++ and heavy metal ions, salts for providing an appropriate buffer capacity, agents for imparting viscosity, such as NaCl or KCl, natural, cellulosic or synthetic polymers such as polyvinylpyrrolidone, thickening superfatting agents such as polyethylene glycol distearate or copra monoethanolamide or diethanolamide, fragrances, preservatives and colorants.
[0091] It is possible to use microemulsions, micellar solutions or any other phase of the ternary or quaternary diagram of water/active principle/surfactant/co-surfactant which permits solubilization of Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D, Cyan-416 E and esters of Cyan-416B in water. These solutions can be used in diluted or undiluted form and can be dispensed for example by means of a vasopump or liquefied or non-liquefied propellants.
[0092] With the same constituents at appropriate concentrations, the product according to the invention can also be used to prepare simple aqueous solutions or aqueous solutions in the form of sprays for making operative fields antiseptic, for postoperative treatments, for the treatment of burns, superinfected eczema, gluteal erythema, wounds or acne, or for deodorants.
[0093] Simple alcoholic solutions or alcoholic solutions in the form of sprays containing 20 to 80% by weight of alcohol can contain, apart from the excipients used in aqueous solutions, excipients which make it possible to penetrate the keratinized layers of the skin and superficial body growths, such as Azone (marketed by Nelson Research) and Transcutol (marketed by Gattefosse). These solutions are to be used for making the skin antiseptic before puncture, for preparing the operative field, by nursing staff for making their hands antiseptic and for treating closed infected dermatosis, folliculitis, perionychia or acne.
[0094] Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D, Cyan-416 E and esters of Cyan-416B according to the invention can be applied in the form of creams together with the fatty substances normally found in the preparation of creams or emulsions.
[0095] Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D, Cyan-416 E and Cyan-416B and esters of Cyan-416B according to the invention can also be used in animals for indications such as the prevention or treatment of infected lesions. In this case, the pharmaceutical compositions are similar to those used in man, in particular creams sprays or solutions.
[0096] Moreover, the rapid lethal action on germs of Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D, Cyan-416 E and esters of Cyan-416B according to the invention may be used as surface disinfectants at concentrations which can vary from about 0.1 to 4% by weight. In this case, Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D, Cyan-416 E and esters of Cyan-416B is used in preparations such as aqueous or non-aqueous foaming detergent solutions, sprays or nebulizers. This type of preparation is particularly useful in the hospital or veterinary sectors. These preparations can contain the same constituents as those used in the antiseptic formulations, although a variety of organic solvents may be added.
[0000] General Fermentation Conditions
[0097] Culture LL-Cyan-416 Acremonium sp. NRRL30631 is inoculated on moist milk-filter paper placed on the surface of a solid, agar medium containing agar, malt extract, peptone, and yeast extract and incubated under stationary conditions at 22° C.
[0000] General Isolation Procedures of Antibiotics Cyan-416 A, B, C, D, and E
[0098] The Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D, and Cyan-416 E are recovered from the fermentation broth by extracting cells with methanol. The methanol extract is evaporated under reduced pressure and the concentrate purified by HPLC on C18 columns using acidic acetonitrile in water to afford Cyan-416 A, Cyan-416 B, Cyan-416 C, Cyan-416 D, and Cyan-416 E.
[0099] The invention is further described in conjunction with the following non-limited examples.
EXAMPLE 1
Inoculum Preparation
[0100] Fungal culture LL-Cyan-416 is plated on Bennett's agar medium (10 g/l Sigma D-glucose, 1 g/l Difco beef extract, 1 g/l Difco yeast extract, 2 g/l N-Z amine A, 20 g/l Difco agar) from a frozen 25% glycerol stock culture and then incubated at 22° C. A small agar slice bearing mycelial growth is used to inoculate 50 ml of Difco potato-dextrose broth in a 250-ml Erlenmeyer flask. This liquid seed culture is shaken at 200 rpm at 22° C. for one week, and then used to inoculate production medium.
EXAMPLE 2
Fermentation
[0101] Production medium (1 L) consisted of malt extract agar (25 g Difco malt extract, 5 g Difco peptone, 0.5 g Difco yeast extract, 20 g Difco agar) that has been sterilized and poured into a 30×20×13 cm polypropylene tray covered with aluminum foil. The solidified agar is then overlaid with a sterile 28×46 cm sheet of nongauze milk-filter paper cut from 18×22 in strips (KenAG Animal Care Group, Ashland, Ohio) that had been sterilized separately. The production medium is inoculated by pipeting 50 ml of seed culture fluid onto the sheet of milk-filter paper. The inoculated tray culture is incubated stationary at 22° C. After 2 weeks of incubation, the milk-filter paper bearing prolific mycelial growth is peeled from the surface of the agar, lyophilized for 5 days, and then extracted with methanol (1.2 L).
EXAMPLES 3a, 3b, and 3c
Purification of New Antibiotics Cyan-416 A(3a), Cyan-416 B(3b), and Cyan-416 C(3c)
[0102]
[0103] The methanol extract obtained in EXAMPLE 2 is chromatographed by reverse phase HPLC on a C18 column (YMC ODS-A, 10 μm particle size, 70×500 mm), using a linear gradient of 30-100% acetonitrile in water containing 0.01% trifluoroacetic acid (TFA) over 35 min. Four fractions at 27.5, 30.5, 35.0, and 38.37 minutes are collected. The materials from the later three fractions at 30.5, 35.0, and 38.37 minutes are respectively purified by a different HPLC system (YMC ODS-A, 5 μm, 30×250 mm column, 40-75% acetonitrile in water containing 0.01% TFA over 30 min) to afford cyan-416 B (4.5 mg), cyan-416 C (4.2 mg), and cyan-416 A (130.8 mg), all as yellow amorphous powders.
EXAMPLES 4a and 4b
Purification of New Antibiotics Cyan-416 D(4a) and Cyan-416 E(4b)
[0104]
[0105] The material from the first fraction at 27.5 minutes described in EXAMPLE 3 is further separated by HPLC (YMC ODS-A, 5 μm, 30×250 mm column, 30-100% acetonitrile in water containing 0.01% TFA over 30 min) to afford pure Cyan-416 D (21.0 mg) and cyan-416 E (3.1 mg), both as pale yellow amorphous powders.
EXAMPLE 5
Production of Cyan-416 B from Cyan-416 A
[0106]
[0107] A solution of Cyan-416 A (120.0 mg) in 1 ml 1:1 Et 2 O/MeOH containing 0.5 M hydrochloric acid is stirred at ambient temperature for 24 hours. The purification of the resulting mixture by HPLC (same system as in Example 4) affords Cyan-416 B (102.5 mg). ESIMS (negative) m/z 571 (M−H) − .
EXAMPLE 6
[0108]
[0109] To a solution of Cyan-416 B (20.0 mg) in dry tetrahydrofuran (0.5 ml), is added dropwise a solution of 7% (v/v) of BF 3 -Et 2 O in butyric anhydride (0.2 ml) at 0° C. The reaction mixture is stirred at this temperature for 2 hours before methanol (2.0 ml) is added. The resulting solution is stirred for 0.5 hour at ambient temperature and then chromatographed by HPLC on a C18 column (YMC ODS-A, 5 μm particle size, 30×250 mm) using a linear gradient (40-100% acetonitrile in water containing 0.01% TFA in 30 minutes) to afford Cyan-416 B butyrate (15.3 mg, Formula I, R═CH 2 CH 2 CH 3 ). ESIMS (negative) m/z 641 (M−H) − .
EXAMPLE 7
[0110]
[0111] Cyan-416 B (20.0 mg) is acylated using isobutyric anhydride to replace butyric anhydride in the procedure described in EXAMPLE 6 to afford Cyan-416 B isobutyrate (12.0 mg, Formula I, R═CH(CH 3 ) 2 ). ESIMS (negative) m/z 641 (M−H) − .
EXAMPLE 8
[0112]
[0113] Cyan-416 B (20.0 mg) is acylated using pentanoic anhydride to replace butyric anhydride in the procedure described in EXAMPLE 6 to afford Cyan-416 B pentanoate (17.2 mg, Formula I, R═CH 2 CH 2 CH 2 CH 3 ). ESIMS (negative) m/z 655 (M−H) − .
EXAMPLE 9
[0114]
[0115] Cyan-416 B (20.0 mg) is acylated using hexanoic anhydride to replace butyric anhydride in the procedure described in EXAMPLE 6 to afford Cyan-416 B hexanoate (17.8 mg, Formula I, R═CH 2 CH 2 CH 2 CH 2 CH 3 ). ESIMS (negative) m/z 669 (M−H) − .
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The invention relates to new antibiotics designated Cyan-416A, Cyan 416B, Cyan-416C, Cyan-416D and Cyan-416E to their production by fermentation of Acremonium sp. NRRL 30631 to methods for recovery and concentration from the crude solutions, and to a process for purification and to semisynthetic ethers of Cyan-416B.
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FIELD OF THE INVENTION
The present invention relates to cylinder heads for combustion engines, and in particular, but not exclusively to cylinder heads for four-stroke internal combustion engines.
BACKGROUND TO THE INVENTION
In a conventional four-stroke internal combustion engine, a power piston is disposed for reciprocating movement within a cylinder. The top of the cylinder is closed by a cylinder head that carries one or more induction poppet valves and one or more exhaust poppet valves. The induction poppet valve is timed so as to open as the power piston moves down the cylinder and, with the resultant partial vacuum, draws a combustible gas past the open poppet valve and into the cylinder. In respect of pressurised induction systems, the partial vacuum becomes positive pressure being forced into the negative pressure part of the cylinder as the piston moves down the cylinder. The induction poppet valve is then timed so as to close at the point when the piston is near the lowest point of its travel, thereby trapping a cylinder full of combustible gas. As the power piston is pushed back up the cylinder, by virtue of being connected to a crank that continues to rotate, it compresses the gas. At a point near the top of this cycle, called the compression stroke, a spark plug, which has been designed into the cylinder head, is sparked, causing the gas to ignite and rapidly expand as it explodes, pushing the piston down. As the piston comes back up again, the exhaust poppet valve (or valves) is (or are) timed to open, allowing the gases to escape.
Poppet valves have been used in internal combustion engines for many years, but display some disadvantages. Poppet valves are relatively expensive to manufacture and incorporate into cylinder heads of combustion chambers, due to the fine machining required to effect tolerances required for use of the valves in the hostile environment within the cylinder head.
Poppet valves, although fairly robust in construction, and although they initially create fluid-tight seals, restrict the flow of fuel and gases into and out of the engine, as the fuel and gas must flow around the valve and its associated stem. Poppet valves are also a source of vibration and noise through the effects of metal to metal contact with the cylinder head of the engine. Furthermore, as revolutions of the engine increase, the ability of poppet valves to open and close in time decreases in efficiency to the point where power output cannot increase further. Poppet valves are also a large source of friction, as is the camshaft and spring loaded follower generally used to open and close the valve.
There are known engines which do not comprise poppet valves, such as rotary engines and two-stroke piston engines, but such engines are generally inefficient in fuel consumption and costly to maintain.
It is therefore an aim of preferred embodiments of the present invention to overcome or mitigate a problem of the prior art, whether expressly mentioned hereinabove or not.
SUMMARY OF THE INVENTION
According to the present invention there is provided a cylinder head for mounting on a cylinder of a combustion engine, the cylinder head comprising a guideway in which is located a rotatable valve comprising a fluid port operable to effect fluid communication between a cylinder and a fluid manifold in the guideway, whereby rotation of the valve effects alignment of the fluid port with the combustion chamber of a cylinder to enable fluid flow between the valve and a cylinder, and wherein the cylinder head further comprises a seal which, in use, is movable from a first, non-sealing position in which the seal is biased away from the valve, and a second, sealing position in which the seal is biased onto the valve by gaseous pressure from within a cylinder.
Preferably there is a single rotatable valve which comprises two fluid ports comprising a fluid inlet and a fluid outlet, cooperable with corresponding inlet and outlet manifolds in the guideway.
The fluid inlet may be diametrically opposite to the fluid outlet on the rotatable valve. Preferably however the fluid inlet is axially spaced apart from the fluid outlet along the rotatable valve.
Alternatively the cylinder head may comprise a first rotatable valve located in a first guideway, and a second rotatable valve, located in a second guideway, the first valve comprising a fluid inlet and the second valve comprising a fluid outlet.
Preferably the rotatable valve comprises a rotatable shaft or bar, and more preferably comprises a rotatable shaft or bar having a substantially circular cross-section.
Suitably the fluid port of the rotatable valve comprises a cut-out portion of the valve.
Preferably the fluid port of the rotatable valve comprises an aperture or slot extending diametrically through the valve such that rotation of the valve effects movement between an open position in which the aperture or slot is substantially aligned with a cylinder and the fluid manifold in the guideway, and a closed position in which the slot or aperture is substantially aligned with the surface of the guideway.
Preferably the seal is in fluid communication with a cylinder.
Suitably the seal comprises a resilient biasing means, the resilient biasing means being arranged to bias the seal to the first non-sealing position, until such a time in the combustion cycle of the combustion engine when the build-up of exhaust gases effects sufficient pressure to effect movement of the seal against the resilient biasing means to the second, sealing position.
Suitably the resilient biasing means is a spring, preferably a helical spring.
Preferably the seal is located in a port or duct in the cylinder head which at one end opens into a cylinder and at the other end opens into the guideway of the cylinder head. Preferably the seal, in the first position, is located substantially within the port or duct, and in the second position extends from the port or duct into the guideway to effect abutment with the rotary valve.
Suitably, in the second position the seal is arranged to extend partway into the rotary valve fluid port when said fluid port is in substantial alignment with the seal.
The cylinder head may be dimensioned to be mounted on a plurality of cylinders and the rotary valve may comprise a fluid port for each cylinder, wherein rotation of the valve effects temporally separate alignment of each fluid port with the combustion chamber of a prescribed cylinder. Suitably the guideway comprises a fluid manifold for each fluid port of the rotary valve. The rotary valve may comprise two fluid ports for each cylinder, comprising a fluid inlet and fluid outlet, cooperable with corresponding fluid manifolds in the guideway. Preferably the cylinder head further comprises at least one cylinder isolation seal, which extends substantially around the rotary valve between the valve and the interior of the guideway, each isolation seal arranged to prevent fluid from flowing through the guideway between adjacent cylinders.
Suitably the rotary valve is arranged to be operably connected to a crankshaft of a combustion engine when the cylinder head is mounted on a cylinder, such that the rotary valve is rotated relative to the crankshaft at one quarter of the speed of the crankshaft.
According to a second aspect of the present invention there is provided a cylinder head for mounting on a cylinder of a combustion engine, the cylinder head comprising a single guideway in which is located a rotary valve comprising a fluid inlet and a fluid outlet, operable to effect fluid communication between a cylinder and a corresponding inlet manifold and outlet manifold in the guideway, wherein rotation of the valve effects alignment of the fluid inlet and fluid outlet with a combustion chamber of a cylinder to enable, in use, fluid flow between the valve and a cylinder, and wherein the fluid inlet and fluid outlet are axially spaced along the rotary valve.
Preferably the rotatable valve comprises a rotatable shaft or bar, and more preferably comprises a rotatable shaft or bar having a substantially circular cross-section.
Suitably the fluid inlet and fluid outlet comprise cut-out portions of the valve.
Preferably the fluid inlet and fluid outlet comprise an aperture or slot extending diametrically through the valve such that rotation of the valve effects movement between an open position in which the aperture or slot of the inlet or outlet is substantially aligned with a cylinder and the corresponding inlet manifold or outlet manifold in the guideway, and a closed position in which the aperture or slot is substantially aligned with the surface of the guideway.
Suitably movement of the fluid inlet between the open and closed position is effected at a different time to movement of the fluid outlet between the open and closed position, and this may be effected by providing a fluid inlet and outlet which each comprise an aperture or slot extending diametrically through the valve at an angle to one another.
Suitably the rotary valve is arranged to be operably connected to a crankshaft of a combustion engine when the cylinder head is mounted on a cylinder, such that the rotary valve is rotated relative to the crankshaft at one quarter of the speed of the crankshaft.
The cylinder head may further comprise one or more seals as described hereinabove for the first aspect of the invention. The cylinder head may be dimensioned to be mounted on a plurality of cylinders and the rotary valve may comprise a fluid inlet and fluid outlet for each cylinder, wherein rotation of the valve effects temporally separate alignment of each fluid inlet and fluid outlet with the combustion cylinder of a prescribed cylinder.
According to a third aspect of the invention there is provided a combustion engine comprising a cylinder head of the first or second aspects of the invention, mounted to a cylinder. Preferably the combustion engine is an internal combustion engine and is more preferably a four-stroke engine.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the various aspects of the invention, and to show how embodiments of the same may be put into effect, preferred embodiments of the invention will now be described with reference to the accompanying drawings, in which:
FIGS. 1A–1D illustrate front sectional views of a preferred embodiment of a cylinder head of the invention, mounted to a cylinder of a four-stroke internal combustion engine, moving through the exhaust, induction, compression and power strokes.
FIG. 2A illustrates a front sectional view of part of the preferred embodiment of a cylinder head mounted on a cylinder of FIGS. 1A–1D , during the induction stroke of the combustion cycle according to the invention;
FIG. 2B illustrates the front sectional view of FIG. 1A , during the exhaust stroke of the combustion cycle.
FIGS. 3A–3D illustrate front sectional views of a second preferred embodiment of a cylinder head of the invention, mounted to a cylinder of any four-stroke internal combustion engine, moving through the exhaust, induction, compression and power strokes of the combustion cycle.
FIG. 4 illustrates a front sectional view of part of the cylinder head of FIGS. 3A–3D , during the exhaust stroke of the combustion cycle; and
FIG. 5 illustrates a side sectional view of a rotary valve useful in a cylinder head (not shown) of the present invention, which is mounted on four cylinders in a four cylinder combustion engine.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring firstly to FIGS. 1A–1D , and FIGS. 2A and 2B , a first preferred embodiment of a cylinder head 2 of the invention, is mounted on a cylinder 4 of a four-stroke internal combustion engine. The cylinder 4 comprises a combustion chamber 5 within which is mounted a piston 6 , rotatably connected to the crankshaft 8 of the engine.
The cylinder head comprises two rotary valves 10 and 12 . The rotary valve 10 comprises a port in the form of an inlet 14 which is a cut-out portion of the rotary valve extending diametrically therethrough.
The rotary valve 12 comprises a port in the form of an outlet 16 which is a cut-out portion of the rotary valve 12 extending diametrically therethrough.
The rotary valves 10 and 12 are linked to the crankshaft 8 by means well known to persons skilled in the art, such that they are arranged to rotate at one quarter the speed of the crankshaft 8 .
The cylinder head 2 also includes a spark plug 18 which is in communication with the combustion chamber 5 of the cylinder 4 .
We turn to FIGS. 2A and 2B , which show a close-up sectional view of the cylinder head 2 showing the rotary valve 10 and inlet 14 . The rotary valve 10 is mounted in a guideway 11 , which guideway is in fluid communication with a manifold inlet port 13 in the cylinder head 2 . The cylinder head 2 also includes two seals 20 which are radially mounted in ducts 24 in fluid communication with the rotary valve 10 and the combustion chamber 5 . The seals 20 comprise a sealing member in the form of a resilient plug 22 which is connected within the ducts 24 by two resilient biasing means in the form of helical springs 26 . The plugs 22 are in communication with the guideway 11 and the ducts 24 .
The rotary valve 12 is mounted in a similar guideway (not shown) which includes a manifold outlet, and the cylinder head 2 comprises two further seals 20 which are mounted in ducts in fluid communication between the rotary valve 12 and the combustion chamber 5 .
In use the engine is started as is known to persons skilled in the art. The engine runs through a four-stroke cycle as shown in FIGS. 1A–1D , comprising an exhaust stroke ( FIG. 1A ), induction stroke ( FIG. 1B ), compression stroke ( FIG. 1C ) and power stroke ( FIG. 1D ), which cycle is well known. During the power stroke, the spark plug 18 is activated to create a spark which ignites fuel injected or carburated into the combustion chamber 5 of the cylinder 2 during the induction stroke.
As the cycle reaches the induction stroke as shown in FIG. 1A , the rotary valve 10 comprising the inlet 14 is rotated by way of rotation of the crankshaft 8 such that the inlet 14 becomes aligned in fluid communication between the inlet manifold 13 and the combustion chamber 5 , as illustrated in FIG. 2A . In this position fuel, or fuel and air, is injected through the inlet manifold 13 , through the inlet 14 and into the combustion chamber 5 .
During the induction stroke the outlet 16 is not in fluid communication with the combustion chamber 5 . After the fuel, or fuel and air, has been injected, the crankshaft 8 continues to rotate, which in turn rotates the valves 10 and 12 . As the crankshaft 8 rotates, the cylinder moves to the compression stroke as shown in FIG. 1B , in which the piston 6 of the cylinder is moved up towards the cylinder head 2 , compressing the fuel (and air). During the compression stroke, neither of the rotary valves 10 or 12 are in fluid communication with either the combustion chamber 5 or their associated guideway manifolds.
At the end of the compression stroke the spark plug 18 is activated to create a spark in the combustion chamber and ignite the fuel or fuel/air mixture. The resultant combustion within the combustion chamber 5 drives the piston downwardly, rotating the crankshaft 6 and thus the valves 10 and 12 . During this power stroke, as illustrated in FIG. 1C , the rotation of the valves 10 and 12 does not result in them moving into fluid communication with the combustion chamber 5 or their associated guideway manifolds.
When the piston has reached its most downward point, further rotation of the crankshaft 8 pushes the piston towards the cylinder head 2 in the exhaust stroke, as illustrated in FIG. 1D . As the cylinder enters the exhaust stroke, the valve 10 comprising the inlet 14 is rotated via the crankshaft 5 such that it remains in non-fluid communication between the combustion chamber 5 and its associated manifold inlet 13 of the guideway 11 . The rotary valve 12 is rotated during the exhaust stroke such that the outlet 16 moves into fluid communication between the combustion chamber 5 and the associated manifold outlet (not shown) of its guideway (not shown). Thus as the piston 6 is pushed upwardly, the exhaust gas generated by combustion in the induction stroke is forced through the outlet 16 in valve 12 , through the manifold outlet of the guideway and out of the cylinder head 2 , to the engine's exhaust (not shown).
We turn now to FIGS. 2A and 2B . During the four-stroke cycle of the engine, a large quantity of gas is generated, especially in the form of exhaust gases. In order to prevent flow of exhaust gases, or any other fluid present, between the valves 10 and 12 and their associated guideways, seals 20 are utilised.
In use, when sufficient gas has built up within the combustion chamber 5 , usually during the exhaust stroke, the seals 20 are activated to prevent fluid flow between the valves 10 and 12 and the guideways.
As gas builds up within the combustion chamber 5 , gaseous pressure builds up in the ducts 24 until the pressure is sufficient to overcome the bias of springs 26 and push the sealing members 22 on to the valves 10 and 12 , thereby forming a seal across their associated guideways in which the valves 10 and 12 are located.
As shown in FIG. 2B , during the exhaust stroke, the valve 10 is oriented such that one end of the inlet 14 is adjacent to, and facing one of the sealing members 22 . Thus as the sealing member 22 is pushed onto the valve 10 , it is pushed into the open end of the inlet 14 , thereby creating a fluid tight seal. The use of rubber or similar material in the sealing member 22 helps to create a fluid-tight seal due to compression of the member 22 as it enters the inlet 14 .
As the four-strike cycle continues and the gaseous pressure drops within the combustion chamber 5 , the drop in pressure in the ducts 24 allows the springs 26 to bias against the lowered pressure and pull the sealing member 22 away from the valves 10 and 12 and allow unrestricted rotation of the valves, as illustrated in FIG. 2A .
Turning now to FIGS. 3A–3D and 4 , a second preferred embodiment of a cylinder head of the present invention is similar to that of FIGS. 1A–1D , 2 A and 2 B. Like reference numerals describe like features.
In this embodiment the cylinder head 2 comprises only one rotary valve 28 which comprises two ports in the form of an inlet 30 and outlet 32 . The inlet 30 and outlet 32 are axially spaced apart, one behind the other, along the rotary valve 28 and each comprises a cut-out portion of the valve 28 extending diametrically therethrough.
The valve 28 is located in a guideway 34 in the cylinder head 2 , as shown in FIG. 4 . The guideway includes an outlet manifold 13 and an inlet manifold (not shown) which are spaced apart along the guideway 34 . Thus the manifolds are arranged in guideway 34 at locations parallel with the outlet 32 and inlet 30 of the valve 28 located within the guideway 34 .
The inlet 30 and outlet 32 of the valve 28 extend diametrically through the valve 28 at a different angle to each other such that when the valve 28 is rotated, the inlet 30 and outlet 32 are in fluid communication between the combustion chamber 5 and their respective manifold inlet and outlet at different times in the combustion cycle.
The cylinder head further comprises four seals 20 . Two seals are provided in the cylinder head adjacent to the guideway 34 axially parallel with the location of the inlet 30 of the valve 28 located in the guideway as shown in FIG. 4 . A further two seals are provided in the cylinder head 2 parallel with the location of the outlet 32 (not shown). The seals 20 are substantially as described for the embodiment of FIGS. 1A–1D and 2 A– 2 B.
In use the combustion cycle is repeated as for the embodiment of FIGS. 1A–1D , 2 A and 2 B but in this embodiment the single valve rotates at a quarter of the speed of the crankshaft and the diametric angles of the inlet 30 and outlet 32 is such that during the exhaust stroke, the outlet 30 is aligned to provide fluid communication between the combustion chamber 5 and the outlet manifold 40 for passage of exhaust gases from the combustion chamber 5 . At the same time, during the exhaust stroke, the inlet 30 is not in fluid communication between the combustion chamber 5 and the inlet manifold (not shown) due to the different diametric angle of the inlet 30 through the valve 28 , as shown in FIG. 4 .
When the engine enters the induction stroke the valve 28 is rotated such that the outlet 32 moves out of fluid communication between the combustion chamber 5 and the outlet manifold 40 of the guideway 34 . At the same time the inlet 30 is rotated to effect fluid communication between the combustion chamber 5 and the inlet manifold of the guideway 34 , such that fuel or fuel and air, is injected into the combustion chamber.
During the compression and power strokes of the combustion cycle, the valve 18 is rotated such that neither the inlet 30 and outlet 32 are in fluid communication with the combustion chamber 5 , as shown in FIGS. 3C and 3D .
The seals 20 work in substantially the same way as do the seals of the embodiment of FIGS. 1A–1D and 2 A– 2 B.
We turn now to FIG. 5 , which shows a side-sectional view of a rotary valve of a cylinder head of the invention mounted on four cylinders in a four cylinder combustion engine. The cylinder head is not shown in this embodiment.
The rotary valve 10 which is located in a guideway (not shown) in the cylinder head, is connected to the cylinder head by bearings 36 located at either end of the valve 10 . The valve 10 is a cylindrical member having four pairs of inlet and outlets (not shown), each pair being spaced apart axially along the valve 10 and each inlet and outlet of a pair being spaced apart axially of each other.
The cylinder head is mounted on top of a four cylinder engine block such that each of the pairs of inlets and outlets of the valve 10 is located aligned over a cylinder 4 A– 4 D.
The valve 10 is connected to the crankshaft of the engine and arranged to rotate at one quarter of the speed of the eligine. The inlets and outlets of the valve 10 are as described for the embodiment of FIGS. 3A–3D and 4 and operate in the same manner. Thus rotation of the valve 10 will move the inlets and outlets through the induction, compression, power and exhaust strokes as described hereinbefore.
Each pair of inlets and outlets are oriented off-set to each of the other pairs, such that each of the four cylinders will separately be in one of the four-strokes of the combustion cycle at any one time.
The rotary valve 10 also comprises split seal gaskets 38 extending substantially around the valve 10 within the guideway, located at either end of the guideway and between each of the cylinders 4 A to 4 D. The split seal gaskets 38 are dimensioned to contact both the valve 10 and guideway and create a seal therebetween. Thus any gas or fluid which may escape into the guideway of the cylinder head will be retained in a prescribed section of the guideway between two of the gaskets 38 and thus prevented from escaping into another cylinder of inlet or outlet of the valve 10 .
The split seal gaskets 38 may be used on the valve 28 of the embodiment of the cylinder head 2 described for FIGS. 3A–3D and 4 , or for each of the valves 10 and 12 of the cylinder head 2 of FIGS. 1A–1D and 2 A– 2 B.
The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.
All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
The invention is not restricted to the details of the foregoing embodiments(s). The invention extend to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
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A cylinder head 12 showing a guideway in which is located a rotatable valve 10, 12 comprising a fluid port operable to effect fluid communication between a cylinder and a fulid manifold in the guideway, whereby rotation of the valve effects alignment of the fluid port with the combustion chamber of a cylinder 4 to enable fluid flow between the valve 10, 12 and a cylinder 4 , and wherein the cylinder head 2 further comprises a seal 22 which, in use, is movable from a first, non-sealing position in which the seal 22 is biased away from the valve 10, 12 , and a second, sealing position in which the seal 22 is biased onto the valve by gaseous pressure from within a cylinder 4.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a National Stage of International Application No. PCT/US2005/045025 filed on Dec. 14, 2005, which claims the benefit of U.S. Provisional Patent Application No. 60/636,313 filed on Dec. 15, 2004. The entire disclosures of International Application No. PCT/US2005/045025 and U.S. Provisional Patent Application No. 60/636,313 are incorporated herein by reference.
BACKGROUND
The present invention relates generally to the field of vehicle seats. More specifically, the present invention relates to a vehicle seat having a manual track release that automatically resets.
It is known to provide seats for vehicles (i.e., automobiles) that include seat backs that are able to be reclined by a user. Such seats may be configured for movement along a track in a fore and aft direction (e.g., forward towards the front of the vehicle and back towards the rear of the vehicle).
In certain applications, a vehicle seat back may be configured to fold downward toward the seat base. For example, a rear seat in a truck or van may be rotated toward the seat base to provide a larger cargo area in the rear of the vehicle. Where the seat is configured for movement along a track, rotation of the seat back toward the seat base may enable free movement of the seat along the track (i.e., the rotation of the seat back may disengage a locking mechanism that secures the seat in place along the track, which in turn allows the folded seat to move freely along the track). However, in order to lock the folded seat in place relative to the track (i.e., to prevent free movement along the track), the user must manually lock the seat in place using, for example, a latching mechanism or the like. One disadvantage of such an arrangement is that locking the seat in place is relatively cumbersome and generally requires two-handed operation (e.g., one hand to move the seat and another to engage the locking mechanism).
It would be advantageous to provide a vehicle seat that is configured for movement relative to a track in the folded position and which may be locked in place relatively easily and with less effort than is known with respect to conventional vehicle seats. It would also be advantageous to provide a track release mechanism for a vehicle seat that may be manually operated and that may manually reset itself to allow the user to relatively simply lock the seat in place along the track. It would be desirable to provide a vehicle seat that provides any one or more of these or other advantageous features as will be apparent from the following description.
SUMMARY
An exemplary embodiment of the invention relates to a track release system for a vehicle seat that includes a device for selectively engaging a track to prevent sliding movement of a vehicle seat, a cable coupled to the device, and a track release mechanism coupled to the cable for actuating the device. The track release mechanism includes a drive arm configured for movement between a first position and a second position. The drive arm is configured to cause the device to disengage the track when moved from the first position to the second position. The track release mechanism also includes a trigger arm configured for rotational movement and configured to cause the device to engage the track when the drive arm is in the second position. The trigger arm is configured to reset the track release system such that sliding movement of the vehicle seat is prevented when the drive arm is in the second position.
Another exemplary embodiment of the invention relates to a track release mechanism for a vehicle seat, with the vehicle seat coupled to a track system having a lower track secured to a vehicle and an upper track slidingly attached to the lower track. The track release mechanism includes a base comprising two substantially parallel arms, a center shaft extending between the arms of the base, a drive arm module provided on the center shaft between the arms of the base, and a cable coupled to the drive arm module and to a track latch device, the track latch device configured to prevent sliding movement of the vehicle seat by selectively engaging the lower track. The drive module includes (a) a drive arm configured to support a locking block and biasing member, with the drive arm positioned between a cable shell having a cable notch and an outer cable shell having a guide pin; (b) a reset spring provided on the center shaft and coupled to the cable shell; and (c) a trigger arm provided on the center shaft and defining a guide slot configured to receive the guide pin, with the trigger arm biased on the center shaft by a trigger spring. Folding the vehicle seat to a stowed position causes the track latch device to disengage the lower track to allow sliding movement of the vehicle seat. The trigger arm is configured to engage a tab provided on the lower track when the vehicle seat is moved along the track system in the stowed position to cause the latch device to engage the lower track and prevent movement of the vehicle seat along the track system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side plan view of a seat including a track release mechanism mounted in a vehicle according to an exemplary embodiment.
FIG. 2 is a partial side view of the seat illustrated in FIG. 1 .
FIG. 3 is a partial perspective front view of the seat illustrated in FIG. 1 .
FIG. 4 is a partial perspective front view of the seat illustrated in FIG. 1 .
FIG. 5 is a partial front plan view of the seat illustrated in FIG. 1 .
FIG. 6 is a partial side plan view of the seat illustrated in FIG. 1 and indicating one motion of the front seat support member.
FIG. 7A is a perspective rear view of several components of a track release mechanism for a seat according to an exemplary embodiment.
FIG. 7B is a plan view a portion of a track release mechanism according to another exemplary embodiment that includes a locking block and its biasing member aligned at an angle other than 90° to the center shaft.
FIG. 8 is a perspective front view of several components of a track release mechanism for a seat according to an exemplary embodiment.
FIG. 9 is a perspective view of a track release mechanism for a seat according to an exemplary embodiment.
FIG. 10 is an exploded illustration of a track release mechanism for a seat according to an exemplary embodiment.
FIGS. 11A-11G are side plan views of a track release mechanism for a seat according to an exemplary embodiment illustrating the operation of the track release mechanism.
DETAILED DESCRIPTION
According to an exemplary embodiment, a vehicle seat is provided that includes a track release mechanism that is relatively simple to operate and that may be reset by movement of the seat along the vehicle track. The track release mechanism may be configured to engage or interact with a feature provided, for example, along the track that may operate to reset the track release mechanism such that the vehicle seat may be locked in place at a predetermined location along the track without the need to manually reset the track release mechanism.
FIG. 1 illustrates a vehicle seat 10 for use in a vehicle 5 and which includes a seat to cushion or base 11 and a seat back 13 . It should be noted that while a particular configuration is illustrated for the seat 10 , the various concepts described herein may be used in conjunction with seats having any of a variety of configurations, whether now known or that may be developed in the future.
According to an exemplary embodiment, the seat cushion 11 and seat back 13 are independently, pivotably connected to seat support members. As shown, for example, in FIG. 1 , the seat cushion 11 is coupled to a rear seat support member 12 and a front seat support member 15 (which is in turn coupled to a second front seat support member 17 ), and the seat back 13 is coupled to the rear seat support member 12 . Similar seat support members may be provided on both the left and right sides of the seat 10 ; for brevity, both seat support members on the right and left sides of the seat 10 will be referred to using identical reference numerals (e.g., a seat support member 12 may be provided at both the left and right rear of the seat 10 ).
The seat back is configured for rotation between an upright position (as shown in FIG. 1 ) and a stored or folded position in which the seat back 13 is rotated toward the seat cushion 11 . The seat back 13 , seat support members 12 , 15 , and 17 , and support frames can be composed of any suitable material such as metal (steel for example) or an engineered plastic of suitable strength (composite materials for example).
The seat 10 can be either a manually adjustable seat or may be provided with electric motors to provide automated adjustment and electronic control of the seat 10 . Such manipulation can be accomplished by the use of a change of position mechanism coupled to the seat back 13 and the seat cushion 11 . It is also contemplated that two separate mechanisms may be used to provide flexibility in seat configuration. The change of position mechanism may provide for a back frame to move in proportional relation to the seat cushion 11 at a predetermined ratio.
As shown in FIGS. 1 and 2 , the seat 10 is coupled by way of the seat support members 12 , 15 , and 17 to a seat track system 16 that includes an upper track 18 , a lower track 20 and a track latch 30 . According to an exemplary embodiment, the upper track 18 may be configured for movement relative to the lower track 20 , which may be secured to the vehicle 5 using fasteners such as screws, bolts, or the like. Because the seat support members 12 and 17 are coupled to the upper track 18 , the seat 10 may be moved forward and backward in the vehicle 5 by moving the upper track 18 and attached vehicle seat 10 relative to the lower track 20 , which is fixed within the vehicle.
A track release mechanism 40 is coupled to one of the seat support members. As shown in FIG. 2 , according to an exemplary embodiment, the track release mechanism 40 is coupled to the seat support member 17 . It should be understood, however, that the track release mechanism 40 can be mounted in any convenient location associated with the vehicle seat 10 .
As shown in FIG. 2 , a track latching mechanism or device 30 (e.g., a track latch) is coupled to the upper track 18 , and includes an operating member 32 that includes a plurality of extensions or teeth 34 that are configured to engage apertures or holes (e.g., windows, openings, etc.) provided in the lower track 20 . The track latch 30 may be operated to move the extensions 34 between a first position in which they engage the apertures in the lower track 20 (to lock the upper track 18 in place relative to the lower track 20 ) and a second position in which they do not engage the apertures in the lower track 20 (to allow the upper track 18 to move freely relative to the lower track 20 ). It should be noted that the configuration of the operating member 32 and extensions may differ according to other exemplary embodiments, and may include a greater or lesser number of extensions that illustrated in the accompanying FIGURES.
The track release mechanism 40 is coupled to the track latch 30 by a cable or wire 42 (the track release mechanism 40 , track latch 30 , and cable 42 may collectively be referred to as a track release system). Movement of the cable 42 may act to operate the track latch 30 to cause the operating member 32 to either engage or disengage the apertures provided in the lower track 20 . In this manner, the track release mechanism 40 may be utilized to either lock the seat in position along the track system 16 or to unlock the seat 10 to allow it to move along the track system 16 .
As illustrated in FIGS. 3 and 6 , coupled to one of the seat support members of the vehicle seat 10 (e.g., seat support member 15 ) is an extension 14 having a rod or pin 19 extending therefrom at substantially a right angle. According to other exemplary embodiments, the pin may extend from the seat support member 15 or from another structure. The pin 19 is configured to contact a portion of the track release mechanism 40 (e.g., a drive arm 58 of the track release mechanism 40 , as shown in FIG. 6 ) when the seat back 13 is folded to a stowed position. Rotation of the seat back 13 causes the seat support member 15 to rotate downward toward the track system 16 as shown in FIG. 6 , at which time the pin 19 will contact the arm 58 .
FIGS. 7-10 illustrate in greater detail the features of the track release mechanism 40 , with FIG. 10 shown as an exploded view of the various components thereof. The track release mechanism 40 includes a base 44 configured with two substantially parallel arms or extensions 46 . The base 44 can be made of a metal such as steel or aluminum or can be made of a composite material of suitable strength.
The base 44 supports the other components of the track release mechanism 40 and is used to couple the track release mechanism 40 to the vehicle seat 10 (e.g., the base 44 of the track release mechanism 40 is coupled to the upper track 18 , which in turn is coupled to the seat cushion 11 by way of seat support members 12 , 15 , and 17 ). The base 44 can be coupled to the vehicle seat 10 by any convenient method such as welding, adhesives, or fasteners.
According to an exemplary embodiment, the arms 46 of the base 44 each define a bore 48 (e.g., an aperture, hole, opening, etc.). The bores 48 are coaxial with each other, and a center shaft 50 is configured to extend through each bore 48 . The drive shaft 50 can be made of a metal such as steel or aluminum.
As shown in FIG. 7A , a drive module 52 is mounted on the center shaft 50 between the arms 46 of the base 44 . The drive module 52 includes a drive arm 58 configured to support a locking block 60 and a biasing member 62 (e.g., a compression spring, a leaf spring, or the like). The drive arm 58 is positioned between a cable shell 54 having a cable notch 56 and an outer cable shell 64 having a guide pin 66 .
According to an exemplary embodiment shown in FIG. 7A , the locking block 60 is aligned radially to the center shaft 50 . According to another exemplary embodiment shown in FIG. 7B ; the locking block 60 is aligned at an angle other than 90° to the center shaft 50 (e.g., the locking block 60 may be pivotably connected to a base 63 and a biasing member 62 such as a spring may be provided to bias the locking block 60 away from the base 63 ).
The center shaft 50 also supports a reset spring 68 mounted on the center shaft 50 and coupled to the cable shell 54 . A trigger arm 70 is mounted on the center shaft 50 and defines a guide slot 72 which is configured to receive the guide pin 66 of the outer cable 64 . The trigger arm 70 is biased on the center shaft 50 by a trigger spring 74 . The reset spring 68 and the trigger spring 74 can be torsion springs as illustrated in the figures any other type of suitable biasing member.
A tab or extension 22 (also referred to as a profile or protrusion) is provided on the lower track 20 , as shown in FIG. 2 . According to an exemplary embodiment, the tab 22 is configured to engage the trigger arm 70 when the seat is moved along the track, as will be described in greater detail below. It should be noted that the size, shape, and configuration of the tab 22 may differ according to other exemplary embodiments from that shown in the accompanying FIGURES.
The operation of the track release mechanism will be described with respect to FIGS. 11A through 11G . For simplicity, the rotation of the arms will be described as “clockwise” or “counterclockwise” as those directions are shown in FIGS. 11A through 11G .
FIG. 11A illustrates the track release mechanism 40 in a locked position. In this position, seat back 13 is in the upright position and the track latch 30 operates to lock the seat 10 in place such that the extensions 34 of the operating member 32 engage apertures in the track (as shown, for example, in FIG. 2 ).
When the seat back 13 is folded down toward the seat cushion 11 , the pin 19 coupled to the seat support member 15 contacts the drive arm 58 , which rotates counterclockwise about the center shaft 50 (as shown in FIG. 11B ). A corresponding rotation of the trigger arm 70 also results, such that the trigger arm 70 is oriented generally perpendicular or normal to the track (i.e., the trigger arm 70 is oriented in a generally vertical position). Additionally, the cable 42 is moved during the rotation to cause the track latch 30 to disengage the track (i.e., the extensions 34 of the operating member 32 disengage the apertures in the track to allow the seat to move freely along the track).
After folding the seat back 13 downward, the seat 10 is moved forward along the track as shown in FIG. 11C . When the vehicle seat 10 moves forward along the track system 16 , the trigger arm 70 contacts the tab 22 that is coupled to the lower track 20 . The trigger arm 70 moves in a counter-clockwise direction as the trigger arm 70 moves over the tab 22 . The movement of the trigger arm 70 at this time is a free (uninhibited) swing (the pin 66 moves within the slot 72 as the trigger arm 70 is rotated counterclockwise). After the trigger arm 70 moves past the tab 22 as shown in FIG. 11D , the trigger arm 70 swings back to its vertical orientation prior to its engagement with the tab 22 .
When the vehicle seat 10 slides back along the track from the forward position, the trigger arm 70 contacts the tab 22 once more as shown in FIG. 11E . The outer shell 64 is forced to rotate in a clockwise direction, which causes the locking block 60 to pull out of engagement with the cable shell 54 . That motion causes the track cable 42 to move the track latch 30 to cause the operating member 32 to lock the vehicle seat 10 in the seat track system 16 . That is, when the trigger arm 70 engages the tab 22 when it is moved back along the track, the track release mechanism is reset, along with the track latch 30 . As a result, the extensions 34 of the spring-loaded track latch 30 will engage the first set of openings in the lower track 20 they reach to lock the seat in place.
In essence, such a configuration allows one-handed locking of a folded seat along a track. For example, the user may move the seat forward such that the trigger arm 70 moves past the tab 22 , after which the seat may be locked in place simply by moving the seat backward along the track until the trigger arm once more engages the tab 22 (and without the need to manually reset the track release mechanism 40 with a lever or the like).
As shown in FIG. 11F , however, the track release mechanism 40 does not automatically reset itself once the trigger arm moves past the tab 22 . After moving past the tab 22 , the trigger arm 70 swings freely back toward the vertical position. However, the drive arm 58 is held by the pin 19 since the seat back 13 is still folded at this time. The track release mechanism 40 thus cannot reset until the pin 19 is released (moved off of the drive arm 58 when the seat back 13 is moved from the folded or stowed position to the upright seating position). However, the vehicle seat 10 can still be moved along the vehicle track system 16 by unlocking the vehicle track system 16 by operation of a remote handle 80 coupled to a release cable 82 which is coupled to the track latch 30 .
As shown in FIG. 11G , when the pin 19 is moved off of the drive arm 58 , the track release mechanism 40 is reset to its original position. The reset spring 68 rotates the drive arm 58 , outer shell 654 , and trigger arm 70 back to their original position (as shown in FIG. 11A ). The locking block 60 is returned to the locked position by the biasing member 62 , and the track release mechanism 40 is ready for the next cycle.
As described above, according to an exemplary embodiment, there is provided a track release mechanism for a vehicle seat. The vehicle seat is coupled to a track system having a lower track secured to a vehicle, an upper track slidingly attached to the lower track, and a track latch configured to lock the seat with an operating member in a preselected position along the lower track. The track release mechanism includes a base configured with two substantial parallel arms, with each arm defining a bore with the bores coaxial. A center shaft is configured to engage in each bore. A drive arm module is mounted on a center shaft between the arms of the base. The drive module includes the drive arm configured to support a locking block and a biasing member. The drive arm is positioned between a cable shell having a cable notch and an outer cable shell having a guide pin. A reset spring is Mounted on the center shaft and coupled to the cable shell. A trigger arm is mounted on the center shaft in defining a guide slot configured to receive the guide pin. The trigger arm is biased on the center shaft by a trigger spring. A tab is coupled to the lower track and configured to move the trigger arm. A cable is coupled to the drive arm module and the track latch. The movement of the vehicle seat along the track system causes the track release mechanism to reset as a trigger arm being moved by the tab. Another embodiment of the track release mechanism includes a remote handle and release cable coupled to the track latch; wherein the remote handle is operated unlocking the track latch.
There is also provided a method for automatic reset of a track release module coupled to a vehicle seat mounted in a vehicle on a track system. The vehicle seat includes a track latch and a seat support member having a mechanical arm (e.g., a pin coupled to a seat support member). The method comprises the steps of providing a cable of predetermined length and coupling one end of the cable to the track release module. Another end of the cable is coupled to the track latch, and the track release module moves from a tripped position to a reset position as the seat is moved from a forward position to a rear position along the track system. Another embodiment of the method includes the step of providing a remote handle and release cable coupled to the track latch, wherein the remote handle and release cable releases the track latch when the track release module is still in the tripped position.
The foregoing description and accompanying drawings relate to seats or chairs particularly adapted for use in motor vehicles such as cars, SUV's, vans, trucks, busses and the like. It will be appreciated by those reviewing this disclosure, however, that the various exemplary embodiments described herein may also be applicable to seating used in aircrafts, railroad vehicles, nautical vehicles, and in other environments. Such seats may be configured as split seats or a bench-type seats, and may have any of a wide variety of configurations.
For purposes of this disclosure, the term “coupled” means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components or the two components and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.
It is also important to note that the construction and arrangement of the vehicle seats and track release mechanisms as shown in the various exemplary embodiments is illustrative only. Although only a few embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Additionally, while certain mechanical systems are described to move seat components to achieve certain results, other mechanisms (either manual or powered) could be substituted therefor (e.g., various mechanical equivalents may be substituted for the seat contours, including, but not limited to, fore-bar linkages, air or hydraulic cylinders, air bladders, rack and pinion systems, cans and cables, gears, etc.). Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the scope of the present inventions as expressed in the appended claims.
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A track release system for a vehicle seat includes a device for selectively engaging a track to prevent sliding movement of a vehicle seat, a cable coupled to the device, and a track release mechanism coupled to the cable for actuating the device. The track release mechanism includes a drive arm configured for movement between a first position and a second position. The drive arm is configured to cause the device to disengage the track when moved from the first position to the second position. The track release mechanism also includes a trigger arm configured for rotational movement and configured to cause the device to engage the track when the drive arm is in the second position. The trigger arm is configured to reset the track release system such that sliding movement of the vehicle seat is prevented when the drive arm is in the second position.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation application of U.S. patent application Ser. No. 13/650,098, filed on Oct. 11, 2012, and all benefits of such earlier application are hereby claimed for this new continuation application.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a primary side control (PSC) switching-mode power supply (SMPS), and particularly to a PSC SMPS that has reduced output voltage jitter.
[0004] 2. Description of the Prior Art
[0005] Power supplies are a necessary electronic device in most electronic products, and are used for converting battery or grid power to power required by the electronic product and having specific characteristics. In most power supplies, switching-mode power supplies have superior electrical energy conversion efficiency and smaller product dimensions, making them popular in the power supply market.
[0006] Two different control schemes are used in current switching-mode power supplies: primary side control (PSC) and secondary side control (SSC). SSC directly couples a detection circuit to an output node of a secondary winding of a power supply, then through a photo coupler, transmits a detection result to a power supply controller located on the primary side to control energy of the power supply that is to be stored and converted on the primary winding. Compared to SSC, PSC indirectly detects voltage outputted by the secondary winding through directly detecting reflected voltage on an auxiliary winding, and indirectly completes detection of output voltage on an output node of the power supply. PSC completes detection and energy conversion control on the primary side. Compared to SSC, PSC is able to lower cost, as PSC does not require the photo coupler having both greater size and cost. PSC may also have higher conversion efficiency, because PSC does not require the detection circuit on the secondary side that constantly drains energy.
[0007] FIG. 1 is a diagram of a switching-mode power supply that uses PSC. Bridge rectifier 20 rectifies alternating current from grid node AC to establish direct current input power at input node IN. Voltage V IN of output power may have an M-shaped waveform, but may also be filtered into a fixed level that roughly does not vary over time. Transformer has three windings: primary winding PRM, secondary winding SEC, and auxiliary winding AUX. Power supply controller 26 periodically controls power switch 34 through gate node GATE. When power switch 34 is ON, primary winding PRM performs energy storage. When power switch 34 is OFF, secondary winding SEC and auxiliary winding AUX discharge to establish output voltage VOUT on output node OUT for supply to load 24 , and control voltage VCC for supply to power supply controller 26 .
[0008] Voltage divider resistors 28 , 30 detect voltage V AUX of auxiliary winding AUX to provide feedback voltage V FB to feedback node FB of power supply controller 26 . According to feedback voltage V FB , power supply controller 26 establishes compensation voltage V COM on compensation capacitor 32 , and controls power switch 34 according thereto.
[0009] FIG. 2 shows the power supply controller 26 of FIG. 1 and some external components. Power supply controller 26 comprises sampler 12 , pulse generator 14 , transconductor 15 , and pulse width controller 16 . During discharging of secondary winding SEC and auxiliary winding AUX, pulse generator 14 provides a short pulse to sampler 12 , so that sampler 12 samples feedback voltage V FB to generate feedback voltage V IFB at intermediate node IFB. Through feedback node FB, voltage divider resistors 28 and 30 , and auxiliary winding AUX, feedback voltage V IFB equivalently represents voltage level of secondary winding voltage V SEC of secondary winding SEC during discharging, and roughly represents output voltage V OUT . Transconductor 15 controls compensation voltage V COM on compensation node COMP according to a comparison result of feedback voltage V IFB and target voltage V REF . Pulse width controller 16 controls power switch 34 according to compensation voltage V COM . Overall, power supply controller 26 provides a feedback mechanism that roughly stabilizes feedback voltage V IFB to target voltage V REF , and is thus able to stabilize output voltage V OUT .
SUMMARY OF THE INVENTION
[0010] According to an embodiment, a primary-side control method comprises providing a feedback voltage, the feedback voltage representing a secondary-side voltage of a secondary winding through an inductance-coupling effect; controlling a power switch by a first switching frequency; comparing the feedback voltage and an over-shot reference voltage; and controlling the power switch by a second switching frequency when the feedback voltage is greater than the over-shot reference voltage. The second switching frequency is lower than the first switching frequency.
[0011] According to an embodiment, a power supply controller for performing primary-side control comprises a comparator and an ON triggering controller. The comparator is for comparing a feedback voltage and an over-shot reference voltage. The feedback voltage represents a secondary-side voltage of a secondary winding through an inductance-coupling effect. The ON-triggering controller is coupled to the comparator. When the feedback voltage is lower than the over-shot reference voltage, the ON-triggering controller causes a power switch to operate at approximately a first switching frequency. When the feedback voltage is higher than the over-shot reference voltage, the ON-triggering controller causes the power switch to operate at approximately a second switching frequency. The second switching frequency is lower than the first switching frequency.
[0012] According to an embodiment, a power management system comprises a transformer, a power switch, and a power supply controller. The transformer has a primary winding, an auxiliary winding, and a secondary winding. The power switch is coupled to the primary winding for controlling an inductance current flowing through the primary winding. The power supply controller is for controlling the power switch, and comprises a feedback node, a comparator, and an ON-triggering controller. The feedback node is coupled to the auxiliary winding. The comparator is for comparing a feedback voltage and an over-shot reference voltage. The feedback voltage represents a secondary-side voltage of the secondary winding through the feedback node and the auxiliary winding. The ON-triggering controller is coupled to the comparator. The ON-triggering controller causes the power switch to operate approximately at a first switching frequency when the feedback voltage is lower than the over-shot reference voltage, and the ON-triggering controller causes the power switch to operate approximately at a second switching frequency when the feedback voltage is higher than the over-shot reference voltage. The second switching frequency is lower than the first switching frequency.
[0013] These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a diagram of a switching-mode power supply that uses PSC.
[0015] FIG. 2 shows the power supply controller of FIG. 1 and some external components.
[0016] FIG. 3 is a diagram of a power supply controller according to an embodiment.
[0017] FIG. 4 is a diagram of a power supply controller according to an embodiment.
DETAILED DESCRIPTION
[0018] In the following examples, components sharing the same reference numerals have similar or the same function, structure, and operation. Persons of ordinary skill in the art may arrive at simple alterations or modifications of the embodiments of the detailed description according to the teachings and disclosure herein without leaving the spirit of the present invention.
[0019] The power supply controller 26 of FIG. 2 may exhibit excessive output voltage VOUT jitter during light-heavy load switching.
[0020] For example, when load 24 suddenly transitions from a heavy load to a light load or no load, output voltage V OUT will suddenly rise. And, power supply controller 26 must wait for a period of time, in which transconductor 15 pulls compensation voltage V COM down to a certain level, such that energy converted by transformer is lower than energy consumed by load 24 , before output voltage V OUT can begin to fall. However, at this time, output voltage V OUT is very likely to already have exceeded the required specification of the power supply management system.
[0021] FIG. 3 is a diagram of a power supply controller 26 a according to an embodiment. Power supply controller 26 a replaces power supply controller 26 of FIG. 1 .
[0022] Power supply controller 26 a comprises sampler 12 , pulse generator 14 , transconductor 15 , comparator 60 , oscillator 62 , and pulse width controller 64 .
[0023] After pulse width controller 64 turns power switch 34 off, secondary winding SEC and auxiliary winding AUX begin to release energy stored previously by primary winding PRM while power switch 34 was turned on. The time for secondary winding SEC and auxiliary winding AUX to release electrical energy is called discharge time T DIS . During discharge time T DIS , pulse generator 14 provides a short pulse to cause sampler 12 to sample feedback voltage V FB on feedback node FB. A sample result is then stored on intermediate node IFB as feedback voltage V IFB . Thus, feedback voltage V IFB approximately represents output voltage V OUT through voltage division and inductive coupling through feedback node FB, voltage divider resistors 28 and 30 , auxiliary winding AUX, and secondary winding SEC.
[0024] Transconductor 15 controls compensation voltage V COM according to feedback voltage V IFB and target voltage V REF . In some embodiments, pulse width controller 64 determines ON time T ON of power switch 34 per one switching period according to compensation voltage V COM on compensation node COMP, which is time in which power switch 34 is short circuited.
[0025] Oscillator 62 provides set signal S SET through set node SET, which periodically triggers turning on of power switch 34 . Thus, switching frequency of power switch 34 is approximately equal to frequency of set signal S SET . In some embodiments, frequency of set signal S SET can be determined from compensation voltage V COM . For example, frequency of set signal S SET can decrease with decreasing compensation voltage V COM .
[0026] Comparator 60 compares feedback voltage V IFB and over-shot reference voltage V OS-REF . Comparison result S OV of comparator 60 affects frequency of set signal S SET provided by oscillator 62 . For example, when feedback voltage V IFB is lower than over-shot reference voltage V OS-REF , comparison result S OV is logic 0, and frequency of set signal S SET may be determined solely by compensation voltage V COM to be, for example, 60 KHz. As soon as feedback voltage V IFB exceeds over-shot reference voltage V OS-REF /comparison result S OV becomes logic 1, and frequency of set signal S SET immediately drops to be fixed at, for example, 25 KHz.
[0027] Power supply controller 26 a of FIG. 3 can suppress output voltage V OUT jitter when transitioning from a heavy load to a light load. The following description is made with reference to FIG. 1 , with power supply controller 26 a replacing power supply controller 26 thereof, and target voltage V REF and over-shot reference voltage V OS-REF assumed to be 2.5V and 2.6V, respectively. As soon as load 24 suddenly transitions from heavy loading to light loading or no loading, because energy output of the transformer exceeds energy consumption of load 24 , output voltage V OUT suddenly rises, causing feedback voltage V IFB to start rising in turn. As soon as feedback voltage V IFB exceeds over-shot reference voltage V OS-REF of 2.6V, frequency of set signal S SET immediately drops to a low value, so that electrical power outputted by transformer immediately drops. Compared to the prior art, which must wait for compensation voltage V COM to be pulled down to a certain level before transmitted energy can drop noticeably, as soon as power supply controller 26 a discovers that feedback voltage V IFB has exceeded over-shot reference voltage V OS-REF of 2.6V, frequency of set signal S SET is dropped immediately, which also lowers electrical power output of the transformer, thus rapidly prohibiting output voltage V OUT from increasing.
[0028] Feedback voltage V IFB is periodically updated as set signal S SET periodically turns on power switch 34 , so as to track current output voltage V OUT . As long as feedback voltage V IFB is lower than over-shot reference voltage V OS-REF of 2.6V, power supply controller 26 a will return to normal operation, e.g. frequency of set signal S SET being determined only on by compensation voltage V COM . So, for normal operation, power supply controller 26 a and power supply controller 26 are the same, each causing feedback voltage V IFB to converge to target voltage V REF of 2.5V.
[0029] FIG. 4 is a diagram of a power supply controller 26 b according to an embodiment. In the following description, power supply controller 26 b replaces power supply controller 26 of FIG. 1 as another embodiment.
[0030] Compared to the power supply controller 26 a of FIG. 2 , power supply controller 26 b has OFF time controller 66 coupled to feedback node FB. OFF time controller 66 may employ valley switching. For example, after discharge time T DIS , auxiliary winding voltage V AUX of auxiliary winding AUX starts oscillating, and gradually converges to 0V. So-called “valley switching” may mean that, after power switch 34 is turned off, power switch 34 is turned on when a 1 st valley, a 2 nd valley, a 3 rd valley, and so on of auxiliary winding voltage V AUX occurs. This type of operating scheme is typically called quasi-resonance (QR) mode.
[0031] Through feedback node FB, OFF time controller 66 can determine when auxiliary winding voltage V AUX drops across 0V, so-called zero crossing. OFF time controller 66 may be designed to trigger pulse width controller 64 to turn on power switch 34 through set node SET a predetermined period after auxiliary winding voltage V AUX drops across 0V. Thus, valley switching can be approximately realized. In order to avoid zero-crossing never being detected, OFF time controller 66 can be designed to forcefully trigger pulse width controller 64 to turn on power switch 34 if no zero-crossing has been detected after a maximum OFF time.
[0032] In the embodiment of FIG. 4 , when feedback voltage V IFB is lower than over-shot reference voltage V OS-REF , comparison result S OV is logic 0. At this time, timing of set signal S SET triggering turning on of power switch 34 may be determined according to compensation voltage V COM and zero-crossing detected by OFF time controller 66 through feedback node FB. Simply speaking, when feedback voltage V IFB is lower than over-shot reference voltage V OS-REF , power supply controller 26 b approximately operates in QR mode, and may trigger turning on of power switch 34 at any valley appearing in auxiliary winding voltage V AUX .
[0033] When feedback voltage V IFB is greater than over-shot reference voltage V OS-REF , comparison result S OV is logic 1, and OFF time controller 66 only triggers pulse width controller 64 to turn on power switch 34 after maximum OFF time. At this time, switching frequency of power switch 34 is necessarily lower than when operating in QR mode.
[0034] Similar to power supply controller 26 a of FIG. 3 , when output voltage V OUT is on the high side, causing feedback voltage V IFB to exceed over-shot reference voltage V OS-REF , power supply controller 26 b of FIG. 4 causes OFF time of power switch 34 to be maximum OFF time, so that switching frequency immediately drops. Electrical power transmitted by the transformer can be lowered rapidly, which can rapidly prevent output voltage V OUT from rising further.
[0035] It is predictable that the power supply controllers of FIG. 3 and FIG. 4 can both rapidly prevent feedback voltage V IFB from rising further, which can reduce output voltage V OUT jitter, and cause output voltage V OUT to converge more rapidly.
[0036] Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.
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Power controllers and related primary-side control methods are disclosed. A disclosed power controller has a comparator and an ON-triggering controller. The comparator compares a feedback voltage with an over-shot reference voltage. Based on an inductance-coupling effect, the feedback voltage represents a secondary-side voltage of a secondary winding. Coupled to the comparator, the ON-triggering controller operates a power switch at about a first switching frequency when the feedback voltage is lower than the over-shot reference voltage. The ON-triggering controller operates the power switch at about a second switching frequency when the feedback voltage exceeds the over-shot reference voltage. The second switching frequency is less than the first switching frequency.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to provisional application No. 61/447,096, filed on Feb. 27, 2011, which application is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
[0004] The present invention relates to a wind blocking device for the C6 convertible Corvette (model years 2005-present) and the C5 convertible Corvette (model years 1997-2004). Several wind blocking devices have been manufactured for convertibles and for the C5 and C6 Corvette. However, due to deficiencies in the design of the wind blocking panel and its related mounting system, all other wind blocking devices for the C5 and C6 Corvette require the wind blocking device to be removed in order to operate the convertible top between the open and closed positions. The present invention, on the other hand, is unique in that it is designed and mounted in such a way that the convertible top can be opened and closed without disturbing the wind blocking device and the present invention also incorporates text or art work which may be abraded onto a solid transparent or translucent wind blocker and then illuminated for dramatic effect.
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention provides a wind blocker for a convertible Corvette which allows the convertible top to be opened and closed without the necessity of removing the wind blocker. In a preferred embodiment, the wind blocker is made of a transparent or translucent material which is abraded with text or art work and illuminated for a dramatic artistic effect.
[0006] The present invention provides a device which comprises a solid panel, bends in the panel to follow the contour of the interior of a convertible Corvette, and a means for attaching the panel to a convertible Corvette. In one embodiment of the invention, the panel is of a transparent or translucent material with abrasions on the face of the panel and a means of illumination. The subject device is installed in a convertible Corvette such that it projects upwards beyond a seat belt tower of the Corvette and provides a customized artistic presentation while redirecting airflow through the passenger compartment of the Corvette.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0007] FIG. 1 is a preferred embodiment of the panel of the wind blocker.
[0008] FIG. 2 is a preferred embodiment of the panel of the wind blocker with various details identified.
[0009] FIG. 3 illustrates the panel and a preferred embodiment of the means of attaching the panel to the corvette.
[0010] FIG. 4 illustrates the frame bracket used to attach the panel bracket to the C6 Corvette.
[0011] FIG. 5 illustrates an anchor that is used to secure the frame bracket to the Corvette.
[0012] FIG. 6 illustrates the panel bracket which is used to secure the panel to the frame bracket.
[0013] FIG. 7 illustrates the method of attaching the anchor to the C6 Corvette.
[0014] FIG. 8 illustrates the method of attaching the frame bracket to the C6 Corvette.
[0015] FIG. 9 illustrates a modified frame bracket for a convertible C5 Corvette.
DETAILED DESCRIPTION OF THE INVENTION
[0016] A convertible Corvette wind blocking device comprising a solid panel 20 which projects upwards beyond a seat belt tower 18 of the convertible Corvette and that has a face 1 , two first bends 2 an equal distance from a centerline of the panel, two second bends 3 an equal distance from the centerline of the panel, an edge 4 , two sets of mounting holes 5 , a means of attaching the panel 20 to the Corvette, an abrasion 19 in the face 1 and a means of illumination. Additionally, the panel has two cutouts 34 arranged to provide clearance for a seat latch of a convertible Corvette.
[0017] The wind blocking device is made in the following manner. In the preferred embodiment, the panel 20 is made from an acrylic plastic. In the preferred embodiment, the panel 20 is cut and bent into a predetermined shape to fit behind seats of a C5 or a C6 Corvette and generally follow the contour of a rear passenger compartment of the Corvette. In the preferred embodiment, the first bends 2 and the second bends 3 are 52 degrees and 48 degrees, respectively. However, it should be understood that any number of angles could be accommodated by the present invention to allow the panel 20 to follow the contour of the rear passenger compartment of the Corvette. In the preferred embodiment, the abrasion 19 is customized text and/or an artistic design which is formed in the face 1 of the panel 20 by water pressure, sand blasting or laser etching, which allows each wind blocking device to be custom designed based upon a customer's requirements.
[0018] In the preferred embodiment, a means of illumination is a strip of light emitting diodes (LEDs) which are readily known in the art and which are affixed to the edge 4 of the panel 20 . Affixing the LED strip to the edge 4 of the panel 20 allows light to pass through the panel 20 and become diffused at the abrasion 19 such that the abrasion 19 is illuminated to observers.
[0019] In the preferred embodiment, the means of attaching the panel 20 to the C6 Corvette comprises a panel bracket plate 6 , a panel bracket 8 , a frame bracket 12 , an anchor 15 , four screws 9 , two nuts 30 and a bolt 10 . The panel bracket plate 6 comprises a flat metal plate with mounting bosses 7 arranged in such a way as to align with one set of the holes 5 in the panel 20 . The panel bracket 8 comprises a stamped sheet metal plate comprising a bottom tab 23 , a front tab 24 and a side tab 25 , with holes 16 in the front tab 24 arranged in such a way as to align with the mounting bosses 7 of the panel bracket plate 6 and holes 21 arranged in such a way as to align with threaded studs 26 the frame bracket 12 . In the preferred embodiment, the bottom tab 23 and the side tab 25 form an angle of approximately 90 degrees and the bottom tab 23 and the front tab 24 form an angle of approximately 102 degrees. However, it should be understood that any number of angles could be accommodated by the present invention to allow the panel bracket 8 to align with both the panel 20 and the frame bracket 12 . The panel bracket 8 is installed onto the panel 20 by attaching the panel bracket 8 to a front side of the panel 20 with the holes 16 of the panel bracket 8 aligned with one set of the holes 5 of the panel 20 . The panel bracket plate 6 is installed onto the panel 20 by attaching the panel bracket plate 6 to a rear side of the panel 20 opposite the panel bracket 8 with the mounting bosses 7 of the panel bracket plate 6 aligned with one set of the holes 5 of the panel 20 . Screws 9 are affixed to the mounting bosses 7 by installing the screws 9 through the holes 16 in the panel bracket and the corresponding set of holes 5 in the panel 20 . A seat belt tower trim 17 is removed from a seat belt tower 18 pursuant to the manufacturer's directions. An anchor 15 is inserted into an existing slot 27 on the seat belt tower 18 as depicted in FIG. 7 . The seat belt tower trim 17 is then reinstalled on the seal belt tower 18 . The frame bracket 12 comprises a sheet metal stamping which is bent to fit the contours of the seat belt tower 18 of the Corvette, two tabs 13 , a hole 22 , a spacer 14 and two threaded studs 26 . The frame bracket 12 is attached to the Corvette by placing the frame bracket 12 over the seat belt tower 18 and pressing it down onto the seat belt tower 18 until the tabs 13 engage an edge of the seatbelt tower 18 . A bolt 10 is inserted through the hole 16 and affixed to the anchor 15 . The anchor 15 is adapted to fit snugly inside the existing slot 27 in the seat belt tower 18 . Inserting the bolt 10 into the anchor 15 causes flanges 28 on the anchor 15 to press firmly against inside edges of the existing slot 27 in the seat belt tower 18 . Raised lips 29 on the flanges 27 prevent the removal of the anchor 15 from the existing slot in the seat belt tower 18 without first removing the bolt 10 . The panel bracket 8 is attached to the frame bracket 12 by aligning the holes 21 with the threaded studs 26 and tightening bolts 30 onto the threaded studs 26 such that the panel bracket is situated between the frame bracket 12 and the bolts 30 .
[0020] The present invention can be easily adapted to a convertible C5 Corvette by modifying the frame bracket 12 . The preferred embodiment of the invention for the C5 Corvette is the same as the embodiment for the C6 Corvette except that the anchor 15 is not used and the a C5 frame bracket 31 is used in place of the frame bracket 12 . The C5 frame bracket 31 comprises a sheet metal stamping which is bent to fit the contours of a frame member 11 of a convertible C5 Corvette, and two threaded studs 32 . The C5 frame bracket 31 is attached to the C5 Corvette by attaching two sided high bonding strength tape which is known by one knowledgeable in the art to a bottom 33 of the C5 frame bracket 31 and placing the C5 frame bracket 31 over the frame member 11 and pressing it down firmly onto the frame member 11 . The panel bracket 8 is attached to the C5frame bracket 31 in the same fashion as the panel bracket 8 is attached to the frame bracket 12 .
[0021] Although a preferred embodiment uses a transparent or translucent acrylic panel, it should be understood that the panel 20 of the wind blocking device can be manufactured from any number of materials capable of redirecting air flow through the passenger compartment of the Corvette and which are known in the art, i.e., ABS plastic, plexi-glass, lexan, aluminum, screen mesh, and so forth. Additionally, while the preferred embodiment utilizes an LED strip for illuminating a transparent or translucent panel 20 , it should also be understood that the means of illuminating the abrasion 19 could be any number of means of illumination known in the art and such illumination can be white, a single color, or multi-colored. The means of illumination can be powered by its own independent power source or powered by the Corvette's power system. In either case, the means of illumination can utilize its own switch to control the flow of electricity. However, if powered by the Corvette's power system, the means of illumination can also be connected to the Corvette's electrical system such that the Corvette's electrical system controls the flow of electricity such that the means of illumination may be always on, on when the vehicle's ignition switch is in the “accessory” or “on” position, or on when one or more of the Corvette's lights are on, such as the parking lights, brake lights or head lights.
[0022] Although it is anticipated that the abrasion 19 will be formed by water pressure, sand blasting or laser etching, it should also be understood that the invention is not dependent on any particular manner of forming the abrasion 19 . The formation of the abrasion 19 can be accomplished by any number of methods known to one skilled in the art.
[0023] It should be understood that the geometry of the panel 20 in FIG. 1 is based upon the contours of a C5 and C6 convertible Corvette. The geometry of the panel 20 can be manufactured with a wide range of geometries capable of fitting behind passenger seats of the Corvette by one skilled in the art. FIG. 2 through FIG. 5 depict the preferred embodiment of the means of attaching the panel 20 to the convertible C6 Corvette. FIG. 6 and FIG. 7 illustrate the method by which the frame bracket 12 is affixed to the convertible C6 Corvette.
[0024] Although the invention has been described in detail with reference to a particular embodiment, it is to be understood that variations or modifications may be made within the spirit and scope of the invention as defined in the appended claims.
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The wind blocker allows the simple and inexpensive manufacture of a wind blocker for the convertible C5 and C6 Corvette which utilizes illuminated text and/or artwork. The design of the wind blocker allows such text or artwork to be quickly and inexpensively applied based on customer requirements. The use of computer aided etching techniques allow the wind blocker to be cost effectively manufactured with custom artwork in quantities as low as one item. This allows the end customer to utilize any artistic design desired to create a completely custom, one-of-a-kind accessory for the customer's C5 or C6 Corvette.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to automobile alternator housings which promote rectifier diode cooling. Specifically this invention relates to the addition of heat dissipation fins to an alternator housing proximate the rectifier.
2. Description of the Prior Art
Automobile alternators typically include a rectifier assembly for converting the alternating current output of the alternator to direct current used by the automobile. These rectifier assemblies normally consist of a system of diodes mounted on a carrier. The carrier is usually fastened to the interior of the rear housing of the alternator. Thus, the rectifier diodes are commonly placed inside an alternator housing which in turn is within the hot engine compartment of an automobile. Since the diodes produce heat, if the rectifier is not adequately cooled then the rectifier diodes may burn out. Many alternator designs have been developed with an eye to cooling an internal rectifier to prevent rectifier diode burnout.
Rectifier cooling is commonly accomplished by means of cooling air as is shown by the following prior art. U.S. Pat. No. 5,019,735 issued May 28, 1991, to J. J. Lee shows a case providing ventilation to cool a fan motor. U.S. Pat. Nos. 4,162,419 issued Jul. 24, 1979, to L. E. DeAngles, and 4,926,076 issued May 15, 1990, to T. Nimura et al. both show alternators having fans to air cool rectifiers. U.S. Pat. Nos. 4,284,914 issued Aug. 18, 1981, and 4,286,186 issued Aug. 25, 1981 to W. Hagenlocher et al. show alternator end caps which may include vents designed to direct air over a rectifier. U.S. Pat. No. 5,233,246 issued Aug. 3, 1993, to S. J. Yockey shows a rectifier terminal including air lovers. As cooling air has been the traditional method of cooling rectifiers, the prior shows few alternatives to this method. U.S Pat. No. 3,553,505, issued Jan. 1, 1971, to S. Sato does show a rectifier carrier having a design which improves efficiency during manufacture, the carrier also may improve heat dissipation. U.S. Pat. No. 4,191,245 issued Mar. 4, 1980, to M. E. Wendt et al. shows the concept of heat dissipation fins applied to a motor mounting arrangement. Foreign Patents which show alternator housings of interest include German patent 1,168,552 dated Apr. 23, 1964 and French Patent 1,352,823 dated Jan. 13, 1964.
None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed.
SUMMARY OF THE INVENTION
As discussed above it is important to carefully design alternators and alternator housings to provide means to cool the rectifier diodes in order to prevent burnout. The present invention provides heat dissipation fins on the alternator housing proximate to the rectifier. These fins promote heat dissipation in the area of the rectifier and, thus, prevent rectifier diode burnout. These fins may be cast as a part of the alternator housing or may be in the form of a supplemental piece attached to the housing. The heat dissipation fins have the advantage of being a useful addition for existing alternators which have known rectifier burnout problems, such as Delco-Remy CS-121 and CS-130 alternators.
Currently an alternator rebuilder will replace the rectifier with a more heavy duty model when refurbishing an alternator known to have a chronic rectifier burnout problem. This solution has not been found to be entirely successful, as in some types of alternators the heavy duty rectifiers will also burnout prematurely. The present invention either in the form of a supplemental attachment to the alternator or in the form of a replacement rear housing for the alternator provides alternator rebuilders with a reliable solution for preventing rectifier burnout in types of alternators known to have chronic rectifier burnout problems.
Accordingly, it is a principal object of the invention to provide heat dissipation fins on the outer surface of an alternator housing proximate to the rectifier to promote rectifier cooling.
It is another object of the invention to provide a supplemental attachment including heat dissipation fins to be fastened to an alternator housing proximate the rectifier.
It is a further object of the invention to provide replacement rear housings providing heat dissipation fins for alternators with existing rectifier diode burnout problems.
It is an object of the invention to provide improved elements and arrangements thereof in an apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view showing the attachment of a rectifier and the heat dissipation attachment of the present invention to a alternator rear housing.
FIG. 2A is a top view of an alternator rear housing according to the present invention.
FIG. 2B is a top view of the heat dissipation attachment shown in FIG. 1.
FIG. 3A is a side view of the alternator rear housing of FIG. 2A.
FIG. 3B is a side view of the heat dissipation attachment shown in FIG. 1.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A heat dissipation attachment 30, for solving chronic alternator rectifier burnout problems, is shown in FIG. 1 with an alternator rear housing 10 and rectifier assembly 12. Alternator housing 10 has a substantially cylindrical shape formed from a substantially cylindrical side wall 16 and a rear wall 14 disposed across an end of side wall 16. Side wall 16 includes attachment points for securing rear housing 10 to a front housing and also includes ventilation openings (see FIG. 3). Rear wall 14 is generally circular and has a centrally disposed ring defining rear bearing aperture 18. A number of attachment points 20 for securing alternator components, such as a rectifier assembly or brush assembly, to the interior of housing 10 are also provided on rear wall 14. Component attachment points may also be provided on side wall 16. Rear wall 14 includes ventilation openings 22 disposed on a section of rear wall 14 adjacent bearing aperture 18 (see FIG. 2A). Rear housing 10 may also include external means for mounting the alternator.
The mounting location of rectifier assembly 12 within the interior of rear housing 10 is shown in FIG. 1. Rectifier assembly 12 is secured to the interior of a solid portion of rear wall 14 located between the rear bearing aperture 18 and the corner 24 connecting rear wall 14 with side wall 16. The rectifier typically abuts a portion of the interior of rear wall extending through at least one quadrant of the rear wall.
The rectifier assembly 12 produces heat which if not dissipated will cause the rectifier to burnout. Heat dissipation attachment 30 is provided to enhance the heat dissipation capability of alternator housing 10 specifically in the area abutting rectifier assembly 12. Heat dissipation attachment 30 is secured to attachment points which have been formed on the exterior of rear housing 10. Also, heat dissipation attachment 30 preserves the existing air flow over the rectifier.
Heat dissipation attachment 30 includes a base 32 from which extends a plurality of heat dissipation fins 34. Attachment 30 is formed from a heat conductive material such as aluminum. Bolt holes 36 are included on attachment 30 for securing the device to attachment points on rear housing 10. Base 32 of attachment 30 has a flat arcuate shape which fits over an exterior portion of rear wall 14 opposite the interior portion of rear wall 14 abutting rectifier assembly 12. Attachment 30 may replace an existing cover placed over side ventilation openings on housing 10. Therefore, attachment 30 includes depending curved side wall 38. Side wall 38 includes ventilation openings 40 to maintain air flow over rectifier assembly 12. Heat dissipation fins 34 are arranged in a closely spaced radial arrangement across base 32. Heat dissipation fins 34 have a narrow width, and long length, thus maximizing the surface area of attachment 30 in the limited space available. The height of fins 34 is limited to less than their length. To facilitate manufacture fins 34 may have wedge shape along the radial dimension producing a slightly tapered horizontal cross section, as shown in FIG. 2. Fins 34 are closely spaced and thus are separated by a distance approximating their width. Heat dissipation attachment 30 is secured to rear housing 10 such that there is substantial contact between heat dissipation attachment 30 and housing 10. When installed, heat from rectifier assembly 12 is conducted through rear housing 10 to attachment 30 where it is dissipated by fins 34. Thus, heat dissipation attachment 30 maintains rectifier assembly 12 at a sufficiently low temperature to prevent rectifier burnout.
Rear housing 50 is shown in FIG. 2A according to an alternate embodiment of the present invention. Rear housing 50 has all of the features of rear housing 10 with the addition of integral external heat dissipation fins 52 disposed on rear wall 14. Heat dissipation fins 52 extend from the exterior of rear housing 40 opposite the interior attachment location of rectifier assembly 12. To maximize the surface area of the exterior of rear housing 50 in the region of rectifier 12, heat dissipation fins 52 are cast as a inherent part of rear housing 50. Rear housing 50 is formed from a heat conductive material such as aluminum. Heat dissipation fins 52 protruding from rear housing 50 have the same characteristics as fins 34 included on heat dissipation attachment 30. Heat dissipation fins 52 protrude from the same solid section 26 situated between ventilation openings 22 and outer corner 24 over which attachment 30 fits on housing 10. Similarly, protruding fins 52 have a closely spaced radial arrangement which extends through at least one quadrant of rear wall 14. Heat dissipation fins 52, thus, provide rear housing 50 with the necessary surface area proximate the rectifier to prevent rectifier diode burnout.
It is to be understood that the present invention is not limited to the sole embodiment described above, but encompasses any and all embodiments within the scope of the following claims.
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A device having a plurality of heat dissipation fins providing improved cooling to an alternator rectifier. The device may be removably attached to the alternator rear housing proximate the location of the rectifier. The device may also be incorporated as an integral part of the alternator rear housing. The device provides improved cooling to the alternator by increasing the surface area of the alternator rear housing at the area of the housing heated by the rectifier.
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This is a divisional of application Ser. No. 08/579,604 filed Dec. 28, 1995.
BACKGROUND OF THE INVENTION
1. Field of the Invention:
The present invention relates in general to turbomachineries such as centrifugal and mixed flow pumps, gas blowers and compressors, and relates in particular to turbomachinery having a variable angle flow guiding device.
2. Description of the Related Art:
Turbomachines, generally referred to as pumps hereinbelow, are sometimes provided with diffusers for converting the dynamic energy of flowing fluid discharged from an impeller efficiently into a static pressure. The diffuser can be formed with or without vanes, but those with vanes are mostly designed simply to utilize the flow passages between the adjacent vanes as expanding flow passages.
A report entitled "Low-Solidity Cascade Diffuser" (Transaction of The Japan Society of Mechanical Engineers, Vol 45, No. 396, S54-8) described an improvement in pump performance when the pitch of the vanes is increased by making the vane chard length less than a value obtained by dividing the circumferential length by the number of vanes. However, the vanes in this report are fixed vanes. Experiments in which vane angles are varied have been reported in "Experimental Results on a Rotatable Low Solidity Vaned Diffuser", ASME, paper 92-GT-19.
Furthermore, when the conventional centrifugal or mixed flow pump is operated at a flow rate much less than a design flow rate, flow separation occurs at the impeller, diffuser and other locations in the operating system, causing a drop in the pressure rise to a value below the maximum pressure of the pump, thereby leading to instability in the pump system (such a phenomenon as termed "surge") eventually disabling a stable operation of the pumping system.
The instability phenomenon is examined in more detail in the following.
The velocity vectors of the flow discharged from the impeller can be divided into radial components and peripheral velocity components, as illustrated in FIG. 1. Assuming that there is no loss in the diffuser and that the fluid is incompressible, then the quantity r 2 Vθ 2 , which is a product of the radius at the diffuser entrance r 2 and the peripheral velocity components Vθ 2 , is maintained to the diffuser exit according to the law of conservation of angular momentum, therefore, the peripheral velocity components Vθ 3 is given by:
Vθ.sub.3 =Vθ.sub.2 ·(r.sub.2 /r.sub.3).
where r 3 is the radius at the diffuser exit. It can be seen that the velocity is reduced by the ratio of the inlet and exit radii of a diffuser.
On the other hand, the area A 2 of the diffuser inlet is given by:
A.sub.2 =2πb.sub.2 r.sub.2
where b is the width of the diffuser.
Similarly, the area A 3 of the diffuser exit is given by:
A.sub.3 =2πb.sub.3 r.sub.3
If the diffuser is a parallel-wall vaneless type diffuser, then the ratio of the areas A 2 /A 3 is the same as the ratio of the radii r 2 /r 3 . Assuming that there is no loss within the diffuser and that the fluid is incompressible, the radial velocity V r3 at the diffuser exit is given by the law of conservation of mass flow as follows:
V.sub.r3 =V.sub.r2 ·(r.sub.2 /r.sub.3)
It follows that the radial velocity component is also reduced by the ratio of the inlet/exit radii of the diffuser, and the inlet flow angle α 2 becomes equal to the exit flow angle α 3 , and the flow pattern becomes a logarithmic spiral flow.
Assuming that the slip effect of the flow inside the impeller is approximately constant regardless of the flow rate, when the flow rate is progressively lowered, although the velocity component in the peripheral direction hardly changes, the radial velocity component decreases nearly proportionally to the flow rate, and the flow angle decreases.
When the flow rate is reduced even further, the flow which maintained the radial velocity component at the diffuser inlet also decreases due to the diffuser area expansion, and the radial velocity component at the diffuser exit becomes small in accordance with the law of conservation of mass flow.
It should be noted that a boundary layer exists at the diffuser wall surface, in which both the flow velocity and the energy values are less than those in the main flow, therefore, even if the radial velocity component is positive at the main flow, flow separation can occur within the boundary layer, and a negative velocity component is generated, and eventually develops into a large-scale reverse flow.
It is becoming clear through various investigations that the reverse flow region becomes a propagating stall accompanied by cyclic fluctuation in flow velocity and acts as a trigger to generate a large scale surge phenomenon in the entire operating system.
In the conventional pumps having a fixed diffuser, it is not possible to prevent flow separation within the boundary layer or the reverse flow caused by low flow rate through the pump. To improve on such conditions, there are several known techniques based on variable diffuser width disclosed in, for example, U.S. Pat. No. 4,378,194; U.S. Pat. No. 3,426,964; Japanese Laid-open Patent Publication No. S58-594; and Japanese Laid-open Patent Publication No. S58-12240. In other techniques, diffuser vane angles can be varied as disclosed in, for example, Japanese Laid-open Patent Publication No. S53-113308; Japanese Laid-open Patent Publication No. S54-119111; Japanese Laid-open Patent Publication No. S54-133611; Japanese Laid-open Patent Publication No. S55-123399; Japanese Laid-open Patent Publication No. S55-125400; Japanese Laid-open Patent Publication No. S57-56699; and Japanese Laid-open Patent Publication No. H3-37397.
Although the method based on decreasing the diffuser width attempts to address the above mentioned problem, the frictional loss at the diffuser wall increases, causing the efficiency of the diffuser to be greatly diminished. Therefore, this type of approach presents a problem that it is applicable only to a narrow range of flow rates.
Another approach based on variable angle diffuser vanes presents a problem that because the diffuser vanes are long, the diffuser vanes touch each other at some finite angle, and therefore, it is not possible to control the flow rate down to the shut-off flow rate.
The other approach disclosed in U.S. Pat. No. 3,957,392 is based on divided diffuser vanes where only an upstream portion thereof is movable, however, it is not possible to control the flow rate down to the shut-off flow rate.
Another problem presented by the variable angle diffuser vanes is that because the purpose is to optimize the performance near some design flow rate, it is not possible to control the pumping operation at or below a flow rate to cause surge. Furthermore, none of these references discloses a clear method of determining the diffuser vane angle, and therefore, they have not contributed to solving the problems of surge in a practical and useful way.
For example, a method of determining the diffuser vane angle has been discussed in a Japanese Laid-open Patent Publication No. H4-81598, but this reference also discloses only a conceptual guide to determining the vane angle near a design flow rate, and there is no clear disclosure related to a concrete method of determining a suitable vane angle for flow rates to the shut-off flow rate.
There are other methods known to prevent instability, for example, based on providing a separate bypass pipe (blow-off for blowers and compressors) so that when a low flow rate to the pump threatens instability in the operation of the pump, a bypass pipe can be opened to maintain the flow to the pump for maintaining the stable operation and reduce the flow to the equipment.
However, according to this method, it is necessary beforehand to estimate the flow rate to cause an instability in the operation of the pump, and to take a step to open a valve for the bypass pipe when this flow rate is reached. Therefore, according to this method, the entire fluid system cannot be controlled accurately unless the flow rate to cause the instability is accurately known. Also, it is necessary to know the operating characteristics of the turbomachinery correctly at various rotational speeds of the pump in order to properly control the entire fluid system. Therefore, if the operation involves continuous changes in rotational speed of the pump, such a control technique is unable to keep up with the changing conditions of the pump operation.
Furthermore, even if the instability point is avoided by activating the valve on the bypass pipe, the operating conditions of the pump itself do not change, and the pump operates ineffectively, and it presents a wasteful energy consumption. Further, this type of approach requires installation of bypass pipes and valves, and the cost of the system becomes high.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide turbomachinery having adjustable angle diffuser vanes to enable operation over a wide range of flow rates while avoiding generation of instability, particularly when the turbomachinery is operated at a very low flow rate, which would have caused instability in the past, to lead to an inoperative pumping system.
The object has been achieved in a basic form of the turbomachinery comprising: flow detection means for determining an inlet flow rate into the turbomachinery; and control means for controlling an angle of the diffuser vanes on a basis of the inlet flow rate and the vane angle in accordance with an equation:
α=arc tan (Q/(K.sub.1 N-K.sub.2 Q)) (1)
where α is an angle of the diffuser vanes; Q is an inlet flow rate; N is rotational speed of an impeller; and K 1 and K 2 are constants respectively given by:
K.sub.1 =(πD.sub.2).sup.2 σb.sub.2 B
K.sub.2 =cot β.sub.2
where D 2 is the exit diameter of the impeller; σ is a slip factor; b 2 is an exit width of the impeller; B is a blockage factor; and β 2 is a blade exit angle of the impeller measured from tangential direction.
If the pump is a variable speed pump where the rotational speed N is allowed to change, it is possible to provide a rotational speed sensor to measure this quantity to control the vane angle.
Another aspect of the basic turbomachinery comprises: detection means for determining an inlet flow rate; detection means for determining a pressure ratio of an inlet pressure to an exit pressure of the turbomachinery; and control means for controlling an angle of the diffuser vanes on a basis of the inlet flow rate, and the pressure ratio determined by the detection means in accordance with an equation:
α=arc tan (1/P.sub.r).sup.1/κ Q/{K.sub.1 N-(1/P.sub.r).sup.1/κ K.sub.2 Q}! (2)
where α is an angle of the diffuser vanes; Q is a flow rate; P r is a pressure ratio at inlet and exit locations of the turbomachinery; N is the rotational speed of an impeller; κ is a ratio of the specific heat of a fluid; and K 1 and K 2 are constants respectively expressed as:
K.sub.1 =(πD.sub.2).sup.2 σb.sub.2 B and
K.sub.2 =cot β.sub.2
where σ is a slip factor; β 2 is a blade exit angle of the impeller measured from tangential direction; D 2 is the exit diameter of the impeller; b 2 is an exit width of the impeller; and B is a blockage factor.
One aspect of the turbomachinery above is that if the rotational speed is allowed to change, a rotational speed sensor is provided to measure this quantity to control the vane angle based on the rotational speed.
By such a configuration of the turbomachinery, it is also permissible to control the turbomachinery from a maximum flow rate to the shut-off flow rate.
Theoretical Description:
The conceptual framework of the invention disclosed above is derived from the following theoretical considerations. Referring to FIG. 2, the directions of exiting flow from the impeller 2 are given as a (design flow rate); b (low flow rate); and c (high flow rate). As seen clearly in this illustration, at flow rates other than the design flow rate, there is misdirecting in the flow with respect to the angle of the diffuser vane. At the high flow rate c, the inlet angle of the flow is directed to the pressure side of the diffuser vane 3a of the diffuser 3; and at the low flow rate, it is directed to the suction side of the diffuser vane 3a. This condition produces flow separation at both higher and lower flow rates than the design flow rate, thus leading to the condition shown in FIG. 3 such that the diffuser loss increases. As a result, the overall performance of the compressor system is that, as shown in FIG. 4 (shown by the correlation between the non-dimensional flow rate and non-dimensional head coefficient), below the design flow rate, not only an instability is introduced as shown by a positive slope of the head curve at low flow rates, but surge also appears in the piping, leading to a large variation in the internal volume and eventually to inoperation of the pump.
This problem can be resolved by making the vane angle of the diffuser adjust the flow angle of the exiting flow from the impeller. A method is discussed as follows:
An exit flow from the impeller is denoted by Q 2 , the impeller diameter by D 2 , the exit width of the impeller by b 2 , and the blockage factor at the impeller exit by B. The radial velocity component Cm 2 at the impeller exit is given by:
Cm.sub.2 =Q.sub.2 /(πD.sub.2 b.sub.2 B) (3)
Assuming that the fluid is incompressible, Q 2 is equal to the inlet flow rate Q, therefore,
Cm.sub.2 =Q/(πD.sub.2 b.sub.2 B) (4)
Here, when a fluid is flowing in a diffuser, the flow velocity near the wall surface is less than that in the main flow. Denoting the main flow velocity by U, the velocity in the boundary layer by u, then the deficient flow rate caused by the slower boundary velocity compared with the main velocity is given by: ##EQU1## where y is the normal distance from the wall. If a flow having the same velocity as the main flow flows in a displacement thickness δ*, then the flow rate is given by Uδ*. Because the two are equal, the displacement thickness is given by: ##EQU2## (Refer to "Fluid Dynamics 2" by Corona or "Internal Flow Dynamics" by Yokendo).
In general, the average flow velocity is calculated by considering the narrowing of the width of the flow passage due to the effect of the displacement thickness. However, in turbomachines, the fluid flow exiting from an impeller is not uniform in the width direction of the passage (refer, for example, to the Transaction of Japan Society of Mechanical Engineers, v. 44, No. 384, FIG. 20). In the region of flow velocity less than the main flow velocity, displacement thickness becomes even thicker than the boundary layer. It follows that it is necessary to correct geometrical width of a flow passage for the effects of the boundary layer and a distortion in the velocity distribution, otherwise the calculated velocity in the flow passage tends to be underestimated and the flow angles thus calculated are also subject to large errors. In the present invention, therefore, correction of the width of the flow passage is made by considering a parameter termed a blockage factor.
It has already been disclosed in references such as those cited above that the effect of the blockage factor is not uniform with flow rate. Therefore, unless some understanding is achieved regarding how the blockage factor varies with flow rate, it is not possible to determine the flow angle at the impeller exit. For this reason, in the present invention, the blockage factor was reversely analyzed from experimental results in which various sensors were attached to the turbomachinery or to supplementary piping to measure some physical parameters such as pressure, temperature, vibration or noise, to obtain an empirical correlation between the flow rate and the angle of the diffuser vanes so as to find the vane angle at which the system exhibits the least vibration. This data together with the equations established in the present invention were used to reversely compute the blockage factor. According to this methodology, if the equations are correct, there should be found a physically meaningful correlation between the blockage factor and the flow rate.
FIG. 5 shows the study results obtained in the present invention. For consistency with the above cited reference, (1-B) was plotted on the y-axis and a non-dimensional flow coefficient (a ratio of a flow rate to a design flow rate) on the x-axis, where B is the blockage factor. The results showed that the correlation obtained by using the correlation in the present invention was different than that disclosed in the above-noted references, and showed that the blockage factor varies almost linearly with the flow rate.
The slope of the line depends on the type of impellers, but it is considered that the overall tendency would be the same. Thus, if such a linear relation is established for each type of turbomachinery, the blockage factor can be obtained from such a graph for any particular turbomachinery, and using the computed blockage factor together with the inlet flow rate, it is possible to accurately determine the flow angle at the impeller exit.
Therefore, an aspect of the present invention is based on the methodology discussed above, so that the blockage factor is a function of the flow rate, and it may vary linearly with the flow rate.
Turning to the other flow velocity component, namely the peripheral velocity component Cu 2 , which is given by:
Cu.sub.2 =σU.sub.2 -Cm.sub.2 cot β.sub.2 ( 5)
where σ is the slip factor and β 2 is the blade exit angle of the impeller measured from a tangential direction and U 2 is the peripheral speed. It follows that the flow angle from the impeller exit, which should coincide with the angle α of the diffuser vanes for optimum performance, is given by: ##EQU3## Let a pair of constants be
K.sub.1 =(πD.sub.2).sup.2 σb.sub.2 B, K.sub.2 =cot β.sub.2( 7)
and designating the rotational speed by N, equation (6) can be rewritten as:
α=arc tan (Q/(K.sub.1 N-K.sub.2 Q)) (8)
In the meantime, if the fluid is compressible, the impeller exit flow rate Q 2 is simply given by:
Q.sub.2 =(1/P.sub.r).sup.1/κ Q (9)
where P r is a ratio of the inlet/exit pressures of the turbomachinery and κ is a specific heat ratio of the fluid. Therefore, it follows that:
Cm.sub.2 =(1/P.sub.r).sup.1/κ Q/(πD.sub.2 b.sub.2 B)(10)
Combining equations (5) and (10), the flow angle from the impeller, i.e. angle of the diffuser vanes, is given by: ##EQU4##
Therefore, it can be seen that, for an incompressible fluid, the angle of the diffuser vanes can be obtained by knowing the inlet flow rate and rotational speed; for a compressible fluid, the same can be obtained by knowing the inlet flow rate, rotational speed and a ratio of the inlet/exit pressures at the turbomachinery. These variables can be measured by sensors, and the detection device can be used to compute the flow angle to which the vane angle is adjusted, thereby preventing flow separation in the diffuser and surge in the pumping system. Since the methodology of computing of vane angles with the use of generalized operating parameters and variables associated with the turbomachinery is independent of the type or size of the system, it can be applied to any type of conventional or new turbomachines having adjustable diffuser vanes. Therefore, it is possible to input correlation of flow rate and suitable vane angles in a control unit in advance without performing individual tests to determine the operating characteristics of each machine.
Another aspect of the present invention is turbomachinery comprising: detection means for determining an inlet flow rate of the turbomachinery; and control means for controlling a size of an opening formed by adjacent diffuser vanes in accordance with the inlet flow rate and a pre-determined relation between the inlet flow rate and the size of an opening.
The conceptual framework of the invention is derived from the following theoretical considerations.
When the diffuser vanes are oriented at an angle, the adjacent vanes form an opening which acts as a flow passage. The size of this opening is denoted by A. If the absolute velocity of the fluid exiting the impeller is denoted by C, then the flow velocity passing through the opening is given by K 3 C where K 3 is the deceleration factor of the velocity in traveling a distance from the impeller to the diffuser vanes. Denoting the radial velocity component by Cm 2 and the peripheral velocity component by Cu 2 from the impeller exit, C is given by:
C=(Cm.sub.2.sup.2 +Cu.sub.2.sup.2).sup.1/2 ( 12)
The flow rate Q 2 of the fluid passing through the opening is given by:
Q.sub.2 =K.sub.3 CA (13)
The peripheral velocity component is given by equation (5) as:
Cu.sub.2 =σU.sub.2 -Cm.sub.2 cot β.sub.2 ( 14)
Therefore, Q 2 becomes: ##EQU5## In the meantime, from equation (3), Q 2 is given by:
Q.sub.2 =πD.sub.2 b.sub.2 B·Cm.sub.2 ( 16)
and the radial velocity component Cm 2 at the impeller exit is given by:
Cm.sub.2 =Q/πD.sub.2 b.sub.2 B (17)
therefore,
Q.sub.2 =K.sub.3 A (πD.sub.2 b.sub.2 BσU.sub.2).sup.2 -2(πD.sub.2 b.sub.2 B)σU.sub.2 Q.sub.2 cot β.sub.2 +(1+cot.sup.2 β.sub.2)Q.sub.2.sup.2 /(πD.sub.2 b.sub.2 B)!.sup.1/2( 18)
replacing the terms with:
K.sub.4 =πD.sub.2 b.sub.2 B (19)
K.sub.5 =(K.sub.4 σπD.sub.2).sup.2 ( 20)
K.sub.6 =2K.sub.4 σπD.sub.2 cot β.sub.2 ( 21)
K.sub.7 =1+cot.sup.2 β.sub.2 ( 22)
and assuming an incompressible fluid, and denoting the inlet flow rate by Q, rotational speed by N, then the size of the opening A is given by:
A=K.sub.4 Q/(K.sub.3 (K.sub.5 N.sup.2 -K.sub.6 NQ+K.sub.7 Q.sup.2).sup.1/2)(23)
For a compressible fluid, the exit flow rate from the impeller is given by:
Q.sub.2 =(1/P.sub.r).sup.1/κ Q (24)
where P r is a ratio of the inlet/exit pressures, and κ is the specific heat ratio.
These equations were used to obtain the experimental values of the opening size between the adjacent vanes, using the pump facility showing in FIG. 6. The experimental values of the opening size were compared with results shown in FIGS. 12 to 24 (explained in detail in embodiments) to obtain the results shown in FIG. 17 which shows an effect of the size of the opening on the flow rate.
In another aspect of the present invention, turbomachinery is operated in accordance with the operating parameters, determined in the equations presented above, to orient the vanes at a suitable vane angle to avoid an onset of instability. In turbomachinery having a variable speed impeller, when the head value is not adequate even after adjusting the angle of the vanes, then the rotational speed can be changed with avoiding an onset of instability.
In another aspect of the present invention, turbomachinery can be operated while controlling both the vane angle and the size of the opening simultaneously to avoid instability.
Turbomachinery may be operated while exercising a control over a range of maximum flow rate to the minimum flow rate.
The above series of turbomachines are based on direct detection of the inlet flow rate, but it is simpler; in some cases, even more accurate to rely on an indirect parameter to determine the angle of the diffuser vanes.
In another aspect of the present invention, turbomachinery is based on this concept, wherein a detection device is provided to detect an operating parameter (or a driver for turbomachinery) which closely reflects the changes of inlet flow rate.
Such an operating parameter can be any of, for example, an input current to the pump driver, rotational speed of the impeller, inlet pressure, flow velocity in piping, a flow temperature difference at inlet/exit locations of the impeller, noise intensity at a certain location of the turbomachinery or piping, and valve opening. When the turbomachinery is cooled by a gas cooler, the amount of heat exchange can also be a parameter.
Some of the critical structural configurations include the setting of the angle of the diffuser vanes when the flow is substantially zero. Under these conditions, it is necessary to close the vanes so that the size of the opening is also substantially zero. The minimum length of a vane is given by dividing the circumferential length at the diffuser attachment location by the number of vanes provided.
Another aspect of the invention is, therefore an arrangement where the diffuser vane length is at or slightly longer than such minimum length so that the leading edge of a vane overlaps the trailing edge of an adjacent vane. According to such a construct, even when there is no substantial flow from the impeller into the diffuser, the vane angle can be adjusted to substantially zero to avoid the generation of instability, thereby enabling the turbomachinery to provide a stable performance over a wide range of flow rates. However, a fully closed condition of the vanes should be avoided because it may lead to a temperature rise in the overall system.
In another aspect of the present invention, the pivoting points of the vanes are arranged along a circumference at a radius given by 1.08 to 1.65 times the impeller radius so as to prevent the edge of the vane from touching the impeller when the vanes are fully opened to a vane angle of 90 degrees.
This is illustrated in FIG. 12, and the requirements for the vane of total length L and the leading edge of the vane to the pivoting point is L 1 , to meet the condition set forth above is given by a line passing through a point (x 1 , y 1 ) where:
x.sub.1 =-(r.sub.v +t) sin (2π/z)
y.sub.1 =(r.sub.v +t) cos (2x/z)
and z is the number of vanes. L 1 is calculated as follows. In FIG. 12, a straight line "a" having a gradient tan (2π/z) and passing through a point (x 1 , y 1 ) at a radius (r v +t) intersects with a line "b" (y=r v -t) at a point (x, y). Therefore,
x=1/ tan (2π/z)! (r.sub.v -t)-{(r.sub.v +t)/cos (2π/z)}!
y=tan (2π/z)x+(r.sub.v +t)/cos (2π/z)
and the length for L 1 is given by:
L.sub.1 = (x-x.sub.1).sup.2 +(y-y.sub.1).sup.2 !.sup.1/2
The condition for the vane edge to not touch the periphery of the impeller at radius r 2 , when the vane angle is set to 90 degrees (again referring to FIG. 12) is given by:
r.sub.v -L.sub.1 >r.sub.2
r.sub.v >r.sub.2 +L.sub.1 =(r.sub.2 +2πr.sub.v /z) (0.2 to 0.5)
r.sub.v (1-2π(0.2 to 0.5)/z))>r.sub.2
r.sub.v >r.sub.2 /{1-(2π(0.2 to 0.5))/z}
It follows that r v is 1.08 to 1.65 when z is in a range between 8 to 18.
Another feature of the diffuser vanes is that the distance between the leading edge of a vane and the pivoting point is between 20 to 50% of the total length of the vane.
This feature is required because the rotational torque required to rotate the vane during an operation about the vane shaft must be greater than a pressure torque generated by the pressure differential between the suction side and the pressure side of the vanes 3a as shown in FIG. 2. When the pressure acting at the leading edge of the vanes is about equal to that acting at the trailing edge of the vanes, the pivoting shaft should be placed in the middle of a vane to minimize the required rotational torque. However, when the vanes are rotated about the vane shaft, the pressure at the leading edge is always slightly greater than that at the trailing edge, therefore, the pivoting shaft should be placed at 20-50%, and more preferably 30-50%, of the total length of the vane so as to minimize the torque necessary to adjust the angle of the vanes against the force exerted by the fluid exiting from the impeller exit.
Depending on operating conditions or applications, it may not be necessary to set the vane angle at nearly zero degrees. In such cases, it is permissible to shorten the length of the vanes so that when they are fully closed, there is an opening formed between the closed vanes.
Another feature of the present invention is aimed at this type of operation so that the length of the vanes is determined on a basis of the minimum flow rate expected to be handled by the turbomachinery.
By making the vane length as small as permissible under the operating condition expected, the frictional loss due to fluid resistance against the vanes can be minimized so as to prevent vibrations and minimize noises generated around the vanes. This feature is also useful for reducing the demand for excessive toughness in the diffuser vanes.
In those specific cases for minimizing the fluid resistance by basing the calculation on the minimum size of the opening (A 4 ) and on the size of the opening (A 5 ) at a design flow rate, the quantity A 4 can be approximated by the size of the opening between adjacent vanes when they are fully closed at a vane angle close to zero degrees. For a given angle of the vanes, the quantity A 5 can be computed by subtracting the equivalent area based on the thickness of a vane measured in the peripheral direction at the radial location of the attachment from the size of the opening.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is cross-sectional view of the flow directions in a vaneless diffuser.
FIG. 2 is a cross-sectional view showing the directions of flows at the impeller exit.
FIG. 3 is a graph showing the relationship between the diffuser loss and the non-dimensional flow for fixed vane and adjustable vane diffusers.
FIG. 4 is a graph showing the relationship between the non-dimensional head coefficient and the non-dimensional flow rate for fixed vane and adjustable vane diffusers.
FIG. 5 is a graph showing the relationship between the blockage factor and the non-dimensional flow rate.
FIG. 6 is a cross sectional view of an application of the turbomachinery having variable guide vanes of the present invention to a single stage centrifugal compressor.
FIG. 7 is a drawing showing an opening section formed between two adjacent plate-type diffuser vanes oriented at an angle of 0 degree.
FIG. 8 is a drawing showing an opening section formed between two adjacent plate-type diffuser vanes oriented at an angle of 10 degrees.
FIG. 9 is a drawing showing an opening section formed between two adjacent plate-type diffuser vanes oriented at an angle of 20 degrees.
FIG. 10 is a drawing showing an opening section formed between two adjacent plate-type diffuser vanes oriented at an angle of 40 degrees.
FIG. 11 is a drawing showing an opening section formed between two adjacent plate-type diffuser vanes oriented at an angle of 60 degrees.
FIG. 12 shows a geometrical arrangement necessary to avoid the rotating impeller touching the diffuser vanes when the diffuser vanes are oriented at an angle of 0 degrees.
FIG. 13 is a graph showing the difference between theoretical results according to equation (2) and experimental results using the compressor shown in FIG. 6.
FIG. 14 is a graph showing the diffuser vane angle according to equation (2) and the flow coefficient.
FIG. 15 is a flowchart showing the operational steps for the turbomachinery of the present invention having adjustable diffuser vanes.
FIG. 16 is a graph showing the relationship between the non-dimensional head coefficient and the non-dimensional flow rate.
FIG. 17 is a graph showing a relationship between a normalized area of the opening section between vanes and a normalized flow rate.
FIG. 18 is a drawing showing an opening section formed between two adjacent airfoil-type diffuser vanes oriented at an angle of 10 degrees.
FIG. 19 is a drawing showing an opening section formed between two adjacent airfoil-type diffuser vanes oriented at an angle of 20 degrees.
FIG. 20 is a drawing showing an opening section formed between two adjacent airfoil-type diffuser vanes oriented at an angle of 40 degrees.
FIG. 21 is a drawing showing an opening section formed between two adjacent airfoil-type diffuser vanes oriented at an angle of 60 degrees.
FIG. 22 is a drawing showing an opening section formed between two adjacent arched plate-type diffuser vanes oriented at an angle of 10 degrees.
FIG. 23 is a drawing showing an opening section formed between two adjacent arched plate-type diffuser vanes oriented at an angle of 20 degrees.
FIG. 24 is a drawing showing an opening section formed between two adjacent arched plate-type diffuser vanes oriented at an angle of 40 degrees.
FIG. 25 is a drawing showing an opening section formed between two adjacent arched plate-type diffuser vanes oriented at an angle of 60 degrees.
FIG. 26 is an illustration showing absolute velocity vectors at the diffuser inlet and the diffuser exit, and velocity vector components in the radial and peripheral directions for a given orientation of diffuser vanes.
FIG. 27 is a block diagram of the control system for the turbomachinery of the present invention.
FIG. 28 is a graph showing a relationship between the temperature difference at the compressor inlet and exit locations and the flow coefficient.
FIG. 29 is a graph showing the work coefficient and the flow coefficient.
FIG. 30 a flowchart showing the operational steps for the turbomachinery of the present invention having adjustable diffuser vanes.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the turbomachinery will be explained in the following with reference to the drawings.
FIG. 6 is a cross-sectional view of a single stage centrifugal compressor for use with the turbomachinery having adjustable diffuser vanes. The flow into the compressor through the inlet pipe 1 is given motion energy by the rotating impeller 2, is sent to the diffuser 3 to increase the fluid pressure, and is passed through the scroll 4, and discharged from the exit pipe 5. The impeller shaft is connected to an electrical motor M (not shown). The inlet pipe 1 is provided with a plurality of inlet guide vanes 6, in the peripheral direction, connected to an actuator 8 coupled to a transmission device 7. The diffuser 3 is provided with diffuser vanes 3a which are also connected to an actuator 10 through a transmission device 9. The actuators 8, 10 are controlled by a controller 11 connected to a CPU 12.
An inlet flow rate detection device S 0 is provided on the inlet side of the compressor, and a rotational speed sensor S 2 is provided on the impeller shaft. An inlet pressure sensor S 8 and a exit pressure sensor S 5 are respectively provided on the inlet pipe 1 and the discharge pipe 5. The actuator 10 is operatively connected to the controller 11 to alter the angle of the diffuser vanes 3a.
As can be seen from this example, the turbomachinery can be used with a pumping system having inlet guide vanes 6. If the motor is driven at a constant velocity, there is no need for a rotational speed sensor S 8 .
The diffuser vanes used for the compressor of this embodiment are the plate-type shown in FIGS. 7 to 11. The length of a diffuser vane is about equal to or slightly greater than a value obtained by dividing the circumference length (at the vane attachment radius location) of the impeller by the number of diffuser vanes. Therefore, when the vanes are fully closed at close to a zero degree at tangent to the circumference, the adjacent vanes touch each other at the leading edge of one vane over the trailing edge of the other vane.
Also, the radial position of the pivoting point of the diffuser vanes for adjusting the vane angle is selected to be within a range between 1.08 to 1.65 times the radius of the impeller so as to prevent the vanes from mechanically interfering with the impeller even when they are fully opened at 90 degrees.
The length between the leading edge of the diffuser vane and the pivoting point is selected to be within 20 to 50%, more preferably 30 to 50%, of overall vane length so as to minimize the rotation torque necessary for adjusting the angle of the diffuser vanes during operation against the resistance force generated by the flowing fluid from the impeller acting on the vanes.
The controller 11 outputs driving signals to the actuator 10 on the basis of the input signals from the detection devices S 0 , S 2 , S 5 and S 8 and a pre-determined correlation presented below, so as to adjust the orientation of the diffuser vanes 3a. This correlation is established by the following equation based on the analysis of the fluid dynamics presented in the Summary of the Invention. For a compressible fluid, the equation is given by:
α=arc tan (Q/(K.sub.1 N-K.sub.2 Q)) (1)
and for an incompressible fluid, the equation is given by:
α=arc tan (1/P.sub.r).sup.1/κ Q/{K.sub.1 N-(1/P.sub.r).sup.1/κ K.sub.2 Q}! (2)
where α is a diffuser vane angle, Q is an inlet flow rate, K 1 is a fixed constant given by (πD 2 ) 2 σb 2 B, N is the rotational speed of the impeller, K 2 is a fixed constant given by cot β 2 , σ is a slip factor, β 2 is a blade exit angle of the impeller measured from the tangential direction, D 2 is the exit diameter of the impeller, b 2 is an exit width of the impeller, B is a blockage factor and P r is a pressure ratio at inlet/exit of the compressor.
By adjusting the diffuser vane angle according to the equations presented above, the diffuser loss at the diffuser vanes 3a can be prevented, as shown by a broken line in FIG. 3. The result is that the overall efficiency of the compressor is improved by avoiding an onset of instability and maintaining stable impeller performance down to low flow rates, as shown by the broken line shown in FIG. 4.
When the pumping system is provided with a variable-speed impeller, and if a specified head value cannot be obtained by adjusting the diffuser vane angle according to either equation (1) or (2) and measured flow rate, then the rotational speed of the impeller can also be varied to avoid an onset of instability.
FIG. 13 shows a comparison between experimental results of vane angles and theoretical results as a function of the flow coefficient. The diffuser vane angles to prevent surge at different flow rates were determined experimentally and were compared with the calculated diffuser vane angles by using suitable parameter values in equation (2). The results validate the correlation equations for predicting the performance of the compressor.
In FIG. 13, circles indicate the results obtained at Mach No. of 0.87 (a ratio of a peripheral impeller velocity to the velocity of sound at the inlet to the compressor) and the inlet guide vane angle of 0 degree (fully open); triangles are those at Mach No. of 0.87 and the inlet guide vane angle of 60 degrees; and squares are those at Mach No. of 1.21 and the inlet guide vane angle of 0 degree (fully open). These results demonstrate that regardless of the peripheral velocity of the impeller, i.e., rotational speed of the impeller, whether or not swirling flow is present at the inlet to the impeller by the inlet guide vanes, the equations (1) and (2) are valid for determining an optimum angle of the diffuser vanes for each flow rate.
FIG. 14 illustrates a relationship of the theoretical angles for the diffuser vanes by plotting the equation (2) against the flow coefficients, and shows that the correlation can be approximated with a second order curve.
FIG. 15 shows a flowchart of the steps for operating step for the turbomachinery. In the following description, "it" refers to CPU 12. As shown in FIG. 15, when the rotational speed is to be controlled, a predetermined speed is entered in step 1. When the speed is not to be controlled, it proceeds to step 2. In step 2, the inlet volume and, if necessary, the ratio of inlet and exit pressures are determined from measurements, and it proceeds to step 3. In step 3, using either equation (1) or (2), the diffuser vane angle is determined, and in step 4, the diffuser vane angle is adjusted.
If it is necessary to control the rotational speed, then it proceeds to step 5 to check whether a specified head value is generated, if it is not, then it returns to step 1.
FIG. 16 shows a comparison of the overall performance of the conventional turbomachinery with fixed-vane-type diffuser and the turbomachinery of the present invention with variable diffuser vane. It can be seen that the present turbomachinery achieves a stable operation down to as low as the shut-off flow rate in comparison to the conventional turbomachinery.
FIGS. 18 to 21 illustrate the vane configurations, including the size of the opening section, which is indicated by a circle, formed by orienting airfoil-type diffuser vanes at various angles to the tangential direction. FIGS. 22 to 25 relate to the corresponding cases for arched plate-type vanes. The results show that the size of the opening depends only on the thickness of the vanes, and all of the different types of vanes show approximately the same behavior in operation, leading to a conclusion that the size of the opening does not depend on the shape of the vanes.
FIG. 17 shows a control methodology in an another embodiment of turbomachinery similar to the one shown in FIG. 6, therefore the explanation for the turbomachinery itself will be omitted. In this embodiment, the vane angles are controlled by regulating the inlet flow rate to adjust the size of the opening formed between the vanes. The method of obtaining the correlation shown in FIG. 17 is the same as that presented earlier.
In FIG. 17, the normalized inlet area, which a ratio of inlet area 2πr v b 2 at the inlet radius r v to the size of the opening between the vanes shown in FIGS. 7 to 11 and FIGS. 18 to 25, are plotted against the normalized flow rate which is a ratio of flow rate Q to the design flow rate Q d . The results are almost linear, and the area ratios depend only on the vane thickness, and it was found that the correlation was the same for different shapes of vanes. It is therefore concluded that the area ratio is independent of the vane shape. Using the correlation shown in FIG. 17 between the normalized inlet area and the normalized flow rate, it is possible to determine the size of the opening of the diffuser vanes from the flow rate Q.
FIG. 26 illustrates the distribution of various velocity vectors in a diffuser with vanes (solid lines) at a given diffuser vane angle, and in a vaneless diffuser (broken lines). The velocity vectors include vectors of the absolute velocity of the flowing from the diffuser inlet (impeller exit) to the diffuser exit, and the vectors of the radial and peripheral velocity components.
At the inlet of the diffuser, the radial velocity vectors are relatively small because of a small flow rate in this direction, and in the case of the vaneless diffuser, the magnitude of the radial velocity component is reduced by the ratio of the diffuser radii up to the diffuser exit. These vectors are shown by broken lines in FIG. 17. It should be noted that FIG. 17 is based on average velocities, and reverse flows are not shown, however, in actual cases, because of the presence of the boundary layer, the flows near the wall surfaces are subject to flow separation and reverse flows can be generated.
When the exit flow from the impeller reaches the opening section formed between the diffuser vanes, there is a narrowing of the flow passage and the flow is accelerated in accordance with the normalized inlet shown in FIG. 17, and the flow angle becomes greater. The velocity vectors for these velocity components are shown by solid lines which are almost normal to the flow path, and their magnitude is determined by the law of conservation of mass flow.
As demonstrated clearly in FIG. 17, the velocity vectors for the radial velocity components are accelerated several times the velocity vectors at the diffuser inlet section, because of decreasing size of the flow passage (opening). The result is that it has become possible to eliminate the problem of unstable flow in the diffuser at a low flow rate.
Furthermore, because both diffuser vane angle and the size of the opening can be changed simultaneously, it is possible to even more effectively suppress the reverse flow within the diffuser at a low flow rate and to operate the pumping system free from surge. By adopting such a control methodology, the compressor operates quite efficiently even at a flow rate less than the design flow rate so that the radial velocity component does not become negative, no excessive loss is experienced and instability is avoided.
FIG. 27 shows another embodiment of the application of the turbomachinery having adjustable diffuser vanes. The compressor is provided with various sensors on its main body or on associated parts, such as current meter S 1 for the detection of input current to the electrical motor, a torque sensor S 2 and a rotational speed sensor S 3 for the impeller shaft; an inlet pressure sensor S 4 disposed on inlet pipe 1 for detection of inlet pressures; and S 5 to S 7 disposed on discharge pipe 1 for measuring, respectively, the discharge pressures, fluid velocities and flow temperatures; inlet temperature sensor S 8 for measuring inlet temperatures; cooler temperature sensors S 9 and S 10 for determining the temperature difference between the inlet and exit ports in the gas cooler 13; noise sensor S 11 ; and valve opening sensor S 12 . These sensors S 1 to S 12 are operatively connected to a sensor interface 14 through which the output sensor signals are input into CPU 12.
In this embodiment of the turbomachinery, the methodology for controlling the diffuser vane angle is based on determining some operating parameter which bears a functional relationship to the inlet flow rate, and establishing a correlation between that operating parameter and the diffuser vane angles directly or indirectly. There are various kinds of operating parameters which can be used, and each of them will be discussed in some detail in the following.
(1) Input Current to Electrical Drive
If the compressor is driven by an electrical driver, an operating parameter related to the inlet flow rate can be an input current to the drive, which provides a reasonable measure of the inlet flow rate. The drive power L is given by:
L=η.sub.m ·η.sub.p ·V·A=ρ·g·H·Q/η
where η m is a driver efficiency; η p is a drive power factor; V is an input voltage to the driver; A is an input current to the driver; ρ is a fluid density; H is a head value; Q is an inlet flow rate; and η is the efficiency of the device being driven. Therefore, it can be seen that the driver current is a parameter of the inlet flow rate. However, it should be noted that there is a limit to the utility of this relation because the efficiency of the driven device decreases along with the decreasing flow rate, and the drive input power is a variable dependent on the fluid density and head values.
(2) Rotational Speed of the Electrical Drive
The drive power L is given by:
L=T·ω
where T is a torque value; and ω is an angular velocity. Thus, by measuring the speed of the drive and the resulting torque, it is possible to estimate the inlet flow rate to some extent. If the rotational speed of the drive is constant, then only the torque needs to be determined.
(3) Inlet Pressure
The flow rate Q flowing through the pipe is given by:
Q=A·v=A·(ρ·(Pt-Ps)/2).sup.1/2
where A is the cross sectional area of the pipe; v is an average flow velocity in the pipe; Pt is a total pressure; and Ps is a static pressure. If the pressure at the inlet side is atmospheric, the total pressure can be made constant, so if the static pressure can be found, the inlet flow rate can be obtained. Therefore, by measuring the static pressure at the inlet constriction section of the compressor, it is possible to obtain data reasonably related to the inlet flow rate. In this case, it is necessary to measure the static pressure of the incoming flow accurately by eliminating the reverse flow which occurs from the impeller at a small flow rate.
(4) Exit Pressure
The exit pressure of the compressor can be measured to estimate the inlet flow rate. If the fluid is incompressible, the exit flow rate is equal to the inlet flow rate, but if the fluid is compressible, then it is necessary to have some method for determining the density of the fluid.
(5) Flow Velocity in the Pipe
The flow velocity within the pipe, similar to the inlet pressure, can be measured to provide some data for the inlet flow rate. Velocity measurement can be carried out by such methods as hot-wire velocity sensor, laser velocity sensor and ultrasound velocity sensor.
(6) Inlet/Exit Temperatures
For compressors, the difference between the inlet and exit temperatures can vary depending upon the operating conditions. FIG. 28 shows that there is some correlation between the temperature difference and the flow coefficient. For compressors, the temperature difference can provide work coefficient (refer to FIG. 29), but the flow rate also shows similar behavior, and therefore, measuring such a parameter can provide data on the inlet flow rate. The results shown in FIG. 28 were obtained under two different rotational velocities N1, N2.
(7) Temperature Difference in Gas Cooling Water
When the heat generated in the compressor is cooled by a gas cooler, the quantity of heat exchanged is given by:
L=(T1-T2)·Cp·W
where T1 is the flow temperature at the inlet of the gas cooler; T2 is the flow temperature at the exit of the gas cooler; Cp is the specific heat of the gas; and W is the flow rate. The heat generated by the compressor depends on the inlet flow rate, therefore, by measuring the temperature difference of the cooling medium, it is possible to obtain some data on the inlet flow rate.
(8) Noise Effects
The noise generated in the compressor or flow velocity related Straw-Hull Number can also provide some data on the flow rate.
(9) Valve Opening
The degree of opening of inlet or exit valve of the driven device attached to the compressor is related to the flow rate, therefore, by measuring the opening of valves, it is possible to correlate data to the flow rate.
FIG. 30 shows a flowchart for the operating steps of the embodied turbomachinery having adjustable diffuser vanes. In the following description, "it" refers to CPU 12. In step 1, the rotational speed of the impeller 2 is selected so as not to exceed a specific velocity. In step 2, a suitable vane angle α for the inlet guide vanes 6 is determined from parameters such as a rotational speed N of the impeller 2, a flow rate Q required and a head value H. In step 3, the operating parameters are measured, and in step 4, the diffuser vane angle is determined from the equations presented earlier. In step 5, the inlet guide vane angles are controlled by operating the controller and actuators. In step 6, it is examined whether the head value H is appropriate, and if it is acceptable, then the operation is continued. However, if the head value H is not acceptable, then in step 7, it is examined whether head value H is too large or too small compared with a specified value. If the head value is too small, the angle of the inlet guide vanes 6 is adjusted in step 8.
Next, in step 9, it is examined whether the inlet guide vane angle is at the lower limit. If the decision is NO, it returns to step 3 to repeat the subsequent steps. If the decision is YES, in step 10, the rotational speed is examined to decide if it is at the limit, and if the decision is YES, the operation is continued. If the decision is NO, then in step 11, the rotational speed is increased by a pre-determined amount, and it returns to step 3 to repeat the subsequent steps.
If, in step 7, the head value H is larger than a specified value, then the angle of the inlet guide vanes is increased in step 12. Next, in step 13, it is examined whether the angle of the inlet guide vanes is at the limit, and if the decision is NO, it returns to step 3 to repeat the subsequent steps. If the decision is YES, the rotational speed is reduced in step 14 by a pre-determined amount, and it returns to step 3 to repeat the subsequent steps.
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A turbomachine having variable angle diffuser vanes wed with a centrifugal pump. The performance of a diffuser is greatly enhanced by the use of adjustable angle diffuser vanes which can be set to a wide range of vane angles to provide a variable size of an opening between adjacent vanes. The demonstrated pumping system has a significantly wider operating range than that in conventional pumping systems over a wide flow rate, and is particularly effective in the low flow rate range in which known diffuser vane arrangements would lead to surge in the entire system and other serious operational problems.
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BACKGROUND OF THE INVENTION
I. Field of the Invention.
The present invention relates generally to measuring apparatuses. More particularly, the invention comprises an indicator system which specifically measures the size of fasteners by digital technology. Typically, the fasteners would be common nuts and bolts.
In general, a first field of use of the disclosed invention are the unique advantages of the instant invention for manufacturers of nuts and bolts. However, many other fields, such as for use by manufacturers of various small components and the like, could find potentially beneficial uses of this invention. Further, individuals, such as mechanics and the like, are obvious users of this invention.
Thus, it can be seen that the potential fields of use for this invention are myriad and the particular preferred embodiments described herein is in no way meant to limit the use of the invention to the particular field chosen for exposition of the details of the invention.
A comprehensive listing of all the possible fields to which this invention may be applied is limited only by the imagination and is, therefore, not provided herein. Some of the more obvious applications are mentioned in the interest of providing a full and complete disclosure of the unique properties of this previously unknown general purpose article of manufacture. It is to be understood from the outset that the scope of this invention is not limited to these fields or to the specific examples of potential uses presented herein.
II. Description of the Related Art.
Presently, in order to determine the size of a nut or bolt head, one uses a trial and error method for fitting different size wrenches over the nut or bolt head until one discovers which wrench fits perfectly. Wrenches are heavy and cumbersome, and time and effort is consumed in this trial and error method because one must keep returning to the tool box to find another size wrench until the right size is finally chosen. Sometimes, nuts and bolts are located in tight spaces where a wrench cannot reach with facility, thus creating a greater waste of time and effort as the user attempts to discover the proper wrench size to use.
The hand and eye comparison method is also used to measure the size of the threads in a particular bolt. Once again, the common process is to compare (or even count) the size of the threads in an existing bolt with the size of the threads in a replacement bolt until one finds a replacement bolt with the correct dimensions. This is time consuming, clumsy and often inaccurate.
In the past, inventors created several types of measuring devices with an infinite scale to measure the distance across the flats of a head of nuts and bolts. Also, there have been paper, cardboard, plastic or metal templates made with individual measuring elements incorporated for measuring bolt head sizes, bolt diameters, etc. Such features generally include a plurality of apertures of different diameters, appropriately sized for the various diameters of bolts.
Various devices are well known in the prior art which deal with measuring apparatuses, and these include U.S. Pat. No. 1,700,857 issued to Schultz which describes a Hem Gauge having a continuously graduated scale with an elongated slot down the center thereof. A slide with an index is installed within the slot. The device is used by placing the first end of the scale at the origin of the length or distance to be measured, and sliding the index to the appropriate measurement point. The length or distance is then read off the scale point aligned with the index, as with a conventional ruler or measurement scale. In contrast, the present invention provides for the precise determination of the most common sizes of nuts and bolts, and has no provision for an infinitely adjustable or readable scale.
U.S. Pat. No. 4,138,820 issued to O'Connor describes a metric gauge including a planar body having formed therein a plurality of integral sockets of varying sizes for wrench size, nut size, bolt size and screw length measuring purposes. Each of the sockets is downwardly formed below the hexagonal configuration area in a hollow cylindrical shape of varying diameter to thereby easily measure the diameter of a bolt by inserting the bolt into one socket after another until the correct diameter is gauged. Again, it appears that the design is intended only for the sorting of mixed nuts, bolts and screws into groups of identical sizes. The planar body of this gauge makes use in practical applications difficult as well.
U.S. Pat. No. 4,138,820 issued to Nishikata et al describes a vernier caliper having a scale body formed of two parallel rods. The device functions in the manner of earlier known vernier calipers, but structural advantages are alleged with the Nishikata et al. caliper, due to the parallel rod body structure. A vernier provides for the reading of dimensions comprising an unbroken continuum of sizes, and includes a secondary vernier scale for finer readings. In contrast, the present invention only includes a limited number of finite standard and metric sizes of nut and bolt dimensions with a single readout on a liquid crystal display, thereby providing the size of the fastener and the corresponding wrench or socket size required.
U.S. Pat. No. 4,730,399 issued to Campbell describes a wheel bolt circle gauge structurally somewhat resembling a vernier caliper. An elongated scale includes a tapered or conical tip, with a slide body having a single scale-viewing window therein and a tapered or conical tip extending therefrom. The scale and corresponding opposite edges of the single window each include a different scale thereon, with one scale slide and window edge providing a series of numbers corresponding to metric dimensions and the opposite side and edge having a set of numbers for inch dimensions. The use of a single window to view all of this information results in a need for a separate table on the scale body for the interpretation of the numbers. The integrated circuit of the present invention permits the information to be obtained in a single operation with no requirement to check a secondary table or the like.
U.S. Pat. No. 4,745,685 issued to Castillo describes a movable jaw measuring apparatus, in which one edge of the jaw is aligned with one of a series of index marks provided on the body of the device when a bolt or nut is measured therein. All of the index marks and their corresponding numbers are visible simultaneously, unlike the liquid crystal display screen of the present invention, which precludes viewing of the entirety of more than the single correct number at any one time. The long index mark leads required by Castillo in order to fit all the fractional numbers on the body of the device are somewhat confusing, and it would be easy to err by visually following an incorrect line to one of the numbers on the body and thereby secure the wrong wrench for the measured nut or bolt.
U.S. Pat. No. 5,345,636 issued to Lamons describes a multi-tool adjustable wrench having a vernier scale on the adjustable wrench jaws. The limitations and disadvantages of a continuously reading and displaying vernier scale, as opposed to the discontinuous incremental readouts provided with the present invention have been discussed further above. A single correct digital readout is displayed on the liquid crystal display screen of the present invention at any one time. Moreover, the present invention is not a wrench, and is not adapted to provide mechanical force or mechanical advantage to a fastener. The present invention measures the width of a nut or bolt head to provide for the selection of an appropriately sized wrench or socket.
U.S. Pat. No. 5,664,921 issued to Leslie describes a fastener component, such as a nut, which has size indicia thereon. The size indicia is used to identify the size of a wrench suitable for adjusting the nut when threaded onto a bolt, without taking measurements. Removal of nuts and bolts found on current machinery and replacing them with Leslie's fastener components would be time consuming and costly. Even if that were not the case, if all fasteners contained size indicia thereon, some fasteners will be located in areas where the raised or recessed numeral is not visible. If this were the case, fastener components would have to be sized by trial and error which would be time consuming and inefficient.
U.S. Pat. No. 5,875,558 issued to Bakke et al describes a measuring tool having a plurality of templates, each template having a socket opening therein. The templates are of ten different sizes with the larger nut socket located in the longer template, while the templates are pivotally mounted together. The operator determines the suitable size wrench to use by alternating templates on a nut or bolt until the correct socket opening is obtained. Again, the present invention with its integrated circuit corresponding precisely to the predetermined incremental dimensions of standardized and metric sizes of nuts and bolts ensures that a single correct digital readout is displayed on the liquid crystal display screen at any one time. As such, the appropriate wrench or socket needed to adjust a nut or bolt can be determined quickly without having to size fastener components using the time consuming and inefficient trial and error approach.
U.S. Patent D-319,404 issued to Jackson, Sr. describes a design for a bolt head and nut sizing gauge. The device has the general configuration of a conventional blade type feeler gauge, in that multiple blades are provided which pivotally fold from and into a housing. Each blade includes a plurality of different slots, each of which matches a differently sized nut or bolt head of standard dimensions. As no dimensional markings are indicated, it appears that the design is intended only for the sorting of mixed nuts and bolts into groups of identical sizes, with no concern being given to the determination of the specific sizes. Thus, the device cannot function as a wrench selector, as even after determining that a given fastener will fit precisely into a corresponding given slot of the Jackson, Sr. device, one still does not know the numerical dimension of the fastener and hence cannot match it up numerically with a dimensionally numbered socket or wrench.
German Patent 311,075 issued to Felsch describes a vernier caliper having slightly spread jaws. The jaws are incrementally marked from zero to five, and provide for the measurement of objects therebetween. The device appears to provide for relatively fine measurement of dimensions, in the manner of a vernier scale, but is easier to read due to the widely spread dimensional markings along the tapered jaws. The constant taper of the jaws, and infinite variation in dimensions of objects, obviously provides for measurements which do not always precisely correspond with any of the markings on the caliper jaws. Again, the present invention, with its integrated circuit corresponding precisely to the predetermined incremental dimensions of standardized and metric sizes of nuts and bolts ensures that a single correct digital readout is displayed on the liquid crystal display screen at any one time.
British Patent 632,671 issued to Nusshold describes a vernier caliper gauge, which includes a micrometer therewith for even more accurate readings. However, the same disadvantages apply to the Nusshold instrument as to most others discussed above, in that the device is adapted for the measurement of practically infinite dimensional variations subject to judgment and moreover being quite difficult to read accurately. The present invention is adapted for the reading of the dimensions of hardware, which is available in a predetermined limited number of standard and metric sizes, and accordingly need not include the complications of verniers and micrometers. The liquid crystal display screen, with only a single reading displayed at any one time, provides quick and accurate measurements at a glance.
None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed. Accordingly, the invention a digital nut and bolt size indicator will overcome the shortcomings of the prior art devices.
BRIEF SUMMARY OF THE INVENTION
The present invention being a digital nut and bolt size indicator concerns an electronic apparatus for measuring nut and bolt sizes. The present invention measures both the shank diameter and the head size of various bolts, and digitally displays the same by utilizing algorithims programmed into an integrated circuit. An operator will place two measuring jaws of the indicator closely adjacent to the nut or bolt which is to be measured, and will then be able to read the size on the digital readout. The digital readout will be of a single discrete number so that the operator will not have to interpret between several numbers, which might be presented to the operator in the manner of a mechanical system.
From the description above, a number of advantages of the digital nut and bolt size indicator become evident. The indicator is easy to operate using only one hand, thereby precluding a situation wherein each measurement requires both hands and the indicator must be set down in order that a wrench or socket may be picked up to complete the operation. The size and shape of the indicator permits it to be inserted one-handed into an area of limited space and visibility to measure a nut or bolt head.
When desiring to make a fastener measurement the operator takes the measurement by moving the movable jaw until the jaws come into contact with the fastener. The operator can perform this operation by moving the movable jaw unit or by pushing a thumb slide until contact is made with the fastener. The latter option is especially useful when the operator is in an area of limited space or visibility.
It is not necessary that the operator read the measurement while the indicator is so engaged and in fact such visual inspection might not be possible. The indicator may be withdrawn after the measurement and the reading made at the convenience of the operator.
The cover of the indicator may include serrations around the outside edges for measuring the number of threads per inch of any number of standard fasteners.
The indicator has an automatic calibration feature that is activated as needed.
A mode switch (not shown) allows the operator to expand the measurement capabilities of this invention. If the mode switch is pressed, nut or bolt size measurements can be made. Otherwise, bolt diameter measurements are possible.
The operator has the option to illuminate a liquid crystal display at his/her discretion by activating a light on/off switch.
The indicator provides a better way for home and professional operators to quickly determine the appropriate size wrench or socket needed to adjust a nut or bolt. As such, use of the indicator can reduce the time required to provide a service since the operator would not need to make multiple trips to a toolbox for the right size socket or wrench.
The invention is simple, easy to use and is economical to manufacture. The invention provides improved elements and arrangements thereof in an apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
Other objects, advantages and capabilities of the invention will become apparent from the following description taken in conjunction with the accompanying drawings showing the preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram of the present invention;
FIG. 2 is a flow chart showing use of the present invention;
FIG. 3 a is a top plan view of the present invention;
FIG. 3 b is a top plan view similar to FIG. 3 a with the jaw cover removed;
FIG. 3 c is an end view taken in the direction of arrow 3 c in FIG. 3 b ;
FIG. 3 d is a side elevation view taken in the direction of arrow 3 d in FIG. 3 b ; and
FIG. 4 is a diagrammatic cross sectional view taken generally along line 4 — 4 in FIG. 3 b.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For a fuller understanding of the nature and desired objects of this invention, reference should be made to the following detailed description taken in connection with the accompanying drawings. Referring to the drawings wherein like reference numerals designate corresponding parts throughout the several figures, reference is made to FIGS. 1 through 4 which illustrate various components of the present invention being a digital nut and bolt size indicator 10 .
A circuit diagram of the digital nut and bolt size indicator 10 is illustrated in FIG. 1 . This circuit 11 includes a highly integrated, application specific integrated circuit 12 that performs the required processing and input/output functions of the indicator 10 . Included within integrated circuit 12 are a micro controller and a program (not shown). A potentiometer 14 is operatively coupled to a resistor 16 and provides a resistance, which varies proportionately with the fastener size. The resistor 16 provides a stable resistance against which the integrated circuit 12 will compare the variable resistance of the potentiometer 14 . The potentiometer 14 regulates the rate of discharge of a capacitor 18 giving the value for “D” rctime.
A liquid crystal display 20 is coupled to the integrated circuit 12 and provides a display of the fastener size received from the integrated circuit 12 . The circuit 11 further includes a power on/off switch 22 , the switch 22 being coupled to the integrated circuit 12 . The circuit 11 includes buttons 24 and 26 , which are coupled to the integrated circuit 12 , and is responsive to closures of these buttons 24 and 26 in accordance with an algorithm programmed with the integrated circuit 12 . When an operator presses the reset button 24 , the circuit 11 begins by sending a signal to the integrated circuit 12 to initiate a reading. The indicator 10 then waits until a stable reading is achieved and calculates the size of the fastener. The fastener size is then outputted to the liquid crystal display 20 and remains displayed until the operator reinitializes the reset button 24 .
The preferred embodiment of this invention would be implemented by repositioning the reset button 24 , so that the movable jaw 28 of the mechanism rests and returns to an initial position resulting in the reset button 24 being automatically activated at the start of a new reading. This is a minor mechanical adjustment to the present embodiment. No modifications to the algorithm of the integrated circuit 12 are required. It will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of this invention. Readouts are displayed on the illuminated liquid crystal display 20 . If no illumination is desired, the operator simply presses the light on/off button 26 . A battery 30 is coupled to the integral circuit 12 . The integrated circuit 12 has a built-in power down function that places the integrated circuit 12 in a ‘sleep’ mode to conserve battery usage. Once the operator has initiated a reading, the ‘sleep’ function is deactivated.
An algorithm programmed within the integrated circuit 12 controls an operation of the digital nut and bolt size indicator 10 . The flow chart of FIG. 2 illustrates the algorithm used in this invention. Initially, the power on/off switch 22 is depressed to initiate a power up sequence, as shown by 32 . During the power up the micro controller is initialized, counters are set to zero and the program begins. The integrated circuit 12 then activates all display segments and turns on the liquid crystal display 20 display light 34 . If the reset button 24 is depressed at 36 , the micro controller advances to a label A routine 38 in the program code.
After the program advances to the label A routine 38 , the integrated circuit 12 clears the liquid crystal display 20 as shown at 40 , and displays a text message 42 entitled “WAIT”. The integrated circuit 12 then initializes an internal queue 44 with invalid data for the purpose of error analysis. This is followed by a pause 46 to allow the user time to adequately place the device before starting a label B routine 48 .
After the program advances to the label B routine 48 , the integrated circuit 12 is initialized as indicated at 50 . The next step within the label B routine is to initialize a rctime “D” 52 within the input circuit 14 , 16 and 18 . The resistance of the potentiometer 14 is then sampled(not shown) to determine the size associated with the fastener. The integrated circuit 12 shifts the data in a queue 54 and then performs an averaging function to determine the error percentage of user movement 56 . If the percentage is within normally accepted boundaries 58 , then the integrated circuit 12 advances to a fastener size routine 60 . If the error percentage is not within acceptable limits, the integrated circuit 12 reinitializes at 50 to re-sample another reading. The program enters into a loop until the readings are acceptable.
Once the program advances to the fastener size routine 60 , a look-up table is utilized to determine the fastener size based on an index value 62 . The fastener size is displayed on the liquid crystal display 20 . Readouts remain on the liquid crystal display 20 until the reset button 24 is activated at the start of the next reading. The program now advances to a light activation routine 66 .
If the light on/off button 26 is depressed as shown at 68 , the first step within the light activation routine 66 is to check a lightstate control variable 70 and determine the current condition of a backlight on the liquid crystal display 20 . Then based on the current condition of the backlight, the integrated circuit 12 executes code to bring about the opposite condition and changes the lightstate variable 72 and 74 to reflect this condition. As the program advances, the status of the backlight is continuously monitored in the background, turning the light on and off in response to user activation.
A top plan view of the digital nut and bolt size indicator 10 is illustrated in FIGS. 3 a and 3 b . FIG. 3 c is an end view, while FIG. 3 d is a side view. FIG. 3 a illustrates the top plan view with a cover 76 and FIG. 3 b illustrates the top plan view without the cover 76 . The cover 76 includes a plurality of a series of serrations 78 . The length of each series of serrations 78 corresponds to a desired predetermined length of thread pitch. There can be indicia adjacent to each series of serrations 78 to indicate the number of threads per inch corresponding to each particular thread pitch. The digital nut and bolt size indicator 10 includes two types of jaws, a fixed jaw 80 and the movable jaw 28 . The movable jaw 28 is normally held open by a spring (not shown). The distance between the jaws 28 , 80 indicates the width of the fastener or the distance being measured. The movable jaw 28 can be moved either by pushing the jaw directly or by using a thumb slide 82 to move the jaw. The liquid crystal display 20 displays a single digital readout of the fastener size at any one time.
A cross sectional view of the digital nut and bolt size indicator 10 is illustrated in FIG. 4. A housing 84 is shown as well as a printed circuit board 86 . The printed circuit board 86 is employed to secure and interconnect the components illustrated in FIG. 1 with the exception of the potentiometer 14 . Conductors 16 and 18 are further included to electrically connect the potentiometer 14 to the printed circuit board 86 for ultimate coupling with the integrated circuit 12 . FIG. 4 further illustrates the placement of the thumb slide 82 on the potentiometer 14 . The thumb slide 82 is then mounted to the movable jaw 28 to facilitate the two modes of operation for the operator. The battery 30 is shown within the housing 84 to provide power to the digital nut and bolt size indicator 10 while maintaining portability.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, various modifications may be made of the invention without departing from the scope thereof and it is desired, therefore, that only such limitations shall be placed thereon as are imposed by the prior art and which are set forth in the appended claims.
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A digital fastener size indicator having a housing. A fixed jaw extends from an end of the housing, while a movable jaw extends from the end of the housing adjacent to and parallel with the fixed jaw. A digital electrical length measuring circuit within the housing is connected to the movable jaw. When the movable jaw and the fixed jaw encompass a fastener and the digital electrical length measuring circuit is activated a digital readout will be presented in the housing of a single discrete number to an operator to indicate the size of the fastener.
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RELATED PATENT APPLICATIONS
[0001] This U.S. patent application claims the benefit of priority from, and hereby incorporates by reference the entire disclosure of, co-pending U.S. Provisional Application for Letters Patent Serial No. 60/366,797, filed Mar. 22, 2002, and titled “Activity Period of Optimization”.
TECHNICAL FIELD
[0002] The present invention relates generally to computers and like devices, and more particularly to methods, apparatuses and systems for selectively caching content data within at least one server or other like device that is configured to provide the cached content data to at least one client or other like device.
BACKGROUND
[0003] The popularity of the Internet, and in particular, the portion of the Internet known as the World Wide Web, continues to grow. The World Wide Web is basically a collection of computers that are operatively linked together through a plurality of communication networks. Typically, users access the World Wide Web through a personal computer or like device, which is connected to the Internet via a modem of some type. For example, many users of the World Wide Web connect to the Internet using a dial-up telephone networked modem configured to establish data communications through an Internet Services Provider (ISP). Other users connect to the Internet with a faster modem, e.g., a cable modem, digital subscriber line (DSL) modem, etc.
[0004] Regardless of how a user ultimately connects to the Internet/World Wide Web, once connected, the user typically accesses information available therein by using a web browser or like application. A web browser is configured to access web pages that are provided through the Internet by other computers. For example, one or more web server computers may be connected to the Internet and configured with one or more web sites or other supporting web applications. A web site typically has one or more static web pages and/or is capable of supplying one or more dynamically generated web pages that the user may selectively download, view and possibly interact with.
[0005] To identify a particular web site/page, the user will typically select a hyper-link to the desired web site/page or may choose to manually enter a unique name for the web site/page. The most common name used for identifying a web site/page is known as the uniform resource locator (URL). By entering a URL, the user will be connected to an appropriate web server which hosts the applicable web application(s), and the requested web page will be downloaded, in this case using a hypertext transfer protocol (HTTP), to the web browser. Within the Internet itself, the selected URL is associated with a specific Internet Protocol (IP) address. This IP address takes the form of a unique numerical identifier, which has been assigned to the targeted web server. Thus, a user may also directly enter an IP address in the web browser. However, the majority of users tend to favor the use of the more easily remembered and entered URL.
[0006] When a typical web server receives a request, e.g., an HTTP request, from a web browser, it needs to handle the request. Hence, a web server process may be configured to handle the request itself, or may need to pass the request on to another process, e.g., a worker process, that is configured to handle the request.
[0007] Regardless as to how the request is handled, the result is that a response is generated. The response includes some type of content data and is provided to the requesting client program/device. One example of content data is a web page that is then processed and typically displayed by a browser. It takes time and computational resources for the web server to handle the request, and to generate or otherwise output the appropriate content data. Typically, a web server handles a plurality of web pages associated with one or more web sites.
[0008] One common practice is to buffer content data in memory after it has been generated. Consequently, when a subsequent request for the buffered content data is received the content data need not be generated again but rather served directly from memory to the client program/device. This usually reduces the response time and/or the processing load. In certain conventional web servers, the buffering techniques include buffering newly generated content data. Since there is only a finite amount of memory available for buffering content data, there is usually not enough memory to hold all of the content data that a web site and/or web server may need to output. As such, eventually some web content will need to be generated fresh/again.
[0009] It would be beneficial to have improved techniques for managing the buffered content data such that the web server's performance is further improved.
SUMMARY
[0010] Methods and apparatuses are provided for use in servers or other like devices that output content data based on requests. Activity and/or other like information is gathered/maintained for each handled request and used to determine if the corresponding content data should be cached in memory to speed up subsequent similar requests for the content data, or conversely not cached in memory. The activity and/or other like information can be considered in light of one or more activity parameters or other useful parameters that essentially define the operation of the resulting content data cache(s).
[0011] By way of example, the above stated needs and others are met by an apparatus for use in a server device. Here, the apparatus includes logic that is operatively coupled to memory and configured to gather information about at least one request for content data, and selectively store the content data in at least one content data cache in the memory based on the gathered information.
[0012] The gathered information may include activity information associated with a defined period of time. The gathered information may include content data type information and/or content data size information.
[0013] The logic may be configured to selectively store the content data in the least one content data cache based on at least one parameter. Here, for example, the parameter may define a period of time associated with the gathered information, define at least one activity level threshold value, define a content data type, and/or define at least one content data size threshold value.
[0014] In certain implementations, the logic can be configured to selectively modify at least one parameter. The logic may even dynamically modify at least one parameter.
[0015] In other implementations, the logic can be configured to selectively store the content data in the at least one content data cache based on a type of the memory being used or available.
[0016] The logic can be configured to output the content data stored in at least one content data cache.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] A more complete understanding of the various methods, apparatuses and systems of the present invention may be had by reference to the following detailed description when taken in conjunction with the accompanying drawings wherein:
[0018] [0018]FIG. 1 is a block diagram that depicts an exemplary device, in the form of a computer, which is suitable for use with certain implementations of the present invention.
[0019] [0019]FIG. 2 is a block diagram depicting a selective content data caching arrangement, in accordance with certain exemplary implementations of the present invention.
DESCRIPTION
[0020] [0020]FIG. 1 depicts a computing environment 120 that includes a general-purpose is computing device in the form of a computer 130 . The components of computer 130 may include one or more processors or processing units 132 , a system memory 134 , and a bus 136 that couples various system components including system memory 134 to processor 132 .
[0021] Bus 136 represents one or more of any of several types of bus structures, including a memory bus or memory controller, a peripheral bus, an accelerated graphics port, and a processor or local bus using any of a variety of bus architectures. By way of example, and not limitation, such architectures include Industry Standard Architecture (ISA) bus, Micro Channel Architecture (MCA) bus, Enhanced ISA (EISA) bus, Video Electronics Standards Association (VESA) local bus, and Peripheral Component Interconnects (PCI) bus also known as Mezzanine bus.
[0022] Computer 130 typically includes a variety of computer readable media. Such media may be any available media that is accessible by computer 130 , and it includes both volatile and non-volatile media, removable and non-removable media.
[0023] In FIG. 1, system memory 134 includes computer readable media in the form of volatile memory, such as random access memory (RAM) 140 , and/or non-volatile memory, such as read only memory (ROM) 138 . A basic input/output system (BIOS) 142 , containing the basic routines that help to transfer information between elements within computer 130 , such as during start-up, is stored in ROM 138 . RAM 140 typically contains data and/or program modules that are immediately accessible to and/or presently being operated on by processor 132 .
[0024] Computer 130 may further include other removable/non-removable, volatile/non-volatile computer storage media. For example, FIG. 1 illustrates a hard disk drive 144 for reading from and writing to a non-removable, non-volatile magnetic media (not shown and typically called a “hard drive”), a magnetic disk drive 146 for reading from and writing to a removable, non-volatile magnetic disk 148 (e.g., a “floppy disk”), and an optical disk drive 150 for reading from or writing to a removable, non-volatile optical disk 152 such as a CD-ROM/R/RW, DVD-ROM/R/RW/+R/RAM or other optical media. Hard disk drive 144 , magnetic disk drive 146 and optical disk drive 150 are each connected to bus 136 by one or more interfaces 154 .
[0025] The drives and associated computer-readable media provide nonvolatile storage of computer readable instructions, data structures, program modules, and other data for computer 130 . Although the exemplary environment described herein employs a hard disk, a removable magnetic disk 148 and a removable optical disk 152 , it should be appreciated by those skilled in the art that other types of computer readable media which can store data that is accessible by a computer, such as magnetic cassettes, flash memory cards, digital video disks, random access memories (RAMs), read only memories (ROM), and the like, may also be used in the exemplary operating environment.
[0026] A number of program modules may be stored on the hard disk, magnetic disk 148 , optical disk 152 , ROM 138 , or RAM 140 , including, e.g., an operating system 158 , one or more application programs 160 , other program modules 162 , and program data 164 .
[0027] The improved methods and systems described herein may be implemented within operating system 158 , one or more application programs 160 , other program modules 162 , and/or program data 164 .
[0028] A user may provide commands and information into computer 130 through input devices such as keyboard 166 and pointing device 168 (such as a “mouse”). Other input devices (not shown) may include a microphone, joystick, game pad, satellite dish, serial port, scanner, camera, etc. These and other input devices are connected to the processing unit 132 through a user input interface 170 that is coupled to bus 136 , but may be connected by other interface and bus structures, such as a parallel port, game port, or a universal serial bus (USB).
[0029] A monitor 172 or other type of display device is also connected to bus 136 via an interface, such as a video adapter 174 . In addition to monitor 172 , personal computers typically include other peripheral output devices (not shown), such as speakers and printers, which may be connected through output peripheral interface 175 .
[0030] Computer 130 may operate in a networked environment using logical connections to one or more remote computers, such as a remote computer 182 . Remote computer 182 may include many or all of the elements and features described herein relative to computer 130 .
[0031] Logical connections shown in FIG. 1 are a local area network (LAN) 177 and a general wide area network (WAN) 179 . Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets, and the Internet.
[0032] When used in a LAN networking environment, computer 130 is connected to LAN 177 via network interface or adapter 186 . When used in a WAN networking environment, the computer typically includes a modem 178 or other means for establishing communications over WAN 179 . Modem 178 , which may be internal or external, may be connected to system bus 136 via the user input interface 170 or other appropriate mechanism.
[0033] Depicted in FIG. 1, is a specific implementation of a WAN via the Internet. Here, computer 130 employs modem 178 to establish communications with at least one remote computer 182 via the Internet 180 .
[0034] In a networked environment, program modules depicted relative to computer 130 , or portions thereof, may be stored in a remote memory storage device. Thus, e.g., as depicted in FIG. 1, remote application programs 189 may reside on a memory device of remote computer 182 . It will be appreciated that the network connections shown and described are exemplary and other means of establishing a communications link between the computers may be used.
[0035] Attention is now drawn to FIG. 2, which is a block diagram illustrating an exemplary client-server arrangement 200 that includes a selective content caching capability in accordance with certain implementations of the present invention. While the following description includes an exemplary web server such as might be found on the Internet, an intranet, etc., it should be understood that other non-web based client-server arrangements and other like configurations can also benefit from the improved methods and apparatuses provided herein.
[0036] With this in mind, client server arrangement 200 includes client logic 202 which is configured to provide a content data request 204 to server logic 206 . Here, for example, content data request 204 may include a web page request that is sent over a network from a client computer to one or more server devices.
[0037] Let this be the first time that content data request 204 has been received by server logic 206 . This means that the requested content data is not readily available in a content data cache, at least not yet. As such, server logic 206 needs to generate a corresponding content data response. To accomplish this task, sever logic 206 includes content data generating logic 208 which is configured to generate content data response 212 , which is provided by server logic 206 to client logic 202 .
[0038] Content data generating logic 208 , in this example, accesses one or more files 210 . Here, file 210 may be stored on a hard drive or other like storage mechanism(s). File 210 may include static data, script data, dynamic data, etc. Content data generating logic 208 processes this data, as/if needed, to produce content data that is included in content data response 212 .
[0039] Server logic 206 also includes caching logic 214 . Within caching logic 214 there is an activity monitor 216 . As illustrated by the solid-lined arrows, server logic 206 is configured to access memory 218 . For example, activity monitor 216 is configured to access activity information 220 and at least one activity parameter 222 stored within memory 218 , and caching logic 214 is configured to access content data 224 within at least one content data cache 226 in memory 218 .
[0040] Returning to the exemplary request handing process started earlier, once content data generating logic 208 has generated content data for content data response 212 , activity monitor 216 modifies activity information 220 to record that the particular content data was requested. In this manner, activity information 220 begins to collect information regarding the demand for the particular content data that was requested.
[0041] In accordance with certain implementations, for example, caching logic 214 can be configured to determine whether a particular content data 224 is to be stored in content data cache 226 based on one or more activity parameters 222 including the level of continuing and/or sustained demand for the content data over a period of time.
[0042] At this point in this exemplary request handing process, it is assumed that the content data generated for this initial request does not qualify for storage in content data cache 226 .
[0043] Assume now that a subsequent content data request 204 is received by server logic 206 . Server logic 206 , using caching logic 214 , determines if the content data for this subsequent request is available within content data cache 226 . Here, the requested content data is not yet in content data cache 226 . As such, server logic 206 needs to generate the content data once again and server logic 206 needs to output content data response 212 as it did before. Activity monitor 216 will once again modify activity information 220 to record this subsequent request for the same content data.
[0044] Caching logic 214 along with activity monitor 216 will determine, based on one or more activity parameters 222 and activity information 220 , if the content data generated for the subsequent request should be stored in content data cache 226 . There are a variety of decisional techniques that may be employed to determine when to add (or remove) content data 224 to (from) content data cache 226 . Several decisional techniques are described in greater detail below. For now, in this example, assume that caching logic 214 and activity monitor 216 are configured to store the content data 224 in content data cache 226 because activity information 220 shows that there have been enough requests for this particular content data within a specified period of time. Here, for example, activity parameters 222 may include a threshold demand storage value and/or a threshold demand removal value that is used to determine is content data 224 is stored or removed, respectively, from content data cache 226 . Activity parameters 222 may include information establishing the period of time over which demand is measured. These and other activity parameters may be programmably set and in certain implementations dynamically adjusted to further optimize or otherwise change the operation of server logic 206 and/or memory 218 .
[0045] In the above exemplary process, assume that receiving two requests within a period of ten seconds qualifies content data 224 to be stored in content data cache 226 . Then assume that a third content data request 204 is received. Now caching logic 214 will be able to quickly access content data 224 from content data cache 226 and therefore server logic 206 can output a corresponding content data response 212 without requiring content data generating logic 208 to again generate such content data.
[0046] Thus, as described above, activity monitor 216 and caching logic 214 can be configured to store content data 224 having “high enough” demand in content data cache 226 , and also to remove/erase content data 224 from content data cache 226 when demand is not high enough.
[0047] In this example, activity information 220 is modified for each request that is handled regardless as to whether the content data was generated or read from content data cache 226 . In the exemplary demand level decision process described above, activity information for any given request for content data need only be stored in activity information 220 for the defined period of time. Thus, for example, in certain implementations, a unique identifier and timestamp can be recorded in activity information 220 for a given request for content data. After the defined period of time has passed within enough subsequent similar requests, then the unique identifier and associated timestamp become stale and can be removed/erased from activity information. What this illustrates is that with the proper settings of activity parameters 222 , the amount of memory required for activity information 220 can be significantly controlled and also only a small amount of information need be recorded in activity information 220 .
[0048] One of the benefits to this arrangement is that content data cache 226 may be configured to only include content data 224 that is in high enough demand. This tends to make the server run more efficiently as it is not buffering content data that is seldom requested.
[0049] As mentioned, caching logic 214 in certain implementations is configured to dynamically change one or more activity parameters 222 that are used to determine what content data is added to, or removed from, content data cache 226 and when. This dynamic relationship is illustrated in FIG. 2 by the dashed-line arrow between caching logic 214 and activity parameters 222 . Thus, for example, caching logic 214 may increase the demand measuring period at times when fewer requests are being received, and/or decrease the demand measuring period at times when more requests are being received to optimize use of the processing and/or memory resources in the server. Similarly, the threshold demand levels can be dynamically adjusted to promote certain efficiencies.
[0050] The above examples are directed towards demand-based caching decisions. Arrangement 200 , may also take into account still other decisional information. Thus, for example, in certain implementations caching logic 214 and/or activity monitor 216 can be configured to base caching decisions on other activity parameters 222 such as the type of content data. Here, some types of content data may be considered better caching candidates than other types of content data. For example, content data that requires additional processing time may be a better caching candidate than content data that is easier to generate. In another example, the size of the content data can be considered. Thus, for example, in certain implementations it may prove beneficial to cache larger sized content data, while in other implementations smaller sized content data may be better caching candidates.
[0051] In still other implementations, caching logic 214 and/or activity monitor 216 also consider the type(s) of memory 218 that content data cache 226 is stored in. Thus, for example, content data cache 226 may extend across different memory structures and certain content data 224 may be better off if stored in particular memory locations.
[0052] In one example, content data cache(s) may include both user-mode and kernel-mode memory, and content data 224 that is in very high demand may be stored in kernel-mode memory for even quicker handling. Similarly, certain types or sizes of content data may be better stored in either kernel-mode or user-mode memory.
[0053] In other implementations, the memory includes different levels (e.g., L1, L2, etc,) memory based on the hardware structure of the server device. Here, again, certain high-demand, low-demand, types, and/or sizes of content data may be better stored in content data cache within certain memory levels.
[0054] Although some preferred implementations of the various methods and apparatuses of the present invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the exemplary embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the spirit of the invention.
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Methods and apparatuses are provided for use in servers or other like devices that output content data based on requests. Activity and/or other like information, e.g., in the form of Metadata, is gathered/maintained for each handled request and used to determine if the corresponding content data should be cached in memory to speed up subsequent similar requests for the content data, or conversely removed from the memory cache. The activity and/or other like information can be considered in light of one or more activity or other useful parameters that define the operation of the resulting content data cache(s).
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BACKGROUND
[0001] Some computer systems operate in highly controlled environments. For example, certain advanced server and storage systems, for which downtime tolerance is very low, operate in a specifically designed raised floor computer room having temperature and humidity control as well as various safety systems such as fire alarms and fire suppression systems.
[0002] In some cases, users of such computer systems operate at locations that are remote from the computer systems. In such a scenario, the user relies on the safety and monitoring systems to lower the risk of particular catastrophic causes of computer system downtime.
[0003] A conventional approach to monitoring the environment in the vicinity of an unattended computer system involves one or more sensing devices individually wired, for example, to an audible fire alarm, or to a response center specific to the sensor, such as a local fire department. The conventional approach uses separate sensors individually connected to selected response locations using communication methods separate from the computer system.
SUMMARY
[0004] The conventional approach to monitoring the environment in the vicinity of an unattended computer system is expensive and inflexible, due to the conventional use of separate communication methods for the sensor devices. The use of communication methods already existing in the computer system itself would reduce the time, equipment cost and labor cost of implementing environmental monitoring systems. The conventional approach is also more complex since any change in the location to be alerted in case of environmental emergency can require costly individual changes to the communication connections.
[0005] Further, in the conventional approach to monitoring, a user at a remote location may only learn about a catastrophe indirectly. For example, a fire alarm may only provide an audible alert and an electronic alert to a local fire station. The remote user would not know about the fire until the computer ceased to function due to the fire, or power being shut off, or water damage to the computer system. In such a situation the user would not have sufficient notice to reduce the operational damage by initiating mirrored computer operations at a back up facility, or storing important data at an emergency data back up location separate from the primary site.
[0006] In contrast to the conventional approach to monitoring the environment in the vicinity of an unattended computer system which is expensive and indirect, an improved technique communicates environmental conditions surrounding a computer system to a user remote from the computer system via a sensor device, for example a smoke detector, connected to a communication port of the computer system. Along these lines, an installer of the computer system may connect a sensor to a port of the computer system. Upon installation, the computer system receives an acknowledgement of the connection with the sensor so that proper sensing is assured. Once the sensor detects some physical condition (i.e. temperature increase, presence of airborne particulates), the sensor sends a message to the computer system. The computer system then relays the message to safety monitors, proper authorities, and/or the user.
[0007] Advantageously, the use of the existing communication methods increases the capability of environmental monitoring by enabling local or remote storage and analysis of the environmental sensor output signals. For example, storage of ongoing sensor data in the computer system may be analyzed so that slowly developing environmental issues, for example a steadily rising temperature, may generate an appropriate response before a critical level is reached.
[0008] One embodiment of the improved technique is directed to a monitoring method communicating environmental conditions in the vicinity of a computer system to a remote user by receiving a signal from an environmental condition sensor located in the vicinity of the computer system at an ingress communication port of the computer system. The ingress port may be any sort of input/output (i.e., I/O) port. The method then stores a value representative of the received signal, indicating a physical condition, for example a temperature or a humidity reading. Then the method transmits a notification signal to the remote user based upon the stored value, using an egress communication port. The egress port may be the same port as the ingress port, or may be a different physical port, or may be a different type of port, for example, a wireless port. The notification signal will indicate a physical condition measured by the sensor, for example a temperature reading, and may indicate a problem that needs emergency attention, for example a high enough temperature to indicate that a fire exists.
[0009] The method may also involve storing the values locally in the computer system and comparing them against stored limit ranges and previously stored values. These comparisons enable evaluating the environmental conditions based on a time dependent function of the stored values or evaluating combinations of different environment factors to form an overall environmental condition, for example, combining temperature with smoke values to better determine when a fire alarm should be issued, or when to copy sensitive records to a safe off site storage facility.
[0010] Another embodiment of the improved technique with improved environmental monitoring capability is directed towards a computer program product with a computer-readable storage medium with code to receive a condition signal from a sensor at an ingress communication port of the computer system, to store a value represented by the condition signal, and to transmit from an egress communication port, a notification signal to the remote user. The ingress and egress ports may be the same physical port and may be any communications port suited to electronic signal transferring, including wired or wireless input ports, output ports or I/O ports. The code to receive condition signals may include capability to receive signals from, for example, smoke, fire, motion, intrusion, power integrity, vibration, humidity, water and temperature sensors.
[0011] Yet another embodiment of the improved technique is directed towards a system constructed and arranged to provide environmental conditions in the vicinity of a computer system to a remote user, may include a network interface, an ingress communication port, an egress communication port which may be the same port as the ingress port, a memory element, and a controller to receive condition signals from environmental sensors. The system can store a value representing the condition signal in the memory, and then transmit a notification signal to the remote user.
[0012] One embodiment of the system can also use the egress communication port to transmit a service signal to a service center in response to an action signal from the remote user. For example, the remote user may receive a fire and a smoke sensor signal and determine that it may be useful to move data stored at the computer system to a secure off site backup storage center. The user may also determine that activating local water shut off valves to prevent flooding, or turning on a local fire suppression system, or activating electronically controlled safety fire doors, may be needed, and may efficiently use the existing computer communications systems to take the needed actions by sending an action signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The foregoing and other objects, features and advantages will be apparent from the following description of particular embodiments of the present disclosure, 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 various embodiments of the present disclosure.
[0014] FIG. 1 is a block diagram illustrating an example computer system using the improved technique.
[0015] FIG. 2 is a block diagram illustrating an example computer system with additional features over the computer system of FIG. 1 .
[0016] FIG. 3 is a flowchart illustrating the improved method.
[0017] FIG. 4 is a flowchart illustrating the improved with additional features over the method of FIG. 3 .
DETAILED DESCRIPTION
[0018] An improved system for communicating environment conditions in the vicinity of a computer system is less expensive, installs more quickly, and has great efficiency than current systems by using the already existing communication system in the computer system as at least a part of the sensor network used to measure the environment and communicate environmental alerts.
[0019] FIG. 1 is a block diagram illustrating an example system 100 using the improved technique with device 110 representing any computer system such as a laptop, a server, a computer disk memory farm, a storage system, a graphics image processor, a super computer, a massively parallel array of microcomputers or any electronic device having computing and communicating ability. Computer system 110 includes a controller 112 having logic circuits and control circuitry to operate the computer system and communicate data and other signals to users or other devices and computer systems. These communications are implemented by a network interface circuit 114 , which is communicatively attached to at least one egress communications port 116 and at least one ingress communications port 118 . The ingress and egress ports are shown as separate and distinct objects, but the invention is not so limited, and the ingress and egress ports may be the same single port, and many be either wired or wireless, or be any sort of communications device, such as an input port, an output port, or an input/output (I/O) port as the particular needs of the computer system 110 require. The communications protocol of the ports 116 and 118 may be of any sort including parallel, serial, USB, 801.11, Ethernet, internet, 4G LTE, 3G or Blue Tooth.
[0020] The computer system 110 receives environmental condition signals from a sensor 120 located at a selected position in the vicinity of the computer system 110 . The position may depend upon the type of sensor, for example a smoke sensor may be located on the ceiling at the top of a staircase or other location where smoke may rise and concentrate. The sensor 120 will send an environmental condition signal on communication path 122 , for example indicating the presence of significant amounts of smoke. Alternatively, sensor 120 may send periodic update signals even when the measured levels are not significant.
[0021] The condition signal on communication path 122 , shown as a wired connection in the illustrative figure, travels to the controller 112 via ingress port 118 and interface 114 , where the condition signal may be interpreted as a value, and stored in memory location 124 . If the value of the condition signal is outside of a limit range, which may also be stored in the memory 124 , then the controller 112 will send a notification signal to the egress port 116 via network interface 114 , and via the communication path 126 to a network 128 , shown in the illustrative figure as the cloud. The network 128 may be any sort of communication network, for example, the internet, an intranet, a LAN, a phone line, a radio transceiver, or a dedicated hard line. The user 130 receives the notification signal from the network via communication path 129 , and can send a signal back to the computer, as will be presently discussed.
[0022] With such an arrangement an environmental condition signal can be rapidly and efficiently transmitted to a remote user 130 from the sensor 120 without need of costly separate communication devices for the sensor 120 . The condition signal can also be analyzed and evaluated as compared to other types of sensors, not shown for simplicity in FIG. 1 , for a more complete evaluation of the environmental condition than is available from the sensor output alone. For example, the sensor 120 shown may be a smoke detector which operates by examining the transparency of a specified column of air, and may incorrectly interpret a cloud of condensing steam as an excessively high level of smoke from a fire. Thus, an erroneous alarm may be broadcast when it might have been avoided by making a comparison to an adjacent ionization type fire detector. The present improved system can use the controller 112 to evaluate the condition signal values from many different sensors stored in memory 124 to determine the presence of an emergency with improved accuracy.
[0023] FIG. 2 is a block diagram illustrating an example system 200 with additional features over the system of FIG. 1 . In FIG. 2 the elements previously discussed with respect to FIG. 1 have similar numbers, and the previous discussion will not be repeated.
[0024] FIG. 2 shows the situation where a computer system, such as a memory storage device, is installed in an environment that already has a previously installed sensor 238 . The improved system provides a parallel and partially redundant environmental condition sensor system to improve reliability and capability at low cost. Fire sensor 238 is shown as being hardwire connected to a local fire station 240 and to a centralized alarm center 242 by communication paths 244 , shown as cables in the illustrative figure, but any sort of communication system may be used. The alarm center 242 may alert the user 230 directly (not shown) or the fire station 240 , and may have connection to the network 228 via communication path 246 , and thus potentially to the user 230 .
[0025] FIG. 2 also shows that the computer system 210 can transfer data or active processes to a back up computer system 248 via communication path 250 to prevent data loss and minimize lost processing capability. For example, in the case were 210 represents a storage system, the data stored may be emergency backed up by storing a current copy of the data at another storage system at 248 . Such a transfer of data may be in response to an action signal from user 230 via communication path 252 via network 228 , and eventually to controller 212 . Alternatively, the controller 212 may have code to determine that in certain environmental conditions, for example, a specified time after sending a notification signal and not receiving a response, that the data transfer may be made. The controller 212 may also receive an action signal to take action to limit the damage of an environment condition, for example turning on a fire suppression system in response to a fire, or turn off a water valve controlling water lines to the vicinity of the computer system in response to a flood indication.
[0026] The system shown may be implemented in any computer system, such as a memory storage system, as a computer program product having a non-transitory, computer-readable storage medium storing code to communicate environmental conditions in the vicinity of a computer system to a remote user as described previously. The software used in the computer system to evaluate the data or to drive the ingress 218 and egress 216 ports may be of any type. The user 230 is shown as being a workstation, but the invention is not so limited, and the user 230 may be in contact with the system 210 via a handheld device using any of a variety of well known mobile applications.
[0027] FIG. 3 is a flowchart illustrating the improved method. At step 302 a condition signal is received, for example at ingress port 218 . At step 304 the condition signal is evaluated, for example in the controller 212 discussed previously, to establish a value representing the environmental condition indicated by the signal. At step 306 the value is stored, for example in a memory such as memory 224 in FIG. 2 as discussed previously.
[0028] At step 308 it is determined if the value from step 304 has exceeded the limit, for example a stored limit range of a single sensor reading, or as a time dependent change as compared to previous sensor reading from the same sensor, or as a combination of readings from a variety of different sensors, some being of different types. If the value is within the allowable range then the process returns to step 302 and repeats with a new sensor signal, either from the same sensor, or from a different sensor of the same type, or from a sensor of a different type. If at step 308 the value is outside the allowable limits then the process moves to step 310 and a notification signal is sent to the user as previously discussed. Although the notification signal is only illustratively shown in FIG. 3 as going to the user, the invention is not so limited and notification signals may be sent to any number of other selected locations.
[0029] FIG. 4 is a flowchart illustrating the improved method with additional features over the method of FIG. 3 . In FIG. 4 the elements have similar numbers to those discussed previously, and the previous discussion will not be repeated.
[0030] In the case where a notification signal is sent to the user, in FIG. 4 the process also determines at step 320 if the sensor which caused the notification signal to be sent was a fire sensor. If the sensor was not a fire sensor the process returns to step 302 and repeats the process from the beginning with a new sensor signal. If the determination at step 320 is that it is a fire sensor then another notification signal is sent to a preselected fire department at step 322 . Alternatively, or in addition to step 322 , an action signal may be sent by the computer system 210 to the fire suppression system in the vicinity of the computer system at step 324 . Step 324 may be restricted to reception of an action signal from the user 230 , or it may be initiated by the processor 212 , as discussed previously. The improved technique uses existing communication systems in a computer system to provide fast environment sensor reports to an easily varied selection of users and responders, while reducing installation cost and time, or providing redundancy and increased analytic capability to pre existing environmental sensor systems. Using the computation power of the computer system to evaluate time varying environmental signals, or to combine the readings from different types of environmental sensors, can result in the accurate determination of an emergency condition before any single sensor can reach the critical level readings required for a proper alarm signal.
[0031] While various embodiments of the present disclosure have been particularly shown and described, 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 present disclosure as defined by the appended claims.
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Improved efficiency in monitoring environmental conditions in the vicinity of an unattended computer system includes using the existing communication systems between the computer system and a network, to provide immediate information to users, emergency responders and anyone connected to the network. The system may also include an ability of the unattended computer system to receive a return message from the user ordering a physical action in response to the reported environmental condition, for example turning on a fire suppression system in response to a smoke alarm. The system may also include storage of environmental conditions and analysis of variations over time, as well as any interactions of various types of environmental conditions, such as giving more weight to a high temperature reading in conjunction with an elevated but not critical level of smoke.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is the U.S. national stage application pursuant to 35 U.S.C. §371 of International Application No. PCT/EP2013/062316, filed on Jun. 14, 2013, which application claims priority from German Patent Application Nos. DE 10 2012 210 859.9, filed on Jun. 26, 2012, and DE 10 2012 212 695.3, filed on Jul. 19, 2012, which applications are incorporated herein by reference in their entireties.
TECHNICAL FIELD
The present invention relates generally to a method for controlling a transmission of a motor vehicle, and, more specifically, for controlling clutch and transmission systems and, even more specifically, for controlling dual-clutch transmission systems.
BACKGROUND
Within the framework of this document, the abbreviation “TCU” is understood to mean any transmission control unit for controlling a motor vehicle transmission, any clutch control unit for controlling one or more motor vehicle shifting clutches, and in particular any control unit for controlling a transmission as well as for controlling one or more shifting clutches, in particular any control unit for controlling a dual-clutch transmission. Dual-clutch transmissions have long been known, and are described, for example, in German reference no. DE 10 2008 023 360 A1 (Eich et al.). The terms “TCU” and “control unit TCU” are used synonymously.
Within the framework of this document, the abbreviation “HCA” is understood to mean any actuator, for example, for operating an automated friction clutch, for example, a hydraulically operated clutch actuator, in particular a hydrostatically operated clutch operator (hydrostatic clutch actuator) as disclosed, for example, in German reference no. DE 10 2010 047 801 (Franz et al.) or German reference no. DE 10 2010 047 800 (Gramann et al.). However, every HCA must have at least one non-volatile memory as well as one local control unit (LCU) unambiguously and firmly assigned to it. The non-volatile memory is located, for example, in the local control unit (LCU) of the HCA.
Dual-clutch transmission systems have, for example, a TCU HCA system.
The abbreviation “SW” is to be understood within the framework of this document to mean software.
Within the framework of this document, the terms diagnostic routine, diagnostic function, diagnostic service and diagnostic command are used interchangeably or essentially synonymously.
Within the framework of this document, the terms software, routine, function and process are likewise used essentially synonymously.
The components used, for example, in dual-clutch transmissions, depending on their design, have one or more control units, including flash memories for the application SW. A SW update may become necessary due to model year updates or error correction (bug fixes).
In dual-clutch systems, normally two actuators are used (one actuator for each clutch), such as, for example, the HCA, whose control unit (LCU) is also equipped with a flash memory. Since the same application SW is used for both LCUs, for reasons of simplification, in the event of a SW update both LCUs must also be updated, each LCU separately. The flash process is usually initiated, carried out and monitored for correct execution by a test device. The flash process takes place via a CAN bus, with the control unit (TCU) connected ahead of the LCU enabling the connection between LCU and tester by means of a gateway function.
The program memory within the LCU is very limited; integrating additional SW functionality must always be reconsidered therefore against the background of the limited memory resources.
In particular, the function which enables the updating of the control unit code (LCU application SW) of the HCA is rarely needed but—if it is carried out by means of the client-specific diagnostic protocol—still demands extensive memory space. By protocol, it is meant a communication protocol, which is well known in the art as a system of rules that allows two or more entities of a communications system to transmit information via any kind of variation of a physical quantity. These are the rules or standard that defines the syntax, semantics, and synchronization of communication and possible error recovery methods. Protocols may be implemented by hardware, software, or a combination of both. A different protocol, for example Open-source CAN Calibration Protocol (CCP) or Universal Measurement and Calibration Protocol (XCP), which is used for this purpose during development, requires much less memory space.
As shown in FIG. 1 , the flashing of LCU 150 , 160 always takes place by means of diagnostic tester 140 ; there is usually no direct connection of LCU 150 , 160 to tester 140 , but rather—by means of a gateway function in TCU 110 —only through transmission control unit TCU 110 . TCU 110 forwards 120 the commands from the tester to the LCU, and as a countermove returns 130 the responses of the LCU to the tester. All of this takes place via the client-specific diagnostic protocol, for example, the Unified Diagnostic Services (UDS) protocol, which must be stored both in TCU 110 and in the LCU for this purpose. The gateway function allows change-free transmission of the messages in both directions. Such methods are also explained, for example, in German Patent No. DE 101 53 085 A1 (Gruenewald et al.), German Patent No. DE 43 15 494 C1 (Keuhner et al.), German Patent No. DE 102 37 715 A1 (Bolz) and German Patent No. DE 196 16 166 A1 (Fackler).
SUMMARY
The present invention comprises a method for controlling a motor vehicle transmission, the motor vehicle transmission having a transmission actuator to actuate the vehicle transmission, a vehicle clutch with a clutch actuator to actuate the vehicle clutch, a first control unit having a first memory area, a second control unit having a second memory area, and a third control unit, the method for controlling the motor vehicle transmission including the steps of: exchanging information between the first and third control units via the second control unit, exchanging information between the first and the second control units on the basis of a first communication protocol and exchanging information between the second and the third control units on the basis of a second communication protocol and controlling the motor vehicle transmission based on the exchanged information between the first and the third control units, the first and the second control units, and the second and the third control units.
A general object of the present invention is to provide the flash functionality with reduced storage space demand within the LCU.
According to the invention, a method is provided for controlling a motor vehicle transmission having a transmission actuator to actuate the vehicle transmission, having a vehicle clutch with a clutch actuator to actuate the vehicle clutch, having a first control unit which has a memory area that is unambiguously assigned to it, having a second control unit which has a memory area that is unambiguously assigned to it. According to the invention, a third control unit is provided, wherein an information exchange between the third and the first control units is provided via the second control unit, wherein to that end an information exchange between the third and the second control unit and an information exchange between the first and the second control unit is provided, wherein the information exchange between the first and the second control unit is provided on the basis of a first communication protocol and the information exchange between the second and the third control unit is provided on the basis of a second communication protocol.
In an example embodiment of the invention it is provided that on the first control unit and the second control unit the first communication protocol is available, and on the second control unit and on the third control unit the second communication protocol is available.
In an example embodiment of the invention it is provided that the memory demand for the first communication protocol is less than for the second communication protocol.
Information exchange may be data exchange, exchange of computer programs, exchange of commands or the like.
For example, this may be the transfer of a computer program (LCU SW) for the LCU (first control unit) which is present in the tester (third control unit)—for example, a new update version—into the memory area of the LCU (first control unit).
However, it may also be the transfer of previously obtained startup data of startup parameters present in the tester (third control unit) into the memory area of the LCU (first control unit).
It may also have to do with a transfer of the startup data from the memory area of the LCU into the memory area of the TCU.
In an example embodiment of the invention it is provided that the first communication protocol is the CCP or XCP protocol, and the second communication protocol is a client-specific diagnostic protocol, for example, the UDS protocol.
The methods according to the invention have the advantage that the memory space for the client-specific diagnostic protocol UDS is not needed in the LCU. Instead, in the LCU memory, space is only needed for a less memory-space-intensive protocol, for example, the CCP or XCP protocol.
In an example embodiment of the invention it is provided that with every information exchange between the third control unit and the first control unit, a change of the communication protocol is carried out in the second control unit, depending on the direction of the information exchange. The change occurs by means of a translation between the two communication protocols.
In an example embodiment of the invention it is provided that with every information exchange from the third control unit in the direction of the first control unit, a change of the communication protocol from the second communication protocol to the first communication protocol is carried out in the second control unit.
In an example embodiment of the invention it is provided that with every information exchange from the first control unit in the direction of the third control unit, a change of the communication protocol from the first communication protocol to the second communication protocol is carried out in the second control unit.
So to continue an information exchange, a change takes place in the TCU, i.e., a translation from one communication protocol into the other, since the first and third control units have no common communication protocol.
The following section explains variants of a first preferred embodiment.
In an example variant of the first embodiment of the invention it is provided that the third control unit causes a computer program to be transferred, by means of a diagnostic command of the second communication protocol, into the memory area of the second control unit.
In an example variant of the first embodiment of the invention it is provided that the computer program is a flash routine and/or a computer program for the first control unit, such as, for example, an application SW program for the first control unit (an LCU application SW program).
Instead of a computer program for the first control unit (LCU SW), this may also be the transfer of startup data of startup parameters, obtained and present in the tester (third control unit), into the memory area of the first control unit (LCU).
However, the flash routine may also already be present in the memory area of the second control unit (TCU) and available on the second control unit (TCU). So, it may also have reached the memory area of the second control unit (TCU) in a different way.
In an example variant of the first embodiment of the invention it is provided that the second control unit is caused by means of the flash routine to transfer the application SW program for the first control unit by means of the first communication protocol into the memory area of the first control unit, while the flash routine and the application SW program for the first control unit are available in the memory area of the second control unit, and while the flash routine is caused to transfer the application SW program by means of a diagnostic command of the second communication protocol issued by the third control unit.
The following section explains variants of a second especially preferred embodiment, an alternative to the first embodiment:
In an example variant of the second embodiment of the invention it is provided that in the second control unit a protocol translator program (translator) is available, which carries out the change of communication protocol. By protocol translator, it is meant a protocol converter, which is well known in the art as a device used to convert standard or proprietary protocol of one device to the protocol suitable for the other device or tools to achieve the interoperability.
In an example variant of the second embodiment of the invention it is provided that in the second control unit (TCU) a gateway function is available for change-free transmission of information or data or computer programs through the second control unit (TCU).
For example, this may be the transfer of startup data of startup parameters, obtained and present in the tester, into the memory area of the LCU.
In an example variant of the second embodiment of the invention it is provided that the third control unit (tester), by means of a diagnostic command of second communication protocol ( 460 ), causes a computer program or startup data to be transferred into the memory area of the first control unit (LCU).
In an example variant of the second embodiment of the invention it is provided that the third control unit (tester), by means of a diagnostic command of second communication protocol ( 460 ), causes a computer program or startup data to be transferred into the memory area of the first control unit (LCU), whereupon the diagnostic command of second communication protocol ( 460 ) is translated in the second control unit (TCU) by means of the protocol translator program (translator) into a diagnostic command of first communication protocol ( 450 ), and/or the computer program for the first control unit (LCU) or the startup data are conducted through the second control unit (TCU) without change by means of the gateway function.
By means of the gateway function and the protocol translator program according to the second embodiment of the invention, neither a flash routine nor the application SW program for the first control unit (LCU application SW program) first has to be brought into the memory area of the second control unit in its entirety, but instead the application SW program for the first control unit (LCU application SW program) present in the third control unit (tester) can be brought in its entirety or “by data packets” into the memory area of the first control unit (LCU) by means of a flash routine, which however now must be present only in the third control unit (tester), or without any flash routine but rather directly by means of commands (diagnostic commands), via the gateway of the TCU. The commands which this requires are sent, emitted from the flash routine or directly through commands (diagnostic commands) of the third control unit (tester) to the second control unit (TCU), and when commands are directed at the first control unit (LCU) are translated directly in the second control unit (TCU) TCU and forwarded to the first control unit (LCU). Replies from the first control unit (LCU) are likewise retranslated immediately upon arrival in the second control unit (TCU) and are also forwarded directly to the third control unit (tester), so that a so-called “simultaneous translation” can take place in the second control unit (TCU) when messages are exchanged in particular between the third control unit (tester) and the first control unit (LCU). In this way the communication can take place between the third and the first control units, both of which use different communication protocols, almost exactly as quickly as between the third and the second control units, both of which use the same communication protocol; the only difference is the direct communication translation in the second control unit, which in practice does not cause any relevant delay. So effectively, the communication but also any data transfer can take place just as bidirectionally between the third and the first control units as between the third and the second control units.
In an example variant of the second embodiment of the invention it is provided that during the change-free transmission, the computer program for the first control unit (LCU) or the startup data are stored temporarily in the memory area of the second control unit (TCU), before being forwarded to the first control unit (LCU).
In an example variant of the second embodiment of the invention it is provided that during the change-free transmission, the computer program for the first control unit (LCU) or the startup data are stored temporarily by data packets in the memory area of the second control unit (TCU) and forwarded to the first control unit (LCU).
The expression “by data packets” is intended to mean within the framework of this document that a data packet may thus comprise less than the whole computer program, or less than all of the startup data. The data packet size may be specified, and may be oriented, for example, on the size of the memory area of the second control unit (TCU). After the intermediate storage, this packet is forwarded to the first control unit (LCU). Another data packet is then stored temporarily in the second control unit (TCU) and then likewise forwarded, etc., until all of the data of the computer program or all of the startup data have been transmitted. The transmission takes place within the framework of this document in the sense “change-free,” as the computer program or the startup data are exactly as present in the memory area of the first control unit (LCU) after transmission as they were present prior to transmission in the memory area of the third control unit (tester) from which they were transmitted.
In an example variant of the second embodiment of the invention it is provided that the forwarding of the computer program for the first control unit (LCU) or of the startup data from the second control unit (TCU) to the first control unit (LCU) takes place by means of the diagnostic command translated by the protocol translator program (translator) into first communication protocol ( 450 ).
In an example variant of the second embodiment of the invention it is provided that the computer program is an application SW program (LCU SW) for the first control unit.
In an example variant of the second embodiment of the invention it is provided that instead of a computer program it involves startup data of startup parameters which are present in the third control unit (tester), and which are to be stored in the memory area of the first control unit (LCU).
In the following section, variants of a third especially preferred embodiment, an alternative to the first and second embodiments, will be explained:
In an example variant of the third embodiment of the invention it is provided—as in the second embodiment—that in the second control unit a protocol translator program (translator) is available, which carries out the change of communication protocol.
In an example variant of the third embodiment of the invention it is provided that the third control unit (tester), by means of a diagnostic command of second communication protocol ( 460 ), causes startup data to be transferred from the memory area of the first control unit (LCU) into the memory area of the second control unit (TCU).
For example, this may be the transfer of startup data of startup parameters stored in the memory area of the first control unit (LCU) into the memory area of the second control unit (TCU). The startup data are obtained, for example, in the transmission works, transferred into the memory area of the first control unit (LCU) and stored there, and later in the vehicle works are recovered again from the memory area of the first control unit (LCU) into the memory area of the second control unit (TCU), since the second control unit (TCU) intended for the vehicle is not connected to the motor vehicle transmission, and in particular to the first control unit (LCU) of the motor vehicle transmission, until it reaches the vehicle works. The startup data obtained in the transmission works are therefore not stored in the second control unit (TCU) in the transmission works, since the second control unit (TCU) is not transferred into the vehicle works along with the motor vehicle transmission including the first control unit (LCU). The startup data for the motor vehicle transmission must therefore be stored in the first control unit (LCU).
In an example variant of the third embodiment of the invention it is provided that the third control unit (tester), by means of a diagnostic command of second communication protocol ( 460 ), causes startup data to be transferred from the memory area of the first control unit (LCU) into the memory area of the second control unit (TCU), whereupon the diagnostic command of second communication protocol ( 460 ) is translated in the second control unit (TCU) by means of the protocol translator program (translator) into a diagnostic command of first communication protocol ( 450 ) and is forwarded to the first control unit (LCU), so that the startup data are transferred from the memory area of the first control unit (LCU) into the memory area of the second control unit (TCU).
The following section explains preferred embodiments both of the variants of the first and also those of the second and third preferred embodiments.
In an example embodiment of the invention it is provided that the protocol translator program (translator) translates a diagnostic command of the one communication protocol directly into a diagnostic command of the other communication protocol.
The term “directly” describes that the translation of the diagnostic command takes place immediately, if the TCU does not give preference to higher-priority tasks of the translation.
In this way there is a “simultaneous translation,” so that a rapid command exchange, or a rapid exchange between command and confirmation or response or the like is possible for example, between the third (tester) and first (LCU) control units.
In an example embodiment of the invention it is provided that the information exchange between the third and the first control units is carried out exclusively through the second control unit.
In an example embodiment of the invention it is provided that the first control unit is a local actuator control unit LCU for controlling the clutch actuator and/or the transmission actuator, and wherein the second control unit is a transmission control unit TCU for controlling the clutch and/or for controlling the transmission, and wherein the third control unit is a tester or a test bench computer.
In an example embodiment of the invention it is provided that the motor vehicle transmission is a dual-clutch transmission system.
In an example embodiment of the invention it is provided that the first communication protocol is the CCP or XCP protocol, and the second communication protocol is a client-specific diagnostic protocol, in particular the UDS protocol.
These and other objects, advantages and features of the present invention will be better appreciated by those having ordinary skill in the art in view of the following detailed description of the invention in view of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The nature and mode of operation of the present invention will now be more fully described in the following detailed description of the invention taken with the accompanying figures, in which:
FIG. 1 shows the flashing of a local control unit by means of a diagnostic tester and a gateway function in a transmission control unit;
FIG. 2 shows a schematic depiction of a first stage of the first preferred embodiment of the method according to the invention;
FIG. 3 shows a schematic depiction of a second stage of the first preferred embodiment of the method according to the invention; and,
FIG. 4 shows a schematic depiction of the second and third preferred embodiments of the method according to the invention.
DETAILED DESCRIPTION
At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements of the invention. While the present invention is described with respect to what is presently considered to be the preferred aspects, it is to be understood that the invention as claimed is not limited to the disclosed aspects.
Furthermore, it is understood that this invention is not limited to the particular methodology, materials and modifications described and, as such, may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the present invention, which is limited only by the appended claims.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs. Although any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the preferred methods, devices, and materials are now described.
The flash process is subdivided into multiple steps: Step 1: Flashing of the LCU SW into control unit (TCU) 210 (see FIG. 2 ); and, Step 2: Activation of an LCU flash routine within TCU 310 (see FIG. 3 ).
Explanation of Step 1 (See FIG. 2 ):
TCU control unit 210 has significantly more free memory space than the LCU: to that extent, the possibility exists to flash the program code for the LCU into TCU 210 , namely into a memory area that is not needed. This flash process can take place by means of the client's own diagnostic protocol. The client's own diagnostic protocol may be, for example, the UDS protocol.
Explanation of Step 2 (See FIG. 3 ):
After completion of the flashing of the LCU application SW LCU SW 300 into TCU 310 , a diagnostic service for flashing the LCU is called 320 by the tester, again by means of client-specific diagnostic protocol 360 . This service starts a function within TCU 310 , the LCU flash routine—referred to hereinafter as flash routine A or also as function A—which flashes 330 the LCU application SW program code LCU SW 300 from TCU 310 into LCU 380 ; this time, however, the calibration protocol which was used already during the development is used. This is, for example, the XCP or the CCP protocol.
This has the advantage that the memory space for the client-specific diagnostic protocol, such as UDS 360 , is not needed in LCU 380 , but only memory space for a less memory-space-intensive protocol 350 , such as, for example, the XCP or the CCP protocol. In addition, memory space is needed in LCU 380 for the LCU application SW program code 300 flashed into LCU 380 . LCU application SW program code 300 , which is flashed into LCU 380 , the flash routine A, which carries out flashing 330 of the LCU application SW program code from the TCU into the LCU, and both protocols 350 , 360 are needed in TCU 310 .
Sequence:
The following steps are carried out in client-specific diagnostic protocol 360 : Step 1 (see FIG. 2 ): Tester 240 flashes 220 LCU SW 230 into TCU control unit 210 by means of client-specific diagnostic protocol; TCU 210 carries out the diagnostic command and acknowledges accordingly. Step 2 (see FIG. 3 ): After completion of flash process 220 , by means of client-specific diagnostic protocol 360 a function A is called 320 in TCU 310 by tester 370 which carries out the flashing of LCU 380 . The status of this routine is reported back 340 to the tester accordingly.
The following steps are carried out in CCP/XCP protocol 350 : The TCU function A now flashes 330 LCU 380 by means of the calibration protocol (e.g., CCP/XCP); the status of this function A is known to the TCU.
The following steps are carried out in client-specific diagnostic protocol 360 : The status of this function A is reported back 340 in the direction of the tester by means of client-specific diagnostic protocol 360 .
An incorporation of a SW functionality into the TCU/LCU SW is also provided, in order to ease the problem of memory capacity in the LCU.
Since the system consists of 2 LCUs 380 , 390 , both LCUs must also be flashed; the following options turn out to be expedient:
1. LCU SW 300 is identical for both LCUs 380 , 390 :
1.1 Function A first flashes 330 LCU 380 and then LCU 390 (or vice versa).
1.2 Function A obtains through tester 370 the information about which LCU is to be flashed, and according flashes only that LCU. The two functions A do not differ otherwise.
2. LCU SW 300 is different for the two LCUs 380 , 390 :
2.1 The tester first flashes 220 SW 300 for LCU 380 into TCU 310 . After that the tester calls function A 320 , which flashes 330 LCU 380 . Next the SW for LCU 390 is flashed 220 into the TCU, after which function B is called 320 , which flashes LCU 390 .
2.2 Tester 370 first flashes 220 SW 300 for LCU 380 into TCU 310 . After that, tester 370 calls 320 function A with the reference to LCU 380 , which flashes 330 LCU 380 . Next, SW 300 for LCU 390 is flashed into the TCU, after which function A is called 320 with the reference to LCU 390 , which flashes LCU 390 .
2.3 The tester flashes the SW for LCU 380 and LCU 390 into TCU 310 . After that, tester 370 calls function A 320 , which flashes LCU 380 and then LCU 390 (or vice versa).
On the basis of FIG. 4 , in the following section a second solution will be explained, which is an alternative to the first.
In this case, in TCU 410 , both protocol translator program (translator) 400 , which performs the change of the communication protocol, and gateway function 500 for the change-free transmission of information or data or computer programs through TCU 410 , are available.
For example, this may be the transfer of startup data of startup parameters, obtained and present in tester 470 , into the memory area of LCU 480 .
To that end it is provided that tester 470 , by means of a diagnostic command of second communication protocol UDS 460 , causes a computer program or startup data to be transferred into the memory area of LCU 480 .
At the same time, tester 470 , by means of a diagnostic command of second communication protocol 460 , causes a computer program or startup data to be transferred into the memory area of LCU 480 , whereupon the diagnostic command of second communication protocol 460 is translated in TCU 410 by means of the protocol translator program (translator) 400 into a diagnostic command of first communication protocol 450 , and/or the computer program for LCU 480 or the startup data are conducted through TCU 410 without change by means of gateway function 500 .
Neither a flash routine nor the application SW program for the LCU (LCU application SW program) first has to be brought into the memory area of the second control unit in its entirety by means of gateway function 500 and protocol translator program 400 , but instead the application SW program for the LCU (LCU application SW program) present in tester 470 can be brought in its entirety or “by data packets” into the memory area of LCU 480 by means of a flash routine, which however now must be present only in tester 470 , or without any flash routine but rather directly by means of commands (diagnostic commands), via gateway 500 of TCU 410 . The commands which this requires are sent, emitted from the flash routine or directly through commands (diagnostic commands) of tester 470 to TCU 410 , and when commands are directed at LCU 480 , are translated directly in the TCU and forwarded to LCU 480 . Replies from LCU 480 are likewise retranslated directly after arrival in TCU 410 , and are also forwarded directly to tester 470 , so that a so-called “simultaneous translation” can take place in the TCU when messages are exchanged, in particular between tester 470 and LCU 480 . In this way, the communication can take place between tester 470 and LCU 480 , both of which use different communication protocols, almost exactly as quickly as between tester 470 and TCU 410 , both of which use the same communication protocol; the only difference is the direct communication translation in TCU 410 , which in practice does not cause any relevant delay. So, effectively, the communication but also any data transfer can take place just as bidirectionally between tester 470 and LCU 480 as between tester 470 and TCU 410 .
Optionally, during the change-free transmission, the computer program for the LCU or the startup data can be stored temporarily in the memory area of TCU 410 , before being forwarded to LCU 480 .
Optionally, during the change-free transmission, the computer program for LCU 480 or the startup data can be stored temporarily by data packets in the memory area of TCU 410 , and forwarded to LCU 480 .
The expression “by data packets” is intended to mean within the framework of this document that a data packet may thus comprise less than the whole computer program, or less than all of the startup data. The data packet size may be specified, and may be oriented for example, on the size of the memory area of TCU 410 . After the intermediate storage this packet is forwarded to LCU 480 . Next, another data packet is stored temporarily in TCU 410 and then likewise forwarded, etc., until the entire computer program or all of the startup data have been transmitted. The transmission takes place within the framework of this document in the sense “change-free,” as the computer program or the startup data are exactly as present in the memory area of LCU 480 after transmission as they were present prior to transmission in the memory area of tester 470 from which they were transmitted.
The transmission of the computer program for LCU 480 or of the startup data from TCU 410 to LCU 480 takes place by means of the diagnostic command translated by the protocol translator program (translator) into first communication protocol 450 .
The computer program may be, for example, an application SW program (LCU SW), LCU 480 .
Instead of a computer program, it may be startup data of startup parameters that are present in tester 470 , and that are to be stored in the memory area of LCU 480 .
A third embodiment of the invention will now be explained on the basis of FIG. 4 .
As in the second embodiment, it is provided that in TCU 410 , protocol translator program (translator) 400 is available, which carries out the change of communication protocol.
By means of a diagnostic command of second communication protocol 460 , tester 470 causes startup data to be transferred from the memory area of LCU 480 into the memory area of TCU 410 .
For example, this may be the transfer of startup data of startup parameters stored in the memory area of LCU 480 into the memory area of TCU 410 . The startup data are obtained, for example, in the transmission works, transferred into the memory area of LCU 480 and stored there, and later in the vehicle works recovered again from the memory area of LCU 480 into the memory area of TCU 410 , since TCU 480 intended for the vehicle is not connected to the motor vehicle transmission, and in particular to LCU 480 of the motor vehicle transmission, until it reaches the vehicle works. The startup data obtained in the transmission works are therefore not stored in the transmission works in the TCU used there, which in most cases is integrated into a test bench computer, since this TCU is not transferred to the vehicle works with the motor vehicle transmission including LCU 480 . The startup data for the motor vehicle transmission must therefore be stored in LCU 480 .
Tester 470 , by means of a diagnostic command of second communication protocol 460 , causes startup data to be transferred from the memory area of LCU 480 into the memory area of TCU 410 , whereupon the diagnostic command of second communication protocol 460 is translated in TCU 410 by means of protocol translator program (translator) 400 into a diagnostic command of first communication protocol 450 and is forwarded to LCU 480 , so that the startup data are transferred from the memory area of LCU 480 into the memory area of TCU 410 .
Protocol translator program (translator) 400 translates a diagnostic command of the one communication protocol directly into a diagnostic command of the other communication protocol.
The term “directly” describes that the translation of the diagnostic command takes place immediately, if the TCU does not give preference to higher-priority tasks of the translation.
In this way, there is a “simultaneous translation,” so that a rapid command exchange or a rapid exchange between command and confirmation or response or the like for example, between tester 470 and LCU 480 is possible, so that bidirectional communication can also occur between tester 470 and LCU 480 .
Thus, it is seen that the objects of the present invention are efficiently obtained, although modifications and changes to the invention should be readily apparent to those having ordinary skill in the art, which modifications are intended to be within the spirit and scope of the invention as claimed. It also is understood that the foregoing description is illustrative of the present invention and should not be considered as limiting. Therefore, other embodiments of the present invention are possible without departing from the spirit and scope of the present invention.
LIST OF REFERENCE NUMBERS
110 TCU control unit with gateway function
120 TCU forwards commands from the tester to the LCU
130 TCU sends responses of the LCU back to the tester
140 Tester
150 LCU clutch 1
160 LCU clutch 2
210 TCU control unit with gateway function
220 Flashing of the LCU software into the TCU
230 LCU software (LCU SW)
240 Tester
250 LCU clutch 1
260 LCU clutch 2
300 LCU software (LCU SW)
310 TCU control unit with gateway function
320 Tester calls function A in the TCU by means of client-specific diagnostic protocol
330 TCU flash function A flashes the LCU SW into the LCU by means of CCP/XCP calibration protocol
340 Status feedback to the tester by means of client-specific diagnostic protocol
350 CCP protocol or XCP protocol
360 Client-specific diagnostic protocol (UDS)
370 Tester
380 LCU clutch 1
390 LCU clutch 2
400 Protocol translator program (translator)
410 TCU control unit with gateway function and protocol translator program (translator)
420 in the TCU, messages (e.g., commands) of the tester to the LCU are translated by protocol translator 400 and sent to the LCU
430 in the TCU, messages (e.g., responses) of the LCU to the tester are translated by protocol translator 400 and sent to the tester
440 Bidirectional communication between tester and TCU
450 CCP protocol or XCP protocol
460 Client-specific diagnostic protocol (UDS)
470 Tester
480 LCU clutch 1
490 LCU clutch 2
500 Gateway
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A method for controlling a motor vehicle transmission having a transmission actuator to actuate the vehicle transmission, having a vehicle clutch with a clutch actuator to actuate the vehicle clutch, having a first control unit which has a memory area that is unambiguously assigned to it, having a second control unit which has a memory area that is unambiguously assigned to it.
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FIELD OF THE INVENTION
The present invention is directed to an internal burner which makes use of regenerative air cooling together with a thermal insulation shield to maximize the useful energy release from an essentially stoichiometric flow of fuel to an air-fuel internal burner producing supersonic flame jets for flame spraying applications.
BACKGROUND OF THE INVENTION
In the past, the HVOF (hypersonic velocity oxy-fuel) continuous spraying of higher melting point powdered materials such as tungsten carbide (in a cobalt matrix) has required the use of oxidizers of much higher oxygen content than that contained in air. For example, in my earlier U.S. Pat. Nos. 4,416,421; 4,634,611; and 4,836,447 in particular, show forms of flame spray devices described as primarily oxy-fuel burners. Air may be one component of the oxidizer flow, but in each case the intensity of the flame jet relies on oxygen percentages greater than that contained in ordinary compressed air. The use of air to cool heated burner parts with this air subsequently entering and supporting the combustion process (regenerative cooling) was not feasible.
In place of "regenerative cooling", where the coolant becomes the oxidizing reactant, these prior flame spray devices rely on forced water cooling which severely limits the peak temperatures and jet velocities theoretically attainable. As an example, using a commercially available HVOF flame spray unit of the type discussed in U.S. Pat. No. 4,416,421, a simple heat balance shows that approximately 30% of heat released during the combustion process is carried away by the cooling water. Assuming a combustion peak flame temperature of 4,700 degrees Fahrenheit for a pure oxygen-propane mixture burning at a chamber pressure of 60 psig, if flame temperature was linearly related to heat content, then the 70% availability of the useful heat achieves a maximum flame temperature of only 3,150 degrees Fahrenheit. Of course, dissociation effects which limit the peak achievable temperature to 4,700 degrees F. release heat upon cooling. Thus, an actual combustion temperature of around 3,600 degrees F. is estimated.
Examining the combustion of compressed air and propane under conditions of essentially zero heat loss, the peak theoretical combustion temperature is about 3,400 degrees F. This is only 200 degrees F. less than that of the pure oxygen burner described above.
SUMMARY OF THE INVENTION
This invention provides an internal burner capable of flame spraying nearly all the high melting point materials previously only sprayed using devices operating with oxygen contents greater than that contained in ordinary compressed air. Needless to say, large operating economics are realized where expensive pure oxygen is not required and simplicity and reliability of the operation are greatly enhanced by eliminating forced cooling water flow for such burners.
BRIEF DESCRIPTION OF THE DRAWINGS
The single FIG. 1 is a longitudinal sectional view of the internal burner forming a preferred embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A better understanding of the invention may be obtained via the FIG. 1 cross-sectional view of the burner of the invention. In the figure flame spray burner 10' comprises an outer shell piece 10 to which the cylindrical flame stabilizer 11 and nozzle adaptor 12 are threadably connected by nuts 17 and 18.
Nozzle 19 pressure-seats against face 33 of adaptor 12 by means of nut 22 which presses outer cylindrical casing 21 against multiple shoulders 27 of multiple fins 20.
Compressed air, with or without mist cooling water passes through adaptor 23 to annular volume 24 defined by nozzle tube 19 and casing 21. The air then passes at high velocity through narrow slots 19a forming fins 20 to provide cooling of nozzle 19. From the slots the air passes through multiple longitudinal holes 26 in cylindrical adaptor 12 to annular volume 37 formed by a radial groove in adaptor 12 and thence through the narrow annular space 34' contained between shell 10 and combustor tube 13. The air, after cooling both adaptor 12 and combustor tube 13, passes radially through multiple circumferentially spaced radial holes 35 to stabilization well 38 formed by an axial bore in cylindrical stabilizer 11, while cooling stabilizer 11.
Fuel for combustion enters stabilizer 11 through adaptor 15 threaded into a tapped axial bore 11a of stabilizer 11 and thence through multiple oblique passages 16 into corresponding radial holes 35 to mix with the air passing to well 38 through holes 35. Ignition in combustion chamber volume 14 is effected by a spark plug (not shown) or by flashback from outlet 40 of nozzle passage or bore 39.
Combustor tube 13, usually made of a refractory metal such as 310 stainless steel has thin circumferentially spaced ridges 34 projecting radially outwardly thereof to provide adequate radial spacing between tube 13 and shell 10. Tube 13 operates at a red heat, expanding and contracting as the burner is turned "on" and "off". It must be provided with adequate space to allow free expansion. Shoulders 36 at opposite ends of tube 13 are notched to prevent air flow cut-off in the event of tube axial expansion against adjacent faces 11b, 12a of elements 11 and 12. The combustion chamber 14 pressure is maintained between 50 psig and 150 psig when compressed air, alone, is the coolant. At greater pressures air cooling is not adequate. A small amount of water, as per arrow pre-mixed into the air A 1 prior to entry to adaptor 23 helps to film cool the heated elements of the burner. A quantity of water which does not lower the oxygen content by weight in the total air-water mixture to less than 12% can be used without need for pure oxygen addition. Such operation is adequate for spraying, as per arrow P, powders such as aluminum, zinc, and copper as even the lowered temperature is capable of adequate heating of such powder. For higher melting point powders such as stainless steel and tungsten carbide it is necessary to add pure oxygen to the air at A 1 to provide the higher temperatures required. At very high pressure the air-contained oxygen will not, in itself, support combustion as the water content will be too great. Thus, under such conditions pure oxygen must be added to keep the total percentage-by-weight of oxygen above 12% in the total mixture.
In some cases the increased cooling required may be met by increasing the inlet air flow A 1 substantially effecting better cooling of the structural elements. This added air is, later, discharged to the atmosphere prior to the point where fuel is injected. In FIG. 1, a dotted line longitudinal bore 41 within flame stabilizer 11 forms the discharge passage for this extra air flow. A valve therein (not shown) controls the discharge flow rate.
The high temperature products of combustion expand to atmospheric pressure in their passage through nozzle bore 39. Powder is introduced essentially radially into these expanding gases through either of two powder injector systems shown in FIG. 1. Where a forward angle of injection of the powder is desired (in the direction of gas flow), powder passes, as per the arrow P 1 labeled "POWDER", from a supply tube (not shown) threadably attached to tapped hole 28 and thence through passage 29, open thereto, abutting the outer circumference of nozzle 19. One of the several oblique injector holes 32 is aligned with hole 29. A carrier gas, usually nitrogen, under pressure forces the powder into the central portion of the hot gas flow.
Where a rearward angle of injection of the powder is desired to increase particle dwell time in its passage through nozzle bore 39, a second injector system is utilized. From hole 28' the particles are forced by carrier gas flow, arrow P 2 , through an oppositely oblique injector hole 31, into the hot gas exiting nozzle bore 12b of adaptor 12, sized to nozzle bore 39 and aligned therewith.
An advantage of the injection system using multiple injectors contained in replaceable nozzle 19 is that when one injector hole erodes by powder scouring to too large a diameter, a second hole 32 of correct size is alignable thereto, to accept powder flow from hole 29. Also, the injector holes 32 may provide different angles of injection as required to optimize the use of powders of different size distribution, density, and melting point. For example, for a given nozzle length "L", aluminum should have a much shorter dwell time in the hot gases than stainless steel. A sharp forward angle would be formed for aluminum in contrast to a closer-to-radial angle for stainless steel.
Any material being sprayed P 1 , P 2 must be provided with an adequate dwell time to reach the plastic or molten state required to form a coating upon impact with a surface being spray-treated. As discussed in my U.S. Pat. No. 4,416,421, spraying of higher melting point materials using oxy-fuel flames requires L/D ratios for nozzle 19, bore 39 and that at 12b with adaptor 12, greater than 5-to-1. The compressed air burners have been found to require about the same length nozzles as priorly used with pure oxygen units. As the air burner nozzles are, usually, about twice the diameter of their oxygen counterparts, the L/D ratio is reduced to 3-to-1.
The L/D ratio is determined by the effective length of the bore 39 from the point of introduction of the powder via a radial passage 32 into the nozzle 19 and its outlet or exit at 40, while the diameter D is the diameter of that bore. Such ratio is critical in ensuring that the particles are effectively molten or near molten at the moment of impact against the substrate S downstream from the exit 40 of nozzle bore 39.
Although the inventor has had a great deal of prior experience in the design of regeneratively-cooled compressed air internal burners, until recently the inventor did not appreciate that when used with extended nozzles, such internal burners would be adequate for spraying other than low melting metals in the form of wires or rods. In fact, the ability of such internal burners to spray tungsten carbide was discovered due to an error when the tungsten carbide was placed in the powder hopper in place of a lower melting point stainless steel.
Nozzle lengths with D/L ratios of over 15-to-1 were originally required to spray tungsten carbide powder successfully using the compressed air internal burner. By reducing the area of heat loss surface, increased flame temperatures were achieved. This achievement results mainly from increasing the combustor tube 13 diameter-to-length ratio. A classical calculus problem to determine the minimum wetted surface of a cylindrical container such as a can of food of given volume leads to the "tuna can" solution where the diameter is double the can's height. For a flame spray unit requiring, say, a combustion volume of 36 cubic inches, many choices involving diameter-to-length ratios exist. For example, the diameter may be 3 inches with a length just over 5 inches, or the "tuna can" solution of D=4.l6 inches and L=2.08 inches. The latter diameter is too great as the copper pieces 11 and 12 are not routinely available in this large a diameter and the unit becomes awkward and heavy. The diameter-to-length ratio of 3-to-5 (that actually used) remains much smaller than previously used by the inventor in other applications of these devices not demanding maximum temperature attainment.
Even though the main loss of heat (that to a water coolant) has been eliminated by regenerative coolant flow of the combustion air, the outer surfaces of the burner reach high temperature during use and radiant heat loss of between 3% and 5% is estimated. Elimination of this loss by adequate thermal insulation means is necessary to reach maximum performance of the spray system. For this purpose, the outer surfaces of pieces or elements 10, 11, 12, and 21 are enclosed in a sheath of high-temperature thermal insulation material such as silica wool 42 covered by a sheet or coating 43. Nuts 17, 18, and 22 and other parts are also preferably coated with such temperature-resistant plastic as 43. It is believed that such thermal insulation of a flame spray internal burner is unique.
Example of a Flame Spray Burner of this Invention
An example of a successful operating system is now provided using the burner 10; provided with 150 scfm of compressed air at 100 psig and propane at 60 psig to yield a combustor chamber 14 pressure of about 50 psig. Under stoichiometric conditions the gas temperature entering nozzle bore 39 from bore 12b adjacent to chamber 14 was about 3,200 degrees F. These hot gases expand to a lower temperature within the 3/4-inch diameter combined nozzle bore 12b, 39 of 6-inch length until a Mach 1 flow region is attained. The temperature is, now, approximately 2,900 degrees F. for the remainder of the passage through the nozzle bore 39. For the 6-inch nozzle, successful spraying of both tungsten carbide and stainless steel powders P 1 were achieved. In fact, it appears that each coating C is at least as dense as when sprayed using the oxy-fuel counterpart. For the case of the stainless steel, nearly no oxides were visible in photomicrographs. There is much less overheating. The Mach 1 flow within the nozzle bore 39 is at a velocity of about 2,750 feet per second and expands beyond the nozzle exit 40 to M=1.65 (4,200 ft/sec). The sample substrates being sprayed was held a distance A=1 foot away from the burner allowing the particles to reach velocities greater than 2,000 ft/sec. This is comparable to those achieved using pure oxygen systems.
The conditions of air and fuel pressure of the example are in the range of those oxy-fuel units currently in commercial use. Pressure increase to very high levels is a simple matter using compressed air and fuel oil in place of propane. For a combustion pressure of 1,200 psi with chamber 14, the fully expanded Mach No. is 4.5 (7,400 ft/sec). This leads to particle impact velocities on substrates of over 4,000 ft/sec, a value never achieved before. Coatings C have been found to improve in quality nearly directly proportional to impact velocity. Compressed air A 1 use above 500 psig therefore opens up a new area of technology in the flame spray field.
By choice of nozzle material and the amount of cooling provided by the compressed air A 1 (and mist) flow, it is possible to vary the inner nozzle surfaces of nozzles 19, 12b to a wide range of temperatures. Where coolest possible nozzle surfaces are desired--as nozzle 19 for spraying plastics, zinc, and aluminum from the nozzle bore 39, copper is the ideal material for forming the nozzle 19 bore 39 with maximum cooling provided. However, for high melting point materials such as stainless steel, tungsten carbide, the ceramics, and the like, it is desirable to maintain the inner nozzle 19 surface of bore 39 as at high a temperature possible. For this case, a refractory metal such as 316 stainless steel is used with either no cooling fins 20, or radially short end fins. Under these conditions, the inner nozzle bore 39 surface runs bright red at very high temperature. Heat losses from the hot product of combustion gas G are greatly reduced, thus maintaining a higher gas temperature throughout the nozzle length L. Also, radiation cooling of the heated particles is reduced substantially. Such use can allow the effective nozzle length to be cut in half and nozzle 19 is capable of spraying higher melting point materials than highly cooled copper nozzles.
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A compressed air with or without water droplets in mist form and additional pure oxygen is passed over the radially exterior hot surfaces of an expansion nozzle having a L/D ratio of at least 3-to-1 and preferably surrounded by thermal insulation to enhance regenerative heat exchange between the expansion nozzle and the compressed air stream, as well as regenerative heat exchange with the exterior of a combustion chamber wall of an internal burner, also surrounded by thermal insulation prior to the compressed air entering the combustion chamber for ignition with a mixture of fuel. This permits large operating economics to be realized, reducing the need for expensive pure oxygen as the oxidant and permits the elimination of forced cooling by confined water flow for such internal burners.
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